TM 10-3920-675-23-1 RTCH RT 240

ARMY *TM 10-3930-675-23-1 MARINE CORPS TM 11078A-OI/1 VOLUME 1 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 03/15/2011 Rel(1.8) root(frntcover) wpno(F00001)

TM 10-3930-675-23-1

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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WARNING SUMMARY - Continued 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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WARNING SUMMARY - Continued 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.

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WARNING SUMMARY - Continued

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.

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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WARNING SUMMARY - Continued 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. This manual has two volumes. Date of issue for the original manual is: Original

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*TM 10-3930-675-23-1 ARMY *TM 10-3930-675-23-1 MARINE CORPS TM 11078A-OI/1 HEADQUARTERS, DEPARTMENT OF THE ARMY HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 01 OCTOBER 2012 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 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 [email protected]. 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 [email protected]. 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.

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TABLE OF CONTENTS Page No. WP Sequence No. Volume 1 HOW TO USE THIS MANUAL .......................................................................................................................... lxix Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1.

List of Abbreviations/Acronyms............................................................................................ 0001-2

EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1.

Major Components............................................................................................................... 0002-2

Table 1.

Description of Major Components........................................................................................ 0002-2

Figure 2.

Major Components............................................................................................................... 0002-3

Table 2.

Description of Major Components........................................................................................ 0002-3

Figure 3.

Major Components............................................................................................................... 0002-4

Table 3.

Description of Major Components........................................................................................ 0002-4

THEORY OF OPERATION.......................................................................................................................... WP 0003 Chapter 2 - TROUBLESHOOTING PROCEDURES ERROR CODE REFERENCES................................................................................................................... WP 0004 Table 1.

Driver Action Icons............................................................................................................... 0004-1

Table 2.

Type of Fault Icons............................................................................................................... 0004-1

Table 3.

Function Icons...................................................................................................................... 0004-2

Table 4.

Error Code Reference Index................................................................................................ 0004-4

TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0005 TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)................................................................. WP 0006 Figure 1.

Starter Motor........................................................................................................................ 0006-3

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING................................................................... WP 0007 Figure 1.

Actuator Harness Test.......................................................................................................... 0007-3

Figure 2.

Actuator Harness Test.......................................................................................................... 0007-5

Figure 3.

Actuator Harness Test.......................................................................................................... 0007-8

Figure 4.

Actuator Harness Test........................................................................................................ 0007-11

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5.

Actuator Harness Test........................................................................................................ 0007-13

Figure 6.

Actuator Harness Test........................................................................................................ 0007-16

Figure 7.

Actuator Harness Test........................................................................................................ 0007-18

Figure 8.

Actuator Harness Test........................................................................................................ 0007-19

Figure 9.

Actuator Harness Test........................................................................................................ 0007-20

Figure 10.

15-Pin Connector Test....................................................................................................... 0007-21

Figure 11.

15-Pin Connector Test....................................................................................................... 0007-22

Figure 12.

Solenoid Connector Test.................................................................................................... 0007-23

Figure 13.

Actuator Harness Test........................................................................................................ 0007-24

Figure 14.

Actuator Harness Connector Test...................................................................................... 0007-25

Figure 15.

Actuator Harness Connector Test...................................................................................... 0007-26

Figure 16.

Injector Wiring Test............................................................................................................ 0007-27

Figure 17.

Actuator Harness Test........................................................................................................ 0007-28

Figure 18.

Solenoid Connector Test.................................................................................................... 0007-29

Figure 19.

Actuator Harness Test........................................................................................................ 0007-30

Figure 20.

Actuator Harness Test........................................................................................................ 0007-31

Figure 21.

Actuator Harness Test........................................................................................................ 0007-32

Figure 22.

Injector Wiring Test............................................................................................................ 0007-33

Figure 23.

Injector Wiring Test............................................................................................................ 0007-34

Figure 24.

Injector Wiring Test............................................................................................................ 0007-35

Figure 25.

Actuator Harness Test........................................................................................................ 0007-36

Figure 26.

Actuator Harness Test........................................................................................................ 0007-37

Figure 27.

Actuator Harness Test........................................................................................................ 0007-38

Figure 28.

Injector Wiring Test............................................................................................................ 0007-39

Figure 29.

Actuator Harness Test........................................................................................................ 0007-40

Figure 30.

Actuator Harness Test........................................................................................................ 0007-41

Figure 31.

Actuator Harness Test........................................................................................................ 0007-42

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 32.

Actuator Harness Test........................................................................................................ 0007-43

Figure 33.

Actuator Harness Test........................................................................................................ 0007-44

Figure 34.

Actuator Harness Test........................................................................................................ 0007-45

Figure 35.

Actuator Harness Test........................................................................................................ 0007-46

Figure 36.

Actuator Harness Test........................................................................................................ 0007-47

Figure 37.

Actuator Harness Test........................................................................................................ 0007-48

Figure 38.

Actuator Harness Test........................................................................................................ 0007-49

Figure 39.

Actuator Harness Test........................................................................................................ 0007-50

Figure 40.

Actuator Harness Test........................................................................................................ 0007-51

Figure 41.

Actuator Harness Test........................................................................................................ 0007-52

Figure 42.

Actuator Harness Test........................................................................................................ 0007-53

Figure 43.

Cylinder #1 Supply and Return.......................................................................................... 0007-54

Figure 44.

Cylinder #5 Supply and Return.......................................................................................... 0007-54

Figure 45.

Cylinder #3 Supply and Return.......................................................................................... 0007-55

Figure 46.

Cylinder #6 Supply and Return.......................................................................................... 0007-55

Figure 47.

Cylinder #2 Supply and Return.......................................................................................... 0007-56

Figure 48.

Cylinder #4 Supply and Return.......................................................................................... 0007-56

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING............................................................ WP 0008 Figure 1.

Accelerator Pedal Wiring Test.............................................................................................. 0008-3

Figure 2.

Accelerator Pedal Wiring Test.............................................................................................. 0008-4

Figure 3.

OEM Harness Connector Test............................................................................................. 0008-5

Figure 4.

OEM Harness Connector Test............................................................................................. 0008-5

Figure 5.

OEM Harness Connector Test............................................................................................. 0008-6

Figure 6.

Accelerator Pedal Wiring Test.............................................................................................. 0008-8

Figure 7.

Accelerator Pedal Wiring Test.............................................................................................. 0008-9

Figure 8.

OEM Wiring Harness Test.................................................................................................. 0008-10

Figure 9.

OEM Wiring Harness Test.................................................................................................. 0008-10

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 10.

Accelerator Pedal Calibration............................................................................................. 0008-11

Figure 11.

Accelerator Pedal Test....................................................................................................... 0008-12

Figure 12.

Accelerator Pedal Resistance Test.................................................................................... 0008-13

Figure 13.

Idle Validation Circuit Voltage Test.................................................................................... 0008-13

Figure 14.

Idle Validation Circuit Voltage Test.................................................................................... 0008-14

Figure 15.

TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-16

Figure 16.

TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-17

COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING............................................. WP 0009 Figure 1.

Cooling Fan Diagnostics...................................................................................................... 0009-5

OVERLOAD PROTECTION TROUBLESHOOTING................................................................................... WP 0010 Figure 1.

Overload Protection Diagnostics........................................................................................ 0010-12

Figure 2.

Overload Protection Diagnostics........................................................................................ 0010-13

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING............................... WP 0011 Figure 1.

Tophandler ECU Diagnostics............................................................................................... 0011-3

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING.................................... WP 0012 Figure 1.

ECU Input Diagnostics......................................................................................................... 0012-8

Figure 2.

ECU Input Diagnostics......................................................................................................... 0012-9

Figure 3.

ECU Input Diagnostics....................................................................................................... 0012-10

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING....................................................................... WP 0013 STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING................................................................................................................................. WP 0014 Figure 1.

Use Test Lead Kit................................................................................................................. 0014-4

Figure 2.

Engine ECU Circuit Test...................................................................................................... 0014-5

Figure 3.

Engine ECU Circuit Test...................................................................................................... 0014-6

Figure 4.

Engine ECU Circuit Test...................................................................................................... 0014-7

Figure 5.

Engine ECU Test.................................................................................................................. 0014-8

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING................................ WP 0015 INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING.............................. WP 0016

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING......................................... WP 0017 Figure 1.

Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-2

Figure 2.

Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-3

Figure 3.

Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-4

Figure 4.

Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-5

Figure 5.

Sensor Voltage Supply Test................................................................................................. 0017-6

Figure 6.

Sensor Voltage Supply Test................................................................................................. 0017-7

Figure 7.

Sensor Voltage Supply Test................................................................................................. 0017-7

Figure 8.

Sensor Voltage Supply Test................................................................................................. 0017-8

Figure 9.

Sensor Voltage Supply Test................................................................................................. 0017-9

Figure 10.

Sensor Voltage Supply Test................................................................................................. 0017-9

Figure 11.

Sensor Voltage Supply Test............................................................................................... 0017-10

Figure 12.

Sensor Voltage Supply Test............................................................................................... 0017-11

Figure 13.

Sensor Voltage Supply Test............................................................................................... 0017-12

Figure 14.

Sensor Voltage Supply Test............................................................................................... 0017-13

Figure 15.

OEM Harness Connector Circuit Check............................................................................. 0017-15

Figure 16.

Oil Pressure/Temperature Sensor Circuits......................................................................... 0017-15

ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING.............................................................. WP 0018 Figure 1.

Engine Harness Circuit Resistance Check........................................................................... 0018-3

Figure 2.

Engine Harness Circuit Resistance Check........................................................................... 0018-4

Figure 3.

Engine Harness Circuit Resistance Check........................................................................... 0018-6

Figure 4.

Engine Harness Circuit Resistance Check........................................................................... 0018-7

Figure 5.

Engine Position Sensor Circuits........................................................................................... 0018-8

ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING...................................................................... WP 0019 Figure 1.

Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-2

Figure 2.

Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-3

Figure 3.

Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-3

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4.

Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-4

Figure 5.

Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-5

Figure 6.

Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-6

Figure 7.

Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-7

Figure 8.

Oil Pressure Sensor Test..................................................................................................... 0019-7

Figure 9.

Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-8

Figure 10.

Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-9

Figure 11.

Oil Pressure Sensor Circuit Resistance Test..................................................................... 0019-10

Figure 12.

Oil Pressure Sensor Circuit Failure Test............................................................................ 0019-11

Figure 13.

Oil Pressure Sensor Circuit Identification........................................................................... 0019-13

ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING......................................... WP 0020 Figure 1.

Coolant Temperature Sensor Test....................................................................................... 0020-3

Figure 2.

Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-4

Figure 3.

Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-5

Figure 4.

Coolant Temperature Sensor Resistance Test.................................................................... 0020-6

Figure 5.

Coolant Temperature Sensor Resistance Test.................................................................... 0020-7

Figure 6.

Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-8

Figure 7.

Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-9

Figure 8.

Intake Air Temperature Sensor Resistance Test............................................................... 0020-10

Figure 9.

Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-11

Figure 10.

Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-12

Figure 11.

Intake Air Temperature Sensor Resistance Test............................................................... 0020-13

Figure 12.

Intake Air Temperature Sensor Resistance Test............................................................... 0020-13

Figure 13.

Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-14

Figure 14.

Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-15

Figure 15.

Oil Temperature Sensor Resistance Test.......................................................................... 0020-17

Figure 16.

Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-18

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 17.

Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-19

Figure 18.

Oil Temperature Sensor Resistance Test.......................................................................... 0020-20

Figure 19.

Oil Temperature Sensor Resistance Test.......................................................................... 0020-21

Figure 20.

Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-22

Figure 21.

Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-23

Figure 22.

Engine Sensors Replacement............................................................................................ 0020-24

Figure 23.

Intake Manifold Temperature Sensor Circuit Information................................................... 0020-25

ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING.......................... WP 0021 Figure 1.

Ambient Air Temperature Sensor Voltage Test.................................................................... 0021-3

Figure 2.

Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-3

Table 1.

Altitude (Ft.) vs. Voltage....................................................................................................... 0021-4

Figure 3.

Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-4

Figure 4.

Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5

Figure 5.

Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5

Figure 6.

Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-6

Figure 7.

Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-7

Table 2.

Altitude (Ft.) vs. Voltage....................................................................................................... 0021-8

Figure 8.

Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-8

Figure 9.

Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-9

Figure 10.

Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-9

Figure 11.

Ambient Air Temperature Sensor Circuit Resistance Test................................................. 0021-10

Figure 12.

Ambient Air Temperature Sensor Circuit Test.................................................................... 0021-11

ENGINE PRESSURE SENSOR TROUBLESHOOTING............................................................................. WP 0022 Figure 1.

Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-3

Figure 2.

Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-3

Figure 3.

Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-4

Figure 4.

Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-4

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-5

Figure 6.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-6

Figure 7.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-7

Figure 8.

Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-8

Figure 9.

Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-9

Figure 10.

Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-9

Figure 11.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-10

Figure 12.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-10

Figure 13.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-11

Figure 14.

Intake Manifold Pressure Sensor Circuit Test.................................................................... 0022-11

Figure 15.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-13

Figure 16.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-13

Figure 17.

Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-14

Figure 18.

Intake Manifold Pressure Sensor Circuit Information......................................................... 0022-14

ENGINE FUEL PRESSURE SENSORS AND CIRCUITS TROUBLESHOOTING...................................... WP 0023 Figure 1.

Fuel Shutoff Solenoid Post Inspection................................................................................. 0023-2

Figure 2.

Fuel Shutoff Solenoid Voltage Test...................................................................................... 0023-2

Figure 3.

Fuel Shutoff Valve Actuator Wire......................................................................................... 0023-3

Figure 4.

Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-4

Figure 5.

Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-5

Figure 6.

Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-5

Figure 7.

Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-6

Figure 8.

Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-7

Figure 9.

Fuel Inlet Restriction Sensor Circuit Resistance Test.......................................................... 0023-8

Figure 10.

Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9

Figure 11.

Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9

Figure 12.

Fuel Inlet Restriction Sensor Circuit Voltage Test.............................................................. 0023-10

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 13.

Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-11

Figure 14.

Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-12

Figure 15.

Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-13

ENGINE BATTERY VOLTAGE CIRCUITS TROUBLESHOOTING............................................................ WP 0024 Figure 1.

OEM Harness Circuit Resistance Test................................................................................. 0024-3

Figure 2.

Starter Solenoid Lockout Relay Circuit Resistance Test...................................................... 0024-6

Figure 3.

Starter Solenoid Lockout Relay Circuit Continuity Test........................................................ 0024-7

Figure 4.

Battery Cranking Voltage Test............................................................................................. 0024-8

Figure 5.

Alternator Charging Amperage Test..................................................................................... 0024-8

TRANSMISSION TEMPERATURE TROUBLESHOOTING........................................................................ WP 0025 Figure 1.

Component Locations.......................................................................................................... 0025-6

TRANSMISSION SPEED SENSORS TROUBLESHOOTING..................................................................... WP 0026 Figure 1.

Component Locations........................................................................................................ 0026-10

TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING..................................................................... WP 0027 MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING..................................................... WP 0028 INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING............................... WP 0029 BRAKE SYSTEM TROUBLESHOOTING.................................................................................................... WP 0030 Figure 1.

Component Locations.......................................................................................................... 0030-6

AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING........................................................................ WP 0031 STEERING VALVE CIRCUIT TROUBLESHOOTING................................................................................. WP 0032 Figure 1.

Connector 770 Numbering................................................................................................. 0032-14

MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING........................................ WP 0033 STEERING SENSOR TROUBLESHOOTING............................................................................................. WP 0034 HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING................................................................................................................................. WP 0035 Figure 1.

Component Locations.......................................................................................................... 0035-2

AUXILIARY PUMP TROUBLESHOOTING.................................................................................................. WP 0036 HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING................................................................ WP 0037

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Component Locations.......................................................................................................... 0037-3

HYDRAULIC FILTER INDICATORS TROUBLESHOOTING...................................................................... WP 0038 Figure 1.

Component Locations.......................................................................................................... 0038-8

Figure 2.

Component Locations.......................................................................................................... 0038-9

BOOM LIFTING/LOWERING TROUBLESHOOTING................................................................................. WP 0039 Figure 1.

Component Locations.......................................................................................................... 0039-9

Figure 2.

Component Locations........................................................................................................ 0039-10

BOOM IN/OUT TROUBLESHOOTING........................................................................................................ WP 0040 Figure 1.

Component Locations.......................................................................................................... 0040-7

Figure 2.

Component Locations.......................................................................................................... 0040-8

TOPHANDLER SLEWING TROUBLESHOOTING...................................................................................... WP 0041 Figure 1.

Component Locations.......................................................................................................... 0041-7

Figure 2.

Component Locations.......................................................................................................... 0041-8

TOPHANDLER TILT TROUBLESHOOTING............................................................................................... WP 0042 Figure 1.

Component Locations.......................................................................................................... 0042-9

Figure 2.

Component Locations........................................................................................................ 0042-10

TOPHANDLER LEVELING TROUBLESHOOTING..................................................................................... WP 0043 Figure 1.

Component Locations. ........................................................................................................ 0043-8

Figure 2.

Component Locations. ........................................................................................................ 0043-9

TOPHANDLER SIDESHIFT TROUBLESHOOTING................................................................................... WP 0044 Figure 1.

Component Locations.......................................................................................................... 0044-6

TOPHANDLER SPREADER TROUBLESHOOTING.................................................................................. WP 0045 Figure 1.

Component Locations.......................................................................................................... 0045-7

TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING.................................... WP 0046 Figure 1.

Tophandler Twistlocks Indication Failure............................................................................. 0046-3

Figure 2.

Component Locations.......................................................................................................... 0046-8

Figure 3.

Component Locations.......................................................................................................... 0046-9

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Introduction...................................... WP 0047 Table 1.

Leakage Definitions for PMCS............................................................................................. 0047-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0048 Table 1.

Preventive Maintenance Checks and Services (PMCS) for the RTCH................................ 0048-1

Table 2.

PMCS Mandatory Replacement Parts List........................................................................... 0048-8

Chapter 4 - MAINTENANCE INSTRUCTIONS SERVICE UPON RECEIPT......................................................................................................................... WP 0049 ENGINE ASSEMBLY REPLACEMENT....................................................................................................... WP 0050 Figure 1.

Engine Removal................................................................................................................... 0050-3

Figure 2.

Engine Removal................................................................................................................... 0050-4

Figure 3.

Engine Removal................................................................................................................... 0050-5

Figure 4.

Engine Removal................................................................................................................... 0050-5

Figure 5.

Engine Removal................................................................................................................... 0050-6

Figure 6.

Engine Removal................................................................................................................... 0050-7

Figure 7.

Engine Removal................................................................................................................... 0050-7

Figure 8.

Engine Removal................................................................................................................... 0050-8

Figure 9.

Engine Removal................................................................................................................... 0050-9

Figure 10.

Engine Removal................................................................................................................. 0050-10

Figure 11.

Engine Installation.............................................................................................................. 0050-12

Figure 12.

Engine Installation.............................................................................................................. 0050-13

Figure 13.

Engine Installation.............................................................................................................. 0050-13

Figure 14.

Engine Installation.............................................................................................................. 0050-14

Figure 15.

Engine Installation.............................................................................................................. 0050-14

Figure 16.

Engine Installation.............................................................................................................. 0050-15

Figure 17.

Engine Installation.............................................................................................................. 0050-16

Figure 18.

Engine Installation.............................................................................................................. 0050-17

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 19.

Engine Installation.............................................................................................................. 0050-18

Figure 20.

Engine Installation.............................................................................................................. 0050-19

ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT............................................................... WP 0051 Figure 1.

Lifting Brackets Removal...................................................................................................... 0051-2

Figure 2.

Lifting Brackets Installation................................................................................................... 0051-3

Figure 3.

Front Engine Mount Installation............................................................................................ 0051-5

Figure 4.

Rear Engine Mount Removal............................................................................................... 0051-7

CYLINDER HEAD REPLACEMENT............................................................................................................ WP 0052 Figure 1.

Cylinder Head Removal....................................................................................................... 0052-1

Figure 2.

Cylinder Head Removal....................................................................................................... 0052-2

Figure 3.

Cylinder Head Removal....................................................................................................... 0052-2

Figure 4.

Cylinder Head Removal....................................................................................................... 0052-3

Figure 5.

Cylinder Head Removal....................................................................................................... 0052-3

Figure 6.

Cylinder Head Removal....................................................................................................... 0052-4

Figure 7.

Cylinder Head Removal....................................................................................................... 0052-4

Figure 8.

Cylinder Head Removal....................................................................................................... 0052-5

Figure 9.

Cylinder Head Removal....................................................................................................... 0052-5

Figure 10.

Cylinder Head Removal....................................................................................................... 0052-6

Figure 11.

Cylinder Head Inspection..................................................................................................... 0052-8

Figure 12.

Cylinder Head Inspection..................................................................................................... 0052-9

Figure 13.

Cylinder Head Inspection................................................................................................... 0052-10

Table 1.

Cylinder Head Flatness Measurements............................................................................. 0052-10

Figure 14.

Cylinder Head Inspection................................................................................................... 0052-11

Figure 15.

Cylinder Head Inspection................................................................................................... 0052-11

Figure 16.

Cylinder Head Installation.................................................................................................. 0052-12

Figure 17.

Cylinder Head Installation.................................................................................................. 0052-13

Figure 18.

Cylinder Head Installation.................................................................................................. 0052-13

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 19.

Cylinder Head Installation.................................................................................................. 0052-14

Figure 20.

Cylinder Head Installation.................................................................................................. 0052-14

Figure 21.

Cylinder Head Installation.................................................................................................. 0052-15

Figure 22.

Cylinder Head Installation.................................................................................................. 0052-15

Figure 23.

Cylinder Head Removal..................................................................................................... 0052-16

Figure 24.

Cylinder Head Installation.................................................................................................. 0052-16

VIBRATION DAMPER REPLACEMENT..................................................................................................... WP 0053 Figure 1.

Vibration Damper Removal.................................................................................................. 0053-2

Figure 2.

Thickness Measure.............................................................................................................. 0053-3

Figure 3.

Eccentricity Check................................................................................................................ 0053-3

Figure 4.

Wobble Check...................................................................................................................... 0053-4

Figure 5.

Vibration Damper Installation............................................................................................... 0053-5

FLYWHEEL ASSEMBLY REPLACEMENT................................................................................................. WP 0054 Figure 1.

Flywheel Assembly Removal............................................................................................... 0054-2

Figure 2.

Flywheel Assembly Removal............................................................................................... 0054-3

Figure 3.

Flywheel Assembly Removal............................................................................................... 0054-4

Figure 4.

Flywheel Assembly Inspection............................................................................................. 0054-5

Figure 5.

Flywheel Assembly Inspection............................................................................................. 0054-6

Table 1.

Flywheel Face Runout.......................................................................................................... 0054-7

Figure 6.

Flywheel Assembly Installation............................................................................................ 0054-8

Figure 7.

Flywheel Assembly Installation............................................................................................ 0054-9

REAR MAIN OIL SEAL REPLACEMENT.................................................................................................... WP 0055 Figure 1.

Rear Main Oil Seal Removal................................................................................................ 0055-2

Figure 2.

Wear Sleeve Removal.......................................................................................................... 0055-3

Figure 3.

Wear Sleeve Removal.......................................................................................................... 0055-3

Figure 4.

Wear Sleeve Removal.......................................................................................................... 0055-4

Figure 5.

Wear Sleeve Removal.......................................................................................................... 0055-4

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 6.

Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-5

Figure 7.

Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-6

Figure 8.

Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-6

Figure 9.

Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-7

Figure 10.

Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-7

Figure 11.

Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-8

Figure 12.

Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-9

ROCKER ARM ASSEMBLY MAINTENANCE............................................................................................. WP 0056 Figure 1.

Push Rods and Push Tubes Removal................................................................................. 0056-2

Figure 2.

Key Stock Installation........................................................................................................... 0056-2

Figure 3.

Front Rocker Arm Assembly Removal................................................................................. 0056-3

Figure 4.

Rocker Levers Removal....................................................................................................... 0056-4

Figure 5.

Rocker Lever Disassembly................................................................................................... 0056-4

Figure 6.

Rocker Lever Bushing Measurement................................................................................... 0056-5

Figure 7.

Rocker Lever Shaft Measurement........................................................................................ 0056-5

Figure 8.

Rocker Arm Shaft Assembly................................................................................................ 0056-6

Figure 9.

Rocker Arm Shaft Assembly................................................................................................ 0056-7

Figure 10.

Rocker Arm Shaft Assembly................................................................................................ 0056-7

Figure 11.

Rocker Arm Shaft Assembly................................................................................................ 0056-8

Figure 12.

Rocker Arm Shaft Installation............................................................................................... 0056-8

Figure 13.

Rocker Arm Shaft Installation............................................................................................... 0056-9

Figure 14.

Rocker Arm Shaft Installation............................................................................................... 0056-9

Figure 15.

Rocker Arm Shaft Installation............................................................................................. 0056-10

Figure 16.

Rocker Arm Shaft Installation............................................................................................. 0056-10

Figure 17.

Rocker Arm Shaft Installation. ........................................................................................... 0056-11

Figure 18.

Rocker Arm Shaft Installation............................................................................................. 0056-11

Figure 19.

Rocker Arm Shaft Installation............................................................................................. 0056-12

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 20.

Rocker Arm Shaft Installation............................................................................................. 0056-12

Figure 21.

Rocker Arm Shaft Installation............................................................................................. 0056-13

Figure 22.

Valve Lash Check.............................................................................................................. 0056-14

Table 1.

Injector and Valve Measurement Sequence...................................................................... 0056-15

Figure 23.

Valve Lash Check.............................................................................................................. 0056-15

Figure 24.

Valve Lash Check.............................................................................................................. 0056-16

Table 2.

M Series Valve Lash Recheck Limits................................................................................. 0056-16

Figure 25.

Injector Lash Check............................................................................................................ 0056-17

Figure 26.

Injector Lash Check............................................................................................................ 0056-18

Table 3.

M Series Injector Lash Recheck Limits.............................................................................. 0056-18

Figure 27.

Injector Adjustment............................................................................................................. 0056-19

Figure 28.

Injector Adjustment............................................................................................................. 0056-19

Figure 29.

Valve Adjustment............................................................................................................... 0056-20

Figure 30.

Valve Adjustment............................................................................................................... 0056-21

Figure 31.

Valve Adjustment............................................................................................................... 0056-21

Figure 32.

Valve Adjustment............................................................................................................... 0056-22

Figure 33.

Valve Adjustment............................................................................................................... 0056-22

Figure 34.

Valve Adjustment............................................................................................................... 0056-23

ROCKER ARM COVER AND GASKET REPLACEMENT........................................................................... WP 0057 Figure 1.

Rocker Arm Cover and Gasket Replacement...................................................................... 0057-2

Figure 2.

Rocker Arm Cover Tightening Sequence............................................................................. 0057-3

OIL PAN REPLACEMENT........................................................................................................................... WP 0058 Figure 1.

Oil Pan Removal.................................................................................................................. 0058-2

Figure 2.

Oil Pan Installation............................................................................................................... 0058-3

Figure 3.

Oil Pan Installation............................................................................................................... 0058-3

ENGINE OIL AND OIL FILTER REPLACEMENT........................................................................................ WP 0059 Figure 1.

Drain Engine Oil................................................................................................................... 0059-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2.

Oil Filter and Gasket............................................................................................................. 0059-3

OIL FILTER HEAD AND OIL COOLER MAINTENANCE............................................................................ WP 0060 Figure 1.

Oil Filter Head and Oil Cooler Removal............................................................................... 0060-2

Figure 2.

Oil Filter Head and Oil Cooler Removal............................................................................... 0060-2

Figure 3.

Oil Filter Head and Oil Cooler Removal............................................................................... 0060-3

Figure 4.

Oil Filter Head and Oil Cooler Disassembly......................................................................... 0060-5

Figure 5.

Oil Cooler Testing................................................................................................................. 0060-7

Figure 6.

Oil Cooler Cleaning.............................................................................................................. 0060-8

Figure 7.

Oil Cooler Pressure Test...................................................................................................... 0060-9

Figure 8.

Oil Filter Head Assembly...................................................................................................... 0060-9

Figure 9.

Oil Filter Head Assembly.................................................................................................... 0060-10

Figure 10.

Oil Filter Head Installation.................................................................................................. 0060-10

Figure 11.

Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-11

Figure 12.

Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-12

Figure 13.

Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-12

ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT..................................................... WP 0061 Figure 1.

Engine Oil Dipstick Replacement and Fill Hose Removal.................................................... 0061-3

Figure 2.

Oil Dipstick Cover and Cylinder Block Cleaning................................................................... 0061-4

Figure 3.

Engine Oil Dipstick and Fill Hoses Installation..................................................................... 0061-5

OIL SAMPLING VALVES AND HOSES REPLACEMENT.......................................................................... WP 0062 Figure 1.

Oil Sampling Valve............................................................................................................... 0062-2

Figure 2.

Engine Oil Sampling Valve Hose......................................................................................... 0062-3

Figure 3.

Transmission Oil Sampling Valve Hose............................................................................... 0062-4

Figure 4.

Hydraulic System Oil Sampling Valve Hose......................................................................... 0062-5

EXHAUST MANIFOLD REPLACEMENT.................................................................................................... WP 0063 Figure 1.

Exhaust Manifold Removal................................................................................................... 0063-1

Figure 2.

Exhaust Manifold Removal................................................................................................... 0063-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3.

Exhaust Manifold Installation................................................................................................ 0063-3

Figure 4.

Exhaust Manifold Installation................................................................................................ 0063-4

Figure 5.

Exhaust Manifold Installation................................................................................................ 0063-5

INTAKE MANIFOLD REPLACEMENT........................................................................................................ WP 0064 Figure 1.

Intake Manifold Removal...................................................................................................... 0064-1

Figure 2.

Intake Manifold Installation................................................................................................... 0064-2

Figure 3.

Intake Manifold Sequence.................................................................................................... 0064-2

FRONT GEAR COVER REPLACEMENT.................................................................................................... WP 0065 Figure 1.

Front Gear Cover Removal.................................................................................................. 0065-2

Figure 2.

Front Gear Cover Removal.................................................................................................. 0065-3

Figure 3.

Front Gear Cover Removal.................................................................................................. 0065-3

Figure 4.

Front Gear Cover Installation............................................................................................... 0065-4

Figure 5.

Front Gear Cover Installation............................................................................................... 0065-5

Figure 6.

Front Gear Cover Installation............................................................................................... 0065-5

Figure 7.

Front Gear Cover Installation............................................................................................... 0065-6

Figure 8.

Front Gear Cover Tightening Sequence.............................................................................. 0065-7

FRONT MAIN OIL SEAL REPLACEMENT.................................................................................................. WP 0066 Figure 1.

Front Main Oil Seal Removal............................................................................................... 0066-1

Figure 2.

Front Main Oil Seal Removal............................................................................................... 0066-2

Figure 3.

Unitized Front Crankshaft Main Oil Seal Removal............................................................... 0066-2

Figure 4.

Unitized Front Crankshaft Main Oil Seal Removal............................................................... 0066-3

Figure 5.

Cleaning and Inspection....................................................................................................... 0066-3

Figure 6.

Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-4

Figure 7.

Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-5

Figure 8.

Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-5

Figure 9.

Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-6

Figure 10.

Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-7

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. FUEL INJECTOR REPLACEMENT............................................................................................................. WP 0067 Figure 1.

Push Rods and Push Tubes Removal................................................................................. 0067-2

Figure 2.

Injector Hold-Down Clamp Removal.................................................................................... 0067-3

Figure 3.

Injector Removal.................................................................................................................. 0067-3

Figure 4.

Injector Installation............................................................................................................... 0067-4

Figure 5.

Injector Installation............................................................................................................... 0067-5

Figure 6.

Push Rods and Push Tubes Installation.............................................................................. 0067-5

FUEL PUMP ASSEMBLY REPLACEMENT................................................................................................ WP 0068 Figure 1.

Fuel Pump Removal............................................................................................................. 0068-3

FUEL HOSES, LINES, AND FITTINGS REPLACEMENT........................................................................... WP 0069 Figure 1.

Cooling Plate-to-Cylinder Head Fuel Line............................................................................ 0069-2

Figure 2.

Fuel Pump-to-Cooling Plate Fuel Line................................................................................. 0069-3

Figure 3.

Engine Fuel Return Line....................................................................................................... 0069-4

Figure 4.

Fuel Return Hose................................................................................................................. 0069-5

FUEL SOLENOID SHUTOFF VALVE REPLACEMENT.............................................................................. WP 0070 Figure 1.

Fuel Solenoid Shutoff Valve Removal.................................................................................. 0070-2

Figure 2.

Fuel Solenoid Shutoff Valve Installation............................................................................... 0070-3

Figure 3.

Fuel Solenoid Shutoff Valve Installation............................................................................... 0070-3

ENGINE AIR CLEANER MAINTENANCE................................................................................................... WP 0071 Figure 1.

Engine Air Cleaner............................................................................................................... 0071-2

Figure 2.

Engine Air Cleaner Filter Elements Removal....................................................................... 0071-3

Figure 3.

Engine Air Cleaner Filter Elements Removal and Installation.............................................. 0071-4

Figure 4.

Engine Air Cleaner Filter Elements Removal and Installation.............................................. 0071-5

ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT................................................................... WP 0072 Figure 1.

Air Cleaner-to-Turbocharger Hoses and Tubes................................................................... 0072-3

Figure 2.

Turbocharger-to-Charge Air Cooler Hoses and Tubes........................................................ 0072-5

Figure 3.

Charger Air Cooler-to-Engine Air Intake Manifold Hoses and Tubes................................... 0072-7

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. TURBOCHARGER REPLACEMENT.......................................................................................................... WP 0073 Figure 1.

Clamps Removal.................................................................................................................. 0073-2

Figure 2.

Turbocharger Removal......................................................................................................... 0073-2

Figure 3.

Turbocharger Removal......................................................................................................... 0073-3

Figure 4.

Turbocharger Removal......................................................................................................... 0073-3

Figure 5.

Turbocharger Axial Clearance Check.................................................................................. 0073-4

Figure 6.

Turbocharger Radial Bearing Clearance Check................................................................... 0073-5

Figure 7.

Turbocharger Installation...................................................................................................... 0073-6

Figure 8.

Turbocharger Installation...................................................................................................... 0073-6

Figure 9.

Turbocharger Installation...................................................................................................... 0073-7

Figure 10.

Turbocharger Installation...................................................................................................... 0073-7

FUEL TANK REPLACEMENT..................................................................................................................... WP 0074 Figure 1.

Fuel Tank Removal.............................................................................................................. 0074-2

Figure 2.

Fuel Tank Replacement....................................................................................................... 0074-3

FUEL SUPPLY AND RETURN HOSES REPLACEMENT.......................................................................... WP 0075 Figure 1.

Fuel Supply Hose................................................................................................................. 0075-3

FUEL FILTER/WATER SEPARATOR REPLACEMENT............................................................................. WP 0076 Figure 1.

Fuel Pump Ball Valve........................................................................................................... 0076-2

Figure 2.

Fuel Filter............................................................................................................................. 0076-3

Figure 3.

Fuel Pump Ball Valve........................................................................................................... 0076-4

ETHER COLD START SYSTEM MAINTENANCE...................................................................................... WP 0077 Figure 1.

Ether Canister Removal....................................................................................................... 0077-1

Figure 2.

Ether Canister Gasket.......................................................................................................... 0077-2

Figure 3.

Ether Canister Installation.................................................................................................... 0077-3

Figure 4.

Cold Start Activation Solenoid Removal............................................................................... 0077-4

Figure 5.

Cold Start Activation Solenoid Removal............................................................................... 0077-5

Figure 6.

Cold Start Activation Solenoid Removal............................................................................... 0077-5

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 7.

Cold Start Activation Solenoid Removal............................................................................... 0077-6

Figure 8.

Cold Start Activation Solenoid Installation............................................................................ 0077-7

Figure 9.

Cold Start Activation Solenoid Installation............................................................................ 0077-8

Figure 10.

Cold Start Activation Solenoid Installation............................................................................ 0077-9

THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT........................................ WP 0078 Figure 1.

Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-1

Figure 2.

Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-2

Figure 3.

Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-2

Figure 4.

Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-3

Figure 5.

Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-3

Figure 6.

Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-4

Figure 7.

Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-5

Figure 8.

Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-6

Figure 9.

Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-7

Figure 10.

Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-8

Figure 11.

Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-9

Figure 12.

Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-9

MUFFLER AND EXHAUST PIPE REPLACEMENT.................................................................................... WP 0079 Figure 1.

Muffler and Exhaust Pipe Removal...................................................................................... 0079-3

Figure 2.

Muffler and Exhaust Pipe Installation................................................................................... 0079-5

DRAINING AND FILLING RADIATOR ASSEMBLY.................................................................................... WP 0080 Figure 1.

Drain Radiator Assembly...................................................................................................... 0080-2

Figure 2.

Fill Radiator Assembly.......................................................................................................... 0080-3

Figure 3.

Fill Radiator Assembly.......................................................................................................... 0080-3

Figure 4.

Check Coolant Level............................................................................................................ 0080-4

RADIATOR ASSEMBLY MAINTENANCE................................................................................................... WP 0081 Figure 1.

Angle Plate Removal............................................................................................................ 0081-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2.

Radiator Grille Removal....................................................................................................... 0081-3

Figure 3.

Radiator Removal................................................................................................................. 0081-4

Figure 4.

Radiator Installation.............................................................................................................. 0081-5

Figure 5.

Radiator Grille Installation.................................................................................................... 0081-6

Figure 6.

Angle Plate Installation......................................................................................................... 0081-7

COOLING SYSTEM EXPANSION TANK MAINTENANCE......................................................................... WP 0082 Figure 1.

Cooling System Expansion Tank Removal.......................................................................... 0082-2

Figure 2.

Cooling System Expansion Tank Removal.......................................................................... 0082-3

Figure 3.

Cooling System Expansion Tank Removal.......................................................................... 0082-4

Figure 4.

Cooling System Expansion Tank Assembly and Installation................................................ 0082-5

Figure 5.

Cooling System Expansion Tank Installation....................................................................... 0082-6

Figure 6.

Cooling System Expansion Tank Installation....................................................................... 0082-7

COOLING SYSTEM HOSES REPLACEMENT........................................................................................... WP 0083 Figure 1.

Cab Interface Unit-to-Water Pump Hose.............................................................................. 0083-2

Figure 2.

Cab Interface Unit-to-Engine Block Hose............................................................................. 0083-3

Figure 3.

Coolant Reservoir-to-Radiator Hose.................................................................................... 0083-4

Figure 4.

Coolant Reservoir-to-Water Manifold Hose.......................................................................... 0083-5

Figure 5.

Coolant Reservoir-to-Water Pump Hose.............................................................................. 0083-6

Figure 6.

Transmission Oil Cooler-to-Radiator Hoses......................................................................... 0083-7

Figure 7.

Transmission Oil Cooler-to-Water Pump Hoses.................................................................. 0083-8

Figure 8.

Transmission Oil Cooler-to-Water Pump Return Hose........................................................ 0083-9

Figure 9.

Transmission Oil Cooler U-Hose........................................................................................ 0083-10

Figure 10.

Water Manifold-to-Radiator Hoses..................................................................................... 0083-11

RADIATOR SPLASH SHIELD REPLACEMENT......................................................................................... WP 0084 Figure 1.

Radiator Splash Shield Installation....................................................................................... 0084-2

RADIATOR TOP GRATING REPLACEMENT............................................................................................. WP 0085 Figure 1.

Radiator Top Grating Replacement...................................................................................... 0085-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. RADIATOR FILL COVER PLATE REPLACEMENT.................................................................................... WP 0086 Figure 1.

Radiator Fill Cover Replacement......................................................................................... 0086-1

THERMOSTAT REPLACEMENT................................................................................................................ WP 0087 Figure 1.

Thermostat Removal............................................................................................................ 0087-1

Figure 2.

Thermostat Removal............................................................................................................ 0087-2

Figure 3.

Thermostat Removal and Installation................................................................................... 0087-2

Figure 4.

Thermostat Installation......................................................................................................... 0087-3

WATER PUMP REPLACEMENT................................................................................................................. WP 0088 Figure 1.

Water Pump Pulley Removal............................................................................................... 0088-2

Figure 2.

Dust and Oil Seal Removal.................................................................................................. 0088-3

Figure 3.

Water Pump Removal.......................................................................................................... 0088-3

Figure 4.

Needle Bearing Inspection................................................................................................... 0088-4

Figure 5.

Water Pump Installation....................................................................................................... 0088-5

Figure 6.

Oil and Dust Seal Installation............................................................................................... 0088-5

Figure 7.

Water Pump Pulley Installation............................................................................................ 0088-6

HYDRAULIC COOLING FAN MAINTENANCE........................................................................................... WP 0089 Figure 1.

Cooling Fan Removal........................................................................................................... 0089-3

Figure 2.

Cooling Fan Installation........................................................................................................ 0089-5

COOLANT FILTER AND FILTER HEAD REPLACEMENT......................................................................... WP 0090 Figure 1.

Coolant Filter Removal......................................................................................................... 0090-2

Figure 2.

Coolant Filter Preparation.................................................................................................... 0090-3

Figure 3.

Coolant Filter Tightening...................................................................................................... 0090-4

Figure 4.

Turn Coolant Filter Head Valve ON...................................................................................... 0090-5

Figure 5.

Coolant Filter Head Replacement........................................................................................ 0090-7

ALTERNATOR REPLACEMENT................................................................................................................. WP 0091 Figure 1.

Alternator Removal............................................................................................................... 0091-1

Figure 2.

Alternator Removal............................................................................................................... 0091-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3.

Alternator Installation............................................................................................................ 0091-3

ALTERNATOR DRIVE BELT MAINTENANCE............................................................................................ WP 0092 Figure 1.

Alternator Drive Belt Removal.............................................................................................. 0092-1

Figure 2.

Alternator Drive Belt Installation........................................................................................... 0092-2

Figure 3.

Alternator Drive Belt Adjustment.......................................................................................... 0092-3

STARTER MOTOR REPLACEMENT.......................................................................................................... WP 0093 Figure 1.

Starter Removal................................................................................................................... 0093-2

Figure 2.

Starter Removal................................................................................................................... 0093-3

Figure 3.

Starter Removal................................................................................................................... 0093-3

Figure 4.

Starter Installation................................................................................................................ 0093-4

Figure 5.

Starter Installation................................................................................................................ 0093-5

INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT............................ WP 0094 Figure 1.

Switch/Gauge Panel Removal.............................................................................................. 0094-2

Figure 2.

Rocker Switch Removal....................................................................................................... 0094-3

Figure 3.

Switch/Gauge Panel Removal.............................................................................................. 0094-4

Figure 4.

Rotary Switch Removal........................................................................................................ 0094-5

Figure 5.

Rotary Switch Removal and Installation............................................................................... 0094-7

Figure 6.

Switch/Gauge Panel Installation........................................................................................... 0094-7

Figure 7.

Rotary Switch Installation..................................................................................................... 0094-8

Figure 8.

Gauge Removal................................................................................................................... 0094-9

Figure 9.

Switch/Gauge Panel Installation......................................................................................... 0094-10

Figure 10.

Instrument Panel Lamp Installation.................................................................................... 0094-11

Figure 11.

Instrument Panel Lamp Installation.................................................................................... 0094-12

Figure 12.

12/24 Connector Removal.................................................................................................. 0094-13

Figure 13.

12/24V Connector Installation............................................................................................ 0094-14

TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT............................................ WP 0095 Figure 1.

Separate Housing................................................................................................................. 0095-1

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2.

Transmission and Accessory Control Levers Removal........................................................ 0095-2

Figure 3.

Panel Removed.................................................................................................................... 0095-3

Figure 4.

Panel Removal..................................................................................................................... 0095-3

Figure 5.

Transmission and Accessory Control Levers Removal........................................................ 0095-4

Figure 6.

Transmission and Accessory Control Levers Installation..................................................... 0095-5

Figure 7.

Panels Installation................................................................................................................ 0095-6

Figure 8.

Panels Installation................................................................................................................ 0095-6

Figure 9.

Housing Installation.............................................................................................................. 0095-7

ECS DISPLAY SCREEN REPLACEMENT................................................................................................. WP 0096 Figure 1.

ECS Display Screen Removal.............................................................................................. 0096-1

Figure 2.

ECS Display Screen Installation........................................................................................... 0096-2

Figure 3.

ECS Display Screen Installation........................................................................................... 0096-3

TOPHANDLER JUNCTION BOX MAINTENANCE..................................................................................... WP 0097 Figure 1.

Tophandler ECU Removal................................................................................................... 0097-2

Figure 2.

Tophandler ECU Installation................................................................................................ 0097-3

Figure 3.

Relay Installation.................................................................................................................. 0097-4

Figure 4.

Tophandler Junction Box Removal...................................................................................... 0097-5

Figure 5.

Tophandler Junction Box Removal...................................................................................... 0097-5

Figure 6.

Tophandler Junction Box Removal...................................................................................... 0097-6

Figure 7.

Tophandler Junction Box Removal...................................................................................... 0097-7

Figure 8.

Tophandler Junction Box Removal...................................................................................... 0097-8

Figure 9.

Tophandler Junction Box Removal...................................................................................... 0097-9

Figure 10.

Tophandler Junction Box Replacement............................................................................. 0097-10

Figure 11.

Tophandler Junction Box Installation................................................................................. 0097-11

Figure 12.

Tophandler Junction Box Installation................................................................................. 0097-12

Figure 13.

Tophandler Junction Box Installation................................................................................. 0097-13

Figure 14.

Tophandler Junction Box Installation................................................................................. 0097-13

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT............................................ WP 0098 Figure 1.

Tophandler Junction Box Cover Removal............................................................................ 0098-1

Figure 2.

Tophandler Junction Box Replacement............................................................................... 0098-3

Figure 3.

Tophandler Junction Box Cover Installation......................................................................... 0098-4

ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT............................................................ WP 0099 Figure 1.

ECU Replacement................................................................................................................ 0099-3

ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT........................................................................ WP 0100 Figure 1.

Access Panels Removal....................................................................................................... 0100-1

Figure 2.

Transmission ECU Removal................................................................................................ 0100-2

Figure 3.

Access Panels Removal....................................................................................................... 0100-3

Figure 4.

Steering System ECU Removal........................................................................................... 0100-4

Figure 5.

Seat Base Cover Removal................................................................................................... 0100-5

Figure 6.

Hydraulic Servo System ECU Removal............................................................................... 0100-6

Figure 7.

Hydraulic Servo System ECU Installation............................................................................ 0100-7

Figure 8.

Seat Base Cover Installation................................................................................................ 0100-8

ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT........................................................................... WP 0101 Figure 1.

Joystick Removal................................................................................................................. 0101-1

Figure 2.

Joystick Installation.............................................................................................................. 0101-2

ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT.......................................... WP 0102 Figure 1.

Joystick Wiring Harness Removal........................................................................................ 0102-2

Figure 2.

Joystick Wiring Harness Removal........................................................................................ 0102-3

Figure 3.

Joystick Wiring Harness Removal........................................................................................ 0102-4

Figure 4.

Seat Base Cover Removal................................................................................................... 0102-5

Figure 5.

Joystick Wiring Harness Removal........................................................................................ 0102-5

Figure 6.

Joystick Wiring Harness Removal........................................................................................ 0102-6

Figure 7.

Joystick Wiring Harness Installation..................................................................................... 0102-7

Figure 8.

Seat Base Cover Installation................................................................................................ 0102-7

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 9.

Joystick Wiring Harness Installation..................................................................................... 0102-8

Figure 10.

Joystick Wiring Harness Installation..................................................................................... 0102-9

CIRCUIT BREAKERS AND RELAYS REPLACEMENT.............................................................................. WP 0103 Figure 1.

Access Panel Removal........................................................................................................ 0103-1

Figure 2.

Circuit Breaker/Relay Box Opening...................................................................................... 0103-2

Figure 3.

Circuit Breaker Panel Separation......................................................................................... 0103-3

Figure 4.

Circuit Breaker Removal...................................................................................................... 0103-3

Figure 5.

Circuit Breaker Removal...................................................................................................... 0103-4

Figure 6.

Relay Removal..................................................................................................................... 0103-5

Figure 7.

Relay Replacement.............................................................................................................. 0103-6

Figure 8.

Relay Connection................................................................................................................. 0103-7

Figure 9.

Circuit Breaker Connection.................................................................................................. 0103-8

Figure 10.

Circuit Breaker Installation................................................................................................... 0103-9

Figure 11.

Circuit Breaker Panel Installation......................................................................................... 0103-9

Figure 12.

Circuit Breaker Panel Installation....................................................................................... 0103-10

Figure 13.

Access Panel Installation................................................................................................... 0103-11

Figure 14.

Circuit Breaker Installation................................................................................................. 0103-13

Figure 15.

Starter Relay Installation.................................................................................................... 0103-14

Figure 16.

Fuse Block Installation....................................................................................................... 0103-15

TOPHANDLER PROXIMITY SWITCHES REPLACEMENT........................................................................ WP 0104 Figure 1.

Twistlock Proximity Switch Removal.................................................................................... 0104-2

Figure 2.

Junction Box Cover Removal............................................................................................... 0104-3

Figure 3.

Twistlock Proximity Switch Installation................................................................................. 0104-5

Figure 4.

Junction Box Cover Installation............................................................................................ 0104-5

Figure 5.

Twistlock Proximity Switch Installation................................................................................. 0104-6

Figure 6.

Forklift Interlock Proximity Switch Removal......................................................................... 0104-7

Figure 7.

Junction Box Cover Removal............................................................................................... 0104-7

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 8.

Forklift Interlock Proximity Switch Removal......................................................................... 0104-8

Figure 9.

Forklift Interlock Proximity Switch Removal......................................................................... 0104-9

Figure 10.

Junction Box Cover Installation............................................................................................ 0104-9

Figure 11.

Twistlock Proximity Switch Installation............................................................................... 0104-10

Figure 12.

Spreader Beam Proximity Switch Removal........................................................................ 0104-11

Figure 13.

Spreader Beam Proximity Switch Removal........................................................................ 0104-11

Figure 14.

Spreader Beam Proximity Switch Removal........................................................................ 0104-12

Figure 15.

Spreader Beam Proximity Switch Installation..................................................................... 0104-13

Figure 16.

Spreader Beam Proximity Switch Installation..................................................................... 0104-14

Figure 17.

Spreader Beam Proximity Switch Installation..................................................................... 0104-15

CAB POSITION PROXIMITY SWITCHES REPLACEMENT....................................................................... WP 0105 Figure 1.

Cab-Mounted Proximity Switch Removal............................................................................. 0105-1

Figure 2.

Cab-Mounted Proximity Switch Removal............................................................................. 0105-2

Figure 3.

Cab-Mounted Proximity Switch Replacement...................................................................... 0105-3

Figure 4.

Cab-Mounted Proximity Switch Installation.......................................................................... 0105-4

Figure 5.

Cab Support-Mounted Proximity Switch Removal............................................................... 0105-5

Figure 6.

Cab Support-Mounted Proximity Switch Installation............................................................ 0105-7

Figure 7.

Cab-Support Mounted Proximity Switch Installation............................................................ 0105-8

SOLAR CHARGER REPLACEMENT (IF EQUIPPED)................................................................................ WP 0106 Figure 1.

Solar Charger Replacement................................................................................................. 0106-1

Figure 2.

Solar Charger Replacement................................................................................................. 0106-2

Figure 3.

Solar Charger Replacement................................................................................................. 0106-3

Figure 4.

Solar Charger Replacement................................................................................................. 0106-3

Figure 5.

Solar Charger Replacement................................................................................................. 0106-4

BOOM WIRING HARNESSES REPLACEMENT........................................................................................ WP 0107 Figure 1.

Boom Wiring Harness Removal........................................................................................... 0107-1

Figure 2.

Boom Wiring Harness Removal........................................................................................... 0107-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3.

Boom Wiring Harness Installation........................................................................................ 0107-3

TOPHANDLER WIRING HARNESSES REPLACEMENT........................................................................... WP 0108 Figure 1.

Wiring Harness A Removal.................................................................................................. 0108-2

Figure 2.

Wiring Harness A Removal.................................................................................................. 0108-3

Figure 3.

Wiring Harness A Removal.................................................................................................. 0108-3

Figure 4.

Wiring Harness A Installation............................................................................................... 0108-5

Figure 5.

Wiring Harness A Installation............................................................................................... 0108-5

Figure 6.

Wiring Harness B Removal.................................................................................................. 0108-6

Figure 7.

Wiring Harness B Removal.................................................................................................. 0108-7

Figure 8.

Wiring Harness B Installation............................................................................................... 0108-8

Figure 9.

Wiring Harness B Installation............................................................................................... 0108-9

Figure 10.

Wiring Harness C Removal................................................................................................ 0108-10

Figure 11.

Wiring Harness C Removal................................................................................................ 0108-11

Figure 12.

Wiring Harness C Installation............................................................................................. 0108-12

Figure 13.

Wiring Harness C Installation............................................................................................. 0108-13

Figure 14.

Wiring Harness D Removal................................................................................................ 0108-13

Figure 15.

Wiring Harness D Removal................................................................................................ 0108-14

Figure 16.

Wiring Harness D Removal................................................................................................ 0108-15

Figure 17.

Wiring Harness D Removal................................................................................................ 0108-16

Figure 18.

Wiring Harness D Installation............................................................................................. 0108-17

Figure 19.

Wiring Harness D Installation............................................................................................. 0108-18

Figure 20.

Wiring Harness D Installation............................................................................................. 0108-18

Figure 21.

Wiring Harness E Removal................................................................................................ 0108-19

Figure 22.

Wiring Harness E Removal................................................................................................ 0108-20

Figure 23.

Wiring Harness E Removal................................................................................................ 0108-21

Figure 24.

Wiring Harness E Installation............................................................................................. 0108-22

Figure 25.

Wiring Harness E Installation............................................................................................. 0108-23

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 26.

Wiring Harness E Installation............................................................................................. 0108-23

HEADLIGHT MAINTENANCE..................................................................................................................... WP 0109 Figure 1.

Headlight Reflector Insert Removal...................................................................................... 0109-2

Figure 2.

Headlight Bulb Replacement................................................................................................ 0109-3

Figure 3.

Headlight Reflector Insert Installation................................................................................... 0109-3

Figure 4.

Light Removal and Installation............................................................................................. 0109-5

BACKUP LIGHT AND WORK LIGHT MAINTENANCE............................................................................... WP 0110 Figure 1.

Reflector Insert Removal...................................................................................................... 0110-2

Figure 2.

Bulb Replacement................................................................................................................ 0110-3

Figure 3.

Reflector Insert Installation................................................................................................... 0110-3

Figure 4.

Light Removal and Installation............................................................................................. 0110-5

BLACKOUT LIGHT MAINTENANCE........................................................................................................... WP 0111 Figure 1.

Bulb/Reflector Replacement................................................................................................. 0111-2

Figure 2.

Bulb/Reflector Replacement................................................................................................. 0111-3

Figure 3.

Bulb/Reflector Replacement................................................................................................. 0111-3

Figure 4.

Blackout Light Replacement................................................................................................. 0111-5

DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE....................................................... WP 0112 Figure 1.

Lens Removal...................................................................................................................... 0112-2

Figure 2.

Bulb and LED Replacement................................................................................................. 0112-3

Figure 3.

Lens Installation................................................................................................................... 0112-3

Figure 4.

Directional Light Replacement............................................................................................. 0112-5

Figure 5.

Side Marker Light Cover Removal....................................................................................... 0112-6

Figure 6.

Bulb Replacement................................................................................................................ 0112-7

TWISTLOCK INDICATOR LIGHTS MAINTENANCE.................................................................................. WP 0113 Figure 1.

Twistlock Indicator Light Bulb Replacement. ....................................................................... 0113-2

Figure 2.

Twistlock Indicator Light Bulb Replacement......................................................................... 0113-3

Figure 3.

Twistlock Indicator Light Removal........................................................................................ 0113-4

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4.

Twistlock Indicator Light Installation..................................................................................... 0113-5

Figure 5.

Twistlock Infrared (IR) Light Replacement........................................................................... 0113-7

CAB INTERIOR LIGHT MAINTENANCE..................................................................................................... WP 0114 Figure 1.

Cab Interior Light Bulb Removal.......................................................................................... 0114-1

Figure 2.

Cab Interior Light Bulb Installation....................................................................................... 0114-3

INFRARED (IR) LIGHTS REPLACEMENT.................................................................................................. WP 0115 Figure 1.

Infrared (IR) Light Removal.................................................................................................. 0115-2

Figure 2.

Infrared (IR) Light Installation............................................................................................... 0115-3

FORDING WATER LEVEL SENSOR REPLACEMENT.............................................................................. WP 0116 Figure 1.

Water Level Sensor Removal............................................................................................... 0116-1

Figure 2.

Water Level Sensor Installation............................................................................................ 0116-2

WHEEL TEMPERATURE SENSOR REPLACEMENT................................................................................ WP 0117 Figure 1.

Wheel Temperature Sensor Replacement........................................................................... 0117-2

ENGINE SENSORS REPLACEMENT......................................................................................................... WP 0118 Figure 1.

Coolant Temperature Sensor Replacement......................................................................... 0118-3

Figure 2.

Engine Position Sensor Removal......................................................................................... 0118-4

Figure 3.

Intake Air Temperature Sensor Replacement...................................................................... 0118-5

Figure 4.

Intake Manifold Pressure Sensor Replacement................................................................... 0118-6

Figure 5.

Ambient Air Pressure Sensor Replacement......................................................................... 0118-7

Figure 6.

Ambient Air Pressure Sensor Removal (New Style)............................................................ 0118-8

Figure 7.

Ambient Temperature Sensor Installation (New Style)........................................................ 0118-9

Figure 8.

Oil Pressure/Temperature Sensor Replacement............................................................... 0118-10

HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT............................................................... WP 0119 Figure 1.

Hydraulic Cylinder Filter Indicator Sensor Replacement...................................................... 0119-3

TRANSMISSION SENSORS REPLACEMENT........................................................................................... WP 0120 Figure 1.

Transmission Sensors.......................................................................................................... 0120-2

Figure 2.

Transmission Sensor Connector.......................................................................................... 0120-3

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3.

Transmission Sensor Removal............................................................................................ 0120-3

Figure 4.

Transmission Sensor Installation......................................................................................... 0120-4

Figure 5.

Transmission Sensor Connector.......................................................................................... 0120-5

BOOM ANGLE SENSOR REPLACEMENT................................................................................................. WP 0121 Figure 1.

Boom Angle Sensor Removal.............................................................................................. 0121-2

Figure 2.

Boom Angle Sensor Removal.............................................................................................. 0121-3

Figure 3.

Boom Angle Sensor Removal.............................................................................................. 0121-4

Figure 4.

Boom Angle Sensor Installation........................................................................................... 0121-5

BOOM EXTENSION SENSOR REPLACEMENT........................................................................................ WP 0122 Figure 1.

Boom Extension Sensor Removal........................................................................................ 0122-1

Figure 2.

Boom Extension Sensor Removal........................................................................................ 0122-2

Figure 3.

Boom Extension Sensor Removal........................................................................................ 0122-3

Figure 4.

Boom Extension Sensor Installation..................................................................................... 0122-4

TOPHANDLER ANGLE SENSOR REPLACEMENT................................................................................... WP 0123 Figure 1.

Tophandler Angle Sensor Removal..................................................................................... 0123-2

Figure 2.

Tophandler Angle Sensor Removal..................................................................................... 0123-3

Figure 3.

Tophandler Angle Sensor Removal..................................................................................... 0123-4

Figure 4.

Tophandler Angle Sensor Removal..................................................................................... 0123-5

Figure 5.

Tophandler Angle Sensor Installation.................................................................................. 0123-6

Figure 6.

Tophandler Angle Sensor Installation.................................................................................. 0123-7

Figure 7.

Tophandler Angle Sensor Installation.................................................................................. 0123-8

Figure 8.

Tophandler Angle Sensor Installation.................................................................................. 0123-9

HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT....................................... WP 0124 Figure 1.

Temperature Sensor Replacement...................................................................................... 0124-2

Figure 2.

Pressure Sensor Replacement............................................................................................ 0124-3

Figure 3.

Lift Cylinder Sensor Replacement........................................................................................ 0124-4

STEERING SYSTEM WHEEL SENSOR REPLACEMENT......................................................................... WP 0125

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Steering System Wheel Sensor Removal............................................................................ 0125-2

Figure 2.

Steering System Wheel Sensor Removal............................................................................ 0125-3

Figure 3.

Steering System Wheel Sensor Removal............................................................................ 0125-4

Figure 4.

Steering System Wheel Sensor Installation......................................................................... 0125-5

Table 1.

Rear Junction Box X167 Wire Connections......................................................................... 0125-6

Table 2.

Front Junction Box X192 Wire Connections......................................................................... 0125-6

Figure 5.

Steering System Wheel Sensor Installation......................................................................... 0125-7

Figure 6.

Steering System Wheel Sensor Installation......................................................................... 0125-8

SEAT WARNING BUZZER REPLACEMENT.............................................................................................. WP 0126 Figure 1.

Seat Warning Buzzer Replacement..................................................................................... 0126-1

Figure 2.

Seat Warning Buzzer Replacement..................................................................................... 0126-2

Figure 3.

Seat Warning Buzzer Replacement..................................................................................... 0126-3

Figure 4.

Seat Warning Buzzer Replacement..................................................................................... 0126-4

ELECTRIC HORN REPLACEMENT............................................................................................................ WP 0127 Figure 1.

Electric Horn Replacement................................................................................................... 0127-2

BATTERY MAINTENANCE......................................................................................................................... WP 0128 Figure 1.

Battery Replacement............................................................................................................ 0128-2

Figure 2.

Battery Service..................................................................................................................... 0128-3

Figure 3.

Battery Installation................................................................................................................ 0128-4

BATTERY CABLES REPLACEMENT......................................................................................................... WP 0129 Figure 1.

Battery Cables Replacement................................................................................................ 0129-2

Figure 2.

Solar Charger Disconnect.................................................................................................... 0129-2

Figure 3.

Battery Cables Replacement................................................................................................ 0129-3

Figure 4.

Battery Cables Replacement................................................................................................ 0129-4

Figure 5.

Solar Charger Connection.................................................................................................... 0129-5

Figure 6.

Battery Cables Replacement................................................................................................ 0129-5

MASTER BATTERY SWITCH REPLACEMENT......................................................................................... WP 0130

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Master Battery Switch Replacement.................................................................................... 0130-1

Figure 2.

Master Battery Switch Replacement.................................................................................... 0130-2

Figure 3.

Master Battery Switch Replacement.................................................................................... 0130-3

AMBIENT TEMPERATURE SENSOR REPLACEMENT............................................................................. WP 0131 Figure 1.

Ambient Temperature Sensor Removal............................................................................... 0131-2

Figure 2.

Ambient Temperature Sensor Installation............................................................................ 0131-3

FUEL LEVEL SENDING UNIT REPLACEMENT......................................................................................... WP 0132 Figure 1.

Fuel Level Sending Unit Connector Removal...................................................................... 0132-1

Figure 2.

Fuel Level Sending Unit Removal........................................................................................ 0132-2

Figure 3.

Fuel Level Sending Unit Installation..................................................................................... 0132-3

BACKUP ALARM REPLACEMENT............................................................................................................. WP 0133 Figure 1.

Backup Alarm Removal........................................................................................................ 0133-1

Figure 2.

Backup Alarm Installation..................................................................................................... 0133-2

SLAVE STARTING RECEPTACLE REPLACEMENT................................................................................. WP 0134 Figure 1.

Right Slave Starting Receptacle Replacement.................................................................... 0134-1

Figure 2.

Right Slave Starting Receptacle Replacement.................................................................... 0134-2

Figure 3.

Right Slave Starting Receptacle Replacement.................................................................... 0134-3

Figure 4.

Left Slave Starting Receptacle Replacement....................................................................... 0134-4

Figure 5.

Left Slave Starting Receptacle Replacement....................................................................... 0134-5

Index Volume 2 Chapter 5 - MAINTENANCE INSTRUCTIONS TRANSMISSION ASSEMBLY MAINTENANCE.......................................................................................... WP 0135 Figure 1.

Transmission Sensors Removal........................................................................................... 0135-3

Figure 2.

Transmission Hoses Removal.............................................................................................. 0135-4

Figure 3.

Transmission Oil Fill Tube Removal..................................................................................... 0135-5

Figure 4.

Flywheel Housing Access Cover.......................................................................................... 0135-5

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5.

Flywheel-to-Damper Plate Access Cover Removal............................................................. 0135-6

Figure 6.

Damper Plates-to-Flywheel Screw Removal........................................................................ 0135-7

Figure 7.

Flywheel Housing Screws Removal..................................................................................... 0135-7

Figure 8.

Transmission-to-Mounting Bracket Removal....................................................................... 0135-8

Figure 9.

Electrical Connectors Removal............................................................................................ 0135-9

Figure 10.

Transmission Sensors Installation...................................................................................... 0135-10

Figure 11.

Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-12

Figure 12.

Flywheel-to-Damper Plate Screw Installation..................................................................... 0135-13

Figure 13.

Flywheel Housing Screws Installation................................................................................ 0135-13

Figure 14.

Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-14

Figure 15.

Flywheel Housing Access Cover Installation...................................................................... 0135-15

Figure 16.

Flywheel-to-Damper Plate Access Cover Installation........................................................ 0135-15

Figure 17.

Transmission Oil Fill Tube Installation................................................................................ 0135-16

Figure 18.

Transmission Hoses Installation......................................................................................... 0135-17

Figure 19.

Transmission Electrical Connectors................................................................................... 0135-18

TRANSMISSION CALIBRATION................................................................................................................. WP 0136 Figure 1.

Calibration............................................................................................................................ 0136-2

Figure 2.

Calibration............................................................................................................................ 0136-3

Table 1.

Main Transmission Calibration Codes.................................................................................. 0136-4

Table 2.

Sub Transmission Calibration Codes................................................................................... 0136-5

TRANSMISSION ASSEMBLY HYDRAULIC HOSES AND PIPES REPLACEMENT.................................. WP 0137 Figure 1.

Transmission Assembly Hose and Pipe Location Diagram.................................................. 0137-2

Figure 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.

Damper Plates Removal...................................................................................................... 0139-1

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2.

Torque Converter Removal.................................................................................................. 0139-3

TRANSMISSION OIL, OIL FILTERS, AND OIL FILTER HEAD MAINTENANCE....................................... WP 0140 Figure 1.

Transmission Oil Draining and Filling................................................................................... 0140-3

Figure 2.

Transmission Oil Filters Replacement.................................................................................. 0140-5

Figure 3.

Transmission Oil Filter Head Replacement.......................................................................... 0140-6

Figure 4.

Transmission Oil Filter Head Replacement.......................................................................... 0140-7

Figure 5.

Transmission Internal Coarse Oil Filter Removal................................................................. 0140-8

Figure 6.

Transmission Internal Coarse Oil Filter Installation............................................................ 0140-10

TRANSMISSION OIL COOLER REPLACEMENT....................................................................................... WP 0141 Figure 1.

Transmission Oil Coolers Removal...................................................................................... 0141-2

Figure 2.

Transmission Oil Coolers Removal...................................................................................... 0141-3

Figure 3.

Transmission Oil Coolers Removal...................................................................................... 0141-4

Figure 4.

Transmission Oil Coolers Removal...................................................................................... 0141-5

Figure 5.

Transmission Oil Coolers Installation................................................................................... 0141-6

Figure 6.

Transmission Oil Coolers Installation................................................................................... 0141-7

Figure 7.

Transmission Oil Coolers Installation................................................................................... 0141-8

TRANSMISSION OIL FILTER HOSES AND OIL COOLER HOSES AND FITTINGS REPLACEMENT.......................................................................................................................................... WP 0142 Figure 1.

Transmission-to-Oil Cooler Hoses Replacement................................................................. 0142-3

Figure 2.

Transmission-to-Oil Filter Hose Replacement. .................................................................... 0142-5

FRONT AND REAR PROPELLER SHAFTS REPLACEMENT................................................................... WP 0143 Figure 1.

Front Propeller Shaft Removal............................................................................................. 0143-2

Figure 2.

Front Propeller Shaft Removal. ........................................................................................... 0143-3

Figure 3.

Rear Propeller Shaft Removal.............................................................................................. 0143-4

Figure 4.

Rear Propeller Shaft Removal.............................................................................................. 0143-5

Figure 5.

Rear Propeller Shaft Installation. ......................................................................................... 0143-7

UNIVERSAL JOINT REPLACEMENT......................................................................................................... WP 0144 Figure 1.

Propeller Shaft Universal Joint Replacement....................................................................... 0144-3

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. FRONT AXLE ASSEMBLY REPLACEMENT.............................................................................................. WP 0145 Figure 1.

Front Axle Removal.............................................................................................................. 0145-2

Figure 2.

Front Axle Removal.............................................................................................................. 0145-3

Figure 3.

Front Axle Removal.............................................................................................................. 0145-4

Figure 4.

Front Axle Removal.............................................................................................................. 0145-5

Figure 5.

Front Axle Removal.............................................................................................................. 0145-6

Figure 6.

Front Axle Installation........................................................................................................... 0145-7

TRANSMISSION AND FRONT AND REAR AXLE VENT HOSES REPLACEMENT.................................. WP 0146 Figure 1.

Front Axle Vent Hose Removal............................................................................................ 0146-2

Figure 2.

Front Axle Vent Hose Replacement..................................................................................... 0146-3

Figure 3.

Rear Axle Vent Hose Replacement...................................................................................... 0146-4

Figure 4.

Rear Axle Vent Hose Replacement...................................................................................... 0146-5

Figure 5.

Transmission Vent Hose Replacement................................................................................ 0146-7

REAR AXLE ASSEMBLY MAINTENANCE................................................................................................. WP 0147 Figure 1.

Rear Axle Rigging................................................................................................................ 0147-2

Figure 2.

Rear Axle Removal.............................................................................................................. 0147-3

Figure 3.

Rear Axle Installation........................................................................................................... 0147-5

CAGING AND UNCAGING PARKING BRAKE........................................................................................... WP 0148 Figure 1.

Caging Parking Brake.......................................................................................................... 0148-2

Figure 2.

Caging Parking Brake.......................................................................................................... 0148-2

Figure 3.

Caging Parking Brake.......................................................................................................... 0148-3

PARKING BRAKE CYLINDER REPLACEMENT........................................................................................ WP 0149 Figure 1.

Parking Brake Cylinder Removal......................................................................................... 0149-3

Figure 2.

Parking Brake Cylinder Installation...................................................................................... 0149-5

Figure 3.

Parking Brake Rotor Removal.............................................................................................. 0149-7

Figure 4.

Parking Brake Bracket Replacement................................................................................... 0149-9

PARKING BRAKE PADS MAINTENANCE.................................................................................................. WP 0150

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Parking Brake Pad Replacement. ....................................................................................... 0150-3

PARKING BRAKE CONTROL VALVE REPLACEMENT............................................................................ WP 0151 Figure 1.

Parking Brake Control Valve Removal................................................................................. 0151-1

Figure 2.

Parking Brake Control Valve Replacement.......................................................................... 0151-3

Figure 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.

Brake Accumulators and Valve Block Replacement............................................................ 0154-2

Figure 2.

Brake Accumulators and Valve Block Replacement............................................................ 0154-3

Figure 3.

Brake Accumulators and Valve Block Replacement............................................................ 0154-4

BRAKE AND STEERING ACCUMULATOR SERVICE............................................................................... WP 0155 Figure 1.

Brake Accumulator Testing.................................................................................................. 0155-2

Figure 2.

Brake Accumulator Testing.................................................................................................. 0155-3

Figure 3.

Brake Accumulator Testing.................................................................................................. 0155-4

Figure 4.

Brake Accumulator Testing.................................................................................................. 0155-5

Figure 5.

Brake Accumulator Testing.................................................................................................. 0155-5

Figure 6.

Brake Accumulator Charging............................................................................................... 0155-6

Figure 7.

Brake Accumulator Charging............................................................................................... 0155-7

Figure 8.

Brake Accumulator Charging............................................................................................... 0155-7

Figure 9.

Brake Accumulator Charging............................................................................................... 0155-8

Figure 10.

Brake Accumulator Charging............................................................................................... 0155-9

Figure 11.

Brake Accumulator Charging............................................................................................... 0155-9

Figure 12.

Brake Accumulator Charging............................................................................................. 0155-10

Figure 13.

Brake Accumulator Charging............................................................................................. 0155-11

Figure 14.

Brake Accumulator Testing................................................................................................ 0155-12

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 15.

Brake Accumulator Charging............................................................................................. 0155-12

Figure 16.

Brake Accumulator Charging............................................................................................. 0155-13

Figure 17.

Brake Accumulator Charging............................................................................................. 0155-13

Figure 18.

Brake Accumulator Charging............................................................................................. 0155-14

Figure 19.

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.

Brake Cooling Filter Replacement........................................................................................ 0158-2

Figure 2.

Brake Cooling Filter Head Removal..................................................................................... 0158-3

Figure 3.

Brake Cooling Filter Head Installation.................................................................................. 0158-4

BRAKE LIGHT AND PRESSURE SWITCHES REPLACEMENT................................................................ WP 0159 Figure 1.

Left Lower Panel Removal................................................................................................... 0159-2

Figure 2.

Right Lower Panel Removal................................................................................................. 0159-2

Figure 3.

Brake Light and Pressure Switch Replacement................................................................... 0159-3

STEERING COLUMN BASE AND BRAKE PEDAL MAINTENANCE.......................................................... WP 0160 Figure 1.

Steering Column Base Removal.......................................................................................... 0160-1

Figure 2.

Steering Column Base Removal.......................................................................................... 0160-2

Figure 3.

Steering Column Base Removal.......................................................................................... 0160-2

Figure 4.

Steering Column Base Disassembly.................................................................................... 0160-3

Figure 5.

Steering Column Base Disassembly.................................................................................... 0160-4

Figure 6.

Steering Column Base Disassembly.................................................................................... 0160-4

Figure 7.

Steering Column Base Assembly......................................................................................... 0160-5

Figure 8.

Steering Column Base Installation....................................................................................... 0160-6

Figure 9.

Steering Column Base Installation....................................................................................... 0160-6

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 10.

Steering Column Base Installation....................................................................................... 0160-7

BRAKE INCHING SWITCH REPLACEMENT............................................................................................. WP 0161 Figure 1.

Brake Inching Switch Removal............................................................................................. 0161-2

Figure 2.

Brake Inching Switch Removal............................................................................................. 0161-3

Figure 3.

Brake Inching Switch Installation.......................................................................................... 0161-4

WHEEL ASSEMBLY REPLACEMENT........................................................................................................ WP 0162 Figure 1.

Raise Front Axle................................................................................................................... 0162-2

Figure 2.

Raise Front Axle................................................................................................................... 0162-3

Figure 3.

Raise Front Axle................................................................................................................... 0162-3

Figure 4.

Raise Front Axle................................................................................................................... 0162-4

Figure 5.

Wheel and Tire Replacement............................................................................................... 0162-5

BOGIE WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0163 Figure 1.

Lower Bogie Wheel.............................................................................................................. 0163-1

Figure 2.

Bogie Wheel Replacement................................................................................................... 0163-3

Figure 3.

Screw Assembly Removal and Installation.......................................................................... 0163-5

Figure 4.

Bogie Wheel Frame Replacement....................................................................................... 0163-7

DOLLY WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0164 Figure 1.

Dolly Wheel Disassembly..................................................................................................... 0164-2

Figure 2.

Dolly Wheel Assembly.......................................................................................................... 0164-3

STEERING WHEEL REPLACEMENT......................................................................................................... WP 0165 Figure 1.

Steering Wheel Removal...................................................................................................... 0165-1

Figure 2.

Steering Wheel Replacement............................................................................................... 0165-2

Figure 3.

Steering Wheel Installation................................................................................................... 0165-3

STEERING COLUMN REPLACEMENT...................................................................................................... WP 0166 Figure 1.

Steering Column Removal................................................................................................... 0166-1

Figure 2.

Steering Column Removal................................................................................................... 0166-2

Figure 3.

Steering Column Removal................................................................................................... 0166-3

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4.

Steering Column Removal................................................................................................... 0166-3

Figure 5.

Steering Column Removal................................................................................................... 0166-4

Figure 6.

Steering Column Removal and Installation.......................................................................... 0166-5

Figure 7.

Steering Column Installation................................................................................................ 0166-6

Figure 8.

Steering Column Installation................................................................................................ 0166-7

Figure 9.

Steering Column Installation................................................................................................ 0166-8

Figure 10.

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.

Steering Column Sensor Removal....................................................................................... 0168-1

Figure 2.

Steering Column Sensor Removal....................................................................................... 0168-2

Figure 3.

Steering Column Sensor Removal....................................................................................... 0168-3

Figure 4.

Steering Column Sensor Installation.................................................................................... 0168-3

Figure 5.

Steering Column Sensor Installation.................................................................................... 0168-4

Figure 6.

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 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.

Steering Control Valve Removal.......................................................................................... 0173-3

Figure 2.

Steering Control Valve Removal and Installation................................................................. 0173-5

STEERING CALIBRATION.......................................................................................................................... WP 0174

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. TRANSMISSION SKID PLATE AND ACCESS COVERS REPLACEMENT............................................... WP 0175 Figure 1.

Skid Plate Replacement....................................................................................................... 0175-3

Figure 2.

Front Access Cover Replacement........................................................................................ 0175-4

Figure 3.

Middle Access Cover and Cab Support Replacement......................................................... 0175-5

Figure 4.

Rear Access Cover Replacement........................................................................................ 0175-6

BOOM SUPPORT MAINTENANCE............................................................................................................ WP 0176 Figure 1.

Boom Support Removal....................................................................................................... 0176-2

Figure 2.

Boom Support Removal....................................................................................................... 0176-3

Figure 3.

Boom Support Removal....................................................................................................... 0176-3

Figure 4.

Boom Support Removal....................................................................................................... 0176-4

Figure 5.

Boom Support Removal....................................................................................................... 0176-5

Figure 6.

Boom Support Removal....................................................................................................... 0176-6

Figure 7.

Boom Support Installation.................................................................................................... 0176-7

Figure 8.

Boom Support Installation.................................................................................................... 0176-8

Figure 9.

Boom Support Installation.................................................................................................... 0176-9

Figure 10.

Boom Support Installation.................................................................................................... 0176-9

Figure 11.

Boom Support Installation.................................................................................................. 0176-10

Figure 12.

Boom Support Installation.................................................................................................. 0176-11

FLEXIBLE CONVEYOR MAINTENANCE................................................................................................... WP 0177 Figure 1.

Boom Wiring Harness and Cable Removal.......................................................................... 0177-2

Figure 2.

Boom Wiring Harness and Cable Removal.......................................................................... 0177-3

Figure 3.

Boom Wiring Harness and Cable Removal.......................................................................... 0177-3

Figure 4.

Hydraulic Hoses Removal.................................................................................................... 0177-4

Figure 5.

Conveyor Removal............................................................................................................... 0177-5

Figure 6.

Conveyor Installation............................................................................................................ 0177-6

Figure 7.

Hydraulic Hoses Installation................................................................................................. 0177-7

Figure 8.

Wiring Harness and Cable Installation................................................................................. 0177-7

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 9.

Wiring Harness and Cable Installation................................................................................. 0177-8

Figure 10.

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.

Cab Transport Lift System Inspection.................................................................................. 0179-2

Figure 2.

Cab Transport Lift System Inspection.................................................................................. 0179-3

Figure 3.

Cab Transport Lift System Inspection.................................................................................. 0179-3

Figure 4.

Cab Transport Lift System Inspection.................................................................................. 0179-4

Figure 5.

Cab Adjustment: Operational Position................................................................................. 0179-5

Figure 6.

Cab Adjustment: Operational Position................................................................................. 0179-6

Figure 7.

Cab Adjustment: Operational Position................................................................................. 0179-7

Figure 8.

Cab Adjustment: Operational Position................................................................................. 0179-7

Figure 9.

Cab Adjustment: Operational Position................................................................................. 0179-8

Figure 10.

Cab Adjustment: Transport Position..................................................................................... 0179-9

Figure 11.

Cab Adjustment: Transport Position................................................................................... 0179-10

Figure 12.

Cab Adjustment: Transport Position................................................................................... 0179-11

Figure 13.

Cab Adjustment: Transport Position................................................................................... 0179-12

Figure 14.

Cab Transport Lift Removal............................................................................................... 0179-13

Figure 15.

Cab Transport Lift Removal............................................................................................... 0179-14

Figure 16.

Cab Transport Lift Removal............................................................................................... 0179-15

Figure 17.

Cab Transport Lift Installation............................................................................................ 0179-16

Figure 18.

Cab Transport Lift Installation............................................................................................ 0179-17

Figure 19.

Cab Transport Lift Installation............................................................................................ 0179-18

Figure 20.

Cab Transport Lift Structure Removal................................................................................ 0179-19

Figure 21.

Cab Transport Lift Structure Removal................................................................................ 0179-20

Figure 22.

Cab Transport Lift Structure Removal................................................................................ 0179-21

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 23.

Cab Transport Lift Structure Installation............................................................................. 0179-22

Figure 24.

Cab Transport Lift Structure Installation............................................................................. 0179-23

Figure 25.

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.

Left-Side Step Assembly Replacement................................................................................ 0181-1

Figure 2.

Left-Side Stair Assembly Removal....................................................................................... 0181-2

Figure 3.

Left-Side Stair Assembly Replacement................................................................................ 0181-3

STORAGE COMPARTMENT DOORS AND LATCHES REPLACEMENT.................................................. WP 0182 Figure 1.

Storage Compartment Door Removal.................................................................................. 0182-1

Figure 2.

Storage Compartment Door Removal and Installation......................................................... 0182-2

Figure 3.

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.

Engine Cover Removal........................................................................................................ 0185-1

Figure 2.

Engine Cover Disassembly.................................................................................................. 0185-2

Figure 3.

Engine Cover Disassembly.................................................................................................. 0185-2

Figure 4.

Engine Cover Disassembly.................................................................................................. 0185-3

Figure 5.

Engine Cover Assembly....................................................................................................... 0185-4

CAB DOOR ASSEMBLY MAINTENANCE.................................................................................................. WP 0186 Figure 1.

Cab Door Assembly Removal.............................................................................................. 0186-1

Figure 2.

Cab Door Assembly Removal.............................................................................................. 0186-2

Figure 3.

Cab Door Disassembly......................................................................................................... 0186-3

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4.

Cab Door Disassembly and Assembly................................................................................. 0186-4

Figure 5.

Cab Door Installation............................................................................................................ 0186-5

Figure 6.

Cab Door Installation............................................................................................................ 0186-6

Figure 7.

Cab Door Installation............................................................................................................ 0186-7

CAB DOOR WEATHERSEAL REPLACEMENT.......................................................................................... WP 0187 Figure 1.

Cab Door Weatherseal Removal.......................................................................................... 0187-1

Figure 2.

Cab Door Weatherseal Removal.......................................................................................... 0187-2

Figure 3.

Cab Door Weatherseal Removal.......................................................................................... 0187-3

Figure 4.

Cab Door Weatherseal Installation....................................................................................... 0187-4

Figure 5.

Cab Door Weatherseal Installation....................................................................................... 0187-5

Figure 6.

Cab Door Weatherseal Installation....................................................................................... 0187-5

WINDSHIELD AND WINDOW GLASS REPLACEMENT............................................................................ WP 0188 Figure 1.

Window Removal and Installation........................................................................................ 0188-3

Figure 2.

Window Removal and Installation........................................................................................ 0188-4

MUDGUARD REPLACEMENT.................................................................................................................... WP 0189 Figure 1.

Mudguard Replacement....................................................................................................... 0189-2

FENDER ASSEMBLY REPLACEMENT...................................................................................................... WP 0190 Figure 1.

Fender and Fender Bracket Removal (RT 240V1)............................................................... 0190-2

Figure 2.

Fender and Fender Bracket Replacement (RT 240V1)........................................................ 0190-3

Figure 3.

Front Fender and Fender Bracket Removal (RT 240V1R)................................................... 0190-4

Figure 4.

Front Fender and Fender Bracket Replacement (RT 240V1R)............................................ 0190-5

Figure 5.

Rear Fender and Fender Bracket Removal (RT 240V2 and RT 240V3).............................. 0190-6

Figure 6.

Rear Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)....................... 0190-7

Figure 7.

Front Fender and Fender Bracket Removal (RT 240V2 and RT 240V3)............................. 0190-8

Figure 8.

Front Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)...................... 0190-9

Figure 9.

Front Bracket Mounting Plate Replacement....................................................................... 0190-10

SEAT ASSEMBLY MAINTENANCE............................................................................................................ WP 0191

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Seat Removal....................................................................................................................... 0191-2

Figure 2.

Seat Disassembly................................................................................................................. 0191-3

Figure 3.

Seat Disassembly and Assembly......................................................................................... 0191-5

Figure 4.

Seat Assembly..................................................................................................................... 0191-7

Figure 5.

Seat Installation.................................................................................................................... 0191-8

SEAT BELT REPLACEMENT...................................................................................................................... WP 0192 Figure 1.

Seatbelt Replacement.......................................................................................................... 0192-2

REARVIEW MIRRORS REPLACEMENT.................................................................................................... WP 0193 Figure 1.

Interior Rearview Mirror Replacement.................................................................................. 0193-1

Figure 2.

Exterior Rearview Mirror Removal....................................................................................... 0193-2

Figure 3.

Exterior Rearview Mirror Removal and Installation.............................................................. 0193-3

WINDSHIELD WIPER MAINTENANCE...................................................................................................... WP 0194 Figure 1.

Front Windshield Wiper and Motor Removal........................................................................ 0194-2

Figure 2.

Front Windshield Wiper and Motor Removal........................................................................ 0194-3

Figure 3.

Front Windshield Wiper and Motor Removal........................................................................ 0194-3

Figure 4.

Front Windshield Wiper and Motor Installation..................................................................... 0194-4

Figure 5.

Front Windshield Wiper and Motor Installation..................................................................... 0194-5

Figure 6.

Front Windshield Wiper and Motor Installation..................................................................... 0194-6

Figure 7.

Rear Windshield Wiper and Motor Removal........................................................................ 0194-7

Figure 8.

Rear Windshield Wiper and Motor Removal........................................................................ 0194-7

Figure 9.

Rear Windshield Wiper and Motor Removal and Installation............................................... 0194-9

Figure 10.

Rear Windshield Wiper and Motor Installation..................................................................... 0194-9

Figure 11.

Roof Window Windshield Wiper and Motor Removal......................................................... 0194-10

Figure 12.

Roof Window Windshield Wiper and Motor Removal......................................................... 0194-11

Figure 13.

Roof Window Windshield Wiper and Motor Removal and Installation............................... 0194-12

Figure 14.

Roof Window Windshield Wiper and Motor Installation...................................................... 0194-13

Figure 15.

Roof Window Windshield Wiper and Motor Installation...................................................... 0194-14

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. WINDSHIELD WASHER RESERVOIR AND PUMP REPLACEMENT....................................................... WP 0195 Figure 1.

Windshield Washer Reservoir Replacement........................................................................ 0195-3

Figure 2.

Windshield Washer Pump Removal..................................................................................... 0195-4

Figure 3.

Windshield Washer Pump Replacement.............................................................................. 0195-5

Figure 4.

Windshield Washer Pump Installation.................................................................................. 0195-6

HEATER HOSES REPLACEMENT............................................................................................................. WP 0196 Figure 1.

Engine Heater Hoses Removal............................................................................................ 0196-2

Figure 2.

Engine Heater Hoses Removal............................................................................................ 0196-3

Figure 3.

Engine Heater Hoses Removal............................................................................................ 0196-3

Figure 4.

Engine Heater Hoses Removal............................................................................................ 0196-4

Figure 5.

Engine Heater Hoses Removal............................................................................................ 0196-5

Figure 6.

Engine Heater Hoses Removal............................................................................................ 0196-5

Figure 7.

Engine.................................................................................................................................. 0196-6

Figure 8.

Engine Heater Hoses Removal............................................................................................ 0196-7

Figure 9.

Cab Heater Hoses Removal – RT 240V1 and RT 240V1R.................................................. 0196-8

Figure 10.

Cab Heater Hoses Removal – RT 240V2 and RT 240V3 Vehicles...................................... 0196-8

Figure 11.

Cab Heater Hoses Removal................................................................................................. 0196-9

Figure 12.

Cab Heater Hoses Removal............................................................................................... 0196-10

Figure 13.

Cab Heater Hoses Removal............................................................................................... 0196-10

Figure 14.

Cab Heater Hoses Removal............................................................................................... 0196-11

Figure 15.

Cab Heater Hoses Installation............................................................................................ 0196-12

Figure 16.

Cab Heater Hoses Installation............................................................................................ 0196-13

Figure 17.

Cab Heater Hoses Installation............................................................................................ 0196-13

Figure 18.

Cab Heater Hoses Installation – RT 240V1 and RT 240V1R Vehicles.............................. 0196-14

Figure 19.

Cab Heater Hoses Installation – RT 240V2 and RT 240V3 Vehicles................................. 0196-14

CAB HEATER/AIR CONDITIONING UNIT MAINTENANCE....................................................................... WP 0197 Figure 1.

Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2.

Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-3

Figure 3.

Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-4

Figure 4.

Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-5

Figure 5.

Cab Heater/Air Conditioning Unit Installation....................................................................... 0197-6

CAB HEATER/AIR CONDITIONING BLOWER MOTOR AND FAN REPLACEMENT................................ WP 0198 Figure 1.

Front Panel Removal............................................................................................................ 0198-1

Figure 2.

Cover Removal..................................................................................................................... 0198-2

Figure 3.

Blower Motor and Fan Replacement.................................................................................... 0198-3

Figure 4.

Blower Motor and Fan Installation........................................................................................ 0198-4

CAB AIR FILTERS REPLACEMENT........................................................................................................... WP 0199 Figure 1.

Cab Grille Removal.............................................................................................................. 0199-2

Figure 2.

Cab Side Air Filter Removal................................................................................................. 0199-3

Figure 3.

Cab Side Air Filter Installation.............................................................................................. 0199-4

Figure 4.

Left Lower Panel Removal – RT 240V1 and RT 240V1R Vehicles Only............................. 0199-5

Figure 5.

Cab Interior Air Filter Removal............................................................................................. 0199-5

Figure 6.

Cab Interior Air Filter Removal............................................................................................. 0199-6

Figure 7.

Left Lower Panel Installation – RT 240V1 and RT 240V1R Vehicles Only.......................... 0199-7

Figure 8.

Cab Interior Air Filter Installation.......................................................................................... 0199-8

CAB AUXILIARY FAN REPLACEMENT...................................................................................................... WP 0200 Figure 1.

Access Panel Removal........................................................................................................ 0200-1

Figure 2.

Auxiliary Fan Replacement.................................................................................................. 0200-2

Figure 3.

Access Cover Installation..................................................................................................... 0200-3

AUTOLUBE SYSTEM MAINTENANCE....................................................................................................... WP 0201 Figure 1.

Autolube Tube Replacement................................................................................................ 0201-2

Figure 2.

Autolube Pump Replacement............................................................................................... 0201-3

Figure 3.

Autolube Distribution Valve Replacement............................................................................ 0201-4

FIRE EXTINGUISHER BRACKET REPLACEMENT................................................................................... WP 0202

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. 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.

Steering Accumulator Evacuation Valve.............................................................................. 0204-2

Figure 2.

Steering Accumulator Evacuation Valves............................................................................ 0204-3

Figure 3.

Float Control and Emergency Control Valves...................................................................... 0204-3

BOOM AND BRAKE SYSTEM HYDRAULIC PUMP REPLACEMENT....................................................... WP 0205 Figure 1.

Pump Replacement.............................................................................................................. 0205-3

Figure 2.

Pump Installation.................................................................................................................. 0205-5

COOLING FAN HYDRAULIC PUMP REPLACEMENT............................................................................... WP 0206 Figure 1.

Pump Removal..................................................................................................................... 0206-3

Figure 2.

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.

Cover Removal..................................................................................................................... 0209-2

Figure 2.

Hose and Wire Disconnects................................................................................................. 0209-3

Figure 3.

Ground Strap and Power Cable Disconnects....................................................................... 0209-3

Figure 4.

Pump Removal..................................................................................................................... 0209-4

Figure 5.

Pump Installation.................................................................................................................. 0209-5

Figure 6.

Ground Strap and Power Cable Connections...................................................................... 0209-5

Figure 7.

Hose and Wire Connections................................................................................................. 0209-6

Figure 8.

Cover Installation.................................................................................................................. 0209-7

TOPHANDLER HYDRAULIC SLEWING MOTORS MAINTENANCE......................................................... WP 0210 Figure 1.

Turning Plate Cover Removal.............................................................................................. 0210-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2.

Hydraulic Manifold and Hose Removal................................................................................ 0210-3

Figure 3.

Hydraulic Manifold and Hose Removal................................................................................ 0210-3

Figure 4.

Slewing Motor and Pinion Gear Removal............................................................................ 0210-5

Figure 5.

Slewing Motor and Hydraulic Manifold Installation............................................................... 0210-6

Figure 6.

Secure Hydraulic Manifold................................................................................................... 0210-7

Figure 7.

Hoses and Fittings Installation and Connection................................................................... 0210-8

Figure 8.

Protective Cover Installation................................................................................................. 0210-9

SLEWING MOTOR BRAKE REPLACEMENT............................................................................................. WP 0211 Figure 1.

Spur Gear Removal.............................................................................................................. 0211-1

Figure 2.

Slewing Motor Brake Removal and Replacement................................................................ 0211-3

Figure 3.

Slewing Motor Gear Replacement....................................................................................... 0211-4

TOPHANDLER AND STEERING HYDRAULIC PUMP ASSEMBLY REPLACEMENT............................... WP 0212 Figure 1.

Pump Removal..................................................................................................................... 0212-2

Figure 2.

Pump Removal..................................................................................................................... 0212-3

Figure 3.

Pump Removal..................................................................................................................... 0212-3

Figure 4.

Pump Removal..................................................................................................................... 0212-4

Figure 5.

Pump Removal..................................................................................................................... 0212-4

Figure 6.

Pump Removal..................................................................................................................... 0212-5

Figure 7.

Pump Removal..................................................................................................................... 0212-6

Figure 8.

Pump Removal..................................................................................................................... 0212-7

Figure 9.

Pump Removal..................................................................................................................... 0212-7

Figure 10.

Pump Removal..................................................................................................................... 0212-8

Figure 11.

Pump Removal..................................................................................................................... 0212-9

Figure 12.

Pump Installation................................................................................................................ 0212-10

Figure 13.

Pump Installation................................................................................................................ 0212-11

Figure 14.

Pump Installation................................................................................................................ 0212-11

Figure 15.

Pump Installation................................................................................................................ 0212-12

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 16.

Pump Installation................................................................................................................ 0212-13

Figure 17.

Pump Installation................................................................................................................ 0212-14

Figure 18.

Pump Installation................................................................................................................ 0212-14

Figure 19.

Pump Installation................................................................................................................ 0212-15

Figure 20.

Pump Installation................................................................................................................ 0212-16

Figure 21.

Pump Installation................................................................................................................ 0212-17

Figure 22.

Pump Installation................................................................................................................ 0212-18

TOPHANDLER AND STEERING HYDRAULIC PUMPS ADJUSTMENT.................................................... WP 0213 Figure 1.

Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-2

Figure 2.

Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-3

Figure 3.

Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-4

Figure 4.

Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-5

Figure 5.

Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-6

Figure 6.

Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-7

MAIN CONTROL VALVE REPLACEMENT................................................................................................. WP 0214 Figure 1.

Main Control Valve Removal................................................................................................ 0214-2

Figure 2.

Main Control Valve Removal................................................................................................ 0214-3

Figure 3.

Main Control Valve Removal................................................................................................ 0214-5

Figure 4.

Main Control Valve Installation............................................................................................. 0214-6

Figure 5.

Main Control Valve Installation............................................................................................. 0214-7

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.

Control Valve Solenoid Replacement – Type A................................................................... 0217-3

Figure 2.

Control Valve Solenoid Replacement – Type B................................................................... 0217-4

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 3.

Control Valve Solenoid Replacement – Type C................................................................... 0217-5

Figure 4.

Control Valve Solenoid Replacement – Type D................................................................... 0217-6

BOOM FOLDING CYLINDERS REPLACEMENT....................................................................................... WP 0218 Figure 1.

Boom Folding Cylinder Replacement................................................................................... 0218-3

Figure 2.

Boom Folding Cylinder Installation....................................................................................... 0218-4

Figure 3.

Boom Folding Cylinder installation....................................................................................... 0218-5

Figure 4.

Boom Folding Cylinder Installation....................................................................................... 0218-6

Figure 5.

Boom Folding Cylinder Installation....................................................................................... 0218-7

Figure 6.

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.

Hydraulic Reservoir Return Oil Filter Removal..................................................................... 0227-2

Figure 2.

Reservoir Return Oil Filter Installation.................................................................................. 0227-3

Figure 3.

Hydraulic Reservoir Breather Filter Installation.................................................................... 0227-4

Figure 4.

Hydraulic System In-Line Filters and Filter Head Replacement........................................... 0227-5

HYDRAULIC SYSTEM VALVE MAINTENANCE......................................................................................... WP 0228 Figure 1.

Pump Shut-Off Valve Removal............................................................................................ 0228-3

Figure 2.

Shift Valve Removal............................................................................................................. 0228-5

Figure 3.

Boom Support/Bogie Supply Valve Removal....................................................................... 0228-6

Figure 4.

Boom Support/Bogie Supply Valve Installation.................................................................... 0228-7

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5.

Servo Pressure Regulator Valve Removal........................................................................... 0228-9

Figure 6.

Bogie/Boom Support Flow Control Valve Removal............................................................ 0228-11

Figure 7.

Boom Support Locking Pin Check Valve Removal............................................................ 0228-12

Figure 8.

Boom Support Locking Pin Check Valve Installation......................................................... 0228-13

Figure 9.

Bogie Pressure Ball Valve Removal................................................................................... 0228-15

Figure 10.

Extension Cylinder Over-Center Valve Replacement........................................................ 0228-17

Figure 11.

Parking Brake Hold Flow Control Valve Removal.............................................................. 0228-18

Figure 12.

Parking Brake Hold Flow Control Valve Installation........................................................... 0228-19

Figure 13.

Brake Charging Valve Replacement.................................................................................. 0228-21

Figure 14.

Brake Drain Shut-Off Valve Replacement.......................................................................... 0228-23

Figure 15.

Brake Circuit Safety Regulating Valve Replacement......................................................... 0228-25

Figure 16.

Front Brake Cooling Bypass Valve Replacement.............................................................. 0228-27

Figure 17.

Rear Brake Cooling Bypass Valve Replacement............................................................... 0228-29

Figure 18.

Cooling Fan Control Valve Removal.................................................................................. 0228-30

Figure 19.

Emergency Steering Pressure Balancing Valve Removal................................................. 0228-33

Figure 20.

Moderation and Tilt Manifold Valve Removal..................................................................... 0228-34

Figure 21.

Tilt Over-Center Valve Removal......................................................................................... 0228-36

Figure 22.

Tilt Over-Center Installation................................................................................................ 0228-37

Figure 23.

Oscillation Over-Center Valve Installation.......................................................................... 0228-39

Figure 24.

Oscillation Float Lock Flow Control Valve Removal........................................................... 0228-40

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.

Boom Lift Cylinder Removal................................................................................................. 0231-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 2.

Boom Lift Cylinder Removal................................................................................................. 0231-3

Figure 3.

Boom Lift Cylinder Removal................................................................................................. 0231-4

Figure 4.

Boom Lift Cylinder Removal................................................................................................. 0231-5

Figure 5.

Boom Lift Cylinder Installation.............................................................................................. 0231-6

Figure 6.

Boom Lift Cylinder Installation.............................................................................................. 0231-7

Figure 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.

Hydraulic Cylinders Replacement........................................................................................ 0234-3

Figure 2.

Hydraulic Cylinders Replacement........................................................................................ 0234-3

Figure 3.

Hydraulic Cylinders Replacement........................................................................................ 0234-4

Figure 4.

Hydraulic Cylinders Replacement........................................................................................ 0234-5

BOOM SUPPORT LOCKING PIN CYLINDER AND LOCKING PIN REPLACEMENT............................... WP 0235 Figure 1.

Locking Pin Cylinder Removal............................................................................................. 0235-2

Figure 2.

Locking Pin Cylinder Removal............................................................................................. 0235-3

Figure 3.

Locking Pin Cylinder Removal............................................................................................. 0235-4

Figure 4.

Locking Pin Cylinder Installation.......................................................................................... 0235-5

Figure 5.

Locking Pin Cylinder Installation.......................................................................................... 0235-6

Figure 6.

Locking Pin Cylinder Installation.......................................................................................... 0235-7

LOCKING PIN BUSHING REPLACEMENT................................................................................................ WP 0236 Figure 1.

Frame Bushings Removal.................................................................................................... 0236-2

Figure 2.

Frame Bushings Installation................................................................................................. 0236-3

Figure 3.

Boom Support Bushings Removal....................................................................................... 0236-4

Figure 4.

Boom Support Bushings Removal....................................................................................... 0236-5

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5.

Boom Support Bushings Installation.................................................................................... 0236-6

Figure 6.

Boom Support Bushings Installation.................................................................................... 0236-7

Figure 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.

Tophandler Twistlock Removal............................................................................................ 0241-2

Figure 2.

Tophandler Twistlock Replacement..................................................................................... 0241-3

DRAINING AND FILLING HYDRAULIC RESERVOIR................................................................................ WP 0242 Figure 1.

Draining Hydraulic Reservoir................................................................................................ 0242-2

Figure 2.

Filling Hydraulic Reservoir.................................................................................................... 0242-3

HYDRAULIC RESERVOIR MAINTENANCE............................................................................................... WP 0243 Figure 1.

Hydraulic Reservoir Removal............................................................................................... 0243-3

Figure 2.

Hydraulic Reservoir Removal............................................................................................... 0243-3

Figure 3.

Hydraulic Reservoir Removal............................................................................................... 0243-4

Figure 4.

Hydraulic Reservoir Removal............................................................................................... 0243-5

Figure 5.

Hydraulic Reservoir Removal............................................................................................... 0243-6

Figure 6.

Hydraulic Reservoir Removal............................................................................................... 0243-7

Figure 7.

Hydraulic Reservoir Removal............................................................................................... 0243-7

Figure 8.

Hydraulic Reservoir Removal............................................................................................... 0243-8

Figure 9.

Hydraulic Reservoir Installation............................................................................................ 0243-9

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 10.

Hydraulic Reservoir Installation............................................................................................ 0243-9

Figure 11.

Hydraulic Reservoir Installation.......................................................................................... 0243-10

Figure 12.

Hydraulic Reservoir Installation.......................................................................................... 0243-10

Figure 13.

Hydraulic Reservoir Installation.......................................................................................... 0243-11

Figure 14.

Hydraulic Reservoir Installation.......................................................................................... 0243-12

Figure 15.

Hydraulic Reservoir Installation.......................................................................................... 0243-13

Figure 16.

Hydraulic Reservoir Installation.......................................................................................... 0243-13

Figure 17.

Hydraulic Reservoir Installation.......................................................................................... 0243-14

HYDRAULIC RESERVOIR SIGHT GAUGE REPLACEMENT.................................................................... WP 0244 Figure 1.

Hydraulic Reservoir Sight Gauge Removal.......................................................................... 0244-1

Figure 2.

Hydraulic Reservoir Sight Gauge Installation....................................................................... 0244-2

HYDRAULIC SYSTEM TEST POINT PROCEDURES................................................................................ WP 0245 Figure 1.

Hydraulic System Test Points.............................................................................................. 0245-2

Figure 2.

System Drain Valves............................................................................................................ 0245-3

Figure 3.

Steering Accumulator Drain Valve....................................................................................... 0245-4

Figure 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

Figure 2.

Rifle Mounting Bracket Replacement................................................................................... 0247-2

Figure 3.

Rifle Mounting Bracket Installation....................................................................................... 0247-3

AIR CONDITIONING SYSTEM MAINTENANCE........................................................................................ WP 0248 Figure 1.

System Recovery................................................................................................................. 0248-3

Figure 2.

Nitrogen Purging.................................................................................................................. 0248-5

AIR CONDITIONER LEAK TEST................................................................................................................ WP 0249 AIR CONDITIONING COMPRESSOR REPLACEMENT............................................................................ WP 0250

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Air Conditioner Compressor Removal.................................................................................. 0250-2

Figure 2.

Air Conditioner Compressor Replacement........................................................................... 0250-3

Figure 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.

Chassis A/C Hoses Removal............................................................................................... 0252-1

Figure 2.

Chassis A/C Hoses Removal and Installation...................................................................... 0252-2

Figure 3.

Chassis A/C Hoses Removal Replacement......................................................................... 0252-3

Figure 4.

Chassis A/C Hoses Installation............................................................................................ 0252-3

Figure 5.

Cab Rear A/C Hose Removal.............................................................................................. 0252-4

Figure 6.

Cab Rear A/C Hose Removal.............................................................................................. 0252-5

Figure 7.

Cab Rear A/C Hose Replacement....................................................................................... 0252-6

Figure 8.

Cab Rear A/C Hose Installation........................................................................................... 0252-7

Figure 9.

Cab Interior A/C Hoses Removal......................................................................................... 0252-8

Figure 10.

Cab Interior A/C Hoses Removal......................................................................................... 0252-9

Figure 11.

Cab Interior A/C Hoses Removal......................................................................................... 0252-9

Figure 12.

Cab Interior A/C Hoses Removal....................................................................................... 0252-10

Figure 13.

Cab Interior A/C Hoses Removal....................................................................................... 0252-11

Figure 14.

Cab Interior A/C Hoses Replacement................................................................................ 0252-12

Figure 15.

Cab Interior A/C Hoses Installation.................................................................................... 0252-13

Figure 16.

Cab Interior A/C Hoses Installation.................................................................................... 0252-14

Figure 17.

Cab Interior A/C Hoses Installation.................................................................................... 0252-15

AIR CONDITIONER CONDENSER REPLACEMENT................................................................................. WP 0253 Figure 1.

Air Conditioner Condenser Removal.................................................................................... 0253-1

Figure 2.

Air Conditioner Condenser Removal.................................................................................... 0253-2

Figure 3.

Air Conditioner Condenser Replacement............................................................................. 0253-3

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4.

Air Conditioner Condenser Installation................................................................................. 0253-4

AIR CONDITIONER RECEIVER/DRYER REPLACEMENT........................................................................ WP 0254 Figure 1.

Air Conditioner Receiver/Dryer Removal............................................................................. 0254-1

Figure 2.

Air Conditioner Receiver/Dryer Replacement...................................................................... 0254-2

Figure 3.

Air Conditioner Receiver/Dryer Installation.......................................................................... 0254-3

AIR CONDITIONER FANS MAINTENANCE............................................................................................... WP 0255 Figure 1.

Condenser Fan Box Cover Removal.................................................................................... 0255-1

Figure 2.

Air Conditioner Fan Replacement........................................................................................ 0255-2

Figure 3.

Condenser Fan Box Cover................................................................................................... 0255-3

Figure 4.

Relays Replacement............................................................................................................ 0255-4

Figure 5.

Resistors Replacement........................................................................................................ 0255-5

Figure 6.

Condenser Fan Box Cover Installation................................................................................. 0255-6

BOOM ASSEMBLY REPLACEMENT.......................................................................................................... WP 0256 Figure 1.

Boom Assembly Removal.................................................................................................... 0256-2

Figure 2.

Boom Assembly Removal.................................................................................................... 0256-3

Figure 3.

Boom Assembly Installation................................................................................................. 0256-6

Figure 4.

Boom Assembly Installation................................................................................................. 0256-7

BOOM AND TOPHANDLER CALIBRATION............................................................................................... WP 0257 Table 1.

Range 600-800..................................................................................................................... 0257-2

Figure 1.

Boom and Tophandler Calibration........................................................................................ 0257-2

Table 2.

Range 200-400..................................................................................................................... 0257-2

Figure 2.

Boom and Tophandler Calibration........................................................................................ 0257-2

Table 3.

Range 200-400..................................................................................................................... 0257-3

Figure 3.

Boom and Tophandler Calibration........................................................................................ 0257-3

Table 4.

Range 600-800..................................................................................................................... 0257-4

Figure 4.

Boom and Tophandler Calibration........................................................................................ 0257-4

Table 5.

Range 35-150....................................................................................................................... 0257-5

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5.

Boom and Tophandler Calibration........................................................................................ 0257-5

Table 6.

Range 400-550..................................................................................................................... 0257-6

Figure 6.

Boom and Tophandler Calibration........................................................................................ 0257-6

Table 7.

Range 500-650..................................................................................................................... 0257-7

Figure 7.

Boom and Tophandler Calibration........................................................................................ 0257-7

Table 8.

Range 800-950..................................................................................................................... 0257-8

Figure 8.

Boom and Tophandler Calibration........................................................................................ 0257-8

Table 9.

Load Check.......................................................................................................................... 0257-8

Table 10.

Boom Calibration Completed............................................................................................... 0257-9

BOOM ASSEMBLY WEAR PLATES (SLIDE PLATE) REPLACEMENT..................................................... WP 0258 Figure 1.

Boom Wear Plates Locations............................................................................................... 0258-2

Figure 2.

Style A Wear Plate Removal................................................................................................ 0258-3

Figure 3.

Style A Wear Plate Removal................................................................................................ 0258-4

Figure 4.

Style A Wear Plate Installation............................................................................................. 0258-5

Figure 5.

Style A Wear Plate Installation............................................................................................. 0258-6

Figure 6.

Style B Wear Plate Removal................................................................................................ 0258-7

Figure 7.

Style B Wear Plate Removal................................................................................................ 0258-8

Figure 8.

Style B Wear Plate Removal................................................................................................ 0258-9

Figure 9.

Style B Wear Plate Removal.............................................................................................. 0258-10

Figure 10.

Style B Wear Plate Removal.............................................................................................. 0258-11

Figure 11.

Style B Wear Plate Installation........................................................................................... 0258-12

Figure 12.

Style B Wear Plate Installation........................................................................................... 0258-13

Figure 13.

Style B Wear Plate Installation........................................................................................... 0258-14

Figure 14.

Style B Wear Plate Installation........................................................................................... 0258-15

Figure 15.

Style B Wear Plate Installation........................................................................................... 0258-16

Figure 16.

Style C (RT 240V1 and RT 240V1R) Wear Plate Replacement........................................ 0258-17

Figure 17.

Style D (RT 240V2 and RT 240V3 ONLY) Wear Plate Replacement................................ 0258-18

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. TOPHANDLER REPLACEMENT................................................................................................................ WP 0259 Figure 1.

Tophandler Removal............................................................................................................ 0259-2

Figure 2.

Tophandler Removal............................................................................................................ 0259-3

Figure 3.

Tophandler Removal............................................................................................................ 0259-3

Figure 4.

Tophandler Removal............................................................................................................ 0259-4

Figure 5.

Tophandler Removal............................................................................................................ 0259-5

Figure 6.

Tophandler Removal............................................................................................................ 0259-5

Figure 7.

Tophandler Removal............................................................................................................ 0259-6

Figure 8.

Tophandler Removal............................................................................................................ 0259-6

Figure 9.

Tophandler Removal............................................................................................................ 0259-7

Figure 10.

Tophandler Removal............................................................................................................ 0259-7

Figure 11.

Tophandler Removal............................................................................................................ 0259-8

Figure 12.

Tophandler Removal............................................................................................................ 0259-9

Figure 13.

Tophandler Removal............................................................................................................ 0259-9

Figure 14.

Tophandler Removal.......................................................................................................... 0259-10

Figure 15.

Tophandler Installation....................................................................................................... 0259-10

Figure 16.

Tophandler Installation....................................................................................................... 0259-11

Figure 17.

Tophandler Installation....................................................................................................... 0259-11

Figure 18.

Tophandler Installation....................................................................................................... 0259-12

Figure 19.

Tophandler Installation....................................................................................................... 0259-13

Figure 20.

Tophandler Installation....................................................................................................... 0259-13

Figure 21.

Tophandler Installation....................................................................................................... 0259-14

Figure 22.

Tophandler Installation....................................................................................................... 0259-14

SPREADER CHAIN MAINTENANCE.......................................................................................................... WP 0260 Figure 1.

Access Panels Removal....................................................................................................... 0260-1

Figure 2.

Protective Plate Removal..................................................................................................... 0260-2

Figure 3.

Sliding Beam Removal from Main Beam.............................................................................. 0260-2

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 4.

Sliding Beam Reference Mark.............................................................................................. 0260-3

Figure 5.

Chain Tensioner Removal.................................................................................................... 0260-3

Figure 6.

Locking Plate Removal......................................................................................................... 0260-4

Figure 7.

Chain Anchor Access........................................................................................................... 0260-5

Figure 8.

Beam and Tensioner Locknut Removal............................................................................... 0260-5

Figure 9.

Hydraulic/Electrical Hose Power Track Support Removal................................................... 0260-6

Figure 10.

Chain Anchor Removal........................................................................................................ 0260-7

Figure 11.

Position Slide Beam............................................................................................................. 0260-8

Figure 12.

Assemble Chain Anchor....................................................................................................... 0260-9

Figure 13.

Idler Shaft Locking Plate Installation.................................................................................... 0260-9

Figure 14.

Chain Adjustment............................................................................................................... 0260-10

Figure 15.

Chain Tension Adjustment................................................................................................. 0260-11

Figure 16.

Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-12

Figure 17.

Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-13

SPREADER 20 AND 40 FOOT ADJUSTMENT.......................................................................................... WP 0261 Figure 1.

Measurement and Adjustment - 20 Ft.................................................................................. 0261-1

Figure 2.

Measurement and Adjustment - 20 Ft.................................................................................. 0261-2

Figure 3.

Measurement and Adjustment - 20 Ft.................................................................................. 0261-3

Figure 4.

Measurement and Adjustment - 20 Ft.................................................................................. 0261-3

Figure 5.

Measurement and Adjustment - 40 Ft.................................................................................. 0261-4

Figure 6.

Measurement and Adjustment - 40 Ft.................................................................................. 0261-4

Figure 7.

Measurement and Adjustment - 40 Ft.................................................................................. 0261-5

Figure 8.

Measurement and Adjustment - 40 Ft.................................................................................. 0261-5

SPREADER MAINTENANCE...................................................................................................................... WP 0262 Figure 1.

Hydraulic Motor Replacement.............................................................................................. 0262-2

Figure 2.

Gear Installation................................................................................................................... 0262-3

TOPHANDLER WEAR PLATES (SLIDE PLATE) REPLACEMENT............................................................ WP 0263

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Tophandler Wear Plate Locations........................................................................................ 0263-3

Figure 2.

Tophandler Wear Plate Locations........................................................................................ 0263-4

Figure 3.

Style A Wear Plate Removal................................................................................................ 0263-5

Figure 4.

Style A Wear Plate Replacement......................................................................................... 0263-6

Figure 5.

Style B Wear Plate Removal................................................................................................ 0263-7

Figure 6.

Style B Wear Plate Removal................................................................................................ 0263-8

Figure 7.

Style B Wear Plate Removal................................................................................................ 0263-9

Figure 8.

Style B Wear Plate Removal.............................................................................................. 0263-10

Figure 9.

Style B Wear Plate Installation........................................................................................... 0263-11

Figure 10.

Style B Wear Plate Installation........................................................................................... 0263-12

Figure 11.

Style B Wear Plate Installation........................................................................................... 0263-13

Figure 12.

Style C Wear Plate Replacement....................................................................................... 0263-15

Figure 13.

Style D Wear Plate Replacement....................................................................................... 0263-17

Figure 14.

Style E Wear Plate Replacement....................................................................................... 0263-18

TOPHANDLER HYDRAULIC SPREADER MOTOR MAINTENANCE........................................................ WP 0264 Figure 1.

Tophandler Access Panels Removal................................................................................... 0264-2

Figure 2.

Tophandler Access Panels Removal................................................................................... 0264-3

Figure 3.

Chain Adjuster Measurement and Removal......................................................................... 0264-3

Figure 4.

Tophandler Hydraulic Spreader Removal............................................................................ 0264-4

Figure 5.

Tophandler Hydraulic Spreader Installation......................................................................... 0264-5

Figure 6.

Chain Adjuster Installation and Measurement...................................................................... 0264-6

Figure 7.

Access Panels Installation.................................................................................................... 0264-6

Figure 8.

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

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Multi-Pin Connector Identifier............................................................................................... 0267-2

Figure 2.

Multi-Pin Connector Identifier............................................................................................... 0267-3

Figure 3.

Multi-Pin Connector Identifier............................................................................................... 0267-4

Figure 4.

Multi-Pin Connector Identifier............................................................................................... 0267-5

Figure 5.

Connector Repair................................................................................................................. 0267-6

Figure 6.

Connector Repair................................................................................................................. 0267-6

Figure 7.

Sealed Connector Repair..................................................................................................... 0267-7

Figure 8.

Receptacle Connector Repair.............................................................................................. 0267-8

Figure 9.

Waterproof Connector Repair.............................................................................................. 0267-9

Figure 10.

Military Connector Repair................................................................................................... 0267-10

Figure 11.

Ring Terminal Repair......................................................................................................... 0267-11

Figure 12.

Wire Splicing...................................................................................................................... 0267-12

Figure 13.

Electrical Ground Points..................................................................................................... 0267-13

Figure 14.

Multimeter Usage............................................................................................................... 0267-14

Figure 15.

Multimeter Usage............................................................................................................... 0267-15

Figure 16.

Multimeter Usage............................................................................................................... 0267-16

Figure 17.

Multimeter Usage............................................................................................................... 0267-17

Figure 18.

Multimeter Usage............................................................................................................... 0267-18

Figure 19.

Relay Inspection and Test.................................................................................................. 0267-19

Figure 20.

Solenoid Inspection and Test............................................................................................. 0267-20

GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0268 Table 1.

Boss Type O-rings................................................................................................................ 0268-7

Table 2.

Flat-Face Type O-rings........................................................................................................ 0268-8

Table 3.

O-ring/Retainer Type Fitting Seals....................................................................................... 0268-8

Table 4.

Split Flange Type O-rings..................................................................................................... 0268-8

Table 5.

Hydraulic Hose Torque Chart............................................................................................... 0268-9

ILLUSTRATED LIST OF MANUFACTURED ITEMS................................................................................... WP 0269

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 1.

Stud, Guide.......................................................................................................................... 0269-1

TORQUE LIMITS......................................................................................................................................... WP 0270 Figure 1.

Torque Patterns.................................................................................................................... 0270-2

Table 1.

Torque Limits........................................................................................................................ 0270-2

LOAD TESTING PROCEDURE................................................................................................................... WP 0271 Figure 1.

Boom Cylinder Drift Test...................................................................................................... 0271-2

Table 1.

Reference Readings 1.......................................................................................................... 0271-3

Figure 2.

Boom Cylinder Drift Test...................................................................................................... 0271-3

Figure 3.

Extension Cylinder Drift Test................................................................................................ 0271-4

Figure 4.

Extension Cylinder Drift Test................................................................................................ 0271-5

Table 2.

Reference Readings 2.......................................................................................................... 0271-5

SCHEMATICS............................................................................................................................................. WP 0272 Figure 1.

ECS Display/CAN-BUS (A34647.0200). (Sheet 1 of 3) ...................................................... 0272-7

Figure 1.

ECS Display/CAN-BUS (A34647.0200). (Sheet 2 of 3) ...................................................... 0272-8

Figure 1.

ECS Display/CAN-BUS (A34647.0200). (Sheet 3 of 3) ...................................................... 0272-9

Figure 2.

ECS Electrical Servo (A34648.0200). (Sheet 1 of 5) ........................................................ 0272-10

Figure 2.

ECS Electrical Servo (A34648.0200). (Sheet 2 of 5) ........................................................ 0272-11

Figure 2.

ECS Electrical Servo (A34648.0200). (Sheet 3 of 5) ........................................................ 0272-12

Figure 2.

ECS Electrical Servo (A34648.0200). (Sheet 4 of 5) ........................................................ 0272-13

Figure 2.

ECS Electrical Servo (A34648.0200). (Sheet 5 of 5) ........................................................ 0272-14

Figure 3.

ECS Engine (A34648.0200). (Sheet 1 of 2) ...................................................................... 0272-15

Figure 3.

ECS Engine (A34648.0200). (Sheet 2 of 2) ...................................................................... 0272-16

Figure 4.

ECS Transmission (A34650.0200). (Sheet 1 of 4) ............................................................ 0272-17

Figure 4.

ECS Transmission (A34650.0200). (Sheet 2 of 4) ............................................................ 0272-18

Figure 4.

ECS Transmission (A34650.0200). (Sheet 3 of 4) ............................................................ 0272-19

Figure 4.

ECS Transmission (A34650.0200). (Sheet 4 of 4) ............................................................ 0272-20

Figure 5.

ECS Steering (A34651.0200). (Sheet 1 of 7) .................................................................... 0272-21

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 5.

ECS Steering (A34651.0200). (Sheet 2 of 7) .................................................................... 0272-22

Figure 5.

ECS Steering (A34651.0200). (Sheet 3 of 7) .................................................................... 0272-23

Figure 5.

ECS Steering (A34651.0200). (Sheet 4 of 7) .................................................................... 0272-24

Figure 5.

ECS Steering (A34651.0200). (Sheet 5 of 7) .................................................................... 0272-25

Figure 5.

ECS Steering (A34651.0200). (Sheet 6 of 7) .................................................................... 0272-26

Figure 5.

ECS Steering (A34651.0200). (Sheet 7 of 7) .................................................................... 0272-27

Figure 6.

ECS Attachment to Tophandler (A34652.0200). (Sheet 1 of 6) ........................................ 0272-28

Figure 6.

ECS Attachment to Tophandler (A34652.0200). (Sheet 2 of 6) ........................................ 0272-29

Figure 6.

ECS Attachment to Tophandler (A34652.0200). (Sheet 3 of 6) ........................................ 0272-30

Figure 6.

ECS Attachment to Tophandler (A34652.0200). (Sheet 4 of 6) ........................................ 0272-31

Figure 6.

ECS Attachment to Tophandler (A34652.0200). (Sheet 5 of 6) ........................................ 0272-32

Figure 6.

ECS Attachment to Tophandler (A34652.0200). (Sheet 6 of 6) ........................................ 0272-33

Figure 7.

Hydraulics (A34654.0200). (Sheet 1 of 2) ......................................................................... 0272-34

Figure 7.

Hydraulics (A34654.0200). (Sheet 2 of 2) ......................................................................... 0272-35

Figure 8.

Current Supply (A34738.0200). (Sheet 1 of 4) .................................................................. 0272-36

Figure 8.

Current Supply (A34738.0200). (Sheet 2 of 4) .................................................................. 0272-37

Figure 8.

Current Supply (A34738.0200). (Sheet 3 of 4) .................................................................. 0272-38

Figure 8.

Current Supply (A34738.0200). (Sheet 4 of 4) .................................................................. 0272-39

Figure 9.

Shifting (A34739.0200). (Sheet 1 of 1) .............................................................................. 0272-40

Figure 10.

Sender (A34740.0200). (Sheet 1 of 2) .............................................................................. 0272-41

Figure 10.

Sender (A34740.0200). (Sheet 2 of 2) .............................................................................. 0272-42

Figure 11.

Wipers (A34741.0200). (Sheet 1 of 1) ............................................................................... 0272-43

Figure 12.

AC and Fan (A34742.0200). (Sheet 1 of 1) ....................................................................... 0272-44

Figure 13.

Cab (A34743.0200). (Sheet 1 of 1) ................................................................................... 0272-45

Figure 14.

Lights (A34744.0200). (Sheet 1 of 5) ................................................................................ 0272-46

Figure 14.

Lights (A34744.0200). (Sheet 2 of 5) ................................................................................ 0272-47

Figure 14.

Lights (A34744.0200). (Sheet 3 of 5) ................................................................................ 0272-48

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TABLE OF CONTENTS - Continued Page No. WP Sequence No. Figure 14.

Lights (A34744.0200). (Sheet 4 of 5) ................................................................................ 0272-49

Figure 14.

Lights (A34744.0200). (Sheet 5 of 5) ................................................................................ 0272-50

Figure 15.

Work Lights (A34745.0200). (Sheet 1 of 1) ....................................................................... 0272-51

Figure 16.

Auxiliary Pump (A34746.0200). (Sheet 1 of 1) .................................................................. 0272-52

Figure 17.

Auto Lubrication (A48665.0100). (Sheet 1 of 1) ................................................................ 0272-53

Figure 18.

Information (A34749.0200). (Sheet 1 of 2) ........................................................................ 0272-54

Figure 18.

Information (A34749.0200). (Sheet 2 of 2) ........................................................................ 0272-55

Figure 19.

Steering System................................................................................................................. 0272-56

Figure 20.

Brake System..................................................................................................................... 0272-57

Figure 21.

Main System....................................................................................................................... 0272-58

Figure 22.

Tophandler System............................................................................................................ 0272-59

Figure 23.

Autolube System Tubing Layout........................................................................................ 0272-60

Figure 24.

Electrical Symbols.............................................................................................................. 0272-61

Figure 25.

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.

Maintenance Allocation Chart (MAC)................................................................................... 0275-1

Table 2.

Tools and Test Equipment................................................................................................. 0275-24

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.

Mandatory Replacement Parts List...................................................................................... 0278-1

Index

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TM 10-3930-675-23-1

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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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. 2. a. WARNING indicates a hazard which may result in death or serious injury to personnel. 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 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

TM 10-3930-675-23-1

0001

FIELD MAINTENANCE GENERAL INFORMATION

SCOPE 1. Type of Manual. This manual is designed for use in performing field maintenance and troubleshooting on the Rough Terrain Container Handler (RTCH) (all models).

NOTE •

RT 240V2 and RT 240V3 models are identical; the only difference between the two models is that 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. 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 3930-01-473-3998) S/N range T5112.0401 to T35112.0742 RT 240V3 (NSN 3930-01-522-7364, and 3930-01-473-3998) S/N range S112.00801 to current

2. Purpose of Equipment. The RTCH (all models) is designed to lift and stack 20 and 40 ft International Standard Organization (ISO) containers, loaded to a gross weight of 53,000 lb (24,062 kg). MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for the equipment will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) User’s Manual. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your RTCH set needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about the equipment. Let us know why you do not like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to http://www.nslcptsmh.csd.disa.mil/webpqdr/webpqdr.htm. The Internet form lets you submit a Product Quality Deficiency Report (PQDR). You may also submit your information using an SF Form 368, Product Quality Deficiency Report. You can send your SF 368 via e-mail, regular mail, or facsimile 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: AMSRD-TAR-E/PDQR, MS 268, 6501 E. 11 mile Road, Warren, MI 48397-5000. The e-mail address is [email protected]. The fax number is DSN 786-5666 or Commercial 586-282-5666.

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0001

CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. OZONE DEPLETING SUBSTANCES Listing to be provided by requiring activity. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use, refer to TM 750-244-6. PREPARATION FOR STORAGE OR SHIPMENT For preparation for storage or shipment procedures, refer to TM 10-3930-675-10. WARRANTY INFORMATION The vehicles are warranted by Kalmar RT in accordance with TB 10-3930-675-14. Warranty starts on the date found in block 23, DA Form 2408-9 in the logbook. Report all defects in material or workmanship to your Supervisor, who will take appropriate action. LIST OF ABBREVIATIONS/ACRONYMS

NOTE Refer to ASME Y14.38 for standard abbreviations. Table 1. List of Abbreviations/Acronyms. ABBREVIATIONS/ACRONYMS DEFINITION AAL

Additional Authorization List

BII

Basic Issue Items

C

Centigrade or Celsius

CAN-BUS

Controller Area Network-BUS

CBRN

Chemical, Biological, Radiological and Nuclear

CID

Cubic Inch Displacement

cm

Centimeter 0001-2

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LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1.

List of Abbreviations/Acronyms - Continued.

ABBREVIATIONS/ACRONYMS DEFINITION COEI

Components of End Item

CPC

Corrosion Prevention and Control

ECM

Electronic Control Module

ECS

Electronic Control System

ECU

Electronic Control Units

EEPROM

Electrically-Erasable Programmable Read-Only Memory

F

Fahrenheit

FGC

Functional Group Code

ft

Feet

GCWR

Gross Combination Weight Rating

GVWR

Gross Vehicle Weight Rating

IETM

Interactive Electronic Technical Manual

hp

Horsepower

in

Inch

ISO

International Standards Organization

kg

Kilogram

km

Kilometer

kPa

Kilopascal

kph

Kilometers per Hour

kW

Kilowatt

L

Liter

lb

Pound

lb-ft

Pound Foot

lph

Liters per Hour

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0001

TM 10-3930-675-23-1

0001

LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1.

List of Abbreviations/Acronyms - Continued.

ABBREVIATIONS/ACRONYMS DEFINITION m

Meter

MAC

Maintenance Allocation Chart

mm

Millimeter

mph

Mile Per Hour

NATO

North Atlantic Treaty Organization

N•m

Newton Meter

OEM

Original Equipment Manufacturer

PMCS

Preventive Maintenance Checks and Services

PTO

Power Take-Off

RTCH

Rough Terrain Container Handler

SOP

Standard Operating Procedure

SPORT

Soldier’s Portable On-System Repair Tool

SRA

Specialized Repair Activity

TAMMS

The Army Maintenance Management System

ULLS-G

Unit Level Logistics System - Ground

V

Volt(s)

yd

Yard

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

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0002

FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 1. Characteristics. a. The Rough Terrain Container Handler (RTCH) is designed to lift, move, stack, or unstack 20 and 40 ft (6.10 to 12.19 m) by 8 ft (2.44 m) wide ISO containers. b. The RTCH has a lift capacity of 53,000 lb (24,040 kg) and operates on hard and/or unimproved surfaces, to include beach operations. c. The RTCH can be utilized as a forklift with an operator-installed forklift kit. 2. Capabilities and Features. a. Capabilities. (1) Container handling capabilities: • Stack or unstack 8 ft (2.44 m) high ISO containers stacked three (3) high with a gross weight of 53,000 lb (24,040 kg) in the first row. • Stack or unstack 8 ft (2.44 m) high ISO containers stacked three (3) high with a gross weight of 27,500 lb (12,474 kg) in the second row. • Stack or unstack 4.3 ft (1.31 m) high ISO containers stacked seven (7) high. • Container tophandler adjusts to 20 or 40 ft (6.10 to 12.19 m) ISO container lengths. • Container tophandler oscillates 7 degrees left and right. • Container tophandler rotates 195 degrees clockwise and 105 degrees (145 degrees for RT 240V2 and RT 240V3) counterclockwise. • Container tophandler tilts 8 degrees forward and 12 degrees to the rear. • Container tophandler side shifts ± 15 in. (± 381 mm) from the center. (2) Forklift kit is operator-installed and attaches to the tophandler. The forktines are adjustable from 24 in. (61cm) center-to-center to 81.5 in. (207 cm) center-to-center. Lift capacity is 44,000 lb (19,958 kg). (3) Maximum speed of RTCH is 23 mph (37 kph) on level ground with NO LOAD; maximum speed on level ground LOADED is 15 mph (24 kph). (4) Maximum fording depth is 60 in. (1.52 m). (5) Operation in temperatures from -25°F (-32°C) to +125°F (+52°C), and to -40°F (-40°C) with arctic kit installed. b. Features. (1) Electronically-controlled 400 hp, six-cylinder turbocharged engine. (2) Electronic semi-automatic shift controlled transmission with 4 ranges forward and 3 reverse. Operator selects range and ECM controls shift points. (3) The drive axles provide traction for 2-wheel or 4-wheel drive. (4) Limited slip differentials and multi-disc wet brakes are an integral part of the axle assemblies. Multi-disc wet brakes are hydraulically cooled to prevent overheating. Accumulators store energy for the emergency braking system. (5) The steering system is capable of 2-wheel, 4-wheel, crab, and emergency modes of operation. (6) The parking brake is hydraulically released and spring-applied by disc brake assemblies mounted on the front and rear differentials. (7) The operator's cab has a fully adjustable operator's seat, fresh air (filtered) ventilation system, and heater/defroster/air conditioning systems. (8) Operator's controls include: adjustable steering wheel; accelerator and brake pedals; transmission range selector; steering mode selection rocker switches; and a single joystick control for all boom, tophandler, and forklift operations.

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c.

0002

Transport Modes.

NOTE Refer to TM 10-3930-675-10 for detailed instructions to prepare the RTCH for transport. Self Deployment Highway Transport Rail Transport Marine Transport Air Transport

• • • • •

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS 2 3 4 5 1

6

7

Figure 1. Table 1.

G0007JCH

Major Components.

Description of Major Components

KEY

COMPONENT

DESCRIPTION

1

Tophandler

Electro-hydraulically operated 20 to 40 ft (6.10 to 12.19 m) tophandler. Capable of sideshifting, rotation, forward/rear tilting, left/right tilting, and load position leveling and locking. Also interfaces with forklift attachment.

2

Boom Assembly

Electro-hydraulically operated heavy duty steel boom designed for moving, lifting, and stacking 20 to 40 ft (6.10 to 12.19 m) ISO containers.

3

Boom Lift Cylinders

Electro-hydraulically operated cylinders raise, lower, and support the boom assembly.

4

Operator's Cab

Contains all driving and container handling controls as well as heating, air conditioning, and filtered ventilation system controls. During air transport operations, the cab is moved to the left side of the chassis, then lowered and secured in place.

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0002

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 1.

Description of Major Components - Continued

KEY

COMPONENT

DESCRIPTION

5

Boom Support

Rear support and pivot point for the boom to include an unlocking device that allows the boom assembly to be lowered into the transport position.

6

Frame

A heavy-duty steel construction with tie-downs, towing lugs, and pintle hook.

7

Remote Hydraulic Control Compartment

Location of selected hydraulic remote controls. Also access to hydraulic system test and sampling ports.

12

11

Figure 2. Table 2.

10

9

8 G0005JCH

Major Components.

Description of Major Components

KEY

COMPONENT

DESCRIPTION

8

Dolly Wheels Storage Compartment

Storage location for the attachable tophandler air transport dolly wheels.

9

Master Battery Switch

ON/OFF control of electrical power from batteries to vehicle electrical system.

10

Slave Receptacle

Provides an electrical connection for slave starting. A receptacle is located on each side of the RTCH.

11

Battery Compartment

Stores four 12V batteries and required cabling. Batteries are accessible from the side and/or the top.

12

Twistlocks

Electro-hydraulically operated and monitored ISO twistlocks, located at each corner of the tophandler. Also utilized to attach forklift attachment to tophandler.

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0002

13 18 20

17

19

16

Figure 3. Table 3.

15 14

10

G0006JCH

Major Components.

Description of Major Components

KEY

COMPONENT

DESCRIPTION

13

Front Service and Blackout Lights

Headlight, blackout drive light, and composite turn signal with blackout markers.

14

Coolant Expansion Tank

Contains cooling system overflow. Provides means to visually check coolant level and add coolant to system.

15

Engine Compartment

Houses the six-cylinder turbocharged diesel engine that supplies power for the automotive, electrical, and hydraulic systems.

16

Hydraulic Reservoir

Stores and vents system hydraulic oil.

17

Hydraulic Reservoir Sight Gauge

Visual indicator of hydraulic oil level. If oil is NOT visible in sight gauge with boom completely lowered and tophandler retracted, DO NOT start engine.

18

Fuel Tank

Stores fuel supply for vehicle.

19

Rear Service and Blackout Lights

Composite tail, stop, and blackout markers; turn signals; and backup lights.

20

Bogie Wheels

Allow weight of machine to be distributed over more wheel area during aircraft loading and transport.

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0002

EQUIPMENT DATA Engine: Manufacturer

Cummins

Model

QSM 11

Horsepower @ 2,150 RPM

400 hp (298 kW)

Torque @ 1,200 RPM

1,450 lb-ft (1,966 N•m)

Cylinders

6

Displacement

661 CID (10.8 L)

Weight

2,070 lb (940 kg)

Fuel System

Fully electronic

Cooling System, Thermostat Range

180° to 200°F (82° to 93°C) NOTE

RT 240V1R machines will either use 6WG-260 or 4WG-310 depending on what they received during RESET. Transmission: Manufacturer

ZF-Hydromedia

Model RT 240V1

6WG-260

Model RT 240V2 and RT 240V3

4WG-310

Type

4 forward and 3 reverse speeds

Range Selection

Automatic, electronically controlled

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TM 10-3930-675-23-1

EQUIPMENT DATA - Continued Axles: Manufacturer

Kessler

Model: Front (RT 240V1, RT 240V1R, and RT 240V2)

LT102PL341/528NLB4650

Rear (RT 240V1, RT 240V1R, and RT 240V2)

LT102PL341/528NLB4460

Front (RT 240V3)

LT102PL341/528NLB5550

Rear (RT 240V3)

LT102PL341/528NLB4460-1

Front

8,379 lb (3,800 kg)

Rear

5,733 lb (2,600 kg)

Weight:

Tires: Front and Rear: Manufacturer

Bridgestone

Size

29.5 35 Series

Inflation

85 psi (586 kPa)

Weight RT 240V1

2,315 lb (1,050 kg)

Weight RT 240V1R, RT 240V2, and RT 240V3

2,750 lb (1,247 kg)

Bogie Wheels (Transport Operations): Manufacturer

Michelin

Size

355/65 R 15 XZM

Inflation

85 psi (586 kPa)

Dolly Wheels (Tophandler Transport): Manufacturer

Michelin

Size

225/75 R 10 XZR

Inflation

85 psi (586 kPa)

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03/15/2011 Rel(1.8) root(descwp) wpno(G00007)

0002

TM 10-3930-675-23-1

EQUIPMENT DATA - Continued Dimensions: Length: Tophandler Lateral

37.7 ft (11.0 m)

Tophandler Longitudinal

49.2 ft (15.0 m)

Operational w/Boom Level

13.1 ft (4.0 m)

Highway Transport Mode

9.8 ft (3.0 m)

Height:

Width, Tophandler Longitudinal

12 ft (3.66 m)

Weights: GVWR w/All Fluids RT 240V1

118,000 lb (53,524 kg)

GVWR w/Forklift Kit RT 240V1

128,400 lb (58,241 kg)

GVWR Operational w/All Fluids (RT 240V1R, RT 240V2, and RT 240V3)

118,500 lb (53,751 kg)

GVWR Operational w/Forklift Kit and/all Fluids (RT 240V1R, RT 240V2, and RT 240V3)

130,050 lb (58,990 kg)

Capacities: Fuel Tank

103 gal. (390 L)

Cooling System

23.7 gal. (90.1 L)

Cooling, Engine Only

3.4 gal. (12.9 L)

Hydraulic Oil Reservoir

180 gal. (680 L)

Engine Crankcase w/Filter

38.6 qt (36.5 L)

Transmission w/Filter

36 qt (34 L)

Electrical System: Type

24V, negative ground

Battery Manufacturer

Hawker, Armasafe Plus

Model

Armasafe Plus Battery

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0002

TM 10-3930-675-23-1

EQUIPMENT DATA - Continued Voltage

12V

Plates per cell

6 Cell lead acid

Rating

120 A/h, electrical capacity

Cold Cranking Amps (CCA SAE)

1,225 Amps per battery

Mass

86 lb (39 kg)

Number of batteries per vehicle

4

Temperature at time of full charge

68° F (20° C)

Miscellaneous: Maximum Lifting Capacity: First Stacking Row

53,000 lb (24,040 kg)

Second Stacking Row

27,500 lb (12,474 kg)

Maximum Lift Height

33 ft (10.06 m)

Maximum Lifting Capacity, w/Forklift Kit: First Stacking Row

44,000 lb (19,958 kg)

Second Stacking Row

24,600 lb (11,158 kg)

Maximum Lift Height, w/Forklift Kit

21.8 ft (6.65 m)

Forklift Kit, Fork Tines Center-to-Center Range 24 to 81.5 inch (61 to 207 cm) Maximum Forward Reach (Boom Level)

20.6 ft (6.28 m)

Curb-to-Curb Turning Circle: 4-Wheel Steering

65 ft (19.8 m)

Ground Clearance

18 inch (45.7 cm)

Fording Depth

60 inch (1.5 m)

Maximum Travel Speeds: Empty

23 mph (37 kph)

Loaded

15 mph (24 kph)

END OF WORK PACKAGE

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0002

TM 10-3930-675-23-1

0003

FIELD MAINTENANCE THEORY OF OPERATION

INTRODUCTION 1. The Rough Terrain Container Handler (RTCH) consists of the following major components and functional systems: drive train, fuel system, exhaust system, cooling system, electrical and electronic systems, steering and brake systems, hydraulic system, cab system, and lifting boom with tophandler. A forklift kit may be added as required. 2. This work package explains how the components and systems of the RTCH work together. A functional description is provided for each major component and system. DRIVE TRAIN 1. The engine is a six-cylinder turbocharged diesel which supplies power to the transmission. The engine cooling system is pressurized and includes a thermostat, controlled bypass, and coolant expansion tank. Engine lubrication is pressurized and full-flow filters continuously clean oil. 2. The transmission is a semi-automatic electronically-controlled unit. The operator electronically selects range of gears and the transmission electronic control module (ECM) controls shift points up to the highest selected gear. A shift inhibitor circuit controls downshifts in forward and reverse gears. The transmission can be manually or electronically shifted through 4 forward and 3 reverse gears. A torque converter provides interface to the engine. 3. The driveshafts transmit rotation of the transmission output to the front and rear axles. Connections at both ends are made through universal joints to compensate for any misalignment due to operating on uneven surfaces. 4. The front and rear axles are identical in operating principles. Both axles are hydraulically steered with planetary wheel ends and wet-disc brakes. The rear axle oscillates above and below horizontal to allow for operation on uneven surfaces. FUEL SYSTEM 1. Fuel to power the engine is pumped from the fuel tank by a fuel transfer pump to the electronically controlled fuel injector nozzles. 2. The engine ECM manages, monitors, and stores key engine functions, to include engine idle speed, limits maximum engine speed, and engine diagnostic data. 3. The engine-mounted fuel/water separator is a spin-on replaceable type with drain. EXHAUST SYSTEM The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flow into exhaust pipes and muffler to the atmosphere along the right side and to the rear of the operator's cab. COOLING SYSTEM 1. The cooling system consists of an engine-mounted circulating pump, 180° to 200°F (82° to 93°C) thermostat, oil cooler/aftercooler manifolds, a radiator, engine-mounted coolant filter, and hydraulically-driven cooling fan. 2. The cooling system cools the engine by means of circulating pressurized ethylene glycol-based coolant through the engine and radiator.

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TM 10-3930-675-23-1

0003

ELECTRICAL SYSTEM 1. The system voltage is 24V. Four 12V batteries, connected in series-parallel and charged by an alternator across electronic rectifying and voltage stabilization circuits, provide the voltage. 2. The negative and positive poles are both connected across the master battery switch. The negative pole is connected to the chassis. 3. NATO slave-starting receptacles are provided. STEERING SYSTEM 1. The electro-hydraulic steering system provides three modes of steering control: 2-wheel steer, 4-wheel steer, and crab steer. 2. The variable rate steering system utilizes two front and two rear hydraulic steering cylinders and electronic wheel position sensors connected to an ECM to maintain direction and control. The variable rate system allows the system to change or adjust to different modes of operation. 3. An emergency steering pump is provided in the event the engine is inoperative. If the engine quits while operating the RTCH, the emergency steering pump provides sufficient hydraulic pressure to control the RTCH until it is brought to a safe stop. BRAKE SYSTEM 1. The brakes are totally enclosed within the front and rear drive axle housings, next to the wheel ends. 2. The brake system is a wet brake system that is comprised of three separate hydraulic circuits: service brake circuit, cooling circuit, and parking brake circuit. 3. The brake system also includes six pressurized accumulators that provide adequate stored energy to stop the RTCH in the event of engine shutdown. 4. The service brake circuit is applied by depressing either the left or right floor-mounted hydraulic brake pedals. Brake pressure is applied to eight cylinders per side within the front axle and one cylinder per side in the rear axle. 5. The brake system cooling circuit cools the brake disks using oil pumped from the main hydraulic system through brake chambers during operation. 6. The parking brake assemblies are mounted at the input flanges of the front and rear axles. The brakes are applied by spring pressure and released hydraulically. A warning buzzer sounds if the driver leaves the seat without applying the parking brakes. The parking brake should never be applied as an emergency brake or while the vehicle is moving. Application of the parking brake while the vehicle is moving can result in major drive train damage. HYDRAULIC SYSTEM 1. The RTCH hydraulic system is comprised of the following major components that provide hydraulic power to operate and control the container tophandler, boom, steering, and brake systems. In addition the hydraulic system is used to place the cab and bogie wheels into transport mode. a. Three variable piston-type hydraulic pumps are driven by the transmission power take-off (PTO). The pumps provide hydraulics for the steering system and tophandler. b. One double vane-type pump is driven by the transmission PTO. It provides hydraulics for the boom cylinders, service, and parking brake systems. c. One single-vane pump is driven by the engine. It provides hydraulics for a cooling fan. d. Main valves control the main hydraulics. The valves are controlled by an electro-hydraulic servo system from the joystick control in the operator's cab. e. High-pressure oil filters clean hydraulic oil before returning oil to the reservoir. Breather filters allow venting of the hydraulic reservoir. f. Hydraulic system oil cooler and fan maintain and control hydraulic oil temperature. The cooling fan is powered by hydraulics from an engine-driven hydraulic pump. g. Emergency systems: one ground-driven hydraulic pump maintains steering control in the event of engine failure; a 24V electric hydraulic pump provides power to lower boom and release the twist

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TM 10-3930-675-23-1

0003

HYDRAULIC SYSTEM - Continued locks in the event of engine failure. The electric pump also provides a means to place the operator's cab into the transport mode. CAB SYSTEM 1. The operator's cab is a sound and weather insulated unit that provides the operator with the systems to control and monitor both standard automotive functions and container handling functions. The following components or systems are also contained within the cab: a. Adjustable steering column and adjustable suspension seat. b. Heater, air conditioning, and filtered ventilation system. c. Portable fire extinguisher and rifle mount. AIR CONDITIONING SYSTEM The air conditioning system unit is part of the heater and is mounted at the front of the cab. It is a single unit consisting of a heater core, air conditioning evaporator coil, blower motor, control valves, and air ducts. The system is turned on by the air conditioning control switch on the instrument panel in the cab. The three-speed blower switch controls flow rate. An even cab temperature is maintained by using the air conditioner temperature control switch to control the refrigerant flow through the evaporator coil. ELECTRONIC SYSTEM The RTCH is equipped with several electronic modules, all connected using CAN-BUS technology. The modules can be diagnosed using the OEM testing equipment. They assist in the operation of major systems such as engine, transmission shifting, steering mode and wheel position, the safe working load control, and many related functions that require data input to operate correctly for the intended uses of the RTCH. LIFTING BOOM AND TOPHANDLER The lifting boom and tophandler is an electro-hydraulic operated heavy-duty telescoping boom and spreader assembly, designed to lift, move, and stack/unstack 20 to 40 ft (6.10 to 12.19 m) ISO containers. The operator joystick provides complete control of the lifting boom and tophandler during container handling operations. The boom provides lifting/lowering, extending/retracting operations. The tophandler or spreader provides for sideshifting, rotation, forward/rear tilting, left/right tilting, and load leveling and locking operations. The tophandler also provides interface capability with a forklift attachment. FORKLIFT KIT The forklift kit is attached to the tophandler twistlocks and two hydraulic hose quick-disconnects. Forklift operation is controlled from the tophandler joystick to include adjustable forktines. The forktines and vertical support beams fold under the forklift framework for transport. END OF WORK PACKAGE

0003-3/4 blank

03/15/2011 Rel(1.8) root(thrywp) wpno(G00008)

TM 10-3930-675-23-1

CHAPTER 2 TROUBLESHOOTING PROCEDURES

TM 10-3930-675-23-1

0004

FIELD MAINTENANCE ERROR CODE REFERENCES

EXPLANATION OF ERROR CODE DISPLAY

NOTE There are three kinds of information in the Electronic Control System (ECS) display 1. Icons in the lower left corner of the display describe what the driver should do. Table 1 defines each of the three driver actions. Table 1. Driver Action Icons. ICON

DESCRIPTION STOP VEHICLE IMMEDIATELY in a safe way. Can be a safety issue. Machine performance may be restricted. Read operator’s manual for instructions. Contact maintenance personnel. Any active “Stop" type error code will de-rate the engine to 1,000 RPMs. The ignition must be shut off to clear the engine de-rate. Any engine temperature or oil pressure codes will de-rate the engine to 1,000 RPMs for 30 seconds and then shut the engine down. WARNING - DEGRADED OPERATION, stop vehicle in a safe way. Read operator's manual (TM 10-3930-675-10) for instructions. Contact maintenance personnel. Confirm that error message is acknowledged by pressing RESET button. Error will appear every three minutes as long as error is active. It can be reset every time it shows. INFORMATION/MAINTENANCE action is needed. Error code shows once when vehicle starts up. Acknowledge error message by pressing RESET. These error codes may be deactivated for driver, so that they only show when maintenance personnel activate them. RT 240V1R, RT 240V2 and RT 240V3. The information/maintenance icon will appear in the ECS display operational screen (weight/load center) to alert the maintenance personnel of potential service. 2. Icons in the center of the display identify the type of fault. Table 2 describes the five fault types used in the display. Table 2. ICON

Type of Fault Icons.

DESCRIPTION

ICON

DESCRIPTION

Sensor

Lever

Valve

Temperature

0004-1

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 2. ICON

Type of Fault Icons - Continued.

DESCRIPTION

ICON

DESCRIPTION

Pressure

3. Icons in the right of the display identify what function or vehicle system the fault is related to. Table 3 lists the various functions or vehicle systems used in the display. Table 3. ICON

Function Icons.

DESCRIPTION

ICON

DESCRIPTION

Battery

Twistlock

Forklift Kit

Up/Down

Emergency Stop or Battery

In/Out

Rotation RT 240V1R, RT 240V2, and RT 240V3 only ECS display; lockout indication

Transmission RT 240V1R, RT 240V2, and RT 240V3 ECS display; lockout indication

Hydraulic Filter

Fan

Communication

Engine

0004-2

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 3. ICON

Function Icons - Continued.

DESCRIPTION

ICON

DESCRIPTION

Sideshifting

No Overload Protection

Oscillation (leveling)

Brake

Spreading

Tilt RT 240V1R, RT 240V2, and RT 240V3 ECS display; lockout indication

Steering

0004-3

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued

Table 4. Error Code Reference Index. ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0038)

Information/Maintenance Lifting/lowering boom. Hydraulic filter clogged.

None.

2

(WP 0038)

Information/Maintenance Steering. Hydraulic filter clogged.

None.

3

(WP 0038)

Information/Maintenance Tophandler attachment. Hydraulic filter clogged.

None.

4

(WP 0038)

Information/Maintenance Return filter. Hydraulic filter clogged.

None.

103

(WP 0013)

Information/Maintenance Appears during replacement of ECU. Software not compatible with other software in system.

Undesired functions and not relevant error codes may appear.

105

(WP 0013)

Stop Vehicle Immediately ECU 790 not responding. Circuit breaker tripped. Cable defective. ECU 790 defective.

Operating system not responding. Boom and tophandler may not work.

106

(WP 0013)

Stop Vehicle Immediately ECU 791 not responding. Circuit breaker tripped. Cable defective. ECU 791 defective.

Operating system not responding. Boom and tophandler may not work.

107

(WP 0013)

Information/Maintenance Communication, cable segment 1 between ECU 795 and 791. Cable between ECU 795 - 791 interrupted or short circuited.

No redundancy in ECS system of boom, display, and tophandler function

0004-4

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

108

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0013)

Information/Maintenance Communication, cable segment 2 between ECU 791 and 790. Cable between ECU 791 - 790 interrupted or short circuited.

No redundancy in ECS system of boom, display, and tophandler function.

109

(WP 0013)

Information/Maintenance Communication, cable segment 3 between ECU 790 and 795. Cable between ECU 790 - 795 interrupted or short circuited.

No redundancy in ECS system of boom, display, and tophandler function.

110

(WP 0013)

Stop Vehicle Immediately Steering may not Communication, ECU 792 function properly. steering computer not responding. Circuit breaker tripped. Cable defective. ECU 792 defective.

111

(WP 0013)

Stop Vehicle Immediately Transmission Communication, ECU 793 may not function transmission computer not properly responding. Circuit breaker tripped. Cable defective. ECU 793 defective.

112

(WP 0013)

Stop Vehicle Immediately Engine may not ECU 794 - engine computer not function properly. responding. Circuit breaker tripped. Cable defective. ECU 794 defective.

118

(WP 0030)

Stop Vehicle Immediately No pressure/signal - both brake systems. Circuit breaker tripped. Hydraulic failure.

Brakes may not function properly.

119

(WP 0030)

Warning - Degraded Operation No pressure - brake circuit 1. Hydraulic failure.

Only half brake capability available.

120

(WP 0030)

Warning - Degraded Operation No pressure - brake circuit 2. Hydraulic failure.

Only half brake capability available.

0004-5

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

121

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0012)

Stop Vehicle Immediately Supply voltage - ECU 790. Emergency stop engaged. Circuit breaker tripped. Cable defective.

Operating system and boom function not working.

122

(WP 0012)

Stop Vehicle Immediately Supply voltage - CAN 790. Circuit breaker tripped. Cable defective.

Operating system and boom function not working.

123

(WP 0012)

Stop Vehicle Immediately Ref. voltages 10V - ECU 790. Circuit breaker tripped. Cable defective.

Operating system and boom function not working.

125

(WP 0035)

Stop Vehicle Immediately Memory fault, check ECU 790. Circuit breaker tripped. Cable defective.

None if code clears. Operating system and boom function not working.

126

(WP 0039)

Stop Vehicle Immediately Signal for lifting/lowering, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning.

Lift/lower does not function properly (hydraulic stops).

127

(WP 0040)

Stop Vehicle Immediately Signal for boom in/out, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning.

Boom in/out does not function properly (hydraulic stops).

128

(WP 0043)

Stop Vehicle Immediately Signal for slewing, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning.

Slewing does not function properly (hydraulic stops).

129

(WP 0042)

Stop Vehicle Immediately Signal for tilt in/out, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning.

Tilt does not function properly (hydraulic stops).

0004-6

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

130

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0042)

Stop Vehicle Immediately Overload protection error. Error codes 131 - 136 or 210 have been active.

No overload protection system. Reduced hydraulic speed.

131

(WP 0010)

Stop Vehicle Immediately Boom sensor - boom length out of range or no signal change when boom is moving. Cable defective. Short circuit. Potentiometer damaged. Hydraulic failure.

No overload protection system. Reduced hydraulic speed.

132

(WP 0010)

Stop Vehicle Immediately Boom sensor - boom angle out of range or no signal change when lowering/lifting boom. Sensor bracket or lever damaged. Cable defective. Short circuit. Potentiometer damaged. Hydraulic failure.

No overload protection system. Reduced hydraulic speed.

133

(WP 0010)

Stop Vehicle Immediately Left lift cylinder pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective.

No overload protection system. Reduced hydraulic speed.

134

(WP 0010)

Stop Vehicle Immediately Right lift cylinder pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective.

No overload protection system. Reduced hydraulic speed.

135

(WP 0010)

Stop Vehicle Immediately Left lift cylinder return pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective.

Stop Vehicle Immediately Left lift cylinder return pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective.

136

(WP 0010)

Stop Vehicle Immediately Right lift cylinder return pressure sensor, signal out of range. Cable

Pressure sensor, signal out of range Cable defective. Short

0004-7

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

defective. Short circuit. Pressure sensor defective.

circuit. Pressure sensor defective. No overload protection system. Reduced hydraulic speed.

141

(WP 0035)

Information/Maintenance Communication fault - ECU 790. Computer hardware fault.

Possible ECU malfunction. Other codes will also show.

142

(WP 0035)

Information/Maintenance Communication fault - ECU 790. Computer hardware fault.

Possible ECU malfunction. Other codes will also show.

151

(WP 0039)

Stop Vehicle Immediately Locking valve, broken circuit. Cable to valve defective.

Boom cannot be lowered with joystick. Emergency lowering is necessary.

152

(WP 0039)

Stop Vehicle Immediately Locking valve, short circuit. Cable to valve defective.

Boom cannot be lowered with joystick. Emergency lowering is necessary.

154

(WP 0039)

Stop Vehicle Immediately Lifting valve, broken circuit. Cable to valve defective.

Lifting is impossible.

155

(WP 0039)

Stop Vehicle Immediately Uncontrolled selfLifting valve, short circuit. Cable to lifting may occur. valve defective.

157

(WP 0039)

Stop Vehicle Immediately Lowering valve, broken circuit. Cable to valve defective.

0004-8

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

Boom cannot be lowered with joystick. Emergency lowering is necessary.

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

158

(WP 0039)

Stop Vehicle Immediately Boom cannot be Lowering valve, short circuit. Cable lowered with to valve defective. joystick. Emergency lowering is necessary. Uncontrolled selflifting may occur.

160

(WP 0040)

Stop Vehicle Immediately Boom in valve, broken circuit. Cable to valve defective.

161

(WP 0040)

Stop Vehicle Immediately Boom cannot be Boom in valve, short circuit. Cable retracted. to valve defective. Uncontrolled selfretraction may occur.

163

(WP 0040)

Stop Vehicle Immediately Boom out valve, broken circuit. Cable to valve defective.

Boom cannot be extended.

164

(WP 0040)

Stop Vehicle Immediately Boom out valve, short circuit. Cable to valve defective.

Boom cannot be extended. Uncontrolled selfextension may occur.

166

(WP 0009)

Warning - Degraded Operation Cooling fan valve, broken circuit. Cable to valve defective.

Cooling fan will run at full speed. No fording activities possible.

167

(WP 0009)

Warning - Degraded Operation Cooling fan valve, short circuit. Cable to valve defective.

Cooling fan may run at any speed. No fording activities possible. Overheating may occur.

169

(WP 0036)

Warning - Degraded Operation Emergency hydraulic valve, broken circuit. Cable to valve defective.

No hydraulic emergency operation is possible.

ERROR CODE CATEGORY/ EXPLANATION

0004-9

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

VEHICLE LIMITATIONS

Boom cannot be retracted.

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

172

(WP 0037)

Information/Maintenance May be difficult to Pump turn off valve, broken circuit. start because of Cable defective. engaged pumps.

191

(WP 0031)

Stop Vehicle Immediately Temperature in front wheel end above 203°F (95°C). Cable defective. No cooling.

Brakes may overheat at front axle.

192

(WP 0031)

Stop Vehicle Immediately Temperature in rear wheel end above 203°F (95°C) Cable defective. No cooling.

Brakes may overheat at rear axle.

201

(WP 0012)

Stop Vehicle Immediately Supply voltage, ECU 791. Emergency stop engaged. Circuit breaker tripped. Cable defective.

Tophandler not working.

202

(WP 0012)

Stop Vehicle Immediately Supply voltage, CAN 791. Circuit breaker tripped. Cable defective.

Operating system and tophandler not working.

203

(WP 0012)

Stop Vehicle Immediately Ref. voltages 10V-791/ Circuit breaker tripped. Cable defective.

Operating system not working.

205

(WP 0011)

Stop Vehicle Immediately Memory fault - check ECU 791. Circuit breaker tripped. Cable defective.

None if code clears. Operating system and tophandler not working.

210

(WP 0010)

Stop Vehicle Immediately Tilt angle sensor, signal out of range. Potentiometer damaged. Cable defective. Short circuit.

Generate error code 130.

212

(WP 0046)

Stop Vehicle Immediately Logical error - left twistlock. Short circuit. Signal from both 7204L and 7205L.

Both locked and unlocked twistlock at the same time. Safe operation is not possible.

ERROR CODE CATEGORY/ EXPLANATION

0004-10

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

VEHICLE LIMITATIONS

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

213

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0046)

Stop Vehicle Immediately Logical error - right twistlock. Short circuit. Signal from both 7204R and 7205R.

Both locked and unlocked twistlock at the same time. Safe operation is not possible.

214

(WP 0046)

Stop Vehicle Immediately Logical error - forklift sensors. Cable defective. Signal from 7206-1 or 7206-2.

Operation of forklift is not possible.

220

(WP 0011)

Warning - Degraded Operation One pulse signal to the steering wheel interrupted. Clock 1. Clock 2.

Stop vehicle by switching to neutral. Steering system will operate but is not redundant. The steering computer uses non interrupted signal to steer the vehicle.

221

(WP 0011)

Information/Maintenance Communication fault - ECU 791, connector 2. Computer hardware fault.

Possible ECU malfunction. Other codes will also show.

225

(WP 0044)

Warning - Degraded Operation Left sideshift is Left sideshift, open circuit. Cable to not possible. valve defective.

226

(WP 0044)

Warning - Degraded Operation Uncontrolled left Left sideshift, short circuit. Cable to sideshift may valve defective. occur.

228

(WP 0044)

Warning - Degraded Operation Right sideshift is Right sideshift, open circuit. Cable not possible. to valve defective.

229

(WP 0044)

Warning - Degraded Operation Uncontrolled Right sideshift, short circuit. Cable right sideshift to valve defective. may occur.

0004-11

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

231

(WP 0045)

Warning - Degraded Operation Spreading from 20 to 40 valve, open circuit. Cable 20 to 40 ft is not to valve defective. possible.

232

(WP 0045)

Warning - Degraded Operation Spreading from 20 to 40 valve, short circuit. Cable 20 to 40 ft is not to valve defective. possible.

234

(WP 0045)

Warning - Degraded Operation Spreading from 40 to 20 valve, open circuit. Cable 40 to 20 ft is not to valve defective. possible.

235

(WP 0045)

Warning - Degraded Operation Spreading from 40 to 20 valve, short circuit. Cable 20 to 40 ft is not to valve defective. possible.

237

(WP 0042)

Warning - Degraded Operation Tophandler Active tilt valve, open circuit. Cable locked, not to valve defective. automatically leveled.

240

(WP 0043)

Warning - Degraded Operation Active pile slope, open circuit. Cable to valve defective.

Tophandler locked, not free oscillated.

243

(WP 0046)

Warning - Degraded Operation Twistlock valve lock, open circuit. Cable to valve defective.

Impossible to lock twistlock.

246

(WP 0046)

Warning - Degraded Operation Twistlock valve unlock, open circuit. Cable to valve defective.

Impossible to unlock twistlock.

250

(WP 0011)

Information/Maintenance Communication fault - ECU 791, connector 3. Computer hardware fault.

Possible ECU malfunction. Other codes will also show.

251

(WP 0011)

Information/Maintenance Communication fault - ECU 791, connector 3. Computer hardware fault.

Possible ECU malfunction. Other codes will also show.

255

(WP 0041)

Warning - Degraded Operation Slewing clockwise valve, open circuit. Cable to valve defective.

Slewing clockwise is not possible.

ERROR CODE CATEGORY/ EXPLANATION

0004-12

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

VEHICLE LIMITATIONS

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

256

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0041)

Warning - Degraded Operation Slewing clockwise valve, short circuit. Cable to valve defective.

Uncontrolled slewing may occur.

258

(WP 0041)

Warning - Degraded Operation Slewing counterclockwise valve, open circuit. Cable to valve defective.

Slewing clockwise is not possible.

259

(WP 0041)

Warning - Degraded Operation Slewing counterclockwise valve, short circuit. Cable to valve defective.

Uncontrolled slewing may occur.

261

(WP 0042)

Warning - Degraded Operation Tilt out is not Tilt out valve, open circuit. Cable to possible. valve defective.

262

(WP 0042)

Warning - Degraded Operation Uncontrolled tilt Tilt out valve, short circuit. Cable to may occur. valve defective.

264

(WP 0042)

Warning - Degraded Operation Tilt in valve, open circuit. Cable to valve defective.

Tilt in is not possible.

265

(WP 0042)

Warning - Degraded Operation Tilt in valve, short circuit. Cable to valve defective.

Uncontrolled tilt may occur.

267

(WP 0043)

Warning - Degraded Operation Right oscillation Right oscillation valve, open circuit. (leveling) is not Cable to valve defective. possible.

268

(WP 0043)

Warning - Degraded Operation Uncontrolled Right oscillation valve, short circuit. oscillation Cable to valve defective. (leveling) may occur.

270

(WP 0043)

Warning - Degraded Operation Left oscillation valve, open circuit. Cable to valve defective.

Left oscillation (leveling) is not possible.

271

(WP 0043)

Warning - Degraded Operation

Uncontrolled oscillation

0004-13

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

Left oscillation valve - short circuit. (leveling) may Cable to valve defective occur. 300

(WP 0014)

Stop Vehicle Immediately Steering system malfunction. Steering computer - hardware error (EEPROM, watchdog, reference voltages, etc.)

No steering or driving functions are available. Reduced power and engine speed.

301 302 303 304 305 306 307 308

(WP 0034)

Warning - Degraded Operation One track of actual value potentiometer out of range (e.g., cable interrupted). Wheel 1, track 1. Wheel 2, track 1. Wheel 3, track 1. Wheel 4, track 1. Wheel 1, track 2. Wheel 2, track 2. Wheel 3, track 2. Wheel 4, track 2.

Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant.

309 310 311 312

(WP 0034)

Stop Vehicle Immediately Both tracks of actual value potentiometer out of range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.

Stop vehicle by switching to NEUTRAL. Faulty wheel is locked immediately. Other wheels remain operational. Reduced power and engine speed.

313 314 315 316

(WP 0034)

Stop Vehicle Immediately Deviation between two potentiometer tracks, but both inside tolerance range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.

Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Reduced power and engine speed.

0004-14

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

317 318 319 320

(WP 0033)

Stop Vehicle Immediately Steering deviation between set point and actual value (tracking error). Wheel 1. Wheel 2. Wheel 3. Wheel 4.

Stop vehicle by switching to NEUTRAL. Steering remains active and tries to close up to set point. System will be active as soon as deviating wheel has closed up. Reduced power and engine speed.

321 322 323 324

(WP 0033)

Stop Vehicle Immediately Wheel alignment values out of range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.

This error prohibits driving after steering calibration if calibration was not successful or calibration values are out of range. Reduced power and engine speed.

325 326 327 328

(WP 0032)

Stop Vehicle Immediately Break in cable to proportional valve.

Stop vehicle by switching to NEUTRAL. Steering computer cannot control wheel with broken cable. Faulty wheel has to be aligned by manual operation of valve. Reduced power and engine speed.

Wheel 1. Wheel 2. Wheel 3. Wheel 4.

329 330 331

(WP 0032)

Stop Vehicle Immediately Cable to proportional valve - short circuit. Wheel 1. Wheel 2. Wheel 3.

0004-15

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

Stop vehicle by switching to NEUTRAL. Steering computer cannot control wheel

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

332

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

Wheel 4.

with broken cable. Faulty wheel has to be aligned by manual operation of valve. Reduced power and engine speed.

339

(WP 0032)

Stop Vehicle Immediately Steering wheel sensor malfunction. Possible loss of ground.

Steering system out of order. No steering or driving functions are available.

340

(WP 0032)

Warning - Degraded Operation Supply pressure below 1450 psi (100 bar). Leaking hydraulics.

Stop vehicle by switching to NEUTRAL. Steering system will operate in a degraded mode.

341

(WP 0032)

Stop Vehicle Immediately Steering wheel signals inconsistent (e.g., two incremental counters deviating). Cables defective. Steering column sensor defective.

Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Steering computer uses one of two counters to steer vehicle. Reduced power and engine speed.

342

(WP 0032)

Warning - Degraded Operation

Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Steering computer uses uninterrupted

0004-16

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

343

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

One pulse signal to steering wheel signal to steer interrupted. Cables defective. vehicle. Steering column sensor defective.

344

(WP 0032)

Stop Vehicle Immediately Both pulse signals to steering wheel interrupted. Cables defective. Steering column sensor defective.

345

(WP 0013)

Warning - Degraded Operation Error codes from No CAN communication to display. steering ECU will Cable defective. not show on display. Steering function is operational.

346

(WP 0013)

Warning - Degraded Operation No CAN communication to transmission. Cables defective.

It is not possible to change from 2WD to 4WD or vice versa. Steering system remains operational, but steering features dependent on driving speed are not available. To keep vehicle in full operation, steering program selection is allowed at this time.

347

(WP 0032)

Information/Maintenance No valid steering program selected.

None.

350 351 352

(WP 0016)

Stop Vehicle Immediately Steering valve solenoid.

Stop vehicle by switching to NEUTRAL. Steering system

0004-17

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

Stop vehicle by switching to NEUTRAL. Steering system will not operate. Reduced power and engine speed.

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

353

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

This error code occurs if the solenoid or circuit resistance differs from the preset value.

will not operate properly.

354 355 356 357

(WP 0016)

Stop Vehicle Immediately Start-up failure in steering system. This error code is caused by incorrect parameter settings in steering computer.

Stop vehicle by switching to NEUTRAL. Steering system will not operate properly.

399

(WP 0016)

Warning - Degraded Operation EEPROM parameter error in steering computer. One or more parameter values inside EEPROM are out of range.

Fully operational. History storage of error codes may not be possible.

401

(WP 0016)

Warning - Degraded Operation Transmission will Digital output short circuit - “Enable not go into neutral driving" (no neutral gear from automatically. steering ECU). Cables defective.

404

(WP 0016)

Information/Maintenance Digital output short circuit - “Control lamp, front wheel steering." Cables defective.

Control lamp on steering selection switch is not working.

405

(WP 0016)

Information/Maintenance Digital output short circuit - “Control lamp, four wheel steering." Cables defective.

Control lamp on steering selection switch is not working.

406

(WP 0016)

Information/Maintenance Digital output short circuit - “Control lamp, crab steering" Cables defective.

Control lamp on steering selection switch is not working.

408

(WP 0016)

Information/Maintenance Control lamp on Digital output short circuit - “Control steering column lamp, unlocked twistlock." Cables is not working. defective.

409

(WP 0016)

Information/Maintenance Control lamp on Digital output short circuit - “Control steering column lamp, locked twistlock." Cables is not working. defective.

0004-18

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

410

(WP 0016)

Information/Maintenance Control lamp on Digital output short circuit - “Control steering column lamp, alignment." Cables is not working. defective.

411

(WP 0036)

Information/Maintenance Digital output short circuit “Auxiliary hydraulic pump." Cables defective.

Cab cannot be moved. No emergency operation of boom or tophandler available.

412

(WP 0016)

Information/Maintenance Digital output short circuit - “Ether start kit." Cables defective.

Ether start not working.

413

(WP 0016)

Information/Maintenance Digital output short circuit - “Oil supply valve, boom folding." Cables defective.

Boom cannot be folded.

414

(WP 0031)

Warning - Degraded Operation Digital output short circuit - “Drive axle cooling, bypass valves." Cables defective.

Brakes may be overheated. Error codes 191 and 192 will show if brakes have overheated.

415

(WP 0016)

Stop Vehicle Immediately Digital output short circuit.

Reduced power and engine speed.

416

(WP 0016)

Stop Vehicle Immediately Digital input not read correctly “Steering pressure." Cables defective.

Steering pressure failure cannot be detected, error code 340.

417

(WP 0036)

Information/Maintenance Digital input not read correctly “Auxiliary hydraulic pump switch." Cables defective.

Auxiliary hydraulic pump cannot be started.

ERROR CODE CATEGORY/ EXPLANATION

0004-19

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

VEHICLE LIMITATIONS

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

418

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0016)

Warning - Degraded Operation Digital input not read correctly “Front wheel steering switch." Cables defective.

2WD cannot be selected.

419

(WP 0016)

Warning - Degraded Operation Digital input not read correctly “Four wheel steering switch" Cables defective.

4WD cannot be selected.

420

(WP 0016)

Warning - Degraded Operation Digital input not read correctly “Crab steering switch." Cables defective.

Crab steering cannot be selected.

422

(WP 0016)

Information/Maintenance Boom folding is Digital input not read correctly not possible. “Sensor, cab in transport position." Cables defective. Steering computer damaged.

423

(WP 0016)

Information/Maintenance Digital input not read correctly “Ether start switch." Cables defective. Steering computer damaged.

Ether injection is not possible.

426

(WP 0009)

Warning - Degraded Operation Digital input not read correctly “Fording level switch." Cables defective. Steering computer damaged.

Fording operations are not possible.

427

(WP 0016)

Information/Maintenance Digital input not read correctly “Tophandler work light switch." Cables defective. Steering computer damaged.

Work lights on tophandler do not function.

432

(WP 0038)

Information/Maintenance Digital input not read correctly “Hydraulic filter indication (lift/ lower; boom in/out)." Cables defective. Steering computer damaged.

None.

0004-20

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

433

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0038)

Information/Maintenance Digital input not read correctly “Hydraulic filter indication, steering." Cables defective. Steering computer damaged.

None.

434

(WP 0038)

Information/Maintenance Digital input not read correctly “Hydraulic filter indication, tophandler." Cables defective. Steering computer damaged.

None.

435

(WP 0038)

Information/Maintenance Digital input not read correctly “Hydraulic filter indication, return oil." Cables defective. Steering computer damaged.

None.

440

(WP 0016)

Information/Maintenance Error on power supply for steering wheel sensor error code can be caused by: Short circuit of analog output terminal 38 to +24V. Short circuit of analog output terminal 38 to ground. Fault in steering computer output.

Steering wheel has no end positions or steering resistance.

450

(WP 0016)

Warning - Degraded Operation Ambient temperature too high. Temperature sensor defective. ECU 792 defective.

None.

451

(WP 0015)

Warning - Degraded Operation Stop vehicle by Supply voltage too high. Alternator switching to defective. neutral.

452

(WP 0015)

Warning - Degraded Operation Supply voltage too low. Power supply off. Alternator defective

Stop vehicle by switching to neutral

453

(WP 0015)

Stop Vehicle Immediately Supply voltage for wheel sensors out of range. The +5 supply voltage for angle transducer track 2 is too low. Error code can be caused by short circuit

The vehicle is stopped by switching to neutral gear. If error code 454 is also active, all

0004-21

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

in one or more angle transducer wheels are tracks or low impedance to ground. locked. 454

(WP 0015)

Stop Vehicle Immediately Supply voltage for wheel sensors out of range. The +5 supply voltage for angle transducer track 1 is too low. Error code can be caused by short circuit in one or more angle transducer tracks or low impedance to ground.

The vehicle is stopped by switching to neutral gear. If error code 454 is also active, all wheels are locked.

618

(WP 0028)

Warning - Degraded Operation Logical error at direction select signal - transmission ECU detected incorrect signal combination for the direction. Cables defective. Shift lever defective.

Stop vehicle by switching to neutral.

622

(WP 0028)

Information/Maintenance Logical error at axle connection axle connection feedback measured by transmission ECU and output signal do not match. Cables defective. Switch defective. Mechanical error.

When shifting from 2WD to 4WD or vice versa, engage forward drive and immediately return to neutral. Turn the ignition switch off for at least 30 seconds, then turn switch back on.

637

(WP 0025)

Information/Maintenance None. Short circuit to battery voltage or open circuit at transmission sump temperature sensor input - voltage too high. Cables defective. Sensor defective. Connector pin broken.

638

(WP 0025)

Information/Maintenance Short circuit to ground at transmission sump temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken.

0004-22

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

None.

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

639

(WP 0025)

Information/Maintenance None. Short circuit to battery voltage or open circuit at converter output temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken.

640

(WP 0025)

Information/Maintenance None. Short circuit to battery voltage or open circuit at converter output temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken.

649

(WP 0026)

Information/Maintenance Short circuit to battery voltage or open circuit at engine speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor defective. Connector pin broken.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

650

(WP 0026)

Information/Maintenance Short circuit to ground at engine speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

651

(WP 0026)

Information/Maintenance Logical error at engine speed input - transmission ECU measures engine speed over a threshold and the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

652

(WP 0026)

Warning - Degraded Operation Short circuit to battery voltage or open circuit at turbine speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed,

ERROR CODE CATEGORY/ EXPLANATION

0004-23

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

VEHICLE LIMITATIONS

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

defective. Incorrect sensor gap size.

transmission ECU shifts to neutral. Limp home.

653

(WP 0026)

Warning - Degraded Operation Short circuit to ground at turbine speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home.

654

(WP 0026)

Warning - Degraded Operation Logical error at turbine speed input - transmission ECU measures turbine speed over a threshold and at the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home.

655

(WP 0026)

Information/Maintenance Short circuit to battery voltage or open circuit at internal speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor defective.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

656

(WP 0026)

Information/Maintenance Short circuit to ground at internal speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

0004-24

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

657

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0026)

Information/Maintenance Logical error at internal speed input - transmission ECU measures internal speed over a threshold and at the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home.

658

(WP 0026)

Warning - Degraded Operation Short circuit to battery voltage or open circuit at output speed input transmission ECU measures a voltage higher than 12.5V at speed input pin. Cables defective. Sensor defective.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home.

659

(WP 0026)

Warning - Degraded Operation Short circuit to battery voltage at output speed input - transmission ECU measures a voltage less than 1.0V at speed input pin. Cables defective. Sensor defective.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home.

660

(WP 0026)

Warning - Degraded Operation Logical error at output speed input - transmission ECU measures internal speed over a threshold and at the next moment the measured

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If

0004-25

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

speed is zero. Cables defective. Sensor defective.

there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home.

662

(WP 0026)

Warning - Degraded Operation Output speed does not fit other speed signals. If transmission is not in neutral and shifting has finished, transmission ECU measures output speed as zero and turbine or internal speed as not equal to zero. Cables defective. Sensor defective. Incorrect sensor gap size.

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home.

684

(WP 0013)

Warning - Degraded Operation CAN message time-out from display computer. Cable defective. Defective display computer.

Error codes from transmission ECU will not show.

685

(WP 0013)

Warning - Degraded Operation CAN message time-out from display computer. Cable defective. Defective steering computer.

Error codes from transmission ECU will not show.

713

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch K1 - measured valve resistance is beyond limit, voltage at K1 valve is too high. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

0004-26

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

714

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch K1 - measured valve resistance is beyond limit, voltage at K1 valve is too low. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

715

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K1 measured valve resistance is beyond limit. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

716

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch K2 - measured valve resistance is beyond limit, voltage at K2 valve is too high. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

717

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch K2 - measured valve resistance is beyond limit, voltage at K2 valve is

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down.

0004-27

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

too low. Cables defective. Regulator defective.

Reduced power and engine speed.

718

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K2 measured valve resistance is beyond limit. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

719

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch K3 - measured valve resistance is beyond limit, voltage at K3 valve is too high. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

720

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch K3 - measured valve resistance is beyond limit, voltage at K3 valve is too low. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

721

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K3 measured valve resistance is

Transmission ECU shifts to neutral. Limp home. If there is also a failure at

0004-28

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

beyond limit. Cables defective. Regulator defective.

another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

729

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch K4 - measured valve resistance is beyond limit, voltage at K4 valve is too high. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

730

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch K4 - measured valve resistance is beyond limit, voltage at K4 valve is too low. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

731

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K4 measured valve resistance is beyond limit. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

0004-29

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

732

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch KV - measured valve resistance is beyond limit, voltage at KV valve is too high. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

733

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch KV - measured valve resistance is beyond limit, voltage at KV valve is too low. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

734

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch KV measured valve resistance is beyond limit. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

735

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch KR - measured valve resistance is beyond limit, voltage

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down.

0004-30

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

at KR valve is too high. Cables defective. Regulator defective.

Reduced power and engine speed.

736

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch KR - measured valve resistance is beyond limit, voltage at KR valve is too low. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

737

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch KR measured valve resistance is beyond limit. Cables defective. Regulator defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

745

(WP 0028)

Information/Maintenance None. Short circuit to ground at reverse warning alarm relay - transmission ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Backup alarm device defective.

746

(WP 0028)

Information/Maintenance None. Short circuit to battery voltage at reverse warning alarm relay transmission ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Backup alarm device defective.

0004-31

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

747

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0028)

Information/Maintenance Open circuit at reverse warning alarm relay - transmission ECU detected incorrect voltage at output pin that looks like an open circuit for this output pin. Cables defective. Backup alarm device defective.

None.

761

(WP 0028)

Warning - Degraded Operation Switching from Short circuit to ground at axle 2WD to 4WD is connection solenoid - transmission not possible. ECU detected incorrect voltage at output pin that looks like a short circuit to vehicle ground. Cables defective. Axle connection solenoid defective.

762

(WP 0028)

Warning - Degraded Operation Switching from Short circuit to battery voltage axle 2WD to 4WD is connection solenoid - transmission not possible. ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Axle connection solenoid defective.

763

(WP 0028)

Warning - Degraded Operation Open circuit at axle connection solenoid - transmission ECU detected incorrect voltage at output pin that looks like an open circuit for this output pin. Cables defective. Axle connection solenoid defective.

Switching from 2WD to 4WD is not possible.

777

(WP 0029)

Stop Vehicle Immediately Slippage at clutch K1 transmission ECU calculates a differential speed at closed clutch K1. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power

0004-32

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

Sensor defective. Incorrect sensor and engine gap size. Clutch defective. speed. 778

(WP 0029)

Stop Vehicle Immediately Slippage at clutch K2 transmission ECU calculates a differential speed at closed clutch K2. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

779

(WP 0029)

Stop Vehicle Immediately Slippage at clutch K3 transmission ECU calculates a differential speed at closed clutch K3. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.

ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

780

(WP 0029)

Stop Vehicle Immediately Slippage at clutch K4 transmission ECU calculates a differential speed at closed clutch K4. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

781

(WP 0029)

Stop Vehicle Immediately Slippage at clutch KV transmission ECU calculates a differential speed at closed clutch KV. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure.

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to

0004-33

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

Sensor defective. Incorrect sensor neutral. ECU will gap size. Clutch defective. shut down. Reduced power and engine speed. 782

(WP 0029)

Stop Vehicle Immediately Slippage at clutch KR transmission ECU calculates a differential speed at closed clutch KR. If this calculated value is outside of range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.

783

(WP 0025)

Warning - Degraded Operation None. Overheated sump - transmission ECU measured temperature in oil sump that is over 212°F (100°C). Low oil level. Temperature sensor defective.

786

(WP 0038)

Information/Maintenance None. Oil filter differential pressure transmission ECU measured a voltage at differential pressure switch outside allowable range. Oil filter polluted. Cable/connector defective. Differential switch defective.

795

(WP 0025)

Warning - Degraded Operation None. Overheated converter output ECU measured oil temperature at converter output that is over 248°F (120°C). Low oil level. Temperature sensor defective.

811

(WP 0015)

Stop Vehicle Immediately Low power at battery - measured voltage at power supply is lower

0004-34

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

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

Transmission ECU shifts to neutral. ECU will shut down. Reduced power

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

than 18V. Cable defective. Battery and engine defective. Connector defective. speed. 812

(WP 0015)

Stop Vehicle Immediately High power at battery - measured voltage at power supply is higher than 32.5V. Cable defective. Battery defective. Connector defective.

Transmission ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

813

(WP 0015)

Stop Vehicle Immediately Error at shift valve power supply (VPS1). Cable defective. Connector defective. ECU defective.

ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

814

(WP 0015)

Stop Vehicle Immediately Error at shift valve power supply (VPS2). Cable defective. Connector defective. ECU defective.

ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

841

(WP 0014)

Information/Maintenance General EEPROM fault - ECU cannot read memory. ECU defective.

None.

843

(WP 0014)

Stop Vehicle Immediately Application error. ECU defective.

Transmission stays in neutral. ECU will shut down. Reduced power and engine speed.

845

(WP 0029)

Stop Vehicle Immediately Clutch failure - AEB was not able to adjust clutch filling parameters. Clutch defective.

Transmission stays in neutral. ECU will shut down. Reduced power and engine speed.

846

(WP 0029)

Information/Maintenance None. Clutch adjustment data lost - ECU was not able to read correct adjustment parameters.

0004-35

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

Interference during data saving process. 1111

(WP 0014)

Stop Vehicle Immediately ECM internal memory error. Hardware defective. Internal microprocessor communication failure.

Engine will not start. Reduced power and engine speed.

1115

(WP 0018)

Stop Vehicle Immediately No engine speed signal detected in either engine position sensor circuits.

Engine will shut down and will not start. Reduced power and engine speed.

1121

(WP 0018)

Warning - Degraded Operation None. No engine speed signal detected in one engine position sensor circuit.

1122

(WP 0022)

Warning - Degraded Operation High voltage detected in intake manifold pressure sensor circuit.

Reduced engine power output.

1123

(WP 0022)

Warning - Degraded Operation Low voltage detected in intake manifold pressure sensor circuit.

Reduced engine power output.

1131

(WP 0008)

Stop Vehicle Immediately High voltage detected in throttle position sensor circuit.

Severe power and speed loss. Limp home power only. Reduced power and engine speed.

1132

(WP 0008)

Stop Vehicle Immediately Low voltage detected in throttle position sensor circuit.

Severe power and speed loss. Limp home power only. Reduced power and engine speed.

1135

(WP 0019)

Warning - Degraded Operation High voltage detected in oil pressure sensor circuit.

Oil pressure warning not working.

0004-36

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1141

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0019)

Warning - Degraded Operation Low voltage detected in oil pressure sensor circuit.

Oil pressure warning not working.

1143

(WP 0019)

Stop Vehicle Immediately Reduced power Oil pressure signal indicates low oil and speed. pressure. Engine will shut down in 30 to 45 seconds.

1144

(WP 0020)

Warning - Degraded Operation High voltage detected in coolant temperature circuit.

Temperature warning not functioning.

1145

(WP 0020)

Warning - Degraded Operation Low voltage detected in coolant temperature circuit.

Temperature warning not functioning.

1151

(WP 0020)

Stop Vehicle Immediately Coolant temperature signal indicated coolant temperature above critical threshold.

Reduced power and speed. Engine will shut down in 30 to 45 seconds.

1153

(WP 0020)

Warning - Degraded Operation High voltage detected in intake manifold temperature sensor circuit.

Possible white smoke. No engine protection for intake manifold temperature.

1154

(WP 0020)

Warning - Degraded Operation Low voltage detected in intake manifold temperature sensor circuit.

Possible white smoke. No engine protection for intake manifold temperature.

1155

(WP 0020)

Stop Vehicle Immediately Intake manifold temperature signal indicated coolant temperature above critical threshold.

Reduced power and speed. Engine will shut down in 30 to 45 seconds.

0004-37

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1187

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0017)

Warning - Degraded Operation Low voltage detected on ECM voltage supply line to some sensors.

Engine will run degraded. No protection for oil pressure.

1212

(WP 0020)

Warning - Degraded Operation High voltage detected in oil temperature sensor circuit.

No engine protection for oil temperature.

1213

(WP 0020)

Warning - Degraded Operation Low voltage detected in oil temperature sensor circuit.

No engine protection for oil temperature.

1214

(WP 0020)

Stop Vehicle Immediately Oil pressure signal indicates temperature above critical threshold.

Reduced power and speed.

1221

(WP 0021)

Information/Maintenance High voltage detected in ambient air pressure sensor circuit.

Reduced power and speed.

1222

(WP 0021)

Information/Maintenance Low voltage detected in ambient air pressure sensor circuit.

Reduced power and speed.

1227

(WP 0017)

Warning - Degraded Operation High voltage detected on ECM voltage supply line to some sensors.

Engine will run degraded. No protection for oil pressure.

1234

(WP 0018)

Stop Vehicle Immediately Engine speed signal indicates engine speed greater than 2,730 RPM.

Fuel shutoff valve is closed until engine speed drops. Fuel shutoff valve will open when engine speed falls below 2,184 RPM. Reduced power and engine speed.

1254

(WP 0023)

Stop Vehicle Immediately

ECM turns off FSO supply voltage. Engine will shut down.

0004-38

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT

Error Code Reference Index - Continued.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

Less than 6V detected at fuel shutoff driver. Excessive current draw. Power supply faulty.

Reduced power and engine speed.

1255

(WP 0023)

Warning - Degraded Operation Externally supplied voltage detected going to fuel shutoff supply circuit.

No performance limitations. Fuel shutoff valve stays open.

1285

(WP 0013)

Warning - Degraded Operation Information from multiplexed device not received by ECM or received too late.

At least one multiplexed device will not operate properly.

1286

(WP 0013)

Warning - Degraded Operation Only a portion of information from multiplexed device received by ECM.

At least one multiplexed device will not operate properly.

1287

(WP 0017)

Stop Vehicle Immediately The engine will Data error received while only idle. multiplexing throttle pedal and IVS. Reduced power and engine speed.

1295

(WP 0021)

Information/Maintenance Engine is Ambient air pressure sensor circuit degraded to no error detected by ECM. air setting.

1298

(WP 0021)

Stop Vehicle Immediately Reduced power Intake system indicates air cleaner and speed. is clogged.

1311

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #1 cylinder #1 when voltage is turned turned OFF. OFF.

1312

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #5 cylinder #5 when voltage is turned turned OFF. OFF.

1313

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #3 cylinder #3 when voltage is turned turned OFF. OFF.

0004-39

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1314

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #6 cylinder #6 when voltage is turned turned OFF. OFF.

1315

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #2 cylinder #2 when voltage is turned turned OFF. OFF.

1321

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #4 cylinder #4 when voltage is turned turned OFF. OFF.

1322

(WP 0007)

Information/Maintenance Injector for No current detected at injector for cylinder #1 cylinder #1 when voltage is turned turned OFF. OFF.

1323

(WP 0007)

Information/Maintenance Injector for No current detected at injector for cylinder #5 cylinder #5 when voltage is turned turned ON. ON.

1324

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #3 cylinder #3 when voltage is turned turned ON. ON.

1325

(WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #6 cylinder #6 when voltage is turned turned ON. ON.

1331

(WP 0007)

Information/Maintenance Injector for No current detected at injector for cylinder #2 cylinder #2 when voltage is turned turned ON. ON.

1332

(WP 0007)

Information/Maintenance Injector for No current detected at injector for cylinder #4 cylinder #4 when voltage is turned turned OFF. ON.

ERROR CODE CATEGORY/ EXPLANATION

0004-40

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

VEHICLE LIMITATIONS

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1341

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0014)

Warning - Degraded Operation Severe loss of data from ECM.

No noticeable performance effects possible. Possibility of engine stopping or difficulty in starting engine.

1343

(WP 0014)

Warning - Degraded Operation Microprocessor communication error inside ECM.

No noticeable performance effects possible. May encounter severe loss of power.

1346

(WP 0014)

Information/Maintenance Software error in ECM.

Possibly too short of time for ECM to power down, less than 30 seconds.

1352

(WP 0017)

Warning - Degraded Operation Low voltage detected at sensor. Faulty power supply.

Engine is degraded to no air setting.

1415

(WP 0019)

Stop Vehicle Immediately Reduced power Oil pressure signal indicates below and speed. critical threshold. Engine will shut down in 30 to 45 seconds.

1419

(WP 0022)

Information/Maintenance Error in intake manifold pressure sensor signal detected by ECM.

1431

(WP 0008)

Information/Maintenance None. Both idle validation off-idle and onidle signals indicate the same voltage reading.

1432

(WP 0008)

Warning - Degraded Operation Idle validation switch voltages are opposite (complementary) but disagree with a valid throttle position sensor.

0004-41

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

Engine is degraded to no air setting.

Engine will only idle.

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1433

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0022)

Information/Maintenance Intake manifold pressure sensor voltage indicates a high pressure reading.

Engine is degraded to no air setting.

1434

(WP 0024)

Warning - Degraded Operation Battery voltage too low or insufficient amount of time for battery power to ECM for powering down after key off.

No noticeable performance effects possible. Possibility of engine stopping or difficulty in starting engine.

1435

(WP 0019)

Warning - Degraded Operation ECM detects error in oil pressure sensor signal.

None. No engine protection for oil pressure.

1441

(WP 0024)

Warning - Degraded Operation Battery voltage below normal operating level.

No noticeable performance effects possible. Possibility of rough idle.

1442

(WP 0024)

Warning - Degraded Operation Battery voltage above normal operating level.

None.

1443

(WP 0017)

Warning - Degraded Operation Low voltage detected on ECM voltage supply line to throttle.

Engine will only idle.

1474

(WP 0024)

Warning - Degraded Operation Low voltage detected in starter lockout relay circuit when energized or voltage detected when circuit de-energized.

None.

1551

(WP 0008)

Warning - Degraded Operation No voltage detected simultaneously in both idle validation off-idle and on-idle circuits.

Engine will only idle.

1581

(WP 0023)

Warning - Degraded Operation High voltage detected in fuel inlet pressure sensor circuit.

None.

0004-42

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

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4.

Error Code Reference Index - Continued.

ERROR DISPLAY CODE LAYOUT

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1596

ERROR CODE CATEGORY/ EXPLANATION

VEHICLE LIMITATIONS

(WP 0024)

Warning - Degraded Operation Battery voltage above normal operating range.

None.

1597

(WP 0024)

Warning - Degraded Operation Battery voltage below normal operating range.

None.

1598

(WP 0024)

Stop Vehicle Immediately Very low battery voltage - critical level.

Engine is degraded to no air setting.

1697

(WP 0020)

Information/Maintenance None. High voltage detected in ECM internal temperature sensor circuit.

1698

(WP 0020)

Information/Maintenance None. Low voltage detected in ECM internal temperature sensor circuit.

1951

(WP 0007)

Information/Maintenance Power imbalance between cylinders detected by ECM.

1999

Engine may rough idle or misfire.

Stop Vehicle Immediately Engine is More than 6 errors active on J1939 degraded to no bus to display. air setting.

END OF WORK PACKAGE

0004-43/44 blank

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

TM 10-3930-675-23-1

0005

FIELD MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX

ERROR CODE SYMPTOM INDEX Malfunction/Symptom

Troubleshooting Procedure

AUXILIARY PUMP 1.

Error Code 169 - Tophandler Emergency Function Supply Valve, Open or Short Circuit Failure ................................................................................................. WP 0036

2.

Error Code 411 - Auxiliary Pump Control, Short Circuit Failure ....................................................... WP 0036

3.

Error Code 417 - Auxiliary Pump Switch, Circuit Input Error ............................................................ WP 0036

AXLE BRAKE COOLING SYSTEM 1.

Error Code 191 - Temperature in Front Axle Above Critical Threshold ......................................................................................................................................... WP 0031

2.

Error Code 192 - Temperature in Rear Axle Above Critical Threshold ......................................................................................................................................... WP 0031

3.

Error Code 414 - Brake Cooling Bypass Valve, Short Circuit Failure .............................................................................................................................................. WP 0031

BOOM IN/OUT 1.

Error Code 127 - Joystick-to-ECU (790) Failure .............................................................................. WP 0040

2.

Error Code 130 - Overload Protection System Failure ..................................................................... WP 0040

3.

Error Code 160 - Extension Cylinder Boom IN Control, Wiring Circuit Failure ................................................................................................................................... WP 0040

4.

Error Code 161 - Extension Cylinder Boom IN Control, Component Failure ........................................................................................................................... WP 0040

5.

Error Code 163 - Extension Cylinder Boom OUT Control Valve, Wiring Circuit Failure ........................................................................................................................ WP 0040

6.

Error Code 164 - Extension Cylinder Boom OUT Control Valve, Component Failure ........................................................................................................................... WP 0040

BOOM LIFTING/LOWERING 1.

Error Code 126 - Joystick-to-ECU (790) Failure .............................................................................. WP 0039

2.

Error Code 130 - Overload Protection System Failure ..................................................................... WP 0039

3.

Error Code 151 - Lift Cylinder Locking Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039

4.

Error Code 152 - Lift Cylinder Locking Valve, Component Failure ................................................... WP 0039

5.

Error Code 154 - Lift Cylinder Boom Up Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039

0005-1

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

TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

6.

Error Code 155 - Lift Cylinder Boom Up Valve, Component Failure .............................................................................................................................................. WP 0039

7.

Error Code 157 - Lift Cylinder Boom Down Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039

8.

Error Code 158 - Lift Cylinder Boom Down Valve, Component Failure .............................................................................................................................................. WP 0039

BRAKE SYSTEM 1.

Error Code 118 - Brake System Pressure, Circuit 1 and Circuit 2 Failure ........................................................................................................................................... WP 0030

2.

Error Code 119 - Brake System Pressure, Circuit 1 Failure ............................................................. WP 0030

3.

Error Code 120 - Brake System Pressure, Circuit 2 Failure ............................................................. WP 0030

COOLING FAN OPERATION AND FAN CONTROL 1.

Error Code 166 - Cooling Fan Speed, Wiring Circuit Failure ........................................................... WP 0009

2.

Error Code 167 - Cooling Fan Speed, Short Circuit Failure ............................................................. WP 0009

3.

Error Code 426 - Fording Level Switch, Circuit Input Error .............................................................. WP 0009

ECU-TO-ECU COMMUNICATIONS 1.

Error Code 103 - ECU (790) Not Responding (RT 240V1R, RT 240V2 and RT 240V3) ..................................................................................................................... WP 0013

2.

Error Code 105 - ECU (790) Not Responding .................................................................................. WP 0013

3.

Error Code 106 - ECU (791) Not Responding .................................................................................. WP 0013

4.

Error Code 107 - Cable Failure Between Tophandler ECU (791) and Display ECU (795) .................................................................................................................... WP 0013

5.

Error Code 108 - Cable Failure Between Tophandler ECU (791) and Servo ECU (790) ....................................................................................................................... WP 0013

6.

Error Code 109 - Cable Failure Between Servo ECU (790) and Display ECU (795) ........................................................................................................................... WP 0013

7.

Error Code 110 - Communication Failure Between Display ECU (795) and Steering ECU (792) ......................................................................................................... WP 0013

8.

Error Code 111 - Communication Failure Between Display ECU (795) and Transmission ECU (793) .................................................................................................. WP 0013

9.

Error Code 112 - Communication Failure Between Display ECU (795) and Engine ECU (794) ............................................................................................................ WP 0013

10.

Error Code 345 - Communication Failure Between Steering ECU (792) and Display ECU (795) ................................................................................................... WP 0013

0005-2

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

11.

Error Code 346 - Communication Failure Between Steering ECU (792) and Transmission ECU (793) ......................................................................................... WP 0013

12.

Error Code 684 - Communication Failure Between Transmission ECU (793) and Display ECU (795) ............................................................................ WP 0013

13.

Error Code 685 - Communication Failure Between Transmission ECU (793) and Steering ECU (792) ........................................................................... WP 0013

14.

Error Code 1285 - Engine Detects a Communication Failure on the J1939 Datalink ........................................................................................................................... WP 0013

15.

Error Code 1286 - Engine Detects a Communication Failure on the J1939 Datalink ........................................................................................................................... WP 0013

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE 1.

Error Code 451 - Voltage Supply Too High for Steering ECU (792) ................................................................................................................................................. WP 0015

2.

Error Code 452 - Voltage Supply Too Low for Steering ECU (792) ................................................................................................................................................. WP 0015

3.

Error Code 453 - Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0015

4.

Error Code 454 - Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0015

5.

Error Code 811 - Voltage Supply Too Low for Transmission ECU (793) ........................................................................................................................................ WP 0015

6.

Error Code 812 - Voltage Supply Too High for Transmission ECU (793) ........................................................................................................................................ WP 0015

7.

Error Code 813 - Voltage Failure at Transmission Gearshift Valve Supply .................................................................................................................................... WP 0015

8.

Error Code 814 - Voltage Failure at Transmission Gearshift Valve Power Supply ......................................................................................................................... WP 0015

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE 1.

Error Code 121 - Supply Voltage to Servo ECU (790) Failure ......................................................... WP 0012

2.

Error Code 122 - Supply Voltage to Servo ECU (790) Failure ......................................................... WP 0012

3.

Error Code 123 - 10V Reference Voltage for Servo ECU (790) Short Circuit Failure ......................................................................................................................... WP 0012

4.

Error Code 201 - Supply Voltage to Tophandler ECU (791) Failure .............................................................................................................................................. WP 0012

5.

Error Code 202 - Supply Voltage to Tophandler ECU (791) Failure .............................................................................................................................................. WP 0012

6.

Error Code 203 - 10V Reference Voltage for Tophandler ECU (791) Failure ..................................................................................................................................... WP 0012

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0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS 1.

Error Code 1221 - High Voltage Detected at Ambient Air Pressure Sensor Circuit ................................................................................................................... WP 0021

2.

Error Code 1222 - Low Voltage Detected at Ambient Air Pressure Sensor Circuit ................................................................................................................... WP 0021

3.

Error Code 1295 - Ambient Air Pressure Sensor Circuit Failure ...................................................... WP 0021

4.

Error Code 1298 - High Intake Air Restriction or Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0021

ENGINE BATTERY VOLTAGE CIRCUITS 1.

Error Code 1434 - Unswitched Battery Supply Circuit Failure ......................................................... WP 0024

2.

Error Code 1441 - Unswitched Battery Supply Circuit Failure ......................................................... WP 0024

3.

Error Code 1442 - Unswitched Battery Supply Circuit Failure. ........................................................ WP 0024

4.

Error Code 1474 - Starter Solenoid Lockout Relay Driver Circuit Failure .............................................................................................................................................. WP 0024

5.

Error Code 1596 - Voltage Monitor, High Voltage Failure ................................................................ WP 0024

ENGINE FUEL INJECTOR CIRCUITS 1.

Error Code 1311 - Injector Circuit Failure ......................................................................................... WP 0007

2.

Error Code 1312 - Injector Circuit Failure ......................................................................................... WP 0007

3.

Error Code 1313 - Injector Circuit Failure ......................................................................................... WP 0007

4.

Error Code 1314 - Injector Circuit Failure ......................................................................................... WP 0007

5.

Error Code 1315 - Injector Circuit Failure ......................................................................................... WP 0007

6.

Error Code 1321 - Injector Circuit Failure ......................................................................................... WP 0007

7.

Error Code 1322 - Injector Circuit Failure ......................................................................................... WP 0007

8.

Error Code 1323 - Injector Circuit Failure ......................................................................................... WP 0007

9.

Error Code 1324 - Injector Circuit Failure ......................................................................................... WP 0007

10.

Error Code 1325 - Injector Circuit Failure ......................................................................................... WP 0007

11.

Error Code 1331 - Injector Circuit Failure ......................................................................................... WP 0007

12.

Error Code 1332 - Injector Circuit Failure ......................................................................................... WP 0007

13.

Error Code 1951 - Injector Circuit Failure ......................................................................................... WP 0007

ENGINE FUEL PRESSURE SENSORS AND CIRCUITS 1.

Error Code 1254 - Fuel Shutoff Solenoid Circuit Failure .................................................................. WP 0023

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0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

2.

Error Code 1255 - Fuel Shutoff Solenoid External Voltage Detected on Circuit ........................................................................................................................... WP 0023

3.

Error Code 1581 - Fuel Inlet Restriction Sensor Circuit Failure ....................................................... WP 0023

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) 1.

Error Code 1187 - Sensor Voltage Supply Failure ........................................................................... WP 0017

2.

Error Code 1227 - Sensor Voltage Supply Failure ........................................................................... WP 0017

3.

Error Code 1287 - Sensor Voltage Supply Failure ........................................................................... WP 0017

4.

Error Code 1352 - Sensor Voltage Supply Failure ........................................................................... WP 0017

5.

Error Code 1443 - Low Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0017

ENGINE OIL PRESSURE 1.

Error Code 1135 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019

2.

Error Code 1141 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019

3.

Error Code 1143 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019

4.

Error Code 1415 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019

5.

Error Code 1435 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019

ENGINE POSITION SENSOR CIRCUITS 1.

Error Code 1115 - Engine Position Sensor Circuit Failure ............................................................... WP 0018

2.

Error Code 1121 - Engine Position Sensor Circuit Failure ............................................................... WP 0018

3.

Error Code 1234 - Engine Overspeed Failure .................................................................................. WP 0018

ENGINE PRESSURE SENSOR 1.

Error Code 1122 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022

2.

Error Code 1123 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022

3.

Error Code 1419 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022

4.

Error Code 1433 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022

ENGINE TEMPERATURE SENSORS AND CIRCUITS 1.

Error Code 1144 - Coolant Temperature Sensor Circuit Failure ...................................................... WP 0020

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

2.

Error Code 1145 - Coolant Temperature Sensor Circuit Failure ...................................................... WP 0020

3.

Error Code 1151 - Coolant Temperature Above Critical Threshold ......................................................................................................................................... WP 0020

4.

Error Code 1153 - Intake Air Temperature Sensor Circuit Failure ................................................... WP 0020

5.

Error Code 1154 - Intake Air Temperature Sensor Circuit Failure ................................................... WP 0020

6.

Error Code 1155 - Intake Air Temperature Above Critical Threshold ......................................................................................................................................... WP 0020

7.

Error Code 1212 - Oil Temperature Sensor Circuit Failure .............................................................. WP 0020

8.

Error Code 1213 - Oil Temperature Sensor Circuit Failure .............................................................. WP 0020

9.

Error Code 1214 - Oil Temperature Above Critical Threshold ......................................................... WP 0020

10.

Error Code 1697 - ECU Internal Temperature Sensor Circuit Failure .............................................................................................................................................. WP 0020

11.

Error Code 1698 - ECU Internal Temperature Sensor Circuit Failure .............................................................................................................................................. WP 0020

ENGINE TPS AND IDLE VALIDATION SWITCH 1.

Error Code 1131 - High Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0008

2.

Error Code 1132 - Low Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0008

3.

Error Code 1431 - High Voltage Detected at Both Idle Validation Signal Circuits .................................................................................................................................. WP 0008

4.

Error Code 1432 - Wrong Voltage Signals Detected at Throttle Position Sensor and Idle Validation Circuits ..................................................................................... WP 0008

5.

Error Code 1551 - No Voltage Detected at Both Idle Validation Signal Circuits .................................................................................................................................. WP 0008

HYDRAULIC FILTER INDICATORS 1.

Error Code 1 - Boom Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038

2.

Error Code 2 - Steering Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038

3.

Error Code 3 - Tophandler Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038

4.

Error Code 4 - Hydraulic Reservoir Return Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038

5.

Error Code 432 - Boom Hydraulic Filter Sensor, Circuit Error Input ................................................................................................................................................. WP 0038

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

6.

Error Code 433 - Steering Hydraulic Filter Sensor, Circuit Input Error ................................................................................................................................................. WP 0038

7.

Error Code 434 - Tophandler Hydraulic Filter Sensor, Circuit Input Error ........................................................................................................................................ WP 0038

8.

Error Code 435 - Hydraulic Reservoir Return System Filter Sensor, Circuit Input Error ................................................................................................................ WP 0038

9.

Error Code 786 - Transmission Hydraulic System Sensor Indicating Clogged Filter .................................................................................................................. WP 0038

HYDRAULIC PISTON PUMP CUT-OFF 1.

Error Code 172 - Hydraulic Piston Pump Cut-Off, Open or Short Circuit Failure ................................................................................................................................... WP 0037

HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) 1.

Error Code 125 - Memory Failure ..................................................................................................... WP 0035

2.

Error Code 141 - Internal Communication Failure ............................................................................ WP 0035

3.

Error Code 142 - Internal Communication Failure ............................................................................ WP 0035

INPUT AND OUTPUT SIGNALS FOR STEERING 1.

Error Code 350 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016

2.

Error Code 351 - Right Rear Wheel Valve Solenoid Error ............................................................... WP 0016

3.

Error Code 352 - Left Rear Wheel Valve Solenoid Error .................................................................. WP 0016

4.

Error Code 353 - Left Front Wheel Valve Solenoid Error ................................................................. WP 0016

5.

Error Code 354 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016

6.

Error Code 355 - Right Rear Wheel Valve Solenoid Error ............................................................... WP 0016

7.

Error Code 356 - Left Rear Wheel Valve Solenoid Error .................................................................. WP 0016

8.

Error Code 357 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016

9.

Error Code 399 - EEPROM Parameter Error in ECU (792) ............................................................. WP 0016

10.

Error Code 401 - Transmission Neutral Signal from Steering ECU (792) Short Circuit Failure ........................................................................................................ WP 0016

11.

Error Code 404 - 2WD Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016

12.

Error Code 405 - 4WD Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016

13.

Error Code 406 - Crab Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016

0005-7

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

14.

Error Code 408 - Unlocked Twistlock Control Lamp, Short Circuit Failure ................................................................................................................................... WP 0016

15.

Error Code 409 - Locked Twistlock Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016

16.

Error Code 410 - Alignment Control Lamp, Short Circuit Failure ..................................................... WP 0016

17.

Error Code 412 - Autolube Pump Control, Short Circuit Failure (RT 240V2 and RT 240V3) .............................................................................................................. WP 0016

18.

Error Code 413 - Boom Folding Supply Valve, Short Circuit Failure .............................................................................................................................................. WP 0016

19.

Error Code 415 - Drag Restriction, Short Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3) ................................................................................................. WP 0016

20.

Error Code 416 - Steering Pressure Switch, Circuit Input Error ....................................................... WP 0016

21.

Error Code 418 - 2WD Steering Selection Switch, Circuit Input Error ................................................................................................................................................. WP 0016

22.

Error Code 419 - 4WD Steering Selection Switch, Circuit Failure .................................................... WP 0016

23.

Error Code 420 - Crab Steering Selection Switch, Circuit Failure .................................................... WP 0016

24.

Error Code 422 - Cab in Transport Proximity Switch, Circuit Input Error ........................................................................................................................................ WP 0016

25.

Error Code 423 - Ether Start Switch, Circuit Failure ......................................................................... WP 0016

26.

Error Code 427 - Tophandler Work Light Switch, Circuit Input Error ................................................................................................................................................. WP 0016

27.

Error Code 440 - Steering Wheel Sensor, Power Supply Error (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0016

28.

Error Code 450 - Temperature Inside Steering ECU (792) Above Critical Threshold [184°F (85°C)] .......................................................................................... WP 0016

INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE 1.

Error Code 777 - Internal Transmission Failure at Clutch K1 ........................................................... WP 0029

2.

Error Code 778 - Internal Transmission Failure at Clutch K2 ........................................................... WP 0029

3.

Error Code 779 - Internal Transmission Failure at Clutch K3 ........................................................... WP 0029

4.

Error Code 780 - Internal Transmission Failure at Clutch K4 ........................................................... WP 0029

5.

Error Code 781 - Internal Transmission Failure at Clutch KV .......................................................... WP 0029

6.

Error Code 782 - Internal Transmission Failure at Clutch KR .......................................................... WP 0029

7.

Error Code 845 - Clutch Failure Detected During Calibration .......................................................... WP 0029

8.

Error Code 846 - Clutch Adjustment Data Lost ................................................................................ WP 0029

0005-8

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

TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

MECHANICAL OR HYDRAULIC STEERING FAILURE 1.

Error Code 317 - Right-Front Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033

2.

Error Code 318 - Right-Rear Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033

3.

Error Code 319 - Left-Rear Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033

4.

Error Code 320 - Left-Front Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033

5.

Error Code 321 - Right-Front Wheel is Not Calibrated Correctly ..................................................... WP 0033

6.

Error Code 322 - Right-Rear Wheel is Not Calibrated Correctly ...................................................... WP 0033

7.

Error Code 323 - Left-Rear Wheel is Not Calibrated Correctly ........................................................ WP 0033

8.

Error Code 324 - Left-Front Wheel is Not Calibrated Correctly ........................................................ WP 0033

MISCELLANEOUS TRANSMISSION FAILURE 1.

Error Code 618 - Signal from Gear Selector Not Correct ................................................................. WP 0028

2.

Error Code 622 - Feedback Signal from 2WD/4WD Switch Not Correct ............................................................................................................................................. WP 0028

3.

Error Code 745 - Backup Alarm Control Circuit, Short Circuit to Chassis Failure ................................................................................................................................ WP 0028

4.

Error Code 746 - Backup Alarm Control Circuit, Short Circuit to Battery Failure .................................................................................................................................. WP 0028

5.

Error Code 747 - Backup Alarm Control Circuit, Open Circuit Failure .............................................................................................................................................. WP 0028

6.

Error Code 761 - 2WD/4WD Connection Valve Circuit, Short Circuit to Chassis Failure ................................................................................................................. WP 0028

7.

Error Code 762 - 2WD/4WD Connection Valve Circuit, Short Circuit to Battery Failure ................................................................................................................... WP 0028

8.

Error Code 763 - 2WD/4WD Connection Valve Circuit, Open Circuit Failure ................................................................................................................................... WP 0028

OVERLOAD PROTECTION 1.

Error Code 130 - Overload Protection System Failure ..................................................................... WP 0010

2.

Error Code 131 - Boom Extension Sensor or Circuit Failure ............................................................ WP 0010

3.

Error Code 132 - Boom Angle Sensor or Circuit Failure .................................................................. WP 0010

4.

Error Code 133 - Left Lift Cylinder Pressure Sensor or Circuit Failure .............................................................................................................................................. WP 0010

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0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

5.

Error Code 134 - Right Lift Cylinder Pressure Sensor or Circuit Failure .............................................................................................................................................. WP 0010

6.

Error Code 135 - Left Lift Cylinder Piston Pressure Sensor or Circuit Failure ................................................................................................................................... WP 0010

7.

Error Code 136 - Right Lift Cylinder Piston Pressure Sensor or Circuit Failure ................................................................................................................................... WP 0010

8.

Error Code 210 - Tophandler Angle Sensor or Circuit Failure ......................................................... WP 0010

STEERING ECU (732), TRANSMISSION ECU (793), AND ENGINE ECU (794) 1.

Error Code 300 - Steering ECU (792) Hardware Failure .................................................................. WP 0014

2.

Error Code 841 - Transmission ECU (793) Memory Failure ............................................................ WP 0014

3.

Error Code 843 - Application Error Failure ....................................................................................... WP 0014

4.

Error Code 1111 - Engine ECU (794) Memory Failure .................................................................... WP 0014

5.

Error Code 1341 - Engine ECU (794) Loss of Data Failure ............................................................. WP 0014

6.

Error Code 1343 - Engine ECU (794) Internal Communication Failure .............................................................................................................................................. WP 0014

7.

Error Code 1346 - Engine ECU (794) Software Failure ................................................................... WP 0014

STEERING SENSOR 1.

Error Code 301 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034

2.

Error Code 302 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034

3.

Error Code 303 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034

4.

Error Code 304 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034

5.

Error Code 305 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034

6.

Error Code 306 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034

7.

Error Code 307 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034

8.

Error Code 308 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034

9.

Error Code 309 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034

10.

Error Code 310 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034

11.

Error Code 311 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034

12.

Error Code 312 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034

13.

Error Code 313 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034

14.

Error Code 314 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034

15.

Error Code 315 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034

16.

Error Code 316 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034

0005-10

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0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 17.

Troubleshooting Procedure

Error Code 339 - Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT 240V3) ............................................................................................ WP 0034

STEERING VALVE CIRCUIT 1.

Error Code 325 - Right-Front Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032

2.

Error Code 326 - Right-Rear Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032

3.

Error Code 327 - Left-Rear Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032

4.

Error Code 328 - Left-Front Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032

5.

Error Code 329 - Right-Front Wheel Valve Solenoid, Short Circuit Failure ................................................................................................................................... WP 0032

6.

Error Code 330 - Right-Rear Wheel Valve Solenoid, Short Circuit Failure ................................................................................................................................... WP 0032

7.

Error Code 331 - Left-Rear Wheel Valve Solenoid, Short Circuit Failure .............................................................................................................................................. WP 0032

8.

Error Code 332 - Left-Front Wheel Valve Solenoid, Short Circuit Failure .............................................................................................................................................. WP 0032

9.

Error Code 339 - Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT 240V3) ............................................................................................ WP 0032

10.

Error Code 340 - Hydraulic Steering Pressure Below Threshold [1,450 psi (100 Bar)] ......................................................................................................................... WP 0032

11.

Error Code 341 - Steering Wheel Signal Not Consistent ................................................................. WP 0032

12.

Error Code 342 - One Steering Wheel Signal is Interrupted ............................................................ WP 0032

13.

Error Code 343 - One Steering Wheel Signal is Interrupted ............................................................ WP 0032

14.

Error Code 344 - Both Steering Wheel Signals are Interrupted ....................................................... WP 0032

15.

Error Code 347 - No Steering Mode Selected .................................................................................. WP 0032

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) 1.

Error Code 205 - Memory Failure ..................................................................................................... WP 0011

2.

Error Code 220 - Internal Communication Failure, Connector 2 ...................................................... WP 0011

3.

Error Code 221 - Internal Communication Failure, Connector 2 ...................................................... WP 0011

4.

Error Code 250 - Internal Communication Failure, Connector 3 ...................................................... WP 0011

5.

Error Code 251 - Internal Communication Failure, Connector 3 ...................................................... WP 0011

0005-11

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

TOPHANDLER LEVELING 1.

Error Code 128 - Joystick-to-ECU (790) Failure .............................................................................. WP 0043

2.

Error Code 130 - Overload Protection System Failure ..................................................................... WP 0043

3.

Error Code 240 - Tophandler Leveling Locking Control, Wiring Circuit Failure ................................................................................................................................... WP 0043

4.

Error Code 267 - Tophandler Leveling Right, Open Circuit Failure .............................................................................................................................................. WP 0043

5.

Error Code 268 - Tophandler Leveling Right, Short Circuit Failure .............................................................................................................................................. WP 0043

6.

Error Code 270 - Tophandler Leveling Left, Open Circuit Failure .................................................... WP 0043

7.

Error Code 271 - Tophandler Leveling Left, Short Circuit Failure .................................................... WP 0043

TOPHANDLER SIDESHIFT 1.

Error Code 225 - Tophandler Sideshift Left, Open Circuit Failure .................................................... WP 0044

2.

Error Code 226 - Tophandler Sideshift Left, Short Circuit Failure .................................................... WP 0044

3.

Error Code 228 - Tophandler Sideshift Right, Open Circuit Failure .............................................................................................................................................. WP 0044

4.

Error Code 229 - Tophandler Sideshift Right, Short Circuit Failure .............................................................................................................................................. WP 0044

TOPHANDLER SLEWING 1.

Error Code 128 - Joystick-to-ECU (790) Failure .............................................................................. WP 0041

2.

Error Code 130 - Overload Protection System Failure ..................................................................... WP 0041

3.

Error Code 255 - Tophandler Clockwise Slewing, Wiring Circuit Failure .............................................................................................................................................. WP 0041

4.

Error Code 256 - Tophandler Clockwise Slewing, Component Failure .............................................................................................................................................. WP 0041

5.

Error Code 258 - Tophandler Counterclockwise Slewing, Wiring Circuit Failure ................................................................................................................................... WP 0041

6.

Error Code 259 - Tophandler Counterclockwise Slewing, Component Failure ........................................................................................................................... WP 0041

TOPHANDLER SPREADER 1.

Error Code 231 - Tophandler Spreader Opening, Open Circuit Failure .............................................................................................................................................. WP 0045

2.

Error Code 232 - Tophandler Spreader Opening, Short Circuit Failure .............................................................................................................................................. WP 0045

0005-12

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

3.

Error Code 234 - Tophandler Spreader Closing, Open Circuit Failure .............................................................................................................................................. WP 0045

4.

Error Code 235 - Tophandler Spreader Closing, Short Circuit Failure .............................................................................................................................................. WP 0045

TOPHANDLER TILT 1.

Error Code 129 - Joystick-to-ECU (790) Failure .............................................................................. WP 0042

2.

Error Code 130 - Overload Protection System Failure ..................................................................... WP 0042

3.

Error Code 237 - Tophandler Tilt Locking Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042

4.

Error Code 261 - Tophandler Tilt OUT Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042

5.

Error Code 262 - Tophandler Tilt OUT Control, Component Failure .............................................................................................................................................. WP 0042

6.

Error Code 264 - Tophandler Tilt IN Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042

7.

Error Code 265 - Tophandler Tilt IN Control, Component Failure .................................................... WP 0042

TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR 1.

Error Code 212 - Tophandler Left Twistlocks Indication Failure ...................................................... WP 0046

2.

Error Code 213 - Tophandler Right Twistlocks Indication Failure .................................................... WP 0046

3.

Error Code 214 - Tophandler Forklift Sensor Indication Failure ....................................................... WP 0046

4.

Error Code 243 - Tophandler Twistlock Locking Circuit Failure ....................................................... WP 0046

5.

Error Code 246 - Tophandler Twistlock Unlocking Circuit Failure .................................................... WP 0046

TRANSMISSION CLUTCH CIRCUIT 1.

Error Code 713 - Clutch K1 Short Circuit to Battery Failure ............................................................. WP 0027

2.

Error Code 714 - Clutch K1 Short Circuit to Chassis Failure ........................................................... WP 0027

3.

Error Code 715 - Clutch K1 Open Circuit Failure ............................................................................. WP 0027

4.

Error Code 716 - Clutch K2 Short Circuit to Battery Failure ............................................................. WP 0027

5.

Error Code 717 - Clutch K2 Short Circuit to Chassis Failure ........................................................... WP 0027

6.

Error Code 718 - Clutch K2 Open Circuit Failure ............................................................................. WP 0027

7.

Error Code 719 - Clutch K3 Open Circuit to Battery Failure ............................................................. WP 0027

8.

Error Code 720 - Clutch K3 Short Circuit to Chassis Failure ........................................................... WP 0027

9.

Error Code 721 - Clutch K3 Open Circuit Failure ............................................................................. WP 0027

10.

Error Code 729 - Clutch K4 Short Circuit to Battery Failure ............................................................. WP 0027

0005-13

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

11.

Error Code 730 - Clutch K4 Short Circuit to Chassis Failure ........................................................... WP 0027

12.

Error Code 731 - Clutch K4 Open Circuit Failure ............................................................................. WP 0027

13.

Error Code 732 - Clutch KV Short Circuit to Battery Failure ............................................................ WP 0027

14.

Error Code 733 - Clutch KV Short Circuit to Chassis Failure ........................................................... WP 0027

15.

Error Code 734 - Clutch KV Open Circuit Failure ............................................................................. WP 0027

16.

Error Code 735 - Clutch KR Short Circuit to Battery Failure ............................................................ WP 0027

17.

Error Code 736 - Clutch KR Short Circuit to Chassis Failure ........................................................... WP 0027

18.

Error Code 737 - Clutch KR Open Circuit Failure ............................................................................ WP 0027

TRANSMISSION SPEED SENSORS 1.

Error Code 649 - Engine Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026

2.

Error Code 650 - Engine Speed Sensor Failure, Short Circuit to Chassis ............................................................................................................................................ WP 0026

3.

Error Code 651 - Engine Speed Sensor Failure, Logical Error ........................................................ WP 0026

4.

Error Code 652 - Turbine Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026

5.

Error Code 653 - Turbine Speed Sensor Failure, Short Circuit to Chassis ........................................................................................................................................ WP 0026

6.

Error Code 654 - Turbine Speed Sensor Failure, Logical Error ....................................................... WP 0026

7.

Error Code 655 - Internal Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026

8.

Error Code 656 - Internal Speed Sensor Failure, Short Circuit to Chassis ........................................................................................................................................ WP 0026

9.

Error Code 657 - Internal Speed Sensor Failure, Logical Error ....................................................... WP 0026

10.

Error Code 658 - Output Speed Sensor Failure, Open Circuit or Short Circuit to Battery ..................................................................................................................... WP 0026

11.

Error Code 659 - Output Speed Sensor Failure, Short Circuit to Chassis ............................................................................................................................................ WP 0026

12.

Error Code 660 - Output Speed Sensor Failure, Logical Error ......................................................... WP 0026

13.

Error Code 662 - Output Speed Sensor Failure, Logical Speed Error ................................................................................................................................................. WP 0026

TRANSMISSION TEMPERATURE 1.

Error Code 637 - Transmission Sump Temperature Sensor Failure, Open Circuit or Short Circuit to Battery ............................................................................... WP 0025

2.

Error Code 638 - Transmission Sump Temperature Sensor Failure, Short Circuit to Chassis ....................................................................................................... WP 0025

0005-14

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

3.

Error Code 639 - Converter Output Temperature Sensor Failure, Open Circuit or Short Circuit to Battery ............................................................................... WP 0025

4.

Error Code 640 - Converter Output Temperature Sensor Failure, Short Circuit to Chassis ....................................................................................................... WP 0025

5.

Error Code 783 - Sump Temperature Critical Threshold [212°F (100°C)] Failure ................................................................................................................................ WP 0025

6.

Error Code 795 - Converter Output Temperature Critical Threshold [248°F (120°C)] Failure ................................................................................................... WP 0025

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Engine Will Not Crank ...................................................................................................................... WP 0006

2.

Engine Will Crank but Will Not Start (Exhaust Smoke or No Exhaust Smoke) ............................................................................................................................... WP 0006

3.

Excessive Exhaust Smoke - White ................................................................................................... WP 0006

4.

Excessive Exhaust Smoke - Black ................................................................................................... WP 0006

5.

Engine Acceleration - Poor .............................................................................................................. WP 0006

6.

Engine Deceleration - Poor .............................................................................................................. WP 0006

7.

Engine Performance (Power) - Low ................................................................................................. WP 0006

8.

Engine Runs Rough ......................................................................................................................... WP 0006

9.

Engine Speed Surges (Idle or Under Load) ..................................................................................... WP 0006

10.

Engine Shuts Off Unexpectedly ....................................................................................................... WP 0006

11.

Engine Starts but Will Not Keep Running ......................................................................................... WP 0006

12.

Engine Vibration Excessive .............................................................................................................. WP 0006

13.

Fuel Consumption Excessive ........................................................................................................... WP 0006

14.

Engine Overheats ............................................................................................................................ WP 0006

15.

Engine Oil Pressure - Low ............................................................................................................... WP 0006

16.

Engine Oil Pressure - High ............................................................................................................... WP 0006

17.

Engine Cold Start System Not Working ........................................................................................... WP 0006

ELECTRICAL TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Headlight(s) (High or Low Beam) Do Not Operate When Switch is Turned On .................................................................................................................................... WP 0006

2.

Front/Rear Side Marker Light(s) or Taillight(s) Do Not Operate When Headlight Switch is Turned On .............................................................................................. WP 0006

3.

Stoplight(s) Do Not Operate When Brake Pedal is Pressed ............................................................ WP 0006

4.

Turn Signals or Emergency Flashers are Not Working .................................................................... WP 0006

0005-15

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

5.

Blackout Drive and Marker Lights Do Not Operate When Switch is Turned On .................................................................................................................................... WP 0006

6.

Blackout Stoplights Not Working ...................................................................................................... WP 0006

7.

Horn Will Not Sound When Button is Pressed ................................................................................. WP 0006

8.

Backup Lights/Alarm Does Not Operate When Vehicle Placed in Reverse ........................................................................................................................................ WP 0006

9.

Boom Work Light(s) Do Not Operate When Switch is Turned On .................................................... WP 0006

10.

Tophandler Work Light(s) Do Not Operate When Switch is Turned On ........................................................................................................................................ WP 0006

11.

Infrared (IR) Work Light(s) Do Not Operate When Switch is Turned On. ....................................................................................................................................... WP 0006

12.

Front Windshield Wiper Motor Not Working ..................................................................................... WP 0006

13.

Rear Windshield Wiper Motor Not Working ...................................................................................... WP 0006

14.

Roof Windshield Wiper Motor Not Working ...................................................................................... WP 0006

15.

Windshield Washer Not Working ...................................................................................................... WP 0006

16.

Cab Interior Light Not Working ......................................................................................................... WP 0006

17.

12V Utility Plug Not Working ............................................................................................................ WP 0006

18.

Blower Motor Not Working ............................................................................................................... WP 0006

19.

Heater/Defroster Producing Low or No Heat .................................................................................... WP 0006

20.

A/C System Not Cooling Properly .................................................................................................... WP 0006

21.

Fuel Gauge Not Working Properly ................................................................................................... WP 0006

22.

Driver’s ECS Display Screen Will Not Display ................................................................................. WP 0006

23.

After Key “On" Functions Not Working (No Crank, Display, etc.). .................................................... WP 0006

24.

Proximity Switches - Tophandler and Cab ....................................................................................... WP 0006

25.

Normal Functions Operate in Blackout Mode ................................................................................... WP 0006

26.

Multiple Boom or Tophandler Functions Not Working (Multiple Error Codes) ..................................................................................................................................... WP 0006

27.

Function(s) Work Uncontrolled ......................................................................................................... WP 0006

BRAKE SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Braking is Poor or Nonexistent ......................................................................................................... WP 0006

2.

Parking Brake Will Not Release ....................................................................................................... WP 0006

3.

Parking Brake Will Not Engage ........................................................................................................ WP 0006

0005-16

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom

Troubleshooting Procedure

STEERING SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Steering Control is Poor or Nonexistent ........................................................................................... WP 0006

OPERATOR’S CAB TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Operator’s Cab Will Not Move To or From Transport Position Properly ............................................................................................................................................ WP 0006

AUXILIARY PUMP TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Auxiliary Pump Not Working ............................................................................................................. WP 0006

BOOM SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Boom Will Not Lift or Lower Properly ............................................................................................... WP 0006

2.

Boom Will Not Extend or Retract Properly ....................................................................................... WP 0006

3.

Boom Folding Cylinders Not Working .............................................................................................. WP 0006

4.

Boom Locking Pin Cylinders Not Working ........................................................................................ WP 0006

TOPHANDLER SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Tophandler Will Not Tilt Forward or Rearward Properly ................................................................... WP 0006

2.

Tophandler Will Not Oscillate (Level) Properly ................................................................................. WP 0006

3.

Tophandler Spreader Will Not Open or Close Properly ................................................................... WP 0006

4.

Tophandler Will Not Rotate Left or Right Properly ........................................................................... WP 0006

5.

Tophandler Twistlocks Will Not Rotate Properly .............................................................................. WP 0006

BOGIE WHEEL SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Bogie Wheels Will Not Lift or Lower ................................................................................................. WP 0006

FORKLIFT KIT TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Fork Functions Not Working Properly .............................................................................................. WP 0006

AUTOLUBE SYSTEM NOT LUBRICATING PROPERLY (IF EQUIPPED) TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1.

Autolube System Not Lubricating Properly (If Equipped) ................................................................. WP 0006

2.

Autolube Pump Not Working (If Equipped) ...................................................................................... WP 0006

END OF WORK PACKAGE

0005-17/18 blank

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TM 10-3930-675-23-1

FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)

INITIAL SETUP: References FO-10 (Volume 2, WP 0272) LO 10-3930-675-13 TM 10-3930-675-10 WP 0004 WP 0008 WP 0013 WP 0018 WP 0020 WP 0026 WP 0047 WP 0050 WP 0051 WP 0052 WP 0069 WP 0070 WP 0071 WP 0072 WP 0073 WP 0076 WP 0077 WP 0080

References (cont.) WP 0081 WP 0083 WP 0088 WP 0093 WP 0094 WP 0095 WP 0103 WP 0109 WP 0110 WP 0114 WP 0115 WP 0123 WP 0127 WP 0129 WP 0133 Volume 2, WP 0159 Volume 2, WP 0194 Volume 2, WP 0195 Volume 2, WP 0267 Volume 2, WP 0272

NOTE Refer to (WP 0004) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) SYMPTOM ENGINE WILL NOT CRANK MALFUNCTION Transmission Shift Lever is NOT in Neutral. CORRECTIVE ACTION Place transmission shift lever in Neutral.

0006-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00011)

0006

TM 10-3930-675-23-1

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Master battery switch is off. CORRECTIVE ACTION Place master battery switch to on position. MALFUNCTION Circuit breaker numbers 2 and 8 are tripped. CORRECTIVE ACTION Reset circuit breakers as required (WP 0103). MALFUNCTION Damaged or loose battery connections. CORRECTIVE ACTION

WARNING

To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electrical shock, damage to equipment, and injury to personnel. Tighten or repair battery connections (WP 0129). MALFUNCTION Check battery voltage. Normal voltage can be 23 to 27V. CORRECTIVE ACTION Test batteries.

0006-2

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0006

TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION No voltage at starter terminal 30. CORRECTIVE ACTION

WARNING

Eye protection must be worn when working under vehicle to avoid injury to personnel. Check wiring back to master battery switch and batteries (Figure 8 (Volume 2, WP 0272)). MALFUNCTION No voltage (24V) at starter solenoid on starter at wire W11 of S terminal while turning the ignition switch to crank (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1.

Check circuit breaker numbers F50-1 and F50-2 for loose or damaged connections.

2.

If voltage is present (24V), replace shorted or damaged starter and solenoid (WP 0093).

T0040JCH

Figure 1. Starter Motor MALFUNCTION Starter relay 360 defective or damage (Volume 2, WP 0267). CORRECTIVE ACTION Replace shorted open or damaged relay (WP 0103).

0006-3

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION No voltage (24V) at XK2 pin 7 while turning the ignition switch to crank (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1.

Check voltage at X8 pin 3 (Figure 8 (Volume 2, WP 0272)).

2.

Unplug X8 and check continuity between pin 2 and 3 with the ignition switch turned to crank (Figure 8 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Replace damaged or faulty ignition switch (WP 0094).

MALFUNCTION No voltage (24V) at XKI2 pin 4 while turning the ignition switch to crank. CORRECTIVE ACTION 1.

Check voltage (24V) at XK2 pin 2 (Figure 8 (Volume 2, WP 0272)) X28 pins 4, 9, and 7 (Figure 9 (Volume 2, WP 0272)) with ignition switch on.

2.

Check continuity of shift lever at the loose part of X28 between pin 9 and 7 with the shift lever in Neutral (Figure 9 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Replace shift lever (WP 0095).

MALFUNCTION Defective relays. CORRECTIVE ACTION Replace relay (WP 0103). SYMPTOM ENGINE WILL CRANK BUT WILL NOT START (EXHAUST SMOKE OR NO EXHAUST SMOKE) MALFUNCTION Fuel line shutoff valve at fuel filter closed. CORRECTIVE ACTION Open fuel line shutoff valve.

0006-4

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TM 10-3930-675-23-1

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Circuit breaker F13 tripped CORRECTIVE ACTION Reset F13 circuit breaker (WP 0013). MALFUNCTION Damaged or leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace fuel/water separator (WP 0076). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service or replace air cleaner element (WP 0071). MALFUNCTION Perform cold starting procedures (TM 10-3930-675-10). CORRECTIVE ACTION See cold starting system maintenance (WP 0077). MALFUNCTION Fuel solenoid shutoff valve (FSOV) inoperative. CORRECTIVE ACTION 1.

Check for voltage at FSOV (12V).

2.

Repair or replace damaged wires or connectors.

3.

Replace fuel solenoid shutoff valve (WP 0070).

0006-5

03/15/2011 Rel(1.8) root(tswp) wpno(T00011)

0006

TM 10-3930-675-23-1

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued SYMPTOM EXCESSIVE EXHAUST SMOKE - WHITE MALFUNCTION Low engine operating temperature (ambient temperature). CORRECTIVE ACTION 1.

Allow engine to warm to operating temperature.

2.

Check cooling fan operation. Enter into “EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures.

MALFUNCTION Engine temperature sensor malfunctioning. CORRECTIVE ACTION 1.

Perform troubleshooting procedure for ERROR CODES 1144 and 1145 for the coolant temperature sensor (WP 0020).

2.

Perform troubleshooting procedure for ERROR CODES 1153 and 1154 for the intake air temperature sensor (WP 0020).

MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION 1.

Compare fuel used with type and grade specifications (TM 10-3930-675-10).

2.

lf problem still exists, replace engine assembly (WP 0050).

SYMPTOM EXCESSIVE EXHAUST SMOKE - BLACK MALFUNCTION Monitor engine operating temperature (low ambient temperature). CORRECTIVE ACTION 1.

Allow engine to warm to operating temperature.

2.

Check cooling fan operation. Enter into “EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures.

0006-6

03/15/2011 Rel(1.8) root(tswp) wpno(T00011)

0006

TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Engine temperature or pressure sensor malfunctioning. CORRECTIVE ACTION 1.

Perform troubleshooting procedure for ERROR CODES 1144 and 1145 for the coolant temperature sensor (WP 0020).

2.

Perform troubleshooting procedure for ERROR CODES 1122, 1123, and 1433 for the intake manifold pressure sensor (WP 0022).

MALFUNCTION Check for poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. Dirty or clogged air cleaner element CORRECTIVE ACTION 1.

Check quality of fuel, type, and grade.

2.

Repair air intake hoses, lines, and clamps (WP 0072).

3.

Service or replace air cleaner element (WP 0071).

MALFUNCTION Plugged crankcase ventilation system. CORRECTIVE ACTION Clean crankcase breather and tube (WP 0057). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073).

0006-7

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TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued

SYMPTOM ENGINE ACCELERATION - POOR MALFUNCTION ERROR CODES or conditions that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE(s)/condition. MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076).

0006-8

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TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE DECELERATION - POOR MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069).

0006-9

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TM 10-3930-675-23-1

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Restrictions in fuel lines, hoses, and fittings. CORRECTIVE ACTION Replace any damaged or restricted fuel line, hose, or fitting (WP 0069). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE PERFORMANCE (POWER) - LOW MALFUNCTION ERROR CODES or conditions that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE(s)/condition. MALFUNCTION Parasitic loads on engine. CORRECTIVE ACTION Check for brakes dragging, hydraulic malfunctions, etc. MALFUNCTION Incorrect engine oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (WP 0047). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076).

0006-10

03/15/2011 Rel(1.8) root(tswp) wpno(T00011)

0006

TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Leaking fuel lines, hoses, and fittings, or restricted fuel lines (supply and return). CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008).

0006-11

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TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued

SYMPTOM ENGINE RUNS ROUGH MALFUNCTION Monitor engine operating temperature (low ambient temperature). CORRECTIVE ACTION 1.

Allow engine to warm to operating temperature.

2.

Incorrect cooling fan operation. Enter into “EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures.

MALFUNCTION Loose or damaged engine mounts. CORRECTIVE ACTION 1.

Tighten loose engine mounts.

2.

Replace engine mounts (WP 0051).

MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings that may allow air into fuel system. Restricted fuel lines (supply and return). CORRECTIVE ACTION 1.

Tighten or repair fuel lines, hoses, and fittings (WP 0069).

2.

Replace clogged fuel/water separator (WP 0076).

MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Engine Position Sensor (EPS) or circuit malfunction. CORRECTIVE ACTION Perform troubleshooting procedures for ERROR CODES 1115 and 1121 (WP 0018).

0006-12

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TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE SPEED SURGES (IDLE OR UNDER LOAD) MALFUNCTION Engine idle speed set too low or idling with excessive load. CORRECTIVE ACTION Monitor idle speed; should be around 700 RPM. Check for excessive hydraulic loads at idle. MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings. Restricted fuel lines (supply and return). CORRECTIVE ACTION 1.

Tighten or repair fuel lines, hoses, and fittings (WP 0069).

2.

Replace clogged fuel/water separator (WP 0076).

MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal.

0006-13

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TM 10-3930-675-23-1

0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Engine Position Sensor (EPS) circuit malfunction CORRECTIVE ACTION Perform troubleshooting procedures for ERROR CODES 1115 and 1121 (WP 0018). SYMPTOM ENGINE SHUTS OFF UNEXPECTEDLY MALFUNCTION ERROR CODES that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures. MALFUNCTION Incorrect battery voltage. CORRECTIVE ACTION Service batteries and connections (WP 0129).

0006-14

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TM 10-3930-675-23-1

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Circuit breakers F13, F4, and F5 tripped. CORRECTIVE ACTION Replace faulty circuit breaker (WP 0103). MALFUNCTION No voltage at X16 pin 9 and EUC (794) pin 38 with the ignition on. CORRECTIVE ACTION Repair or replace wires or connectors (Figure 3 (Volume 2, WP 0272)). MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076). MALFUNCTION Check for restricted fuel lines (supply and return). CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE STARTS BUT WILL NOT KEEP RUNNING MALFUNCTION ERROR CODES that de-rate engine RPM and shut down after 30 seconds (RT 240V1R, RT 240V2 and RT 240V3). CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures.

0006-15

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0006

TM 10-3930-675-23-1

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect battery voltage. CORRECTIVE ACTION Service batteries and connections. MALFUNCTION Tripped circuit breakers F13, F4, and F5. CORRECTIVE ACTION Replace faulty circuit breaker (WP 0103). MALFUNCTION No voltage at X16 pin 9 and EUC (794) pin 38 with the ignition on. CORRECTIVE ACTION Repair or replace wires or connectors (Volume 2, WP 0267). MALFUNCTION Parasitic loads on engine. CORRECTIVE ACTION Check for hydraulic malfunctions, etc., that cause loading on engine. MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). SYMPTOM ENGINE VIBRATION EXCESSIVE MALFUNCTION Engine misfiring. CORRECTIVE ACTION Perform troubleshooting procedure for Engine Runs Rough in this work package.

0006-16

03/15/2011 Rel(1.8) root(tswp) wpno(T00011)

0006

TM 10-3930-675-23-1

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Belt-driven accessories malfunctioning. CORRECTIVE ACTION Check alternator and air conditioner compressor operation. MALFUNCTION Loose or damaged engine mounts. CORRECTIVE ACTION 1.

Tighten loose engine mounts.

2.

Replace engine mounts (WP 0051).

MALFUNCTION Loose or damaged engine vibration damper. CORRECTIVE ACTION 1.

Tighten loose engine vibration damper.

2.

Replace vibration damper (WP 0053).

SYMPTOM FUEL CONSUMPTION EXCESSIVE MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (WP 0047). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE OVERHEATS MALFUNCTION Coolant level low. CORRECTIVE ACTION Fill the coolant to the proper level in the coolant expansion tank (LO 10-3930-675-13). MALFUNCTION Incorrect engine oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (LO 10-3930-675-13).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Radiator, radiator cap, and louvers damaged or obstructed. CORRECTIVE ACTION 1.

Clean dirt and debris from radiator and louvers.

2.

Replace leaking radiator cap (WP 0080).

3.

Replace louvers (WP 0081).

MALFUNCTION Coolant system hoses loose, damaged, leaking, or collapsed. CORRECTIVE ACTION 1.

Inspect and tighten any loose clamps.

2.

Replace any damaged, leaking, or collapsed hoses (WP 0083).

MALFUNCTION Incorrect cooling fan operation. CORRECTIVE ACTION 1.

Start engine and enter into “EXTRA FUNCT 11(13)" in the diagnostic menu. Change the fan speed and observe if fan speed changes properly (0%, 33%, 66%, and 100%).

2.

If fan does not change speeds, check hydraulic pressure of engine driven pump (WP 0214).

MALFUNCTION Incorrect status of fording switch. CORRECTIVE ACTION 1.

Enter into “EXTRA FUNCT 4(13)" in the diagnostic menu. “WATER LEVEL" should indicate “1".

2.

If “0" is indicated, perform troubleshooting of fording switch circuit (Figure 7 (Volume 2, WP 0272)).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect thermostat operation. CORRECTIVE ACTION 1.

With the engine cold, connect a 3/8 in. (10 mm) hose to the barbed bleeder valve on the metal line coming from top of hose to radiator thermostat housing.

2.

Open the coolant expansion tank and place the other end of the hose in the top of the tank and hold. Open the bleeder valve.

3.

Start the engine and observe the coolant flow from the hose. Coolant flow should not exceed 4 oz (0.12 L) per minute.

4.

Run the engine until it reaches operating temperature. The coolant flow should increase when the thermostat opens.

5.

Replace the thermostat if the coolant does not flow at operating temperature or flow exceeds 4 oz (0.12 L) per minute with the engine cold.

MALFUNCTION Incorrect water pump operation. CORRECTIVE ACTION 1.

Inspect water pump for leakage at weep hole. Unplug the weep hole if found plugged with debris.

2.

If no flow is observed in the coolant expansion tank or the pump is leaking, replace water pump (WP 0088).

SYMPTOM ENGINE OIL PRESSURE - LOW MALFUNCTION ERROR CODES that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures. MALFUNCTION Engine oil is contaminated. CORRECTIVE ACTION 1.

Take an oil sample and have it tested for contaminants, type, and specifications (WP 0047).

2.

Change oil and filter (LO 10-3930-675-13).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued

SYMPTOM ENGINE OIL PRESSURE - HIGH MALFUNCTION Engine oil is contaminated. CORRECTIVE ACTION Replace engine oil and filter (LO 10-3930-675-13). SYMPTOM ENGINE COLD START SYSTEM NOT WORKING MALFUNCTION Circuit breaker F17 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker.

2.

Replace faulty circuit breaker (WP 0103).

MALFUNCTION Cold start ether canister, system tubing, activation solenoid, or engine temperature sensor damaged. CORRECTIVE ACTION 1.

Replace empty or missing canister (WP 0077).

2.

Replace any damaged or disconnected tubing (WP 0077).

3.

Replace damaged activation solenoid or engine temperature sensor (WP 0077).

MALFUNCTION Cold start system wiring damaged. CORRECTIVE ACTION Repair any loose or missing connections (Volume 2, WP 0267).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Cold start system inoperative. CORRECTIVE ACTION 1.

The resistance should be 3 to 4 Ohms.

2.

Unplug the activation solenoid and check resistance between the two pins.

3.

Check continuity between each pin and ground.

4.

Unplug the engine temperature sensor and check continuity between the two pins.

5.

There should not be any continuity.

6.

There should be continuity up to 120°F (49°C). Replace open or shorted activation solenoid or engine temperature sensor (WP 0077).

MALFUNCTION Incorrect cold start system voltage. CORRECTIVE ACTION 1.

If voltage (24V) is found at activation solenoid, replace activation solenoid (WP 0077).

2.

If no voltage (24V) is found, check continuity of wires 162, W12B, and W12A where they connect to 360 start solenoid pin 85.

3.

Remove the ether canister from activation solenoid.

4.

Press the cold start switch. You should hear the activation solenoid “click".

5.

Unplug the activation solenoid and check for voltage (24V) while pressing the cold start system switch.

6.

Enter “EXTRA FUNC 8(13)" in the diagnostic menu. a.

If “1", go to “Incorrect voltage (24V) at X16 pin 2 with ignition on".

b.

If “1" indication does not appear, go to “Incorrect voltage (24V) at X67 pin 1&4 with ignition on".

MALFUNCTION Incorrect voltage (24V) at X67 pin 1 and 4 with the ignition on (Figure 16 (Volume 2, WP 0272)). CORRECTIVE ACTION 1.

If no voltage is found at X67 pin 1, check circuit breaker F17 and continuity of wire A678 and A671 (Figure 15 (Volume 2, WP 0272)).

2.

Replace faulty circuit breaker (WP 0103).

3.

If no voltage (24V) is found at X67 pin 4, check continuity of wires 671, 671A, 674, A479, 479, and A17415, and test continuity of cold start system switch (Figure 16 (Volume 2, WP 0272)).

4.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

5.

Replace cold start system switch if faulty (WP 0094).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect voltage (24V) at X16 pin 2 with the ignition on (Figure 16 (Volume 2, WP 0272)). CORRECTIVE ACTION 1.

If no voltage (24V) is found at X16 pin 2, check continuity of wires A17415A, 16011, A1508, 294, and A162A (Figure 16 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

Electrical Troubleshooting Procedures (Non-Error Code) SYMPTOM HEADLIGHT(S) (HIGH OR LOW BEAM) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F16, F18, F19, F20, and F21 tripped. CORRECTIVE ACTION 1.

Reset circuit breakers as required.

2.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Headlights are damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0109).

2.

Replace damaged headlight (WP 0109).

MALFUNCTION Headlight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X6 pin 2 with the headlight switch turned on. CORRECTIVE ACTION 1.

Replace damaged or faulty switch (WP 0094).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X19 pin 5 with the headlight switch turned on. CORRECTIVE ACTION 1.

Check continuity of wire A62 (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X19 pin 6 and 7 with the headlight switch turned on and operating the HI/LO beams. CORRECTIVE ACTION 1.

Check continuity of wires 195, 196, and 197 (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Check accessory control lever for damage and continuity (Figure 14 (Volume 2, WP 0272)).

4.

Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

MALFUNCTION No voltage (24V) at X11 pin 7 and X12 pin 6 with the headlight switch turned on and in LOW beam. CORRECTIVE ACTION 1.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

2.

Replace damaged or faulty circuit breaker (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X11 pin 8 and X12 pin 8 with the headlight switch turned on and in HIGH beam. CORRECTIVE ACTION 1.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

2.

Replace damaged or faulty circuit breaker (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued SYMPTOM FRONT/REAR SIDE MARKER LIGHT(S) OR TAILLIGHTS(S) DO NOT OPERATE WHEN HEADLIGHT SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F22 and F23 are tripped. CORRECTIVE ACTION 1.

Reset circuit breakers as required.

2.

Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Marker and taillights are damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0109).

2.

Replace damaged marker or taillights (WP 0109).

MALFUNCTION Marker and taillight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X6 pin 1 with the headlight switch turned on (headlights working). CORRECTIVE ACTION 1.

Remove headlight switch from the instrument panel and check for continuity.

2.

Replace damaged or faulty switch (WP 0094).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at F22 and F23 with the headlight switch on. CORRECTIVE ACTION Replace damaged or faulty circuit breaker (WP 0103). MALFUNCTION No voltage (24V) at X11 pin 1, X12 pin 7, X14 pin 2, X14 pin 9, X15 pin 2, and X15 pin 7 with the headlight switch turned on. CORRECTIVE ACTION 1.

Check continuity, using the wiring diagram, of wires A149, A157, A149B, A149A, A157A, and A157B (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Check continuity, using the wiring diagram, of the marker and taillight wiring harnesses from X11 pin 1 to left front marker, X12 pin 7 to the right front marker, X15 pin 2 to the left rear marker, X14 pin 2 to the right rear marker, X14 pin 9 to the right taillight, and X15 pin 7 to the left taillight. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM STOPLIGHT(S) DO NOT OPERATE WHEN BRAKE PEDAL IS PRESSED MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F10 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

Replace damaged or faulty circuit breaker (Volume 2, WP 0267).

MALFUNCTION Damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0109).

2.

Replace damaged stoplights (Volume 2, WP 0159).

MALFUNCTION Stoplight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X26 pin 2 and 3 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION 1.

Remove the kick panel in front of the steering column and check brake light switch 216 for continuity while depressing the brake pedal (Volume 2, WP 0159).

2.

Replace damaged or faulty switch (Volume 2, WP 0159).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at XK13 pin 6 and 9 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION Replace damaged or faulty relay 3010 (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity between XK13 pin 9 and 3010 terminal 30, and XK 13 pin 6 and 3010 terminal 87a. CORRECTIVE ACTION Replace damaged or faulty relay board (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK14 pin 4 and 7 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up). CORRECTIVE ACTION Replace relay 3015R (Volume 2, WP 0267). MALFUNCTION No continuity of wires A036 and A263 (Figure 14 & Figure 10 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No continuity between XK14 pin 7 and 3015R terminal 30, and XK14 pin 4 and 3015R terminal 87a with the 3015R relay removed. CORRECTIVE ACTION Replace relay board (WP 0103). MALFUNCTION No voltage (24V) at XK15 pin 4 and 7 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION 1.

Check continuity of wires A036 and A263 (Figure 14 & Figure 10 (Volume 2, WP 0272)).

2.

Replace damaged or faulty relay (WP 0103).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Incorrect continuity between XK15 pin 7 and 3015L terminal 30, and XK15 pin 4 and 3015L terminal 87a with the 3015L relay removed. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No continuity of the stoplight wiring harnesses from XK14 pin 7 to the right stoplight and XK15 pin 7 to the left stoplight (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM TURN SIGNALS OR EMERGENCY FLASHERS ARE NOT WORKING MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F2 and F6 are tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Volume 2, WP 0272). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

MALFUNCTION Inspect signal lights for damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0109).

2.

Replace damaged signal lights (WP 0109).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Signal light wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X19 pin 1, 2, and 3 while operating the turn signal lever. There should be voltage (24V) at pin 2 when signaling left and at pin 3 for right. CORRECTIVE ACTION 1.

Check circuit breaker F6 and wire A191 (Figure 14 (Volume 2, WP 0272)).

2.

If no voltage (24V) is found at X19 pin 2 or 3 while operating the signal lever; check accessory control lever for damage and continuity and check continuity of wires 191, 192, and 193 (Figure 14 (Volume 2, WP 0272)).

3.

Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

4.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at XK14 pin 8 and XK15 pin 8 while operating the turn signal lever. There should be voltage at pin XK15 pin 8 when signaling left and at XK14 pin 8 for right. CORRECTIVE ACTION 1.

Check continuity of wires A192 and A193 (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at XK1 pin 5 and pin 1 while operating the turn signals. There should be constant voltage at pin 5 and flashing voltage at pin 1. CORRECTIVE ACTION 1.

Check blackout drive/marker light switch and circuit from circuit breaker F2 (Figure 13 (Volume 2, WP 0272)).

2.

Replace damaged or faulty 323 flasher relay (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity, with 323 flasher relay removed, between XK1 pin 5 and 323 terminal 49, and XK1 pin 1 and 323 terminal 49a, and XK1 pin 2 and 323 terminal 31. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No voltage (24V) at XK14 pin 3 and XK15 pin 3 while operating the turn signals. There should be flashing voltage at XK14 pin 3 for signaling right and a XK15 pin 3 for left. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage (24V) at XK14 pin 7 and XK15 pin 7 while operating the turn signals. There should be flashing voltage at XK14 pin 7 for signaling right and at XK15 pin 7 for left. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No continuity of the signal wiring harnesses from XK14 pin 7 to the right rear and XK14 pin 3 for the right front, and XK15 pin 7 to the left rear and XK15 pin 3 for the left front (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X6 pin 4, 5, and 6 with the emergency flasher switch depressed. CORRECTIVE ACTION 1.

Check continuity, using the wiring diagram, of wires 64, 65, and 66 (Figure 14 (Volume 2, WP 0272)).

2.

Replace damaged or faulty switch (WP 0094).

SYMPTOM BLACKOUT DRIVE AND MARKER LIGHTS DO NOT OPERATE WHEN SWITCH IS TURNED ON

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Circuit breakers F24 and F25 are tripped. CORRECTIVE ACTION 1.

Reset circuit breakers as required.

2.

If any breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 14 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Blackout drive and marker lights damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0109).

2.

Replace damaged blackout lights (WP 0109).

MALFUNCTION Blackout drive and marker light wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X7 pin 9 and 6 with the blackout drive marker light switch turned on. CORRECTIVE ACTION 1.

Check the continuity of the wires A79, 79, 76 and A76, (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Replace damaged or faulty switch (WP 0094).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X11 pin 3, X11 pin 9, X12 pin 1, X14 pin 1, and X15 pin 1 with the blackout drive marker light switch turned on. CORRECTIVE ACTION 1.

Check continuity of wires A113, A153, A119, A121, and A141 (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No continuity of the blackout drive marker light wiring harnesses from X11 pin 3 to left front blackout position light, X12 pin 1 to right front blackout position light, X14 pin 1 to right blackout taillight, X15 pin 3 to the left blackout taillight, and X11 pin 9 to blackout headlight. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM BLACKOUT STOPLIGHTS NOT WORKING MALFUNCTION Check the operation of the normal stoplights. CORRECTIVE ACTION If stoplights are not working, perform troubleshooting procedure for “Stop Light (s) Do Not Operate When Brake Pedal is Pressed" in this work package. MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Stoplights are damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0109).

2.

Replace damaged blackout stoplights (WP 0109).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Blackout stoplight wiring harnesses or connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK13 pin 3 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up). CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No continuity of the blackout drive marker light wiring harnesses from XK13 pin 3 to right and left blackout stoplights. (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM HORN WILL NOT SOUND WHEN BUTTON IS PRESSED MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Check circuit breaker F9 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION Horn, connectors, or wiring damaged. CORRECTIVE ACTION 1.

Test horn using 24V source.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2.

Repair or replace damaged harnesses or connectors (Volume 2, WP 0267).

3.

Replace damaged horn (WP 0127).

MALFUNCTION No voltage (24V) at X20 pin 1 and 2 with the horn switch depressed. CORRECTIVE ACTION 1.

Check continuity of wire A201 (Figure 11 (Volume 2, WP 0272)).

2.

If no voltage (24V) is found at X20 pin 2, check accessory control lever for damage and continuity (Figure 13 (Volume 2, WP 0272)).

3.

Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

MALFUNCTION No voltage (24V) at X13 pin 9 with the horn switch depressed. CORRECTIVE ACTION 1.

Check continuity of wires 202, A202, and A139 (Figure 13 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Replace damaged or faulty relay (WP 0103).

MALFUNCTION No voltage (24V) between the two pins of the harness with the horn switch depressed. CORRECTIVE ACTION 1.

Check continuity of wires 139 and 135B (Figure 13 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

SYMPTOM BACKUP LIGHTS/ALARM DOES NOT OPERATE WHEN VEHICLE PLACED IN REVERSE MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F10 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 14 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Backup lights and alarm damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0110).

2.

Replace damaged backup lights (WP 0110).

3.

Replace damaged backup alarm (WP 0133).

MALFUNCTION Backup lights/alarm wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK5 pin 1 and 7 with the ignition on and the transmission control lever placed in Reverse. CORRECTIVE ACTION 1.

Check continuity of wire A57 (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Replace damaged or faulty relay (WP 0103).

MALFUNCTION No voltage (24V) at XK13 pin 4 and 7 with the ignition on and the transmission control lever placed in Reverse. CORRECTIVE ACTION 1.

Check continuity of wire A51 (Figure 14 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 3.

Replace damaged or faulty relay (WP 0103).

MALFUNCTION No voltage (24V) at XK5 pin 5 with the ignition on while switching transmission control lever between Neutral and Reverse. There should be voltage (24V) when in Neutral and no voltage (OV) when in Reverse. CORRECTIVE ACTION 1.

Check continuity of wires A55 and 293 (Figure 14 (Volume 2, WP 0272)).

2.

Check continuity of wires 16010 and A17710 (Figure 4 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Replace ECU (793).

MALFUNCTION No continuity, using the wiring diagram, of the backup light/alarm wiring harnesses from X14 and X15 to the backup lights and alarm. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). SYMPTOM BOOM WORK LIGHTS(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F12 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 15 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Boom work lights damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0110).

2.

Replace damaged lights (WP 0110).

MALFUNCTION Boom work lights wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X7 pin 1 and 3 with the boom work light switch turned on. CORRECTIVE ACTION 1.

Check the continuity of wires A73, 73, 71, and A71 (Figure 15 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Replace damaged or faulty switch (WP 0094).

MALFUNCTION Inoperative relay 3013 (Volume 2, WP 0267). CORRECTIVE ACTION Replace relay (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at XK11 pin 6, X31 pin 1, X151 pin 1, X157 pin 5, and X169 pin 5 with the boom work light switch turned on. CORRECTIVE ACTION 1.

Check continuity of wires A311, 311, A1511, and YE (Figure 15 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION High resistance between two GY wires at X169 pin 5 and ground. CORRECTIVE ACTION 1.

Replace boom work light wiring harness (Volume 2, WP 0267).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

SYMPTOM TOPHANDLER WORK LIGHTS(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F17 in cab distribution box and F43, located in the tophandler junction box tripped. CORRECTIVE ACTION 1.

Reset circuit breakers as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 15 & Figure 16 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Work lights damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0110).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2.

Replace damaged tophandler work lights (WP 0110).

MALFUNCTION Work lights wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION Work light switch inoperative. CORRECTIVE ACTION Enter “EXTRA FUNC 5(13)" in the diagnostic menu. Press the tophandler work light switch. Should have a “1" next to “WORK LIGHT ATTACH". a.

If there is a “0", go to “No voltage (24V) at X67 pin 8 and 9 with the tophandler work light switch turned on."

b.

If there is a “1", go to “Inoperative relay 3017."

MALFUNCTION No voltage (24V) at X67 pin 8 and 9 with the tophandler work light switch turned on. CORRECTIVE ACTION 1.

Check the continuity of the wires A678, 678, and 679 (Figure 15 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Replace damaged or faulty switch (WP 0094).

MALFUNCTION No voltage (24V) at X46 pin 6, X174 pin 11, and ECU (792) pin 102 with the tophandler work light switch turned on. CORRECTIVE ACTION 1.

Check continuity of wires A466, 466, and A17411 (Figure 15 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Inoperative relay 3017 (Volume 2, WP 0267). CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage at relay 3017 socket pin 30. CORRECTIVE ACTION 1.

Check continuity of wires A513 and A1861B (Figure 6 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage at 3017 socket pin 86. CORRECTIVE ACTION 1.

Check continuity of wire A3018A (Figure 6 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No resistance between pin A and B, or C and D on the loose part of X194. (Ensure the tophandler work light lamps are not burned out). CORRECTIVE ACTION 1.

Replace X194 harness to tophandler work lights (Volume 2, WP 0267).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No continuity of wires A194A, A194B, A194C, and A194D (Figure 6 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No voltage at pin 14 of ECU connector 2 with the ignition on. CORRECTIVE ACTION 1.

Check continuity of wire A18052B (Figure 6 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Replace ECU (791) (WP 0100).

SYMPTOM INFRARED (IR) WORK LIGHT(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Circuit breaker F2 tripped. CORRECTIVE ACTION 1.

Reset circuit breakers as required.

2.

If any breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 13 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION IR work lights damaged or burned out lights. (A digital camera can be used to check the operation of IR lights.) CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0115).

2.

Replace damaged IR light (WP 0115).

MALFUNCTION IR work light wiring harnesses or connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X6 pin 8 and X7 pin 7 with the blackout drive marker light switch and IR work light switch turned on. CORRECTIVE ACTION 1.

Check the continuity of wires A77, 77, 1211, and 68 (Figure 13 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

Replace damaged or faulty switch (WP 0094).

MALFUNCTION No voltage (24V) at X15 pin 5, X11 pin 5, X31 pin 3, X151 pin 3, X157 pin 7, and X169 pin 7 with the blackout drive marker light switch and IR work light switch turned on. CORRECTIVE ACTION 1.

Check continuity of wires A155, A115, A313, 313, A1513, and WH (Figure 13, Figure 14 & Figure 15 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No continuity of the IR work light wiring harnesses from X16 pin 7 to left and right boom IR work lights, X15 pin 5 to left rear IR work light, and X11 pin 5 to left front IR work light (Figure 14 & Figure 15 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM FRONT WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F6 and F9 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 10 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0123).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1.

Correct binding wiper arm (Volume 2, WP 0194).

2.

Replace damage wiper arm (Volume 2, WP 0194).

MALFUNCTION No voltage (24V) at X20 pin 1, 4, and 5 with the ignition on while operating the front wiper control switch. CORRECTIVE ACTION 1.

There should be voltage (24V) at pin 4 for intermittent wiper and at pin 5 for continuous wiper. If no voltage (24V) is found at X20 pin 1, check circuit breaker F9 and continuity of wire A201 (Figure 11 (Volume 2, WP 0272)).

2.

If no voltage (24V) is found at X20 pin 4 or 5 while operating the front wiper control switch, check accessory control lever for damage and continuity and check continuity of wires 201, 204, and 205 (Figure 11 (Volume 2, WP 0272)).

3.

Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

4.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Defective relay 316. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). MALFUNCTION No continuity between XK2 pin 9 and terminal 30, XK2 pin 3 and terminal 87, XK2 pin 6 and terminal 87a, XK2 pin 8 and terminal 86, and XK3 pin 5 and terminal 85. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No voltage (24V) at X27 pin 6 and 7 with the ignition on while operating the front wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1.

Check circuit breaker F6 and continuity of wires A276, A66, and A191 (Figure 14 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2.

If no voltage (24V) is found at X27 pin 7 while operating the front wiper control switch to the "CONTINUOUS" position, check continuity of wires A23 and A29 (Figure 11 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Intermittent relay 321-1 damaged. CORRECTIVE ACTION 1.

Disconnect relay plug and check voltage (24) at pin 3 and 5 with the ignition on while operating the front wiper control switch to the "INTERMITTENT" position. If no voltage (24V) is found at 321-1 pin 3 or 5, check continuity of wires A201A, A204, A26, and A278 (Figure 11 (Volume 2, WP 0272)).

2.

Replace damaged or faulty relay (WP 0103).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V)at XS4 pin 3 and 4 with the ignition on while operating the front wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1.

Check continuity of wires 276, 277, and 278 (Figure 11 (Volume 2, WP 0272)).

2.

Check ground connection at wiper motor. Check continuity of wires 279, A279, and ground connection at 37-1 (Figure 11 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Replace damaged or faulty front wiper motor (Volume 2, WP 0194).

SYMPTOM REAR WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F15 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Volume 2, WP 0272). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1.

Correct binding wiper arm (Volume 2, WP 0194).

2.

Replace damaged wiper arm (Volume 2, WP 0194).

MALFUNCTION No voltage (24V) at X9 pin 1, 2, and 3 with the ignition on while operating the rear wiper control switch. There should be voltage (24V) at pin 1 (intermittent voltage) and 2 for intermittent wiper. CORRECTIVE ACTION 1.

Check circuit breaker F15 and continuity of wires A89 and A89A (Figure 11 (Volume 2, WP 0272)).

2.

If no voltage (24V) is found at X9 pin 1 or 2 while operating the rear wiper control switch, check rear wiper switch for damage and continuity and check continuity of wires 91, 92, 93, 94, and A94 (Figure 11 (Volume 2, WP 0272)).

3.

Replace damaged or faulty rear wiper switch (WP 0094).

4.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at pin 3 and 5 with the ignition on while operating the rear wiper control switch to the "INTERMITTENT" position. CORRECTIVE ACTION 1.

Check continuity of wires A91, A92, A93, A138, A136, A246, and A84B (Figure 11 (Volume 2, WP 0272)).

2.

Replace damaged or faulty relay (WP 0103).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at XS5 pin 2 and 3 with the ignition on while operating the rear wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1.

Check continuity of wires 136, 137, and 138 (Figure 11 (Volume 2, WP 0272)).

2.

Check ground connection at wiper motor. Check continuity of wire 135 and ground connection at 37-1 (Figure 11 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Replace damaged or faulty rear wiper motor (Volume 2, WP 0194).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued SYMPTOM ROOF WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F15 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 10 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1.

Correct binding wiper arm (Volume 2, WP 0194).

2.

Replace damage wiper arm (Volume 2, WP 0194).

MALFUNCTION No voltage (24V) at X8 pin 7, 8, and 9 with the ignition on while operating the roof wiper control switch. CORRECTIVE ACTION 1.

There should be voltage (24V) at pin 8 and 9, and intermittent voltage at pin 7. Check circuit breaker F15 and continuity of wire A89 (Figure 11 (Volume 2, WP 0272)).

2.

If no voltage (24V) is found at X8 pin 7 or 8 while operating the roof wiper control switch, check roof wiper switch for damage and continuity and check continuity of wires 87, 88, and 89 (Figure 11 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Replace damaged or faulty roof wiper switch (WP 0094).

MALFUNCTION No voltage (24V) at XS6 pin 2 and 3 with the ignition on while operating the roof wiper control switch. CORRECTIVE ACTION 1.

Check continuity of wires A89A, A93, A246, 246, A88, 249, A87, and 244 (Figure 11 (Volume 2, WP 0272)).

2.

Check ground connection at wiper motor. Check continuity of wire 241A and ground connection at 37-2 (Figure 11 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Figure 11 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 4.

Replace damaged or faulty rear wiper motor (Volume 2, WP 0194).

SYMPTOM WINDSHIELD WASHER NOT WORKING MALFUNCTION Washer reservoir damaged or washer solvent level low. CORRECTIVE ACTION 1.

Fill washer reservoir with proper washer solvent (TM 10-3930-675-10).

2.

Replace damaged washer reservoir (Volume 2, WP 0195).

MALFUNCTION Washer pump, tubing, fittings, connectors, or wiring damaged. CORRECTIVE ACTION 1.

Replace damaged tubing or fittings (Volume 2, WP 0195).

2.

Replace damaged washer pump (Volume 2, WP 0195).

3.

Repair or replace damaged harnesses or connectors (Volume 2, WP 0195).

MALFUNCTION Circuit breaker F9 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION No voltage (24V) at X20 pin 1 and 3 with the ignition on and the washer switch depressed. CORRECTIVE ACTION 1.

Check circuit breaker F9 and check continuity of wire A201 (Figure 11 (Volume 2, WP 0272)).

2.

If no voltage (24V) is found at X20 pin 3, check continuity of wires 201 and 203 (Figure 13 (Volume 2, WP 0272)).

3.

Check accessory control lever for damage and continuity (Figure 13 (Volume 2, WP 0272)).

4.

Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage between the two pins if the harness with the ignition on and the washer switch depressed. CORRECTIVE ACTION 1.

Check continuity of wires A203, 131, A135A, and ground connection of wire A132D at 37-1 (Figure 13 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connector (Volume 2, WP 0267).

MALFUNCTION No resistance of the pump. CORRECTIVE ACTION If there is no resistance or pump fails test, replace washer pump (Volume 2, WP 0195). Resistance should be 3 to 4 Ohms. SYMPTOM CAB INTERIOR LIGHT NOT WORKING MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Emergency flashers inoperative. CORRECTIVE ACTION 1.

Perform troubleshooting procedure “Turn Signals or Emergency Flashers Not Working" in this work package.

2.

Continue with Step 3.

MALFUNCTION Cab interior light damaged or burned out lamps. CORRECTIVE ACTION 1.

Replace burned out lamps (WP 0114).

2.

Replace damaged cab interior light (WP 0114).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at cab interior light between the gray and white wires. CORRECTIVE ACTION 1.

If no voltage (24V) is found, check continuity of wires 248, A69, 241B, and connection at 37-2 (Figure 13 (Volume 2, WP 0272)). Check continuity of light switch.

2.

If the switch is damaged or faulty, replace cab interior light (WP 0114).

SYMPTOM 12V UTILITY PLUG NOT WORKING MALFUNCTION Circuit breaker F14 tripped. CORRECTIVE ACTION Replace circuit breaker as required. MALFUNCTION No voltage at the 12V utility plug, CORRECTIVE ACTION 1.

With the ignition on, between pins 1 and 4. There should be 12V. Check voltage between pins 2 and 4. There should be 24V. If voltage (24V) is found at pin 2 and none at pin 1, remove the cab electrical distribution box to gain access to the voltage converter.

2.

If no voltage (24V) is found at pin 2, check circuit breaker F14 and continuity of wires 108, A108A, 101, 102, and A102 (Figure 13 (Volume 2, WP 0272)).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION The 5 amp fuse on the voltage converter blown. CORRECTIVE ACTION Replace the 5 amp fuse if blown. MALFUNCTION No input voltage (24V) of the voltage converter to one of the two middle pins on the converter. CORRECTIVE ACTION 1.

With ignition on if no input voltage (24V) is found, check circuit breaker F14 and check continuity of wire A108 (Figure 13 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2.

Reinstall jumper wire A101B and check wires A101A and A101 continuity/ground connection at 37-5 (Figure 13 (Volume 2, WP 0272)).

3.

With the ignition on, check the output voltage (12V) of the converter to one of the two middle pins on the converter.

4.

If no output voltage from converter is found, replace voltage converter (WP 0103).

SYMPTOM BLOWER MOTOR NOT WORKING MALFUNCTION Circuit breaker F11 tripped. (For rear blower troubleshooting, go to “Binding blower wheel or damage to the motor or wiring.") CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 12 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

3.

Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Blower damaged or blower wheel binding (Volume 2, WP 0198). CORRECTIVE ACTION Replace damaged or binding blower motor/assembly (Volume 2, WP 0198). MALFUNCTION Blower assembly wiring and connectors damaged (Volume 2, WP 0198). CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X9 pin 6 and 9 with the ignition on while operating the fan control switch. CORRECTIVE ACTION 1.

There should be varied voltage (14 to 24V) at pin 6. If no voltage (24V) is found at X9 pin 9, check circuit breaker F11 and continuity of wires A99 and 99 (Figure 12 (Volume 2, WP 0272)).

2.

If no voltage (14 to 24V) is found at X9 pin 6 at any on speed, remove fan control switch and check for continuity (WP 0094).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 3.

Replace damaged or faulty switch (Volume 2, WP 0272).

4.

If switch is good, check the continuity of wires 96, 97, 98, A96, A97, and A98 (Volume 2, WP 0267).

5.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X657 pin 2, 3, and 4 with the ignition on while operating the fan control switch. CORRECTIVE ACTION 1.

There should be voltage (24V) at pin 2 for LOW, pin 4 for MED, and pin 3 for HIGH. If no voltage is found, check continuity of wires, 271, 272, and 273 (Figure 12 (Volume 2, WP 0272)).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No ground connection for the white wire at X657 pin 1 and at 37-10. CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No voltage between the two blower motor connectors with the ignition on while operating the fan control switch to HIGH speed. CORRECTIVE ACTION 1.

Replace the internal blower assembly harness (Volume 2, WP 0198).

2.

Replace blower motor/assembly (Volume 2, WP 0198).

MALFUNCTION Binding blower wheel or damage to the motor or wiring (Volume 2, WP 0198). CORRECTIVE ACTION 1.

Replace damaged or binding blower motor/assembly (Volume 2, WP 0198).

2.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X69 pin 1 with the ignition on while operating the fan control switch. CORRECTIVE ACTION There should be varied voltage (14 to 24V). If no voltage is found and front blower operates properly, check continuity of wires A691 and A692 (Figure 10 (Volume 2, WP 0272)). MALFUNCTION No voltage (24V) X657-1 with the ignition on while operating the fan control switch to HIGH speed. CORRECTIVE ACTION 1.

Check continuity of wires BU and BK (Figure 10 (Volume 2, WP 0272)).

2.

If voltage is found, replace rear blower motor/assembly (Volume 2, WP 0198).

SYMPTOM HEATER/DEFROSTER PRODUCING LOW OR NO HEAT MALFUNCTION Incorrect operating temperature of engine. CORRECTIVE ACTION 1.

Perform proper PMCS for coolant system (TM 10-3930- 675-10).

2.

Warm engine to proper operating temperature (TM 10-3930-675-10).

MALFUNCTION Heater hoses between the cab and chassis kinked. CORRECTIVE ACTION 1.

Straighten any kinked hoses (Volume 2, WP 0198).

2.

Replace any damaged hoses or kinked hose that will not straighten (Volume 2, WP 0196).

MALFUNCTION Inoperative blower. CORRECTIVE ACTION If blower not functioning, perform troubleshooting procedure for “Blower Motor Not Working" in this work package.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Inoperative heater temperature control switch and heater/defroster selection switch operation. CORRECTIVE ACTION 1.

Replace damaged or binding heater temperature control switch (WP 0094).

2.

Replace damaged or binding heater/defroster selection switch (WP 0094).

MALFUNCTION Heater control valve and cable inoperative. CORRECTIVE ACTION 1.

Replace bent or kinked control cable (WP 0094) and (Volume 2, WP 0198).

2.

Replace damaged, leaking, or non-operational heater control valve (Volume 2, WP 0196).

3.

Correct any binding of air flow door and cable.

MALFUNCTION Inoperative air flow door while operating the heater/defrost selection switch. CORRECTIVE ACTION Replace damaged or binding heater/defrost selection switch. MALFUNCTION Air conditioning ducts damaged. CORRECTIVE ACTION Repair or replace any damaged or separated ducts. MALFUNCTION Restricted airflow through heater core. CORRECTIVE ACTION If air flow is very low through heater core, perform A/C system maintenance (Volume 2, WP 0248). SYMPTOM A/C SYSTEM NOT COOLING PROPERLY

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Blower inoperative. CORRECTIVE ACTION If blower not functioning, perform troubleshooting procedure for “Blower Motor Not Working" in this work package. MALFUNCTION Poor condition of the A/C compressor belts. CORRECTIVE ACTION Replace and/or adjust belts as required (Volume 2, WP 0251). MALFUNCTION Improper A/C operation. CORRECTIVE ACTION 1.

If compressor operates and condenser fans are on, go to Step 4.

2.

If compressor does not operate, go to malfunction AA.

3.

If condenser fans do not operate, go to malfunction BB.

4.

Run the A/C system for about 15 minutes to stabilize. Feel the air coming from the condenser fans; it should be warmer than the ambient temperature. Feel the temperature of the larger pipe connected to the compressor; it should be cool or cold and possibly sweating. a.

If condenser air is warm and the compressor pipe is cool/ cold, check if the heater control valve is fully closed and the air is properly flowing through the ducts (Volume 2, WP 0251).

b.

If condenser air is not warm and the compressor pipe is not cool/cold, perform A/C system maintenance (Volume 2, WP 0248).

MALFUNCTION Malfunction AA: No voltage (24V) at X27 pin 4 and 5 while operating the A/C system to maximum cool. CORRECTIVE ACTION 1.

At X27 pin 4, remove the A/C control switch and check continuity of wires 99A, 95, and A95 (Figure 12 (Volume 2, WP 0272)).

2.

At X27 pin 5, remove A/C temperature control switch and check continuity of wires 274 and 275 (Figure 12 (Volume 2, WP 0272)).

3.

Replace damaged or faulty switch (WP 0094).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X17 pin 8 while operating the A/C system to maximum cool. CORRECTIVE ACTION 1.

At X17 pin 8, check continuity of wires A327, 327, 328, and A178 (Figure 12 (Volume 2, WP 0272)).

2.

At X17 pin 8 and all wires are functioning properly, remove the cover of the condenser and unplug the pressure switch. Check continuity of the pressure switch between wires RD/WH and BK/WH (X810 pins 3 and 4).

3.

If no continuity is found at pressure switch, perform A/C system maintenance (Volume 2, WP 0248) to check the refrigerant charge of the system.

MALFUNCTION No voltage (24V) at compressor clutch while operating the A/C system to maximum cool. CORRECTIVE ACTION 1.

Check continuity of wire 178 (Figure 12 (Volume 2, WP 0272)).

2.

If voltage (24V) is found, check the resistance of the compressor clutch to ground. Resistance should be 12 to 16 Ohms.

3.

If resistance of compressor clutch is not as specified, replace compressor (Volume 2, WP 0250).

MALFUNCTION Malfunction BB: Circuit breaker F1 tripped. CORRECTIVE ACTION 1.

Reset circuit breaker as required.

2.

Unplug X810 and check voltage (24V) at X810 pins 1 and 2 while operating the A/C system.

3.

If no voltage (24V) is found at X810 pin 2, check continuity of wires A95A and 322 (Figure 12 (Volume 2, WP 0272)).

4.

If no voltage (24V) is found at X810 pin 3, check circuit breaker F1 and continuity of wires A323 and 323 (Figure 12 (Volume 2, WP 0272)).

5.

Check continuity of wires (X810 pin 6) 329, A329, and ground connection at 37-5 (Figure 12 (Volume 2, WP 0272)).

6.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Fans, Relay or wiring damage. CORRECTIVE ACTION 1.

Replace damaged or faulty relay (WP 0103).

0006-56

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TM 10-3930-675-23-1

0006

Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2.

Replace damaged fans (Volume 2, WP 0254).

3.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Resistance out of range for fans and resistors. CORRECTIVE ACTION Resistance should be 2 Ohms. If resistance is not as specified replace faulty fan(s) or resistor(s) (Volume 2, WP 0254). SYMPTOM FUEL GAUGE NOT WORKING PROPERLY MALFUNCTION Circuit breaker F7 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION Fuel level sending unit damaged. CORRECTIVE ACTION Replace fuel level sending unit. MALFUNCTION Fuel gauge damaged. Remove the dash panel to access the fuel gauge. CORRECTIVE ACTION Replace damaged fuel gauge (WP 0094). MALFUNCTION Wire connector damaged (WP 0094). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267).

0006-57

03/15/2011 Rel(1.8) root(tswp) wpno(T00011)

TM 10-3930-675-23-1

0006

Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at the + terminal of the gauge. CORRECTIVE ACTION Check circuit breaker F7 and continuity of wires A211, A104, and 104 (Figure 10 (Volume 2, WP 0272)). MALFUNCTION Float for damaged, sticking, or “waterlog." CORRECTIVE ACTION Replace damaged fuel level sending unit (WP 0132). MALFUNCTION Incorrect resistance of fuel level sending unit. CORRECTIVE ACTION 1.

Float at bottom = 110 Ohms, float in middle = approx. 50 Ohms, and float at top = 100K OHMS

>100K OHMS T0041JCH

Figure 1. Actuator Harness Test. c.

d.

3.

Measure resistance from actuator harness connector pin 10 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 10 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a.

Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 1 injector solenoid. a.

b.

Measure resistance from 15-pin connector pin 1 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 to all other pins in connector. Resistance should be greater than 100k Ohms.

0007-3

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

5.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid.

6.

Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid.

8.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1312 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a.

Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

0007-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2.

Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks. a.

b.

c.

d.

Measure resistance from actuator harness connector pin 3 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 3 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 4 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 4 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

>100K OHMS T0042JCH

Figure 2. Actuator Harness Test.

0007-5

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a.

Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 5 injector solenoid. a.

b.

Measure resistance from 15-pin connector pin 9 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 10 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

5.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid.

6.

Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid.

8.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

0007-6

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1313 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a.

Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

0007-7

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2.

Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a.

Measure resistance from actuator harness connector pin 6 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

>100K OHMS

Figure 3. Actuator Harness Test. b.

c.

d.

Measure resistance from actuator harness connector pin 6 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 16 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 16 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

0007-8

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0043JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a.

Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from15-pin connector and from no. 3 injector solenoid. a.

b.

Measure resistance from 15-pin connector pin 5 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 6 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

5.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid.

6.

Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid.

8.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

0007-9

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1314 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a.

Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required Electrical General Maintenance Instructions (Volume 2, WP 0267).

b.

Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals Electrical General Maintenance Instructions (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a.

b.

Measure resistance from actuator harness connector pin 2 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 2 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

0007-10

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c.

d.

Measure resistance from actuator harness connector pin 1 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 1 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

>100K OHMS

Figure 4. Actuator Harness Test. 3.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a.

Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 6 injector solenoid. a.

Measure resistance from 15-pin connector pin 5 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

0007-11

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0044JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) b.

c.

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 11 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 12 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

5.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid.

6.

Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid.

8.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1315 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover.

0007-12

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a.

Measure resistance from actuator harness connector pin 7 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

>100K OHMS

Figure 5. Actuator Harness Test. b.

Measure resistance from actuator harness connector pin 7 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

0007-13

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0045JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c.

d.

3.

Measure resistance from actuator harness connector pin 8 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 8 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a.

Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals Electrical General Maintenance Instructions (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 2 injector solenoid. a.

b.

Measure resistance from 15-pin connector pin 3 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 4 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

5.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid.

6.

Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid.

8.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

0007-14

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1321 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a.

Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a.

b.

c.

Measure resistance from actuator harness connector pin 26 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 26 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 36 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

0007-15

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) d.

If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 36 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

>100K OHMS

Figure 6. Actuator Harness Test. 3.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a.

Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 4 injector solenoid. a.

b.

Measure resistance from 15-pin connector pin 7 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 8 to all other pins in connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

0007-16

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0056JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2)

If internal actuator harness requires replacement, notify SRA.

5.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid.

6.

Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0099).

b.

If resistance is not as specified, replace injector (WP 0067).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid.

8.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1322 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. a.

Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

0007-17

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15pin connector at front of engine below rocker arm cover. Install jumper wire from pin 1 to pin 2 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 9 to actuator harness connector pin 10. Resistance should be less than 10 Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

100K OHMS

>100K OHMS

Figure 8. Actuator Harness Test. d.

Measure resistance from actuator harness connector pin 10 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

0007-19

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0048JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4.

Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a.

b.

Measure resistance from actuator harness connector pin 9 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 10 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

>100K OHMS

Figure 9. Actuator Harness Test. 5.

Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 1 injector solenoid and internal actuator harness from 15-pin connector. a.

Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

6.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 1 injector solenoid.

0007-20

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0049JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

b.

Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1)

If resistance is not as specified, repair or replace connectors (WP 0100).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

100K OHMS

>100K OHMS

Figure 11. 15-Pin Connector Test. 9.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 1 injector solenoid. a.

Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

b.

Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-22

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0051JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

T0052JCH

Figure 12. Solenoid Connector Test. 10.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no.1 injector solenoid from internal actuator harness.

11.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1323 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

0007-23

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 9 to pin 10 at 15-pin connector, actuator harness side.

3.

Measure resistance from actuator harness connector pin 3 to pin 4. Resistance should be less than 10 Ohms. a.

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

b.

If engine harness requires replacement, notify SRA.

100K OHMS T0042JCH

Figure 14. Actuator Harness Connector Test.

0007-25

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5.

Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a.

b.

Measure resistance from actuator harness connector pin 3 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 4 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

>100K OHMS

T0054JCH

Figure 15. Actuator Harness Connector Test. 6.

Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 5 injector solenoid and internal actuator harness from 15-pin connector. a.

Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 5 injector solenoid.

0007-26

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

b.

Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

100K OHMS

Figure 17. Actuator Harness Test. 10.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 5 injector solenoid. a.

Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

b.

Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-28

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0056JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

Figure 18. Solenoid Connector Test. 11.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no.5 injector solenoid from internal actuator harness.

12.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1324 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

0007-29

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0057JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 5 to pin 6 at 15-pin connector, actuator harness side.

3.

Measure resistance from actuator harness connector pin 6 to pin 16. Resistance should be less than 10 Ohms. a.

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

b.

If engine harness requires replacement, notify SRA.

100K OHMS

Figure 20. Actuator Harness Test. 5.

Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a.

Measure resistance from actuator harness connector pin 6 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

0007-31

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0059JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b.

Measure resistance from actuator harness connector pin 16 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

>100K OHMS

Figure 21. Actuator Harness Test. 6.

Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 3 injector solenoid and internal actuator harness from 15-pin connector. a.

Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 3 injector solenoid. a.

Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

0007-32

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0043JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

100K OHMS

Figure 23. Injector Wiring Test. 10.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 3 injector solenoid. a.

Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

b.

Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-34

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0056JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

Figure 24. Injector Wiring Test. 11.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 3 injector solenoid from internal actuator harness.

12.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0100).

b.

If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1325 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

0007-35

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0057JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 11 to pin 12 at 15-pin connector, actuator harness side.

3.

Measure resistance from actuator harness connector pin 1 to pin 2. Resistance should be less than 10 Ohms. a.

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

b.

If engine harness requires replacement, notify SRA.

100K OHMS

Figure 26. Actuator Harness Test. 5.

Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a.

Measure resistance from actuator harness connector pin 1 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

0007-37

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0059JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b.

Measure resistance from actuator harness connector pin 2 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

>100K OHMS

Figure 27. Actuator Harness Test. 6.

Place ignition switch in OFF position. Remove rocker arm cover (WP 0057)). Disconnect injector solenoid connector from no. 6 injector solenoid and internal actuator harness from 15-pin connector. a.

Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 6 injector solenoid. a.

b.

Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the No. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the No. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms.

0007-38

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0060JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If resistance is not as specified, notify SRA to replace internal actuator harness.

100K OHMS

>100K OHMS

Figure 29. Actuator Harness Test. 10.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 6 injector solenoid. a.

Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

b.

Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-40

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0062JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

Figure 30. Actuator Harness Test. 11.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 6 injector solenoid from internal actuator harness.

12.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0099).

b.

If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1331 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

0007-41

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0063JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 3 to pin 4 at 15-pin connector, actuator harness side.

3.

Measure resistance from actuator harness connector pin 8 to pin 7. Resistance should be less than 10 Ohms. a.

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

b.

If engine harness requires replacement, notify SRA.

100K OHMS

Figure 32. Actuator Harness Test.

0007-43

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0065JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5.

Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a.

b.

Measure resistance from actuator harness connector pin 7 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 8 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

>100K OHMS

T0066JCH

Figure 33. Actuator Harness Test. 6.

Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 2 injector solenoid and internal actuator harness from 15-pin connector. a.

Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 2 injector solenoid.

0007-44

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

b.

Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

100K OHMS

>100K OHMS

Figure 35. Actuator Harness Test. 10.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 2 injector solenoid. a.

Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

b.

Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-46

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0068JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

Figure 36. Actuator Harness Test. 11.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 2 injector solenoid from internal actuator harness.

12.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0099).

b.

If resistance is not as specified, replace injector (WP 0067).

SYMPTOM ERROR CODE 1332 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. a.

Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins.

0007-47

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0069JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued Clean and repair connector(s) as required (Volume 2, WP 0267). b.

Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

2.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 7 to pin 8 at 15-pin connector, actuator harness side.

3.

Measure resistance from actuator harness connector pin 26 to pin 36. Resistance should be less than 10 Ohms. a.

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

b.

If engine harness requires replacement, notify SRA.

100K OHMS

Figure 38. Actuator Harness Test.

0007-49

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0071JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5.

Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a.

b.

Measure resistance from actuator harness connector pin 26 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 36 to engine block ground. Resistance should be greater than 100k Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If engine harness requires replacement, notify SRA.

>100K OHMS

Figure 39. Actuator Harness Test. 6.

Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 4 injector solenoid and internal actuator harness from 15-pin connector. a.

Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267).

b.

Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

7.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 4 injector solenoid.

0007-50

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0072JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a.

b.

Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1)

If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

(2)

If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

100K OHMS

>100K OHMS

Figure 41. Actuator Harness Test. 10.

Place ignition switch in OFF position and, with rockerarm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 4 injector solenoid. a.

Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

b.

Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-52

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0074JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

Figure 42. Actuator Harness Test. 11.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 4 injector solenoid from internal actuator harness.

12.

Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a.

If resistance is as specified, replace engine ECU (WP 0099).

b.

If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1951 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION Notify SRA.

0007-53

03/15/2011 Rel(1.8) root(tswp) wpno(T00012)

T0075JCH

TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0076JCH

Figure 43. Cylinder #1 Supply and Return.

T0077JCH

Figure 44. Cylinder #5 Supply and Return.

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TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0078JCH

Figure 45. Cylinder #3 Supply and Return.

T0079JCH

Figure 46. Cylinder #6 Supply and Return.

0007-55

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0080JCH

Figure 47. Cylinder #2 Supply and Return.

T0081JCH

Figure 48. Cylinder #4 Supply and Return. END OF WORK PACKAGE

0007-56

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TM 10-3930-675-23-1

FIELD MAINTENANCE ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 48) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52)

References (cont.) WP 0078 WP 0100 Volume 2, WP 0185 Volume 2, WP 0267 Volume 2, WP 0272 Volume 2, WP 0277

References WP 0005

NOTE Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components.

0008-1

03/15/2011 Rel(1.8) root(tswp) wpno(T00013)

0008

TM 10-3930-675-23-1

0008

TROUBLESHOOTING PROCEDURE ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING SYMPTOM

ERROR CODE 1131 MALFUNCTION High Voltage Detected at Throttle Position Sensor Circuit. CORRECTIVE ACTION

NOTE • Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. • Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1.

Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078).

2.

Check connector. Access the cab distribution box in the panel behind the operator’s seat. Pull the box out and disconnect connector X23.

3.

Inspect connector X23 for damage. Check resistance on the loose part of connector X23 between pins 4 and 5. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). a.

If resistance is not as specified, continue with Step 4.

b.

Repair or replace damaged connector (Volume 2, WP 0267).

4.

Check resistance on the loose part of connector X23 between pins 3 and 4. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, continue with Step 5.

5.

Check connector. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness.

6.

Check for continuity. Disconnect X690 and inspect for damage. Check resistance on the accelerator pedal part of connector X690 between pins 4 and 5. Check each pin for continuity to ground. Resistance should be 2,000 to 3,000 Ohms and there should be no continuity to ground (Figure 3 (Volume 2, WP 0272)).

0008-2

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TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

2000-3000 OHMS

PIN 5 X690 BK 6 RD 5 WH 4

1 OR 2 GN 3 BU

PIN 4 USE TEST LEAD KIT P/N 3823994

T0082JCH

Figure 1. Accelerator Pedal Wiring Test.

0008-3

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TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 7.

Check resistance on the accelerator pedal part of connector X690 between pins 5 and 6. Check each pin for continuity to ground. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms With the pedal depressed. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). a.

If resistance is not as specified, replace accelerator pedal assembly (WP 0078).

b.

If resistance is as specified, check continuity and for continuity to ground for wires 233, 234, and 235 (Figure 3 (Volume 2, WP 0272)).

c.

Repair or replace damaged connector (Volume 2, WP 0267).

d.

Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267). 1500-3000 OHMS RELEASED 250-1500 OHMS DEPRESSED

PIN 6

X690 BK 6 RD 5 WH 4

1 OR 2 GN 3 BU

USE TEST LEAD KIT P/N 3823994 PIN 5

Figure 2. Accelerator Pedal Wiring Test. 8.

Inspect pins. Reconnect connector X23 and connector X690. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. a.

Clean and repair connector as required (Volume 2, WP 0267).

b.

Replace damaged ECU (794) (WP 0100).

0008-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00013)

T0083JCH

TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

1500-3000 Ohms

USE TEST LEAD KIT P/N 3822758

T0084JCH

Figure 3. OEM Harness Connector Test. 9.

Check resistance at the OEM harness connector between pins 48 and 49. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, proceed with Step 10.

10.

Check resistance at the OEM harness connector between pins 47 and 48. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, proceed with Step 11.

>1500-3000 OHMS RELEASED 250-1500 Ohms DEPRESSED

USE TEST LEAD KIT P/N 3822758

T0085JCH

Figure 4. OEM Harness Connector Test.

0008-5

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TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 11.

Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity and for continuity to ground for wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found at any one wire or any wire is found to be open, notify SRA.

12.

Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)).

13.

a.

Repair or replace damaged connector (Volume 2, WP 0267).

b.

Replace any damaged, open, or grounded wires.

Check for continuity. Disconnect the OEM harness connector and connector X16. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector. There should be continuity between pins. If there is continuity between pin 47 and any other pin in the OEM harness connector, notify SRA.

>1500-3000 OHMS RELEASED 250-1500 Ohms DEPRESSED

USE TEST LEAD KIT P/N 3822758

T0085JCH

Figure 5. OEM Harness Connector Test.

0008-6

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TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1132 MALFUNCTION Low Voltage Detected at Throttle Position Sensor Circuit. CORRECTIVE ACTION

NOTE • Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. • Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1.

Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078).

2.

Check connector. Access the cab distribution box in the panel behind the operator’s seat. Pull the box out and disconnect connector X23.

3.

Inspect connector X23 for damage. Check resistance on the loose part of connector X23 between pins 4 and 5. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). a.

If resistance is not as specified, continue with Step 4.

b.

Repair or replace damaged connector (Volume 2, WP 0267).

4.

Check continuity on the loose part of connector X23 between pin 3 and ground and pin 4 and ground. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found continue with Step 5.

5.

Inspect wiring. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness.

0008-7

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TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6.

Check for continuity. Disconnect connector X690 and inspect for damage. Check resistance on the acceleration pedal part of connector X690 between pins 4 and 5. Check each pin for continuity to ground. Resistance should be 2,000 to 3,000 Ohms and there should not be continuity to ground (Figure 3 (Volume 2, WP 0272)). a.

If resistance is not as specified; replace accelerator pedal assembly (WP 0078).

b.

Repair or replace damaged connector (Volume 2, WP 0267).

2000-3000 OHMS

X690

PIN 4 BK 6 RD 5 WH 4 USE TEST LEAD KIT P/N 3823996

1 OR 2 GN 3 BU

PIN 5

Figure 6. Accelerator Pedal Wiring Test. 7.

Check continuity on the accelerator pedal part of connector X690 between pin 5 and ground and pin 6 and ground. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). a.

If continuity to ground is found, replace accelerator pedal assembly (WP 0078).

b.

If continuity to ground is not found, check continuity and for continuity to ground for wires 233, 234, and 235 (Figure 3 (Volume 2, WP 0272)).

c.

Repair or replace damaged connector (Volume 2, WP 0267).

d.

Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).

0008-8

03/15/2011 Rel(1.8) root(tswp) wpno(T00013)

T0087JCH

TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

X690

PIN 5 AND PIN 6

BK 6 RD 5 WH 4

1 OR 2 GN 3 BU

USE TEST LEAD KIT P/N 3823996

T0088JCH

Figure 7. Accelerator Pedal Wiring Test. 8.

Inspect pins. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. a.

Clean and repair connector as required (Volume 2, WP 0267).

b.

Replace damaged ECU (794) (WP 0100).

9.

Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity and for continuity to ground for wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found at any one wire or any wire is found to be open, notify SRA.

10.

Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)). a.

Repair or replace damaged connector (Volume 2, WP 0267).

b.

Replace any damaged, open or grounded wires.

0008-9

03/15/2011 Rel(1.8) root(tswp) wpno(T00013)

TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0089JCH

Figure 8. OEM Wiring Harness Test. 11.

Check for continuity. Disconnect the OEM harness connector and connector Xl6. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector and between pin 48 and all of the other pins in the connector. There should be continuity between pins. If there is continuity between pin 47 or 48 and any other pin in the OEM harness connector, notify SRA.

T0090JCH

Figure 9. OEM Wiring Harness Test.

0008-10

03/15/2011 Rel(1.8) root(tswp) wpno(T00013)

TM 10-3930-675-23-1

0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued SYMPTOM

ERROR CODE 1431 MALFUNCTION Voltage Detected at Both Idle Validation Signal Circuits. CORRECTIVE ACTION

NOTE • Use test lead, female - part number Volume 2, WP 0277, Table 1, Item 47 to test connector X690. • Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1.

Check calibration. Turn the ignition on and depress and release the accelerator pedal three times to calibrate the pedal. If ERROR CODE remains active continue with Step 2. 3 TIMES

T0091JCH

Figure 10. Accelerator Pedal Calibration. 2.

Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078).

3.

Inspect connector X23 for damage. Access the cab distribution box in the panel behind the operator’s seat. Pull the box out and disconnect connector X23. Repair or replace damaged connector (Volume 2, WP 0267).

4.

Check resistance on the loose part of connector X23 between pins 6 and 9. Resistance should be 40í 0mA 0mA 40í->20í 0mA 0mA

ERROR CODE 231 MALFUNCTION Tophandler Spreader Opening, Open Circuit Failure CORRECTIVE ACTION 1.

Check wires and connectors at tophandler control valve and tophandler junction box for damage. a.

Repair or replace connectors (Volume 2, WP 0267).

b.

Replace damaged wiring harness (WP 0108).

2.

Enter "DIAG ATTACHMENT 8(16)" in the diagnostic menu. Activate the spreader opening function. If no "INPUT" mA values display, continue with troubleshooting procedure.

3.

Disconnect connector 6018 from the tophandler spreading out solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector.

4.

a.

If no voltage (15 to 18V) is found, check continuity of wires 188J and 188K (Figure 6 (Volume 2, WP 0272)).

b.

If voltage (15 to 18V) is found, check resistance of 6018 solenoid. Resistance should be 18 to 26 Ohms.

c.

Replace open or faulty solenoid (Volume 2, WP 0217).

d.

Replace X188 to solenoids wiring harness to solenoids wiring harness (WP 0108).

Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins J and K. a.

If no voltage (15 to 18V) is found, check continuity of wires A3018A through H, and A188K (Figure 6 (Volume 2, WP 0272)).

b.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

0045-2

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TM 10-3930-675-23-1

0045

CORRECTIVE ACTION - Continued

NOTE Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5.

Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a.

Repair or replace damaged connector (Volume 2, WP 0267)).

b.

Replace ECU (791) (WP 0100).

SYMPTOM

DIAG ATTACHMENT 8(16) OUTPUT INPUT 20í->40í 0mA 0mA 40í->20í 0mA 0mA

ERROR CODE 232 MALFUNCTION Tophandler Spreader Opening, Open Circuit Failure CORRECTIVE ACTION 1.

Check wires and connectors at tophandler control valve and tophandler junction box for damage. a.

Repair or replace connectors (Volume 2, WP 0267).

b.

Replace damaged wiring harness (WP 0108).

CAUTION Uncontrolled function may occur with this ERROR CODE. 2.

Disconnect connector 6018 from the tophandler left sideshift solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217).

3.

Disconnect connector X188 from tophandler junction box and disconnect solenoid 6018. Check for short to ground at loose part of X188 at pin K (wire 188K) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X188 to solenoids wiring harness (WP 0108).

0045-3

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TM 10-3930-675-23-1

0045

CORRECTIVE ACTION - Continued

NOTE Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4.

Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. Check wire A188K (pin 4) for short to ground (Figure 6 (Volume 2, WP 0272)). a.

Repair or replace shorted wires or connectors (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100).

SYMPTOM

DIAG ATTACHMENT 8(16) OUTPUT INPUT 20í->40í 0mA 0mA 40í->20í 0mA 0mA

ERROR CODE 234 MALFUNCTION Tophandler Spreader Closing, Open Circuit Failure CORRECTIVE ACTION 1.

Check wires and connectors at tophandler control valve and tophandler junction box for damage. a.

Repair or replace connectors (Volume 2, WP 0267).

b.

Replace damaged wiring harness (WP 0108).

2.

Enter "DIAG ATTACHMENT 8(16)" in the diagnostic menu. Activate the spreader opening function. If no "INPUT" mA values display, continue with troubleshooting procedure.

3.

Disconnect connector 6019 from the tophandler spreading out solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector.

4.

a.

If no voltage (15 to 18V) is found, check continuity of wires 188L and 188M (Figure 6 (Volume 2, WP 0272)).

b.

If voltage (15 to 18V) is found, check resistance of 6019 solenoid. Resistance should be 18 to 26 Ohms.

c.

Replace open or faulty solenoid (Volume 2, WP 0217).

d.

Replace X188 to solenoids wiring harness to solenoids wiring harness (WP 0108).

Disconnect connector X188 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins L and M.

0045-4

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TM 10-3930-675-23-1

0045

CORRECTIVE ACTION - Continued a.

If no voltage (15 to 18V) is found, check continuity of wires A3018A through H, and A188M (Figure 6 (Volume 2, WP 0272)).

b.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

NOTE Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5.

Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a.

Repair or replace damaged connector (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100).

SYMPTOM

DIAG ATTACHMENT 8(16) OUTPUT INPUT 20í->40í 0mA 0mA 40í->20í 0mA 0mA

ERROR CODE 235 MALFUNCTION Tophandler Spreader Closing, Open Circuit Failure CORRECTIVE ACTION 1.

Check wires and connectors at tophandler control valve and tophandler junction box for damage. a.

Repair or replace connectors (Volume 2, WP 0267).

b.

Replace damaged wiring harness (WP 0108).

CAUTION Uncontrolled function may occur with this ERROR CODE. 2.

Disconnect connector 6019 from the tophandler left sideshift solenoid. Check resistance of the solenoid between both pins and between each pin and ground (Figure 6 (Volume 2, WP 0272)). Resistance of the solenoid should be 18 to 26 Ohms. Replace open or shorted solenoid (Volume 2, WP 0217).

3.

Disconnect connector X188 from tophandler junction box and disconnect solenoid 6019. Check for short to ground at loose part of X188 at pin M (wire 188M) (Figure 6 (Volume 2, WP 0272)). Replace shorted/grounded X188 to solenoids wiring harness (WP 0108).

0045-5

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TM 10-3930-675-23-1

0045

CORRECTIVE ACTION - Continued

NOTE Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 4.

Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. Check wire A188M (pin 12) for short to ground (Figure 6 (Volume 2, WP 0272)). a.

Repair or replace shorted wires or connectors (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100).

0045-6

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TM 10-3930-675-23-1

0045

CORRECTIVE ACTION - Continued

T0270JCH

Figure 1. Component Locations. END OF WORK PACKAGE

0045-7/8 blank

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TM 10-3930-675-23-1

0046

FIELD MAINTENANCE TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0004 WP 0005

References (cont.) WP 0100 WP 0104 WP 0108 Volume 2, WP 0217 Volume 2, WP 0267 Volume 2, WP 0272

NOTE • Refer to (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. • Refer also to illustrations at end of work package for component location. TROUBLESHOOTING PROCEDURE SYMPTOM

DIAG ATTACHMENT 4(16) TWIST LOCK LE UNL. 1 RI UNL. 1 LE LOCK 0 RI LOCK 0

ERROR CODE 212 MALFUNCTION Tophandler Left Twistlocks Indication Failure CORRECTIVE ACTION 1.

2.

Enter "DIAG ATTACHMENT 4(16)" in the diagnostic menu. Check the left twistlocks "LOCKED" and "UNLOCKED" status. (Logical Error indicates both twistlock signals are ON at the same time.) a.

Use the override switch to operate the twistlocks (TM 10-3930-675-10). Observe the status indication in the diagnostic menu screen. Observe the changing of the twistlock indicator lights.

b.

If both "LOCKED" and "UNLOCKED" are “1" at the same time, continue with step 2.

Inspect the left twistlock proximity switches for damage, obstructions, and adjustments.

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TM 10-3930-675-23-1

0046

CORRECTIVE ACTION - Continued a.

Replace damaged proximity switch (WP 0104).

b.

Remove any obstructions and clean proximity switch ends.

c.

Check and adjust proximity switch gap (5 mm) (WP 0104).

3.

Remove cover to X183. Inspect wire connections at pins 5 and 6 (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)).

4.

Make sure the twistlocks are in the UNLOCKED position. Check voltage (24V) between X183 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 6, replace left twistlock LOCKED proximity switch (WP 0104).

5.

Make sure the twistlocks are in the LOCKED position. Check voltage (24V) between X183 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 5, replace left twistlock “locked" proximity switch (WP 0104).

6.

Remove the cover to X182. Inspect wire connections (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. a.

Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)).

b.

Check cable X182 to X183 for damage, continuity, or shorts between wires (Volume 2, WP 0267).

c.

Replace X182 to X183 cable (WP 0108).

7.

Check X182 to X181 cable for damage, continuity, or shorts between wires (Volume 2, WP 0267). If X182 and X181 cable is damaged, has no continuity, or is shorted between wires, replace X182 to X181 cable (WP 0108).

8.

Disconnect ECU (791) connector 1. Inspect ECU and connector pins for damage. Check continuity and for shorts between wires of the wiring from connector 1 (Figure 6 (Volume 2, WP 0272)). a.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100)).

SYMPTOM ERROR CODE 213

0046-2

03/15/2011 Rel(1.8) root(tswp) wpno(T00051)

TM 10-3930-675-23-1

0046

SYMPTOM - Continued

>100K Ohms

USE TEST LEAD KIT P/N 3822758

T0171J

Figure 1.

Tophandler Twistlocks Indication Failure.

MALFUNCTION Tophandler Right Twistlocks Indication Failure CORRECTIVE ACTION 1.

2.

Enter "DIAG ATTACHMENT 4(16)" in the diagnostic menu. Check the right twistlocks "LOCKED" and "UNLOCKED" status. (Logical Error indicates both twistlock signals are “on" at the same time.) a.

Use the override switch to operate the twistlocks (TM 10-3930-675-10). Observe the status indication in the diagnostic menu screen. Observe the changing of the twistlock indicator lights.

b.

If both "LOCKED" and "UNLOCKED" are “1" at the same time, continue with Step 2.

Inspect the left twistlock proximity switches for damage, obstructions, and adjustments. a.

Replace damaged proximity switch (WP 0104).

b.

Remove any obstructions and clean proximity switch ends.

c.

Check and adjust proximity switch gap (5 mm) (WP 0104)).

3.

Remove cover to X184. Inspect wire connections at pins 5 and 6 (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)).

4.

Make sure the twistlocks are in the UNLOCKED position. Check voltage (24V) between X184 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 6, replace left twistlock LOCKED proximity switch (WP 0104).

5.

Make sure the twistlocks are in the LOCKED position. Check voltage (24V) between X184 pins 4 and 5 and between 4 and 6 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found between pins 4 and 6, replace left twistlock LOCKED proximity switch (WP 0104).

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TM 10-3930-675-23-1

0046

CORRECTIVE ACTION - Continued 6.

Remove the cover to X182. Inspect wire connections (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. a.

Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)).

b.

Check cable X182 to X184 for damage, continuity, or shorts between wires (Volume 2, WP 0267).

c.

Replace X182 to X184 cable (WP 0108).

7.

Check X182 to X181 cable for damage, continuity, or shorts between wires (Volume 2, WP 0267). If X182 and X181 cable is damaged, has no continuity, or is shorted between wires, replace X182 to X181 cable (WP 0108).

8.

Disconnect ECU (791) connector 1. Inspect ECU and connector pins for damage. Check continuity and for shorts between wires of the wiring from connector X181 to ECU (791) connector 1 (Figure 6 (Volume 2, WP 0272)). a.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100).

SYMPTOM

DIAG ATTACHMENT 5(16) Rotation Damping Attachment Attachment

4/-25 20/40 SIG 1 SIG 2

ERROR CODE 214 MALFUNCTION Tophandler Forklift Sensor Indication Failure CORRECTIVE ACTION 1.

2.

Enter "DIAG ATTACHMENT 5(16)" in the diagnostic menu. Check the attachment signal 1 and 2 status. (Logical Error indicates one attachment sig. is not ON when both signals should be ON at the same time.) a.

Check the actuating plunger by pushing up on the bottom of the shaft.

b.

Clean and lubricate stuck actuating plunger.

c.

If one attachment signal is “0", push the actuating plunger several times to observe any indication changes.

Inspect the forklift sensor proximity switches for damage, obstructions, and adjustment (WP 0104). a.

Replace damaged proximity switch (WP 0104).

0046-4

03/15/2011 Rel(1.8) root(tswp) wpno(T00051)

TM 10-3930-675-23-1

0046

CORRECTIVE ACTION - Continued b.

Remove any obstructions and clean proximity switch ends.

c.

Check and adjust proximity switch gap (5 mm) (WP 0104).

3.

Remove the cover to X183. Inspect wire connections at pins 3, 4, 7, and 8 (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)).

4.

Check voltage (24V) between X183 pins 4 and 7 (Figure 6 (Volume 2, WP 0272)). If no voltage (24V) is found between pins 4 and 7, replace proximity switch 7206-1 (WP 0104).

5.

Check voltage (24V) between X183 pins 4 and 8 (Figure 6 (Volume 2, WP 0272)). If no voltage (24V) is found between pins 4 and 8, replace proximity switch 7206-2 (WP 0104).

6.

Remove the cover to X182. Inspect wire connections (Figure 6 (Volume 2, WP 0272)). Compare wire connections with the diagram. a.

Correct any wiring error or damage (Figure 6 (Volume 2, WP 0272)).

b.

Check cable X182 to X183 for damage, continuity, or shorts between wires (Volume 2, WP 0267).

c.

Replace X182 to X183 cable (WP 0108).

7.

Check X182 to X181 cable for damage, continuity, or shorts between wires (Volume 2, WP 0267). If X182 to X181 cable is damaged, has no continuity, or is shorted between wires, replace X182 to X181 cable (WP 0108).

8.

Disconnect ECU (791) connector 1. Inspect ECU and connector pins for damage. Check continuity and for shorts between wiring from connector X181 to ECU (791) connector 1 (Figure 6 (Volume 2, WP 0272)). a.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100).

SYMPTOM

DIAG ATTACHMENT 6(16) TW-LOCK OUTPUT INPUT 0Ma UNLOCKED 0.00V LOCKED 0.00V 0mA

ERROR CODE 243

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03/15/2011 Rel(1.8) root(tswp) wpno(T00051)

TM 10-3930-675-23-1

0046

MALFUNCTION Tophandler Twistlock Locking Circuit Failure CORRECTIVE ACTION 1.

Check wires and connectors at tophandler junction box for damage. a.

Repair or replace connectors (Volume 2, WP 0267).

b.

Replace damaged wiring harness (WP 0108).

2.

Enter "DIAG ATTACHMENT 6(16)" in the diagnostic menu. Activate the twistlock function (override twistlocks). If no INPUT mA values display, continue with troubleshooting procedure.

3.

Disconnect connector 6040 from the tophandler twistlock locking solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector.

4.

a.

If no voltage (15 to 18V) is found, check continuity of wires 189L and 189M (Figure 6 (Volume 2, WP 0272)).

b.

If voltage (15 to 18V) is found, check resistance of 6040 solenoid. Resistance should be 18 to 26 Ohms.

c.

Replace open or faulty solenoid (Volume 2, WP 0217).

d.

Replace X189 to solenoids wiring harness (WP 0108).

Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins L and M. a.

If no voltage (15 to 18V) is found, check continuity of wires A3018A through A3018F and A189M (Figure 6 (Volume 2, WP 0272)).

b.

Repair or replace damaged wires or connectors (Volume 2, WP 0267).

NOTE Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5.

Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a.

Repair or replace damaged connector (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100).

SYMPTOM

DIAG ATTACHMENT 6(16) TW-LOCK OUTPUT INPUT 0Ma UNLOCKED 0.00V LOCKED 0.00V 0mA

ERROR CODE 246

0046-6

03/15/2011 Rel(1.8) root(tswp) wpno(T00051)

TM 10-3930-675-23-1

0046

MALFUNCTION Tophandler Twistlock Unlocking Circuit Failure CORRECTIVE ACTION 1.

Check wires and connectors at tophandler control valve and tophandler junction box for damage. a.

Repair or replace connectors (Volume 2, WP 0267)).

b.

Replace damaged wiring harness (WP 0108).

2.

Enter "DIAG ATTACHMENT 6(16)" in the diagnostic menu. Activate the twistlock function (override twistlocks). If no INPUT mA values display, continue with troubleshooting procedure.

3.

Disconnect connector 6039 from the tophandler twistlock unlocking solenoid. Turn the ignition ON and check voltage (15 to 18V) between both pins of the connector.

4.

a.

If no voltage (15 to 18V) is found, check continuity of wires 189J and 189K (Figure 6 (Volume 2, WP 0272)).

b.

If voltage (15 to 18V) is found, check resistance of 6039 solenoid. Resistance should be 18 to 26 Ohms.

c.

Replace open or faulty solenoid (Volume 2, WP 0217).

d.

Replace X189 to solenoids wiring harness (WP 0108).

Disconnect connector X189 from the tophandler junction box. Turn the ignition ON. Check voltage (15 to 18V) at the mounted part of the connector between pins J and K. If no voltage (15 to 18V) is found, check continuity of wires A3018A through A3018E, and A189K (Figure 6 (Volume 2, WP 0272)).

NOTE Multiple ERROR CODES associated with a common connector on ECU (791) may be the result of a short to ground in the harness for the common solenoid voltage. (See ERROR CODE References (WP 0004) for troubleshooting multiple ERROR CODES.) 5.

Disconnect ECU (791) connector 2. Inspect ECU and connector pins for damage. a.

Repair or replace damaged connector (Volume 2, WP 0267).

b.

Replace ECU (791) (WP 0100).

0046-7

03/15/2011 Rel(1.8) root(tswp) wpno(T00051)

TM 10-3930-675-23-1

0046

CORRECTIVE ACTION - Continued

T0275JCH

Figure 2. Component Locations.

0046-8

03/15/2011 Rel(1.8) root(tswp) wpno(T00051)

TM 10-3930-675-23-1

0046

CORRECTIVE ACTION - Continued

T0276JCH

Figure 3. Component Locations. END OF WORK PACKAGE

0046-9/10 blank

03/15/2011 Rel(1.8) root(tswp) wpno(T00051)

TM 10-3930-675-23-1

CHAPTER 3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

TM 10-3930-675-23-1

0047

FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION

GENERAL PMCS PROCEDURES 1. Always perform PMCS in the same order so it gets to be a habit. Once you've had some practice, you'll spot anything wrong in a hurry. If any deficiency is discovered, perform the appropriate troubleshooting task in Chapter 2 of this manual. If any component or system is not serviceable, or if the given service does not correct the deficiency, notify your Supervisor. 2. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all tools needed to make all checks. Have several clean rags handy. Perform ALL inspections at the applicable interval. a. Keep It Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work and as needed. Use Detergent and water when you clean. b. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and apply a light coat of lubricating oil OE/HDO 10. Report it to your Supervisor. c. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, and for missing, bent, or broken condition. You can't try them all with a tool, but look for chipped paint, bare metal, or rust around bolt heads. If you find a fastener you think is loose, tighten it. d. Welds. Look for loose or chipped paint, rust, or gaps where parts are welded together. If you find a bad weld, report it to your Supervisor. e. Electric Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connectors. Tighten loose connectors and ensure wires are in good condition. f. Hydraulic Hoses and Lines. Look for wear, damage, and signs of leaks. Ensure clamps and fittings are tight. Wet spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose fitting or connector, tighten it. If something is broken or worn out, correct it if authorized by the Maintenance Allocation Chart (MAC) (Volume 2, WP 0275). If not authorized, notify your Supervisor. g. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your vehicle. The following are definitions of the types/classes of leakage you need to know to be able to determine the status of your vehicle. Learn and be familiar with them, and remember: when in doubt, notify your Supervisor. Table 1.

Leakage Definitions for PMCS.

Class I

Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.

Class II

Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item being checked/inspected.

Class III

Leakage of fluid great enough to form drops that fall from item being checked/inspected.

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TM 10-3930-675-23-1

0047

PMCS INITIAL SETUP 1. General a. This paragraph lists tools, materials, and personnel required for PMCS and lubrication. b. Mandatory replacement parts for PMCS and lubrication are listed after PMCS, in Table 2, Preventive Maintenance Checks and Services (PMCS) (WP 0048). 2. Tools. a. Tool Kit, General Mechanics 3. Materials. a. Detergent b. Grease, Automotive and Artillery, GAA c. Rag, Wiping 4. Personnel. a. Driver/Operator b. Field Maintenance Mechanic GENERAL 1. To ensure the RTCH is ready for operation at all times, it must be lubricated and inspected on a regular basis so defects may be found before they result in serious damage, equipment failure, or injury to personnel. 2. The types, amounts, and temperature ranges of the lubricants required for specified intervals are contained in Lubrication Order (LO 10-3930-675-13). 3. Table 1 in Preventive Maintenance Checks and Services (PMCS) (WP 0048) contains systematic instructions on lubrications, inspections, adjustments, and corrections to be performed by Field Maintenance to keep the vehicles in good operating condition and ready for their primary mission. 4. Table 2 in Preventive Maintenance Checks and Services (PMCS) (WP 0048) lists PMCS mandatory replacement parts, by interval. EXPLANATION OF TABLE ENTRIES 1. Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indicating a fault. Item numbers also appear in the order you must perform checks and services for the interval listed. 2. Interval Column. This column tells you when you must perform the procedure in the Procedure column. Intervals are based on calendar dates and hours (in parentheses). a. Quarterly procedures must be done every three months. b. Semi-annual procedures must be done once every six months. c. Biennial procedures must be done once every two years. 3. Item to Checked or Serviced Column. This column identifies the item to be checked or serviced.

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

0047-2

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TM 10-3930-675-23-1

0048

FIELD MAINTENANCE PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Socket Set, 3/4 in. Drive, Regular Length, Standard (Volume 2, WP 0277, Table 1, Item 71) Wrench, Torque, Click, Ratcheting, 3/4 in. Drive, 600 lb-ft (Volume 2, WP 0277, Table 1, Item 96) References LO 10-3930-675-13 TM 10-3930-675-10

Table 1.

ITEM NO.

INTERVAL

References (cont.) WP 0090 WP 0128 Volume 2, WP 0140 Volume 2, WP 0150 Volume 2, WP 0155 Volume 2, WP 0158 Volume 2, WP 0227 Volume 2, WP 0245 Volume 2, WP 0248 Volume 2, WP 0258

Preventive Maintenance Checks and Services (PMCS) for the RTCH.

ITEM TO BE CHECKED OR SERVICED

PROCEDURE

WARNING Perform all lubrication and preventive maintenance checks and services with vehicle on level ground, transmission in N (Neutral), parking brake applied, and engine off. Failure to follow this warning may result in personnel injury.

0048-1

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00009)

EQUIPMENT NOT READY/ AVAILABLE IF:

TM 10-3930-675-23-1

Table 1.

ITEM NO.

INTERVAL

0048

Preventive Maintenance Checks and Services (PMCS) for the RTCH - Continued. ITEM TO BE CHECKED OR SERVICED

PROCEDURE

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.

CAUTION Operation is allowable with Class I and Class II leakage, except for fuel. WHEN IN DOUBT, NOTIFY YOUR SUPERVISOR. When operating with Class I or Class II leaks, check fluid levels more frequently. Class III leaks must be reported immediately to your Supervisor. Failure to do this will result in damage to vehicle and/or components.

0048-2

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00009)

EQUIPMENT NOT READY/ AVAILABLE IF:

TM 10-3930-675-23-1

Table 1.

ITEM NO.

INTERVAL

0048

Preventive Maintenance Checks and Services (PMCS) for the RTCH - Continued. ITEM TO BE CHECKED OR SERVICED

PROCEDURE

EQUIPMENT NOT READY/ AVAILABLE IF:

NOTE • DO NOT lubricate boom and tophandler wear plates. • After initial 100 hours of operation, Field Maintenance must perform 100-hour initial break-in services as indicated in Lubrication Order (LO 10-3930-675-13). • Field Maintenance shall also check torque of wheel nuts [497 lb-ft (650 N·m)] and torque of boom wear plate mounting hardware (Volume 2, WP 0258). 1

Quarterly Engine Oil and (300 Hours) Filter

Access engine compartment and change engine oil filter. (1) Start engine and bring to operating temperature (TM 10-3930-675-10). (2) Shut down engine (TM 10-3930-675-10). Drain engine oil and replace filter Lubrication Order (LO 10-3930-675-13).

2

Quarterly Engine Fuel (300 Hours) Filter/Water Separator

WARNING

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. a. Replace fuel filter/water separator (WP 0076). b. Inspect fuel lines, fuel tank, and fuel system components for leaks and damage. If authorized, replace damaged components.

0048-3

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00009)

Any fuel leaks are evident.

TM 10-3930-675-23-1

Table 1.

ITEM NO. 3

INTERVAL

0048

Preventive Maintenance Checks and Services (PMCS) for the RTCH - Continued. ITEM TO BE CHECKED OR SERVICED

Quarterly Engine Coolant (300 Hours) Filter

PROCEDURE

EQUIPMENT NOT READY/ AVAILABLE IF:

WARNING

• 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/surge tank when engine is hot. Allow engine to cool down. Failure to follow this warning may cause serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to follow this warning may result in injury. a. Replace coolant filter (WP 0090). b. Inspect cooling system for leaks and damage. If authorized, replace damaged components. 4

Quarterly Front and Rear (300 Hours) Propeller Shafts

Lubricate front and rear propeller shafts. Lubrication Order (LO 10-3930-675-13).

5

Quarterly Tophandler (300 Hours) Pinion and Ring Gear

Lubricate pinion and ring gear. Lubrication Order (LO 10-3930-675-13).

6

SemiAnnual

PRIOR TO ROAD TEST

Pre-Service Checks

Any Class III coolant leaks are evident.

a. Perform all BEFORE operator/crew PMCS listed in TM 10-3930-675-10 on the machine. Starter is inoperative or b. Start engine (TM 10-3930-675-10). Ensure starter engages smoothly and turns the engine at normal makes excessive grinding noise. cranking speed. DURING OPERATIONAL TEST

NOTE While performing Operational Driving test, operate vehicle in a location large enough to simulate normal operating conditions of the RTCH. c. Perform all DURING operator/crew PMCS listed in TM 10-3930-675-10 on the machine.

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TM 10-3930-675-23-1

Table 1.

ITEM NO.

INTERVAL

0048

Preventive Maintenance Checks and Services (PMCS) for the RTCH - Continued. ITEM TO BE CHECKED OR SERVICED

PROCEDURE

EQUIPMENT NOT READY/ AVAILABLE IF:

d. Observe response to accelerator pedal. Listen Accelerator pedal does for unusual noises. Observe for hesitation, varying idle not respond to commands, engine hesitates, idle is speed, and sticking or binding of accelerator pedal. not steady or pedal is sticking or binding. e. Be alert of excessive vibration and the smell of Engine knocks, rattles, or smokes excessively. fuel, oil, coolant, and excessive exhaust smoke. f. Ensure transmission is engaging and shifting smoothly through all gear ranges. Be alert for unusual noises and difficulty shifting in all gear ranges

Transmission shifts improperly, does not shift, or makes excessive noise during operation.

g. Check operation of steering modes (TM 10-3930-675-10). Ensure steering modes engage smoothly without grinding or vibration.

Any steering mode inoperative or excessive grinding noise.

h. Turn steering wheel to left, then right, to detect Steering binds, grabs, wanders, or has excessive hard steering, steering backlash, or shimmy. Vehicle play. should respond instantly. With vehicle moving on straight, level terrain, lightly hold steering wheel to check for pull and wandering. Brakes chatter, pull to one i. Apply brake pedal with steady force. Vehicle side, or are inoperative. should slow and stop without pulling to one side or jerking. Release brake pedal. The brakes should release immediately and without difficulty. j. Bring vehicle to a full stop. Engage parking brake Parking brake does not while transmission is in high range and engine is at idle hold vehicle stationary. speed. k. Shift transmission into N (Neutral), engage parking brake. Stop engine (TM 10-3930-675-10). AFTER ROAD TEST

NOTE Ensure vehicle has been cleaned of mud, gravel, etc., from the underbody, outside, and crew compartment area. l. Perform all AFTER operator/crew PMCS listed in the TM 10-3930-675-10 on machine. 7

SemiTransmission Oil Remove and replace transmission oil filters and oil Annual (900 Filter (Volume 2, WP 0140) and Lubrication Order (LO Hours) 10-3930-675-13).

8

SemiAnnual

Transmission Vent Hose

Replace servo filter and top off hydraulic fluid (Volume 2, WP 0227) and Lubrication Order (LO 10-3930-675-13).

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03/15/2011 Rel(1.8) root(pmcswp) wpno(I00009)

Engine will not stop.

TM 10-3930-675-23-1

Table 1.

ITEM NO.

INTERVAL

0048

Preventive Maintenance Checks and Services (PMCS) for the RTCH - Continued. ITEM TO BE CHECKED OR SERVICED

PROCEDURE

9

SemiHydraulic Annual (900 System Servo Hours) Filter

10

SemiHydraulic Replace pressure filters and top off hydraulic fluid Annual (900 System Pressure (Volume 2, WP 0227) and Lubrication Order (LO Hours) Filters 10-3930-675-13).

11

SemiHydraulic Replace breather filters (Volume 2, WP 0227) and Annual (900 System Breather Lubrication Order (LO 10-3930-675-13). Hours) Filters

12

SemiHydraulic Replace return filters and top off hydraulic fluid and Annual (900 Reservoir Return Lubrication Order (LO 10-3930-675-13). Hours) Filters

13

SemiHydraulic Annual (900 System Ball Hours) Valves

EQUIPMENT NOT READY/ AVAILABLE IF:

Replace servo filter and top off hydraulic fluid (Volume 2, WP 0227) and Lubrication Order (LO 10-3930-675-13).

a. Inspect all Hydraulic system ball valves for leaks, Hydraulic system ball valves are not operational. cracks, and loose or missing hardware. b. Check operation of all hydraulic system ball valves.

14

SemiFront Axle Brake Replace front axle brake cooling filters (Volume 2, Annual (900 Cooling Filters WP 0158) and Lubrication Order (LO 10-3930-675-13). Hours)

15

SemiFront Axle Drain and refill front axle differential housing and hub end Annual (900 Differential and Lubrication Order (LO 10-3930-675-13). Hours) Housing and Hub End

16

SemiRear Axle Brake Annual (900 Cooling Filters Hours)

17

SemiRear Axle Drain and refill rear axle differential housing and hub Annual (900 Differential end. Lubrication Order (LO 10-3930-675-13). Hours) Housing and Hub End

18

SemiAnnual

Front and Rear Axle Vent Hoses

19

SemiAnnual

Hydraulic Perform Hydraulic System Test Point Procedures. Test Any pressure outside the Pressure Checks Points 1 through 12 (Volume 2, WP 0245). limits specified in (Volume 2, WP 0245).

20

SemiAnnual

Parking Brakes

21

SemiTophandler Gear Drain and refill. Lubrication Order (LO 10-3930-675-13). Annual (900 Motors Hours)

Replace rear axle brake cooling filter and Lubrication Order (LO 10-3930-675-13).

Inspect for plugged hoses and valves. Clean if necessary.

Perform parking brake checks (Volume 2, WP 0150).

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TM 10-3930-675-23-1

Table 1.

ITEM NO.

INTERVAL

0048

Preventive Maintenance Checks and Services (PMCS) for the RTCH - Continued. ITEM TO BE CHECKED OR SERVICED

PROCEDURE

EQUIPMENT NOT READY/ AVAILABLE IF:

22

SemiEngine Bell Annual (900 Housing Hours)

Remove drain plug from bell housing and check for signs If any Class III leaks are of oil or water. If water or oil is noted, investigate source evident. and correct.

23

SemiAnnual

Bogie Wheel Assembly

Exercise bogie wheel assembly (TM 10-3930-675-10). Inspect and clean as required.

24

SemiAnnual

Cab Tracks and Locking Bars

Place cab and boom in transport mode (TM 10-3930-675-10) and check for free movement of cab rollers in tracks. Clean and inspect for damage. Replace any damaged component (Volume 2, WP 0179).

25

SemiAnnual

Cab Drain Valves Inspect two drain valves under cab. Press valve with two fingers to drain water.

26

SemiAnnual

Front and Rear Propeller Shafts

Perform cleaning inspection procedures of drive shafts IAW (Volume 2, WP 0143).

27

SemiAnnual

Cab Air Filters

Service cab air filters (Volume 2, WP 0199).

28

SemiAnnual

Cab Air Conditioner

Remove plug from condenser fan box behind cab. With engine and air conditioner running, inspect sight gauge on top of receiver-drier for bubbles. If bubbles are present, recharge air conditioning system IAW (Volume 2, WP 0248).

29

SemiFuel Tank Annual (900 Hours)

Remove drain plug from bottom of fuel tank to drain water and debris (WP 0074).

30

SemiBatteries Annual (900 Hours)

Perform battery service IAW (WP 0128).

If one or more batteries fail test. If hold-down brackets or hardware or slide-out trays are bent or damaged, and would prevent the batteries from being properly secured.

31

Annual

Brake Accumulators

Perform brake accumulator pre-charge check IAW (Volume 2, WP 0155).

Any pressure readings outside limits specified in (Volume 2, WP 0155).

32

Annual

Steering Accumulators

Perform steering accumulator pre-charge check IAW (Volume 2, WP 0155).

Any pressure readings outside limits specified in (Volume 2, WP 0155).

33

Biennial

Boom Support Locking Pin Bellows

Replace boom support pin rubber bellows IAW (Volume 2, WP 0235).

34

Biennial

Hydraulic System Oil

Drain and refill. Lubrication Order (LO 10-3930-675-13).

0048-7

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00009)

Drive shaft is damaged, missing hardware, or damaged U Joints.

TM 10-3930-675-23-1

Table 2. ITEM NO. PART NUMBER

0048

PMCS Mandatory Replacement Parts List.

NSN

NOMENCLATURE

QTY

Quarterly 1

LF9080

Filter, Engine Oil

1

2

FS1000

Filter, Fuel

1

3

WF207100

Filter, Engine Coolant

1

Semi-Annual 4

9238280610

Filter, Transmission Oil

2

5

9238990289

Filter, Transmission Oil, Internal, Coarse

1

6

9230710001

Filter, Servo, Hydraulic System

1

7

9230710002

Filter, Pressure, Hydraulic System

2

8

9216890009

Filter, Pressure, Hydraulic System

1

9

920130009

Filter, Hydraulic Reservoir, Breather

2

10

9231100668

Filter, Hydraulic Reservoir, Return

2

11

9231100669

Filter, Brake Cooling, Axles

2

12

9238990684

Washer, Copper, Hydraulic Motor Drain Plug

2

13

9238990685

Washer, Copper, Hydraulic Motor Drain Plug

3

END OF TASK END OF WORK PACKAGE

0048-8

03/15/2011 Rel(1.8) root(pmcswp) wpno(I00009)

TM 10-3930-675-23-1

CHAPTER 4 MAINTENANCE INSTRUCTIONS

TM 10-3930-675-23-1

0049

FIELD MAINTENANCE SERVICE UPON RECEIPT

INITIAL SETUP: References DA Form 5986-E DD Form 1397 SF Form 364

References (cont.) TM 10-3930-675-10 WP 0048

GENERAL

1.

When a new, used, or reconditioned RTCH is first received, determine whether it has been properly prepared for service and is in condition to perform its mission.

2.

Follow the inspection and servicing instructions below.

INSPECTION INSTRUCTIONS 1.

Read and follow all precautions and instructions on DD Form 1397.

2.

Remove all packing and shipping material, such as tape, tiedowns, protective covers, and shipping seals.

3.

Inspect equipment for any damage incurred during shipment. Check if equipment has been modified.

4.

Check equipment against packing slip to ensure shipment is complete. Report any discrepancies on SF Form 364.

5.

Remove all Basic Issue Item (BII), Additional Authorization List (AAL), and Components of End Item (COEI) equipment and stow IAW TM 10-3930-675-10.

END OF TASK SERVICING INSTRUCTIONS 1.

Service the vehicle IAW TM 10-3930-675-10 and Preventive Maintenance Checks and Services (PMCS) (WP 0048). Schedule the next PMCS on DA Form 5986-E.

2.

Refer to TM 10-3930-675-10 and perform functional checks of all major vehicle systems.

END OF TASK END OF WORK PACKAGE

0049-1/2 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00007)

TM 10-3930-675-23-1

0050

FIELD MAINTENANCE ENGINE ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Barring Tool, Engine (Volume 2, WP 0277, Table 1, Item 7) Guide, Electrical Connector (Volume 2, WP 0277, Table 1, Item 35) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54) Plate, Surface Adapter, Engine Stand (Volume 2, WP 0277, Table 1, Item 55) Sling, Engine and Transmission (Volume 2, WP 0277, Table 1, Item 68) Stand, Engine Rebuild (Volume 2, WP 0277, Table 1, Item 75) Stand, Maintenance, Automotive Engine Support (Volume 2, WP 0277, Table 1, Item 76) Wrench, Torque, Click, Ratcheting, 3/8 In. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Wrench, Torque, Click, Ratcheting, 1/2 In. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Lifting device, 3,000 lb minimum lifting capacity Materials/Parts Compound, Gasket Forming, Silicone (Volume 2, WP 0276, Table 1, Item 13) Diesel Fuel, DF-2 (Volume 2, WP 0276, Table 1, Item 21) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Gasket (Volume 2, WP 0278, Table 1, Item 19) Gasket (Volume 2, WP 0278, Table 1, Item 24)

Materials/Parts (cont.) Nut, Self-Locking (Volume 2, WP 0278, Table 1, Item 87) Washer, Lock (Volume 2, WP 0278, Table 1, Item 96) Qty: 12 Personnel Required (2) References WP 0051 WP 0089 Volume 2, WP 0139 Volume 2, WP 0143 Equipment Condition Boom raised to maximum angle (TM 10-3930-675-10) Cab in transport position (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185) Access covers and skid plates removed (Volume 2, WP 0175) Battery cables disconnected (WP 0129) Alternator removed (WP 0091) Coolant drained and coolant lines disconnected from engine (WP 0080) Oil drained from engine (WP 0059) Oil sampling supply hose disconnected (WP 0062) Transmission dipstick removed (Volume 2, WP 0138) Fuel supply and drain return hoses disconnected (WP 0075) Air intake ducts removed (WP 0072) Exhaust system disconnected from turbocharger (WP 0079) Turbocharger removed (WP 0073) Electrical interface wiring harness disconnected (WP 0100) Electrical wiring harness and leads disconnected from starter (WP 0093) Ether cold start system removed (WP 0077) Air conditioning compressor drive belt removed (Volume 2, WP 0251)

0050-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

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 engine 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.

NOTE Remove engine from front of vehicle using suitable 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. • Engine weighs 2,070 lb (940 kg). Lifting device must have sufficient capacity to lift engine. 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. • Fuel lines and hoses may contain residual amounts of fuel that may be spilled. To prevent personnel injury from slipping on spilled fuel, spilled fuel should be cleaned up immediately.

NOTE If A/C compressor is being removed for access, it is not necessary to disconnect refrigerant lines. 1.

Remove all tiedown straps and clamps securing A/C refrigerant lines to engine. Discard tiedown straps.

2.

Remove screw (Figure 1, Item 5), washer (Figure 1, Item 6), and nut (Figure 1, Item 7) securing drive belt adjustment arm (Figure 1, Item 8) to A/C compressor (Figure 1, Item 4).

3.

Remove screw (Figure 1, Item 5), washer (Figure 1, Item 6), and nut (Figure 1, Item 7) securing drive belt adjustment arm (Figure 1, Item 8) to engine mount bracket (Figure 1, Item 9). Remove drive belt adjustment arm and retain for installation.

4.

Remove screw (Figure 1, Item 1), washer (Figure 1, Item 2), and nut (Figure 1, Item 3) securing A/C compressor to engine mount bracket (Figure 1, Item 10).

0050-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued

NOTE When positioning A/C compressor and refrigerant lines free of engine, ensure refrigerant line connections are not loosened or broken, allowing refrigerant to escape from system. 5.

With assistance, remove A/C compressor (Figure 1, Item 4) with refrigerant lines attached and position free of engine compartment. 4

1,2,3 5,6,7

8

10

5,6,7

9

Figure 1.

M0647JCH

Engine Removal.

0050-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued 6.

Remove screw (Figure 2, Item 4), two washers (Figure 2, Item 3), locknut (Figure 2, Item 2), hose clamp (Figure 2, Item 5), and transmission vent hose (Figure 2, Item 6) from bracket (Figure 2, Item 1). Secure vent hose free of engine and discard locknut. 2,3,4

5

6

1

M0648JCH

Figure 2.

Engine Removal.

NOTE Tag transmission coolant lines to ensure correct installation. 7.

Loosen hose clamp (Figure 3, Item 8) and disconnect coolant inlet hose (Figure 3, Item 7) from transmission oil cooler (Figure 3, Item 6).

8.

Loosen hose clamp (Figure 3, Item 8) and disconnect coolant outlet hose (Figure 3, Item 9) from transmission oil cooler (Figure 3, Item 6).

NOTE When removing transmission oil cooler for access, it is not necessary to disconnect oil hoses from transmission oil cooler. 9.

Remove hose clamps, screws, washers, and nuts as needed to release transmission oil hoses.

10.

Disconnect hydraulic hose (Figure 3, Item 2).

11.

Remove three screws (Figure 3, Item 3) and washers (Figure 3, Item 4) securing transmission oil cooler bracket (Figure 3, Item 5) to flywheel housing (Figure 3, Item 1).

12.

With assistance, remove transmission oil cooler (Figure 3, Item 6) with hoses attached from flywheel housing (Figure 3, Item 1). Position transmission oil cooler and hoses free of engine lift area.

0050-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued 3,4 5 2 1 6

7

8 9 8

Figure 3.

M0649JCH

Engine Removal.

NOTE When removing transmission oil filters and bracket for access, it is not necessary to disconnect transmission oil hoses from filters. 13.

Remove two screws (Figure 4, Item 2) and washers (Figure 4, Item 3) securing transmission oil filter bracket (Figure 4, Item 4) to flywheel housing (Figure 4, Item 1).

14.

Remove transmission oil filters (Figure 4, Item 5) and bracket (Figure 4, Item 4) from flywheel housing (Figure 4, Item 1). Position free of engine lift area. 1

2,3 4

M0650JCH

5

Figure 4.

Engine Removal

0050-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued

NOTE When removing cooling fan hydraulic pump from engine, it is not necessary to disconnect two hydraulic hoses attached. 15.

Remove cooling fan hydraulic pump from drive adapter of engine and set pump aside (WP 0089).

WARNING

Engine weighs 2,070 lb (940 kg). Lifting device must have sufficient capacity to lift engine. Failure to follow this warning may result in death or injury to personnel. 16.

Connect engine lifting fixture and suitable lifting device to engine front and rear lifting brackets. Take slack out of chains.

17.

Remove four screws (Figure 5, Item 4), access cover (Figure 5, Item 1), and gasket (Figure 5, Item 2) from bottom of flywheel housing (Figure 5, Item 3). Discard gasket. 2

3

1

4

M0651JCH

Figure 5.

Engine Removal.

0050-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued 18.

Remove 12 screws (Figure 6, Item 1) and lockwashers (Figure 6, Item 2) securing transmission to engine flywheel housing (Figure 6, Item 3). Discard lockwashers.

1,2

3

M0652JCH

Figure 6.

Engine Removal.

NOTE Ensure engine weight is supported by lifting device. 19.

Remove four screws (Figure 7, Item 2) securing right rear engine and transmission mounting bracket (Figure 7, Item 1) to flywheel housing (Figure 7, Item 3).

2 1

3 M0653JCH

Figure 7.

Engine Removal.

0050-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued 20.

Remove four screws (Figure 8, Item 2) securing left rear engine and transmission mounting bracket (Figure 8, Item 3) to flywheel housing (Figure 8, Item 1).

1

2 2

3

M0654JCH

Figure 8. 21.

Engine Removal.

Disconnect front engine mounts from engine and frame. Move front engine mounts forward to gain access to remove engine (WP 0051).

NOTE • Damper plates and torque converter should remain with engine during engine removal. • It may be necessary to tap on transmission-to-engine connection point with plastic-faced hammer to break seal between two units. 22.

Carefully separate engine from transmission and lift engine from vehicle.

0050-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued

NOTE If replacement engine is being installed, inspect removed engine for components to be removed and transferred to replacement engine. 23.

Secure engine on suitable stand or in container.

24.

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

1

2

3 M0655JCH

Figure 9.

Engine Removal.

0050-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

REMOVAL - Continued

NOTE Flywheel is secured to transmission damper plates with 12 screws. 25.

With assistance, bar engine in clockwise direction using accessory drive while observing through access hole. Stop rotation when screw is visible through access hole.

26.

Remove screw (Figure 10, Item 1) securing flywheel to damper plate.

27.

Repeat Steps 25 and 26 to remove remaining eleven screws (Figure 10, Item 1).

28.

Upon removal of last screw, insert guide stud and secure to damper plate.

1

M0656JCH

Figure 10.

Engine 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. 29.

Remove torque converter and damper plates from engine.

END OF TASK

0050-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION

WARNING

Engine weighs 2,070 lb (940 kg). Lifting device must have sufficient capacity to lift engine. Failure to follow this warning may result in death or injury to personnel.

NOTE • Ensure all bracket mounting, engine mating, and transmission mating surfaces have been cleaned and are free of old gasket forming compound and gasket material. • Prior to lowering engine into vehicle, ensure flywheel-to-damper plate screw hole is visible through access hole in flywheel housing. 1.

Install torque converter and damper plates on transmission (Volume 2, WP 0139).

2.

Using suitable lifting device and engine lifting fixture, lower engine into vehicle.

3.

Apply coat of silicone gasket forming compound to engine and transmission mating surface.

NOTE It may be necessary to adjust transmission damper plate by hand to align guide stud with mating flywheel screw hole. 4.

Position engine to allow damper plate guide stud to pass through flywheel-to-damper screw hole and flywheel housing access.

0050-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION - Continued

NOTE Flywheel and damper plates are secured with 12 screws; final tightening is done after all screws are installed. 5.

Remove guide stud and install screw (Figure 11, Item 1). Tighten screw hand-tight.

6.

Bar engine over until next screw hole is visible and install screw (Figure 11, Item 1). Tighten screw hand-tight.

7.

Repeat Step 6 for remaining screws until 12 screws are installed securing flywheel to damper plate.

8.

Bar engine over clockwise and tighten each screw (Figure 11, Item 1) to 48 ft-lb (65 N•m).

1

M0656JCH

Figure 11.

Engine Installation.

0050-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION - Continued 9.

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

1,2

3

M0652JCH

Figure 12. 10.

Engine Installation.

Install access cover (Figure 13, Item 1) and new gasket (Figure 13, Item 2) on bottom of flywheel housing (Figure 13, Item 3) with four screws (Figure 13, Item 4). 2

3

1

4

M0651JCH

Figure 13.

Engine Installation.

0050-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION - Continued 11.

Install cover (Figure 14, Item 3) and new gasket (Figure 14, Item 1) with two screws (Figure 14, Item 2) over flywheel-to-damper plate screw access.

1

2

3 M0655JCH

Figure 14. 12.

Engine Installation.

Apply gasket forming compound to mounting surface and install four screws (Figure 15, Item 2) to secure right rear engine and transmission mounting bracket (Figure 15, Item 1) to flywheel housing (Figure 15, Item 3). Tighten screws to 116 ft-lb (157 N•m).

2 1

3 M0653JCH

Figure 15.

Engine Installation.

0050-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION - Continued 13.

Apply gasket forming compound to mounting surface and install four screws (Figure 16, Item 2) to secure left rear engine and transmission mounting bracket (Figure 16, Item 3) to flywheel housing (Figure 16, Item 1). Tighten screws to 116 ft-lb (157 N•m).

1

2 2

3

M0654JCH

Figure 16.

Engine Installation.

0050-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION - Continued 14.

Install front engine mounts on frame and engine (WP 0051).

15.

Release tension on engine lifting fixture chains and disconnect lifting device and lifting fixture from engine lifting brackets.

16.

Apply gasket forming compound to mounting surface on flywheel housing (Figure 17, Item 1) and install two screws (Figure 17, Item 2) and washers (Figure 17, Item 3) to secure transmission oil filter bracket (Figure 17, Item 4) with transmission oil filters (Figure 17, Item 5) and hoses in place. Tighten screws to 116 ft-lb (157 N•m). 1

2,3 4

M0650JCH

5

Figure 17.

Engine Installation.

0050-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION - Continued 17.

Install cooling fan hydraulic pump on drive adapter of engine (WP 0089).

18.

Apply gasket forming compound to mounting surface on flywheel housing (Figure 18, Item 1) and install three screws (Figure 18, Item 3) and washers (Figure 18, Item 4) to secure transmission oil cooler bracket (Figure 18, Item 5) with oil cooler (Figure 18, Item 6) and transmission oil hoses. Tighten screws to 116 ft-lb (157 N•m).

19.

Connect hydraulic hose (Figure 18, Item 2).

20.

Install hose clamps, screws, washers, and nuts as necessary to secure transmission oil hoses.

21.

Install coolant inlet hose (Figure 18, Item 7) and coolant hose outlet (Figure 18, Item 9) on transmission oil cooler (Figure 18, Item 6) and secure with hose clamps (Figure 18, Item 8). 3,4 5 2 1 6

7

8 9 8

Figure 18.

Engine Installation.

0050-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

M0649JCH

TM 10-3930-675-23-1

0050

INSTALLATION - Continued 22.

Install transmission vent hose (Figure 19, Item 6), hose clamp (Figure 19, Item 5), screw (Figure 19, Item 4), two washers (Figure 19, Item 3), and new locknut (Figure 19, Item 2) on bracket (Figure 19, Item 1). 2,3,4

5

6

1

M0648JCH

Figure 19.

Engine Installation.

0050-18

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

0050

INSTALLATION - Continued 23.

Position A/C compressor (Figure 20, Item 4) with refrigerant lines on engine mount bracket (Figure 20, Item 10) and secure with screw (Figure 20, Item 1), washer (Figure 20, Item 2), and nut (Figure 20, Item 3).

24.

Position drive belt adjustment arm (Figure 20, Item 8) and secure one end to engine mount bracket (Figure 20, Item 9) and opposite end to A/C compressor (Figure 20, Item 4) with two screws (Figure 20, Item 5), washers (Figure 20, Item 6), and nuts (Figure 20, Item 7). 4

1,2,3 5,6,7

8

10

5,6,7

9

Figure 20.

M0647JCH

Engine Installation.

END OF TASK

0050-19

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Install and adjust A/C compressor drive belt (Volume 2, WP 0251).

2.

Install ether cold start system (WP 0077).

3.

Connect electrical wiring harness and leads to starter (WP 0093).

4.

Connect electrical interface wiring harness to ECU (WP 0100).

5.

Install turbocharger (WP 0073).

6.

Connect exhaust system to turbocharger (WP 0079).

7.

Install air intake ducts (WP 0072).

8.

Connect fuel supply and drain return hoses (WP 0075).

9.

Install transmission dipstick (Volume 2, WP 0138).

10.

Connect oil sampling supply hose to engine (WP 0062).

11.

Connect coolant lines to engine (WP 0080).

12.

Install alternator (WP 0091).

13.

Connect battery cables (WP 0129).

14.

Check and fill all fluids (fuel, coolant, engine oil, transmission oil) to proper level (WP 0047).

CAUTION If normal engine oil pressure is not indicated within 15 seconds, shut down engine immediately. Failure to follow this caution may result in serious engine damage. 15.

Operate engine for three minutes, shut down, and check for fluid leaks and proper indications (TM 10-3930-675-10).

16.

Operate engine to normal temperature and check operation (TM 10-3930-675-10).

17.

Install access covers and skid plates (Volume 2, WP 0175).

18.

Install engine cover (Volume 2, WP 0185).

19.

Return cab to operational position and lower boom (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0050-20

03/15/2011 Rel(1.8) root(maintwp) wpno(M00010)

0050

TM 10-3930-675-23-1

0051

FIELD MAINTENANCE ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Stand, Vehicle Support (Volume 2, WP 0277, Table 1, Item 77) Wrench, Torque, Click, Ratcheting, 3/4 in. Drive, 600 ft-lb (Volume 2, WP 0277, Table 1, Item 96) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Sealing Compound Dissimilar Metal Protection (Volume 2, WP 0276, Table 1, Item 58) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Personnel Required (2) Equipment Condition Engine cover removed (Volume 2, WP 0185) Cab in transport position (TM 10-3930-675-10) Access covers removed (Volume 2, WP 0175)

0051-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

TM 10-3930-675-23-1

0051

LIFTING BRACKETS REMOVAL 1.

Remove four screws (Figure 1, Item 1) securing front lifting bracket (Figure 1, Item 2) and two screws (Figure 1, Item 4) securing rear lifting bracket (Figure 1, Item 3).

2.

Remove front and rear lifting brackets (Figure 1, Items 2 and 3) from cylinder head (Figure 1, Item 5).

2 3 1

1

4

5 Figure 1.

Lifting Brackets Removal.

END OF TASK

0051-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

M0657JCH

TM 10-3930-675-23-1

0051

LIFTING BRACKETS INSTALLATION

CAUTION DO NOT use or install a cracked, bent, or otherwise damaged lifting bracket. Do not weld a cracked bracket. Doing so may cause severe equipment damage during lifting operations.

NOTE Ensure lifting brackets are not cracked or bent and are clean and free of dirt. 1.

Position front lifting bracket (Figure 2, Item 2) and secure with four screws (Figure 2, Item 1). Tighten screws to 35 ft-lb (47 N•m).

2.

Position rear lifting bracket (Figure 2, Item 3) and secure with two screws (Figure 2, Item 4). Tighten screws to 60 ft-lb (81 N•m).

2 3 1

1

4

5 Figure 2.

Lifting Brackets Installation.

END OF TASK

0051-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

M0657JCH

TM 10-3930-675-23-1

0051

FRONT ENGINE MOUNT REMOVAL

CAUTION Position trestle under front of engine to assist with supporting weight while front engine mounts are not in place. DO NOT, however, position trestle under oil pan. Damage to oil pan may result. 1.

Position suitable lifting device and attach to engine front lifting bracket (Figure 2, Item 2).

NOTE Right and left front engine shock mounts are removed in the same manner. Perform steps 2 thru 5 on both front engine shock mounts. 2.

Loosen two jamnuts (Figure 3, Item 9) and adjusting screws (Figure 3, Item 8).

NOTE Adjust lifting device to support weight of engine without applying tension on mounting hardware. 3.

Remove screw (Figure 3, Item 5) and washer (Figure 3, Item 6) securing front engine mount (Figure 3, Item 4) to shock mount (Figure 3, Item 7).

4.

Remove two nuts (Figure 3, Item 13), four washers (Figure 3, Items 11 and 12), and two screws (Figure 3, Item 10) securing shock mount (Figure 3, Item 7) in place.

5.

Lift engine (Figure 3, Item 1) slightly to relieve pressure on shock mount (Figure 3, Item 7). Remove shock mount.

NOTE To remove front engine mount, perform steps 6 and 7. 6.

Remove six screws (Figure 3, Item 2) and washers (Figure 3, Item 3) securing front engine mount (Figure 3, Item 4) to engine (Figure 3, Item 1).

7.

Remove front engine mount (Figure 3, Item 4) from vehicle.

END OF TASK

0051-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

TM 10-3930-675-23-1

0051

FRONT ENGINE MOUNT INSTALLATION

NOTE If front engine mount was removed, perform step 1 to reinstall. 1.

Apply a light coat of sealing compound to front engine mount (Figure 3, Item 4) and install on engine (Figure 3, Item 1) with six washers (Figure 3, Item 3) and screws (Figure 3, Item 2). Tighten screws to 50 ft-lb (68 N•m).

NOTE Ensure engine is supported by suitable lifting device and remove trestle from under front of engine. 2.

Position shock mount (Figure 3, Item 7) and secure in place with two screws (Figure 3, Item 10), four washers (Figure 3, Items 11 and 12), and two nuts (Figure 3, Item 13). Tighten nuts to 125 ft-lb (169 N•m).

3.

Position front engine mount (Figure 3, Item 4) over shock mount (Figure 3, Item 7) and secure with screw (Figure 3, Item 5) and washer (Figure 3, Item 6). Tighten screw to 288 ft-lb (390 N•m).

4.

Set front engine mount adjusting screws (Figure 3, Item 8) for a clearance of 0.12 in. (3 mm) and tighten jamnuts (Figure 3, Item 9).

1 2,3 4 5,6 7 8 8 9 10,11,12,13

9

0.12 in. (3 mm) M0658JCH

Figure 3.

Front Engine Mount Installation.

END OF TASK

0051-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

TM 10-3930-675-23-1

0051

REAR ENGINE MOUNT REMOVAL

CAUTION Position trestle under rear of engine to assist with supporting weight while rear engine mount is not in place. DO NOT, however, position trestle under oil pan. Damage to oil pan may result. 1.

Position suitable lifting device and attach to engine lifting brackets.

NOTE Left and right rear engine shock mounts are removed in the same manner. 2.

Loosen two jamnuts (Figure 4, Item 10) and adjusting screws (Figure 4, Item 9).

NOTE Adjust lifting device to support weight of engine without applying tension on mounting hardware. 3.

Remove four screws (Figure 4, Item 5) and washers (Figure 4, Item 6) to disconnect rear support bracket (Figure 4, Item 4) from engine.

4.

Remove two screws (Figure 4, Item 7) and washers (Figure 4, Item 8) to disconnect rear support bracket (Figure 4, Item 4) from transmission.

5.

Remove screw (Figure 4, Item 2) and washer (Figure 4, Item 3) securing rear support bracket (Figure 4, Item 4) to shock mount (Figure 4, Item 1).

6.

With assistance, lift rear support bracket (Figure 4, Item 4) from installed location.

7.

Remove two nuts (Figure 4, Item 14), four washers (Figure 4, Items 12 and 13), two screws (Figure 4, Item 11), and shock mount (Figure 4, Item 1).

END OF TASK

0051-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

TM 10-3930-675-23-1

0051

REAR ENGINE MOUNT INSTALLATION 1.

Position shock mount (Figure 4, Item 1) and secure in place with two screws (Figure 4, Item 11), four washers (Figure 4, Items 12 and 13), and two nuts (Figure 4, Item 14). Tighten nuts to 125 ft-lb (169 N•m).

NOTE Ensure engine and transmission are supported by suitable lifting device and remove trestle from under engine. 2.

With assistance, lower rear support bracket (Figure 4, Item 4) into position over shock mount (Figure 4, Item 1) and secure with screw (Figure 4, Item 2) and washer (Figure 4, Item 3). Tighten screw to 288 ft-lb (390 N•m).

3.

Position rear support bracket (Figure 4, Item 4) on engine and secure four screws (Figure 4, Item 5) and washers (Figure 4, Item 6). Tighten screws to 115 ft-lb (156 N•m).

4.

Position rear support bracket (Figure 4, Item 4) on transmission and secure with two screws (Figure 4, Item 7) and washers (Figure 4, Item 8). Tighten screws to 100 ft-lb (135 N•m).

5.

Set rear support bracket adjusting screws (Figure 4, Item 9) for a clearance of 0.12 in. (3 mm) and tighten jamnuts (Figure 4, Item 10).

4

10

2,3 1

5,6 5,6

9 7,8

11,12,13,14

10 9

0.12 in. (3 mm) M0659JCH

Figure 4.

Rear Engine Mount Removal.

END OF TASK

0051-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Install access covers (Volume 2, WP 0175).

2.

Return cab to operational position (TM 10-3930-675-10).

3.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0051-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00011)

0051

TM 10-3930-675-23-1

0052

FIELD MAINTENANCE CYLINDER HEAD REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Expansion Plug Driver (Volume 2, WP 0277, Table 1, Item 25) Gage, Capscrew, Cylinder Head (Volume 2, WP 0277, Table 1, Item 26) Lifting Bracket, Cylinder Head (Volume 2, WP 0277, Table 1, Item 51) Straight Edge (36 in. Length) (Volume 2, WP 0277, Table 1, Item 78) Materials/Parts Abrasive Pad (Volume 2, WP 0276, Table 1, Item 1) Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Diesel Fuel, DF-2 Grade Bulk (Volume 2, WP 0276, Table 1, Item 21)

Materials/Parts (cont.) Oil, Lubricating, Engine (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 71) References TM 10-3930-675-10 WP 0056 Equipment Condition Air intake ducts removed (WP 0072) Rocker arm cover removed (WP 0057) Turbocharger removed (WP 0073) Exhaust manifold removed (WP 0063) Cooling system drained (WP 0080)

REMOVAL 1.

Remove four screws (Figure 1, Item 1) securing front lifting bracket (Figure 1,Item 2) and two screws (Figure 1, Item 4) securing rear lifting bracket (Figure 1, Item 3) to cylinder head (Figure 1, Item 5).

2 3 1

1

4

5 Figure 1.

Cylinder Head Removal.

0052-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

M0657JCH

TM 10-3930-675-23-1

0052

REMOVAL - Continued 2.

Disconnect connector (Figure 2, Item 1) of cylinder head wiring harness (Figure 2,Item 3) from engine harness (Figure 2, Item 2).

1

2

3

M0660JCH

Figure 2.

Cylinder Head Removal.

NOTE Tag wiring harness to identify injector connections and positions prior to removal to ensure correct connection on installation. 3.

Disconnect six fuel injector connectors (Figure 3, Item 4) from cylinder head wiring harness (Figure 3, Item 1).

4.

Remove screws (Figure 3, Item 2) securing clamps (Figure 3, Item 3) and cylinder head wiring harness (Figure 3, Item 1) in place and remove cylinder head wiring harness. 2 3 1

4

4

Figure 3.

M0661JCH

Cylinder Head Removal.

0052-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

REMOVAL - Continued

NOTE Mark position of valve push tubes and injector push rods. Push tubes and rods must be installed in the same positions during installation. 5.

Loosen rocker lever adjusting screws (Figure 4, Item 1). Remove valve push tubes (Figure 4, Item 3) and injector push rods (Figure 4, Item 2). 2

1

3

Figure 4. 6.

M0662JCH

Cylinder Head Removal.

Remove rocker arm assembly (WP 0056).

NOTE Mark position of crossheads prior to removal. Crossheads must be installed in the same position during assembly. 7.

Remove crossheads (Figure 5, Item 1). 1

M0663JCH

Figure 5.

Cylinder Head Removal.

0052-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

REMOVAL - Continued

NOTE Rocker lever housing and intake manifold are removed as a single unit. 8.

Remove 24 screws (Figure 6, Item 1) securing rocker lever housing (Figure 6, Item 2) and gasket (Figure 6, Item 3) to cylinder head (Figure 6, Item 4). Remove rocker lever housing and intake manifold as a single unit. 2

1

3

4

Figure 6.

M0664JCH

Cylinder Head Removal.

9.

Disconnect fuel supply line (Figure 7, Item 1) and fuel drain line (Figure 7, Item 3) from cylinder head (Figure 7, Item 5).

10.

Remove seven 12-point cylinder head screws (Figure 7, Item 2) and sealing washers (Figure 7, Item 4) from fuel pump side of engine. 2

2

2

3 4

1

5

M0665JCH

Figure 7.

Cylinder Head Removal.

0052-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

REMOVAL - Continued

NOTE Three cylinder head screws are located inside intake ports. 11.

Remove remaining 32 cylinder head screws in sequence shown in Figure 8. 22 28 26

18 16

12

8 6

2

4 7

20 10 14 17 24 27 30

32

29 31 25

11

21 15

Figure 8. 12.

9

1 3

5

19 13

23

M0666JCH

Cylinder Head Removal.

Install cylinder head lifting bracket (Figure 9, Item 1) on cylinder head (Figure 9, Item 2) and secure with two rocker lever support mounting screws and two long rocker housing screws. Tighten screws to 35 ft-lb (47 N•m). 1

2

M0667JCH

Figure 9.

Cylinder Head Removal.

0052-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

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 Place cylinder head on wooden blocks to prevent damage to combustion face. 13.

Attach lifting device to cylinder head lifting bracket (Figure 10, Item 1). Lift cylinder head (Figure 10, Item 2) from engine and place on wooden blocks. Remove and discard head gasket (Figure 10, Item 3). 1

2

3

M0668JCH

Figure 10. Cylinder Head Removal. END OF TASK

0052-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

CLEANING

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.

NOTE Place clean, lint-free rags over cam followers and above pistons to prevent dirt and other foreign matter from entering engine. Plug or cover coolant and oil passages in cylinder block deck. 1.

Remove all gasket material from cylinder block deck surface.

CAUTION DO NOT use caustic or acid solutions to clean cylinder head screws. Doing so will result in damage to equipment. 2.

Clean threads of cylinder head screws with cleaning compound, solvent and wire brush.

WARNING

• When using steam cleaner, wear protective clothing and eye protection. Hot steam will cause serious burns. • 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. 3.

Steam clean cylinder head and dry with compressed air.

4.

Use Abrasive Pad to clean exhaust gasket surface, rocker housing gasket surface, and combustion face of cylinder head.

END OF TASK

0052-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

INSPECTION 1.

Visually inspect fuel drillings and water passages for restrictions or foreign material. Remove any obstructions.

NOTE If conditions in steps 2 and 3 below are found, cylinder head must be disassembled and repaired. If conditions are not noted, proceed to step 4. 2.

Visually inspect valves (Figure 11, Item 1) and valve springs (Figure 11, Item 4) for cracks, bent or broken valve stems (Figure 11, Item 2), broken valve spring collets (Figure 11, Item 3), or other damage.

3.

Visually inspect valves (Figure 11, Item 1) for indications of leakage or burning. 1

2 3 4

M0669JCH

Figure 11. 4.

Cylinder Head Inspection.

Perform leak test for exhaust valves as follows: a.

Place cylinder head (Figure 12, Item 1) on work bench with exhaust ports facing up.

b.

Pour fuel into exhaust port (Figure 12, Item 2) until full.

c.

If fuel drips (Figure 12, Item 3) or runs down face of head within 30 seconds, disassemble and repair cylinder head.

d.

Perform steps b and c for each exhaust port.

0052-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

INSPECTION - Continued 1

2

3

M0670JCH

Figure 12. 5.

Cylinder Head Inspection.

Perform leak test for intake valves as follows: a.

Place cylinder head on work bench with exhaust ports facing up.

b.

Pour fuel into one intake port until full.

NOTE Each intake port supplies two cylinders on M Series cylinder heads. c.

If fuel drips or runs down face of cylinder head within 30 seconds, disassemble and repair cylinder head.

d.

Perform steps b and c for all six cylinders.

0052-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

INSPECTION - Continued

NOTE Dimensions CC and DD must be checked from front to rear of cylinder head if head is going to be rebuilt. 6.

Measure flatness of cylinder head combustion face surface as follows: a.

AA and BB (corner to corner).

b.

CC (across combustion face).

c.

DD (across entire head surface).

d.

Measurements must be as noted in Table 1.

D B

A

B

Figure 13. Table 1.

A

D

C

M0671JCH

Cylinder Head Inspection.

Cylinder Head Flatness Measurements.

CYLINDER HEADFLATNESS

MM

MAXIMUM

ALLOWABLE DEVIATION IN.

AA and BB

0.200

MAX

0.008

CC

0.076

MAX

0.003

DD

0.127

MAX

0.005

0052-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

INSPECTION - Continued

NOTE Use slot marked for L10 cylinder head screws when checking M11 cylinder head screws. 7.

Check free length of 32 cylinder head screws (Figure 14, Item 2) using screw length gauge (Figure 14, Item 1). If end of screw touches foot of gauge, screw is too long and must be replaced. If there is clearance between end of screw and bottom base of gauge, screw can be reused. 1

Clearance 2

Figure 14. 8.

M0672JCH

Cylinder Head Inspection.

Inspect push rods (Figure 15, Item 2) and push tubes (Figure 15, Item 1) for excessive or uneven wear and bending. If push rod or tube is bent, shows excessive wear, or is filled with oil, it must be replaced.

2

M0673JCH

1 Figure 15.

Cylinder Head Inspection.

END OF TASK

0052-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

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.

CAUTION DO NOT drop cylinder head on gasket. Gasket material can be damaged.

NOTE Ensure shipping plug and plastic insert are removed from fuel inlet and fuel drain passage. If plastic insert is not removed from passage of fuel inlet line connection, engine will not start. 1.

Position new cylinder head gasket (Figure 16, Item 5) on engine block and set cylinder head (Figure16, Item 1) in place.

2.

Apply a light coating of clean lubricating oil to thread (Figure 16, Item 4) and flange (Figure 16, Item 3) area of cylinder head screws (Figure 16, Item 2).

NOTE Ensure three cylinder head screws are installed inside intake ports. 3.

Install and hand-tighten 32 cylinder head screws (Figure 16, Item 2).

1

5

2

4 Figure 16.

Cylinder Head Installation.

0052-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

3

M0686JCH

TM 10-3930-675-23-1

0052

INSTALLATION - Continued 4.

Tighten cylinder head screws to 100 ft-lb (136 N•m) in sequence shown in Figure 17. Repeat sequence and tighten to 160 ft-lb (217 N•m). 22 28 26

18 16

12

8 6

2

4 7

20 10 14 17 24 27 30

32

29 31 25

11

21

Figure 17.

9

1 3

15

19

5

13

23

M0687JCH

Cylinder Head Installation.

5.

Tighten cylinder head screws (Figure 18, Item 2) an additional 90 degrees after completing step 4.

6.

Install seven new sealing washers (Figure 18, Item 4) and screws (Figure 18, Item 2) on fuel pump side of cylinder head (Figure 18, Item 5).

7.

Connect fuel supply line (Figure 18, Item 1) and fuel drain line (Figure 18, Item 3). 2

2

2

3 4

1

5

M0665JCH

Figure 18.

Cylinder Head Installation.

0052-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

INSTALLATION - Continued 8.

Tighten cylinder head screws to 50 ft-lb (68 N•m) in sequence shown in Figure 19.

7

5

3

2

1

4

6

M0688JCH

Figure 19.

Cylinder Head Installation.

NOTE Ensure rocker lever housing is clean and free of old gasket material. 9.

Install new gasket (Figure 20, Item 3) and rocker lever housing (Figure 20, Item 2) on cylinder head (Figure 20, Item 4).

10.

Install and tighten 24 screws (Figure 20, Item 1) to 25 ft-lb (34 N•m) in sequence shown in Figure 21. Repeat sequence, tightening to 45 ft-lb (61 N•m). 2

1

3

4

Figure 20.

Cylinder Head Installation.

0052-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

M0664JCH

TM 10-3930-675-23-1

0052

INSTALLATION - Continued 15

11

1

7

13 17

3 5

22 19

24

21 20 16 12

9

Figure 21.

8

2 4

6 10 14 18

23

M0690JCH

Cylinder Head Installation.

11.

Install rocker arm assembly (WP 0056).

12.

Position cylinder head wiring harness (Figure 22, Item 3). Connect cylinder head wiring harness connector (Figure 22, Item 1) to engine wiring harness (Figure 22, Item 2).

1

2

3 Figure 22.

M0660JCH

Cylinder Head Installation.

0052-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

TM 10-3930-675-23-1

0052

INSTALLATION - Continued 13.

Install wire clamps (Figure 23, Item 3) and secure cylinder head wiring harness (Figure 23, Item 1) in place with screws (Figure 23, Item 2). Tighten screws to 15 ft-lb (20 N•m).

14.

Connect six fuel injector connectors (Figure 23, Item 4) to cylinder head wiring harness (Figure 23, Item 1). 2 3 1

4

4

M0661JCH

Figure 23. Cylinder Head Removal.

NOTE Crossheads must be installed in the same position from which they were removed. 15.

Install crossheads (Figure 23, Item 1).

16.

Apply a light coat of clean lubricating oil to ball end of valve push tubes (Figure 23, Item 2) and injector push rods (Figure 23, Item 3).

NOTE Injector push rods are smaller diameter and longer than valve push tubes. Both push rods and push tubes must be installed as noted during removal. 17.

Install valve push tubes (Figure 23, Item 2) and injector push rods (Figure 23, Item 3) as noted during removal. 1

2

3

Figure 24.

2

Cylinder Head Installation.

0052-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

M0691JCH

TM 10-3930-675-23-1

INSTALLATION - Continued 18.

Adjust valves and injectors (WP 0056).

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install exhaust manifold (WP 0063).

2.

Install turbocharger (WP 0073).

3.

Install rocker arm cover (WP 0057).

4.

Install air intake ducts (WP 0072).

5.

Fill cooling system (WP 0080).

6.

Operate engine and check for leaks (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0052-17/18 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00012)

0052

TM 10-3930-675-23-1

0053

FIELD MAINTENANCE VIBRATION DAMPER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Barring Tool, Engine (Volume 2, WP 0277, Table 1, Item 7) Guide Roller and Pin Kit Assy (Volume 2, WP 0277, Table 1, Item 36) Indicator, Dial (Volume 2, WP 0277, Table 1, Item 40) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95)

Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)

0053-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00013)

TM 10-3930-675-23-1

0053

REMOVAL 1.

Remove two screws (Figure 1, Item 1) from clamping plate (Figure 1, Item 3). Install guide studs (Figure 1, Item 2) in holes.

2.

Remove three remaining screws (Figure 1, Item 1) and replace with guide studs (Figure 1, Item 2).

CAUTION DO NOT use hammer or screwdriver to remove vibration damper. These tools can damage vibration damper. 3.

Remove clamping plate (Figure 1, Item 3), crankshaft pulley (Figure 1, Item 5), and vibration damper (Figure 1, Item 4) from engine. 3 4

5

2

1

3

M0700JCH

Figure 1. Vibration Damper Removal. END OF TASK INSPECTION

NOTE Ensure vibration damper has been cleaned and is free of dirt, grease, and other foreign matter. 1.

Check mounting web for cracks and housing for dents or raised surfaces. If any of these conditions are noted, vibration damper must be replaced.

2.

Scrape paint from four locations on either side of vibration damper as shown.

NOTE • Thickness check will result in a total of eight measurements. • If thickness recorded varies more than 0.010 in. (0.25 mm) between any of eight measurements, or if thickness at any one point exceeds 1.772 in. (45 mm), replace vibration damper. 3.

Measure and record thickness of vibration damper at two places on each of four selected locations as follows: a.

Measure thickness at 0.125 in. (3.18 mm) from outer lip.

0053-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00013)

TM 10-3930-675-23-1

0053

INSPECTION - Continued b.

Measure thickness at 1.0 in. (25.4 mm) from outer lip.

0.125 in. (3.18 mm)

1 in. (25.4 mm) Figure 2.

M0701JCH

Thickness Measure

NOTE Eccentricity (out of round) and wobble (face alignment) checks are performed to verify correct installation and serviceability of vibration damper. If either check exceeds 0.011 in. (0.28 mm), vibration damper is defective and must be replaced. 4.

Attach dial indicator to front cover as indicated and "0" dial indicator. Manually bar engine over one complete revolution (360 degrees) and record total movement of dial indicator.

ECCENTRICITY CHECK

Figure 3.

Eccentricity Check.

0053-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00013)

M0702JCH

TM 10-3930-675-23-1

0053

INSPECTION - Continued

NOTE Ensure crankshaft is to front or rear of engine and “0" dial indicator. 5.

Position dial indicator to measure wobble (face alignment) as shown. Manually bar engine over one complete revolution (360 degrees) and record total indicator movement.

WOBBLE CHECK

Figure 4.

Wobble Check.

END OF TASK

0053-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00013)

M0703JCH

TM 10-3930-675-23-1

0053

INSTALLATION

NOTE Ensure mounting surface of crankshaft is clean and free of dirt. 1.

Position vibration damper (Figure 5, Item 4) over guide studs (Figure 5, Item 2) and slide in place.

NOTE Ensure mounting screw threads are lubricated with clean oil prior to installation. 2.

Install clamping plate (Figure 5, Item 3) and crankshaft pulley (Figure 5, Item 5). Remove three guide studs (Figure 5, Item 2) and install screws (Figure 5, Item 1) hand-tight.

3.

Remove two guide studs (Figure 5, Item 2) and install remaining screws (Figure 5, Item 1). Tighten all screws in a star pattern to 150 ft-lb (203 N•m).

3 4

5

2

1

3 Figure 5.

Vibration Damper Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Start engine (TM 10-3930-675-10) and check operation.

2.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0053-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00013)

M0704JCH

TM 10-3930-675-23-1

0054

FIELD MAINTENANCE FLYWHEEL ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Attachment Dial (Volume 2, WP 0277, Table 1, Item 6) Barring Tool, Engine (Volume 2, WP 0277, Table 1, Item 7) Guide Roller and Pin Kit Assy (Volume 2, WP 0277, Table 1, Item 36) Indicator, Dial (Volume 2, WP 0277, Table 1, Item 40)

Tools and Special Tools (cont.) Stand, Maintenance, Automotive Engine Support (Volume 2, WP 0277, Table 1, Item 76) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Personnel Required (2) Equipment Condition Engine removed (WP 0050)

0054-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

TM 10-3930-675-23-1

0054

REMOVAL

NOTE Two screws are installed into tapped holes in flywheel and are used to loosen flywheel from crankshaft. 1.

Install two screws (Figure 1, Item 1) at positions “A" and “B" on flywheel (Figure 1, Item 4).

2.

Remove two mounting screws (Figure 1, Item 3) and replace with guide pins (Figure 1, Item 2). B

A

1

2

3

2

4 1

Figure 1. Flywheel Assembly Removal.

0054-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

M0705JCH

TM 10-3930-675-23-1

0054

REMOVAL - Continued

NOTE • T-handles, or similar devices, are used to provide attachment points for lifting device sling. T-handles are normally fabricated using bar stock. Suitably-sized bolts or eyebolts may also be used. • Check torque converter mounting holes for thread size and use appropriate T-handles. Normal U. S. customary thread sizes are 3/8-16 in., 7/16-20 in., and ½-13 in., Ensure correct size is used. 3.

Install two T-handles (Figure 2, Item 3) into flywheel (Figure 2, Item 1) at opposite points suitable for lifting.

4.

Remove remaining mounting screws (Figure 2, Item 2) from flywheel (Figure 2, Item 1). 1

2

3

2

2

Figure 2.

Flywheel Assembly Removal.

0054-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

M0706JCH

TM 10-3930-675-23-1

0054

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. • Flywheel weighs 50 lb (23 kg) or more. Use suitable lifting device or assistance to lift flywheel. 5.

Install nylon sling on T-handles and attach to suitable lifting device.

6.

Tighten screws (Figure 3, Item 3) in alternating sequence to loosen and remove flywheel (Figure 3, Item 2) from crankshaft (Figure 3, Item 1). 1

3

2

M0707JCH

Figure 3. Flywheel Assembly Removal. END OF TASK

0054-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

TM 10-3930-675-23-1

0054

INSPECTION

NOTE Flywheel bore runout and face runout checks confirm serviceability and proper installation of flywheel. If flywheel does not meet requirements of either check, flywheel must be replaced. 1.

Install dial indicator (Figure 4, Item 2) and attachments (Figure 4, Item 1) and check flywheel bore runout.

1

1

2 2 Figure 4.

Flywheel Assembly Inspection.

0054-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

M0708JCH

TM 10-3930-675-23-1

0054

INSPECTION - Continued 2.

Rotate flywheel, using engine barring tool, one revolution and record indication. Total indicator reading MUST NOT exceed 0.0050 in. (0.127 mm).

NOTE Flywheel face runout check results in five readings. If any one of the readings exceeds the maximum, flywheel must be replaced. 3.

Measure flywheel face runout as follows: a.

Install dial indicator (Figure 5, Item 3) and attachments (Figure 5, Item 1).

b.

Push flywheel (Figure 5, Item 2) forward to remove crankshaft end thrust.

A

1

2

3

M0709JCH

Figure 5.

Flywheel Assembly Inspection.

0054-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

TM 10-3930-675-23-1

0054

INSPECTION - Continued c.

Zero and position dial indicator at radius indicated in Table 1, Flywheel Face Runout.

d.

Rotate crankshaft, using engine barring tool, one revolution and record total indicator reading.

e.

Repeat steps a thru d for each radius setting listed in Table 1, Flywheel Face Runout. Table 1. RADIUS (A)

Flywheel Face Runout. MAXIMUM TIR

MM

IN.

MM

IN.

203

8

0.203

0.008

254

10

0.254

0.010

305

12

0.305

0.012

356

14

0.356

0.014

406

16

0.406

0.016

END OF TASK

0054-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

TM 10-3930-675-23-1

0054

INSTALLATION

NOTE Ensure flywheel mounting surface and crankshaft is free of dirt. 1.

Install guide pin (Figure 6, 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. • Flywheel weighs 50 lb (23 kg) or more. Use suitable lifting device or assistance to lift flywheel. 2.

Using nylon sling, T-handles, and suitable lifting device, position flywheel (Figure 6, Item 2) on guide pin (Figure 6, Item 1).

1

2 Figure 6. Flywheel Assembly Installation.

0054-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00014)

M0710JCH

TM 10-3930-675-23-1

0054

INSTALLATION - Continued 3.

Secure flywheel (Figure 7, Item 1) in place with seven screws (Figure 7, Item 4) hand-tight.

4.

Disconnect lifting device and sling. Remove T-handles (Figure 7, Item 3).

5.

Remove guide pin (Figure 7, Item 2) and install last mounting screw (Figure 7, Item 4). Tighten screws in star pattern to 135 ft-lb (183 N•m).

2 1 3

4

3 4

4 Figure 7.

M0711JCH

Flywheel Assembly Installation.

END OF TASK FOLLOW-ON MAINTENANCE Install engine (WP 0050). END OF TASK END OF WORK PACKAGE

0054-9/10 blank

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TM 10-3930-675-23-1

0055

FIELD MAINTENANCE REAR MAIN OIL SEAL REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Tool Kit, Internal Combustion Engine (Volume 2, WP 0277, Table 1, Item 86) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98)

Materials/Parts (cont.) Oil, Lubricating, Engine (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Retainer, Seal (Volume 2, WP 0278, Table 1, Item 50)

Materials/Parts Cloth, Abrasive, Emery (Volume 2, WP 0276, Table 1, Item 12)

Equipment Condition Flywheel assembly removed (WP 0054)

0055-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

REMOVAL

NOTE The rear main oil seal contact surface of the crankshaft may have a wear sleeve installed. Check for presence of wear sleeve by inspecting the end of the crankshaft to determine if wear sleeve was previously installed. If wear sleeve is NOT present, follow steps 1 through 3 only below to remove the oil seal. If there IS a wear sleeve present, follow steps 4 through 14 only, instructions for Rear Main Oil Seal with Wear Sleeve. 1.

Remove 12 screws (Figure 1, Item 3).

NOTE Ensure oil seal and dust seal are removed as a unit. 2.

Remove oil seal (Figure 1, Item 2) and dust seal (Figure 1, Item 4) from crankshaft (Figure 1, Item 5). Discard oil seal and dust seal.

3.

Remove and discard gasket (Figure 1, Item 1) . 1 2 3 4

5

M0696JCH

Figure 1. Rear Main Oil Seal Removal.

NOTE The rear main oil seal contact surface of the crankshaft may have a wear sleeve installed. Check for presence of wear sleeve by inspecting the end of the crankshaft to determine if wear sleeve was previously installed. If wear sleeve is present, follow Steps 4 through 14 below to remove the wear sleeve and oil seal. 4.

Position thick wear sleeve and oil seal mandrel tool (Figure 2, Item 5) onto crankshaft (Figure 3, Item 4) against thick wear sleeve (Figure 2, Item 5).

5.

Rotate each of three jaw pullers (Figure 3, Item 3) until the large flat edge is aligned with the thick wear sleeve (Figure 2, Item 5) and slot in end is positioned straight up and down.

6.

Insert each jaw puller (Figure 2, Item 3) into its bore, as shown in Figure 2, until it bottoms.

7.

Rotate each jaw puller (Figure 2, Item 3) clockwise 90 degrees. This will lock the jaw pullers with the thick wear sleeve.

8.

Install three flat washers (Figure 2, Item 2) onto each of the jaw pullers (Figure 2, Item 3).

9.

Install three nuts (Figure 2, Item 1) to jaw pullers (Figure 2, Item 3). Tighten nuts to 100 in-lb (11 N•m).

0055-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

REMOVAL - Continued

2

4,5

3

1

M1754JCH

6

Figure 2. 10.

Wear Sleeve Removal.

Lubricate the tip of the forcing screw (Figure 3, Item 1) and install into center of thick wear sleeve and oil seal mandrel tool (Figure 3, Item 2). Rotate forcing screw until it is finger-tight.

2 1

M1755JCH

Figure 3.

Wear Sleeve Removal.

0055-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

REMOVAL - Continued 11.

Rotate forcing screw (Figure 4, Item 1) clockwise until rear crankshaft thick wear sleeve (Figure 4, Item 2) and rear main oil seal (Figure 4, Item 3) are removed. 2,3 1

M1756JCH

Figure 4.

Wear Sleeve Removal.

12.

Remove the thick wear sleeve and oil seal mandrel tool (Figure 5, Item 2), thick wear sleeve (Figure 5, Item 3) and rear main oil seal (Figure 5, Item 4) as an assembly.

13.

Loosen the 3 nuts (Figure 5, Item 5) on the jaw pullers (Figure 5, Item 1).

14.

Rotate each of the three jaw pullers (Figure 5, Item 1) 90 degrees counter-clockwise to unlock the wear sleeve (Figure 5, Item 3).

2 3 3 1

4 5 Figure 5.

5 M1757JCH

Wear Sleeve Removal.

END OF TASK

0055-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

CLEANING AND INSPECTION

NOTE If crankshaft sealing surface is found to be scored or grooved when rear main oil seal is removed, or if a wear sleeve was removed, it will be necessary to install a thick wear sleeve and new oil seal together. Perform Steps 7 through 15 of Installation Procedures only. 1.

Clean and inspect all parts IAW General Maintenance Instructions.

2.

Check the crankshaft sealing surface for nicks, burrs and grooves. Remove any nicks and/or burrs using crocus cloth.

3.

If crankshaft sealing surface is damaged, and a wear sleeve is needed, or if a wear sleeve was removed, clean and inspect crankshaft sealing surface and thick wear sleeve and oil seal mandrel tool with crocus cloth to remove any dirt or deposits on both tool and crankshaft sealing surface.

4.

Use a lint-free cloth to remove any traces of oil from crankshaft flange and oil seal mandrel tool.

END OF TASK INSTALLATION 1.

Install three studs (Figure 6, Item 1) into three threaded holes in end of crankshaft (Figure 6, Item 2) as shown in Figure 6 until finger-tight.

1

2

M1758JCH

Figure 6. Rear Main Oil Seal and Thick Wear Sleeve Installation.

0055-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

INSTALLATION - Continued

NOTE Do NOT separate oil seal from thick wear sleeve at any time during assembly process. A new thick wear sleeve and seal assembly MUST be used. 2.

Do NOT use any lubricant to install oil seal (Figure 7, Item 1). lip of oil seal and crankshaft (Figure 7, Item 2) MUST be oil free and dry for proper installation of oil seal.

2

1

1

4 M1759JCH

Figure 7. Rear Main Oil Seal and Thick Wear Sleeve Installation.

NOTE • Yellow lip of oil seal must face outward (towards you). • Thick wear sleeve, oil seal, and gasket MUST be installed as one assembly. 3.

Position thick wear sleeve (Figure 8, Item 2), main oil seal (Figure 8, Item 1), gasket (Figure 8, Item 3), into proper counter-bore location in thick wear sleeve and oil seal mandrel tool (Figure 8, Item 4).

1

2

4

3 M1760JCH

Figure 8. Rear Main Oil Seal and Thick Wear Sleeve Installation.

0055-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

INSTALLATION - Continued 4.

Position thick wear sleeve (Figure 9, Item 2), main oil seal (Figure 9, Item 3), gasket (Figure 9, Item 3), and thick wear sleeve mandrel tool (Figure 9, Item 4) against crankshaft flange (Figure 9, Item 6). 2,3

1

4

6 5

M1761JCH

Figure 9. Rear Main Oil Seal and Thick Wear Sleeve Installation. 5.

Lubricate one side of each of three flat washers (Figure 10, Item 2), and install so that lubricated side faces toward thick wear sleeve and oil seal mandrel tool (Figure 10, Item 3).

6.

Install three nuts (Figure 10, Item 1) onto studs (Figure 10, Item 4). Tighten three nuts finger-tight. 3

2 1

4

Figure 10.

M1762JCH

Rear Main Oil Seal and Thick Wear Sleeve Installation.

0055-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

INSTALLATION - Continued

CAUTION When installing oil seal and thick wear sleeve into bore area, make certain that thick wear sleeve remains parallel to housing when tightening three nuts. Failure to do so can result in damage to oil seal and thick wear sleeve. 7.

Tighten three nuts (Figure 11, Item 2) one-half turn at a time, alternately, in a clockwise pattern until thick wear sleeve and oil seal mandrel tool (Figure 11, Item 1) seats against crankshaft flange (Figure 11, Item 3) as shown in Figure 11. Tighten nuts (Figure 11, Item 2) to 50 ft-lb (68 N•m) in a clockwise pattern. 1

3

2 M1763JCH

Figure 11.

Rear Main Oil Seal and Thick Wear Sleeve Installation.

8.

Remove three nuts (Figure 12 Item 1), three washers (Figure 12, Item 2), mandrel tool (Figure 12, Item 7) and three studs (Figure 12, Item 6) from crankshaft flange (Figure 12, Item 5).

9.

Install 12 screws (Figure 12, Item 4) through oil seal (Figure 12, Item 3). Tighten in a star-shaped pattern to 60 lb-in (7 N•M).

0055-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0055

INSTALLATION - Continued

4 3

5 2 1

M1764JCH

Figure 12.

Rear Main Oil Seal and Thick Wear Sleeve Installation.

END OF TASK FOLLOW-ON MAINTENANCE Install flywheel assembly (WP 0054). END OF TASK END OF WORK PACKAGE

0055-9/10 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00015)

TM 10-3930-675-23-1

0056

FIELD MAINTENANCE ROCKER ARM ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Adjustment Kit, Injector (Volume 2, WP 0277, Table 1, Item 4) Crowfoot Attachment Set, Socket Wrench, 3/8 in. Female Sq. Dr. (Volume 2, WP 0277, Table 1, Item 20) Caliper, Micrometer, Outside (1-2 in.) (Volume 2, WP 0277, Table 1, Item 13) Gauge, Thickness (0.051 to 1.00 mm) (Volume 2, WP 0277, Table 1, Item 31) Gauge, Telescoping (1.250 to 2.125 in.) (Volume 2, WP 0277, Table 1, Item 30) Indicator, Dial (Volume 2, WP 0277, Table 1, Item 40) Wrench, Torque, Click, Ratcheting, 1/2 in. Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98)

Tools and Special Tools (cont.) Wrench, Pipe (Volume 2, WP 0277, Table 1, Item 92) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Equipment Condition Engine cover removed (Volume 2, WP 0185) Rocker arm cover removed (WP 0057)

0056-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

REMOVAL

NOTE Tag or mark all items removed or disassembled while performing these procedures. For proper operation and adjustment, items must be assembled and installed in the location from which they were removed. 1.

Loosen rocker lever adjusting screws (Figure 1, Item 1) and remove push rods (Figure 1, Item 3) and push tubes (Figure 1, Item 2).

1

2

3

M0722JCH

Figure 1. Push Rods and Push Tubes Removal. 2.

Position ¼ x 18 in. key stock (Figure 2, Item 1) or similar item on top of rocker lever assembly supports (Figure 2, Items 3 and 4). Secure in place with four screws (Figure 2, Item 2). 2

1

3

4

M0723JCH

Figure 2.

Key Stock Installation.

0056-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

REMOVAL - Continued 3.

Loosen four rocker shaft screws (Figure 3, Item 1). Remove front section of rocker arm assembly. 1

1

FRONT SECTION

REAR SECTION M0724JCH

Figure 3. Front Rocker Arm Assembly Removal. 4.

Repeat steps 1 thru 3 and remove rear section of rocker arm assembly.

END OF TASK

0056-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

DISASSEMBLY

NOTE Mark or tag each rocker lever, shaft, and support with relative position in rocker assembly. 1.

Remove four rocker shaft screws (Figure 4, Item 1) and retaining clamps (Figure 4, Item 5).

2.

Lift shaft (Figure 4, Item 8) and three rocker levers (Figure 4, Items 2, 3, and 4) out of supports (Figure 4, Items 7, 9, and 6).

3.

Remove three rocker levers (Figure 4, Items 2, 3, and 4) from shaft (Figure 4, Item 8). 1

1

1 5

5

3

5 1

3 2

2

4

3

2

4

4 6

5 9

7

M0725JCH

8

Figure 4. Rocker Levers Removal. 4.

Remove adjusting nut (Figure 5, Item 2) and adjusting screw (Figure 5, Item 1) from each rocker lever (Figure 5, Items 3, 5, and 4). 2 2

5

1

1

3,4

M0726JCH

Figure 5. Rocker Lever Disassembly. END OF TASK

0056-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

INSPECTION

NOTE If the following conditions are noted or specifications are not met, item being inspected must be replaced. 1.

Ensure components have been thoroughly cleaned and visually inspect rocker levers for these conditions: a.

Cracks, excessive pitting, or other visible damage.

b.

Thread damage to adjusting screw threads.

c.

Sockets and pads for cracks, pits, wear, or other damage.

2.

Visually inspect adjusting nut and adjusting screw for damaged threads.

3.

Visually inspect shaft for pitting, scoring, or other damage.

4.

Visually inspect supports for cracks, pitting, or other damage.

5.

Measure rocker lever bushing inside diameter. Measurement must be 1.3735 to 1.3776 in. (34.887 to 34.99 mm). If not within range, replace bushing.

INSIDE DIAMETER, ROCKER LEVER BUSHING

Figure 6. 6.

M0727JCH

Rocker Lever Bushing Measurement.

Measure outside diameter of rocker lever shaft. Diameter must be 1.3715 to 1.3726 in. (34.837 to 34.864 mm). If diameter is not within range, replace rocker lever shaft.

OUTSIDE DIAMETER, ROCKER LEVER SHAFT

Figure 7.

Rocker Lever Shaft Measurement.

END OF TASK

0056-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0728JCH

TM 10-3930-675-23-1

0056

ASSEMBLY

CAUTION Ensure rocker lever shafts are installed in support with arrow on end of shaft pointed down. Failure to install rocker lever shafts with arrow down will have an adverse effect on rocker lever lubrication and may cause damage to rocker arm assemblies.

NOTE Ensure rocker lever shafts are oriented according to marking on shaft ends. 1.

Apply a light coat of clean lubricating oil to each rocker lever shaft (Figure 8, Item 2) and install front end support (Figure 8, Item 4) on each rocker lever shaft.

2.

Install screw (Figure 8, Item 1) and retaining clamp (Figure 8, Item 3) to secure rocker lever shaft (Figure 8, Item 2) to front end support (Figure 8, Item 4).

2 3

1

4

M0729JCH

Figure 8. Rocker Arm Shaft Assembly. 3.

Install adjusting screw (Figure 9, Item 4) and adjusting nut (Figure 9, Item 9) in three rocker levers (Figure 9, Items 2, 3, and 4) and position rocker levers on shaft (Figure 9, Item 6) in correct sequence as noted in disassembly.

4.

Position one center support (Figure 9, Item 9) and secure in place with retaining clamp (Figure 9, Item 5) and screw (Figure 9, Item 7).

5.

Install three rocker levers (Figure 9, Items 1, 2, and 3) and remaining support (Figure 9, Item 8) with rocker levers in correct position as noted in disassembly.

0056-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

ASSEMBLY - Continued

5 4

3

2

6

1

7

8 9 9

Figure 9. 6.

4

M0730JCH

Rocker Arm Shaft Assembly.

Install support (Figure 10, Item 8) and remaining retaining clamps (Figure 10, Item 2) and screws (Figure 10, Item 3) on front and rear sections of rocker arm assembly (Figure 10, Items 7 (1,2,3,4,5,6,8, and 9). 7

3

2

4

5

6

1 8

9 1

8 9

Figure 10.

M0731JCH

Rocker Arm Shaft Assembly.

0056-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

ASSEMBLY - Continued 7.

Position key stock (Figure 11, Item 1) used to remove assembly on top of supports and secure in place with four screws (Figure 11, Item 2). 2

1

M0732JCH

Figure 11. Rocker Arm Shaft Assembly. END OF TASK INSTALLATION

NOTE Rocker arm assembly must be installed in same position from which it was removed. 1.

Position rocker arm assembly (Figure 12, Item 1) on cylinder head (Figure 12, Item 3). Hand-tighten eight screws (Figure 12, Item 2) and remove key stock (Figure 12, Item 4). 1 2

2

2

4 3

M0733JCH

Figure 12. Rocker Arm Shaft Installation.

0056-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

INSTALLATION - Continued

NOTE Rocker lever side clearance MUST be adjusted before screws are fully tightened. 2.

Set side clearance for rear section of rocker arm assembly as follows: a.

Tap number five rocker lever support (Figure 13, Item 1) toward front of engine. Tighten mounting screw (Figure 13, Item 2) to 45 in-lb. (5 N•m).

1 2

FRONT OF ENGINE

Figure 13.

REAR SECTION

M0734JCH

Rocker Arm Shaft Installation.

b.

Insert 0.020 in. (0.50 mm) feeler gauge between number five support (Figure 14, Item 3) and intake lever for number four cylinder.

c.

Push or tap number six support (Figure 14, Item 1) toward front of engine. Tighten mounting screw (Figure 14, Item 2) to 45 in-lb. (5 N•m).

0.20 in. (.50 mm) 1

2

3 INTAKE LEVER

Figure 14.

Rocker Arm Shaft Installation.

0056-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M1144JCH

TM 10-3930-675-23-1

0056

INSTALLATION - Continued d.

Insert 0.020 in. (0.50 mm) feeler gauge between number six support (Figure 15, Item 2) and exhaust lever for number five cylinder.

e.

Push or tap number seven support (Figure 15, Item 2) toward front of engine. Tighten mounting screw (Figure 15, Item 1) to 45 in-lb. (5 N•m).

f.

Insert 0.020 in. (0.50 mm) feeler gauge between number seven support (Figure 15, Item 2) and intake lever for number six cylinder.

0.20 in. (.50 mm) EXHAUST LEVER 1

FRONT OF ENGINE

2

M0735JCH

Figure 15. Rocker Arm Shaft Installation. g.

Push or tap number eight support (Figure 16, Item 1) toward front of engine. Push or tap number eight support Figure 16, Item 13) toward front of engine.

h.

Fully tighten four support mounting screws (Figure 16, Item 2) to 135 ft-lb (183 N•m).

0.20 in. (.50 mm) INTAKE LEVER

1

3

3

2

Figure 16. Rocker Arm Shaft Installation.

0056-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0736JCH

TM 10-3930-675-23-1

0056

INSTALLATION - Continued 3.

Set side clearance for front section of rocker arm assembly as follows: a.

Push or use hammer to tap number four support (Figure 17, Item 2) toward rear of engine. Tighten mounting screw (Figure 17, Item 1) to 45 in-lb (5 N•m).

1

2

FRONT SECTION

Figure 17.

REAR OF ENGINE

M0737JCH

Rocker Arm Shaft Installation.

b.

Insert 0.020 in. (0.50 mm) feeler gauge between number four support (Figure 18, Item 2) and intake lever of number three cylinder.

c.

Push or tap number three support (Figure 18, Item 1) toward rear of engine. Tighten mounting screw (Figure 18, Item 2) to 45 in-lb. (5 N•m).

INTAKE LEVER

0.20 in. (.50 mm)

1

3

REAR OF ENGINE

2

Figure 18.

Rocker Arm Shaft Installation.

0056-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0738JCH

TM 10-3930-675-23-1

0056

INSTALLATION - Continued d.

Insert 0.020 in. (0.50 mm) feeler gauge between number three support (Figure 19, Item 1) and exhaust lever for number two cylinder.

e.

Push or tap number two support (Figure 19, Item 1) toward rear of engine. Tighten mounting screw (Figure 19, Item 2) to 45 in-lb. (5 N•m).

0.20 in. (.50 mm) EXHAUST LEVER

1

REAR OF ENGINE

2

3

M0739JCH

Figure 19. Rocker Arm Shaft Installation. f.

Insert 0.020 in. (0.50 mm) feeler gauge between number two support (Figure 20, Item 2) and intake lever for number one cylinder.

g.

Push or tap number one support (Figure 20, Item 1) toward rear of engine.

h.

Fully tighten four support mounting screws (Figure 20, Item 3) to 135 ft-lb (183 N•m).

0.20 in. (.50 mm) 2

INTAKE LEVER 1

REAR OF ENGINE 3

3

M0740JCH

Figure 20. Rocker Arm Shaft Installation.

0056-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

INSTALLATION - Continued

NOTE Injector push rods are smaller in diameter and longer than valve push tubes. 4.

Apply a light coat of clean lubricating oil to ball end of push rods (Figure 21, Item 3) and push tubes (Figure 21, Item 2).

NOTE Ensure push rods and tubes are installed in position as noted in removal. 5.

Install valve push tubes (Figure 21, Item 2) and injector push rods (Figure 21, Item 3) and tighten adjusting screws (Figure 21, Item 1) enough to hold push rods and tubes in position.

1

2 3 2 Figure 21. 6.

Rocker Arm Shaft Installation.

Adjust valves and injectors.

END OF TASK

0056-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0741JCH

TM 10-3930-675-23-1

0056

VALVE LASH CHECK

NOTE • All overhead valve and injector lash measurements and adjustments MUST be made when engine is cold. • Valve set marks “A", “B", and “C" are located on accessory drive pulley. Marks align with pointer on gear housing. • Engine cylinders are numbered from front to rear 1-2-3-4-5-6. • Crankshaft rotation is clockwise when viewed from front of engine. Firing order is 1-5-3-6-2-4. • One pair of valves and one injector are checked or adjusted at each pulley index mark before rotating accessory drive to next mark. • Two crankshaft rotations are required to check or adjust all valves and injectors. 1.

Perform valve lash check on each cylinder until all cylinders have been checked.

2.

Rotate accessory drive clockwise until valve set mark “A" is aligned with pointer on gear cover. GEAR COVER

GEAR COVER POINTER

VALVE SET MARK

Figure 22.

Valve Lash Check.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0742JCH

TM 10-3930-675-23-1

0056

VALVE LASH CHECK - Continued

NOTE Each cylinder has three rocker levers: long lever (E)—exhaust valve; middle lever–injector; short lever (I)—intake valve. 3.

Observe rocker lever arms of cylinder and compare rocker lever arm positions to Table 1. Intake and exhaust valves must be closed and injector plunger must be at bottom of stroke for cylinder 1. If this is not correct, cylinder 6 must be ready to check. Table 1. Injector and Valve Measurement Sequence. SET CYLINDER

BAR ENGINE DIRECTION OF ROTATION PULLEY POSITION INJECTOR

VALVE

Start

A

1

1

Advance to

B

5

5

Advance to

C

3

3

Advance to

A

6

6

Advance to

B

2

2

Advance to

C

4

4

Firing Order: 1-5-3-6-2-4 GEAR COVER

GEAR COVER POINTER

VALVE SET MARK

Figure 23.

Valve Lash Check.

0056-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0742JCH

TM 10-3930-675-23-1

0056

VALVE LASH CHECK - Continued

NOTE Ensure rocker levers on both intake and exhaust valves of cylinder being checked can be “rattled" or push tubes can be freely rotated. 4.

With thickness gauge, measure and record amount of clearance between crosshead and rocker lever nose for both intake and exhaust valve.

ROCKER LEVER NOSE THICKNESS GAGE

CROSSHEAD (HIDDEN)

M0744JCH

Figure 24. 5.

Valve Lash Check.

If valve lash clearance is not within specifications listed in Table 2, valves must be adjusted. Table 2.

M Series Valve Lash Recheck Limits.

MM INTAKE

EXHAUST

IN.

0.10

MIN

0.004

0.41

MAX

0.016

0.46

MIN

0.018

0.76

MAX

0.030

END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

INJECTOR LASH CHECK

NOTE To ensure accurate measurement, securely tighten all hold-down screws and thumbscrews. 1.

Install dial indicator on cylinder being checked to measure injector rocker arm lever.

2.

Adjust and set dial indicator for reading as follows: a.

Set tip of dial indicator to rest on rocker lever directly above socket.

b.

Loosen height adjustment thumbscrew and lower indicator against injector rocker lever until stem is fully compressed.

c.

Raise indicator approximately 0.500 in. (12.7 mm) and tighten height adjustment thumbscrew to hold position.

ROCKER LEVER HEIGHT ADJUSTMENT THUMBSCREW

STEM

M0745JCH

Figure 25.

Injector Lash Check.

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TM 10-3930-675-23-1

0056

INJECTOR LASH CHECK - Continued

WARNING Injector plunger is under spring tension. DO NOT allow tool to slip. Serious personal injury can result. 3.

With actuator, operate injector plunger three or four times to ensure fuel has been removed from injector assembly.

4.

With actuator, operate lever again and, while holding injector plunger to bottom of travel, set dial indicator at “0" (zero).

Figure 26. 5.

Injector Lash Check.

Slowly release actuator and check dial indicator travel. Record measured value. If injector lash setting is not within specifications listed in Table 3, injector must be adjusted. Table 3.

M Series Injector Lash Recheck Limits.

MM

IN.

0.51

MIN

0.020

2.04

MAX

0.080

END OF TASK INJECTOR ADJUSTMENT

NOTE • Set injectors on cylinders before setting valves. • Adjustment may begin with any valve set mark. Position “A" is described in the following steps. 1.

Rotate accessory drive clockwise until “A" valve set mark on accessory drive pulley is aligned with pointer on gear cover.

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TM 10-3930-675-23-1

0056

INJECTOR ADJUSTMENT - Continued GEAR COVER

GEAR COVER POINTER

VALVE SET MARK

Figure 27.

M0747JCH

Injector Adjustment.

2.

With valve set mark “A" aligned with pointer, observe both valve rocker levers for cylinder 1. Intake and exhaust valves for cylinder must be closed. If condition is not met, then cylinder 6 injector and valves must be ready to set.

3.

Adjust injector as follows: a.

Loosen injector adjusting screw locknut.

b.

Bottom injector plunger three or four times to remove fuel.

NOTE DO NOT use excessive force when bottoming plunger. c.

Turn adjusting screw in until you can feel it lightly bottom plunger.

d.

Back out adjusting screw two flats or 120 degrees.

e.

Hold adjusting screw and tighten locknut to 45 ft-lb (61 N•m).

ADJUSTING SCREW LOCKNUT

ADJUSTING SCREW

120∞

Figure 28.

INJECTOR PLUNGER Injector Adjustment.

0056-19

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0748JCH

TM 10-3930-675-23-1

0056

INJECTOR ADJUSTMENT - Continued 4.

Perform valve adjustments on same cylinder.

END OF TASK VALVE ADJUSTMENT

NOTE Ensure valve set mark “A" is aligned with pointer on gear cover and both valves are closed on cylinder to be adjusted. 1.

Loosen adjusting screw locknuts on intake and exhaust valves.

2.

Select thickness gauge for correct valve lash specification listed: a.

Intake valve—0.014 in. (0.36 mm)

b.

Exhaust valve—0.027 in. (0.69 mm)

GAGE, INTAKE VALVE

0.14 in. (0.36 mm)

0.27 in. (0.69 mm) GAGE, EXHAUST VALVE ADJUSTING SCREW LOCKNUTS Figure 29.

Valve Adjustment.

0056-20

03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

M0749JCH

TM 10-3930-675-23-1

0056

VALVE ADJUSTMENT - Continued 3.

Insert thickness gauge between top of crosshead and rocker lever pad.

NOTE Two methods of adjusting valve lash can be used. The first method, which is preferred, is described in steps 4 thru 7 and uses the inch-pound torque wrench; the second method is described in steps 8 thru 11. 4.

With inch-pound torque wrench, tighten adjusting screw to 6 in-lb. (0.7 N•m).

ROCKER LEVER TORQUE WRENCH

THICKNESS GAGE

M0750JCH

Figure 30.

Valve Adjustment.

5.

Hold adjusting screw in position and tighten locknut.

6.

With adapter, tighten locknut to 35 ft-lb (47 N•m).

ADJUSTING SCREW LOCKNUT ADAPTER M0751JCH

Figure 31.

Valve Adjustment.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

VALVE ADJUSTMENT - Continued 7.

Check adjustment by ensuring thickness gauge will slide backward and forward with only slight drag.

ROCKER LEVER NOSE THICKNESS GAGE

CROSSHEAD (HIDDEN)

M0752JCH

Figure 32. 8.

Valve Adjustment.

Tighten adjusting screw until a slight drag is felt on thickness gauge.

THICKNESS GAGE

ADJUSTING SCREW

Figure 33.

M0753JCH

Valve Adjustment.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00016)

TM 10-3930-675-23-1

0056

VALVE ADJUSTMENT - Continued 9.

Hold adjusting screw and tighten locknut.

10.

With adapter, tighten locknut to 35 ft-lb (47 N•m).

ADJUSTING SCREW LOCKNUT ADAPTER M0754JCH

Figure 34.

Valve Adjustment.

11.

Check adjustment by attempting to insert a 0.001 in. (0.03 mm) feeler gauge between crosshead and rocker lever pad. Valve lash is not correct if gauge can be inserted.

12.

Perform injector and valve adjustments for remaining cylinders.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install rocker arm cover (WP 0057).

2.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0057

FIELD MAINTENANCE ROCKER ARM COVER AND GASKET REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Seal, Plain (Volume 2, WP 0278, Table 1, Item 29)

Materials/Parts (cont.) Gasket (Volume 2, WP 0278, Table 1, Item 59) Spacer, Straight (Volume 2, WP 0278, Table 1, Item 60) Qty: 6 Equipment Condition Air intake tubes and hoses removed from intake manifold (WP 0072)

0057-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00017)

TM 10-3930-675-23-1

0057

REMOVAL

NOTE For ease in removing rocker arm cover, wiring harness bracket may be removed from left front of engine and set aside. 1.

Disconnect crankcase breather tube (Figure 1, Item 9) from breather tube adapter (Figure 1, Item 5).

2.

Remove breather tube adapter (Figure 1, Item 5) and grommet seal (Figure 1, Item 6) from rocker arm cover (Figure 1, Item 1). Discard grommet seal.

3.

Remove 16 screws (Figure 1, Item 3), noise isolators (Figure 1, Item 2), and spacers (Figure 1, Item 4) from rocker arm cover (Figure 1, Item 1). Discard noise isolators.

4.

Remove rocker arm cover (Figure 1, Item 1) and gasket (Figure 1, Item 7) from engine (Figure 1, Item 8). Discard gasket. 3 4 2

1

5,6

7

9 8

M0007JCH

Figure 1.

Rocker Arm Cover and Gasket Replacement.

END OF TASK INSTALLATION

NOTE Ensure all gasket material has been removed from rocker arm cover surface and rocker housing. 1.

Install rocker arm cover (Figure 1, Item 1) and new gasket (Figure 1, Item 7) on engine (Figure 1, Item 8).

2.

Install 16 screws (Figure 1, Item 3), new noise isolators (Figure 1, Item 2), and spacers (Figure 1, Item 4) on rocker arm cover (Figure 1, Item 1). Tighten screws to 130 in-lb (15 N•m) in sequence shown in Figure 2.

0057-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00017)

TM 10-3930-675-23-1

0057

INSTALLATION - Continued 14

10

6

2

4

8

9

5

1

3

7

12

16

15

13

11

M0008JCH

Figure 2. Rocker Arm Cover Tightening Sequence. 3.

Install new grommet seal (Figure 1, Item 6) and breather tube adapter (Figure 1, Item 5) on rocker arm cover (Figure 1, Item 1).

4.

Connect crankcase breather hose (Figure 1, Item 9) to breather tube adapter (Figure 1, Item 5).

END OF TASK FOLLOW-ON MAINTENANCE Install air intake tubes and hoses on intake manifold (WP 0072). END OF TASK END OF WORK PACKAGE

0057-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00017)

TM 10-3930-675-23-1

0058

FIELD MAINTENANCE OIL PAN REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Hammer Set, Holder and Inserts (Volume 2, WP 0277, Table 1, Item 37) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Sealant, Silicone (Volume 2, WP 0276, Table 1, Item 53)

Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 27) Qty: 2 Gasket (Volume 2, WP 0278, Table 1, Item 46) References TM 10-3930-675-10 Equipment Condition Engine oil drained (WP 0059) Front propeller shaft disconnected from front axle flange only (Volume 2, WP 0143)

0058-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00018)

TM 10-3930-675-23-1

0058

REMOVAL 1.

Remove 32 screws (Figure 1, Item 1) securing oil pan (Figure 1, Item 2) to engine block.

NOTE It may be necessary to tap lightly on oil pan with a plastic-faced hammer to break seal between oil pan and engine block. 2.

Lower oil pan (Figure 1, Item 2) and remove from engine.

3.

Remove and discard oil pan gasket (Figure 1, Item 5).

4.

Remove screw (Figure 1, Item 3) from oil pan suction tube (Figure 1, Item 4) and remove from oil pan (Figure 1, Item 7).

5.

Remove two O-ring seals (Figure 1, Item 2) and oil transfer tube (Figure 1, Item 1) from oil pan suction tube (Figure 1, Item 4). Discard O-ring seals. 3 4 2

5

1

7

6

Figure 1.

M0756JCH

Oil Pan Removal.

END OF TASK INSTALLATION 1.

Apply sealant on block joints as shown in Figure 2.

2.

Install oil transfer tube (Figure 1, Item 1) with two new O-ring seals (Figure 1, Item 2).

0058-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00018)

TM 10-3930-675-23-1

0058

INSTALLATION - Continued

CYLINDER BLOCK-TO-GEAR HOUSING JOINT

FLYWHEEL HOUSING-TO-CYLINDER BLOCK JOINT Figure 2.

M0757JCH

Oil Pan Installation.

3.

Place new gasket (Figure 1, Item 5) on oil pan (Figure 1, Item 7) mounting flange.

4.

Install oil pan suction tube (Figure 1, Item 4) to oil pan (Figure 1, Item 7) with screw (Figure 1, Item 3).

CAUTION During installation, carefully align transfer tube to connection on block. Failure to properly align could cause connector to break and result in low/no oil pressure. 5.

Align oil suction tube (Figure 1, Item 4) with engine block and install oil pan (Figure 1, Item 7) on engine block.

6.

Secure oil pan (Figure 1, Item 2) with 32 screws (Figure 1, Item 1). Tighten screws to 35 ft-lb (47 N•m) in sequence shown in Figure 3. 32 31 30

29 19 15 11 7 3 1 5 9 13 17 21 23

28 18 14 10 6 2 4 8 12 16 20 22

25

24 27 26

TIGHTENING SEQUENCE

Figure 3.

Oil Pan Installation.

END OF TASK

0058-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00018)

M0758JCH

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Fill engine oil (WP 0059).

2.

Start engine (TM 10-3930-675-10) and build up oil pressure. Shut down engine.

3.

Check oil pan for leaks.

4.

Connect front propeller shaft (Volume 2, WP 0143).

END OF TASK END OF WORK PACKAGE

0058-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00018)

0058

TM 10-3930-675-23-1

0059

FIELD MAINTENANCE ENGINE OIL AND OIL FILTER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Oil Filter, Strap (Volume 2, WP 0277, Table 1, Item 91) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Lubricating Oil, Gear OE/HDO 10 (Volume 2, WP 0276, Table 1, Item 45) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49)

Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Filter Element, Fluid (Volume 2, WP 0278, Table 1, Item 174) References LO 10-3930-675-13 TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)

0059-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00019)

TM 10-3930-675-23-1

0059

REMOVAL

WARNING • Hot oil can cause serious burns. Allow engine to cool before draining oil or changing oil filter element. • Engine oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

NOTE Engine oil change and filter replacement should be performed on a warm engine. 1.

Place suitable container under engine oil pan (Figure 1, Item 1) to catch draining oil.

2.

Remove plug (Figure 1, Item 3) and washer (Figure 1, Item 2) from bottom of engine oil pan (Figure 1, Item 1) and allow oil to drain. Dispose of oil in accordance with standard operating procedures (SOP). Check condition of washer and plug.

2

1

3 M0009JCH

Figure 1.

Drain Engine Oil.

NOTE Ensure oil pan plug and oil pan threads are clean and free of deposits. 3.

Install washer (Figure 2, Item 2) and plug (Figure 2, Item 3) in oil pan (Figure 2, Item 1). Tighten plug to 65 ft-lb (88 N•m).

NOTE Position drain pan to catch oil from oil filter head as needed. 4.

Remove oil filter (Figure 2, Item 1) and gasket from filter head (Figure 2, Item 2) with strap wrench. Discard filter with gasket.

5.

Clean filter head sealing surface (Figure 2, Item 3) with a rag.

0059-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00019)

TM 10-3930-675-23-1

0059

REMOVAL - Continued 2

3

1 M0010JCH

Figure 2.

Oil Filter and Gasket.

END OF TASK INSTALLATION

CAUTION Ensure new oil filter is filled with clean engine oil prior to installation. Lack of lubrication to engine during delay to fill filter when starting engine may cause damage to engine. 1.

Apply a light coat of clean engine oil to filter gasket and fill new oil filter (Figure 2, Item 1) with clean engine oil.

NOTE Ensure old gasket material has been removed from sealing surface on filter head. 2.

Install oil filter (Figure 2, Item 1) on filter head (Figure 2, Item 2) and hand tighten until gasket contacts sealing surface (Figure 2, Item 3).

CAUTION Overtightening of filter can distort threads or damage filter element seal. 3.

Tighten oil filter (Figure 2, Item 1) ¼ turn with strap wrench.

4.

Add engine oil to required level (LO 10-3930-675-13).

END OF TASK

0059-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00019)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Start vehicle (TM 10-3930-675-10) and check for oil leaks.

2.

Recheck oil level (LO 10-3930-675-13).

3.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0059-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00019)

0059

TM 10-3930-675-23-1

0060

FIELD MAINTENANCE OIL FILTER HEAD AND OIL COOLER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Accessory Kit, Test Set Lubricating Oil Cooler 120 (Volume 2, WP 0277, Table 1, Item 1) Pliers Set, Retaining Ring (Volume 2, WP 0277, Table 1, Item 56) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) O-Ring (Volume 2, WP 0278, Table 1, Item 8) Qty: 2 Gasket (Volume 2, WP 0278, Table 1, Item 52) Gasket (Volume 2, WP 0278, Table 1, Item 65) Qty: 2

Materials/Parts (cont.) Spacer, Straight (Volume 2, WP 0278, Table 1, Item 60) Qty: 2 Ring, Retaining Ring, Retaining Personnel Required (2) References LO 10-3930-675-13 TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Oil filter removed (WP 0059) Radiator drained (WP 0080) Turbocharger removed (WP 0073)

0060-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

0060

REMOVAL 1.

Disconnect turbocharger oil supply line (Figure 1, Item 2) and remove elbow fitting (Figure 1, Item 1) from oil filter head (Figure 1, Item 3). 2

1

3

M0759JCH

Figure 1. 2.

Oil Filter Head and Oil Cooler Removal.

Remove four screws (Figure 2, Item 1) securing oil cooler thermostat housing flange (Figure 2, Item 3) to thermostat housing (Figure 2, Item 2). 1

2

3

Figure 2.

Oil Filter Head and Oil Cooler Removal.

0060-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

M0760JCH

TM 10-3930-675-23-1

0060

REMOVAL - 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 When removing oil filter head and oil cooler as a unit, ensure oil cooler thermostat housing flange, O-ring adapters, and thermostat housing flange O-rings are removed with oil cooler. 3.

Remove six screws (Figure 3, Item 5) and washers (Figure 3, Item 6) securing oil filter head (Figure 3, Item 4) to engine and, with assistance, remove oil cooler (Figure 3, Item 1) and oil filter head as a unit from engine. Discard oil filter head gasket (Figure 3, Item 3) and two oil cooler thermostat housing flange O-rings (Figure 3, Item 2). 1 2

3 5,6 4 5,6

M0761JCH

Figure 3. Oil Filter Head and Oil Cooler Removal. END OF TASK

0060-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

0060

DISASSEMBLY 1.

Slide seal retainer (Figure 4, Item 3) and two seal retainers (Figure 4, Item 2) from oil cooler (Figure 4, Item 5).

2.

Remove and discard two oil cooler inlet (Figure 4, Item 1) and outlet O-rings (Figure 4, Item 4).

3.

Remove four screws (Figure 4, Item 6) securing oil cooler (Figure 4, Item 5) to oil filter head (Figure 4, Item 13).

4.

Remove oil cooler (Figure 4, Item 5) and two gaskets (Figure 4, Item 14) from oil filter head (Figure 4, Item 13). Discard gaskets.

5.

Remove retaining ring (Figure 4, Item 11) securing oil filter head thermostat (Figure 4, Item 12) in oil filter head (Figure 4, Item 13). Remove thermostat. Discard retaining ring.

6.

Remove retaining ring (Figure 4, Item 10) securing bypass valve plunger (Figure 4, Item 7) in oil filter head (Figure 4, Item 13). Discard retaining ring.

7.

Remove washer (Figure 4, Item 9), spring (Figure 4, Item 8), and bypass valve plunger (Figure 4, Item 7) from oil filter head (Figure 4, Item 13).

0060-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

0060

DISASSEMBLY - Continued

6

5 3 4 2 1 4

14

7 13

8 9

10

12 11 Figure 4. Oil Filter Head and Oil Cooler Disassembly. END OF TASK

0060-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

M0762JCH

TM 10-3930-675-23-1

CLEANING

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.

Clean thermostat and bypass valve plunger with solvent and dry with compressed air.

NOTE Ensure oil filter head open passages are cleaned and dried. 2.

Clean oil filter head with solvent and dry with compressed air.

3.

Clean all mating surfaces of oil cooler, oil filter head, and engine to remove old gasket material.

0060-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

0060

TM 10-3930-675-23-1

0060

CLEANING - Continued 4.

Clean oil cooler as follows: a.

Install pressure test plate (Figure 5, Item 2), gasket (Figure 4, Item 7), and two screws (Figure 5, Item 1), washers (Figure 5, Item 3), and nuts (Figure 5, Item 4) on one of two oil passage openings in oil cooler (Figure 5, Item 6).

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. b.

Attach air pressure line to pressure test plate (Figure 5, Item 2) and clear oil from inside oil passage. 1 2

5

3 7 4

6

Figure 5.

M0763JCH

Oil Cooler Testing.

0060-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

0060

CLEANING - Continued c.

Install pressure test plate (Figure 6, Item 2), gasket (Figure 6, Item 3), and two screws (Figure 6, Item 1) washers (Figure 6, Item 4), and nuts (Figure 6, Item 5) on second oil passage opening in oil cooler (Figure 6, Item 6).

NOTE Both oil passage openings must be sealed before cleaning oil cooler water core. d.

Use water pressure, attached to outlet side of housing, to clean oil cooler water core.

1

2 3 4 5 OUTLET

6

M0764JCH

Figure 6. Oil Cooler Cleaning. END OF TASK INSPECTION 1.

Inspect oil filter head for cracks or other damage. If damaged, replace oil filter head.

2.

Inspect oil thermostat and bypass valve for cracks or other damage. If damaged, replace.

3.

Inspect oil cooler for cracks or other damage. If damaged, replace.

END OF TASK

0060-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

0060

TEST

NOTE Oil cooler is not a repairable component. If oil cooler is defective, it must be replaced. To determine oil cooler serviceability, perform pressure test as follows 1. Ensure both oil passages are sealed with pressure test plates and install air pressure line to one pressure test plate. 2. Place oil cooler in tank of water heated to 180°F (82°C). 3. Apply air pressure not to exceed 60 psi (414 kPa) and observe oil cooler. If leaks are detected, oil cooler is defective and must be replaced.

OIL COOLER PRESSURE TEST Figure 7.

M0765JCH

Oil Cooler Pressure Test.

END OF TASK ASSEMBLY 1.

Install thermostat (Figure 8, Item 1) in oil filter head (Figure 8, Item 2) and secure with new retaining ring (Figure 8, Item 3).

2

1

3 Figure 8.

M0766JCH

Oil Filter Head Assembly.

0060-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

0060

ASSEMBLY - Continued 2.

Install bypass valve plunger (Figure 9, Item 2), spring (Figure 9, Item 3), and washer (Figure 9, Item 4) in oil filter head (Figure 9, Item 1) and secure with new retaining ring (Figure 9, Item 5). 1

5 2 3 4

M0767JCH

Figure 9. Oil Filter Head Assembly. END OF TASK INSTALLATION 1.

With assistance, position oil filter head (Figure 10, Item 2) with new gasket (Figure 10, Item 1) on engine.

2.

Secure oil filter head (Figure 10, Item 2) with six washers (Figure 10, Item 4) and screws (Figure 10, Item 3). Tighten screws to 35 ft-lb (47 N•m).

1

2

4

Figure 10. Oil Filter Head Installation.

0060-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

3

M0768JCH

TM 10-3930-675-23-1

0060

INSTALLATION - Continued 3.

Lubricate two new O-rings (Figure 11, Item 4) with clean engine oil and install on oil cooler inlet and outlet tubes.

NOTE Ensure seal retainer flat sides are facing each other when inserted into seal retainer. 4.

Place seal retainer (Figure 11, Item 3) on oil cooler (Figure 11, Item 5) and insert, as far as possible, two seal retainers (Figure 11, Item 2).

5.

Lubricate two new O-rings (Figure 11, Item 1) with clean engine oil and insert into seal retainers (Figure 11, Item 2).

6.

Position new gaskets (Figure 11, Item 7) on oil filter head (Figure 11, Item 8).

7.

Install oil cooler (Figure 11, Item 5) into thermostat housing and on oil filter head (Figure 11, Item 8). Secure oil cooler to oil filter head with four screws (Figure 11, Item 6). Tighten screws to 35 ft-lb (47 N•m).

6

5 3 4 2 1 4

7

8

M0769JCH

Figure 11. Oil Filter Head and Oil Cooler Installation.

0060-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

0060

INSTALLATION - Continued 8.

Secure oil cooler thermostat housing flange (Figure 12, Item 3) in thermostat housing (Figure 12, Item 2) with four screws (Figure 12, Item 1). Tighten screws to 35 ft-lb (47 N•m). 1

2

3

M0770JCH

Figure 12. Oil Filter Head and Oil Cooler Installation. 9.

Install elbow fitting (Figure 13, Item 1) on oil filter head (Figure 13, Item 3) and connect turbocharger oil supply line (Figure 13, Item 2).

2

1

3

M0771JCH

Figure 13. Oil Filter Head and Oil Cooler Installation. END OF TASK

0060-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Install turbocharger (WP 0073).

NOTE Ensure cooling system drains are closed. 2.

Fill cooling system (WP 0080).

3.

Install oil filter (WP 0059).

4.

Top off oil (LO 10-3930-675-13).

CAUTION Engine oil pressure MUST be indicated on gauge within 15 seconds after starting. If oil pressure is not registered within 15 seconds, shut off engine immediately to avoid engine damage. 5.

Start engine (TM 10-3930-675-10). Operate engine at idle for 3 minutes to check for leaks.

6.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0060-13/14 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00020)

0060

TM 10-3930-675-23-1

0061

FIELD MAINTENANCE ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Gasket (Volume 2, WP 0278, Table 1, Item 62) O-ring (Volume 2, WP 0278, Table 1, Item 82) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Equipment Condition Engine cover removed (Volume 2, WP 0185)

NOTE Engine oil dipstick hose and transmission oil dipstick hose are at same location. Engine oil dipstick is indicated by a data plate with an engine symbol. Note location of data plate for ease in installation.

0061-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00021)

TM 10-3930-675-23-1

0061

ENGINE OIL DIPSTICK HOSE REMOVAL 1.

Remove dipstick (Figure 1, Item 2) from engine oil dipstick hose Figure 1, Item 15).

2.

Remove upper end of dipstick hose (Figure 1, Item 15), nipple (Figure 1, Item 3), washer (Figure 1, Item 4) and data plate (Figure 1, Item 5) from bracket (Figure 1, Item 1).

3.

Remove lower end of dipstick hose (Figure 1, Item 15) from adapter (Figure 1, Item 17).

4.

Remove locknut (Figure 1, Item 12), screw (Figure 1, Item 16), two washers (Figure 1, Item 13), and release dipstick hose (Figure 1, Item 15) from clamps (Figure 1, Item 14). Discard locknut.

5.

Remove dipstick hose (Figure 1, Item 15) from vehicle.

6.

Remove adapter (Figure 1, Item 17) and O-ring (Figure 1, Item 18) from cover (Figure 1, Item 21). Discard O-ring.

END OF TASK ENGINE OIL DIPSTICK HOSE INSTALLATION 1.

Install new O-ring (Figure 1, Item 18) and adapter (Figure 1, Item 17) on cover (Figure 1, Item 21).

2.

Position dipstick hose (Figure 1, Item 15) on vehicle.

3.

Connect lower end of dipstick hose (Figure 1, Item 15) to adapter (Figure 1, Item 17).

4.

Connect upper end of dipstick hose (Figure 1, Item 15) to bracket (Figure 1, Item 1) with washer (Figure 1, Item 4) and nipple (Figure 1, Item 3).

5.

Secure dipstick hose (Figure 1, Item 15) with clamps (Figure 1, Item 14), screw (Figure 1, Item 16), two washers (Figure 1, Item 13), and new locknut (Figure 1, Item 12). Ensure clamp is positioned on hose so dipstick (Figure 1, Item 2) can be installed into hose.

6.

Install dipstick (Figure 1, Item 2) into dipstick hose (Figure 1, Item 15).

END OF TASK OIL FILL HOSE REMOVAL 1.

Remove cap (Figure 1, Item 6) from socket (Figure 1, Item 7).

2.

Loosen hose clamp (Figure 1, Item 10) and disconnect upper end of oil fill hose (Figure 2, Item 9) from fitting (Figure 1, Item 8).

3.

Remove fitting (Figure 1, Item 8), and socket (Figure 1, Item 7) from bracket (Figure 2, Item 1).

4.

Loosen hose clamp (Figure 1, Item 22) and disconnect lower end of oil fill hose (Figure 2, Item 11) from cover (Figure 1, Item 21).

5.

Remove remaining clamps (Figure 1, Item 14) and remove oil fill hose (Figure 1, Item 11) from vehicle.

6.

Remove four capscrews (Figure 1, Item 20) and cover (Figure 1, Item 21). Remove and discard gasket (Figure 1, Item 19).

0061-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00021)

TM 10-3930-675-23-1

0061

OIL FILL HOSE REMOVAL - Continued 2

6

7

3

4 5 DI

OI

LL L FI

ENGI

NE

NE ENGI TICK PS

1

8

9

10 11

15

12 13 14

14

15 13 17

11 16 22 21

18

19

20 M1705JCH

Figure 1.

Engine Oil Dipstick Replacement and Fill Hose Removal.

END OF TASK 0061-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00021)

TM 10-3930-675-23-1

0061

CLEANING

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. 1.

Clean and inspect all parts IAW General Maintenance Instructions.

2.

Clean oil dipstick cover (Figure 2, Item 1) and cylinder block gasket surfaces (Figure 2, Item 2). Remove all gasket material from cover and cylinder block. 2

1

M2991JCH

Figure 2.

Oil Dipstick Cover and Cylinder Block Cleaning.

END OF TASK OIL FILL HOSE INSTALLATION 1.

Install four capscrews (Figure 3, Item 20) and cover (Figure 3, Item 21) with new gasket (Figure 3, Item 19). Tighten capscrews to 35 ft-lb (47 N•m).

2.

Position oil fill hose (Figure 3, Item 11) on vehicle.

3.

Connect lower end of oil fill hose (Figure 3, Item 11) to cover (Figure 3, Item 21) and tighten hose clamp (Figure 3, Item 22).

4.

Install socket (Figure 3, Item 7), and fitting (Figure 3, Item 8) on bracket (Figure 3, Item 1).

5.

Connect upper end of oil fill hose (Figure 3, Item 9) to fitting (Figure 3, Item 8) and tighten hose clamp (Figure 3, Item 10).

6.

Install cap (Figure 3, Item 6) on socket (Figure 3, Item 7).

7.

Install remaining clamps (Figure 3, Item 14) to secure oil fill hose (Figure 3, Item 11) to vehicle.

0061-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00021)

TM 10-3930-675-23-1

0061

OIL FILL HOSE INSTALLATION - Continued 2

6

7

3

4 5 DI

OI

LL L FI

ENGI

NE

NE ENGI TICK PS

1

8

9

10 11

15

12 13 14

14

15 13 17

11 16 22 21

18

19

20 M1705JCH

Figure 3.

Engine Oil Dipstick and Fill Hoses Installation

END OF TASK 0061-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00021)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE

0061-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00021)

0061

TM 10-3930-675-23-1

0062

FIELD MAINTENANCE OIL SAMPLING VALVES AND HOSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0276, Table 1, Item 9) Lubricating Oil, Gear OE/HDO 10 (Volume 2, WP 0276, Table 1, Item 45) Oil, Lubricating Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Strap, Tiedown (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References TM 10-3930-675-10 Volume 2, WP 0268 Equipment Condition Engine OFF (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185)

NOTE • Refer to General Maintenance Instructions (Volume 2, WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. • Ensure controls are in neutral and vehicle engine is OFF prior to removal of oil sampling valves or hoses. • Note number and location of tiedown straps to aid in installation.

0062-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00022)

TM 10-3930-675-23-1

0062

OIL SAMPLING VALVE REMOVAL

NOTE Oil sampling valves for engine, transmission, and hydraulic system are located in remote hydraulic control compartment. Removal is the same for all three oil sampling valves. Engine oil sampling valve is detailed. 1.

Hold fitting jamnut in place and disconnect engine oil sampling valve from fitting.

2.

Cover fitting with protective cap. TRANSMISSION OIL SAMPLING VALVE

HYDRAULIC SYSTEM OIL SAMPLING VALVE

ENGINE OIL SAMPLING VALVE

M0012JCH

Figure 1.

Oil Sampling Valve.

END OF TASK OIL SAMPLING VALVE INSTALLATION Remove protective cap and install oil sampling valve. END OF TASK

0062-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00022)

TM 10-3930-675-23-1

0062

ENGINE OIL SAMPLING VALVE HOSE REMOVAL

NOTE Tag and trace routing of oil sampling valve hose prior to disconnecting. 1.

Remove tiedown straps and clamps as necessary. Discard tiedown straps.

2.

Disconnect hose from oil sampling valve fitting and engine fitting. Remove hose.

3.

Remove engine fitting.

HOSE CONNECTION, ENGINE OIL SAMPLING

M0013JCH

Figure 2.

Engine Oil Sampling Valve Hose.

END OF TASK ENGINE OIL SAMPLING VALVE HOSE INSTALLATION 1.

Install engine fitting.

2.

Connect hose to engine fitting and route to oil sampling valve.

3.

Connect hose to oil sampling valve fitting and secure hose with new tiedown straps and clamps as necessary.

END OF TASK

0062-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00022)

TM 10-3930-675-23-1

0062

TRANSMISSION OIL SAMPLING VALVE HOSE REMOVAL

NOTE Tag and trace routing of oil sampling valve hose prior to disconnecting. 1.

Move cab to transport position (TM 10-3930-675-10).

2.

Remove tiedown straps and clamps as necessary. Discard tiedown straps.

3.

Disconnect hose from oil sampling valve fitting and transmission fitting. Remove hose.

4.

Remove transmission fitting.

TRANSMISSION OIL SAMPLING VALVE HOSE

M0014JCH

Figure 3.

Transmission Oil Sampling Valve Hose.

END OF TASK TRANSMISSION OIL SAMPLING VALVE HOSE INSTALLATION 1.

Install transmission fitting.

2.

Connect hose to transmission fitting and route to oil sampling valve.

3.

Connect hose to oil sampling valve fitting and secure hose with new tiedown straps and clamps as necessary.

END OF TASK

0062-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00022)

TM 10-3930-675-23-1

0062

HYDRAULIC SYSTEM OIL SAMPLING VALVE HOSE REMOVAL

NOTE Tag and trace routing of oil sampling valve hose prior to disconnecting. 1.

Move cab to transport position (TM 10-3930-675-10).

2.

Remove tiedown straps and clamps as necessary. Discard tiedown straps.

3.

Disconnect hose from oil sampling valve fitting and hydraulic control valve fitting. Remove hose.

4.

Remove hydraulic control valve fitting. INNER SURFACE OF RIGHT FRAME

HYDRAULIC SYSTEM OIL SAMPLING VALVE HOSE

FORWARD MAIN CONTROL VALVE

M0015JCH

Figure 4. Hydraulic System Oil Sampling Valve Hose. END OF TASK

0062-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00022)

TM 10-3930-675-23-1

0062

HYDRAULIC SYSTEM OIL SAMPLING VALVE HOSE INSTALLATION 1.

Install hydraulic control valve fitting.

2.

Connect hose to hydraulic control valve fitting and route to oil sampling valve.

3.

Connect hose to oil sampling valve fitting and secure hose with new tiedown straps and clamps as necessary.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install engine cover (Volume 2, WP 0185).

2.

Start engine (TM 10-3930-675-10) and check for oil leaks.

3.

Return cab to operation position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0062-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00022)

TM 10-3930-675-23-1

0063

FIELD MAINTENANCE EXHAUST MANIFOLD REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Guide, Electrical Connector (Volume 2, WP 0277, Table 1, Item 35) Wrench, Torque, Click, Ratcheting, 3/8in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Antiseize Compound (Volume 2, WP 0276, Table 1, Item 7)

Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 44) Qty: 2 References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Air duct removed (WP 0072) Turbocharger removed (WP 0073)

REMOVAL 1.

Remove three cap screws (Figure 1, Item 3), heat shield (Figure 1, Item 1), clamp (Figure 1, Item 2), and three long spacers (Figure 1, Item 4) from front of exhaust manifold (Figure 1, Item 5). 2

1

3

4

5 M0772JCH

Figure 1.

Exhaust Manifold Removal.

0063-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00023)

TM 10-3930-675-23-1

0063

REMOVAL - Continued 2.

Remove two screws (Figure 2, Item 2) and spacers (Figure 2, Item 4) from end sections of exhaust manifold (Figure 2, Item 5).

3.

Install guide pins (Figure 2, Item 1) in place of removed screws (Figure 2, Item 2).

4.

Remove ten remaining screws (Figure 2, Item 2), spacers (Figure 2, Item 4), exhaust manifold (Figure 2, Item 5), and six gaskets (Figure 2, Item 3). Discard gaskets. 3 3

1 1

3 2

4 2

4

2

Figure 2.

5

Exhaust Manifold Removal.

END OF TASK

0063-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00023)

4

M0773JCH

TM 10-3930-675-23-1

0063

INSTALLATION

NOTE • Ensure exhaust manifold is free of cracks or other damage. If cracks are present, replace exhaust manifold. • Ensure old gasket material is removed from exhaust ports and exhaust manifold mating surfaces. 1.

If guide pins (Figure 3, Item 1) were removed, install guide pins in outside top holes of exhaust ports.

NOTE DO NOT use adhesive of any kind to hold gaskets in place. 2.

Place new gasket (Figure 3, Item 3) on each guide pin (Figure 3, Item 1).

3.

Position exhaust manifold (Figure 3, Item 5) on guide pins (Figure 3, Item 1).

NOTE Apply a light coat of antiseize compound to screw threads only. 4.

Install four new gaskets (Figure 3, Item 3), ten spacers (Figure 3, Item 4), and screws (Figure 3, Item 2) to secure exhaust manifold (Figure 3, Item 5) in place. Tighten screws hand-tight.

5.

Remove guide pins (Figure 3, Item 1) and replace with two spacers (Figure 3, Item 4) and screws (Figure 3, Item 2). Tighten screws hand-tight. 3 3

1 1

3 2

4 2

4

2

Figure 3.

5

Exhaust Manifold Installation.

0063-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00023)

4

M0773JCH

TM 10-3930-675-23-1

0063

INSTALLATION - Continued 6.

Tighten screws (Figure 3, Item 2) in two steps following sequence shown in Figure 4. a.

First step: 20 ft-lb (27 N•m).

b.

Second step: 35 ft-lb (47 N•m). 9

1

5

4

8

12

10

6

7

11

2

3

TIGHTENING SEQUENCE

Figure 4.

Exhaust Manifold Installation.

0063-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00023)

M0774JCH

TM 10-3930-675-23-1

0063

INSTALLATION - Continued 7.

Install clamp (Figure 5, Item 2), three long spacers (Figure 5, Item 4), heat shield (Figure 5, Item 1), and three cap screws (Figure 5, Item 3) at front of exhaust manifold (Figure 5, Item 5). 1

2

3

4

5 (HIDDEN) M0775JCH

Figure 5.

Exhaust Manifold Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install turbocharger (WP 0073).

2.

Install air ducts (WP 0072).

3.

Start engine (TM 10-3930-675-10). Operate engine and check for exhaust leaks.

4.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0063-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00023)

TM 10-3930-675-23-1

0064

FIELD MAINTENANCE INTAKE MANIFOLD REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97)

Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 31) References TM 10-3930-675-10

Materials/Parts Detergent General Purpose Liquid (Volume 2, WP 0276, Table 1, Item 15)

Equipment Condition Air duct removed (WP 0072) Engine sensors removed from intake manifold (WP 0118)

REMOVAL 1.

Remove 24 screws (Figure 1, Item 2) securing intake manifold (Figure 1, Item 1) in position.

2.

Remove intake manifold (Figure 1, Item 1) and gasket (Figure 1, Item 3). Discard gasket.

2

1

ROCKER ARM HOUSING

3

M0776JCH

Figure 1.

Intake Manifold Removal.

END OF TASK

0064-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00024)

TM 10-3930-675-23-1

0064

INSTALLATION

NOTE Ensure intake manifold and rocker arm housing mating surfaces have been cleaned and all old gasket material removed. 1.

Position new gasket (Figure 2, Item 3) and intake manifold (Figure 2, Item 1).

2.

Secure intake manifold (Figure 2, Item 1) with 24 screws (Figure 2, Item 2).

2

1

ROCKER ARM HOUSING

3

M0776JCH

Figure 2. Intake Manifold Installation. 3.

Tighten screws (Figure 2, Item 2) in sequence shown in Figure 3 to 35 ft-lb (47 N•m). 6 10 18 14 11 7

3

13 17

2

20

22 24

21

23

19

16

12

8

4

1

5

9

TIGHTENING SEQUENCE

Figure 3. Intake Manifold Sequence. END OF TASK

0064-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00024)

15 M0778JCH

TM 10-3930-675-23-1

0064

FOLLOW-ON MAINTENANCE 1.

Install engine sensors on intake manifold (WP 0118).

2.

Install air ducts (WP 0072).

3.

Start engine (TM 10-3930-675-10). Operate engine at high idle and use a solution of soapy water to check for air leaks.

END OF TASK END OF WORK PACKAGE

0064-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00024)

TM 10-3930-675-23-1

0065

FIELD MAINTENANCE FRONT GEAR COVER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Seal, Rectangular Ring (Volume 2, WP 0278, Table 1, Item 38) Qty: 6 O-Ring (Volume 2, WP 0278, Table 1, Item 55) Retainer, Packing (Volume 2, WP 0278, Table 1, Item 56)

Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 58) Seal, Plain Encased (Volume 2, WP 0278, Table 1, Item 63) Personnel Required (2) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Alternator drive belt and pulley removed (WP 0092) A/C compressor drive belt and pulley removed (Volume 2, WP 0251) Vibration damper removed (WP 0053) Front main oil seal removed (WP 0066) Water pump oil seal removed (WP 0088) Front engine mount removed (WP 0051)

0065-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00025)

TM 10-3930-675-23-1

0065

REMOVAL

NOTE Wiring harness attachment brackets and belt tensioning arm bracket are mounted to front cover. Ensure these additional items and accessories are tagged or marked for location prior to removal. 1.

Remove three flange head screws (Figure 1, Item 1) securing wiring harness brackets (Figure 1, Item 6). Remove two screws (Figure 1, Item 3) and washers (Figure 1, Item 4) securing belt tensioning arm bracket (Figure 1, Item 5) to front cover (Figure 1, Item 2). 1

2

5

6

3,4

M0779JCH

Figure 1. Front Gear Cover Removal. 2.

Remove 17 remaining flange head screws (Figure 2, Item 1) securing front cover (Figure 2, Item 3) to gear housing (Figure 2, Item 2).

3.

With assistance, remove front cover (Figure 2, Item 3) from gear housing (Figure 2, Item 2).

0065-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00025)

TM 10-3930-675-23-1

0065

REMOVAL - Continued 1 2

3

M0780JCH

Figure 2.

Front Gear Cover Removal.

4.

Remove six rectangular seals (Figure 3, Item 5) at crankshaft seal mounting. Discard seals.

5.

Remove two rectangular seals (Figure 3, Items 1 and 3) at accessory drive mounting and water pump mounting. Discard seals.

6.

Remove O-ring (Figure 3, Item 4) from hydraulic drive idler retainer. Discard O-ring.

7.

Remove front gear cover seal (Figure 3, Item 2) from gear housing groove. Discard seal. 2 2

1

3

5

Figure 3.

4

Front Gear Cover Removal.

END OF TASK

0065-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00025)

M0781JCH

TM 10-3930-675-23-1

0065

CLEANING

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.

Clean mating surface of front cover and gear housing with cleaning solvent and remove old gasket material.

2.

Clean seal grooves with cleaning solvent and remove all residue of old seals.

END OF TASK INSTALLATION

NOTE Ensure O-ring and seal grooves are clean and free of old material. Apply a light coat of lubricating oil to new O-ring and seals prior to installing. 1.

Install two new rectangular seals (Figure 4, Items 1 and 2) in grooves around water pump mounting and accessory drive mounting.

2.

Install six new rectangular seals (Figure 4, Item 4) at crankshaft seal mounting.

3.

Install new O-ring (Figure 4, Item 3) at hydraulic drive idler retainer. 2

1

2

4

3

Figure 4. Front Gear Cover Installation.

0065-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00025)

M0782JCH

TM 10-3930-675-23-1

0065

INSTALLATION - Continued 4.

Install new front gear cover seal (Figure 5, Item 2) in gear housing groove. Apply silicone sealant to overlap joint at top of gear housing (Figure 5, Item 1). 1 2

M0783JCH

Figure 5. 5.

Front Gear Cover Installation.

With assistance, position gear cover (Figure 6, Item 2) on gear housing (Figure 6, Item 1). 1

2

9

M0784JCH

Figure 6.

Front Gear Cover Installation.

0065-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00025)

TM 10-3930-675-23-1

0065

INSTALLATION - Continued 6.

Install three wiring harness brackets (Figure 7, Item 6) and belt tensioning arm bracket (Figure 7, Item 5) on front cover (Figure 7, Item 2). Secure in place with three flange head screws (Figure 7, Item 1) and two washers (Figure 7, Item 4) and screws (Figure 7, Item 3). Tighten screws to 55 in-lb. (6 N•m). 1

2

5

6

3,4

M0785JCH

Figure 7. Front Gear Cover Installation. 7.

Apply silicone sealant to threads of screws at locations 3, 4, and 23 in Figure 8. Install remaining flange head screws. Tighten screws to 55 in-lb. (6N•m).

8.

Tighten all front cover screws in sequence as shown in Figure 8. a.

Screws 1 to 22: 15 ft-lb (20 N•m)

b.

Screws 23 to 28: 50 ft-lb (68 N•m)

0065-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00025)

TM 10-3930-675-23-1

0065

INSTALLATION - Continued 22

21

19

20

17 18 16

15

14 13

12

8

11

10

7

9 6 5 28 4

26 24

1

2

3 25

Figure 8.

27

23

Front Gear Cover Tightening Sequence.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install front engine mount (WP 0051).

2.

Install front main oil seal (WP 0066).

3.

Install vibration damper (WP 0053).

4.

Install water pump oil seal (WP 0088).

5.

Install and adjust A/C compressor drive belt and pulley (Volume 2, WP 0251).

6.

Install and adjust alternator drive belt and pulley (WP 0092).

7.

Start and run engine to operational temperature (TM 10-3930-675-10). Shut down and check for leaks.

8.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0065-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00025)

M0786JCH

TM 10-3930-675-23-1

0066

FIELD MAINTENANCE FRONT MAIN OIL SEAL REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Tool Kit, Internal Combustion Eng (Volume 2, WP 0277, Table 1, Item 86) Wrench, Torque, Dial, 3/8 in. Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98)

Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Sealant, Silicone (Volume 2, WP 0276, Table 1, Item 53) Sealing Compound (Volume 2, WP 0276, Table 1, Item 55)

Materials/Parts Cloth, Abrasive, Emery, Fine (Volume 2, WP 0276, Table 1, Item 12) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49)

Equipment Condition Vibration damper removed (WP 0053)

REMOVAL

NOTE The front main oil seal contact surface of the crankshaft may have a wear sleeve installed. Check for presence of wear sleeve by inspecting the end of the crankshaft to determine if a wear sleeve was previously installed. If wear sleeve is NOT present, follow Steps 1 through 3 only below to remove the front main crankshaft oil seal. If there IS a wear sleeve present, follow Steps 4 through 8 only, to remove unitized front main crankshaft oil seal with wear sleeve. This unitized seal requires the use of a special tool to remove and install it. 1.

Remove six screws (Figure 1, Item 1) and clamping ring (Figure 1, Item 2).

2.

Remove oil seal (Figure 1, Item 3) and dust seal (Figure 1, Item 5) together. Discard oil seal and dust seal.

3.

Remove and discard gasket (Figure 1, Item 4).

3

4 2 1 5 Figure 1.

Front Main Oil Seal Removal.

0066-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00026)

M0692JCH

TM 10-3930-675-23-1

0066

REMOVAL - Continued

NOTE • Steps 4 through 8 below are for models which are equipped with a unitized front main oil seal with wear sleeve. For models WITHOUT a wear sleeve, use Steps 1 through 3 above to remove the front crankshaft main oil seal. • The unitized front crankshaft main oil seal (with wear sleeve) requires the use of the Unitized Oil Seal Installation and Removal Tool to remove and install the unitized front crankshaft main oil seal and wear sleeve. Use Steps 4 through 8 below to remove the unitized front main oil seal and wear sleeve. 4.

Remove six mounting screws (Figure 2, Item 1) from front main oil seal (Figure 2, Item 2). 2

1

M1766JCH

Figure 2. 5.

Front Main Oil Seal Removal.

Position seal replacer (Figure 3, Item 1) over crankshaft nose (Figure 3, Item 4) and oil seal flange (Figure 3, Item 2).

NOTE It may be necessary to use additional sheet metal screws if the seal is difficult to remove. 6.

Using hand drill, drive three sheet metal screws (Figure 3, Item 3) into front main oil seal (Figure 3, Item 2) using small holes in seal replacer (Figure 3, Item 1).

1

2

3

4 Figure 3.

M1767JCH

Unitized Front Crankshaft Main Oil Seal Removal.

0066-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00026)

TM 10-3930-675-23-1

0066

REMOVAL - Continued 7.

Assemble the base (Figure 4, Item 1) and center-screw (Figure 4, Item 7) of the puller to the replacer (Figure 4, Item 3) using two washers (Figure 4, Item 5), and two 3/8-16 capscrews (Figure 4, Item 6).

8.

Turn the center screw (Figure 4, Item 7) of the puller to remove the unitized front main oil seal and wear sleeve (Figure 4, Item 2) from the front gear housing (Figure 4, Item 4).

2 1

3

5 6 4 7

6 Figure 4.

5

M1768JCH

Unitized Front Crankshaft Main Oil Seal Removal.

END OF TASK CLEANING AND INSPECTION 1.

Clean the front crankshaft oil seal gasket surface (Figure 5, Item 1) of the gear cover (Figure 5, Item 2).

2.

Inspect the front crankshaft sealing surface (Figure 5, Item 2) for nicks, burrs, and grooves. Dress the front crankshaft sealing surface with crocus cloth. Remove metal shavings with a magnet.

1

2

3

M1769JCH

Figure 5.

Cleaning and Inspection.

END OF TASK

0066-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00026)

TM 10-3930-675-23-1

0066

INSTALLATION

CAUTION The wear sleeve must NOT be disassembled from the front main oil seal prior to (or during) seal installation. If the wear sleeve and front main oil seal become separated during installation, the assembly must be discarded. • The unitized crankshaft front main oil seal/wear sleeve must be installed when replacing any crankshaft front main oil seal. • The capscrew hole spacing on the unitized crankshaft front oil seal/wear sleeve is NOT symmetrical. 1.

Start 3 60 mm X 2 in. setscrews (Figure 6, Item 4) into 3 holes in the front gear cover (Figure 6, Item 3) as shown in Figure 6.

NOTE The gear cover, unitized front crankshaft oil seal/wear sleeve, and gasket are each marked with an arrow, located at approximately the three-o'clock location. 2.

Align gear cover (Figure 6, Item 3), unitized crankshaft oil seal/wear sleeve (Figure 6, Item 1), and gasket (Figure 6, Item 2), with all three arrows aligned and pointing in a clockwise direction. 1

2

3

4

M1770JCH

Figure 6. Front Unitized Crankshaft Main Oil Seal Installation.

NOTE Confirm orientation of the installer took, seal, gasket, and gear cover holes. Make sure they all align. 3.

Position the unitized crankshaft front main oil seal/wear sleeve (Figure 7, Item 3) and seal replacer (Figure 7, Item 2) over the three setscrews (Figure 7, Item 1) together, to avoid accidentally separating the oil seal from the wear sleeve.

4.

Install three washers (Figure 7, Item 4), and three nuts (Figure 7, Item 5) onto setscrews (Figure 7, Item 1).

0066-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00026)

TM 10-3930-675-23-1

0066

INSTALLATION - Continued

1 2

3

5

M1771JCH

4

Figure 7. Front Unitized Crankshaft Main Oil Seal Installation.

CAUTION When tightening the nuts to install the oil seal onto the crankshaft, make certain that the seal remains perfectly parallel to the front gear cover. Failure to follow this Caution may result in damage to the oil seal. 5.

Tighten three nuts (Figure 8, Item 1) one revolution at a time, alternately, in a clockwise pattern until the seal (Figure 8, Item 3) and installer tool (Figure 8, Item 2) seat against the front gear cover (Figure 8, Item 4).

6.

Tighten the three nuts (Figure 8, Item 1) to 62 in-lb (7 N•m). 1 2

3

4 M1772JCH

Figure 8. Front Unitized Crankshaft Main Oil Seal Installation.

0066-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00026)

TM 10-3930-675-23-1

0066

INSTALLATION - Continued 7.

Apply sealing compound to three bolts (Figure 9, Item 1). Install three bolts through holes (Figure 9, Item 3) of replacer plate tool (Figure 9, Item 2). Tighten bolts to 62 in-lb (7 N•m) in a circular pattern.

8.

Remove three nuts (Figure 9, Item 4), bolts (Figure 9, Item 5), installer tool plate Figure 9, Item 2), and three setscrews from front gear case (Figure 9, Item 6).

1 2

6 4

5

3

M1773JCH

Figure 9. Front Unitized Crankshaft Main Oil Seal Installation.

0066-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00026)

TM 10-3930-675-23-1

0066

INSTALLATION - Continued 9.

Apply sealing compound to three remaining bolts (Figure 10, Item 1) and install to unitized front crankshaft main oil seal (Figure 10, Item 2). Tighten three bolts to 62 in-lb (7 N•m).

10.

Tighten all six unitized front crankshaft oil seal bolts (Figure 10, Item 2) to final torque of 177 in-lb (20 N•m) in a star-shaped pattern.

11.

Check the difference in the installed height of the new wear sleeve versus the crankshaft flange. The difference must not exceed 0.04 in. (1 mm). 1 2

M1774JCH

Figure 10. Front Unitized Crankshaft Main Oil Seal Installation. END OF TASK FOLLOW-ON MAINTENANCE Install vibration damper (WP 0053). END OF TASK END OF WORK PACKAGE

0066-7/8 blank

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TM 10-3930-675-23-1

0067

FIELD MAINTENANCE FUEL INJECTOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Gloves, Rubber, Industrial (Volume 2, WP 0277, Table 1, Item 32) Puller, Mechanical (Volume 2, WP 0277, Table 1, Item 59) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 32) O-Ring (Volume 2, WP 0278, Table 1, Item 33) O-Ring (Volume 2, WP 0278, Table 1, Item 34) References WP 0056 Equipment Condition Rocker arm cover removed (WP 0057)

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.

0067-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00027)

TM 10-3930-675-23-1

0067

REMOVAL

NOTE • Due to engine operating characteristics, adjustments, and alignments, mark or tag push rods, push tubes, crossheads, and injector assemblies for identification as they are removed. If removed, these items MUST be replaced in original locations during installation. • Some push rods are under compression due to valve position. To relieve spring tension, hold push rod while rotating crankshaft CLOCKWISE with accessory drive. 1.

Loosen injector and valve adjusting screws (Figure 1, Item 1) and remove push rods (Figure 1, Item 3) and push tubes (Figure 1, Item 2) on cylinder requiring injector replacement. 1 2

3 M0825JCH

Figure 1. Push Rods and Push Tubes Removal.

0067-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00027)

TM 10-3930-675-23-1

0067

REMOVAL - Continued 2.

Remove crossheads (Figure 2, Item 1) and disconnect injector connector (Figure 2, Item 4).

3.

Remove screw (Figure 2, Item 2) and injector hold-down clamp (Figure 2, Item 3). 1 2

4 3

M0826JCH

Figure 2. Injector Hold-Down Clamp Removal. 4.

Using injector tool (Figure 3, Item 1), remove injector (Figure 3, Item 2) from cylinder head.

5.

Remove three O-rings (Figure 3, Item 3) from injector and discard. 1

3

2

Figure 3.

M0827JCH

Injector Removal.

END OF TASK

0067-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00027)

TM 10-3930-675-23-1

0067

INSTALLATION 1.

Install three new O-rings (Figure, 4, Item 3) on injector. O-rings are color coded for location as follows: red – top, white – middle, blue – bottom.

2.

Lubricate three new O-rings (Figure 4, Item 3) with clean engine oil.

3.

Position injector (Figure 4, Item 1) in cylinder head injector bore with solenoid valve toward intake port.

4.

Align injector (Figure 4, Item 1) between valve springs.

CAUTION DO NOT drive injector in by striking solenoid valve area. This can damage solenoid or cause injector to be out of alignment in bore, which will result in O-ring damage. 5.

Using injector tool (Figure 4, Item 2), seat injector (Figure 4, Item 1) in bore.

2 1

3

M0828JCH

Figure 4.

Injector Installation.

CAUTION Injector must be fully seated before installing hold-down clamp. Engine damage can occur if injector is not fully seated. 6.

Install injector hold-down clamp (Figure 5, Item 2) and screw (Figure 5, Item 1). Tighten screw to 55 ft-lb (75 N•m).

7.

Connect injector connector (Figure 5, Item 3). Check lock tab to ensure connector is locked in place.

0067-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00027)

TM 10-3930-675-23-1

0067

INSTALLATION - Continued 3

2

1

M1117JCH

Figure 5.

Injector Installation.

NOTE Ensure crossheads are installed in the same positions from which they were removed. 8.

Install crossheads (Figure 6, Item 1) on intake and exhaust valves.

NOTE Ensure push rods and push tubes are installed in the same positions from which they were removed. 9.

Rotate rocker arms down and install push rods (Figure 6, Item 2) and push tubes (Figure 6, Item 3). 1

2

3

Figure 6. Push Rods and Push Tubes Installation. 10.

Adjust valves and injectors (WP 0056).

END OF TASK

0067-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00027)

M0829JCH

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE Install rocker arm cover (WP 0057). END OF TASK END OF WORK PACKAGE

0067-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00027)

0067

TM 10-3930-675-23-1

0068

FIELD MAINTENANCE FUEL PUMP ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Diesel Fuel, DF-2 Grade (Volume 2, WP 0276, Table 1, Item 21) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Gasket (Volume 2, WP 0278, Table 1, Item 69)

References TM 10-3930-675-10 Volume 2, WP 0185 Equipment Condition Battery cables disconnected (WP 0129) Fuel line and hose disconnected from fuel pump (WP 0069) Fuel filter/water separator removed (WP 0076) Wire lead disconnected from fuel solenoid shutoff valve (WP 0070)

WARNING

• 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. • Some residual fuel may remain in fuel lines and hoses. Spilled fuel is slippery and must be cleaned up as soon as possible. Failure to clean up spills may result in injury to personnel.

0068-1

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

TM 10-3930-675-23-1

0068

REMOVAL

NOTE If not replacing the fuel pump, replace filter element. 1.

Remove four screws (Figure 1, Item 2), nuts (Figure 1, Item 7), and eight washers (Figure 1, Item 6) securing fuel pump (Figure 1, Item 1) to accessory drive.

2.

Remove fuel pump (Figure 1, Item 1), gasket (Figure 1, Item 5), and jaw coupling spider (Figure 1, Item 4) from accessory drive. Discard gasket.

END OF TASK INSPECTION 1.

Inspect fuel pump mounting flange for cracks and other damage. If cracks are found, replace fuel pump.

2.

Inspect jaw coupling spider and jaw coupling hub for wear and other damage. If either component is worn or damaged, replace component.

END OF TASK INSTALLATION

NOTE Ensure both fuel pump and accessory drive mating flanges are clean and free of old gasket material. 1.

Install jaw coupling spider (Figure 1, Item 4), new gasket (Figure 1, Item 5), and fuel pump (Figure 1, Item 1) on accessory drive.

2.

Secure in place with four screws (Figure 1, Item 2), nuts (Figure 1, Item 7), and eight washers (Figure 1, Item 6). Tighten screws to 35 ft-lb (47 N•m).

0068-2

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

TM 10-3930-675-23-1

0068

INSTALLATION - Continued 1

7

4 5 6 3

Figure 1.

2

M1706JCH

Fuel Pump Removal.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Connect wire lead to fuel solenoid shutoff valve (WP 0070).

NOTE To reduce engine cranking time, fill fuel filter with fuel prior to installation. 2.

Install fuel filter/water separator (WP 0076).

3.

Connect fuel hose from fuel tank to pump. Connect fuel line from fuel pump to cylinder head (WP 0069).

4.

Connect battery cables (WP 0129).

5.

Operate engine (TM 10-3930-675-10) and check for fuel leaks.

6.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0068-3/4 blank

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

TM 10-3930-675-23-1

0069

FIELD MAINTENANCE FUEL HOSES, LINES, AND FITTINGS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Sealing Compound Pipe (Volume 2, WP 0276, Table 1, Item 59) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)

WARNING

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.

0069-1

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

TM 10-3930-675-23-1

0069

NOTE • Fuel lines and hoses may contain residual amounts of fuel which may be spilled when replacing fuel lines. Spilled fuel should be cleaned up immediately. • Ensure all lines and fittings are clear of debris and excess pipe sealing compound does not enter lines or fittings. COOLING PLATE-TO-CYLINDER HEAD FUEL LINE REMOVAL 1.

Disconnect fuel line (Figure 1, Item 2) from cooling plate (Figure 1, Item 1) and cylinder head fitting (Figure 1, Item 3).

2.

Remove fitting (Figure 1, Item 3) from cylinder head (Figure 1, Item 4).

END OF TASK COOLING PLATE-TO-CYLINDER HEAD FUEL LINE INSTALLATION 1.

Apply a light coat of sealing compound to fitting (Figure 1, Item 3) and install in cylinder head (Figure 1, Item 4).

2.

Connect fuel line (Figure 1, Item 2) to cylinder head fitting (Figure 1, Item 3) and cooling plate (Figure 1, Item 1). 2 1 3

4

M0028JCH

Figure 1. Cooling Plate-to-Cylinder Head Fuel Line. END OF TASK

0069-2

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

TM 10-3930-675-23-1

0069

FUEL PUMP-TO-COOLING PLATE FUEL LINE REMOVAL 1.

Disconnect fuel line (Figure 2, Item 2) from cooling plate (Figure 2, Item 3) and fuel pump fitting (Figure 2, Item 1).

2.

Remove fitting (Figure 2, Item 1) from fuel pump (Figure 2, Item 4).

END OF TASK FUEL PUMP-TO-COOLING PLATE FUEL LINE INSTALLATION 1.

Apply a light coat of sealing compound to fitting (Figure 2, Item 1) and install in fuel pump (Figure 2, Item 4).

2.

Connect fuel line (Figure 2, Item 2) to fuel pump fitting (Figure 2, Item 1) and cooling plate (Figure 2, Item 3). 2

3

1 4 M0029JCH

Figure 2. Fuel Pump-to-Cooling Plate Fuel Line. END OF TASK

0069-3

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

TM 10-3930-675-23-1

0069

ENGINE FUEL RETURN LINE REMOVAL 1.

Disconnect fuel return line (Figure 3, Item 2) from cylinder head fitting (Figure 3, Item 1). Remove fitting from cylinder head (Figure 3, Item 5).

2.

Disconnect fuel return line (Figure 3, Item 4) from elbow adapter fitting (Figure 3, Item 3).

END OF TASK ENGINE FUEL RETURN LINE INSTALLATION 1.

Apply a light coat of sealing compound to cylinder head fitting (Figure 3, Item 1) and install fitting in cylinder head (Figure 3, Item 5).

2.

Connect fuel return line (Figure 3, Item 2) to cylinder head fitting (Figure 3, Item 1).

3.

Connect fuel return line (Figure 3, Item 4) to elbow adapter fitting (Figure 3, Item 3). 1

3

2

4

5

M0030JCH

Figure 3. Engine Fuel Return Line. END OF TASK FUEL RETURN HOSE REMOVAL

NOTE Fuel tank must be drained prior to removal of fuel return hose. Fuel lines may retain small amounts of fuel. 1.

Remove fuel tank drain plug (Figure 4, Item 6) and drain fuel into a suitable clean container. Replace plug.

2.

Disconnect fuel return hose (Figure 4, Item 4) and remove elbow (Figure 4, Item 1) and adapter (Figure 4, Item 2).

3.

Trace and tag fuel return hose (Figure 4, Item 4) from fuel tank (Figure 4, Item 7) to elbow adapter fitting (Figure 4, Item 3).

4.

Remove hose clamps (Figure 4, Item 5) as required and disconnect fuel return hose (Figure 4, Item 4)

0069-4

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TM 10-3930-675-23-1

0069

FUEL RETURN HOSE REMOVAL - Continued from elbow adapter fitting (Figure 4, Item 3). END OF TASK FUEL RETURN HOSE INSTALLATION 1.

Apply a thin coat of sealing compound to elbow (Figure 4, Item 1) and adapter (Figure 4, Item 2) and install in fuel tank (Figure 4, Item 7).

2.

Install fuel return hose (Figure 4, Item 4) on elbow (Figure 4, Item 1).

3.

Route fuel return hose (Figure 4, Item 4) and connect to elbow adapter fitting (Figure 4, Item 3).

4.

Secure fuel return hose (Figure 4, Item 4) in place with hose clamps (Figure 4, Item 5) as needed. 2

1

4

7

3

5

6

Figure 4.

Fuel Return Hose.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Replace fuel in fuel tank, start engine, and check for fuel leaks (TM 10-3930-675-10).

2.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0069-5/6 blank

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

4

M0032JCH

TM 10-3930-675-23-1

0070

FIELD MAINTENANCE FUEL SOLENOID SHUTOFF VALVE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 in. Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98)

References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)

Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) O-Ring (Volume 2, WP 0278, Table 1, Item 10) Qty: 2

WARNING

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.

0070-1

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TM 10-3930-675-23-1

0070

REMOVAL 1.

Remove nut (Figure 1, Item 3) and disconnect wire lead (Figure 1, Item 2) from fuel shutoff valve (Figure 1, Item 4). Replace nut hand-tight on terminal.

2.

Remove four screws (Figure 1, Item 1) securing fuel shutoff valve (Figure 1, Item 4) to fuel pump (Figure 1, Item 5).

3.

Remove fuel shutoff valve (Figure 1, Item 4), spacer (Figure 1, Item 6), and O-ring seal (Figure 1, Item 7) from fuel pump (Figure 1, Item 5). Discard O-ring seal. 1

2

7 3 6

5 1

4

M0016JCH

Figure 1. Fuel Solenoid Shutoff Valve Removal. END OF TASK INSTALLATION

NOTE • Assemble components of new fuel shutoff valve in the following order. • Ensure coil is a single-terminal coil. 1.

Place spacer (Figure 2, Item 3) with O-ring groove, coil side up, on clean surface and install new O-ring seal (Figure 2, Item 2).

2.

Install actuator disc (Figure 2, Item 4) with cup side toward coil (Figure 2, Item 8).

3.

Install valve disc (Figure 2, Item 5) with raised area up.

4.

Install spring washer (Figure 2, Item 6) with cup side toward coil (Figure 2, Item 8).

5.

Install fuel shield (Figure 2, Item 7) and coil (Figure 2, Item 8).

6.

Hold assembly together and install with new O-ring seal (Figure 2, Item 2) on fuel pump (Figure 2, Item 1).

0070-2

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TM 10-3930-675-23-1

0070

INSTALLATION - Continued 1

2

3 2

4 5 6

7 8

M0017JCH

Figure 2.

Fuel Solenoid Shutoff Valve Installation.

7.

Secure fuel shutoff valve (Figure 3, Item 4) to fuel pump (Figure 3, Item 5) with four screws (Figure 3, Item 1). Tighten screws to 30 in-lb. (3.4 N•m).

8.

Connect wire lead (Figure 3, Item 2) to fuel shutoff valve (Figure 3, Item 4) with nut (Figure 3, Item 3). Tighten nut to 25 in-lb. (2.8 N•m). 2

1

3

5 1

Figure 3.

4

M0018JCH

Fuel Solenoid Shutoff Valve Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Start engine, run, and check for leaks (TM 10-3930-675-10).

2.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0070-3/4 blank

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

TM 10-3930-675-23-1

FIELD MAINTENANCE ENGINE AIR CLEANER MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Filter Element, Intake Air Cleaner (Volume 2, WP 0278, Table 1, Item 113) Filter Element, Intake Air Cleaner (Volume 2, WP 0278, Table 1, Item 114)

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

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

0071

TM 10-3930-675-23-1

0071

FILTER ELEMENTS REPLACEMENT 1.

Open six spring clips (Figure 1, Item 1) and remove cover (Figure 1, Item 2) from end of engine air cleaner (Figure 1, Item 3). 1

2

M0019JCH

3

Figure 1.

Engine Air Cleaner.

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TM 10-3930-675-23-1

0071

FILTER ELEMENTS REPLACEMENT - Continued 2.

Remove primary filter element (Figure 2, Item 2) and secondary filter element (Figure 2, Item 3) from air cleaner (Figure 2, Item 1). Discard filter elements.

3.

Using rags, wipe interior of air cleaner (Figure 2, Item 1) free of dust and dirt.

4.

Install new secondary filter element (Figure 2, Item 3) and new primary filter element (Figure 2, Item 2) in air cleaner (Figure 2, Item 1).

5.

Install cover (Figure 1, Item 2) on air cleaner (Figure 1, Item 3) and close six spring clips (Figure 1, Item 1). 1

1

2

3

Figure 2. Engine Air Cleaner Filter Elements Removal. END OF TASK

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

M0020JCH

TM 10-3930-675-23-1

0071

AIR CLEANER REMOVAL 1.

Loosen clamp (Figure 3, Item 3) and remove cap (Figure 3, Item 2) from air cleaner (Figure 3, Item 1).

2.

Remove vacuum indicator (Figure 3, Item 4) and nipple (Figure 3, Item 5) from air cleaner (Figure 3, Item 1).

3.

Loosen clamp (Figure 3, Item 7) holding elbow (Figure 3, Item 6) to air cleaner (Figure 3, Item 1).

4.

Remove four nuts (Figure 3, Item 8), washers (Figure 3, Item 9), screws (Figure 3, Item 10), and air cleaner (Figure 3, Item 1) from elbow (Figure 3, Item 6) and top of vehicle.

5.

Remove rubber dust vent (Figure 3, Item 11) from cover (Figure 3, Item 12). 2

1

3

4,5

6

12

11

8, 9,10

7

Figure 3. Engine Air Cleaner Filter Elements Removal and Installation. END OF TASK

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

M0021JCH

TM 10-3930-675-23-1

0071

AIR CLEANER INSTALLATION 1.

Install rubber dust vent (Figure 4, Item 11) on cover (Figure 4, Item 12) of air cleaner (Figure 4, Item 1).

2.

Position air cleaner (Figure 4, Item 1) on top of vehicle and elbow (Figure 4, Item 6) and install four screws (Figure 4, Item 10), washers (Figure 4, Item 9), and nuts (Figure 4, Item 8).

3.

Tighten clamp (Figure 4, Item 7) holding elbow (Figure 4, Item 6) to air cleaner (Figure 4, Item 1)

4.

Install nipple (Figure 4, Item 5) and vacuum indicator (Figure 4, Item 4) in air cleaner (Figure 4, Item 1).

5.

Install cap (Figure 4, Item 2) on air cleaner (Figure 4, Item 1) and tighten clamp (Figure 4, Item 3). 2

1

3

4,5

6

12

11

8, 9,10

7

Figure 4. Engine Air Cleaner Filter Elements Removal and Installation. END OF TASK END OF WORK PACKAGE

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M0021JCH

TM 10-3930-675-23-1

0072

FIELD MAINTENANCE ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References WP 0084 WP 0085

Materials/Parts Clamp, Hose (Volume 2, WP 0278, Table 1, Item 101) Qty: As needed

Equipment Condition Engine cover removed (Volume 2, WP 0185)

NOTE • Note position of elbows and tubes to aid in installation. • Inspect all hose clamps. If damaged, replace as necessary. • Metal rings installed over hoses may be replaced as necessary.

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TM 10-3930-675-23-1

0072

AIR CLEANER-TO-TURBOCHARGER HOSES AND TUBES REMOVAL 1.

Loosen six hose clamps (Figure 1, Item 9) and remove elbow (Figure 1, Item 8), 7 1/4-in. tube (Figure 1, Item 11), rubber elbow (Figure 1, Item 12), 4 1/2-in. tube (Figure 1, Item 13), and rubber elbow (Figure 1, Item 14) from air cleaner (Figure 1, Item 10).

2.

Remove clamp (Figure 1, Item 6) holding 7 1/4-in. tube (Figure 1, Item 7) to bracket (Figure 1, Item 15).

3.

Loosen two hose clamps (Figure 1, Item 4) and remove 71/4-in. tube (Figure 1, Item 7) and elbow (Figure 1, Item 5) from 25-in. tube (Figure 1, Item 3).

4.

Remove clamp (Figure 1, Item 16) holding 25-in. tube (Figure 1, Item 3) to bracket (Figure 1, Item 17).

5.

Loosen four hose clamps (Figure 1, Item 2) and remove 25-in. tube (Figure 1, Item 3), rubber elbow (Figure 1, Item 1), tube (Figure 1, Item 20), and rubber elbow (Figure 1, Item 19) from turbocharger (Figure 1, Item 18).

END OF TASK AIR CLEANER-TO-TURBOCHARGER HOSES AND TUBES INSTALLATION 1.

Install rubber elbow (Figure 1, Item 19), tube (Figure 1, Item 20), rubber elbow (Figure 1, Item 1), and 25-in. tube (Figure 1, Item 3) to turbocharger (Figure 1, Item 18) and tighten four hose clamps (Figure 1, Item 2).

2.

Install 25-in. tube (Figure 1, Item 3) on bracket (Figure 1, Item 17) with clamp (Figure 1, Item 16).

3.

Install elbow (Figure 1, Item 5) and 7 1/4-in. tube (Figure 1, Item 7) on 25-in. tube (Figure 1, Item 3) and tighten two hose clamps (Figure 1, Item 4).

4.

Install 7 1/4-in. tube (Figure 1, Item 7) on bracket (Figure 1, Item 15) with clamp (Figure 1, Item 6).

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TM 10-3930-675-23-1

0072

AIR CLEANER-TO-TURBOCHARGER HOSES AND TUBES INSTALLATION - Continued

CAUTION Ensure there is clearance between rubber elbow and sheet metal or a hole will develop in rubber elbow. 5.

Install rubber elbow (Figure 1, Item 14), 4 1/2-in. tube (Figure 1, Item 13), rubber elbow (Figure 1, Item 12), 7 1/4-in. tube (Figure 1, Item 11), and elbow (Figure 1, Item 8) on air cleaner (Figure 1, Item 10) and tighten six hose clamps (Figure 1, Item 9).

10 2

1

3

8

4

9

45 67

2 20 2 19

9 11 9

17 16 15 9

2

18

12

14 9

9

13

SIDE VIEW Figure 1.

Air Cleaner-to-Turbocharger Hoses and Tubes.

END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK

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

M0022JCH

TM 10-3930-675-23-1

0072

TURBOCHARGER-TO-CHARGE AIR COOLER HOSES AND TUBES REMOVAL 1.

Remove radiator top grating (WP 0085).

2.

Loosen four hose clamps (Figure 2, Item 3) and remove hose (Figure 2, Item 4), tube (Figure 2, Item 5), and hose (Figure 2, Item 6) from turbocharger (Figure 2, Item 2) and tube (Figure 2, Item 7).

3.

Loosen two hose clamps (Figure 2, Item 8) and remove hose (Figure 2, Item 9) from tube (Figure 2, Item 10) and tube (Figure 2, Item 7).

4.

Remove U-clamp (Figure 2, Item 11) holding tube (Figure 2, Item 10) to bracket (Figure 2, Item 1).

5.

Loosen two hose clamps (Figure 2, Item 12) and remove tube (Figure 2, Item 10) and hose (Figure 2, Item 13) from charge air cooler (Figure 2, Item 14).

END OF TASK TURBOCHARGER-TO-CHARGE AIR COOLER HOSES AND TUBES INSTALLATION 1.

Install hose (Figure 2, Item 13) and tube (Figure 2, Item 10) on charge air cooler (Figure 2, Item 14) and tighten two hose clamps (Figure 2, Item 12).

2.

Install tube (Figure 2, Item 10) on bracket (Figure 2, Item 1) with U-clamp (Figure 2, Item 11).

3.

Install hose (Figure 2, Item 9) on tube (Figure 2, Item 10) and tube (Figure 2, Item 7) and tighten two hose clamps (Figure 2, Item 8).

4.

Install hose (Figure 2, Item 6), tube (Figure 2, Item 5), and hose (Figure 2, Item 4) on tube (Figure 2, Item 7) and turbocharger (Figure 2, Item 2) and tighten four clamps (Figure 2, Item 3).

5.

Install radiator top grating (WP 0085).

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0072

TURBOCHARGER-TO-CHARGE AIR COOLER HOSES AND TUBES INSTALLATION - Continued

TOP VIEW

1

2 3 4 3 5 3 6 3

7 12 13 12 11

14

10 9

8

8

Figure 2. Turbocharger-to-Charge Air Cooler Hoses and Tubes. END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK

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

M0023JCH

TM 10-3930-675-23-1

0072

CHARGE AIR COOLER-TO-ENGINE AIR INTAKE MANIFOLD HOSES AND TUBES REMOVAL 1.

Remove radiator top grating (WP 0085).

2.

Remove radiator splash shield (WP 0084).

3.

Loosen two hose clamps (Figure 3, Item 2) and remove hose (Figure 3, Item 3) from charge air cooler (Figure 3, Item 1) and tube (Figure 3, Item 5).

4.

Remove U-clamp (Figure 3, Item 4) holding tube (Figure 3, Item 5) to bracket (Figure 3, Item 17).

5.

Loosen two hose clamps (Figure 3, Item 6) and remove tube (Figure 3, Item 5) and hose (Figure 3, Item 7) from tube (Figure 3, Item 8).

6.

Loosen two hose clamps (Figure 3, Item 9) and remove hose (Figure 3, Item 10) from tube (Figure 3, Item 8) and tube (Figure 3, Item 8).

7.

Remove U-clamp (Figure 3, Item 12) holding tube (Figure 3, Item 11) to bracket (Figure 3, Item 13).

8.

Loosen two hose clamps (Figure 3, Item 14) and remove tube (Figure 3, Item 11) and hose (Figure 3, Item 15) from air intake connector (Figure 3, Item 16) of engine air intake manifold.

END OF TASK CHARGE AIR COOLER-TO-ENGINE AIR INTAKE MANIFOLD HOSES AND TUBES INSTALLATION 1.

Install hose (Figure 3, Item 15) and tube (Figure 3, Item 11) on air intake connector (Figure 3, Item 16) of engine air intake manifold and tighten two hose clamps (Figure 3, Item 14).

2.

Install tube (Figure 3, Item 11) on bracket (Figure 3, Item 13) with U-clamp (Figure 3, Item 12).

3.

Install hose (Figure 3, Item 10) on tube (Figure 3, Item 11) and tube (Figure 3, Item 8) and tighten two hose clamps (Figure 3, Item 9).

4.

Install hose (Figure 3, Item 7) and tube (Figure 3, Item 5) on tube (Figure 3, Item 8) and tighten two hose clamps (Figure 3, Item 6).

5.

Install tube (Figure 3, Item 5) on bracket (Figure 3, Item 17) with U-clamp (Figure 3, Item 4).

6.

Install hose (Figure 3, Item 3) on tube (Figure 3, Item 5) and charge air cooler (Figure 3, Item 1) and tighten two hose clamps (Figure 3, Item 2).

7.

Install radiator splash shield (WP 0084).

8.

Install radiator top grating (WP 0085).

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TM 10-3930-675-23-1

0072

CHARGE AIR COOLER-TO-ENGINE AIR INTAKE MANIFOLD HOSES AND TUBES INSTALLATION Continued

7

6 5

6 8 9 10 9

4

1 2

3

11

2

12 13

14 15 14 16 17 TOP VIEW

M0024JCH

Figure 3. Charger Air Cooler-to-Engine Air Intake Manifold Hoses and Tubes. END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE

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0073

FIELD MAINTENANCE TURBOCHARGER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanic's (Volume 2, WP 0277, Table 1, Item 85) Gage, Depth (Volume 2, WP 0277, Table 1, Item 27) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Antiseize Compound (Volume 2, WP 0276, Table 1, Item 7) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) O-Ring (Volume 2, WP 0278, Table 1, Item 28)

Materials/Parts (cont.) Gasket (Volume 2, WP O-Ring (Volume 2, WP Gasket (Volume 2, WP O-Ring (Volume 2, WP

0278, Table 1, Item 36) 0278, Table 1, Item 61) 0278, Table 1, Item 67) 0278, Table 1, Item 68)

Personnel Required (2) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185)

WARNING

DO NOT perform maintenance on turbocharger unless engine has been allowed to cool down. Turbocharger maintenance involves working around exhaust system. Exhaust manifold and pipes may be hot and will cause serious burns.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00033)

TM 10-3930-675-23-1

0073

REMOVAL 1.

Loosen hose clamp screws (Figure 1, Item 3) and remove clamps (Figure 1, Item 2) from exhaust and intake pipes (Figure 1, Items 1 and 4) and from turbocharger (Figure 1, Item 5). 3 1

3

2

2

5 4

Figure 1.

M0833JCH

Clamps Removal.

2.

Disconnect oil supply line (Figure 2, Item 4) from fitting (Figure 2, Item 1) on top of turbocharger (Figure 2, Item 6). Remove fitting and two O-ring seals (Figure 2, Items 2 and 3) from turbocharger. Discard O-ring seals.

3.

Remove two screws (Figure 2, Item 8) securing oil drain line (Figure 2, Item 5) and gasket (Figure 2, Item 7) to bottom of turbocharger (Figure 2, Item 6). Disconnect oil drain line. Discard gasket. 6

5

4 1,2,3

7

8

Figure 2. Turbocharger Removal.

0073-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00033)

M0834JCH

TM 10-3930-675-23-1

0073

REMOVAL - Continued 4.

Remove v-band clamp (Figure 3, Item 1), discharge elbow (Figure 3, Item 2), and O-ring seal (Figure 3, Item 3) from turbocharger (Figure 3, Item 4). Discard O-ring seal. 1

2

3

4

Figure 3. 5.

M0835JCH

Turbocharger Removal.

Remove four nuts (Figure 4, Item 4) securing turbocharger (Figure 4, Item 3) to exhaust manifold (Figure 4, Item 1). With assistance, remove turbocharger and gasket (Figure 4, Item 2) from exhaust manifold. Discard gasket. 1 2

3

M0839JCH

4

Figure 4.

Turbocharger Removal.

END OF TASK

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TM 10-3930-675-23-1

0073

INSPECTION 1.

Perform turbocharger axial clearance check as follows: a.

Loosen hose clamp screws and remove intake and exhaust pipes from turbocharger. Install dial depth gage as shown and push rotor assembly away from gauge.

b.

Set gauge to zero.

c.

Push rotor assembly toward gauge and record reading.

d.

Recorded reading must be 0.0015 to 0.0035 in. (0.038 to 0.089 mm). If axial clearance reading is not within specified range, replace turbocharger.

AXIAL CLEARANCE CHECK Figure 5. 2.

M0837JCH

Turbocharger Axial Clearance Check.

Perform turbocharger radial bearing clearance check as follows: a.

Loosen hose clamp screws and remove intake and exhaust pipes from turbocharger.

b.

Push compressor wheel toward compressor housing. Measure clearance with gauge and record reading.

c.

Push compressor wheel away from housing. Measure clearance, in same location, with gauge and record reading.

d.

Subtract smaller clearance from larger clearance to obtain radial bearing clearance reading. Radial bearing clearance must be 0.006 to 0.025 in. (0.152 to 0.635 mm). If reading is not within specified range, replace turbocharger.

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TM 10-3930-675-23-1

0073

INSPECTION - Continued

RADIAL BEARING CLEARANCE CHECK

M0838JCH

Figure 6. Turbocharger Radial Bearing Clearance Check. 3.

Inspect compressor impeller blades and turbine wheel for damage. If damage is found, replace turbocharger.

4.

Visually check turbine and compressor housings for cracks. If cracks exist on outer walls, replace turbocharger.

5.

Visually check turbocharger intake and discharge for oil. If noted on turbine side, and oil discharge line is not restricted, replace turbocharger. If oil is on intake side and no restriction is found, replace turbocharger.

NOTE Mounting flanges must be inspected after removal of turbocharger from engine. 6.

Visually check mounting flange surfaces for cracks. Cracks longer than 0.6 in. (15.2 mm) or cracks which extend to mounting holes are not acceptable. Cracks of any length which extend through divider are acceptable only if separated by at least 0.5 in. (12.7 mm).

END OF TASK

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TM 10-3930-675-23-1

0073

INSTALLATION

NOTE Ensure mounting flanges on exhaust manifold and turbocharger are clean and free of old gasket material. 1.

Apply a thin coat of antiseize compound to exhaust manifold (Figure 7, Item 1) mounting studs.

2.

With assistance, install new gasket (Figure 7, Item 2) and turbocharger (Figure 7, Item 3) on exhaust manifold (Figure 7, Item 1). Secure with four nuts (Figure 7, Item 4). Tighten nuts to 45 ft-lb (61 N•m). 1 2

3

M0839JCH

4

Figure 7. 3.

Turbocharger Installation.

Install discharge elbow (Figure 8, Item 2), v-band clamp (Figure 8, Item 1), and new O-ring seal (Figure 8, Item 3) on turbocharger (Figure 8, Item 4). Tighten v-band clamp. 1

2

3

4

Figure 8.

M0840JCH

Turbocharger Installation.

4.

Install oil drain line (Figure 9, Item 5) and new gasket (Figure 9, Item 7) on turbocharger (Figure 9, Item 6) with two screws (Figure 9, Item 8). Tighten screws to 20 ft-lb (27 N•m).

5.

Pour 2 to 3 oz (50 to 60 cc) of clean engine oil into turbocharger inlet port.

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TM 10-3930-675-23-1

0073

INSTALLATION - Continued 6.

Install fitting (Figure 9, Item 1) and new O-ring seals (Figure 9, Items 2 and 3) on turbocharger inlet port and connect oil supply line (Figure 9, Item 4) to fitting. 6

5

4 1,2,3

7

8

Figure 9. 7.

M0841JCH

Turbocharger Installation.

Install exhaust and intake pipes (Figure 10, Items 1 and 4) and clamps (Figure 10, Item 2) on turbocharger (Figure 10, Item 5). Tighten hose clamp screws (Figure 10, Item 3). 3 1

3

2

2

5 4

Figure 10.

Turbocharger Installation.

END OF TASK

0073-7

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M0842JCH

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Start engine (TM 10-3930-675-10). Check for air, exhaust, coolant, and oil leaks.

2.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00033)

0073

TM 10-3930-675-23-1

0074

FIELD MAINTENANCE FUEL TANK REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Lifting Device (300 lb minimum capacity) Sling, Nylon (Volume 2, WP 0277, Table 1, Item 70)

References TM 10-3930-675-10

Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 5

Equipment Condition Fuel level sending unit removed (WP 0132) Muffler removed (WP 0079) Fuel drained from fuel tank (TM 10-3930-675-10) Fuel supply and return hoses disconnected from fuel tank (WP 0075) Right-side step removed (Volume 2, WP 0180) Cab sliding cylinder disconnected from fuel tank (Volume 2, WP 0233)

Personnel Required (3)

WARNING

• 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. • 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 Fuel tank may contain residual amounts of fuel, which may be spilled when replacing tank. Spilled fuel should be cleaned up immediately.

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TM 10-3930-675-23-1

0074

REMOVAL 1.

Attach a nylon sling to lifting eyes at top of fuel tank (Figure 1, Item 4) and to suitable lifting device. Take up slack in sling.

2.

Remove three locknuts (Figure 1, Item 1), screws (Figure 1, Item 2), and six washers (Figure 1, Item 3) from fuel tank (Figure 1, Item 4) and frame. Discard locknuts.

1,2,3 4

M0843JCH

Figure 1. Fuel Tank Removal. 3.

Remove two locknuts (Figure 2, Item 2), screws (Figure 2, Item 1), and four spacer washers (Figure 2, Item 3) from fuel tank (Figure 2, Item 4) and bracket (Figure 2, Item 5). Discard locknuts.

CAUTION Use caution not to allow fuel tank to contact hydraulic reservoir or other components of RTCH as it is being removed. 4.

Raise fuel tank (Figure 2, Item 4) to clear bracket (Figure 2, Item 5) and remove from frame.

END OF TASK

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TM 10-3930-675-23-1

0074

INSTALLATION 1.

Attach a nylon sling to lifting eyes at top of fuel tank (Figure 2, Item 4) and to suitable lifting device. Take up slack in sling.

CAUTION Use caution not to allow fuel tank to contact hydraulic reservoir or other components of RTCH as it is being installed. 2.

Raise fuel tank (Figure 2, Item 4) and position fuel tank at frame.

3.

Secure fuel tank (Figure 2, Item 4) to frame with three screws (Figure 2, Item 2), six washers (Figure 2, Item 3), and three new locknuts (Figure 2, Item 1).

4.

Install four spacer washers (Figure 2, Item 7), two screws (Figure 2, Item 5), and new locknuts (Figure 2, Item 6) on fuel tank (Figure 2, Item 4) and bracket (Figure 2, Item 8). 1

3

2

4

5 M0844JCH

Figure 2.

Fuel Tank Replacement.

END OF TASK

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TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Connect cab sliding cylinder to fuel tank (Volume 2, WP 0233).

2.

Install right-side step (Volume 2, WP 0180).

3.

Connect fuel supply and return hoses to fuel tank (WP 0075).

4.

Install muffler (WP 0079).

5.

Install fuel level sending unit (WP 0132).

6.

Fill fuel tank (TM 10-3930-675-10).

7.

Start engine (TM 10-3930-675-10) and check for leaks.

END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00034)

0074

TM 10-3930-675-23-1

0075

FIELD MAINTENANCE FUEL SUPPLY AND RETURN HOSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54)

Equipment Condition Engine cover removed (Volume 2, WP 0185)

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0075

REMOVAL

NOTE • Fuel tank must be drained prior to removal of fuel supply hose. Fuel lines may retain small amounts of fuel. Spilled fuel should be cleaned up immediately. • Fuel tank may contain residual amounts of fuel, which may be spilled when replacing tank. Spilled fuel should be cleaned up immediately. 1.

Remove fuel tank drain plug (Figure 1, Item 6) and drain fuel into a suitable clean container. Replace plug.

2.

Disconnect fuel supply hose (Figure 1, Item 4) and remove elbow (Figure 1, Item 1) and adapter (Figure 1, Item 2).

3.

Trace and tag fuel supply hose (Figure 1, Item 4) from fuel tank (Figure 1, Item 7) to fuel filter (Figure 1, Item 5).

4.

Remove hose clamps (Figure 1, Item 3) as required and disconnect fuel supply hose (Figure 1, Item 4) from fuel filter (Figure 1, Item 5).

END OF TASK

0075-2

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TM 10-3930-675-23-1

0075

INSTALLATION 1.

Apply a thin coat of sealing compound to elbow (Figure 1, Item 1) and adapter (Figure 1, Item 2) and install in fuel tank (Figure 1, Item 7).

2.

Install fuel supply hose (Figure 1, Item 4) on elbow (Figure 1, Item 1).

3.

Route fuel supply hose (Figure 1, Item 4) and connect to fuel filter (Figure 1, Item 5).

4.

Secure fuel supply hose (Figure 1, Item 4) in place with hose clamps (Figure 1, Item 3) as needed.

5.

Replace fuel in fuel tank, start engine, and check for fuel leaks (TM 10-3930-675-10). 2

1

8

7

6

5

Figure 1.

4

Fuel Supply Hose.

END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE

0075-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00035)

3

M0031JCH

TM 10-3930-675-23-1

0076

FIELD MAINTENANCE FUEL FILTER/WATER SEPARATOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54) Wrench, Oil Filter, Strap (Volume 2, WP 0277, Table 1, Item 91)

Materials/Parts (cont.) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Filter Element, Fluid (Volume 2, WP 0278, Table 1, Item 173)

Materials/Parts Diesel Fuel, DF-1 Grade (Volume 2, WP 0276, Table 1, Item 18) Diesel Fuel, DF-2 (Volume 2, WP 0276, Table 1, Item 21)

References TM10-3930-675-10

WARNING

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.

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TM 10-3930-675-23-1

0076

REMOVAL

NOTE Step 1 applies to RT 240V1R, RT 240V3 and RT 240V1R vehicles only. 1.

Close ball valve (Figure 1, Item 2) on fuel pump (Figure 1, Item 1).

1

2

M0025JCH

Figure 1. 2.

Fuel Pump Ball Valve.

Open drain valve (Figure 2, Item 3) on fuel filter (Figure 2, Item 2) and drain fluid into a suitable container. Dispose of drained fluid in accordance with SOP.

NOTE For RT 240V1 vehicle, fuel will drain from fuel pump as fuel filter is removed. Be prepared to install new fuel filter quickly to minimize fuel spillage. 3.

Remove fuel filter (Figure 2, Item 2) from fuel pump (Figure 2, Item 1). Discard fuel filter.

4.

Remove threaded adapter seal ring (Figure 2, Item 4) from fuel pump (Figure 2, Item 1). Discard seal ring.

END OF TASK

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TM 10-3930-675-23-1

0076

INSTALLATION

NOTE Ensure fuel pump sealing surface is clean and free of old gasket material. 1.

Install new threaded adapter seal ring (Figure 2, Item 4) provided with new fuel filter on fuel pump (Figure 2, Item 1).

2.

Apply a light coat of lubricating oil to new filter gasket and fill fuel filter with correct fuel.

3.

Install new fuel filter (Figure 2, Item 2) on fuel pump (Figure 2, Item 1) and tighten until gasket contacts fuel pump surface.

CAUTION Overtightening of filter can distort threads and damage fuel filter seal. 4.

Tighten fuel filter (Figure 2, Item 3) an additional ½ to ¾ turn. 1

2

3

4

M0026JCH

Figure 2.

Fuel Filter.

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TM 10-3930-675-23-1

0076

INSTALLATION - Continued

NOTE Step 4 applies to RT 240V1R , RT 240V2 and RT 240V3 vehicles only. 5.

Open ball valve (Figure 3, Item 2) on fuel pump (Figure 3, Item 1).

1

2

M0027JCH

Figure 3.

Fuel Pump Ball Valve.

END OF TASK FOLLOW-ON MAINTENANCE Start engine and check for leaks (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0077

FIELD MAINTENANCE ETHER COLD START SYSTEM MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185)

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

WARNING

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. ETHER CANISTER REMOVAL 1.

Loosen clamp screw (Figure 1, Item 3) and turn canister (Figure 1, Item 1) counterclockwise to remove from clamp (Figure 1, Item 2) and solenoid (Figure 1, Item 4). 2

1

3

4

M0033JCH

Figure 1.

Ether Canister Removal.

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TM 10-3930-675-23-1

0077

ETHER CANISTER REMOVAL - Continued 2.

Inspect gasket (Figure 2, Item 1) for damage. Remove and discard only if damaged.

1

2

M0034JCH

Figure 2.

Ether Canister Gasket.

END OF TASK

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TM 10-3930-675-23-1

0077

ETHER CANISTER INSTALLATION 1.

Ensure gasket (Figure 3, Item 1) is positioned inside top of solenoid (Figure 3, Item 2).

2.

Position canister (Figure 3, Item 1) inside clamp (Figure 3, Item 2). Install on solenoid (Figure 3, Item 4) by turning canister clockwise.

3.

Tighten clamp screw (Figure 3, Item 3). 2

1

3

4

M0035JCH

Figure 3.

Ether Canister Installation.

END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK

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TM 10-3930-675-23-1

0077

COLD START ACTIVATION SOLENOID REMOVAL

NOTE Remove and discard tiedown straps. 1.

Remove canister. Refer to Ether Canister Removal in this work package.

2.

Disconnect connector (Figure 4, Item 2) of solenoid harness from wiring harness connector (Figure 4, Item 1).

1

2

M0036JCH

Figure 4. Cold Start Activation Solenoid Removal. 3.

Disconnect ether supply tube (Figure 5, Item 1) from elbow on underside of solenoid (Figure 5, Item 3).

4.

Remove two screws (Figure 5, Item 4), washers (Figure 5, Item 5), and solenoid (Figure 5, Item 3) from mounting bracket (Figure 5, Item 2).

5.

Remove elbow from bottom of solenoid (Figure 5, Item 3).

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TM 10-3930-675-23-1

0077

COLD START ACTIVATION SOLENOID REMOVAL - Continued

2 1

3

4,5

M0037JCH

Figure 5. Cold Start Activation Solenoid Removal. 6.

If replacing ether supply tube (Figure 6, Item 1), disconnect tube from fitting (Figure 6, Item 2) at air intake elbow (Figure 6, Item 3). 3

2 1

M0038JCH

Figure 6. Cold Start Activation Solenoid Removal.

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TM 10-3930-675-23-1

0077

COLD START ACTIVATION SOLENOID REMOVAL - Continued 7.

Remove ether supply tube (Figure 7, Item 1) through grommet (Figure 7, Item 3) in mounting bracket (Figure 7, Item 2).

END OF TASK COLD START ACTIVATION SOLENOID INSTALLATION 1.

If removed, feed ether supply tube (Figure 7, Item 1) through grommet (Figure 7, Item 3) in mounting bracket (Figure 7, Item 2). 3 2 1

M0039JCH

Figure 7. Cold Start Activation Solenoid Removal.

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TM 10-3930-675-23-1

0077

COLD START ACTIVATION SOLENOID INSTALLATION - Continued 2.

Connect ether supply tube (Figure 8, Item 1) to fitting (Figure 8, Item 2) at air intake elbow (Figure 8, Item 3). 3

2 1

M0040JCH

Figure 8. Cold Start Activation Solenoid Installation.

0077-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00037)

TM 10-3930-675-23-1

0077

COLD START ACTIVATION SOLENOID INSTALLATION - Continued 3.

Install elbow on bottom of solenoid (Figure 9, Item 3).

4.

Connect other end of ether supply tube (Figure 9, Item 1) to elbow.

5.

Position solenoid (Figure 9, Item 3) on mounting bracket (Figure 9, Item 2) and install two washers (Figure 9, Item 5) and screws (Figure 9, Item 4).

2 1

3

4,5

M0037JCH

Figure 9. Cold Start Activation Solenoid Installation.

0077-8

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TM 10-3930-675-23-1

0077

COLD START ACTIVATION SOLENOID INSTALLATION - Continued 6.

Connect connector (Figure 10, Item 2) of solenoid harness to wiring harness connector (Figure 10, Item 1).

7.

Install canister. Refer to Ether Canister Installation in this work package.

8.

Install new tiedown straps.

1

2

Figure 10.

M0041JCH

Cold Start Activation Solenoid Installation.

END OF TASK FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0078

FIELD MAINTENANCE THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28)

RT 240V1 AND RT 240V1R - REMOVAL 1.

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

2.

Remove three screws (Figure 1, Item 4), washers (Figure 1, Item 5), and right lower panel (Figure 1, Item 6) from vehicle. 1,2

3

4,5 6

RT 240V1 AND RT 240V1R VEHICLES

Figure 1. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.

0078-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00038)

M0042JCH

TM 10-3930-675-23-1

0078

RT 240V1 AND RT 240V1R - REMOVAL - Continued 3.

Remove four screws (Figure 2, Item 2), washers (Figure 2, Item 3), and cover (Figure 2, Item 1) from right side of cab floor. 1

2,3

M0044JCH

Figure 2. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R. 4.

Disconnect connector (Figure 3, Item 3) of throttle position sensor wiring harness (Figure 3, Item 1) from Electronic Control Module (ECM) wiring harness connector (Figure 3, Item 4).

5.

Remove two screws (Figure 3, Item 5) and throttle position sensor assembly (Figure 3, Item 2) from vehicle. 2

3

4

1

5

M0045JCH

Figure 3. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R. END OF TASK

0078-2

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TM 10-3930-675-23-1

0078

RT 240V2 AND RT 240V3 - REMOVAL 1.

Remove three screws (Figure 4, Item 1), washers (Figure 4, Item 2), and left lower panel (Figure 4, Item 3) from vehicle.

2.

Remove three screws (Figure 4, Item 4), washers (Figure 4, Item 5), and right lower panel (Figure 4, Item 6) from vehicle. 1,2

4,5

3

6

RT 240V2 AND RT 240V3 VEHICLES

M0043JCH

Figure 4. Throttle Position Sensor Removal - RT 240V2 and RT 240V3. 3.

Remove four screws (Figure 5, Item 2), washers (Figure 5, Item 3), and cover (Figure 5, Item 1) from right side of cab floor. 1

2,3

M0044JCH

Figure 5. Throttle Position Sensor Removal - RT 240V2 and RT 240V3.

0078-3

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TM 10-3930-675-23-1

0078

RT 240V2 AND RT 240V3 - REMOVAL - Continued 4.

Disconnect connector (Figure 6, Item 3) of throttle position sensor wiring harness (Figure 6, Item 1) from Electronic Control Module (ECM) wiring harness connector (Figure 6, Item 4).

5.

Remove two screws (Figure 6, Item 5) and throttle position sensor assembly (Figure 6, Item 2) from vehicle. 2

3

4

1

5

M0045JCH

Figure 6. Throttle Position Sensor Removal - RT 240V2 and RT 240V3. END OF TASK

0078-4

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TM 10-3930-675-23-1

0078

RT 240V2 AND RT 240V3 - INSTALLATION 1.

Install throttle position sensor assembly (Figure 7, Item 2) on vehicle with two screws (Figure 7, Item 5).

2.

Connect connector (Figure 7, Item 3) of throttle position sensor wiring harness (Figure 7, Item 1) to ECM wiring harness connector (Figure 7, Item 4). 2

3

4

1

5

M0045JCH

Figure 7. Throttle Position Sensor Installation - RT 240V2 and RT 240V3.

0078-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00038)

TM 10-3930-675-23-1

0078

RT 240V2 AND RT 240V3 - INSTALLATION - Continued 3.

Install cover (Figure 8, Item 1) on right side of cab floor with four washers (Figure 8, Item 3) and screws (Figure 8, Item 2). 1

2,3

M0044JCH

Figure 8. Throttle Position Sensor Installation - RT 240V2 and RT 240V3.

0078-6

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TM 10-3930-675-23-1

0078

RT 240V2 AND RT 240V3 - INSTALLATION - Continued 4.

Install right lower panel (Figure 9, Item 6) in vehicle with three washers (Figure 9, Item 5) and screws (Figure 9, Item 4).

5.

Install left lower panel (Figure 9, Item 3) in vehicle with three washers (Figure 9, Item 2) and screws (Figure 9, Item 1). 1,2

4,5

3

6

RT 240V2 AND RT 240V3 VEHICLES

Figure 9. Throttle Position Sensor Installation - RT 240V2 and RT 240V3. END OF TASK

0078-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00038)

M0043JCH

TM 10-3930-675-23-1

0078

RT 240V1 AND RT 240V2 - INSTALLATION 1.

Install throttle position sensor assembly (Figure 10, Item 2) on vehicle with two screws (Figure 10, Item 5).

2.

Connect connector (Figure 10, Item 3) of throttle position sensor wiring harness (Figure 10, Item 1) to ECM wiring harness connector (Figure 10, Item 4). 2

3

4

1

5

M0045JCH

Figure 10. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R. 3.

Install cover (Figure 11, Item 1) on right side of cab floor with four washers (Figure 11, Item 3) and screws (Figure 11, Item 2).

0078-8

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TM 10-3930-675-23-1

0078

RT 240V1 AND RT 240V2 - INSTALLATION - Continued 1

2,3

M0044JCH

Figure 11. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R. 4.

Install right lower panel (Figure 12, Item 6) in vehicle with three washers (Figure 12, Item 5) and screws (Figure 12, Item 4).

5.

Install left lower panel (Figure 12, Item 3) in vehicle with three washers (Figure 12, Item 2) and screws (Figure 12, Item 1). 1,2

3

4,5 6

RT 240V1 AND RT 240V1R VEHICLES

Figure 12. Throttle Position Sensor Installation - RT 240V1 and RT 240V1R. END OF TASK END OF WORK PACKAGE

0078-9/10 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00038)

M0042JCH

TM 10-3930-675-23-1

0079

FIELD MAINTENANCE MUFFLER AND EXHAUST PIPE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Engine cover removed (Volume 2, WP 0185)

0079-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00039)

TM 10-3930-675-23-1

0079

REMOVAL

WARNING

Exhaust system components may be hot to the touch. Avoid contact with any part of exhaust system until sufficiently cool. Failure to do so could result in injury to personnel. 1.

Remove eight nuts (Figure 1, Item 4), washers (Figure 1, Item 5), four U-bolts (Figure 1, Item 1), and heat shield (Figure 1, Item 3) from exhaust pipe (Figure 1, Item 2).

2.

Remove four nuts (Figure 1, Item 4), washers (Figure 1, Item 5), and two U-bolts (Figure 1, Item 6) holding exhaust pipe (Figure 1, Item 2) to two brackets (Figure 1, Item 7).

3.

While supporting muffler (Figure 1, Item 13), remove two nuts (Figure 1, Item 10), four washers (Figure 1, Item 2), and muffler (Figure 1, Item 13) from vehicle.

NOTE Perform Step 4 to remove support brackets. 4.

Remove four nuts (Figure 1, Item 10), eight washers (Figure 1, Item 9), screws (Figure 1, Item 8), and two brackets (Figure 1, Item 7) from vehicle.

5.

Remove six nuts (Figure 1, Item 4) and washers (Figure 1, Item 5), three U-bolts (Figure 1, Item 1), and heat shield (Figure 2, Item 24) from exhaust pipe (Figure 1, Item 23) and exhaust hose (Figure 1, Item 21).

6.

Loosen two clamps (Figure 1, Item 20) on exhaust hose (Figure 1, Item 21).

7.

Remove two nuts (Figure 1, Item 4) and washers (Figure 2, Item 5), U-bolt (Figure 1, Item 6), exhaust pipe (Figure 1, Item 23), and exhaust hose (Figure 1, Item 21) from bracket (Figure 1, Item 22).

8.

Remove two bolts (Figure 1, Item 14), four washers (Figure 1, Item 5), and two spacers (Figure 1, Item 16) from bracket (Figure 1, Item 15).

9.

Remove two nuts (Figure 1, Item 18), four washers (Figure 1, Item 5), two bolts (Figure 1, Item 17), and two brackets (Figure 1, Item 15) from machine.

10.

Loosen clamp (Figure 1, Item 20) and remove exhaust pipe (Figure 1, Item 19) from turbocharger.

NOTE Perform Step 11 to remove exhaust system support bracket. 11.

Remove nut (Figure 1, Item 4), washer (Figure 1, Item 5), U-clamp (Figure 1, Item 6), screw (Figure 1, Item 17), and bracket (Figure 1, Item 22) from vehicle.

0079-2

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TM 10-3930-675-23-1

0079

REMOVAL - Continued

3

4 1

3

5 3 1 1

2 1 6

RT 240V2 AND RT 240V3 ONLY

6 7 8 7 9 10

11

5 4

9

5 4

25 9 10

12 11 9

24

4 5

5

9 10

13

14 5 15 5

17

14

16 5 17

23 6 1

6

19 1

5 16

18 5

15

20

22 20 6 22 5 4

17

20

21

M1710JCH

Figure 1.

Muffler and Exhaust Pipe Removal.

END OF TASK

0079-3

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TM 10-3930-675-23-1

0079

INSTALLATION

NOTE Perform Step 1 to install exhaust system support bracket, if removed. 1.

Install bracket (Figure 2, Item 22) on vehicle with screw (Figure 2, Item 17), washer (Figure 2, Item 5), and nut (Figure 2, Item 4), and U-clamp (Figure 2, Item 6).

2.

Install exhaust pipe (Figure 2, Item 19) on turbocharger and tighten clamp (Figure 2, Item 20).

3.

Install two brackets (Figure 2, Item 15), two bolts (Figure 2, Item 17), four washers (Figure 2, Item 5), and two nuts (Figure 2, Item 18).

4.

Install bracket (Figure 2, Item 15), two spacers (Figure 2, Item 16), four washers (Figure 2, Item 5), and two bolts (Figure 2, Item 14).

5.

Install exhaust hose (Figure 2, Item 21) and exhaust pipe (Figure 2, Item 23) on bracket (Figure 2, Item 22) with U-bolt (Figure 2, Item 6), two washers (Figure 2, Item 5), and nuts (Figure 2, Item 4).

6.

Tighten two clamps (Figure 2, Item 20) on exhaust hose (Figure 2, Item 21).

7.

Install heat shield (Figure 2, Item 24) on exhaust hose (Figure 2, Item 21) and exhaust pipe (Figure 2, Item 23) with three U-bolts (Figure 2, Item 1), six washers (Figure 2, Item 5), and nuts (Figure 2, Item 4).

NOTE Perform Step 8 to install support brackets. 8.

Install two brackets (Figure 2, Item 9) on vehicle with four screws (Figure 2, Item 15), washers (Figure 2, Item 14), and nuts (Figure 2, Item 13).

9.

While supporting muffler (Figure 2, Item 13), install muffler and exhaust pipe (Figure 2, Item 2) on vehicle with two clamps (Figure 2, Items 12 and 25), two screws (Figure 2, Item 11), four washers (Figure 2, Item 9), and two nuts (Figure 2, Item 10).

10.

Install exhaust pipe (Figure 2, Item 2) on two brackets (Figure 2, Item 7) with two U-bolts (Figure 2, Item 6), four washers (Figure 2, Item 5), and nuts (Figure 2, Item 4).

11.

Install heat shield (Figure 2, Item 3) on exhaust pipe (Figure 2, Item 2) with four U-bolts (Figure 2, Item 1), eight washers (Figure 2, Item 5), and nuts (Figure 2, Item 4).

0079-4

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TM 10-3930-675-23-1

0079

INSTALLATION - Continued

3

4 1

3

5 3 1 1

2 1 6

RT 240V2 AND RT 240V3 ONLY

6 7 8 7 9 10

11

5 4

9

5 4

25 9 10

12 11 9

24

4 5

5

9 10

13

14 5 15 5

17

14

16 5 17

23 6 1

6

19 1

5 16

18 5

15

20

22 20 6 22 5 4

17

20

21

M1710JCH

Figure 2.

Muffler and Exhaust Pipe Installation.

END OF TASK

0079-5

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TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00039)

0079

TM 10-3930-675-23-1

FIELD MAINTENANCE DRAINING AND FILLING RADIATOR ASSEMBLY

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References TM 10-3930-675-10

Materials/Parts Antifreeze Ethylene Glycol (Volume 2, WP 0276, Table 1, Item 5) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Equipment Condition Radiator splash shield removed (WP 0084)

WARNING

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.

0080-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00040)

0080

TM 10-3930-675-23-1

0080

DRAINING

NOTE Bottom of radiator has two drain fittings. Fitting toward rear of vehicle is for draining coolant. Drain fitting toward front of vehicle is for draining possible condensation from engine air intake system. 1.

Attach drain hose to drain fitting (Figure 1, Item 2) at bottom of radiator assembly (Figure 1, Item 1).

NOTE Cooling system capacity is 23.7 gal. (90.1 L). 2.

Open drain fitting (Figure 1, Item 2) and allow coolant to drain into a suitable container.

3.

Close drain fitting (Figure 1, Item 2) and remove drain hose. 1

2

M0050JCH

Figure 1.

Drain Radiator Assembly.

END OF TASK FILLING 1.

Remove four screws (Figure 2, Item 1), washers (Figure 2, Item 2), and fill cover plate (Figure 2, Item 3) from top of vehicle.

0080-2

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TM 10-3930-675-23-1

0080

FILLING - Continued 3

1,2

M0051JCH

Figure 2. 2.

Fill Radiator Assembly.

Remove radiator cap (Figure 3, Item 1).

NOTE Use type of coolant appropriate to the anticipated ambient temperature. 3.

Add coolant through filler opening (Figure 3, Item 2) at top of radiator assembly (Figure 3, Item 3) until coolant level reaches bottom of filler opening.

4.

Install radiator cap (Figure 3, Item 1). 1

2

3

M0052JCH

Figure 3.

Fill Radiator Assembly.

0080-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00040)

TM 10-3930-675-23-1

0080

FILLING - Continued 5.

Install fill cover plate (Figure 2, Item 3) on top of vehicle with four washers (Figure 2, Item 2) and screws (Figure 2, Item 1).

6.

Start engine (TM 10-3930-675-10) and allow engine to reach operating temperature.

7.

Note coolant level in expansion tank (Figure 4, Item 1). Level should be between MIN and MAX lines on tank when engine is at operating temperature. Add coolant to expansion tank as needed.

8.

Stop engine (TM 10-3939-675-10).

1

M0053JCH

Figure 4. Check Coolant Level. END OF TASK FOLLOW-ON MAINTENANCE Install radiator splash shield (WP 0084). END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0081

FIELD MAINTENANCE RADIATOR ASSEMBLY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Lifting Device (1,000 lb capacity)

References (cont.) WP 0083 Volume 2, WP 0220 Volume 2, WP 0227 Volume 2, WP 0268

Materials/Parts Cap Set, Protective, Dust and Moisture Seal (Volume 2, WP 0276, Table 1, Item 9) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 4 Washer, Lock (Volume 2, WP 0278, Table 1, Item 120) Qty: 6

Equipment Condition Radiator assembly drained (WP 0080) Fording water level sensor removed (WP 0116) Hydraulic system pressure relieved (Volume 2, WP 0204)

Personnel Required (2) References WP 0072

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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0081

REMOVAL 1.

Remove eight screws (Figure 1, Item 1), washers (Figure 1, Item 2), and angle plate (Figure 1, Item 3) from top of vehicle. 1,2

3

M0845JCH

Figure 1.

Angle Plate Removal.

2.

Disconnect air intake hoses and tubes from radiator assembly (WP 0072).

3.

Disconnect cooling system hoses from radiator assembly (WP 0083).

4.

Disconnect hydraulic cooling fan hoses and fittings from radiator assembly (Volume 2, WP 0220).

5.

Disconnect hydraulic hoses from cooling fan motor and bypass valve (Volume 2, WP 0220).

6.

Disconnect electrical connection from bypass valve and remove wiring harness from radiator fan support.

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TM 10-3930-675-23-1

0081

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 objects supported only by a lifting device. Failure to follow this warning may result in injury or death to personnel. • Lifting device must have a capacity of approximately 1,000 lb (454 kg) to lift radiator grille and radiator. Failure to follow this warning may result in injury or death to personnel. 7.

Attach a suitable lifting device to radiator grille (Figure 2, Item 3).

8.

Remove six screws (Figure 2, Item 1), washers (Figure 2, Item 2), and radiator grille (Figure 2, Item 3) from side of vehicle.

1,2 3 M0846JCH

Figure 2.

Radiator Grille Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00041)

TM 10-3930-675-23-1

0081

REMOVAL - Continued 9.

Attach a suitable lifting device to top of radiator assembly (Figure 3, Item 4) with two bolts.

10.

Remove two locknuts (Figure 3, Item 1), washers (Figure 3, Item 2), and screws (Figure 3, Item 3) to separate radiator bracket (Figure 3, Item 8) from vehicle. Discard locknuts.

11.

Remove six screws, lockwashers, rubber bushings, and radiator assembly (Figure 3, Item 4) from frame. Remove two bolts and lifting device. Discard lockwashers.

12.

Remove two screws (Figure 3, Item 6), washers (Figure 3, Item 7), radiator bracket (Figure 3, Item 8), and two rubber bushings (Figure 3, Item 5) from radiator assembly (Figure 3, Item 4). 1,2,3

4

8

6,7

M0847JCH

5

Figure 3.

Radiator Removal.

END OF TASK INSTALLATION 1.

Install two rubber bushings (Figure 4, Item 5) and radiator bracket (Figure 4, Item 8) on radiator assembly (Figure 4, Item 4) with two washers (Figure 5, Item 7) and screws (Figure 4, Item 6).

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0081

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 objects supported only by a lifting device. Failure to follow this warning may result in injury or death to personnel. • Lifting device must have a capacity of approximately 1,000 lb (454 kg) to lift radiator grille and radiator. Failure to follow this warning may result in injury or death to personnel. 2.

Attach a suitable lifting device to top of radiator assembly (Figure 4, Item 4) with two bolts.

3.

Install radiator assembly (Figure 4, Item 4) on frame with six rubber bushings, new lockwashers, and screws. Remove two bolts and lifting device.

4.

Secure radiator bracket (Figure 4, Item 8) to vehicle with two screws (Figure 4, Item 3), washers (Figure 4, Item 2), and new locknuts (Figure 4, Item 1). 1,2,3

4

8

6,7

M0848JCH

5

Figure 4.

Radiator Installation.

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TM 10-3930-675-23-1

0081

INSTALLATION - Continued 5.

Attach lifting device to radiator grille (Figure 5, Item 3).

6.

Install radiator grille (Figure 5, Item 3) on side of vehicle with six washers (Figure 5, Item 2) and screws (Figure 5, Item 1).

1,2 3 M0846JCH

Figure 5. Radiator Grille Installation. 7.

Connect electrical connection to bypass valve. Screw wiring to radiator fan support.

NOTE Refer to General Maintenance Instructions (Volume 2, WP 0268) for complete instructions on connecting hydraulic hoses and applying proper torque. 8.

Connect hydraulic hoses to cooling fan motor and bypass valve (Volume 2, WP 0220).

9.

Connect hydraulic cooling fan hoses and fittings to radiator assembly (Volume 2, WP 0220).

10.

Connect cooling system hoses to radiator assembly (WP 0083).

11.

Connect air intake hoses and tubes to radiator assembly (WP 0072).

12.

Install angle plate (Figure 6, Item 3) on top of vehicle with eight washers (Figure 6, Item 2) and screws (Figure 6, Item 1).

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TM 10-3930-675-23-1

0081

INSTALLATION - Continued 1,2

3

M0849JCH

Figure 6.

Angle Plate Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install fording water level sensor (WP 0116).

NOTE Replace hydraulic reservoir return filters after 100 hours of operation (Volume 2, WP 0227). 2.

Fill radiator (WP 0080).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0082

FIELD MAINTENANCE COOLING SYSTEM EXPANSION TANK MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Detergent General Purpose Liquid (Volume 2, WP 0276, Table 1, Item 15) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown (Volume 2, WP 0276, Table 1, Item 63)

Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 83) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 4 Gasket (Volume 2, WP 0278, Table 1, Item 95) References WP 0080

WARNING

DO NOT perform maintenance on 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.

NOTE • Tag hoses to aid in installation. • Use a suitable container to catch any draining coolant. • Clean coolant spills immediately.

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TM 10-3930-675-23-1

0082

REMOVAL 1.

Loosen two hose clamps (Figure 1, Item 5) and disconnect two hoses (Figure 1, Items 6 and 7) from top side of expansion tank (Figure 1, Item 9).

2.

Remove four locknuts (Figure 1, Item 4), screws (Figure 1, Item 2), eight washers (Figure 1, Item 3), and two clamps (Figure 1, Item 1) from expansion tank (Figure 1, Item 9). Discard locknuts.

3.

Empty coolant from expansion tank (Figure 1, Item 9) by pouring coolant from two openings at top side of tank.

4.

Release two hoses (Figure 1, Items 6 and 7) by removing two tiedown straps (Figure 1, Item 8). Discard tiedown straps. 3,4

2,3 1

5

6

7

9

8

Figure 1. Cooling System Expansion Tank Removal.

0082-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00042)

M0064JCH

TM 10-3930-675-23-1

0082

REMOVAL - Continued 5.

Loosen two hose clamps (Figure 2, Item 4) and disconnect two hoses (Figure 2, Item 5) from underside of expansion tank (Figure 2, Item 3).

6.

Remove expansion tank (Figure 2, Item 3).

7.

Loosen clamp (Figure 2, Item 2) and remove hose (Figure 2, Item 1) from bottom side of expansion tank (Figure 2, Item 3). 2

3

4

1

5

M0065JCH

Figure 2. Cooling System Expansion Tank Removal.

0082-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00042)

TM 10-3930-675-23-1

0082

REMOVAL - Continued 8.

Remove two nuts (Figure 3, Item 4), four washers (Figure 3, Item 5), two screws (Figure 3, Item 6), and expansion tank mounting bracket (Figure 3, Item 3).

END OF TASK DISASSEMBLY 1.

Remove cover (Figure 3, Item 1) and rubber ring (Figure 3, Item 2).

2.

Remove nipple (Figure 3, Item 7), O-ring (Figure 3, Item 8), plug (Figure 3, Item 9), and gasket (Figure 3, Item 10) from underside of expansion tank (Figure 3, Item 11). Discard O-ring and gasket. 1

2

3

11

7,8 9,10 4,5,6 M0067JCH

Figure 3. Cooling System Expansion Tank Removal. END OF TASK CLEANING Wash expansion tank with soap and water. Rinse thoroughly. END OF TASK

0082-4

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TM 10-3930-675-23-1

0082

INSPECTION 1.

Inspect expansion tank for cracks that could cause leaks. Replace if tank is cracked or otherwise damaged.

2.

Inspect all other removed components for damage. Replace if damaged.

END OF TASK ASSEMBLY 1.

Install new gasket (Figure 4, Item 10), plug (Figure 4, Item 9), new O-ring (Figure 4, Item 8), and nipple (Figure 4, Item 7) on underside of expansion tank (Figure 2, Item 11).

2.

Install rubber ring (Figure 4, Item 2) and cover (Figure 4, Item 1).

END OF TASK INSTALLATION 1.

Install expansion tank mounting bracket (Figure 4, Item 3) with two screws (Figure 4, Item 6), four washers (Figure 4, Item 5), and two nuts (Figure 4, Item 4). 1

2

3

11

7,8 9,10 4,5,6 M0067JCH

Figure 4. Cooling System Expansion Tank Assembly and Installation.

0082-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00042)

TM 10-3930-675-23-1

0082

INSTALLATION - Continued 2.

Install hose (Figure 5, Item 6) on bottom side of expansion tank (Figure 5, Item 3) and tighten clamp (Figure 5, Item 2).

3.

Position expansion tank (Figure 5, Item 3) and connect two hoses (Figure 5, Item 5) to underside of tank. Tighten two hose clamps (Figure 5, Item 4). 2

3

4

1

5 M0068JCH

Figure 5.

Cooling System Expansion Tank Installation.

4.

Secure expansion tank (Figure 6, Item 9) to mounting bracket (Figure 4, Item 3) with two clamps (Figure 6, Item 1), four screws (Figure 6, Item 2), eight washers (Figure 6, Item 3), and four new locknuts (Figure 6, Item 4).

5.

Connect two hoses (Figure 6, Items 6 and 7) to top side of expansion tank (Figure 6, Item 9). Tighten two hose clamps (Figure 6, Item 5).

6.

Install two new tiedown straps (Figure 6, Item 8) to secure hoses (Figure 6, Items 6 and 7) together.

0082-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00042)

TM 10-3930-675-23-1

0082

INSTALLATION - Continued 3,4

2,3 1

5

6

7

9

Figure 6.

8

Cooling System Expansion Tank Installation.

END OF TASK FOLLOW-ON MAINTENANCE Check coolant level and add as necessary (WP 0080). END OF TASK END OF WORK PACKAGE

0082-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00042)

M0069JCH

TM 10-3930-675-23-1

0083

FIELD MAINTENANCE COOLING SYSTEM HOSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition (cont.) Remove radiator top grating (WP 0085) Remove transmission access covers (Volume 2, WP 0175)

Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) References WP 0085 Volume 2, WP 0175 Equipment Condition Cooling system drained (WP 0080)

NOTE Note location of hose support clamps for installation. Remove hose support clamps, as necessary.

0083-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

TM 10-3930-675-23-1

0083

CAB INTERFACE UNIT-TO-WATER PUMP HOSE REMOVAL 1.

Loosen clamp (Figure 1, Item 5) and disconnect hose (Figure 1, Item 4) from cab interface unit (Figure 1, Item 1) at rear of cab.

2.

Loosen clamp (Figure 1, Item 2) and remove other end of hose (Figure 1, Item 4) from water pump (Figure 1, Item 3).

END OF TASK CAB INTERFACE UNIT-TO-WATER PUMP HOSE INSTALLATION 1.

Install hose (Figure 1, Item 4) on water pump (Figure 1, Item 3) and tighten clamp (Figure 1, Item 2).

2.

Connect other end of hose (Figure 1, Item 4) to cab interface unit (Figure 1, Item 1) at rear of cab and tighten clamp (Figure 1, Item 5). 2

3 1

5

4 RIGHT SIDE

Figure 1.

Cab Interface Unit-to-Water Pump Hose.

END OF TASK

0083-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

M0054JCH

TM 10-3930-675-23-1

0083

CAB INTERFACE UNIT-TO-ENGINE BLOCK HOSE REMOVAL 1.

Loosen clamp (Figure 2, Item 2) and disconnect hose (Figure 2, Item 3) from cab interface unit (Figure 2, Item 1) at rear of cab.

2.

Loosen clamp (Figure 2, Item 4) and remove other end of hose (Figure 2, Item 3) from engine block (Figure 2, Item 5).

END OF TASK CAB INTERFACE UNIT-TO-ENGINE BLOCK HOSE INSTALLATION 1.

Install hose (Figure 2, Item 3) on engine block (Figure 2, Item 5) and tighten clamp (Figure 2, Item 4).

2.

Connect other end of hose (Figure 2, Item 3) to cab interface unit (Figure 2, Item 1) and tighten clamp (Figure 2, Item 2). 3

1

2

4

5

3

RIGHT SIDE

Figure 2.

Cab Interface Unit-to-Engine Block Hose.

END OF TASK

0083-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

M0055JCH

TM 10-3930-675-23-1

0083

COOLANT RESERVOIR-TO-RADIATOR HOSE REMOVAL 1.

Loosen clamp (Figure 3, Item 4) and disconnect hose (Figure 3, Item 5) from coolant reservoir (Figure 3, Item 3).

2.

Loosen clamp (Figure 3, Item 2) and remove other end of hose (Figure 3, Item 5) from radiator (Figure 3, Item 1).

END OF TASK COOLANT RESERVOIR-TO-RADIATOR HOSE INSTALLATION 1.

Install hose (Figure 3, Item 5) on radiator (Figure 3, Item 1) and tighten clamp (Figure 3, Item 2).

2.

Connect other end of hose (Figure 3, Item 5) to coolant reservoir (Figure 3, Item 3) and tighten clamp (Figure 3, Item 4). 3

2

4

1

5

FRONT VIEW

Figure 3.

Coolant Reservoir-to-Radiator Hose.

END OF TASK

0083-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

M0056JCH

TM 10-3930-675-23-1

0083

COOLANT RESERVOIR-TO-WATER MANIFOLD HOSE REMOVAL 1.

Loosen clamp (Figure 4, Item 2) and disconnect hose (Figure 4, Item 1) from coolant reservoir (Figure 4, Item 3).

2.

Loosen clamp (Figure 4, Item 4) and remove other end of hose (Figure 4, Item 1) from water manifold (Figure 4, Item 5).

END OF TASK COOLANT RESERVOIR-TO-WATER MANIFOLD HOSE INSTALLATION 1.

Install hose (Figure 4, Item 1) on water manifold (Figure 4, Item 5) and tighten clamp (Figure 4, Item 4).

2.

Connect other end of hose (Figure 4, Item 1) to coolant reservoir (Figure 4, Item 3) and tighten clamp (Figure 4, Item 2). 2

1

3

4 1

5

FRONT VIEW

RIGHT SIDE

Figure 4. Coolant Reservoir-to-Water Manifold Hose. END OF TASK

0083-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

M0057JCH

TM 10-3930-675-23-1

0083

COOLANT RESERVOIR-TO-WATER PUMP HOSE REMOVAL 1.

Loosen clamp (Figure 5, Item 1) and disconnect hose (Figure 5, Item 3) from coolant reservoir (Figure 5, Item 2).

2.

Loosen clamp (Figure 5, Item 5) and remove other end of hose (Figure 5, Item 3) from water pump (Figure 5, Item 4).

END OF TASK COOLANT RESERVOIR-TO-WATER PUMP HOSE INSTALLATION 1.

Install hose (Figure 5, Item 3) on water pump (Figure 5, Item 4) and tighten clamp (Figure 5, Item 5).

2.

Connect other end of hose (Figure 5, Item 3) to coolant reservoir (Figure 5, Item 2) and tighten clamp (Figure 5, Item 1). 2 1 3 4

FRONT VIEW

3

RIGHT SIDE

M0058JCH

5

Figure 5.

Coolant Reservoir-to-Water Pump Hose.

END OF TASK

0083-6

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TM 10-3930-675-23-1

0083

TRANSMISSION OIL COOLER-TO-RADIATOR HOSES REMOVAL 1.

Loosen six clamps (Figure 6, Item 4).

2.

Remove three hoses (Figure 6, Items 5, 6, and 8) and two cooling pipes (Figure 6, Items 1 and 3) between transmission oil cooler (Figure 6, Item 2) and radiator (Figure 6, Item 7).

END OF TASK TRANSMISSION OIL COOLER-TO-RADIATOR HOSES INSTALLATION 1.

Install two cooling pipes (Figure 6, Items 1 and 3) and three hoses (Figure 6, Items 5, 6, and 8) between radiator (Figure 6, Item 7) and transmission oil cooler (Figure 6, Item 2).

2.

Tighten six clamps (Figure 6, Item 4). 4

3

2

5

1

6

7

8 TOP VIEW

Figure 6. Transmission Oil Cooler-to-Radiator Hoses. END OF TASK

0083-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

M0059JCH

TM 10-3930-675-23-1

0083

TRANSMISSION OIL COOLER-TO-WATER PUMP HOSES REMOVAL 1.

Loosen four clamps (Figure 7, Item 2).

2.

Remove two hoses (Figure 7, Items 3 and 5) and pipe (Figure 7, Item 4) between transmission oil cooler (Figure 7, Item 6) and water pump (Figure 7, Item 1).

END OF TASK TRANSMISSION OIL COOLER-TO-WATER PUMP HOSES INSTALLATION 1.

Install pipe (Figure 7, Item 4) and two hoses (Figure 7, Items 3 and 5) between water pump (Figure 7, Item 1) and transmission oil cooler (Figure 7, Item 6).

2.

Tighten four clamps (Figure 7, Item 2).

1

2

3

5

4

2

6 TRANSMISSION OIL COOLER-TO-WATER PUMP HOSES

Figure 7. Transmission Oil Cooler-to-Water Pump Hoses. END OF TASK

0083-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

M0060JCH

TM 10-3930-675-23-1

0083

TRANSMISSION OIL COOLER-TO-WATER PUMP RETURN HOSE REMOVAL 1.

Loosen clamp (Figure 8, Item 5) and disconnect hose (Figure 8, Item 1) from transmission oil cooler (Figure 8, Item 4).

2.

Loosen clamp (Figure 8, Item 3) and remove other end of hose (Figure 8, Item 1) from water pump (Figure 8, Item 2).

END OF TASK TRANSMISSION OIL COOLER-TO-WATER PUMP RETURN HOSE INSTALLATION 1.

Install hose (Figure 8, Item 1) on water pump (Figure 8, Item 2) and tighten clamp (Figure 8, Item 3).

2.

Connect other end of hose (Figure 8, Item 1) to transmission oil cooler (Figure 8, Item 4) and tighten clamp (Figure 8, Item 5).

2

1

3 5 1

4 RIGHT SIDE

Figure 8. Transmission Oil Cooler-to-Water Pump Return Hose. END OF TASK

0083-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00043)

M0061JCH

TM 10-3930-675-23-1

0083

TRANSMISSION OIL COOLER U-HOSE REPLACEMENT 1.

Loosen two clamps (Figure 9, Item 2) and remove U-hose (Figure 9, Item 1) from transmission oil cooler (Figure 9, Item 3).

2.

Install U-hose (Figure 9, Item 1) on transmission oil cooler (Figure 9, Item 3) and tighten two clamps (Figure 9, Item 2). 2

3

1

2 RIGHT SIDE

M0062JCH

Figure 9. Transmission Oil Cooler U-Hose. END OF TASK WATER MANIFOLD-TO-RADIATOR HOSES REMOVAL 1.

Loosen six clamps (Figure 10, Item 1).

2.

Remove two U-clamps (Figure 10, Item 3) from cooling pipe (Figure 10, Item 2).

3.

Remove three hoses (Figure 10, Items 5, 8, and 9) and two cooling pipes (Figure 10, Items 2 and 6) from water manifold (Figure 10, Item 4) and radiator (Figure 10, Item 7).

END OF TASK WATER MANIFOLD-TO-RADIATOR HOSES INSTALLATION 1.

Install two cooling pipes (Figure 10, Items 2 and 6) and three hoses (Figure 10, Items 5, 8, and 9) between radiator (Figure 10, Item 7) and water manifold (Figure 10, Item 4).

2.

Install two U-clamps (Figure 10, Item 3) on cooling pipe (Figure 10, Item 2).

3.

Tighten six clamps (Figure 10, Item 1).

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0083

WATER MANIFOLD-TO-RADIATOR HOSES INSTALLATION - Continued 3

2

1 4

1

5

9

8

1

7

6 TOP VIEW

Figure 10.

M0063JCH

Water Manifold-to-Radiator Hoses.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install transmission access covers (Volume 2, WP 0175).

2.

Install radiator top grating (WP 0085).

3.

Refill cooling system (WP 0080).

END OF TASK END OF WORK PACKAGE

0083-11/12 blank

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TM 10-3930-675-23-1

FIELD MAINTENANCE RADIATOR SPLASH SHIELD REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Personnel Required (2)

Materials/Parts Locknut (Volume 2, WP 0278, Table 1, Item 2)

0084-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00044)

0084

TM 10-3930-675-23-1

0084

REMOVAL 1.

Remove locknut (Figure 1, Item 1) and washer (Figure 1, Item 2) from stud of bracket at left front corner of radiator splash shield (Figure 1, Item 3). Discard locknut.

2.

Remove four screws (Figure 1, Item 4), washers (Figure 1, Item 5), and radiator splash shield (Figure 1, Item 3) from vehicle.

END OF TASK INSTALLATION 1.

Position radiator splash shield (Figure 1, Item 3) on vehicle and install four washers (Figure 1, Item 5) and screws (Figure 1, Item 4).

2.

Install washer (Figure 1, Item 2) and new locknut (Figure 1, Item 1) on stud of bracket. 1,2

3

4,5

Figure 1.

Radiator Splash Shield Installation.

END OF TASK END OF WORK PACKAGE

0084-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00044)

M0416JCH

TM 10-3930-675-23-1

FIELD MAINTENANCE RADIATOR TOP GRATING REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

WARNING

Exhaust and cooling system components may be hot to the touch. Ensure these components have cooled down before replacing radiator top grating. Failure to follow this warning may result in serious burns.

0085-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00045)

0085

TM 10-3930-675-23-1

0085

REPLACEMENT

NOTE Radiator top grating closest to front of vehicle has five mounting screws and hold-down brackets. 1.

Remove four screws (Figure 1, Item 1), eight washers (Figure 1, Item 2), four hold-down brackets (Figure 1, Item 3), and grating (Figure 1, Item 4) from vehicle frame.

2.

Install grating (Figure 1, Item 4) on vehicle frame with four hold-down brackets (Figure 1, Item 3), eight washers (Figure 1, Item 2), and four screws (Figure 1, Item 1). 1,2,3

4

M0417JCH

Figure 1. Radiator Top Grating Replacement. END OF TASK END OF WORK PACKAGE

0085-2

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0086

FIELD MAINTENANCE RADIATOR FILL COVER PLATE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

WARNING

Exhaust and cooling system components may be hot to the touch. Ensure these components have cooled down before replacing radiator top grating. Failure to follow this warning may result in serious burns. REPLACEMENT 1.

Remove four screws (Figure 1, Item 1), washers (Figure 1, Item 2), and fill cover plate (Figure 1, Item 3) from plate (Figure 1, Item 4).

2.

Install fill cover plate (Figure 1, Item 3) on plate (Figure 1, Item 4) with four washers (Figure 1, Item 2) and screws (Figure 1, Item 1). 1,2

3

4

Figure 1.

Radiator Fill Cover Replacement.

END OF TASK END OF WORK PACKAGE

0086-1/2 blank

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M0418JCH

TM 10-3930-675-23-1

0087

FIELD MAINTENANCE THERMOSTAT REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Seal, Thermo (Volume 2, WP 0278, Table 1, Item 20) Suitable container References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Radiator splash shield removed (WP 0084) Alternator removed (WP 0091) Engine coolant drained (WP 0080)

REMOVAL 1.

Loosen coolant bypass hose clamps (Figure 1, Item 1) on upper and lower hoses (Figure 1, Items 2 and 4).

2.

Remove upper hose (Figure 1, Item 2) and lower hose (Figure 1, Item 4) from thermostat housing (Figure 1, Item 3). Ensure flow restriction disc (Figure 1, Item 5) is retained for installation. 2 1

3 5

4

Figure 1.

Thermostat Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00047)

1

M0070JCH

TM 10-3930-675-23-1

0087

REMOVAL - Continued 3.

Remove four screws (Figure 2, Item 3) securing thermostat housing (Figure 2, Item 1) to housing support (Figure 2, Item 2).

4.

Remove thermostat housing (Figure 2, Item 1) from housing support (Figure 2, Item 2). 1

3

2 M0071JCH

Figure 2. Thermostat Removal. 5.

Remove thermostat (Figure 3, Item 1) and seal (Figure 3, Item 2) from thermostat housing (Figure 3, Item 3). Discard seal. 1 2 3

M0072JCH

Figure 3.

Thermostat Removal and Installation.

END OF TASK

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TM 10-3930-675-23-1

0087

INSTALLATION

NOTE Ensure sealing surfaces of thermostat housing and housing support are clean and free of all material. 1.

Install thermostat (Figure 3, Item 1) and new seal (Figure 3, Item 2) in thermostat housing (Figure 3, Item 3).

2.

Position thermostat housing (Figure 2, Item 3) on housing support (Figure 2, Item 2) and secure with four screws (Figure 2, Item 2). Tighten screws to 40 ft-lb (54 N·m).

3.

Connect upper hose (Figure 4, Item 2) and lower hose (Figure 4, Item 4) to thermostat housing (Figure 4, Item 3) and secure with hose clamps (Figure 4, Item 1). Ensure flow restriction disc (Figure 4, Item 5) is installed. 2

1

3 5

1

4

Figure 4.

Thermostat Installation.

END OF TASK FOLLOW-ON MAINTENANCE

NOTE Ensure radiator draincock is closed. 1.

Replace coolant in system (WP 0080).

2.

Install alternator (WP 0091).

3.

Install radiator splash shield (WP 0084).

4.

Start engine (TM 10-3930-675-10) and check for leaks.

5.

Top off coolant level as needed (WP 0080).

6.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0087-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00047)

M0073JCH

TM 10-3930-675-23-1

0088

FIELD MAINTENANCE WATER PUMP REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Pan, Drain (Volume 2, WP 0277, Table 1, Item 54) Puller Attachment, Mechanical (Volume 2, WP 0277, Table 1, Item 58) Puller, Mechanical (Volume 2, WP 0277, Table 1, Item 60) Puller, Mechanical (Volume 2, WP 0277, Table 1, Item 61) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 lb-ft (Volume 2, WP 0277, Table 1, Item 97) Wrench, Torque, Dial, 3/8 in. Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Oil, Lubricating,Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Sealant, Silicone (Volume 2, WP 0276, Table 1, Item 53) Gasket (Volume 2, WP 0278, Table 1, Item 25) Seal, Oil (Volume 2, WP 0278, Table 1, Item 37) Gasket (Volume 2, WP 0278, Table 1, Item 41) O-Ring (Volume 2, WP 0278, Table 1, Item 57) O-Ring (Volume 2, WP 0278, Table 1, Item 64) Seal, Dust (Volume 2, WP 0278, Table 1, Item 66) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Alternator removed (WP 0091) Thermostat housing removed (WP 0087)

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0088

REMOVAL

WARNING

DO NOT perform maintenance on 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.

NOTE Use a drain pan to catch any remaining coolant. 1.

Remove water pump pulley retaining screw (Figure 1, Item 1).

NOTE Ensure puller mounting screws are threaded all the way through puller before applying pressure to puller screw. 2.

Use mechanical puller (Figure 1, Item 2) to remove water pump pulley (Figure 1, Item 3).

2

3 1

M0074JCH

Figure 1.

Water Pump Pulley Removal.

NOTE Dust seal is removed as seal carrier is removed, or use a heel bar or similar tool to pry dust seal away from seal case, then remove by hand. 3.

Remove dust seal (Figure 2, Item 1). Discard dust seal.

4.

Remove five screws (Figure 2, Item 5), clamping ring (Figure 2, Item 4), oil seal (Figure 2, Item 3), and gasket (Figure 2, Item 2). Discard oil seal and gasket.

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TM 10-3930-675-23-1

0088

REMOVAL - Continued 1

2

5

3

4 5

Figure 2.

M0075JCH

Dust and Oil Seal Removal.

5.

Remove two water pump transfer connection screws (Figure 3, Item 1).

6.

Remove three water pump mounting screws (Figure 3, Item 7).

NOTE Rotate water pump outward to access transfer connection for removal. 7.

Disconnect water transfer connection (Figure 3, Item 4) and gasket (Figure 3, Item 3) from engine and remove transfer connection and seal (Figure 3, Item 5) from water pump (Figure 3, Item 2). Discard gasket and seal.

NOTE Water pump must be rotated outward and angled downward while being removed to allow pump to pass thermostat housing support. 8.

Remove water pump (Figure 3, Item 2) and seal (Figure 3, Item 6). Discard seal. 1

2

7

3 4 6 5 M0076JCH

Figure 3.

Water Pump Removal.

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TM 10-3930-675-23-1

0088

REMOVAL - Continued 9.

Inspect needle bearing (Figure 4, Item 1) in front cover (Figure 4, Item 2) for damage. 1

2

M0077JCH

Figure 4.

Needle Bearing Inspection.

END OF TASK INSTALLATION

NOTE Water pump must be rotated outward from the top until transfer outlet clears thermostat housing support during installation. 1.

Install new seal (Figure 5, Item 6) on water pump (Figure 5, Item 2) and install water pump.

2.

Install new seal (Figure 5, Item 5) on transfer connection (Figure 5, Item 4) and install transfer connection into water pump (Figure 5, Item 2).

3.

Rotate water pump (Figure 5, Item 2) inward and install three water pump mounting screws (Figure 5, Item 7). Tighten screws to 35 ft-lb (47 N·m).

4.

Install new gasket (Figure 5, Item 3) on water pump transfer connection (Figure 5, Item 4).

5.

Position transfer connection (Figure 5, Item 4) and secure in place with two screws (Figure 5, Item 1). Tighten screws to 18 ft-lb (24 N·m).

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TM 10-3930-675-23-1

0088

INSTALLATION - Continued 1

2

7

3 4 6 5 M0078JCH

Figure 5.

Water Pump Installation.

NOTE Oil seal must be installed with lip of seal and shaft clean and dry. Yellow lip of seal must face out. 6.

Install new gasket (Figure 6, Item 2) and new oil seal (Figure 6, Item 3).

NOTE To prevent oil leakage, use sealant on clamping ring mounting screws. 7.

Install clamping ring (Figure 6, Item 4) and secure in place with five screws (Figure 6, Item 5). Tighten screws to 60 in-lbs. (7 N·m). Repeat tightening screws to 180 in-lbs. (20 N·m).

8.

Apply a light coat of oil to inside of new dust seal (Figure 6, Item 1) and install dust seal. 1

2

5

3

4 5

Figure 6.

Oil and Dust Seal Installation.

0088-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00048)

M0079JCH

TM 10-3930-675-23-1

0088

INSTALLATION - Continued 9.

Using pusher adapter and pulley pusher, install water pump pulley (Figure 7, Item 2).

10.

Install water pump pulley retaining screw (Figure 7, Item 1). Tighten screw to 55 ft-lb (75 N·m). 2

1

M0080JCH

Figure 7. Water Pump Pulley Installation. END OF TASK FOLLOW-ON MAINTENANCE 1.

Install thermostat and thermostat housing (WP 0087).

2.

Install alternator (WP 0091).

3.

Start engine and check for operation and leaks (TM 10-3930-675-10).

4.

Ensure cooling system is topped off (WP 0080).

5.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0089

FIELD MAINTENANCE HYDRAULIC COOLING FAN MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 75) Qty: 2 Pin, Cotter (Volume 2, WP 0278, Table 1, Item 169) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

Materials/Parts (cont.) Washer, Lock (Volume 2, WP 0278, Table 1, Item 119) Qty: 2 Washer, Lock (Volume 2, WP 0278, Table 1, Item 23) Qty: 4 Personnel Required (2) Equipment Condition Radiator assembly removed from vehicle (WP 0081)

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TM 10-3930-675-23-1

0089

REMOVAL 1.

Remove eight screws (Figure 1, Item 2), four lockwashers (Figure 1, Item 4), and nuts (Figure 1, Item 11) securing fan support frame (Figure 1, Item 3) to radiator assembly (Figure 1, Item 14) and fan shroud (Figure 1, Item 1). Discard lockwashers.

NOTE Fan motor, blade, bracket with bypass valve, and fan support frame are removed as a unit from radiator assembly. 2.

With assistance, lift cooling fan from radiator assembly (Figure 1, Item 14) and place on work surface with fan blade (Figure 1, Item 10) facing up.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00049)

TM 10-3930-675-23-1

0089

REMOVAL - Continued

1

14 2

12,13 3

2 11

5 4 6

9

2

10 7 8 4 2 2 M1704JCH

Figure 1.

Cooling Fan Removal.

END OF TASK

0089-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00049)

TM 10-3930-675-23-1

0089

DISASSEMBLY 1.

Remove cotter pin (Figure 2, Item 12) and castle nut (Figure 2, Item 13), and lift fan blade (Figure 2, Item 10) from hydraulic motor (Figure 2, Item 5). Discard cotter pin.

2.

Remove two locknuts (Figure 2, Item 9), screws (Figure 2, Item 8), lockwashers (Figure 2, Item 7), and hydraulic motor (Figure 2, Item 5), and bracket (Figure 2, Item 6) with bypass valve from fan support frame (Figure 2, Item 3). Discard locknuts and lockwashers.

END OF TASK ASSEMBLY 1.

Install bracket (Figure 2, Item 6) with bypass valve and hydraulic motor (Figure 2, Item 5) on fan support frame (Figure 2, Item 3) with two screws (Figure 2, Item 8), new lockwashers (Figure 2, Item 7), and new locknuts (Figure 2, Item 9).

2.

Install fan blade (Figure 2, Item 10) on hydraulic motor (Figure 2, Item 5) and secure with castle nut (Figure 2, Item 13) and new cotter pin (Figure 2, Item 12).

END OF TASK INSTALLATION

NOTE Fan motor, blade, bracket with bypass valve, and fan support frame are installed as a unit on radiator assembly. 1.

With assistance, install cooling fan on radiator assembly (Figure 2, Item 14) and secure with eight screws (Figure 2, Item 2), new lockwashers (Figure 2, Item 4), and nuts (Figure 2, Item 11).

2.

Rotate fan blade (Figure 2, Item 10) by hand to ensure blade turns freely in fan shroud.

0089-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00049)

TM 10-3930-675-23-1

0089

INSTALLATION - Continued

1

14 2

12,13 3

2 11

5 4 6

9

2

10 7 8 4 2 2 M1704JCH

Figure 2.

Cooling Fan Installation.

END OF TASK FOLLOW-ON MAINTENANCE Install radiator assembly (WP 0081). END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00049)

TM 10-3930-675-23-1

0090

FIELD MAINTENANCE COOLANT FILTER AND FILTER HEAD REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 40) Qty: 2 O-Ring (Volume 2, WP 0278, Table 1, Item 51)

Materials/Parts Antiseize Compound 1 Pound Can (Volume 2, WP 0276, Table 1, Item 7) Cleaning Compound, Solvent Type III (Volume 2, WP 0276, Table 1, Item 10) Oil, Lubricating, Engine 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Sealing Compound Pipe (Volume 2, WP 0276, Table 1, Item 59)

References TM 10-3930-675-10 Volume 2, WP 0185 Equipment Condition Engine cover removed (Volume 2, WP 0185) Drain engine coolant (WP 0080)

0090-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 10-3930-675-23-1

0090

COOLANT FILTER REMOVAL

WARNING

DO NOT perform maintenance on 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. 1.

Turn valve (Figure 1, Item 3) on cooling filter head (Figure 1, Item 2) to OFF position.

2.

Remove and discard coolant filter (Figure 1, Item 1). 3

2

1 M0081JCH

Figure 1. Coolant Filter Removal. END OF TASK

0090-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 10-3930-675-23-1

0090

COOLANT FILTER INSTALLATION

NOTE Ensure coolant filter sealing surface is free of old gasket material. 1.

Apply light coat of lubricating oil to gasket sealing surface (Figure 2, Item 1) of new coolant filter (Figure 2, Item 2).

1

2

M0082JCH

Figure 2.

Coolant Filter Preparation.

0090-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 10-3930-675-23-1

0090

COOLANT FILTER INSTALLATION - Continued 2.

Install coolant filter (Figure 3, Item 2) on filter head (Figure 3, Item 1) and tighten until gasket (Figure 3, Item 3) contacts filter head surface.

CAUTION Overtightening can distort filter threads or damage filter head 3.

Tighten coolant filter (Figure 3, Item 2) an additional 1/2 to 3/4 turn. 1

3

2 M0083JCH

Figure 3.

Coolant Filter Tightening.

0090-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 10-3930-675-23-1

0090

COOLANT FILTER INSTALLATION - Continued

NOTE Coolant filter head valve must be in ON position to prevent damage to engine. 4.

Turn coolant filter head valve (Figure 4, Item 1) to ON. 1

M0084JCH

Figure 4.

Turn Coolant Filter Head Valve ON.

END OF TASK

0090-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 10-3930-675-23-1

0090

COOLANT FILTER HEAD REMOVAL 1.

Drain engine coolant (WP 0080).

2.

Remove coolant coolant filter (Coolant Filter Removal, in this work package).

3.

Remove two capscrews (Figure 5, Item 5), washers (Figure 5, Item 6), capscrew (Figure 5, Item 10), washer (Figure 5, Item 9) and coolant filter head (Figure 5, Item 1) from engine.

4.

On backside of coolant filter head (Figure 5, Item 1) remove and discard two O-rings (Figure 5, Item 7).

5.

Remove pipe nipple (Figure 5, Item 8) from bottom of coolant filter head (Figure 5, Item 1).

6.

Remove capscrew (Figure 5, Item 11), washer (Figure 5, Item 12), and control valve (Figure 5, Item 2) from coolant filter head (Figure 5, Item 1).

7.

Remove spring washer (Figure 5, Item 4) and O-ring (Figure 5, Item 3) from control valve (Figure 5, Item 2).

END OF TASK CLEANING AND INSPECTION 1.

Clean coolant filter head and control valve with cleaning solvent and a brush.

2.

Inspect coolant filter head for cracks or other damage. Replace as necessary.

3.

Inspect control valve and control valve bore for corrosion or pitting. Replace control valve and/or coolant filter housing as necessary.

END OF TASK COOLANT FILTER HEAD INSTALLATION 1.

Lubricate new control valve O-ring (Figure 5, Item 3) with a film of anti-seize compound. Install new control valve O-ring (Figure 5, Item 3) to place on control valve (Figure 5, Item 2).

2.

Install spring washer (Figure 5, Item 4) and control valve (Figure 5, Item 2) to the coolant filter head (Figure 5, Item 1).

3.

Install washer (Figure 5, Item 12) and capscrew (Figure 5, Item 11) to coolant filter head (Figure 4, Item 1). Tighten capscrew to 90 in-lbs (10 N•m).

4.

Coat pipe nipple (Figure 5, Item 8) with pipe sealing compound, and install to coolant filter head (Figure 5, Item 1).

5.

Lubricate two new O-rings (Figure 5, Item 7) with clean engine oil. Install the O-rings to the backside of the coolant filter head (Figure 5, Item 1).

6.

Install coolant filter head (Figure 5, Item 1) with O-rings (Figure 5, Item 7) in place, two washers (Figure 5, Item 6) and capscrews (Figure 5, Item 5). Tighten capscrews to 40 ft-lb (54 N•m).

7.

Install washer (Figure 5, Item 9) and capscrew (Figure 5, Item 10) to coolant filter head (Figure 5, Item 1). Tighten capscrew to 40 ft-lb (54 N•m).

8.

Install coolant filter to coolant filter head (Coolant Filter Replacement, in this work package).

9.

Turn control valve (Figure 5, Item 2) to ON position.

0090-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00051)

TM 10-3930-675-23-1

0090

COOLANT FILTER HEAD INSTALLATION - Continued

2 5 3

1

4 6

12 7

11

10

9 8 M1726JCH

Figure 5.

Coolant Filter Head Replacement.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Fill cooling system (WP 0080).

2.

Start engine and check for leaks (TM 10-3930-675-10).

3.

Check and fill coolant level as necessary (WP 0080).

4.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0090-7/8 blank

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TM 10-3930-675-23-1

0091

FIELD MAINTENANCE ALTERNATOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Personnel Required (2)

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 175) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Battery cables disconnected (WP 0129) Alternator drive belt removed (WP 0092)

REMOVAL

NOTE Tag wire leads prior to disconnection to ensure proper connection on installation. 1.

Remove two nuts (Figure 1, Item 2) and bolt (Figure 1, Item 5) and disconnect four wiring harness leads (Figure 1, Items 1, 3, 4, and 6) from alternator (Figure 1, Item 7). Replace hardware on alternator terminal. 1

2

3

4

5

6

7

Figure 1.

M0085JCH

Alternator Removal.

0091-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00053)

TM 10-3930-675-23-1

0091

REMOVAL - Continued 2.

Remove adjusting link screw (Figure 2, Item 2) securing alternator (Figure 2, Item 1) to adjusting bracket (Figure 2, Item 3).

3.

With assistant holding alternator (Figure 2, Item 1), remove mounting screw (Figure 2, Item 4), locknut (Figure 2, Item 6), and washer (Figure 2, Item 7) securing alternator to mounting bracket (Figure 2, Item 5). Remove alternator and discard locknut. 2

3

1

4

6,7

Figure 2.

5

M0086JCH

Alternator Removal.

END OF TASK INSTALLATION 1.

Position alternator (Figure 2, Item 1) on mounting bracket (Figure 2, Item 5) and secure with screw (Figure 2, Item 4), washer (Figure 2, Item 7), and new locknut (Figure 2, Item 6). Tighten hand-tight.

2.

Install adjusting link screw (Figure 2, Item 2). Tighten hand-tight.

3.

Connect four wiring harness leads (Figure 3, Items 1, 3, 4, and 6) to alternator (Figure 3, Item 7) and secure with two nuts (Figure 3, Item 2) and bolt (Figure 3, Item 5).

0091-2

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TM 10-3930-675-23-1

0091

INSTALLATION - Continued 2

1

3

4

5

6

7

Figure 3.

M0087JCH

Alternator Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install and adjust alternator belt (WP 0092).

2.

Connect battery cables (WP 0129).

3.

Start engine (TM 10-3930-675-10) and verify operation of alternator.

4.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0092

FIELD MAINTENANCE ALTERNATOR DRIVE BELT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Belt, Tension Gauge (Volume 2, WP 0277, Table 1, Item 9) Wrench, Torque, Click, Ratcheting, 3/8 in. Drive, 75 ft-lb (Volume 2, WP 0277, Table 1, Item 97)

References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Master battery switch in OFF position

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 175)

REMOVAL 1.

Loosen jamnut (Figure 1, Item 2).

2.

Loosen adjusting link retaining screw (Figure 1, Item 3).

3.

Loosen alternator mounting screw (Figure 1, Item 5) and locknut (Figure 1, Item 6). Discard locknut.

4.

Turn adjusting screw (Figure 1, Item 1) counterclockwise to release alternator drive belt (Figure 1, Item 4) tension.

5.

Remove alternator drive belt (Figure 1, Item 4). 3

2

1

6

Figure 1.

Alternator Drive Belt Removal.

END OF TASK

0092-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00054)

5

4

M0088JCH

TM 10-3930-675-23-1

0092

INSTALLATION

CAUTION Do not roll drive belt over pulley or pry on drive belt with tools. Rolling or prying on belt can cause damage and shorten life of belt.

NOTE Ensure sufficient slack adjustment has been allowed to install drive belt. 1.

Install drive belt (Figure 2, Item 4).

2.

Position alternator (Figure 2, Item 7) to remove slack in drive belt (Figure 2, Item 4) and tighten adjusting link retaining screw (Figure 2, Item 3) to hold alternator in place.

3.

Turn adjusting screw (Figure 2, Item 1) clockwise to increase belt tension and tighten jamnut (Figure 2, Item 2) (refer to Adjustment) in this work package.

4.

Tighten retaining screw (Figure 2, Item 3) to 60 ft-lb (81 N•m).

5.

Tighten alternator mounting screw (Figure 2, Item 5) and new locknut (Figure 2, Item 6) to 35 ft-lb (47 N•m). 3

2

1

7

6

5

4

M0089JCH

Figure 2. Alternator Drive Belt Installation. END OF TASK ADJUSTMENT

NOTE • Belt tension for new alternator drive belt should be 140 ft-lb (190 N•m). For a used belt, adjustment range on belt tension is 60-110 ft-lb (81-149 N•m). • A drive belt which has been in service more than 10 minutes is considered a used belt. 1.

Measure belt tension with gauge (Figure 3, Item 4). If measurement is within specified range, no adjustment is required. If measurement is not as specified, proceed to next step.

2.

Loosen jamnut (Figure 3, Item 2).

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0092

ADJUSTMENT - Continued

NOTE Turn adjusting screw clockwise to increase tension. Turn adjusting screw counterclockwise to decrease tension. 3.

Turn adjusting screw (Figure 3, Item 1) to obtain correct tension. Tighten jamnut (Figure 3, Item 2).

4.

Tighten retaining screw (Figure 3, Item 3) to 60 ft-lb (81 N•m).

5.

Tighten alternator mounting screw (Figure 2, Item 5) and locknut (Figure 2, Item 6) to 35 ft-lb (47 N•m). 4

3

2

1 M0090JCH

Figure 3.

Alternator Drive Belt Adjustment.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Start engine (TM 10-3930-675-10) and run for approximately 10 minutes. Shut engine down and check belt tension. Readjust belt tension as required.

3.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0093

FIELD MAINTENANCE STARTER MOTOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 1/2 Inch Drive, 250 ft-lb (Volume 2, WP 0277, Table 1, Item 95) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Gasket (Volume 2, WP 0278, Table 1, Item 26) Personnel Required (2) References TM 10-3930-675-10 Equipment Condition Engine cover removed (Volume 2, WP 0185) Battery cables disconnected (WP 0129)

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TM 10-3930-675-23-1

0093

REMOVAL

WARNING

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 personnel injury or death.

NOTE • Tag cables prior to disconnection to ensure proper connection on installation. • Remove tiedown straps and discard. • Perform Step 1 at rear of starter solenoid. 1.

Remove nut (Figure 1, Item 1), washer (Figure 1, Item 2), and terminals of cables (Figure 1, Item 3) from solenoid (Figure 1, Item 4). Reinstall washer and nut. 3

4 1,2

3

M0091JCH

Figure 1.

Starter Removal.

NOTE Perform Step 2 at rear of starter. 2.

Remove nut (Figure 2, Item 1), washer (Figure 2, Item 2), and terminals of cables (Figure 2, Item 4) from starter (Figure 2, Item 3). Reinstall washer and nut.

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TM 10-3930-675-23-1

0093

REMOVAL - Continued 1,2

3

4

4

4

Figure 2. 3.

M0092JCH

Starter Removal.

Remove three screws (Figure 3, Item 4), starter (Figure 3, Item 1), and gasket (Figure 3, Item 2) from engine (Figure 3, Item 3). Discard gasket. 2

1

3

4

M0093JCH

Figure 3.

Starter Removal.

END OF TASK

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TM 10-3930-675-23-1

0093

INSTALLATION

NOTE Ensure all old gasket material has been removed from mating surfaces. 1.

Install new gasket (Figure 3, Item 2) and starter (Figure 3, Item 1) on engine (Figure 3, Item 3) with three screws (Figure 3, Item 4). Tighten screws to 140 ft-lb (190 N•m).

NOTE Perform Step 2 at rear of starter. 2.

Install terminals of cables (Figure 4, Item 4) to starter (Figure 4, Item 3) with washer (Figure 4, Item 2) and nut (Figure 4, Item 1). 1,2

3

4

4

4

Figure 4.

Starter Installation.

0093-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00055)

M0092JCH

TM 10-3930-675-23-1

0093

INSTALLATION - Continued

NOTE Perform Step 3 at rear of starter solenoid. 3.

Install terminals of cables (Figure 5, Item 3) on solenoid (Figure 5, Item 4) with washer (Figure 5, Item 2) and nut (Figure 5, Item 1).

4.

Install new tiedown straps. 3

4 1,2

3

M0091JCH

Figure 5.

Starter Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Connect battery cables (WP 0129).

2.

Perform operational check of engine (TM 10-3930-675-10).

3.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

FIELD MAINTENANCE INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

NOTE • Instrument panel switches, gauges, and panel lamps are replaced the same way, except where minor differences are noted. • Remove and discard tiedown straps as required. Use new tiedown straps on installation. • Tag wires and connectors as required.

0094-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

0094

TM 10-3930-675-23-1

0094

ROCKER SWITCH REMOVAL

NOTE • Perform Step 1 for left or right switch/gauge panel. Left panel (shown) has 10 screws. Right panel has five screws. • To replace switch/gauge panel, perform Switch/Gauge Removal and Installation procedure for each panel component per this work package. Prior to reinstalling switches and gauges, replace panel. 1.

Remove 10 screws (Figure 1, Item 3) from switch/gauge panel (Figure 1, Item 1).

2.

Lift switch/gauge panel (Figure 1, Item 1) upward from instrument panel (Figure 1, Item 2) to gain access to rear of panel. 1

2

3

M0096JCH

Figure 1.

Switch/Gauge Panel Removal.

3.

Lift tab of instrument panel wiring harness connector (Figure 2, Item 1) and disconnect connector from switch (Figure 2, Item 2).

4.

To remove switch lamp, refer to Instrument Panel Lamp Removal in this work package.

5.

Depress tabs at sides of switch (Figure 2, Item 2) and push switch upward and out of switch/gauge panel (Figure 2, Item 3).

END OF TASK

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TM 10-3930-675-23-1

0094

ROCKER SWITCH INSTALLATION 1.

Push switch (Figure 2, Item 2) down into switch/gauge panel (Figure 2, Item 3) until flush with panel.

2.

To install switch lamp, refer to Instrument Panel Lamp Installation in this work package.

3.

Connect instrument panel wiring harness connector (Figure 2, Item 1) to switch (Figure 2, Item 2).

4.

Install switch/gauge panel (Figure 2, Item 1) on instrument panel (Figure 2, Item 2) with 10 screws (Figure 2, Item 3).

5.

Turn master battery switch to on position (TM 10-3930-675-10).

6.

Check gauges/switches for proper operation (TM 10-3930-675-10). 1

2

3

M0097JCH

Figure 2.

Rocker Switch Removal.

END OF TASK

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TM 10-3930-675-23-1

0094

ROTARY SWITCH REMOVAL 1.

Remove 10 screws (Figure 3, Item 3) from switch/gauge panel (Figure 3, Item 1).

2.

Lift switch/gauge panel (Figure 3, Item 1) upward from instrument panel (Figure 3, Item 2). 1

2

3

M0096JCH

Figure 3.

Switch/Gauge Panel Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

TM 10-3930-675-23-1

0094

ROTARY SWITCH REMOVAL - Continued 3.

Remove six screws (Figure 4, Item 4) and washers (Figure 4, Item 5) from instrument panel (Figure 4, Item 2) to gain access to switches (Figure 4, Item 3).

4.

Remove three screws (Figure 4, Item 1) to separate switch plate (Figure 4, Item 6) from instrument panel (Figure 4, Item 2) and pull switch plate downward for access to switches (Figure 4, Item 3). 2

1

6 4,5

Figure 4.

3

Rotary Switch Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

M0100JCH

TM 10-3930-675-23-1

0094

ROTARY SWITCH REMOVAL - Continued 5.

Loosen setscrew (Figure 5, Item 3) and remove knob (Figure 5, Item 1) from switch (Figure 5, Item 4) to be replaced.

6.

Remove nut (Figure 5, Item 2) and switch (Figure 5, Item 4) from switch plate (Figure 5, Item 10).

NOTE Perform Step 7 for switches with electrical connectors. 7.

Disconnect connector(s) (Figure 5, Item 5) of instrument panel wiring harness from rear of switch (Figure 5, Item 4).

NOTE Perform Steps 8 and 9 for switches with control cables. 8.

Remove pushnut (Figure 5, Item 8) and disconnect control cable (Figure 5, Item 7) from rear of switch (Figure 5, Item 9).

9.

Remove tiedown strap, lift tab of clip (Figure 5, Item 6), and remove clip and control cable (Figure 5, Item 7) from switch (Figure 5, Item 9). Discard tiedown strap.

END OF TASK ROTARY SWITCH INSTALLATION

NOTE Perform Steps 1 and 2 for switches with control cables. 1.

Install control cable (Figure 5, Item 7) on switch (Figure 5, Item 9) with clip (Figure 5, Item 6) and install new tiedown strap.

2.

Connect control cable (Figure 5, Item 7) to rear of switch (Figure 5, Item 9) and install pushnut (Figure 5, Item 8).

NOTE Perform Step 3 for switches with electrical connectors. 3.

Connect instrument panel wiring harness connector(s) (Figure 5, Item 5) to rear of switch (Figure 5, Item 4).

4.

Push switch (Figure 5, Item 4) upward through hole in switch plate (Figure 5, Item 10) and install nut (Figure 5, Item 2).

5.

Press knob (Figure 5, Item 1) onto shaft of switch (Figure 5, Item 4) and tighten setscrew (Figure 5, Item 3).

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TM 10-3930-675-23-1

0094

ROTARY SWITCH INSTALLATION - Continued 2

1

3

4

10

5

9

8

Figure 5.

7

6

M0101JCH

Rotary Switch Removal and Installation.

6.

Install switch plate (Figure 6, Item 5) on instrument panel (Figure 6, Item 2) with three screws (Figure 6, Item 1).

7.

Install instrument panel (Figure 6, Item 2) with six washers (Figure 6, Item 4) and screws (Figure 6, Item 3). 1

2

3

M0103JCH

Figure 6.

Switch/Gauge Panel Installation.

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TM 10-3930-675-23-1

0094

ROTARY SWITCH INSTALLATION - Continued 8.

Install switch/gauge panel (Figure 7, Item 1) on instrument panel (Figure 7, Item 2) with 10 screws (Figure 7, Item 3).

9.

Turn master battery switch to ON position (TM 10-3930-675-10).

10.

Check gauges/switches for proper operation (TM 10-3930-675-10). 2

1

5

3,4 M0102JCH

Figure 7. Rotary Switch Installation. END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

TM 10-3930-675-23-1

0094

GAUGE REMOVAL 1.

Perform Steps 1 and 2 of Rocker Switch Removal in this work package to gain access to rear of gauge.

2.

To remove gauge lamp, refer to Instrument Panel Lamp Removal in this work package.

NOTE Perform Steps 3 and 4 for fuel gauge. 3.

Disconnect instrument panel wiring harness connector (Figure 8, Item 8) from rear of gauge (Figure 8, Item 1).

4.

Remove retainer (Figure 8, Item 2) and gauge (Figure 8, Item 1) from switch/gauge panel (Figure 8, Item 3).

NOTE Perform Steps 5 and 6 for hour meter gauge. 5.

Disconnect instrument panel wiring harness connector (Figure 8, Item 7) from rear of gauge (Figure 8, Item 4).

6.

Remove two nuts (Figure 8, Item 6), retainer (Figure 8, Item 5), and gauge (Figure 8, Item 4) from switch/gauge panel (Figure 8, Item 3). 1

3

2

4

5 8 6

7

Figure 8.

Gauge Removal.

END OF TASK

0094-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

M0104JCH

TM 10-3930-675-23-1

0094

GAUGE INSTALLATION

NOTE Perform Steps 1 and 2 for hour meter gauge. 1.

Install gauge (Figure 8, Item 4) on switch/gauge panel (Figure 8, Item 3) with retainer (Figure 8, Item 5) and two nuts (Figure 8, Item 6).

2.

Connect instrument panel wiring harness connector (Figure 8, Item 7) to gauge (Figure 8, Item 4).

NOTE Perform Steps 3 and 4 for fuel gauge. 3.

Install gauge (Figure 8, Item 1) on switch/gauge panel (Figure 8, Item 3) with retainer (Figure 8, Item 2).

4.

Connect instrument panel wiring harness connector (Figure 8, Item 8) to gauge (Figure 8, Item 1).

5.

To install gauge lamp, refer to Instrument Panel Lamp Installation in this work package.

6.

Install switch/gauge panel (Figure 9, Item 1) on instrument panel (Figure 9, Item 2) with 10 screws (Figure 9, Item 3).

7.

Turn master battery switch to ON position (TM 10-3930-675-10).

8.

Check gauges/switches for proper operation (TM 10-3930-675-10). 1

3

2

M0105JCH

Figure 9.

Switch/Gauge Panel Installation.

END OF TASK

0094-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

TM 10-3930-675-23-1

0094

INSTRUMENT PANEL LAMP REMOVAL 1.

Perform Steps 1 and 2 of Rocker Switch Removal in this work package to gain access to instrument panel lamps.

2.

Disconnect lamp (Figure 10, Item 1), with connector (Figure 10, Item 2) attached, from switch or gauge.

3.

Remove lamp (Figure 10, Item 1) from connector (Figure 10, Item 2).

1

2

M0106JCH

Figure 10.

Instrument Panel Lamp Installation.

END OF TASK

0094-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

TM 10-3930-675-23-1

0094

INSTRUMENT PANEL LAMP INSTALLATION 1.

Install lamp (Figure 11, Item 1) on connector (Figure 11, Item 2).

2.

Connect lamp (Figure 11, Item 1), with connector (Figure 11, Item 2) attached, to switch or gauge.

3.

Install switch/gauge panel (Figure 11, Item 1) on instrument panel (Figure 11, Item 2) with 10 screws (Figure 11, Item 3).

4.

Turn master battery switch to ON position (TM 10-3930-675-10).

5.

Check gauges/switches for proper operation (TM 10-3930-675-10). 1

3

2

M0108JCH

Figure 11. Instrument Panel Lamp Installation. END OF TASK

0094-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

TM 10-3930-675-23-1

0094

12/24V CONNECTOR REMOVAL 1.

Perform Steps 1 and 2 of Rocker Switch Removal in this work package to gain access to 12/24V connector (Figure 12, Item 6).

2.

Remove three nuts (Figure 12, Item 3), two screws (Figure 12, Item 5), and 12/24V connector (Figure 12, Item 6) from switch/gauge panel (Figure 12, Item 4).

3.

Loosen three screws (Figure 12, Item 2) and disconnect three wires (Figure 12, Item 1) from rear of 12/24V connector (Figure 12, Item 6). 2

1

3 4

5 6

M0109JCH

Figure 12.

12/24 Connector Removal.

END OF TASK

0094-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

TM 10-3930-675-23-1

0094

12/24V CONNECTOR INSTALLATION 1.

Thread three wires (Figure 13, Item 1) through switch/gauge panel (Figure 13, Item 4).

2.

Connect three wires (Figure 13, Item 1) to rear of 12/24V connector (Figure 13, Item 6) and tighten three screws (Figure 13, Item 2).

3.

Install 12/24V connector (Figure 13, Item 6) on switch/gauge panel (Figure 13, Item 4) with two screws (Figure 13, Item 5) and three nuts (Figure 13, Item 3).

4.

Install switch/gauge panel (Figure 13, Item 1) on instrument panel (Figure 13, Item 2) with 10 screws (Figure 13, Item 3).

5.

Turn master battery switch to ON position (TM 10-3930-675-10).

6.

Check gauges/switches for proper operation (TM 10-3930-675-10). 1

3

2

M0108JCH

Figure 13. 12/24V Connector Installation. END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check gauges/switches for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0094-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00056)

TM 10-3930-675-23-1

0095

FIELD MAINTENANCE TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Steering wheel removed Volume 2, WP 0165

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

REMOVAL 1.

Remove eight screws (Figure 1, Item 1) and washers (Figure 1, Item 2) and separate two halves of plastic housing (Figure 1, Item 3). 1,2 3

M0300JCH

Figure 1.

Separate Housing.

0095-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00057)

TM 10-3930-675-23-1

0095

REMOVAL - Continued

NOTE Mark position of transmission control lever and accessory control lever on steering column for installation. 2.

Remove two screws (Figure 2, Item 4) to free transmission control lever (Figure 2, Item 1) and accessory control lever (Figure 2, Item 3) from steering column (Figure 2, Item 2). 1

2

3

4 M0301JCH

Figure 2.

Transmission and Accessory Control Levers Removal.

3.

Remove seven screws (Figure 3, Item 7), washers (Figure 3, Item 8), and two halves of steering column housing (Figure 3, Item 9).

4.

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

5.

Remove three screws (Figure 3, Item 4), washers (Figure 3, Item 5), and right lower panel (Figure 3, Item 6).

0095-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00057)

TM 10-3930-675-23-1

0095

REMOVAL - Continued 1,2

4,5

3

6

RT 240V1 AND RT 240V1R VEHICLES

Figure 3. 1,2

9 M0302JCH

Panel Removed. 4,5

3

RT 240V2 AND RT 240V3 VEHICLES

Figure 4.

7,8

Panel Removal.

0095-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00057)

7,8

6

9

M0303JCH

TM 10-3930-675-23-1

0095

REMOVAL - Continued

NOTE • Perform Steps 6 and 7 to remove transmission control lever. • Remove and discard tiedown straps as necessary. 6.

Disconnect connector (Figure 5, Item 1) of transmission control lever (Figure 5, Item 1) from instrument panel wiring harness (Figure 5, Item 2).

7.

Remove transmission control lever (Figure 5, Item 1) from steering column (Figure 5, Item 2).

NOTE • Perform Steps 8 and 9 to remove accessory control lever. • Remove and discard tiedown straps as necessary. 8.

Disconnect two connectors (Figure 5, Item 3) of accessory control lever (Figure 5, Item 3 ) from instrument panel wiring harness (Figure 5, Item 2).

9.

Remove accessory control lever (Figure 5, Item 3) from steering column (Figure 5, Item 2). 2 1

3

M0304JCH

Figure 5.

Transmission and Accessory Control Levers Removal.

END OF TASK

0095-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00057)

TM 10-3930-675-23-1

0095

INSTALLATION

NOTE • Perform Steps 1 and 2 to install accessory control lever. • Install new tiedown straps as necessary. • Control lever bracket should be positioned 3/4-inch (20 mm) from bracket to top edge of column tube to which it secures. 1.

Install accessory control lever (Figure 6, Item 3) on steering column (Figure 6, Item 2).

2.

Connect two connectors (Figure 6, Item 3) of accessory control lever (Figure 6, Item 3) to instrument panel wiring harness (Figure 6, Item 2).

NOTE • Perform Steps 3 and 4 to install transmission control lever. • Install new tiedown straps as necessary. • Control lever bracket should be positioned 3/4-in. (20 mm) from bracket to top edge of column tube to which it secures. 3.

Install transmission control lever (Figure 6, Item 1) and accessory control lever (Figure 6, Item 3) on steering column (Figure 6, Item 2), in position marked, with two screws (Figure 6, Item 4). Tighten screws. 1

2

3

4 M0305JCH

Figure 6. Transmission and Accessory Control Levers Installation.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00057)

TM 10-3930-675-23-1

0095

INSTALLATION - Continued 4.

Connect connector (Figure 7, Item 1) of transmission control lever (Figure 7, Item 3) to instrument panel wiring harness (Figure 5, Item 2).

5.

Install right lower panel (Figure 7, Item 1) with three screws (Figure 7, Item 2) and washers (Figure 7, Item 3).

6.

Install left lower panel (Figure 7, Item 4) with three screws (Figure 7, Item 5) and washers (Figure 7, Item 6). 1,2

4,5

3

6

RT 240V1 AND RT 240V1R VEHICLES

Figure 7. 7.

7,8

9

M0306JCH

Panels Installation.

Install two halves of steering column housing (Figure 8, Item 9) with seven washers (Figure 8, Item 8) and screws (Figure 8, Item 7). 1,2

4,5

3

RT 240V2 AND RT 240V3 VEHICLES

Figure 8.

Panels Installation.

0095-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00057)

7,8

6

9

M0307JCH

TM 10-3930-675-23-1

0095

INSTALLATION - Continued 8.

Install two halves of plastic housing (Figure 9, Item 3) together with eight washers (Figure 9, Item 2) and screws (Figure 9, Item 1). 1,2 3

M0308JCH

Figure 9.

Housing Installation.

END OF TASK FOLLOW-ON MAINTENANCE Install steering wheel (Volume 2, WP 0165). END OF TASK END OF WORK PACKAGE

0095-7/8 blank

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TM 10-3930-675-23-1

0096

FIELD MAINTENANCE ECS DISPLAY SCREEN REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Steering wheel removed Volume 2, WP 0165

References WP 0094

NOTE • To replace exterior panels (Figure 1, Items 1 and 2), proceed with this work package as instructed. Prior to reinstalling exterior panels (Figure 1, Items 1 and 2), replace with new components as required. • Refer to Instrument Panel Switches, Gauges, and Panel Lamps Replacement (WP 0094) for Rocker Switch and Instrument Panel Light Removal and Installation instructions. REMOVAL 1.

Remove eight screws (Figure 1, Item 3) and washers (Figure 1, Item 4) to separate top plastic housing (Figure 1, Item 1) from bottom plastic housing (Figure 1, Item 2). Raise front of top plastic housing (Figure 2, Item 2) upward for access to display screen (Figure 2, Item 3). 2 1

3,4

Figure 1.

ECS Display Screen Removal.

0096-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00058)

M0159JCH

TM 10-3930-675-23-1

0096

REMOVAL - Continued 2.

Disconnect two-wire ground connector (Figure 2, Item 5) from display screen (Figure 2, Item 3).

3.

Disconnect multi-pin connector (Figure 2, Item 4) from display screen (Figure 2, Item 3).

NOTE • Display screen is a unit consisting of display screen, flat wire connector, and touch pad. • Note position of display screen for installation. 4.

Remove two screws (Figure 2, Item 1) and display screen (Figure 2, Item 3) from top plastic housing (Figure 2, Item 2).

END OF TASK INSTALLATION

NOTE Ensure four hexagonal studs are positioned against the display protective window before tightening display securing screws. 1.

Install display screen (Figure 2, Item 3) in top plastic housing (Figure 2, Item 2) with two screws (Figure 2, Item 1).

2.

Connect multi-pin connector (Figure 2, Item 4) to display screen (Figure 2, Item 3).

3.

Connect two-wire ground connector (Figure 2, Item 5) to display screen (Figure 2, Item 3).

4.

Lower front of top plastic housing (Figure 2, Item 2). 2 3

4

1 5

M0160JCH

Figure 2. ECS Display Screen Installation.

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TM 10-3930-675-23-1

0096

INSTALLATION - Continued 5.

Install top plastic housing (Figure 3, Item 1) on bottom plastic housing (Figure 3, Item 2) with eight washers (Figure 3, Item 4) and screws (Figure 3, Item 3). 2 1

3,4

Figure 3.

M0161JCH

ECS Display Screen Installation.

END OF TASK FOLLOW-ON MAINTENANCE Install steering wheel (Volume 2, WP 0165). END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0097

FIELD MAINTENANCE TOPHANDLER JUNCTION BOX MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66)

Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 6 O-Ring (Volume 2, WP 0278, Table 1, Item 143) Qty: 8

References WP 0113 Volume 2, WP 0257 Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

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TM 10-3930-675-23-1

0097

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) REMOVAL

NOTE Tophandler ECU is located inside junction box at end of boom, above tophandler. Tophandler ECU is identified as No. 791on system electrical diagrams (Volume 2, WP 0272). 1.

Loosen six screws (Figure 1, Item 1) and remove cover (Figure 1, Item 2) from tophandler junction box (Figure 1, Item 4). Three circuit breakers (Figure 1, Item 5) should be in ON position.

2.

Inspect rubber seal (Figure 1, Item 3) on cover (Figure 1, Item 2). Replace seal only if damaged. 2 1

3

5

4

M0145JCH

Figure 1.

Tophandler ECU Removal.

NOTE • Perform Step 3 for each of three connectors. • Tag connectors for installation. 3.

With a flat-tip screwdriver, slide red latch segment (Figure 2, Item 3) on connector away from black connector (Figure 2, Item 2) and remove connector from tophandler ECU (Figure 2, Item 1).

4.

Remove four screws (Figure 2, Item 5), washers (Figure 2, Item 6), and tophandler ECU (Figure 2, Item 1) from tophandler junction box (Figure 2, Item 4).

END OF TASK

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TM 10-3930-675-23-1

0097

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) INSTALLATION

CAUTION DO NOT overtighten screws or damage to screws will result. 1.

Install tophandler ECU (Figure 2, Item 1) in tophandler junction box (Figure 2, Item 4) with four washers (Figure 2, Item 6) and screws (Figure 2, Item 5).

NOTE Perform Step 2 for each of three connectors. 2.

Position black connector (Figure 2, Item 2) on tophandler ECU (Figure 2, Item 1) and connect connector by sliding red latch segment (Figure 2, Item 3) of connector inward.

3.

Install cover (Figure 1, Item 2) on tophandler junction box (Figure 1, Item 4) and tighten six screws (Figure 1, Item 1).

3 4

2

5,6

1

M0146JCH

Figure 2. 4.

Tophandler ECU Installation.

Perform boom and tophandler calibration (Volume 2, WP 0257).

END OF TASK

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TM 10-3930-675-23-1

0097

RELAY REMOVAL

NOTE All five relays are removed the same. 1.

Loosen six screws (Figure 3, Item 1) and remove cover (Figure 3, Item 2) from tophandler junction box (Figure 3, Item 4). Three circuit breakers (Figure 3, Item 5) should be in ON position.

2.

Inspect rubber seal (Figure 3, Item 3) on cover (Figure 3, Item 2). Remove and discard seal only if damaged.

3.

Remove relay (Figure 3, Item 6) from relay holder (Figure 3, Item 7).

END OF TASK RELAY INSTALLATION

NOTE All five relays are installed the same. 1.

Install relay (Figure 3, Item 6) in relay holder (Figure 3, Item 7).

2.

If removed, install new rubber seal (Figure 3, Item 3) on cover (Figure 3, Item 2).

3.

Install cover (Figure 3, Item 2) on tophandler junction box (Figure 3, Item 4) and tighten six screws (Figure 3, Item 1). 2 1

3

5

6

4

7

Figure 3.

7

M0147JCH

Relay Installation.

END OF TASK TOPHANDLER JUNCTION BOX REMOVAL 1.

Loosen six screws (Figure 4, Item 2) and remove cover (Figure 4, Item 1) from tophandler junction box

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX REMOVAL - Continued (Figure 4, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged.

1

2

3

M0876JCH

Figure 4. 2.

Tophandler Junction Box Removal.

Remove two plastic covers (Figure 5, Item 1).

1

Figure 5.

Tophandler Junction Box Removal.

0097-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

M0877JCH

TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX REMOVAL - Continued

NOTE • Tag wires to ensure proper connection on installation. • Remove and discard tiedown straps as necessary. 3.

At top of junction box (Figure 6, Item 5), remove locknut (Figure 6, Item 1) and washer (Figure 6, Item 2) and disconnect terminal of large black wire (Figure 6, Item 3), marked “black", and terminal of small white wires (Figure 6, Item 4) from terminal stud. Discard locknut.

4.

Remove locknut (Figure 6, Item 12) and washer (Figure 6, Item 13) and disconnect terminal of large black wire (Figure 6, Item 11), marked “red", and terminal of small black wires (Figure 6, Item 10) from terminal stud. Discard locknut.

NOTE Note location of fittings for installation. 5.

Loosen cap (Figure 6, Item 7) on each of five fittings (Figure 6, Item 6) and remove fittings from junction box (Figure 6, Item 5).

6.

Pull large black wires (Figure 6, Items 3 and 11) out from junction box (Figure 6, Item 5).

7.

Trace route of each wire (Figure 6, Item 9) in three cables (Figure 6, Item 8) to connecting point and disconnect wire. Note connecting point.

8.

Pull each wire (Figure 6, Item 9) out from junction box (Figure 6, Item 5). 1,2

3

5

4

6

7

8

12,13

11

Figure 6.

10

9

Tophandler Junction Box Removal.

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

M0878JCH

TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX REMOVAL - Continued 9.

At bottom of junction box (Figure 7, Item 2), disconnect connectors (Figure 7, Item 6) of four cables (Figure 7, Item 7).

10.

Loosen cap (Figure 7, Item 5) on fitting (Figure 7, Item 4) and remove fitting from junction box (Figure 7, Item 2).

11.

Trace route of three wires (Figure 7, Item 1) of cable (Figure 7, Item 3) to connecting point and disconnect wires. Note connecting point.

12.

Pull cable (Figure 7, Item 3) out from junction box (Figure 7, Item 2). 1

2

3

4 5

7

Figure 7.

6

Tophandler Junction Box Removal.

0097-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

M0879JCH

TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX REMOVAL - Continued 13.

Loosen cap (Figure 8, Item 1) on fitting (Figure 8, Item 2) and remove fitting from junction box (Figure 8, Item 3).

14.

Trace route of eight wires (Figure 8, Item 4) of cable (Figure 8, Item 8) to connecting point and disconnect wires. Note connecting point.

15.

Pull cable (Figure 8, Item 8) out from junction box (Figure 8, Item 3).

16.

Remove two screws (Figure 8, Item 5), washers (Figure 8, Item 6), and twistlock indicator light assembly (Figure 8, Item 7) from side of junction box (Figure 8, Item 3). Also remove twistlock indicator IR lights (WP 0113). 1

2

3

4 5

7

Figure 8.

6

Tophandler Junction Box Removal.

0097-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

M0880JCH

TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX REMOVAL - Continued 17.

For RT 240V1 and RT 240V1R vehicles, remove four screws (Figure 9, Item 1), washers (Figure 9, Item 2), loop clamp (Figure 9, Item 8), and 791 junction box (Figure 9, Item 9), with two brackets (Figure 9, Item 6) from tophandler.

18.

For RT 240V1 and RT 240V1R vehicles, remove four locknuts (Figure 9, Item 3), screws (Figure 9, Item 4), eight washers (Figure 9, Item 5), two brackets (Figure 9, Item 6), and four rubber grommets (Figure 9, Item 7) from 791 junction box (Figure 9, Item 9). Discard locknuts. 1,2

3,4,5

7

6

8

9

M0881JCH

Figure 9.

Tophandler Junction Box Removal.

0097-9

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TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX REMOVAL - Continued 19.

For RT 240V2 and RT 240V3 vehicles, remove four capscrews (Figure 10, Item 1), washers (Figure 10, Item 2), spacers (Figure 10, Item 3), eight O-rings (Figure 10, Item 4), and junction box (Figure 10, Item 5) from boom. Discard O-rings.

END OF TASK TOPHANDLER JUNCTION BOX INSTALLATION 1.

For RT 240V2 and RT 240V3 vehicles, install junction box (Figure 10, Item 5) with four capscrews (Figure 10, Item 1), washers (Figure 10, Item 2), spacers (Figure 10, Item 3), and eight new O-rings (Figure 10, Item 4).

1,2,3,4

5

M0882JCH

Figure 10. Tophandler Junction Box Replacement.

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TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX INSTALLATION - Continued 2.

For RT 240V1 and RT 240V1R vehicles, install four rubber grommets (Figure 11, Item 7) and two brackets (Figure 11, Item 6) in junction box (Figure 11, Item 9) with eight washers (Figure 11, Item 5), four screws (Figure 11, Item 4), and four new locknuts (Figure 11, Item 3).

3.

For RT 240V1 and RT 240V1R vehicles, install two brackets (Figure 11, Item 6), junction box (Figure 11, Item 9), and loop clamp (Figure 11, Item 8) on tophandler with four washers (Figure 11, Item 2) and screws (Figure 11, Item 1). 1

2

3

4

5

7

Figure 11.

6

Tophandler Junction Box Installation.

0097-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

M0883JCH

TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX INSTALLATION - Continued 4.

Install twistlock indicator light assembly (Figure 12, Item 7) on side of junction box (Figure 12, Item 3) with two washers (Figure 12, Item 6) and screws (Figure 12, Item 5). Also install twistlock indicator IR lights (WP 0113).

5.

Push twistlock indicator light assembly cable (Figure 12, Item 8) into junction box (Figure 12, Item 3).

6.

Connect eight wires (Figure 12, Item 4) of cable (Figure 12, Item 8) to connecting points, as noted during removal.

7.

Install fitting (Figure 12, Item 2) in junction box (Figure 12, Item 3) and tighten cap (Figure 12, Item 1). 1,2

3

5

4

6

7

8

12,13

11

10

9

M0884JCH

Figure 12. Tophandler Junction Box Installation. 8.

Push cable (Figure 13, Item 3) into junction box (Figure 13, Item 2).

9.

Connect three wires (Figure 13, Item 1) of cable (Figure 13, Item 3) to connecting points, as noted during removal.

10.

Install fitting (Figure 13, Item 4) in junction box (Figure 13, Item 2) and tighten cap (Figure 13, Item 5).

11.

At bottom of junction box (Figure 13, Item 2), connect connectors (Figure 13, Item 6) of four cables (Figure 13, Item 7).

12.

Push wires (Figure 12, Item 9) of three cables (Figure 12, Item 8) into junction box (Figure 12, Item 5).

13.

Connect wires (Figure 12, Item 9) of three cables (Figure 12, Item 8) to connecting points, as noted during removal.

14.

Push wires (Figure 12, Items 3 and 11) into junction box (Figure 12, Item 5).

15.

Install five fittings (Figure 12, Item 6) in junction box (Figure 12, Item 5) and tighten five caps (Figure 12, Item 7).

16.

Connect terminal of small black wires (Figure 12, Item 10) and terminal of large black wire (Figure 12, Item 11), marked “red", to terminal stud and install washer (Figure 12, Item 13) and new locknut (Figure 12, Item 12).

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TM 10-3930-675-23-1

0097

TOPHANDLER JUNCTION BOX INSTALLATION - Continued 17.

Connect terminal of small white wires (Figure 12, Item 4) and terminal of large black wire (Figure 12, Item 3), marked “black", to terminal stud and install washer (Figure 12, Item 2) and new locknut (Figure 12, Item 1).

18.

Install two plastic covers (Figure 13, Item 1).

1

Figure 13. 19.

M0885JCH

Tophandler Junction Box Installation.

Install cover (Figure 14, Item 1) on tophandler junction box (Figure 14, Item 3) and tighten six screws (Figure 14, Item 2).

1

2

3

M0886JCH

Figure 14.

Tophandler Junction Box Installation.

END OF TASK

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TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE

NOTE Calibration must be performed only if ECU inside tophandler junction box is new. 1.

Perform boom and tophandler calibration (Volume 2, WP 0257).

2.

Operate tophandler to check operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0097-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00061)

0097

TM 10-3930-675-23-1

0098

FIELD MAINTENANCE TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Wrench, Torque, Dial, 3/8 Inch Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

NOTE The following procedure is for tophandler junction boxes. The procedure is identical for boom junction box. REMOVAL 1.

Loosen four screws (Figure 1, Item 1) and remove cover (Figure 1, Item 2) from junction box (Figure 1, Item 3).

2.

Inspect rubber seal (Figure 1, Item 4) on cover (Figure 1, Item 2). Replace seal only if damaged. 2

3 4

1

M0148JCH

Figure 1.

Tophandler Junction Box Cover Removal.

0098-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00062)

TM 10-3930-675-23-1

0098

REMOVAL - Continued

NOTE Perform Steps 3 and 4 in five places. 3.

Loosen cable nut (Figure 2, Item 11) and slide cable nut and grommet (Figure 2, Item 9) back on cable (Figure 2, Item 8).

NOTE Tag wires for installation. 4.

Using a jeweler’s screwdriver, disconnect wires (Figure 2, Item 5) from terminal blocks (Figure 2, Item 3) and pull cables (Figure 2, Item 8) with wires from junction box (Figure 2, Item 4).

5.

Remove two screws (Figure 2, Item 8), terminal block holder (Figure 2, Item 2), and terminal blocks (Figure 2, Item 3) from junction box (Figure 2, Item 4).

NOTE Perform Step 6 in five places. 6.

Remove plastic nut (Figure 2, Item 7) and fitting (Figure 2, Item 9) from bottom of junction box (Figure 2, Item 4).

7.

Remove four screws (Figure 2, Item 10) and junction box (Figure 2, Item 4) from tophandler.

END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00062)

TM 10-3930-675-23-1

0098

INSTALLATION 1.

Install junction box (Figure 2, Item 4) on tophandler with four screws (Figure 2, Item 10).

NOTE Perform Step 2 in five places. 2.

Install fitting (Figure 2, Item 6) and plastic nut (Figure 2, Item 7) on bottom of junction box (Figure 2, Item 4).

3.

Install terminal blocks (Figure 2, Item 3) and terminal block holder (Figure 2, Item 2) on junction box (Figure 2, Item 4) with two screws (Figure 2, Item 1).

NOTE Perform Steps 4 and 5 in five places. 4.

Push cable (Figure 2, Item 8) into junction box (Figure 2, Item 4) and use jeweler’s screwdriver to connect wires (Figure 2, Item 5) to terminal blocks (Figure 2, Item 3).

5.

Install grommet (Figure 2, Item 9) and cable nut (Figure 2, Item 11) on junction box (Figure 2, Item 4). Tighten cable nut. 2

3

1

M0150JCH

Figure 2.

Tophandler Junction Box Replacement.

0098-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00062)

TM 10-3930-675-23-1

0098

INSTALLATION - Continued 6.

Install cover (Figure 3, Item 2) on junction box (Figure 3, Item 3) with four screws (Figure 3, Item 1). 2

3

1

M0150JCH

Figure 3. Tophandler Junction Box Cover Installation. END OF TASK END OF WORK PACKAGE

0098-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00062)

TM 10-3930-675-23-1

0099

FIELD MAINTENANCE ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8 Inch Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98)

Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28)

References Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Engine cover removed Volume 2, WP 0185

NOTE Engine ECU is located on left side of engine. Engine ECU is identified as No. 794 on system electrical diagrams (Volume 2, WP 0272).

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00064)

TM 10-3930-675-23-1

0099

REMOVAL

NOTE Tag wires prior to disconnection to ensure correct connection on installation. 1.

Loosen three connector captive screws (Figure 1, Item 13) and disconnect actuator harness connector (Figure 1, Item 6), sensor harness connector (Figure 1, Item 8), and OEM harness connector (Figure 1, Item 4) from ECU (Figure 1, Item 5).

2.

Disconnect wiring harness (Figure 1, Item 11) from 32-pin connector (Figure 1, Item 12).

NOTE Note type and location of mounting hardware to aid in installation. 3.

Remove screw (Figure 1, Item 9) and washer (Figure 1, Item 3) securing 32-pin connector (Figure 1, Item 12) and bracket (Figure 1, Item 10) to ECU (Figure 1, Item 5).

4.

Remove screw (Figure 1, Item 2), washer (Figure 1, Item 3), and cable clamp (Figure 1, Item 1) securing engine wiring harness (Figure 1, Item 14) to ECU (Figure 1, Item 5). Reposition engine wiring harness and OEM wiring harness.

5.

Remove remaining screws (Figure 1, Items 2 and 9) and washers (Figure 1, Item 3) securing ECU (Figure 1, Item 5) to cooling plate (Figure 1, Item 7).

6.

Remove ECU (Figure 1, Item 5) from cooling plate (Figure 1, Item 7).

END OF TASK INSTALLATION 1.

Position ECU (Figure 1, Item 5) on cooling plate (Figure 1, Item 7).

NOTE • If ECU is new, ensure it contains the correct program. • Ensure mounting screws are installed as noted in removal. 2.

Temporarily secure ECU (Figure 1, Item 5) to cooling plate (Figure 1, Item 7) with screws (Figure 1, Items 2 and 9) and washers (Figure 1, Item 3).

NOTE • Ensure connectors are clean and dry prior to connection to ECU. • Apply light coat of electrical grease to connectors prior to connecting. 3.

Position actuator harness connector (Figure 1, Item 6), sensor harness connector (Figure 1, Item 8), and 32-pin connector (Figure 1, Item 12) with bracket (Figure 1, Item 10).

4.

Install screw (Figure 1, Item 9) and washer (Figure 1, Item 3) to secure bracket (Figure 1, Item 10) to ECU (Figure 1, Item 5). Tighten captive screws (Figure 1, Item 13) to 25 in-lb (3 N•m) to secure connectors.

5.

Position engine wiring harness (Figure 1, Item 14) and OEM wiring harness. Secure engine wiring harness with cable clamp (Figure 1, Item 1), screw (Figure 1, Item 2), and washer (Figure 1, Item 3). Tighten captive screw (Figure 1, Item 13) on OEM wiring harness to 25 in-lb (3 N•m).

6.

Connect wiring harness (Figure 1, Item 11) to 32-pin connector (Figure 1, Item 12).

7.

Fully tighten ECU screws (Figure 1, Items 2 and 9) evenly to 180 in-lb (20 N•m).

0099-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00064)

TM 10-3930-675-23-1

0099

INSTALLATION - Continued 4

6

5

7

8

3,9 10

2,3

11

1

12

14

13

Figure 1.

M0151JCH

ECU Replacement.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Start engine and check for proper operation (TM 10-3930-675-10).

3.

Install engine cover (Volume 2, WP 0185).

END OF TASK END OF WORK PACKAGE

0099-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00064)

TM 10-3930-675-23-1

0100

FIELD MAINTENANCE ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References (cont.) Volume 2, WP 0257 Volume 2, WP 0272

References Volume 2, WP 0136 Volume 2, WP 0174

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) REMOVAL

NOTE Transmission ECU is located in cab behind driver’s seat, behind right-rear panel. Transmission ECU is identified as No. 793 on system electrical diagrams (Volume 2, WP 0272). 1.

Lift and remove two access panels (Figure 1, Items 1 and 2) from rear of cab. 1

2

M0152JCH

Figure 1.

Access Panels Removal.

0100-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00065)

TM 10-3930-675-23-1

0100

TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) REMOVAL - Continued 2.

Remove duct (Figure 2, Item 10) from rear outlet connector.

3.

Disconnect connector (Figure 2, Item 9) of wiring harness (Figure 2, Item 7) from transmission ECU (Figure 2, Item 1) by sliding out handle of connector.

4.

Remove two screws (Figure 2, Item 2) and plate (Figure 2, Item 8) with transmission ECU (Figure 2, Item 1) from electrical panel (Figure 2, Item 3).

5.

Remove four nuts (Figure 2, Item 4), screws (Figure 2, Item 5), 8 washers (Figure 2, Item 6), and transmission ECU (Figure 2, Item 1) from plate (Figure 2, Item 8).

2

3

1

4,6

10

5,6

9

8

Figure 2.

7

M0153JCH

Transmission ECU Removal.

END OF TASK TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) INSTALLATION 1.

Install transmission ECU (Figure 2, Item 1) on plate (Figure 2, Item 8) with four washers (Figure 2, Item 6), screws (Figure 2, Item 5), and nuts (Figure 2, Item 4).

2.

Position plate (Figure 2, Item 8) with transmission ECU (Figure 2, Item 1) on electrical panel (Figure 2, Item 3) and install two screws (Figure 2, Item 2).

3.

Connect connector (Figure 2, Item 9) of wiring harness (Figure 2, Item 7) to transmission ECU (Figure 2, Item 1) by sliding in handle of connector.

4.

Reattach the duct (Figure 2, Item 10) to rear outlet connector.

5.

Install access panels (Figure 3, Items 1 and 2) in rear of cab.

0100-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00065)

TM 10-3930-675-23-1

0100

TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) INSTALLATION - Continued 1

2

M0154JCH

Figure 3.

Access Panels Removal.

NOTE If transmission ECU was removed only for access to steering system ECU, no transmission calibration is required. END OF TASK

0100-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00065)

TM 10-3930-675-23-1

0100

STEERING SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL

NOTE Steering system ECU is located in cab behind driver’s seat, behind right-rear panel and behind transmission ECU. Steering system ECU is identified as No. 792 on system electrical diagrams (Volume 2, WP 0272). 1.

Perform Transmission Electronic Control Unit (ECU) Removal in this work package for access to steering system ECU (Figure 4, Item 3).

2.

Disconnect 3 ECU electrical connectors (Figure 4, Item 4) from steering system ECU (Figure 4, Item 3).

3.

Loosen four flanged-head nuts (Figure 4, Item 2) to free steering system ECU (Figure 4, Item 3).

4.

Slide steering ECU (Figure 4, Item 3) to right (toward passenger side of vehicle) and remove from panel (Figure 4, Item 1) over four flanged-head nuts (Figure 4, Item 2). 2

1

3

4

2

M0155JCH

Figure 4. Steering System ECU Removal. END OF TASK

0100-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00065)

TM 10-3930-675-23-1

0100

STEERING SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION 1.

Position steering system ECU (Figure 4, Item 3) over four flanged-head nuts (12) and slide left (towards driver side of vehicle).

2.

Tighten four flanged-head nuts (Figure 4, Item 2) to secure steering system ECU (Figure 4, Item 3).

3.

Connect 3 electrical connectors (Figure 4, Item 4) to steering system ECU (Figure 4, Item 3).

4.

Perform Transmission Electronic Control Unit (ECU) Installation in this work package.

END OF TASK HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL

NOTE Hydraulic servo system ECU is located in cab under driver’s seat. Hydraulic servo system ECU is identified as No. 790 on system electrical diagrams (Volume 2, WP 0272). 1.

Rotate three turnbuttons (Figure 5, Item 1) and remove cover (Figure 5, Item 3) from seat base (Figure 5, Item 2).

1

2

3

M0156JCH

Figure 5.

Seat Base Cover Removal.

0100-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00065)

TM 10-3930-675-23-1

0100

HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL - Continued 2.

Slide electrical tray (Figure 6, Item 6) outward from seat base (Figure 6, Item 2).

NOTE Perform Step 3 for each of two connectors. 3.

Disconnect connector (Figure 6, Item 3) from hydraulic servo system ECU (Figure 6, Item 1) by sliding out red latch of connector.

4.

Remove four screws (Figure 6, Item 4), washers (Figure 6, Item 5), and hydraulic servo system ECU (Figure 6, Item 1) from electrical tray (Figure 6, Item 6).

2 1

6 3

4,5

Figure 6.

Hydraulic Servo System ECU Removal.

END OF TASK

0100-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00065)

M0157JCH

TM 10-3930-675-23-1

0100

HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION

CAUTION DO NOT overtighten screws or damage to screws will result. 1.

Install hydraulic servo system ECU (Figure 7, Item 1) on electrical tray (Figure 7, Item 6) with four washers (Figure 7, Item 5) and screws (Figure 7, Item 4).

NOTE Perform Step 2 for each of two connectors. 2.

Connect connector (Figure 7, Item 3) to hydraulic servo system ECU (Figure 7, Item 1) by sliding in red latch of connector.

3.

Slide electrical tray (Figure 7, Item 6) into seat base (Figure 7, Item 2).

2 1

6 3

4,5

Figure 7. Hydraulic Servo System ECU Installation.

0100-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00065)

M0158JCH

TM 10-3930-675-23-1

0100

HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION - Continued 4.

Install cover (Figure 8, Item 3) on seat base (Figure 8, Item 2) and rotate three turnbuttons (Figure 8, Item 1). 2

3

1

4

M0114JCH

Figure 8.

Seat Base Cover Installation.

END OF TASK FOLLOW-ON MAINTENANCE

NOTE If transmission ECU was removed only for access to steering system ECU, no transmission calibration is required. 1.

Perform transmission calibration (Volume 2, WP 0136).

2.

Perform boom and tophandler calibration (Volume 2, WP 0257).

3.

Turn master battery switch to ON position (TM 10-3930-675-10).

4.

Check gauges/switches for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0101

FIELD MAINTENANCE ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References WP 0102

REMOVAL 1.

Remove three socket screws (Figure 1, Item 3), screws (Figure 1, Item 4), and small half of joystick housing (Figure 1, Item 2). Disconnect plug for override switch.

2.

Remove emergency switch and wiring harness from joystick (WP 0102).

3.

Remove large half of joystick housing (Figure 1, Item 1) from joystick bracket (Figure 1, Item 7).

4.

Remove four screws (Figure 1, Item 5) and joystick (Figure 1, Item 6) from joystick bracket (Figure 1, Item 7).

2

6 3

5 1 7 4

M0162JCH

Figure 1.

Joystick Removal.

END OF TASK

0101-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00066)

TM 10-3930-675-23-1

0101

INSTALLATION 1.

Install joystick (Figure 2, Item 6) on joystick bracket (Figure 2, Item 7) with four screws (Figure 2, Item 5).

2.

Install large half of joystick housing (Figure 2, Item 1) on joystick bracket (Figure 2, Item 7).

3.

Install emergency switch and wiring harness at joystick (WP 0102).

4.

Connect plug for override switch and install small half of joystick housing (Figure 2, Item 2) with three screws (Figure 2, Item 4) and socket screws (Figure 2, Item 3).

2

6 3

5

1

7 4

M0163JCH

Figure 2. Joystick Installation. END OF TASK END OF WORK PACKAGE

0101-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00066)

TM 10-3930-675-23-1

FIELD MAINTENANCE ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References Volume 2, WP 0272

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

NOTE • Refer to wiring diagrams (Volume 2, WP 0272) and use marker tags, as necessary, to ensure proper connection of connectors. • Note position of washers on release lever to aid in installation.

0102-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

0102

TM 10-3930-675-23-1

0102

REMOVAL 1.

Turn joystick positioning lever (Figure 1, Item 1) counterclockwise and lift joystick assembly upward to free joystick assembly from seat.

2.

Turn joystick housing (Figure 1, Item 5) over for access to bottom of joystick housing.

3.

Remove screw (Figure 1, Item 4) and clamp (Figure 1, Item 2) from protective cover of joystick wiring harness (Figure 1, Item 3).

1

5

4

3

2 M0164JCH

Figure 1. Joystick Wiring Harness Removal 4.

Loosen two screws (Figure 2, Item 2) and disconnect connector (Figure 2, Item 7) of joystick wiring harness (Figure 2, Item 8) from bottom of joystick (Figure 2, Item 1).

NOTE Remove emergency stop switch to allow remaining cover to be removed. 5.

Move lever (Figure 2, Item 5) on emergency stop switch (Figure 2, Item 6) left to release switch from push button knob (Figure 2, Item 3). Pull switch down and away from push button knob.

NOTE Note position of the window on top of emergency stop switch before removing knob. Window should be toward right wall of cab. 6.

Unscrew push button knob (Figure 2, Item 3) from plastic nut (Figure 2, Item 4).

0102-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

TM 10-3930-675-23-1

0102

REMOVAL - Continued 5 3

4

2 1

6 8

7 M0165JCH

Figure 2.

Joystick Wiring Harness Removal.

0102-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

TM 10-3930-675-23-1

0102

REMOVAL - Continued

NOTE • If emergency stop switch is to be replaced, perform Steps 7 and 8. If not, proceed to Step 9. • Mark or tag position of all wires on emergency stop switch. 7.

Loosen four screws (Figure 3, Item 2) and disconnect wires (Figure 3, Item 1) from connector (Figure 3, Item 3).

8.

Insert four wires (Figure 3, Item 1) into new connector (Figure 3, Item 3) and tighten four screws (Figure 3, Item 2). 2

1

3

M0166JCH

Figure 3. Joystick Wiring Harness Removal. 9.

Loosen three turnbuttons (Figure 4, Item 3) and remove cover (Figure 4, Item 2) from seat base (Figure 4, Item 1).

0102-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

TM 10-3930-675-23-1

0102

REMOVAL - Continued 1

2 3

M0167JCH

Figure 4. 10.

Seat Base Cover Removal.

Slide electrical tray (Figure 5, Item 5) out from seat base (Figure 5, Item 2) for access to underside of tray.

NOTE Remove and discard tiedown straps as necessary. 11.

Depress tabs of two connectors (Figure 5, Item 3) and disconnect two connectors of joystick wiring harness (Figure 5, Item 4) from two terminal blocks (Figure 5, Item 1). 1 2

5

4

Figure 5.

3

Joystick Wiring Harness Removal.

0102-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

M0168JCH

TM 10-3930-675-23-1

0102

REMOVAL - Continued 12.

Remove nut (Figure 6, Item 1) from inside seat base (Figure 6, Item 2) and remove joystick wiring harness (Figure 6, Item 3) from vehicle. 1

2

3

M0169JCH

Figure 6. Joystick Wiring Harness Removal. END OF TASK INSTALLATION 1.

Position joystick wiring harness (Figure 7, Item 4) inside seat base (Figure 7, Item 2) and install nut (Figure 6, Item 1).

NOTE Install new tiedown straps as necessary. 2.

Connect two connectors (Figure 7, Item 3) of joystick wiring harness (Figure 7, Item 4) to two terminal blocks (Figure 7, Item 1).

3.

Slide electrical tray (Figure 7, Item 5) into seat base (Figure 7, Item 2).

0102-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

TM 10-3930-675-23-1

0102

INSTALLATION - Continued 1 2

5

4

M0168JCH

3

Figure 7. Joystick Wiring Harness Installation. 4.

Install cover (Figure 8, Item 2) on seat base (Figure 8, Item 1) and tighten three turnbuttons (Figure 8, Item 3). 1

2 3

M0170JCH

Figure 8.

Seat Base Cover Installation.

0102-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

TM 10-3930-675-23-1

0102

INSTALLATION - Continued 5.

Align push button knob (Figure 9, Item 3) in housing (Figure 9, Item 5).

NOTE Ensure window of push button is in proper position when tight. 6.

Install plastic nut (Figure 9, Item 4) from bottom and rotate push button knob (Figure 9, Item 3) to tighten

7.

Position emergency stop switch (Figure 9, Item 7) over push button (Figure 9, Item 3) shaft and slide lever (Figure 9, Item 6) right to secure.

8.

Connect connector (Figure 9, Item 8) of joystick wiring harness (Figure 9, Item 9) to bottom of joystick (Figure 9, Item 1) and tighten two screws (Figure 9, Item 2). 6 3

4

2 1

5

7 9

8 M0171JCH

Figure 9. Joystick Wiring Harness Installation.

0102-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

TM 10-3930-675-23-1

0102

INSTALLATION - Continued 9.

Install clamp (Figure 10, Item 2) on protective cover of joystick wiring harness (Figure 10, Item 3) with screw (Figure 10, Item 4).

NOTE Note position of washers on release lever when removed. 10.

Position joystick housing (Figure 10, Item 5) on seat and turn joystick positioning lever (Figure 10, Item 1) clockwise to secure.

1

5

4

Figure 10.

Joystick Wiring Harness Installation.

END OF TASK END OF WORK PACKAGE

0102-9/10 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00067)

3

2 M0172JCH

TM 10-3930-675-23-1

0103

FIELD MAINTENANCE CIRCUIT BREAKERS AND RELAYS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References WP 0129 Volume 2, WP 0185

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL

NOTE All circuit breakers and relays are replaced the same way, except where minor differences are noted. 1.

Lift and remove access panel (Figure 1, Item 1) from left rear of cab. 1

M0110JCH

Figure 1.

Access Panel Removal.

0103-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued 2.

Disconnect elastic loop (Figure 2, Item 1) from top of circuit breaker/relay box (Figure 2, Item 2). Tilt box forward.

1 2

M0111JCH

Figure 2. Circuit Breaker/Relay Box Opening. 3.

Remove two screws (Figure 3, Item 2) from side of circuit breaker/relay box (Figure 3, Item 3) and separate circuit breaker panel (Figure 3, Item 1) from relay panel (Figure 3, Item 4).

0103-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued 1

2

3

4 M0112JCH

Figure 3.

Circuit Breaker Panel Separation.

NOTE Each of 34 circuit breakers is removed the same way. 4.

Remove two screws (Figure 4, Item 2) and washers (Figure 4, Item 3) from circuit breaker panel (Figure 4, Item 1) (RT 240V1 and RT 240V1R) or remove the nut (Figure 4, Item 4) from the circuit breaker (RT 240V2 and RT 240V3). 1

2,3

4

M0113JCH

Figure 4.

Circuit Breaker Removal.

0103-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued 5.

Push circuit breaker (Figure 5, Item 1) downward through hole in circuit breaker panel (Figure 5, Item 2).

NOTE Tag connectors for installation. 6.

Disconnect three connectors (Figure 5, Item 3) of wiring harness (Figure 5, Item 4) from rear of circuit breaker (Figure 5, Item 1). Remove circuit breaker. 2

3

1

4

M0114JCH

Figure 5.

Circuit Breaker Removal.

0103-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued

NOTE Perform Step 7 to remove each of 15 relays. 7.

Disconnect relay (Figure 6, Item 2) from terminal block (Figure 6, Item 3) of relay panel (Figure 6, Item 1).

1

2

3

Figure 6.

M0115JCH

Relay Removal.

0103-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL - Continued

NOTE Perform Step 8 to remove each of two relays. 8.

Remove screw (Figure 7, Item 1) and disconnect connector (Figure 7, Item 3) of wiring harness (Figure 7, Item 4) from relay (Figure 7, Item 2).

END OF TASK CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION

NOTE Perform Step 1 to install each of two relays. 1.

Connect connector (Figure 7, Item 3) of wiring harness (Figure 7, Item 4) to relay (Figure 7, Item 2) and install screw (Figure 7, Item 1). 3

2

4 1

M0116JCH

Figure 7. Relay Replacement.

0103-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION - Continued

NOTE Perform Step 2 to install each of 15 relays. 2.

Connect relay (Figure 8, item 2) to terminal block (Figure 8, Item 3) of relay panel (Figure 8, Item 1).

1

2

3

Figure 8.

M0115JCH

Relay Connection.

0103-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION - Continued

NOTE Each of 34 circuit breakers is installed the same way. 3.

Connect three connectors (Figure 9, Item 3) of wiring harness (Figure 9, Item 4) to rear of circuit breaker (Figure 9, Item 1).

4.

Push circuit breaker (Figure 9, Item 1) upward through hole in circuit breaker panel (Figure 9, Item 2). 2

3

1

4

M0114JCH

Figure 9. Circuit Breaker Connection. 5.

Install circuit breaker (Figure 10, Item 5) with two washers (Figure 10, Item 3) and screws (Figure 10, Item 2) (RT 240V1 and RT 240V1R) or install circuit breaker (Figure 10, Item 5) with nut (Figure 10, Item 4) (RT 240V2 and RT 240V3) to circuit breaker panel (Figure 10, Item 1).

0103-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION - Continued 1

2,3

4

5

M0119JCH

Figure 10. 6.

Circuit Breaker Installation.

Position circuit breaker panel (Figure 11, Item 1) on relay panel (Figure 11, Item 3) and install two screws (Figure 11, Item 2). 1

2

3 M0120JCH

Figure 11.

Circuit Breaker Panel Installation.

0103-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION - Continued

NOTE Ensure all circuit breakers remain in ON position while circuit breaker/relay box is secured. 7.

Tilt circuit breaker/relay box (Figure 12, Item 2) rearward and connect elastic loop (Figure 12, Item 1) to top of box.

1 2

M0121JCH

Figure 12. Circuit Breaker Panel Installation.

0103-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION - Continued 8.

Install access panel (Figure 13, Item 1) on cab. 1

M0122JCH

Figure 13.

Access Panel Installation.

END OF TASK

0103-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

50A CIRCUIT BREAKERS REMOVAL 1.

Remove engine cover (Volume 2, WP 0185).

2.

Disconnect battery cables (WP 0129).

NOTE Tag wires for installation. 3.

Remove protective covers (Figure 14, Item 2) from 50A circuit breaker terminals.

4.

Remove nuts (Figure 14, Item 3), washers (Figure 14, Item 4), and terminal leads (Figure 14, Item 5) from circuit breakers (Figure 14, Item 6).

5.

Remove screws (Figure 14, Item 7), nuts (Figure 14, Item 8), washers (Figure 14, Item 9), and circuit breakers (Figure 14, Item 6) from mounting plate (Figure 14, Item 1).

END OF TASK 50A CIRCUIT BREAKERS INSTALLATION 1.

Position 50A circuit breakers (Figure 14, Item 6) on mounting plate (Figure 14, Item 1) and secure with screws (Figure 14, Item 7), nuts (Figure 14, Item 8), and washers (Figure 14, Item 9).

2.

Connect terminal leads (Figure 14, Item 5) to circuit breakers (Figure 14, Item 6) and secure with nuts (Figure 14, Item 3) and washers (Figure 14, Item 4).

3.

Place protective covers (Figure 14, Item 2) over circuit breaker terminals.

4.

Reconnect battery cables (WP 0129).

5.

Install engine cover (Volume 2, WP 0185).

0103-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

50A CIRCUIT BREAKERS INSTALLATION - Continued 1

2

3,4,5

6,7,8,9

M0123JCH

Figure 14.

Circuit Breaker Installation.

END OF TASK

0103-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

TM 10-3930-675-23-1

0103

STARTER RELAY REMOVAL 1.

Remove engine cover (Volume 2, WP 0185).

2.

Disconnect battery cables (WP 0129).

NOTE Tag wires for installation. 3.

Remove nuts (Figure 15, Item 6), washers (Figure 15, Item 7), and terminal leads (Figure 15, Item 8) from starter relay (Figure 15, Item 5).

4.

Remove screws (Figure 15, Item 2), nuts (Figure 15, Item 3), washers (Figure 15, Item 4), and starter relay (Figure 15, Item 5) from mounting brackets (Figure 15, Item 1).

END OF TASK STARTER RELAY INSTALLATION 1.

Position starter relay (Figure 15, Item 5), on mounting brackets (Figure 15, Item 1) and secure with screws (Figure 15, Item 2), nuts (Figure 15, Item 3), and washers (Figure 15, Item 4).

2.

Connect terminal leads (Figure 15, Item 8) to starter relay (Figure 15, Item 5) and secure with nuts (Figure 15, Item 6) and washers (Figure 15, Item 7).

3.

Connect battery cables (WP 0129).

4.

Install engine cover (Volume 2, WP 0185).

1

5

6,7,8

Figure 15.

Starter Relay Installation.

END OF TASK

0103-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

2,3,4

M0124JCH

TM 10-3930-675-23-1

0103

150A FUSE BLOCK REMOVAL (RT 240V1R, RT 240V2 and RT 240V3) 1.

Open battery compartment door.

2.

Disconnect battery cables (WP 0129).

3.

Remove plastic fuse cover (Figure 16, Item 1).

NOTE Tag wires for installation. 4.

Remove nuts (Figure 16, Item 2), washers (Figure 16, Item 3), terminal leads (Figure 16, Item 4), and fuse (Figure 16, Item 9) from fuse block (Figure 16, Item 6).

5.

Remove screws (Figure 16, Item 7), washers (Figure 16, Item 8), and fuse block from mounting bracket (Figure 16, Item 5).

END OF TASK 150A FUSE BLOCK INSTALLATION (RT 240V1R, RT 240V2 and RT 240V3) 1.

Position fuse block (Figure 16, Item 6) on mounting bracket (Figure 16, Item 9) and secure with screws (Figure 16, Item 7) and washers (Figure 16, Item 8).

2.

Install fuse (Figure 16, Item 5) and connect terminal leads (Figure 16, Item 4) to fuse block (Figure 16, Item 6) and secure with nuts (Figure 16, Item 2) and washers (Figure 16, Item 3).

3.

Install plastic fuse cover (Figure 16, Item 1).

4.

Connect battery cables (WP 0129).

5.

Close battery compartment door.

1 4 2,3 9 4

5 7,8

6

Figure 16.

Fuse Block Installation.

END OF TASK END OF WORK PACKAGE

0103-15/16 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00068)

M0125JCH

TM 10-3930-675-23-1

FIELD MAINTENANCE TOPHANDLER PROXIMITY SWITCHES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Wrench, Torque, Dial, 3/8 Inch Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

0104-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

0104

TM 10-3930-675-23-1

0104

TWISTLOCK PROXIMITY SWITCH REMOVAL

NOTE • These steps cover eight twistlock proximity switches at middle and at each end of spreader beam. • To aid in gaining access to junction box in Step 3, spreader beam may be extended. 1.

Remove two jamnuts (Figure 1, Item 2) and proximity switch (Figure 1, Item 1) from mounting bracket (Figure 1, Item 3). 2

1

3

M0126JCH

Figure 1. Twistlock Proximity Switch Removal.

0104-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

TWISTLOCK PROXIMITY SWITCH REMOVAL - Continued 2.

Loosen four screws (Figure 2, Item 3) and remove cover (Figure 2, Item 1) from junction box (Figure 2, Item 2). Inspect rubber seal in groove of cover. Replace only if damaged. 1

2

3

M0127JCH

Figure 2.

Junction Box Cover Removal.

0104-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

TWISTLOCK PROXIMITY SWITCH REMOVAL - Continued 3.

Loosen cable nut (Figure 3, Item 6) and slide cable nut and grommet (Figure 3, Item 5) back on proximity switch (Figure 3, Item 4) cable.

CAUTION To avoid damage to junction box, a fine-tipped jeweler’s screwdriver should be used when disconnecting proximity switch wires. DO NOT use a punch.

NOTE Tag wires for installation. 4.

Using a jeweler’s screwdriver, disconnect proximity switch wires (Figure 3, Item 3) from terminal blocks (Figure 3, Item 2).

NOTE Remove cable clamps and tiedown straps as needed. Discard tiedown straps. 5.

Remove proximity switch (Figure 3, Item 4) with cable from tophandler.

END OF TASK

0104-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

TWISTLOCK PROXIMITY SWITCH INSTALLATION 1.

Position proximity switch (Figure 3, Item 4) with cable on tophandler.

2.

Using a jeweler’s screwdriver, connect proximity switch wires (Figure 3, Item 3) to terminal blocks (Figure 3, Item 2).

3.

Install grommet (Figure 3, Item 5) and cable nut (Figure 3, Item 6) on junction box (Figure 3, Item 1). Tighten cable nut. 1

2

3

4 5

6

M0128JCH

Figure 3. Twistlock Proximity Switch Installation. 4.

Install cover (Figure 4, Item 1) on junction box (Figure 4, Item 2) and tighten four screws (Figure 4, Item 3). 1

2

3

M0127JCH

Figure 4.

Junction Box Cover Installation.

0104-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

TWISTLOCK PROXIMITY SWITCH INSTALLATION - Continued 5.

Loosely install proximity switch (Figure 5, Item 1) and two jamnuts (Figure 5, Item 2) on mounting bracket (Figure 5, Item 3).

CAUTION Overtightening jamnuts will damage proximity switch threads.

NOTE Plunger must be raised in order to properly make adjustment. 6.

Position proximity switch (Figure 5, Item 1) so a gap of 0.20 inch (5.08 mm) is obtained from the containerindicator plunger (Figure 5, Item 4). Tighten two jamnuts (Figure 5, Item 2) to 177 in-lb (20 N•m). 2

1

3

5 MM

4

M0129JCH

Figure 5. 7.

Twistlock Proximity Switch Installation.

Install cable clamps and new tiedown straps as needed.

END OF TASK

0104-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

FORKLIFT INTERLOCK PROXIMITY SWITCH REMOVAL 1.

Remove two screws (Figure 6, Item 4), plastic clamp (Figure 6, Item 3), and proximity switch (Figure 6, Item 2) from tophandler (Figure 6, Item 1). 1

3

2

4

M0130JCH

Figure 6. Forklift Interlock Proximity Switch Removal. 2.

Loosen four screws (Figure 7, Item 3) and remove cover (Figure 7, Item 1) from junction box (Figure 7, Item 2). Inspect rubber seal in groove of cover. Replace seal only if damaged. 1

2

3

M0131JCH

Figure 7.

Junction Box Cover Removal.

0104-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

FORKLIFT INTERLOCK PROXIMITY SWITCH REMOVAL - Continued 3.

Loosen cable nut (Figure 8, Item 6) and slide cable nut and grommet (Figure 8, Item 5) back on proximity switch (Figure 8, Item 2) cable.

CAUTION To avoid damage to junction box, a fine-tipped jeweler’s screwdriver should be used when disconnecting proximity switch wires. DO NOT use a punch.

NOTE Tag wires for installation. 4.

Using a jeweler's screwdriver, disconnect proximity switch wires (Figure 8, Item 3) from terminal blocks (Figure 8, Item 2). 1

2

3

4 5

6

Figure 8. Forklift Interlock Proximity Switch Removal.

NOTE Remove cable clamps and tiedown straps as needed. Discard tiedown straps. 5.

Remove proximity switch (Figure 9, Item 2) with cable from tophandler.

0104-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

M0132JCH

TM 10-3930-675-23-1

0104

FORKLIFT INTERLOCK PROXIMITY SWITCH REMOVAL - Continued 1

3

2

4

M0130JCH

Figure 9. Forklift Interlock Proximity Switch Removal. END OF TASK FORKLIFT INTERLOCK PROXIMITY SWITCH INSTALLATION 1.

Position proximity switch (Figure 10, Item 2) with cable on tophandler.

2.

Using a jeweler's screwdriver, connect proximity switch wires (Figure 10, Item 3) to terminal blocks (Figure 10, Item 2).

3.

Install grommet (Figure 10, Item 5) and cable nut (Figure 10, Item 6) on junction box (Figure 10, Item 1). Tighten cable nut. 1

2

3

M0131JCH

Figure 10.

Junction Box Cover Installation.

0104-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

FORKLIFT INTERLOCK PROXIMITY SWITCH INSTALLATION - Continued 4.

Install cover (Figure 11, Item 1) on junction box (Figure 11, Item 2) and tighten four screws (Figure 11, Item 3). 2

1

3

5 MM

4

M0129JCH

Figure 11. Twistlock Proximity Switch Installation. 5.

Loosely install proximity switch (Figure 12, Item 2) on tophandler with plastic clamp (Figure 12, Item 3) and two screws (Figure 12, Item 4).

6.

Position proximity switch (Figure 12, Item 2) so a gap of 0.20 inch (5.08 mm), between end of proximity switch and ring (Figure 12, Item 1) of actuating plunger, is obtained. Tighten two screws (Figure 12, Item 4).

7.

Install cable clamps and new tiedown straps as needed.

END OF TASK SPREADER BEAM PROXIMITY SWITCH REMOVAL 1.

Remove two screws (Figure 12, Item 1), washers (Figure 12, Item 2), and proximity switch plate (Figure 12, Item 6) from top of tophandler spreader beam (Figure 12, Item 5).

2.

Measure position of proximity switch (Figure 12, Item 3) in proximity switch plate (Figure 12, Item 6), to ensure correct installation. Record measurement.

3.

Remove two jamnuts (Figure 12, Item 4) and proximity switch (Figure 12, Item 3) from proximity switch plate (Figure 12, Item 6).

0104-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

SPREADER BEAM PROXIMITY SWITCH REMOVAL - Continued 3 1,2

5

6

Figure 12. 4.

4

M0133JCH

Spreader Beam Proximity Switch Removal.

Loosen four screws (Figure 13, Item 1) and remove cover (Figure 13, Item 2) from junction box (Figure 13, Item 3). Inspect rubber seal in groove of cover. Replace seal only if damaged. 1

2

3

M0134JCH

Figure 13.

Spreader Beam Proximity Switch Removal.

0104-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

SPREADER BEAM PROXIMITY SWITCH REMOVAL - Continued 5.

Loosen cable nut (Figure 14, Item 5) and slide cable nut and grommet (Figure 14, Item 4) back on proximity switch (Figure 14, Item 6) cable.

CAUTION To avoid damage to junction box, a fine-tipped jeweler’s screwdriver should be used when disconnecting proximity switch wires. DO NOT use a punch.

NOTE Tag wires for installation. 6.

Using a jeweler’s screwdriver, disconnect proximity switch wires (Figure 14, Item 3) from terminal blocks (Figure 14, Item 2).

NOTE Remove tiedown straps as needed. Discard tiedown straps. 7.

Remove proximity switch (Figure 14, Item 6) with cable from tophandler.

8.

Remove cable cover (Figure 14, Item 7) from proximity switch (Figure 14, Item 6) cable. 2

1

3

4

5 6

7

Figure 14.

Spreader Beam Proximity Switch Removal.

END OF TASK

0104-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

M0135JCH

TM 10-3930-675-23-1

0104

SPREADER BEAM PROXIMITY SWITCH INSTALLATION 1.

Install cable cover (Figure 15, Item 7) on proximity switch (Figure 15, Item 6) cable.

2.

Position proximity switch (Figure 15, Item 6) with cable on tophandler.

3.

Using a jeweler's screwdriver, connect proximity switch wires (Figure 15, Item 3) to terminal blocks (Figure 15, Item 2).

4.

Install grommet (Figure 15, Item 4) and cable nut (Figure 15, Item 5) on junction box (Figure 15, Item 1). Tighten cable nut. 2

1

3

4

5 6

7

Figure 15.

Spreader Beam Proximity Switch Installation.

0104-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

M0136JCH

TM 10-3930-675-23-1

0104

SPREADER BEAM PROXIMITY SWITCH INSTALLATION - Continued 5.

Install cover (Figure 16, Item 2) on junction box (Figure 16, Item 3) and tighten four screws (Figure 16, Item 1). 1

2

3

M0137JCH

Figure 16. 6.

Spreader Beam Proximity Switch Installation.

Loosely install proximity switch (Figure 17, Item 3) on proximity switch plate (Figure 17, Item 6) with two jamnuts (Figure 17, Item 4).

CAUTION Overtightening jamnuts will damage proximity switch threads. 7.

Place proximity switch (Figure 17, Item 3) in same position measured during removal and tighten two jamnuts (Figure 17, Item 4) to 177 in-lb (20 N•m).

NOTE Clearance between sensor end of proximity switch and flat rod below should be 0.20 inch (5.08 mm). 8.

Install proximity switch (Figure 17, Item 3) and proximity switch plate (Figure 17, Item 6) on spreader beam (Figure 17, Item 5) with two washers (Figure 17, Item 2) and screws (Figure 17, Item 1).

0104-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

TM 10-3930-675-23-1

0104

SPREADER BEAM PROXIMITY SWITCH INSTALLATION - Continued 3 1,2

6

Figure 17. 9.

5

Spreader Beam Proximity Switch Installation.

Install new tiedown straps.

END OF TASK END OF WORK PACKAGE

0104-15/16 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00069)

4

M0138JCH

TM 10-3930-675-23-1

0105

FIELD MAINTENANCE CAB POSITION PROXIMITY SWITCHES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66)

Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 2

References Volume 2, WP 0175 Equipment Condition Cab in transport position, but not lowered (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10)

CAB-MOUNTED PROXIMITY SWITCH REMOVAL

NOTE Note position of proximity switch relative to cab to ensure accurate installation. 1.

From outside of cab, remove jamnut (Figure 1, Item 2) from proximity switch (Figure 1, Item 1). 1

2

M0139JCH

Figure 1.

Cab-Mounted Proximity Switch Removal.

0105-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

TM 10-3930-675-23-1

0105

CAB-MOUNTED PROXIMITY SWITCH REMOVAL - Continued 2.

From inside rear of cab, remove right access panel (Figure 2, Item 1) and middle access panel (Figure 2, Item 2). 2

1

M0140JCH

Figure 2.

Cab-Mounted Proximity Switch Removal.

3.

Pull proximity switch (Figure 3, Item 1) out from side of cab and remove jamnut (Figure 3, Item 2) from proximity switch.

4.

Disconnect connector (Figure 3, Item 4) of proximity switch (Figure 3, Item 1) from electrical panel (Figure 3, Item 3).

5.

Remove proximity switch (Figure 3, Item 1) from cab.

END OF TASK

0105-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

TM 10-3930-675-23-1

0105

CAB-MOUNTED PROXIMITY SWITCH INSTALLATION 1.

Position proximity switch (Figure 3, Item 1) on cab.

2.

Connect connector (Figure 3, Item 4) of proximity switch (Figure 3, Item 1) to electrical panel (Figure 3, Item 3).

3.

Install jamnut (Figure 3, Item 2) on proximity switch (Figure 3, Item 1) and push proximity switch outside of cab. 3

4 1,2

M0141JCH

Figure 3. Cab-Mounted Proximity Switch Replacement.

0105-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

TM 10-3930-675-23-1

0105

CAB-MOUNTED PROXIMITY SWITCH INSTALLATION - Continued 4.

Outside of cab, install jamnut (Figure 4, Item 2) on proximity switch (Figure 4, Item 1). DO NOT fully tighten jamnut.

NOTE Proximity switch should be positioned and adjusted flush with the end of protector collar. 5.

Adjust position of proximity switch (Figure 4, Item 1), as noted during removal, by adjusting position of jamnuts (Figures 3 and 4, Item 2).

6.

Tighten jamnut (Figure 4, Item 2). 2

1

M0142JCH

Figure 4.

Cab-Mounted Proximity Switch Installation.

END OF TASK

0105-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

TM 10-3930-675-23-1

0105

CAB SUPPORT-MOUNTED PROXIMITY SWITCH REMOVAL 1.

Remove middle and rear transmission access covers (Volume 2, WP 0175).

NOTE Note position of proximity switch relative to bracket to ensure accurate installation. 2.

Remove upper jamnut (Figure 5, Item 6) from proximity switch (Figure 5, Item 5) and push proximity switch downward from bracket (Figure 5, Item 4).

3.

Remove jamnut (Figure 5, Item 7) from proximity switch (Figure 5, Item 5).

NOTE Perform Step 4 to remove bracket from cab support. 4.

Remove two locknuts (Figure 5, Item 8), screws (Figure 5, Item 9), four washers (Figure 5, Item 10), and bracket (Figure 5, Item 4) from cab support (Figure 5, Item 11). Discard locknuts.

5.

Loosen four screws (Figure 5, Item 2) and remove cover (Figure 5, Item 3) from junction box (Figure 5, Item 1). 3

5

4

2

6

1

7

11

8,9,10

Figure 5. Cab Support-Mounted Proximity Switch Removal.

0105-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

M0143JCH

TM 10-3930-675-23-1

0105

CAB SUPPORT-MOUNTED PROXIMITY SWITCH REMOVAL - Continued

NOTE Tag wires for installation. 6.

Using a jeweler's screwdriver, disconnect three wires of cable (Figure 6, Item 6) from terminal blocks (Figure 6, Item 1) of junction box (Figure 6, Item 2).

7.

Loosen cable nut (Figure 6, Item 5) and slide cable nut, grommet (Figure 6, Item 4), and bushing (Figure 6, Item 3) back on cable (Figure 6, Item 6).

NOTE Remove tiedown straps as needed. Discard tiedown straps. 8.

Remove cable (Figure 6, Item 6) from junction box (Figure 6, Item 2).

9.

Remove proximity switch (Figure 7, Item 5) from vehicle.

END OF TASK CAB SUPPORT-MOUNTED PROXIMITY SWITCH INSTALLATION 1.

Position proximity switch (Figure 7, Item 5) on vehicle.

2.

Feed cable (Figure 6, Item 6) through cable nut (Figure 6, Item 5), grommet (Figure 6, Item 4), and bushing (Figure 6, Item 3) and into junction box (Figure 6, Item 2).

3.

Using a jeweler's screwdriver, connect three wires of cable (Figure 6, Item 6) to terminal blocks (Figure 6, Item 1) of junction box (Figure 6, Item 2).

4.

Install bushing (Figure 6, Item 3), grommet (Figure 6, Item 4), and cable nut (Figure 6, Item 5) on junction box (Figure 6, Item 2).

0105-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

TM 10-3930-675-23-1

0105

CAB SUPPORT-MOUNTED PROXIMITY SWITCH INSTALLATION - Continued 1 2

3

4

6

Figure 6.

5

Cab Support-Mounted Proximity Switch Installation.

0105-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

M0144JCH

TM 10-3930-675-23-1

0105

CAB SUPPORT-MOUNTED PROXIMITY SWITCH INSTALLATION - Continued 5.

Install cover (Figure 7, Item 3) on junction box (Figure 7, Item 1) and tighten four screws (Figure 7, Item 2).

NOTE Perform Step 6 to install bracket to cab support. 6.

Install bracket (Figure 7, Item 4) on cab support (Figure 7, Item 11) with four washers (Figure 7, Item 10), two screws (Figure 7, Item 9), and new locknuts (Figure 7, Item 8).

7.

Loosely install jamnut (Figure 7, Item 7) on proximity switch (Figure 7, Item 5).

8.

Position proximity switch (Figure 7, Item 5) upward through bracket (Figure 7, Item 4) and loosely install upper jamnut (Figure 7, Item 6).

9.

Adjust two jamnuts (Figure 7, Items 6 and 7) to position proximity switch (Figure 7, Item 5) as noted during removal and tighten jamnuts. Correct dimension is 1.20 inch (30 mm) from bracket to tip of sensor.

10.

Install new tiedown straps as needed.

11.

Install middle and rear transmission access covers (Volume 2, WP 0175). 3

5

4

2

6

1

7

11

Figure 7.

8,9,10

Cab-Support Mounted Proximity Switch Installation.

END OF TASK FOLLOW-ON MAINTENANCE Return cab to operational position (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

0105-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00070)

M0143JCH

TM 10-3930-675-23-1

0106

FIELD MAINTENANCE SOLAR CHARGER REPLACEMENT (IF EQUIPPED)

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Battery compartment door open (TM 10-3930-675-10)

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 87) Qty: 4

REMOVAL 1.

Inside battery compartment (Figure 1, Item 1), disconnect connector (Figure 1, Item 3) and wire (Figure 1, Item 2) of solar charger from connector (Figure 1, Item 4). 1

2

3

4

M0262JCH

Figure 1.

Solar Charger Replacement.

0106-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00071)

TM 10-3930-675-23-1

0106

REMOVAL - Continued 2.

At top of battery compartment (Figure 2, Item 1), remove four locknuts (Figure 2, Item 2), screws (Figure 2, Item 3), and washers (Figure 2, Items 4 and 5) to separate solar charger (Figure 2, Item 8) and grating (Figure 2, Item 7) from four grommets (Figure 2, Item 6). Discard locknuts.

3.

Remove large grommet (Figure 2, Item 9), wire (Figure 2, Item 10) of solar charger (Figure 2, Item 8), grating (Figure 2, Item 7), and solar charger from vehicle.

4.

Remove four grommets (Figure 2, Item 6) from top of battery compartment (Figure 2, Item 1). 2,3,4,5,6 1

7 8 9,10

M0263JCH

Figure 2.

Solar Charger Replacement.

0106-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00071)

TM 10-3930-675-23-1

0106

REMOVAL - Continued

NOTE • Perform Steps 5 and 6 to remove pulse generator. • Only one fuse completes circuit. Other fuse is a spare. 5.

Separate two halves of fuse holder (Figure 3, Item 1) and remove two fuses (Figure 3, Item 2). 2

1

1

M0264JCH

Figure 3. 6.

Solar Charger Replacement.

Remove two bolts (Figure 4, Item 3), washers (Figure 4, Item 4), and pulse generator (Figure 4, Item 2) from battery compartment (Figure 4, Item 1). 2

1

3,4

Figure 4.

M0265JCH

Solar Charger Replacement.

END OF TASK

0106-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00071)

TM 10-3930-675-23-1

0106

INSTALLATION

NOTE Perform Steps 1 and 2 to install pulse generator. 1.

Install pulse generator (Figure 4, Item 2) in battery compartment (Figure 4, Item 1) with two washers (Figure 4, Item 4) and bolts (Figure 4, Item 3).

2.

Install two fuses (Figure 3, Item 2) and connect two halves of fuse holder (Figure 3, Item 1).

3.

Install four grommets (Figure 2, Item 6) in top of battery compartment (Figure 2, Item 1).

4.

Install wire (Figure 2, Item 10) of solar charger (Figure 2, Item 8) and large grommet (Figure 2, Item 9) on top of battery compartment (Figure 2, Item 1) and position grating (Figure 2, Item 7) and solar charger on four grommets (Figure 2, Item 6).

5.

Install grating (Figure 2, Item 7) and solar charger (Figure 2, Item 8) on four grommets (Figure 2, Item 6) with four washers (Figure 2, Item 5), washers (Figure 2, Item 4), screws (Figure 2, Item 3), and new locknuts (Figure 2, Item 2).

6.

Inside battery compartment (Figure 5, Item 1), connect wire (Figure 5, Item 2) and connector (Figure 5, Item 3) of solar charger to connector (Figure 5, Item 4). 1

2

3

4

M0266JCH

Figure 5.

Solar Charger Replacement.

END OF TASK FOLLOW-ON MAINTENANCE Close battery compartment door (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

0106-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00071)

TM 10-3930-675-23-1

0107

FIELD MAINTENANCE BOOM WIRING HARNESSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References WP 0097

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

REMOVAL 1.

Disconnect wiring harness (Figure 1, Item 5) connector (Figure 1, Item 8) from chassis wiring harness connector (Figure 1, Item 9) on side of boom (Figure 1, Item 6).

2.

Remove four screws (Figure 1, Item 2). Disconnect wiring harness (Figure 1, Item 4) connector (Figure 1, Item 3) from chassis wiring harness connector (Figure 1, Item 1).

NOTE Note routing of wiring harnesses and positioning of tiedown straps to assist in installation. 3.

Trace wiring harnesses (Figure 1, Items 4 and 5) along boom (Figure 1, Item 6), removing and discarding all tiedown straps that secure wiring harnesses to channels (Figure 1, Item 7). 1

9

8

3

2

5

4,5

4

2

Figure 1.

7

6

M0850JCH

Boom Wiring Harness Removal.

0107-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00072)

TM 10-3930-675-23-1

0107

REMOVAL - Continued 4.

Trace wiring harnesses (Figure 2, Items 2 and 3) to tophandler junction box (Figure 2, Item 4) and disconnect from junction box (WP 0097).

5.

Remove and discard tiedown straps that secure wiring harnesses (Figure 2, Items 2 and 3) together at tophandler junction box (Figure 2, Item 4).

NOTE Note routing of wiring harnesses through middle portion of flexible conveyer. 6.

Pull wiring harnesses (Figure 2, Items 2 and 3) toward front of vehicle, pulling them through box channel (Figure 2, Item 1) and flexible conveyer.

7.

Remove wiring harnesses (Figure 2, Items 2 and 3) from vehicle. 1

2,3

4

Figure 2. Boom Wiring Harness Removal. END OF TASK

0107-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00072)

M0851JCH

TM 10-3930-675-23-1

0107

INSTALLATION 1.

Starting from rear of flexible conveyer (Figure 3, Item 7) and working toward tophandler, feed wiring harnesses (Figure 3, Items 4 and 5) through middle portion of flexible conveyer and into box channel (Figure 3, Item 11), until wiring harness ends reach tophandler junction box (Figure 3, Item 12).

2.

Connect wiring harnesses (Figure 3, Items 4 and 5) to tophandler junction box (Figure 3, Item 12) (WP 0097).

3.

Install new tiedown straps to secure wiring harnesses (Figure 3, Items 4 and 5) together at tophandler junction box (Figure 3, Item 12).

4.

Position wiring harnesses (Figure 3, Items 4 and 5) inside channels (Figure 3, Item 8) along boom (Figure 3, Item 6), until ends of wiring harnesses reach connection points to chassis wiring harnesses.

5.

Connect wiring harness (Figure 3, Item 4) connector (Figure 3, Item 3) to chassis wiring harness connector (Figure 3, Item 1). Install four screws (Figure 3, Item 2).

6.

Connect wiring harness (Figure 3, Item 5) connector (Figure 3, Item 9) to chassis wiring harness connector (Figure 3, Item 10).

7.

Secure wiring harnesses (Figure 3, Items 4 and 5) to channels (Figure 3, Item 8) with new tiedown straps. 1

10

3

2

9

5

4,5

4

2

Figure 3.

8

6

7

M0852JCH

Boom Wiring Harness Installation.

END OF TASK END OF WORK PACKAGE

0107-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00072)

TM 10-3930-675-23-1

FIELD MAINTENANCE TOPHANDLER WIRING HARNESSES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Wire, Nonelectrical (Volume 2, WP 0276, Table 1, Item 70) Seal, Nonmetallic Strip (Volume 2, WP 0278, Table 1, Item 157)

Personnel Required (2) References Volume 2, WP 0257 Volume 2, WP 0272 Equipment Condition Boom and tophandler fully lowered (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10)

NOTE Replacement of wiring harnesses D and E is easier to perform with tophandler extended to 40 ft (12.2 m) width.

0108-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

0108

TM 10-3930-675-23-1

0108

WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 REMOVAL 1.

Disconnect wiring harness A (Figure 1, Item 2) connector from tophandler junction box (Figure 1, Item 1) connector.

1

2

M0853JCH

Figure 1. Wiring Harness A Removal. 2.

Trace routing of wiring harness A (Figure 2, Item 2). Loosen cable clamps (Figure 2, Item 1) and cut tiedown straps as needed to gain free movement of harness A.

3.

Unwrap upper and lower cable guard (Figure 2, Item 6) from harness A (Figure 2, Item 2) routing. Retain for installation.

4.

Loosen four screws (Figure 2, Item 4) and remove cover (Figure 2, Item 3) from junction box 182 (Figure 2, Item 5). Inspect rubber seal in groove of cover. Replace only if damaged.

0108-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 REMOVAL - Continued 1

2

3

4

5 6 M0854JCH

Figure 2.

Wiring Harness A Removal.

NOTE Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 5.

Using jeweler’s screwdriver, disconnect wiring harness A (Figure 3, Item 1) leads from junction box 182 (Figure 3, Item 3) terminal block (Figure 3, Item 2).

6.

Remove retainer nut (Figure 3, Item 4), grommet (Figure 3, Item 5), sleeve (Figure 3, Item 6), and wiring harness A (Figure 3, Item 1) from junction box 182 (Figure 3, Item 3). Retain retainer nut, grommet, and sleeve for installation. 2

3

1

4,5,6

M0855JCH

Figure 3.

Wiring Harness A Removal.

0108-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 REMOVAL - Continued 7.

From tophandler junction box end, with assistance, pull wiring harness A (Figure 4, Item 2) from routing until wiring harness A is approximately 18 in. (46 cm) from tophandler carriage frame above control valve.

NOTE Nonelectrical wire is secured to wiring harness to be used as a guide wire during installation of new harness. 8.

Secure approximately 6 ft (183 cm) of nonelectrical wire to wiring harness A (Figure 4, Item 2).

9.

With assistance, continue to pull wiring harness A (Figure 4, Item 2) and nonelectrical wire through cable routing until wiring harness is free of tophandler carriage frame.

10.

Remove wiring harness A (Figure 4, Item 2) from nonelectrical wire leaving nonelectrical wire in place through wiring harness routing.

END OF TASK WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 INSTALLATION

CAUTION Ensure sufficient length of wiring harness is coiled within tophandler opening, so that tophandler can rotate freely in both directions without damaging harness. 1.

Attach junction box 182 (Figure 4, Item 5) end of wiring harness A (Figure 4, Item 2) to nonelectrical wire at tophandler junction box.

2.

With assistance, pull other end of nonelectrical wire and wiring harness A (Figure 4, Item 2) through tophandler carriage frame until approximately 18 in. (46 cm) of wiring harness A is exposed.

3.

Remove nonelectrical wire from wiring harness A (Figure 4, Item 2) and continue to route wiring harness A to junction box 182 (Figure 4, Item 5).

4.

Install wiring harness A (Figure 4, Item 2) through retainer nut (Figure 3, Item 4), grommet (Figure 3, Item 5), sleeve (Figure 3, Item 6), and use a jeweler’s screwdriver to connect leads to terminal block (Figure 3, Item 2) as noted during removal. Tighten retainer nut.

5.

Install cover (Figure 4, Item 3) on junction box 182 (Figure 4, Item 5) and tighten four screws (Figure 4, Item 4).

6.

Tighten cable clamps (Figure 4, Item 1) and install new tiedown straps as needed to secure wiring harness A (Figure 4, Item 2).

7.

Install upper and lower cable guard (Figure 4, Item 6).

0108-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182 INSTALLATION - Continued 1

2

3

4

5 6 M0856JCH

Figure 4. 8.

Wiring Harness A Installation.

Connect connector of wiring harness A (Figure 5, Item 2) to connector of tophandler junction box (Figure 5, Item 1).

1

2

M0857JCH

Figure 5.

Wiring Harness A Installation.

END OF TASK

0108-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL 1.

Disconnect wiring harness B (Figure 6, Item 2) connector from tophandler junction box (Figure 6, Item 1) connector.

1

2

M0860JCH

Figure 6. Wiring Harness B Removal. 2.

Remove upper cable guard from wiring harness B (Figure 7, Item 1). Retain cable guard for installation.

3.

Remove screw (Figure 7, Item 3) and cable clamp (Figure 7, Item 4) from wiring harness B (Figure 7, Item 1) grommet.

NOTE Use wiring diagrams (Volume 2, WP 0272), as needed, and ensure diagram or record of wire lead connections is made prior to disconnection to ensure correct connection of leads. 4.

At control valve, locate these wire leads, press in on retaining clips, and disconnect leads from solenoids (Figure 7, Item 2) as follows: WIRE NUMBER

SOLENOID FUNCTION

6008

Rotation Clockwise

6009

Rotation Counterclockwise

6010

Tilt Out

6011

Tilt In

6018

Spreader Out

6019

Spreader In

0108-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL - Continued 5.

Disconnect wire lead 6034-1 from leveling lock solenoid (Figure 7, Item 5).

NOTE Nonelectrical wire is secured to wiring harness to be used as a guide wire during installation of new harness. 6.

Secure all loose leads of wiring harness B (Figure 7, Item1) to nonelectrical wire.

7.

With assistance, pull wiring harness B (Figure 7, Item 1) up through tophandler carriage until nonelectrical wire is exposed approximately 18 in. (46 cm).

8.

Remove wiring harness B (Figure 7, Item 1) from nonelectrical wire, leaving nonelectrical wire in place as a guide wire. 3,4 2 1

1

5

M0858JCH

Figure 7.

Wiring Harness B Removal.

END OF TASK

0108-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION

CAUTION Ensure sufficient length of wiring harness is coiled within tophandler opening, so that tophandler can rotate freely in both directions without damaging harness. 1.

Attach wiring harness B (Figure 8, Item 1) control valve wire leads to upper end of nonelectrical wire.

2.

With assistance, pull nonelectrical wire and wiring harness B (Figure 8, Item 1) down through tophandler carriage frame.

3.

Remove wiring harness B (Figure 8, Item 1) leads from nonelectrical wire.

4.

Connect wire leads to solenoids (Figure 8, Item 2) as follows: WIRE NUMBER

SOLENOID FUNCTION

6008

Rotation Clockwise

6009

Rotation Counterclockwise

6010

Tilt Out

6011

Tilt In

6018

Spreader Out

6019

Spreader In

5.

Connect lead 6034-1 to leveling lock solenoid (Figure 8, Item 5).

6.

Install cable clamp (Figure 8, Item 4) on wiring harness B (Figure 8, Item 1) grommet with screw (Figure 8, Item 3). 3,4 2 1

1

5

M0858JCH

Figure 8. Wiring Harness B Installation.

0108-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION - Continued 7.

Connect wiring harness B (Figure 9, Item 2) connector to tophandler junction box (Figure 9, Item 1) connector and install cable guard.

1

2

M0860JCH

Figure 9.

Wiring Harness B Installation.

END OF TASK

0108-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL 1.

Disconnect wiring harness C (Figure 10, Item 2) connector from tophandler junction box (Figure 10, Item 1) connector.

1

2

M0862JCH

Figure 10. Wiring Harness C Removal. 2.

Remove upper cable guard from wiring harness C (Figure 11, Item 1). Retain cable guard for installation.

3.

Remove screw (Figure 11, Item 2) and cable clamp (Figure 11, Item 3) from wiring harness C (Figure 11, Item 1) grommet.

NOTE Use wiring diagrams (Volume 2, WP 0272), as needed, and ensure a diagram or record of wire lead connections is made prior to disconnection to ensure correct connection of leads. 4.

At control valve, locate these wire leads, press in on retaining clips, and disconnect leads from solenoids (Figure 11, Item 4) as follows: WIRE NUMBER

SOLENOID FUNCTION

6020

Sideshift Left

6021

Sideshift Right

6035

Leveling Right

6036

Leveling Left

6039

Unlock Twistlocks

6040

Lock Twistlocks

0108-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE REMOVAL - Continued 5.

Disconnect wire lead 6034-2 from leveling lock solenoid (Figure 11, Item 5).

NOTE Nonelectrical wire is secured to wiring harness to be used as a guide wire during installation of new harness. 6.

Secure all loose leads of wiring harness C (Figure 11, Item 1) to nonelectrical wire.

7.

With assistance, pull wiring harness C (Figure 11, Item 1) up through tophandler carriage until nonelectrical wire is exposed approximately 18 in. (46 cm).

8.

Remove wiring harness C (Figure 11, Item 1) from nonelectrical wire and leave nonelectrical wire in place as a guide wire. 2,3

4

1

5 1 M0861JCH

Figure 11.

Wiring Harness C Removal.

END OF TASK

0108-11

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION

CAUTION Ensure sufficient length of wiring harness is coiled within tophandler opening, so that tophandler can rotate freely in both directions without damaging harness. 1.

Attach wiring harness C (Figure 12, Item 1) control valve wire leads to upper end of nonelectrical wire.

2.

With assistance, pull nonelectrical wire and wiring harness C (Figure 12, Item 1) down through tophandler carriage frame.

3.

Remove wiring harness C (Figure 12, Item 1) leads from nonelectrical wire.

4.

Connect wire leads to solenoids (Figure 12, Item 5) as follows: WIRE NUMBER

SOLENOID FUNCTION

6020

Sideshift Left

6021

Sideshift Right

6035

Leveling Right

6036

Leveling Left

6039

Unlock Twistlocks

6040

Lock Twistlocks

5.

Connect lead 6034-2 to leveling lock solenoid (Figure 12, Item 5).

6.

Install cable clamp (Figure 12, Item 3) on wiring harness C (Figure 12, Item 1) grommet with screw (Figure 12, Item 2). 2,3

4

1

5 1 M0861JCH

Figure 12. Wiring Harness C Installation.

0108-12

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE INSTALLATION - Continued 7.

Connect wiring harness C (Figure 13, Item 2) connector to tophandler junction box (Figure 13, Item 1) connector and install cable guard.

1

2

M0862JCH

Figure 13.

Wiring Harness C Installation.

END OF TASK WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL 1.

Loosen four screws (Figure 14, Item 1) and remove cover (Figure 14, Item 2) from junction box 182 (Figure 14, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged. 1

2

3

M0863JCH

Figure 14.

Wiring Harness D Removal.

0108-13

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL - Continued 2.

Remove retainer nut (Figure 15, Item 3), grommet (Figure 15, Item 4), and sleeve (Figure 15, Item 5).

NOTE Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 3.

Using jeweler’s screwdriver, disconnect wiring harness D (Figure 15, Item 6) leads from junction box 182 (Figure 15, Item1) terminal block (Figure 15, Item 2). Remove harness from junction box. 1

6

2

3,4,5

Figure 15. Wiring Harness D Removal.

0108-14

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

M0864JCH

TM 10-3930-675-23-1

0108

WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL - Continued 4.

Trace wiring harness D (Figure 16, Item 1) from junction box 182 (Figure 15, Item 1) to junction box 183 (Figure 16, Item 4). Cut tiedown straps and loosen clamps, as needed, to gain free movement of wiring harness. Discard tiedown straps.

5.

Loosen four screws (Figure 16, Item 3) and remove cover (Figure 16, Item 2) from junction box 183 (Figure 16, Item 4). Inspect rubber seal in groove of cover. Replace only if damaged. 3

2

4

1

M0865JCH

Figure 16.

Wiring Harness D Removal.

0108-15

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 REMOVAL - Continued 6.

Remove retainer nut (Figure 17, Item 4), grommet (Figure 17, Item 5), and sleeve (Figure 17, Item 6).

NOTE Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 7.

Using jeweler’s screwdriver, disconnect wiring harness D (Figure 17, Item 1) leads from junction box 183 (Figure 17, Item 2) terminal block (Figure 17, Item 3). Remove harness from junction box.

8.

Remove wiring harness D (Figure 17, Item 1) from cable guard (Figure 17, Item 7) along cable routing. Retain cable guard. 3

2

1

4,5,6 7

M0866JCH

Figure 17. Wiring Harness D Removal. END OF TASK

0108-16

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 INSTALLATION 1.

Install wiring harness D (Figure 17, Item 1) through cable guard (Figure 17, Item 7) and position wiring harness along cable routing.

2.

Position retainer nut (Figure 17, Item 4), grommet (Figure 17, Item 5), and sleeve (Figure 17, Item 6) on wiring harness D (Figure 17, Item 1) at junction box 183 (Figure 17, Item 2). Install harness into junction box.

3.

Using jeweler’s screwdriver, connect wiring harness D (Figure 17, Item 1) leads to terminal block (Figure 17, Item 3).

4.

Install sleeve (Figure 17, Item 6), grommet (Figure 17, Item 5), and retainer nut (Figure 17, Item 4).

5.

With wiring harness D (Figure 18, Item 1) secured, install cover (Figure 18, Item 2) on junction box 183 (Figure 18, Item 4) and tighten four screws (Figure 18, Item 3). 3

2

4

1

M0867JCH

Figure 18.

Wiring Harness D Installation.

0108-17

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 INSTALLATION - Continued 6.

Position retainer nut (Figure 19, Item 3), grommet (Figure 19, Item 4), and sleeve (Figure 19, Item 5) on other end of wiring harness D (Figure 19, Item 6) at junction box 182 (Figure 19, Item 1). Install harness into junction box.

7.

Using jeweler’s screwdriver, connect wiring harness D leads to terminal block (Figure 19, Item 2).

8.

Install sleeve (Figure 19, Item 5), grommet (Figure 19, Item 4), and retainer nut (Figure 19, Item 3). 1

6

2

3,4,5

M0868JCH

Figure 19. Wiring Harness D Installation. 9.

Install cover (Figure 20, Item 2) on junction box 182 (Figure 20, Item 3) and tighten four screws (Figure 20, Item 1). 2

1

3

M0869JCH

Figure 20. Wiring Harness D Installation.

0108-18

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183 INSTALLATION - Continued 10.

Secure wiring harness D along cable routing by tightening clamps and installing new tiedown straps as needed.

END OF TASK WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 REMOVAL 1.

Loosen four screws (Figure 20, Item 1) and remove cover (Figure 20, Item 2) from junction box 182 (Figure 20, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged.

2.

Remove retainer nut (Figure 21, Item 3), grommet (Figure 21, Item 4), and sleeve (Figure 21, Item 5).

NOTE Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 3.

Using jeweler’s screwdriver, disconnect wiring harness E (Figure 21, Item 6) leads from junction box 182 (Figure 21, Item 1) terminal block (Figure 21, Item 2). Remove harness from junction box.

4.

Trace wiring harness E (Figure 21, Item 6) from junction box 182 (Figure 21, Item 1) through conduit along top of tophandler to junction box 184 (Figure 22, Item 3). 1

2

3,4,5

6 M0870JCH

Figure 21.

Wiring Harness E Removal.

0108-19

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 REMOVAL - Continued 5.

Loosen four screws (Figure 22, Item 2) and remove cover (Figure 22, Item 1) from junction box 184 (Figure 22, Item 3). Inspect rubber seal in groove of cover. Replace only if damaged. 1

2

3

M0871JCH

Figure 22. Wiring Harness E Removal.

0108-20

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 REMOVAL - Continued 6.

Remove retainer nut (Figure 23, Item 4), grommet (Figure 23, Item 5), and sleeve (Figure 23, Item 6).

NOTE Use wiring diagrams (Volume 2, WP 0272), as needed, and note terminal block numbers to wire lead numbers for installation. 7.

Using jeweler’s screwdriver, disconnect wiring harness E (Figure 23, Item 1) leads from junction box 184 (Figure 23, Item 2) terminal block (Figure 23, Item 3). Remove harness from junction box.

8.

Secure all loose leads of wiring harness E (Figure 23, Item 1) to nonelectrical wire.

9.

With assistance, pull wiring harness E (Figure 23, Item 1) out from conduit until approximately 18 in. (46 cm) of nonelectrical wire is exposed.

10.

Remove wiring harness E (Figure 23, Item 1) leads from nonelectrical wire and leave nonelectrical wire in place as a guide wire. 3

2

1

4,5,6

M0872JCH

Figure 23.

Wiring Harness E Removal.

END OF TASK

0108-21

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 INSTALLATION 1.

At junction box 182 (Figure 23, Item 2), secure all loose leads of wiring harness E (Figure 23, Item 1) to nonelectrical wire.

2.

With assistance, pull wire harness E (Figure 24, Item 4) through conduit until sufficient length is exposed to reach junction box 184 (Figure 24, Item 3).

3.

Remove wiring harness E (Figure 24, Item 4) from nonelectrical wire.

4.

Position retainer nut (Figure 24, Item 4), grommet (Figure 24, Item 5), and sleeve (Figure 24, Item 6) on wiring harness E (Figure 24, Item 4) at junction box 184 (Figure 24, Item 3). Install harness into junction box.

5.

Using jeweler’s screwdriver, connect wiring harness E (Figure 24, Item 4) leads to terminal block (Figure 24, Item 3).

6.

Install sleeve (Figure 24, Item 6), grommet (Figure 24, Item 5), and retainer nut (Figure 24, Item 4).

7.

Install cover (Figure 24, Item 1) on junction box 184 (Figure 24, Item 3) and tighten four screws (Figure 24, Item 2). 1

2

3

4

M0873JCH

Figure 24.

Wiring Harness E Installation.

8.

Position retainer nut (Figure 25, Item 3), grommet (Figure 25, Item 4), and sleeve (Figure 25, Item 5) on other end of wiring harness E (Figure 25, Item 6) at junction box 182 (Figure 25, Item 1). Install harness into junction box.

9.

Using jeweler’s screwdriver, connect wiring harness E (Figure 25, Item 6) leads to terminal block (Figure 25, Item 2).

10.

Install sleeve (Figure 25, Item 5), grommet (Figure 25, Item 4), and retainer nut (Figure 25, Item 3).

0108-22

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

0108

WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184 INSTALLATION - Continued 1

2

6

Figure 25. 11.

3,4,5

M0874JCH

Wiring Harness E Installation.

Install cover (Figure 26, Item 2) on junction box 182 (Figure 26, Item 3) and tighten four screws (Figure 26, Item 1). 1

2

3

M0875JCH

Figure 26.

Wiring Harness E Installation.

END OF TASK

0108-23

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Perform boom and tophandler calibration (Volume 2, WP 0257).

2.

Perform operational check of tophandler (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0108-24

03/15/2011 Rel(1.8) root(maintwp) wpno(M00073)

0108

TM 10-3930-675-23-1

FIELD MAINTENANCE HEADLIGHT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References Volume 2, WP 0267

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Washer, Lock (Volume 2, WP 0278, Table 1, Item 14)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

0109-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00074)

0109

TM 10-3930-675-23-1

0109

BULB REPLACEMENT 1.

Remove reflector insert (Figure 1, Item 2) from rubber ring (Figure 1, Item 1) on light housing (Figure 1, Item 3) with medium flat-tip screwdriver. 1

2

3

M0173JCH

Figure 1. Headlight Reflector Insert Removal. 2.

Disconnect black plastic connector (Figure 2, Item 2) from rear of bulb (Figure 2, Item 3).

3.

Release wire clip (Figure 2, Item 4) at rear of reflector insert (Figure 2, Item 1) and remove bulb (Figure 2, Item 3).

4.

Place new bulb (Figure 2, Item 3) into rear of reflector insert (Figure 2, Item 1) and fasten wire clip (Figure 2, Item 4).

5.

Connect black plastic connector (Figure 2, Item 2) to rear of bulb (Figure 2, Item 3).

0109-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00074)

TM 10-3930-675-23-1

0109

BULB REPLACEMENT - Continued 2

1

3

4

Figure 2. 6.

M0174JCH

Headlight Bulb Replacement.

Position reflector insert (Figure 3, Item 2) on rubber ring (Figure 3, Item 1) on light housing (Figure 3, Item 3) and push into place. 1

2

3 M0175JCH

Figure 3.

Headlight Reflector Insert Installation.

END OF TASK

0109-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00074)

TM 10-3930-675-23-1

0109

LIGHT REMOVAL

NOTE • Use marker tags to ensure proper connection of connectors. • Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1.

Remove bulb (refer to Bulb Replacement in this work package).

2.

Remove nut (Figure 4, Item 5), lockwasher (Figure 4, Item 6), and light assembly (Figure 4, Item 2) from bracket (Figure 4, Item 3). Discard lockwasher.

3.

Disconnect two connectors (Figure 4, Item 7) from black plastic connector (Figure 4, Item 1) and remove two wires (Figure 4, Item 4) with connectors from rear of light assembly (Figure 4, Item 2).

END OF TASK LIGHT INSTALLATION 1.

Route two connectors (Figure 4, Item 7) and wires (Figure 4, Item 4) through rear of light assembly (Figure 4, Item 2) and connect two connectors to black plastic connector (Figure 4, Item 1).

2.

Install light assembly (Figure 4, Item 2) on bracket (Figure 4, Item 3) with new lockwasher (Figure 4, Item 6) and nut (Figure 4, Item 5).

3.

Install bulb (refer to Bulb Replacement in this work package).

0109-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00074)

TM 10-3930-675-23-1

0109

LIGHT INSTALLATION - Continued

1

2

3

4

5,6

7

Figure 4.

Light Removal and Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check light for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0109-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00074)

M0176JCH

TM 10-3930-675-23-1

FIELD MAINTENANCE BACKUP LIGHT AND WORK LIGHT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References Volume 2, WP 0267

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Washer, Lock (Volume 2, WP 0278, Table 1, Item 106)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

0110-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00075)

0110

TM 10-3930-675-23-1

0110

BULB REPLACEMENT 1.

Remove reflector insert (Figure 1, Item 2) from rubber ring (Figure 1, Item 1) on light housing (Figure 1, Item 3) with medium flat tip screwdriver. 1

2

3

M0177JCH

Figure 1. Reflector Insert Removal. 2.

Disconnect connector (Figure 2, Item 2) of bulb (Figure 2, Item 3) from connector of wiring harness (Figure 2, Item 1).

3.

Release wire clip (Figure 2, Item 5) at rear of reflector insert (Figure 2, Item 4) and remove bulb (Figure 2, Item 3).

4.

Place new bulb (Figure 2, Item 3) into rear of reflector insert (Figure 2, Item 4) and fasten wire clip (Figure 2, Item 5).

5.

Connect connector (Figure 2, Item 2) of bulb (Figure 2, Item 3) to connector of wiring harness (Figure 2, Item 1).

0110-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00075)

TM 10-3930-675-23-1

0110

BULB REPLACEMENT - Continued 1

2

3

4

5

M0178JCH

Figure 2. 6.

Bulb Replacement.

Position reflector insert (Figure 3, Item 2) on rubber ring (Figure 3, Item 1) on light housing (Figure 3, Item 3) and push into place. 1

2

3 M0179JCH

Figure 3.

Reflector Insert Installation.

END OF TASK

0110-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00075)

TM 10-3930-675-23-1

0110

LIGHT REMOVAL

NOTE Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1.

Remove bulb (Figure 2, Item 3) (refer to Bulb Replacement in this work package).

2.

Remove nut (Figure 4, Item 5), lockwasher (Figure 4, Item 6), and light assembly (Figure 4, Item 2) from bracket (Figure 4, Item 1). Discard lockwasher.

3.

Remove wire of wiring harness (Figure 4, Item 3) with connector (Figure 4, Item 4) from rear of light assembly (Figure 4, Item 2).

END OF TASK LIGHT INSTALLATION 1.

Route connector (Figure 4, Item 4) and wire of wiring harness (Figure 4, Item 3) through rear of light assembly (Figure 4, Item 2).

2.

Install light assembly (Figure 4, Item 2) on bracket (Figure 4, Item 1) with new lockwasher (Figure 4, Item 6) and nut (Figure 4, Item 5).

3.

Install bulb (refer to Bulb Replacement in this work package).

0110-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00075)

TM 10-3930-675-23-1

0110

LIGHT INSTALLATION - Continued

2

3

4

1

5,6

Figure 4.

Light Removal and Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check light for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0110-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00075)

M0180JCH

TM 10-3930-675-23-1

FIELD MAINTENANCE BLACKOUT LIGHT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28)

References Volume 2, WP 0267 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

0111-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

0111

TM 10-3930-675-23-1

0111

BULB/REFLECTOR REPLACEMENT

NOTE RT 240V1R, RT 240V2 and RT 240V3 blackout lights are replaced using the same procedure. 1.

Loosen three screws (Figure 1, Item 4) and remove bulb/reflector assembly (Figure 1, Item 1) with ring (Figure 1, Item 2) from blackout light housing (Figure 1, Item 3). 1

2

3 4

M0187JCH

Figure 1. Bulb/Reflector Replacement. 2.

Disconnect terminal plug (Figure 2, Item 3) and connector (Figure 2, Item 4) from inside blackout light housing (Figure 2, Item 2).

3.

Remove two spring clips (Figure 2, Item 6) and remove bulb/reflector assembly (Figure 2, Item 5) from ring (Figure 2, Item 1).

4.

Install new bulb/reflector assembly (Figure 2, Item 5) on ring (Figure 2, Item 1) and install two spring clips (Figure 2, Item 6).

5.

Connect connector (Figure 2, Item 4) and terminal plug (Figure 2, Item 3) inside blackout light housing (Figure 2, Item 2).

0111-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

TM 10-3930-675-23-1

0111

BULB/REFLECTOR REPLACEMENT - Continued 1

6

Figure 2. 6.

3

2

4

5

M0188JCH

Bulb/Reflector Replacement.

Install bulb/reflector assembly (Figure 3, Item 1) with ring (Figure 3, Item 2) in blackout light housing (Figure 3, Item 3) and tighten three screws (Figure 3, Item 4). 1

2

3 4

Figure 3.

Bulb/Reflector Replacement.

END OF TASK

0111-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

M0189JCH

TM 10-3930-675-23-1

0111

BLACKOUT LIGHT REMOVAL

NOTE Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1.

At rear of bracket (Figure 4, Item 1), disconnect connector (Figure 4, Item 3) of wiring harness from rear of blackout light (Figure 4, Item 2).

2.

Remove nut (Figure 4, Item 4), washer (Figure 4, Item 5), and blackout light (Figure 4, Item 2) from bracket (Figure 4, Item 1).

END OF TASK BLACKOUT LIGHT INSTALLATION 1.

Install blackout light (Figure 4, Item 2) on bracket (Figure 4, Item 1) with washer (Figure 4, Item 5) and nut (Figure 4, Item 4).

NOTE Apply electrically conductive grease to connector before connection is made. 2.

At rear of bracket (Figure 4, Item 1), connect connector (Figure 4, Item 3) of wiring harness to rear of blackout light (Figure 4, Item 2).

0111-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

TM 10-3930-675-23-1

0111

BLACKOUT LIGHT INSTALLATION - Continued

1

3

2

4,5

Figure 4.

M0190JCH

Blackout Light Replacement.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check light for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0111-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00076)

TM 10-3930-675-23-1

0112

FIELD MAINTENANCE DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Materials/Parts (cont.) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 86) Qty: 2 Washer, Lock (Volume 2, WP 0278, Table 1, Item 105) Qty: 2 References Volume 2, WP 0267 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

0112-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00077)

TM 10-3930-675-23-1

0112

DIRECTIONAL LIGHT BULB AND LED REPLACEMENT 1.

Loosen five screws (Figure 1, Item 1) and remove lens assembly (Figure 1, Item 2) from light housing (Figure 1, Item 3). 1

2

3

M0181JCH

Figure 1.

Lens Removal.

2.

Remove two bulbs (Figure 2, Items 1 and 2) from lamp holder (Figure 2, Item 3)

3.

To remove Light Emitting Diode (LED) (Figure 2, Item 4), pull outward on LED panel until panel just separates from black plastic section of connector.

4.

Grasp black plastic and push in and rotate connector slightly counterclockwise and remove LED (Figure 2, Item 4) from socket.

5.

To install LED (Figure 2, Item 4), grasp black plastic section of connector and insert connector into socket. Push in and rotate slightly clockwise.

6.

Push LED (Figure 2, Item 4) panel over black plastic until fully seated.

7.

Install two new bulbs (Figure 2, Items 1 and 2) in lamp holder (Figure 2, Item 3).

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00077)

TM 10-3930-675-23-1

0112

DIRECTIONAL LIGHT BULB AND LED REPLACEMENT - Continued 2

1

3

4

M0182JCH

Figure 2. 8.

Bulb and LED Replacement.

Install lens assembly (Figure 3, Item 2) on light housing (Figure 3, Item 3) and tighten five screws (Figure 3, Item 1). 1

2

3

M0183JCH

Figure 3.

Lens Installation.

END OF TASK

0112-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00077)

TM 10-3930-675-23-1

0112

DIRECTIONAL LIGHT REMOVAL

NOTE • Front and rear directional lights are removed the same way. • Use marker tags to ensure proper connection of connectors. • Electrical connectors of light may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). 1.

Remove directional light bulbs and LED(s) (refer to Directional Light Bulb and LED Replacement in this work package).

2.

Disconnect two connectors (Figure 4, Item 6) of directional light (Figure 4, Item 1) from connectors of wiring harness (Figure 4, Item 5).

3.

Remove two screws (Figure 4, Item 7), ground terminals (Figure 4, Item 2) of wiring harness (Figure 4, Item 5), washers (Figure 4, Item 3), and directional light (Figure 4, Item 1) from bracket (Figure 4, Item 4).

END OF TASK DIRECTIONAL LIGHT INSTALLATION

NOTE Front and rear directional lights are installed the same way. 1.

Install directional light (Figure 4, Item 1) and ground terminals (Figure 4, Item 2) of wiring harness (Figure 4, Item 5) on bracket (Figure 4, Item 4) with two washers (Figure 4, Item 3) and screws (Figure 4, Item 7).

2.

Connect two connectors (Figure 4, Item 6) of directional light (Figure 4, Item 1) to connectors of wiring harness (Figure 4, Item 5).

3.

Install bulbs and LED(s) (refer to Directional Light Bulb and LED Replacement in this work package).

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00077)

TM 10-3930-675-23-1

0112

DIRECTIONAL LIGHT INSTALLATION - Continued 1

5

4

2, 3

7

6

Figure 4.

Directional Light Replacement.

END OF TASK

0112-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00077)

M0184JCH

TM 10-3930-675-23-1

0112

SIDE MARKER LIGHT BULB REPLACEMENT 1.

Pry cover (Figure 5, Item 2) of side marker light from lamp housing (Figure 5, Item 1). 1

2

M0185JCH

Figure 5. Side Marker Light Cover Removal. 2.

Remove bulb (Figure 6, Item 4) from lamp housing (Figure 6, Item 1).

3.

Install new bulb (Figure 6, Item 4) in lamp housing (Figure 6, Item 1).

4.

Install cover (Figure 5, Item 2) on lamp housing (Figure 5, Item 1).

END OF TASK SIDE MARKER LIGHT REMOVAL

NOTE Front and rear side marker lights are removed the same way. 1.

Remove side marker light bulb (refer to Side Marker Light Bulb Replacement in this work package).

2.

Remove two locknuts (Figure 6, Item 6), washers (Figure 6, Item 7), screws (Figure 6, Item 8), white wire terminal (Figure 6, Item 5), and lamp housing (Figure 6, Item 1) from bracket (Figure 4, Item 4). Discard locknuts.

3.

Remove black wire terminal (Figure 6, Item 3) from lamp housing (Figure 6, Item 1).

END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00077)

TM 10-3930-675-23-1

0112

SIDE MARKER LIGHT INSTALLATION

NOTE Front and rear side marker lights are installed the same way. 1.

Install black wire terminal (Figure 6, Item 3) on lamp housing (Figure 6, Item 1).

2.

Install lamp housing (Figure 6, Item 1) and white wire terminal (Figure 6, Item 5) on bracket (Figure 6, Item 2) with two screws (Figure 6, Item 8), washers (Figure 6, Item 7), and new locknuts (Figure 6, Item 6).

3.

Install side marker light bulb (refer to Side Marker Light Bulb Replacement in this work package). 1

3

2

4

5

6,7,8

Figure 6.

Bulb Replacement.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Test light for operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0112-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00077)

M0186JCH

TM 10-3930-675-23-1

0113

FIELD MAINTENANCE TWISTLOCK INDICATOR LIGHTS MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 2 References Volume 2, WP 0267 Volume 2, WP 0272 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

0113-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00078)

TM 10-3930-675-23-1

0113

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

NOTE Electrical connectors of lights may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267). TWISTLOCK INDICATOR LIGHT BULB REPLACEMENT

NOTE Each of three twistlock indicator light bulbs is replaced the same way. 1.

Remove two screws (Figure 1, Item 1) and lens (Figure 1, Item 2) from lamp housing (Figure 1, Item 3). 1

2

3

M0191JCH

Figure 1.

Twistlock Indicator Light Bulb Replacement.

0113-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00078)

TM 10-3930-675-23-1

0113

TWISTLOCK INDICATOR LIGHT BULB REPLACEMENT - Continued 2.

Remove bulb (Figure 2, Item 1) from lamp housing (Figure 2, Item 2).

3.

Install new bulb (Figure 2, Item 1) in lamp housing (Figure 2, Item 2).

4.

Install lens (Figure 1, Item 2) on lamp housing (Figure 1, Item 3) with two screws (Figure 1, Item 1). 1

2

M0192JCH

Figure 2.

Twistlock Indicator Light Bulb Replacement.

END OF TASK

0113-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00078)

TM 10-3930-675-23-1

0113

TWISTLOCK INDICATOR LIGHT REMOVAL

NOTE Each of three twistlock indicator lights is removed the same way. Top (red) indicator light is shown. 1.

Remove bulb from indicator light (refer to Twistlock Indicator Light Bulb Replacement in this work package).

2.

Disconnect connector (Figure 3, Item 4) and connector (Figure 3, Item 6) from lamp housing (Figure 3, Item 3).

NOTE Cable clamp at rear of top (red) indicator light housing will also be removed as screws and locknuts are removed. 3.

Remove two locknuts (Figure 3, Item 1), screws (Figure 3, Item 2), and lamp housing (Figure 3, Item 3) from light bracket (Figure 3, Item 5). Discard locknuts. 1,2

3

4

6

5

M0193JCH

Figure 3.

Twistlock Indicator Light Removal.

END OF TASK

0113-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00078)

TM 10-3930-675-23-1

0113

TWISTLOCK INDICATOR LIGHT INSTALLATION

CAUTION For proper operation of twistlock indicator light, bend two metal tabs at lamp housing mounting screws 180 degrees to prevent grounding lamp housing to light bracket.

NOTE Cable clamp at rear of top (red) indicator light housing will also be installed as screws and new locknuts are installed. 1.

Install lamp housing (Figure 4, Item 4) on light bracket (Figure 4, Item 6) with two screws (Figure 4, Item 3) and new locknuts (Figure 4, Item 2).

2.

Connect connector (Figure 4, Item 5) and connector (Figure 4, Item 1) to lamp housing (Figure 4, Item 4).

3.

Install bulb on indicator light (refer to Twistlock Indicator Light Bulb Replacement in this work package).

4

2,3

5

1

6

M0194JCH

Figure 4.

Twistlock Indicator Light Installation.

END OF TASK

0113-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00078)

TM 10-3930-675-23-1

0113

TWISTLOCK INFRARED (IR) LIGHT REMOVAL

NOTE • If one IR light needs replacing, all six IR lights MUST be replaced. • Remove tiedown straps as required and discard. 1.

Loosen nut (Figure 5, Item 2) and remove IR light (Figure 5, Item 1) from IR light bracket (Figure 5, Item 6).

2.

Repeat step 1 for five remaining IR lights (Figure 5, Item 1).

NOTE Refer to wiring diagrams for assistance (Volume 2, WP 0272). 3.

Trace wiring harness (Figure 5, Item 3) for IR lights (Figure 5, Item 1) to tophandler junction box and disconnect wires of wiring harness. Remove wiring harness from tophandler junction box. Remove IR lights from vehicle.

END OF TASK TWISTLOCK INFRARED (IR) LIGHT INSTALLATION 1.

Position IR lights (Figure 5, Item 4) on IR light bracket (Figure 5, Item 6) and tighten nuts (Figure 5, Item 5).

NOTE Refer to wiring diagrams for assistance (Volume 2, WP 0272). 2.

Position wiring harness (Figure 5, Item 3) for IR lights (Figure 5, Item 4) at tophandler junction box and connect wires of wiring harness.

3.

Install new tiedown straps as required.

0113-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00078)

TM 10-3930-675-23-1

0113

TWISTLOCK INFRARED (IR) LIGHT INSTALLATION - Continued 1,2

1,2

6

3 4,5

Figure 5.

Twistlock Infrared (IR) Light Replacement.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check light for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0113-7/8 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00078)

M0195JCH

TM 10-3930-675-23-1

0114

FIELD MAINTENANCE CAB INTERIOR LIGHT MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

BULB REPLACEMENT 1.

Remove interior light (Figure 1, Item 1) from cab. 1

M0196JCH

Figure 1.

Cab Interior Light Bulb Removal.

0114-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00079)

TM 10-3930-675-23-1

BULB REPLACEMENT - Continued 2.

Remove two bulbs (Figure 2, Item 2) from interior light (Figure 2, Item 1).

3.

Install two bulbs (Figure 2, Item 2) in interior light (Figure 2, Item 1).

4.

Install interior light (Figure 1, Item 1) in cab.

END OF TASK CAB INTERIOR LIGHT REMOVAL 1.

Remove interior light and two bulbs from cab (refer to Bulb Replacement in this work package).

NOTE Tag wires prior to disconnection to ensure proper connection on installation. 2.

Disconnect two wiring harness connectors (Figure 2, Item 3) from interior light (Figure 2, Item 1) and remove light.

END OF TASK CAB INTERIOR LIGHT INSTALLATION 1.

Connect two wiring harness connectors (Figure 2, Item 3) to interior light (Figure 2, Item 1).

2.

Install two bulbs and interior light in cab (refer to Bulb Replacement in this work package).

0114-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00079)

0114

TM 10-3930-675-23-1

0114

CAB INTERIOR LIGHT INSTALLATION - Continued 2

1

3

Figure 2.

M0197JCH

Cab Interior Light Bulb Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check operation of light (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0114-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00079)

TM 10-3930-675-23-1

FIELD MAINTENANCE INFRARED (IR) LIGHTS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

References WP 0113 Volume 2, WP 0267

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

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

NOTE • Twistlock indicator infrared (IR) lights are replaced in Twistlock Indicator Lights Maintenance (WP 0113). • IR lights at front and rear of vehicle and on each side of boom are replaced the same way. • Electrical connectors may be repaired in accordance with Electrical General Maintenance Instructions (Volume 2, WP 0267).

0115-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00080)

0115

TM 10-3930-675-23-1

0115

REMOVAL 1.

Disconnect connector (Figure 1, Item 5) of IR light (Figure 1, Item 1) from connector (Figure 1, Item 4) of wiring harness.

2.

Remove locknut (Figure 1, Item 2) and washer (Figure 1, Item 3) from rear of IR light (Figure 1, Item 1). Discard locknut. 1

2,3

4

5

M0198JCH

Figure 1. Infrared (IR) Light Removal.

0115-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00080)

TM 10-3930-675-23-1

0115

REMOVAL - Continued 3.

Remove IR light (Figure 2, Item 1) from bracket (Figure 2, Item 2).

END OF TASK INSTALLATION 1.

Position IR light (Figure 2, Item 1) on bracket (Figure 2, Item 2).

2.

Install washer (Figure 1, Item 3) and new locknut (Figure 1, Item 2) on rear of IR light (Figure 1, Item 1).

3.

Connect connector (Figure 1, Item 5) of IR light (Figure 1, Item 1) to connector (Figure 1, Item 4) of wiring harness. 1

2

M0199JCH

Figure 2.

Infrared (IR) Light Installation.

END OF TASK

0115-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00080)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check infrared lights for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0115-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00080)

0115

TM 10-3930-675-23-1

0116

FIELD MAINTENANCE FORDING WATER LEVEL SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Radiator splash shield removed (WP 0084)

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 87) Qty: 2

REMOVAL 1.

Disconnect sensor connector (Figure 1, Item 9) from wiring harness connector (Figure 1, Item 10).

2.

Remove screw (Figure 1, Item 5), washer (Figure 1, Item 6), and clamp (Figure 1, Item 7) from fan shroud (Figure 1, Item 8) and sensor cable (Figure 1, Item 11).

3.

Remove two locknuts (Figure 1, Item 2), washers (Figure 1, Item 3), and screws (Figure 1, Item 4), and remove clamp (Figure 1, Item 1) and sensor (Figure 1, Item 12) from fan shroud (Figure 1, Item 8). Discard locknuts. 2,3,4

7

5,6

8

9

10

1

12

FORWARD

Figure 1.

11

Water Level Sensor Removal.

END OF TASK

0116-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00081)

M0200JCH

TM 10-3930-675-23-1

0116

INSTALLATION 1.

Install sensor (Figure 2, Item 12) on fan shroud (Figure 2, Item 8) with clamp (Figure 2, Item 1), two screws (Figure 2, Item 4), washers (Figure 2, Item 3), and new locknuts (Figure 2, Item 2).

2.

Connect sensor connector (Figure 2, Item 9) to wiring harness connector (Figure 2, Item 10).

3.

Secure sensor cable (Figure 2, Item 11) to fan shroud (Figure 2, Item 8) with clamp (Figure 2, Item 7), washer (Figure 2, Item 6), and screw (Figure 2, Item 5). 2,3,4

7

5,6

8

9

10

1

12

FORWARD

11

Figure 2. Water Level Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE Install radiator splash shield (WP 0084). END OF TASK END OF WORK PACKAGE

0116-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00081)

M0201JCH

TM 10-3930-675-23-1

FIELD MAINTENANCE WHEEL TEMPERATURE SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Attachment Set, Torx (Volume 2, WP 0277, Table 1, Item 65)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

NOTE Each of two wheel temperature sensors (left front and left rear) is replaced the same way on RT 240V1, RT 240V1R, and RT 240V2.

0117-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00082)

0117

TM 10-3930-675-23-1

0117

REMOVAL 1.

Disconnect connector (Figure 1, Item 4) of wheel temperature sensor (Figure 1, Item 2) from connector (Figure 1, Item 5) of vehicle wiring harness.

2.

Remove wheel temperature sensor (Figure 1, Item 2) and copper washer from adapter (Figure 1, Item 1) of brake housing (Figure 1, Item 3).

END OF TASK INSTALLATION 1.

Install copper washer and wheel temperature sensor (Figure 1, Item 2) on adapter (Figure 1, Item 1) of brake housing (Figure 1, Item 3).

2.

Connect connector (Figure 1, Item 5) of vehicle wiring harness to connector (Figure 1, Item 4) of wheel temperature sensor (Figure 1, Item 2). 4

5

3 2

1

M0204JCH

Figure 1. Wheel Temperature Sensor Replacement. END OF TASK END OF WORK PACKAGE

0117-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00082)

TM 10-3930-675-23-1

0118

FIELD MAINTENANCE ENGINE SENSORS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Installation Tool, ESP (Volume 2, WP 0277, Table 1, Item 41) Socket, Socket Wrench, 1/2" DR, 6PT, Long, 1-1/4" (Volume 2, WP 0277, Table 1, Item 73) Wrench, Torque, Dial, 3/8" Drive, 300 lb-in (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Oil, Lubricating, 15/40 (Volume 2, WP 0276, Table 1, Item 49) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 28) Qty: 2 O-Ring (Volume 2, WP 0278, Table 1, Item 30) O-Ring (Volume 2, WP 0278, Table 1, Item 45) Qty: 2 References WP 0080 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Engine cover removed (Volume 2, WP 0185)

NOTE • Tag wiring harness leads to ensure correct installation. • Use electrically conductive grease on all electrical connections before they are made.

0118-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

TM 10-3930-675-23-1

0118

COOLANT TEMPERATURE SENSOR REMOVAL

WARNING

DO NOT perform maintenance on cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam, hot water or coolant will cause serious burns. 1.

Drain cooling system (WP 0080).

2.

Disconnect connector (Figure 1, Item 3) of engine wiring harness (Figure 1, Item 2) from coolant temperature sensor (Figure 1, Item 4).

3.

Remove coolant temperature sensor (Figure 1, Item 4) with O-ring seal (Figure 1, Item 5) from engine (Figure 1, Item 1). Discard O-ring seal.

END OF TASK COOLANT TEMPERATURE SENSOR INSTALLATION

NOTE Ensure new sensor has O-ring seal installed. 1.

Apply a light coat of lubricating oil to new O-ring seal (Figure 1, Item 5).

2.

Install O-ring seal (Figure 1, Item 5) and coolant temperature sensor (Figure 1, Item 4) on engine (Figure 1, Item 1). Tighten sensor to 120 in-lb (14 N•m).

0118-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

TM 10-3930-675-23-1

0118

COOLANT TEMPERATURE SENSOR INSTALLATION - Continued

NOTE Ensure locking tab on connector snaps in place. 3.

Connect connector (Figure 1, Item 3) of engine wiring harness (Figure 1, Item 2) to coolant temperature sensor (Figure 1, Item 4).

4.

Fill cooling system and check for leaks (WP 0080). 1

5

2

4

3

Figure 1. Coolant Temperature Sensor Replacement. END OF TASK

0118-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

M0205JCH

TM 10-3930-675-23-1

0118

ENGINE POSITION SENSOR REMOVAL 1.

Disconnect connector (Figure 2, Item 4) of engine position sensor (Figure 2, Item 3) from engine wiring harness connector (Figure 2, Item 5).

2.

Remove engine position sensor (Figure 2, Item 3) and O-ring seal (Figure 2, Item 2) from engine front cover (Figure 2, Item 1). Discard O-ring seal.

END OF TASK ENGINE POSITION SENSOR INSTALLATION

NOTE Ensure engine position sensor is free of debris and is not chipped, cracked, or damaged. 1.

Install new O-ring seal (Figure 2, Item 2) on engine position sensor (Figure 2, Item 3).

2.

Install engine position sensor (Figure 2, Item 3) on engine front cover (Figure 2, Item 1). Tighten sensor to 216 in-lb (24 N•m).

NOTE Ensure locking tab on connector snaps in place. 3.

Connect engine wiring harness connector (Figure 2, Item 5) to connector (Figure 2, Item 4) of engine position sensor (Figure 2, Item 3). 1

2

3

5

Figure 2.

Engine Position Sensor Removal.

END OF TASK

0118-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

4

M0206JCH

TM 10-3930-675-23-1

0118

INTAKE AIR TEMPERATURE SENSOR REMOVAL 1.

Disconnect connector (Figure 3, Item 2) of engine wiring harness (Figure 3, Item 1) from intake air temperature sensor (Figure 3, Item 3).

2.

Remove intake air temperature sensor (Figure 3, Item 3) and O-ring seal (Figure 3, Item 4) from intake manifold (Figure 3, Item 5). Discard O-ring seal.

END OF TASK INTAKE AIR TEMPERATURE SENSOR INSTALLATION 1.

Install new O-ring seal (Figure 3, Item 4) on intake air temperature sensor (Figure 3, Item 3).

2.

Install intake air temperature sensor (Figure 3, Item 3) on intake manifold (Figure 3, Item 5). Tighten sensor to 120 in-lb (14 N•m).

NOTE Ensure locking tab on connector snaps in place. 3.

Connect connector (Figure 3, Item 2) of engine wiring harness (Figure 3, Item 1) to intake air temperature sensor (Figure 3, Item 3). 1

5

Figure 3.

2

4

Intake Air Temperature Sensor Replacement.

END OF TASK

0118-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

3

M0208JCH

TM 10-3930-675-23-1

0118

INTAKE MANIFOLD PRESSURE SENSOR REMOVAL 1.

Disconnect connector (Figure 4, Item 2) of engine wiring harness (Figure 4, Item 1) from intake manifold (Figure 4, Item 3).

NOTE Ensure a 1-1/4-in. deep well socket is used for removal and installation of intake manifold pressure sensor. 2.

Remove intake manifold pressure sensor (Figure 4, Item 5) and O-ring seal (Figure 4, Item 4) from intake manifold (Figure 4, Item 3). Discard O-ring seal.

END OF TASK INTAKE MANIFOLD PRESSURE SENSOR INSTALLATION 1.

Install new O-ring seal (Figure 4, Item 4) on intake manifold pressure sensor (Figure 4, Item 5).

2.

Install intake manifold pressure sensor (Figure 4, Item 5) on intake manifold (Figure 4, Item 3). Tighten sensor to 120 in-lb (14 N•m).

NOTE Ensure locking tab on connector snaps in place. 3.

Connect connector (Figure 4, Item 2) of engine wiring harness (Figure 4, Item 1) to intake manifold pressure sensor (Figure 4, Item 5). 1

5

2

4

Figure 4. Intake Manifold Pressure Sensor Replacement. END OF TASK

0118-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

3

M0208JCH

TM 10-3930-675-23-1

0118

AMBIENT AIR PRESSURE SENSOR REMOVAL

NOTE The ambient air pressure sensor is located on a bracket on the left side of the engine to the right-rear of the engine ECU. It is replaced in the same manner as the intake manifold pressure sensor. 1.

Disconnect connector of engine wiring harness (Figure 5, Item 1) from ambient air pressure sensor (Figure 5, Item 2).

2.

Remove ambient air pressure sensor (Figure 5, Item 2) from mounting bracket (Figure 5, Item 3).

END OF TASK AMBIENT AIR PRESSURE SENSOR INSTALLATION 1.

Install ambient air pressure sensor (Figure 5, Item 2) on mounting bracket (Figure 5, Item 3). Tighten sensor to 120 in-lb (14 N•m).

NOTE Ensure locking tab on connector snaps in place. 2.

Connect connector of engine wiring harness (Figure 5, Item 1) to air pressure sensor (Figure 5, Item 2).

NOTE RT 240V2 sensor does not have harness connector adapter. Sensor is connected to engine harness and attached to harness using tiedown straps.

1 2

3

M0209JCH

Figure 5. Ambient Air Pressure Sensor Replacement. END OF TASK

0118-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

TM 10-3930-675-23-1

0118

AMBIENT AIR PRESSURE SENSOR REMOVAL (NEW STYLE) 1.

Disconnect connector of engine wiring harness (Figure 6, Item 1) from ambient air pressure sensor (Figure 6, Item 2).

2.

Remove old style ambient air pressure sensor (Figure 6, Item 2) from mounting bracket (Figure 5, Item 3). 1

2

M0210JCH

Figure 6. Ambient Air Pressure Sensor Removal (New Style). END OF TASK

0118-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

TM 10-3930-675-23-1

0118

AMBIENT AIR PRESSURE SENSOR INSTALLATION (NEW STYLE) 1.

Install new style ambient air pressure sensor (Figure 7, Item 3) on to harness connector adapter (Figure 7, Item 2).

NOTE Ensure locking tab on connector snaps in place. RT 2402 sensor does not have harness connector adapter. Sensor is connected to engine harness and attached to harness using tiedown straps. 2.

Connect connector of engine wiring harness (Figure 7, Item 1) to sensor harness connector adapter (Figure 7, Item 2).

3.

Attach sensor and harness connector adapter to engine wiring harness using tiedown straps. 2

1

2

3

M0211JCH

Figure 7. Ambient Temperature Sensor Installation (New Style). END OF TASK

0118-9

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

TM 10-3930-675-23-1

0118

OIL PRESSURE/TEMPERATURE SENSOR REMOVAL 1.

Disconnect connector (Figure 8, Item 4) of engine wiring harness (Figure 8, Item 5) from oil pressure/ temperature sensor (Figure 8, Item 2).

2.

Remove oil pressure/temperature sensor (Figure 8, Item 2) and O-ring seal (Figure 8, Item 1) from engine (Figure 8, Item 3). Discard O-ring seal.

END OF TASK OIL PRESSURE/TEMPERATURE SENSOR INSTALLATION 1.

Install new O-ring seal (Figure 8, Item 1) on oil pressure/temperature sensor (Figure 8, Item 2).

2.

Install oil pressure/temperature sensor (Figure 8, Item 2) on engine (Figure 8, Item 3). Tighten sensor to 120 in-lb (14 N•m).

NOTE Ensure locking tab on connector snaps in place. 3.

Connect connector (Figure 8, Item 4) of engine wiring harness (Figure 8, Item 5) to sensor (Figure 8, Item 2). 1

2

5

Figure 8.

Oil Pressure/Temperature Sensor Replacement.

END OF TASK

0118-10

03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

3

4

M0212JCH

TM 10-3930-675-23-1

FOLLOW-On MAINTENANCE Install engine cover (Volume 2, WP 0185). END OF TASK END OF WORK PACKAGE

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00083)

0118

TM 10-3930-675-23-1

0119

FIELD MAINTENANCE HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66)

Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28)

Equipment Condition Cab in transport position (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10) Transmission access cover(s) removed (Volume 2, WP 0175) Hydraulic system pressure relieved (Volume 2, 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 removing switches. • Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

0119-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00084)

TM 10-3930-675-23-1

REMOVAL

NOTE • There are three filter indicator sensors located in filter heads of high-pressure hydraulic filters. Ease of access to remove these sensors varies. In some cases, it may be necessary to remove both filter and filter head to access sensor. • Remove and discard tiedown straps. • Tag wires to ensure correct installation. 1.

Trace electrical cable (Figure 1, Item 3) from sensor (Figure 1, Item 10) located on filter head (Figure 1, Item 11) back to junction box (Figure 1, Item 12).

2.

Loosen four screws (Figure 1, Item 2) and remove cover (Figure 1, Item 1) from junction box (Figure 1, Item 12). Inspect rubber seal in groove of cover. Replace seal only if damaged.

3.

Loosen cable nut (Figure 1, Item 8) and slide cable nut and grommet (Figure 1, Item 7) back on cable (Figure 1, Item 9).

4.

Using a jeweler’s screwdriver, disconnect cable wires (Figure 1, Item 6) from terminal blocks (Figure 1, Item 5). Remove cable (Figure 1, Item 9) from junction box (Figure 1, Item 4).

5.

Remove sensor (Figure 1, Item 10) with cable (Figure 1, Item 3) from filter head (Figure 1, Item 11).

END OF TASK

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00084)

0119

TM 10-3930-675-23-1

0119

INSTALLATION

NOTE • Use electrically conductive grease on wire connections before connections are made. • Install new tiedown straps as necessary. 1.

Install sensor (Figure 1, Item 10) on filter head (Figure 1, Item 11).

2.

Feed cable (Figure 1, Item 6) through grommet (Figure 1, Item 7) and cable nut (Figure 1, Item 8) and into junction box (Figure 1, Item 1).

3.

Using a jeweler’s screwdriver, connect cable wires (Figure 1, Item 6) to terminal blocks (Figure 1, Item 5).

4.

Install grommet (Figure 1, Item 7) and cable nut (Figure 1, Item 8) on junction box (Figure 1, Item 4). Tighten cable nut.

5.

Install cover (Figure 1, Item 1) on junction box (Figure 1, Item 12) and tighten four screws (Figure 1, Item 2). 1

5

4

2

3

10

6 7

11

9

12

Figure 1. Hydraulic Cylinder Filter Indicator Sensor Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1.

Install transmission access cover(s) (Volume 2, WP 0175).

2.

Return cab to operational position (TM 10-3930-675-10).

3.

Check hydraulic system for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0119-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00084)

8

M1711JCH

TM 10-3930-675-23-1

0120

FIELD MAINTENANCE TRANSMISSION SENSORS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Dial, 3/8" Drive, 300 in-lb (Volume 2, WP 0277, Table 1, Item 98) Materials/Parts Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) O-Ring (Volume 2, WP 0278, Table 1, Item 144) Qty: 3 O-Ring (Volume 2, WP 0278, Table 1, Item 147)

Materials/Parts (cont.) O-Ring (Volume 2, WP 0278, Table 1, Item 151) O-Ring (Volume 2, WP 0278, Table 1, Item 153) References Volume 2, WP 0136 Equipment Condition Cab in transport position (TM 10-3930-675-10) Master battery switch in OFF position (TM 10-3930-675-10) Transmission access covers removed (Volume 2, WP 0175)

NOTE • Transmission has provisions for seven sensors: turbine speed, internal gear speed, engine speed, output speed, gearbox temperature, 2WD/4WD, and filter indicator sensor. • Each sensor is replaced in the same manner. A locator diagram is provided to aid in locating each sensor. Procedures for gearbox temperature sensor are detailed as an example. • Tag connectors to ensure correct connection on installation.

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TM 10-3930-675-23-1

0120

REMOVAL 1.

Using locator diagram, locate sensor to be removed. GEARBOX TEMPERATURE SENSOR

FRONT ENGINE SPEED SENSOR

GEARBOX CONNECTOR

OUTPUT SPEED SENSOR 2WD/4WD VALVE

2WD/4WD DRIVE SENSOR

FILTER INDICATOR SENSOR

TURBINE SPEED SENSOR

RIGHT SIDE

INTERNAL GEAR SPEED SENSOR

LEFT SIDE

Figure 1. Transmission Sensors. 2.

Press in on connector retaining clip and disconnect electrical connector from sensor.

0120-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00085)

M0216JCH

TM 10-3930-675-23-1

0120

REMOVAL - Continued

CONNECTOR

SENSOR RETAINING CLIP M0217JCH

Figure 2.

Transmission Sensor Connector.

CAUTION Engine speed, internal gear speed, turbine speed, and output speed sensors are installed and positioned with spacers. Spacers are removed with their respective sensor and must be retained for installation. Failure to follow this caution may result in damage to equipment or improper sensor operation. 3.

Remove sensor and O-ring from transmission. Discard O-ring.

SENSOR

O-RING

M0218JCH

Figure 3.

Transmission Sensor Removal.

END OF TASK

0120-3

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TM 10-3930-675-23-1

0120

INSTALLATION

CAUTION Spacers removed with sensors must be reinstalled with same sensor. If sensor is replaced, spacer must be replaced with the same type and quantity when installing sensor. Failure to follow this caution may result in damage to equipment or improper sensor operation.

NOTE If reinstalling sensor, ensure new O-ring seal is used. If installing new sensor, ensure new O-ring provided is installed. 1.

Install sensor with new O-ring in transmission. Tighten sensors as follows: a.

Outspeed speed sensor: 204 in-lb (23 N•m).

b.

All other sensors: 265 in-lb (30 N•m).

SENSOR

O-RING

M0219JCH

Figure 4. Transmission Sensor Installation.

NOTE Ensure connector and sensor key are aligned prior to connection. 2.

Connect electrical connector to sensor.

0120-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00085)

TM 10-3930-675-23-1

0120

INSTALLATION - Continued

CONNECTOR

SENSOR

M0220JCH

Figure 5.

Transmission Sensor Connector.

END OF TASK FOLLOW-ON MAINTENANCE 1.

If any sensor except for gearbox temperature or filter indicator sensor was replaced, perform transmission calibration (Volume 2, WP 0136).

2.

Perform operational check (TM 10-3930-675-10).

3.

Install transmission access covers (Volume 2, WP 0175).

4.

Return cab to operational position (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

FIELD MAINTENANCE BOOM ANGLE SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66)

References Volume 2, WP 0257 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

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03/15/2011 Rel(1.8) root(maintwp) wpno(M00086)

0121

TM 10-3930-675-23-1

0121

REMOVAL 1.

Remove two screws (Figure 1, Item 1), washers (Figure 1, Item 2), and boom angle sensor (Figure 1, Item 4) assembly from boom and bolt (Figure 1, Item 9).

2.

Loosen setscrew (Figure 1, Item 5) of lever (Figure 1, Item 8) and remove lever from boom angle sensor (Figure 1, Item 4).

3.

Remove three screws (Figure 1, Item 6), washers (Figure 1, Item 7), and bracket (Figure 1, Item 3) from boom angle sensor (Figure 1, Item 4). 1,2

4

3

5

6,7

9

8

Figure 1. Boom Angle Sensor Removal.

0121-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00086)

M0227JCH

TM 10-3930-675-23-1

0121

REMOVAL - Continued 4.

Loosen four screws (Figure 2, Item 2) and remove cover (Figure 2, Item 1) from junction box (Figure 2, Item 3), located on right side of boom. Inspect rubber seal in groove of cover. Replace seal only if damaged. 1

3

2

M0228JCH

Figure 2.

Boom Angle Sensor Removal.

0121-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00086)

TM 10-3930-675-23-1

0121

REMOVAL - Continued 5.

Loosen cable nut (Figure 3, Item 4) and slide cable nut, grommet (Figure 3, Item 5), and bushing (Figure 3, Item 6) back on cable (Figure 3, Item 3) of boom angle sensor (Figure 4, Item 4).

CAUTION To avoid damage to junction box, a fine-tipped jeweler’s screwdriver should be used when disconnecting wires. DO NOT use a punch.

NOTE Tag wires for installation. 6.

Using a jeweler’s screwdriver, disconnect three wires of cable (Figure 3, Item 3) from terminal blocks (Figure 3, Item 1) of junction box (Figure 3, Item 2).

NOTE Remove tiedown straps as needed. Discard tiedown straps. 7.

Remove boom angle sensor (Figure 4, Item 4) with cable (Figure 3, Item 3) from vehicle. 1

2

6

5

4

Figure 3. Boom Angle Sensor Removal END OF TASK

0121-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00086)

3

M0229JCH

TM 10-3930-675-23-1

0121

INSTALLATION 1.

Position boom angle sensor (Figure 4, Item 4) with cable (Figure 3, Item 3) on vehicle.

2.

Using a jeweler’s screwdriver, connect three wires of cable (Figure 3, Item 3) to terminal blocks (Figure 3, Item 1) of junction box (Figure 3, Item 2).

3.

Install bushing (Figure 3, Item 6), grommet (Figure 3, Item 5), and cable nut (Figure 3, Item 4) on junction box (Figure 3, Item 2).

4.

Install cover (Figure 2, Item 1) on junction box (Figure 2, Item 3) and tighten four screws (Figure 2, Item 2).

NOTE Position angle sensor wire and nut between six and nine o’clock position. 5.

Install boom angle sensor (Figure 4, Item 4) on bracket (Figure 4, Item 3) with three washers (Figure 4, Item 7) and screws (Figure 4, Item 6).

6.

Install lever (Figure 4, Item 8) on boom angle sensor (Figure 4, Item 4) and tighten setscrew (Figure 4, Item 5).

7.

Position boom angle sensor (Figure 4, Item 4) assembly on bolt (Figure 4, Item 9) and boom and install two washers (Figure 4, Item 2) and screws (Figure 4, Item 1). Tighten screws.

8.

Install new tiedown straps. 1,2

3

4

5

6,7

8

9

Figure 4.

M0230JCH

Boom Angle Sensor Installation.

END OF TASK

0121-5

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TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE Perform boom and tophandler calibration (Volume 2, WP 0257). END OF TASK END OF WORK PACKAGE

0121-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00086)

0121

TM 10-3930-675-23-1

0122

FIELD MAINTENANCE BOOM EXTENSION SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Boom fully retracted (TM 10-3930-675-10) Master battery switch in OFF position (TM 103930-675-10)

References Volume 2, WP 0257

REMOVAL 1.

Remove two screws (Figure 1, Item 2), washers (Figure 1, Item 3), and cover plate (Figure 1, Item 1) from rear of boom (Figure 1, Item 4). 1

4

2,3

Figure 1.

M0231JCH

Boom Extension Sensor Removal.

0122-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00087)

TM 10-3930-675-23-1

0122

REMOVAL - Continued 2.

Open cable connector (Figure 2, Item 2) and remove cable connector to disconnect ring of cable (Figure 2, Item 1) from rear of extension boom (Figure 2, Item 3). 1

3

2

M0232JCH

Figure 2. Boom Extension Sensor Removal. 3.

While holding ring of cable (Figure 2, Item 1), allow cable to retract into boom extension sensor (Figure 3, Item 2).

4.

Disconnect connector (Figure 3, Item 1) of wiring harness from boom extension sensor (Figure 3, Item 2).

5.

Remove two screws (Figure 3, Item 3), washers (Figure 3, Item 4), and boom extension sensor (Figure 3, Item 2) from boom (Figure 3, Item 5).

END OF TASK

0122-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00087)

TM 10-3930-675-23-1

0122

INSTALLATION 1.

Install boom extension sensor (Figure 3, Item 2) on boom (Figure 3, Item 5) with two washers (Figure 3, Item 4) and screws (Figure 3, Item 3).

2.

Connect connector (Figure 3, Item 1) of wiring harness to boom extension sensor (Figure 3, Item 2).

3.

Extend ring of cable (Figure 2, Item 1) from boom extension sensor (Figure 3, Item 2).

4.

Install ring of cable (Figure 2, Item 1) on rear of extension boom (Figure 2, Item 3) with cable connector (Figure 2, Item 2). Close cable connector. 1

2

3,4

5

M0233JCH

Figure 3.

Boom Extension Sensor Removal.

0122-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00087)

TM 10-3930-675-23-1

0122

INSTALLATION - Continued 5.

Install cover plate (Figure 4, Item 1) on rear of boom (Figure 4, Item 4) with two washers (Figure 4, Item 3) and screws (Figure 4, Item 2). 1

4

2,3

M0234JCH

Figure 4. Boom Extension Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE Perform boom and tophandler calibration (Volume 2, WP 0257). END OF TASK END OF WORK PACKAGE

0122-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00087)

TM 10-3930-675-23-1

FIELD MAINTENANCE TOPHANDLER ANGLE SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66)

References Volume 2, WP 0257 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

0123-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

0123

TM 10-3930-675-23-1

0123

REMOVAL

NOTE If removing tophandler, perform Step 1 only. 1.

Remove two screws (Figure 1, Item 1), washers (Figure 1, Item 2), and tophandler angle sensor (Figure 1, Item 4) assembly from boom extension and bolt (Figure 1, Item 3). 1,2

4

M0235JCH

3

Figure 1. Tophandler Angle Sensor Removal.

0123-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 10-3930-675-23-1

0123

REMOVAL - Continued 2.

Loosen setscrew (Figure 2, Item 3) of lever (Figure 2, Item 5) and remove lever from tophandler angle sensor (Figure 2, Item 6).

3.

Remove three screws (Figure 2, Item 1), washers (Figure 2, Item 2), and bracket (Figure 2, Item 4) from tophandler angle sensor (Figure 2, Item 6). 3

4

1,2

5

6

M0236JCH

Figure 2.

Tophandler Angle Sensor Removal.

0123-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 10-3930-675-23-1

0123

REMOVAL - Continued 4.

Remove three screws (Figure 3, Item 7), washers (Figure 3, Item 8), cable (Figure 3, Item 6), and three cable clamps (Figure 3, Item 9) from boom extension.

5.

Loosen cable nut (Figure 3, Item 5) and slide cable nut and grommet (Figure 3, Item 4) back on cable (Figure 3, Item 6) of tophandler angle sensor (Figure 2, Item 6).

6.

Loosen six screws (Figure 3, Item 1) and remove cover (Figure 3, Item 2) from tophandler junction box (Figure 3, Item 3). Inspect rubber seal in groove of cover. Replace seal only if damaged. 2

3

4

5

1

6

7,8,9

M0237JCH

Figure 3. Tophandler Angle Sensor Removal.

0123-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 10-3930-675-23-1

0123

REMOVAL - Continued 7.

Remove plastic covers (Figure 4, Item 4) to expose cable (Figure 4, Item 1) of tophandler angle sensor (Figure 2, Item 6).

NOTE Tag wires for installation. 8.

Using a jeweler’s screwdriver, disconnect three wires of cable (Figure 4, Item 1) from terminal block (Figure 4, Item 2) in tophandler junction box (Figure 4, Item 3).

9.

Remove tophandler angle sensor (Figure 2, Item 6) with cable (Figure 4, Item 1) from vehicle.

2 1 3

4

4

1 M0238JCH

Figure 4.

Tophandler Angle Sensor Removal.

END OF TASK

0123-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 10-3930-675-23-1

0123

INSTALLATION 1.

Position tophandler angle sensor (Figure 2, Item 6) with cable (Figure 5, Item 1) on vehicle.

2.

Using a jeweler’s screwdriver, connect three wires of cable (Figure 5, Item 1) to terminal block (Figure 5, Item 2) in tophandler junction box (Figure 5, Item 3).

3.

Install plastic covers (Figure 5, Item 4) over excess cable (Figure 5, Item 1) of tophandler angle sensor (Figure 2, Item 6).

2 1 3

4

4

1 M0239JCH

Figure 5.

Tophandler Angle Sensor Installation.

0123-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 10-3930-675-23-1

0123

INSTALLATION - Continued 4.

Install cover (Figure 6, Item 2) on tophandler junction box (Figure 6, Item 3) and tighten six screws (Figure 6, Item 1).

5.

Install grommet (Figure 6, Item 4) and tighten cable nut (Figure 6, Item 5).

6.

Install cable (Figure 6, Item 6) on boom extension with three cable clamps (Figure 6, Item 9), washers (Figure 6, Item 8), and screws (Figure 6, Item 7). 2

3

4

5

1

6

7,8,9

M0240JCH

Figure 6.

Tophandler Angle Sensor Installation.

0123-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 10-3930-675-23-1

0123

INSTALLATION - Continued

NOTE Position angle sensor wire and nut between three and six o’clock position. 7.

Install tophandler angle sensor (Figure 7, Item 6) on bracket (Figure 7, Item 4) with three washers (Figure 7, Item 2) and screws (Figure 7, Item 1).

8.

Install lever (Figure 7, Item 5) on tophandler angle sensor (Figure 7, Item 6) and tighten setscrew (Figure 7, Item 3). 3

4

1,2

5

6

M0241JCH

Figure 7.

Tophandler Angle Sensor Installation.

0123-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00088)

TM 10-3930-675-23-1

0123

INSTALLATION - Continued 9.

Position tophandler angle sensor (Figure 8, Item 4) assembly on bolt (Figure 8, Item 3) and boom extension and install two washers (Figure 8, Item 2) and screws (Figure 8, Item 1). Tighten screws. 1,2

4

M0242JCH

3

Figure 8.

Tophandler Angle Sensor Installation.

END OF TASK FOLLOW-ON MAINTENANCE Perform boom and tophandler calibration (Volume 2, WP 0257). END OF TASK END OF WORK PACKAGE

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TM 10-3930-675-23-1

0124

FIELD MAINTENANCE HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Wrench, Torque, Click, Ratcheting, 3/8" Drive,75 ftlb (Volume 2, WP 0277, Table 1, Item 97)

Materials/Parts (cont.) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

Materials/Parts Cap Set, Protective Dust and Moisture Seal (Volume 2, WP 0276, Table 1, Item 9) Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Lubricating, Oil, OE/HDO 10 (Volume 2, WP 0276, Table 1, Item 45)

References Volume 2, WP 0242 Volume 2, WP 0257 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Hydraulic system pressure relieved (Volume 2, 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 removing switches. • 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.

0124-1

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TM 10-3930-675-23-1

0124

NOTE • Remove and discard tiedown straps. • Apply electrically conductive grease to connectors before connections are made. • New o-rings and gaskets are included with new sensors. TEMPERATURE SENSOR REPLACEMENT 1.

Drain hydraulic reservoir (Volume 2, WP 0242).

2.

Disconnect connector (Figure 1, Item 2) of temperature sensor (Figure 1, Item 4) from wiring harness (Figure 1, Item 1).

3.

Remove temperature sensor (Figure 1, Item 4) and copper washer (Figure 1, Item 5) from hydraulic reservoir (Figure 1, Item 3). 1

2

3

M0243JCH

4,5

Figure 1. Temperature Sensor Replacement. 4.

Install copper washer (Figure 1, Item 5) and hydraulic temperature sensor (Figure 1, Item 4) on hydraulic reservoir (Figure 1, Item 3).

5.

Connect connector (Figure 1, Item 2) of temperature sensor (Figure 1, Item 4) to wiring harness (Figure 1, Item 1).

END OF TASK

0124-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00089)

TM 10-3930-675-23-1

0124

PRESSURE SENSOR REPLACEMENT 1.

Remove four socket head screws (Figure 2, Item 3) from flange (Figure 2, Item 4).

2.

Remove flange (Figure 2, Item 4), sensor (Figure 2, Item 2), and O-ring (Figure 2, Item 5) from hydraulic reservoir (Figure 2, Item 1). Discard O-ring.

3.

Trace sensor cable (Figure 2, Item 6) back to junction box. Disconnect wires of cable from terminal blocks. Remove cable from junction box.

NOTE Replacement sensor comes with new O-ring. 4.

Lubricate new O-ring (Figure 2, Item 5) with lubricating oil. Install O-ring and sensor (Figure 2, Item 2) on hydraulic reservoir (Figure 2, Item 1) with flange (Figure 2, Item 4) and four socket head screws (Figure 2, Item 3).

5.

Position sensor cable (Figure 2, Item 6) in junction box. Connect wires of sensor cable to terminal blocks in junction box.

6.

Secure sensor cable (Figure 2, Item 6) with new tiedown straps. 1

3

2

4,5

M0244JCH

6

Figure 2.

Pressure Sensor Replacement.

END OF TASK

0124-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00089)

TM 10-3930-675-23-1

0124

LIFT CYLINDER SENSOR REPLACEMENT 1.

Disconnect electrical connector (Figure 3, Item 1) from sensor (Figure 3, Item 2).

2.

Remove sensor (Figure 3, Item 2) and O-ring from locking valve (Figure 3, Item 4) at base of lift cylinder (Figure 3, Item 3). Discard O-ring.

NOTE Replacement sensor comes with new O-ring. 3.

Lubricate new O-ring with lubricating oil. Install O-ring and sensor (Figure 3, Item 2) to locking valve (Figure 3, Item 4). Tighten sensor to 35 ft-lb (47 N·m).

4.

Connect electrical connector (Figure 3, Item 1) to sensor (Figure 3, Item 2). 1

2

3

4

Figure 3.

Lift Cylinder Sensor Replacement.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Fill hydraulic reservoir (Volume 2, WP 0242).

2.

Calibrate boom and tophandler (Volume 2, WP 0257).

END OF TASK END OF WORK PACKAGE

0124-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00089)

M0245JCH

TM 10-3930-675-23-1

0125

FIELD MAINTENANCE STEERING SYSTEM WHEEL SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Screwdriver Set, Jeweler's (Volume 2, WP 0277, Table 1, Item 66)

Materials/Parts (cont.) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 87) Qty: 3

Materials/Parts Grease, Electrically Conductive (Volume 2, WP 0276, Table 1, Item 28) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

References Volume 2, WP 0174 Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) Steering hydraulic system pressure relieved (Volume 2, WP 0204) Engine cover removed (to replace front wheel sensors) (Volume 2, WP 0185)

WARNING

Do not stand between wheel and frame if engine is running or steering system pressure has not been relieved. Failure to follow this warning may result in injury or death to personnel.

NOTE Four steering system wheel sensors are replaced the same way. Left front sensor is shown.

0125-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

TM 10-3930-675-23-1

0125

REMOVAL

NOTE Remove and discard tiedown straps as needed. 1.

Remove screw (Figure 1, Item 12), washer (Figure 1, Item 13), and clamp (Figure 1, Item 14).

2.

Remove two screws (Figure 1, Item 9) and washers (Figure 1, Item 10) to loosen bracket (Figure 1, Item 1) from axle.

3.

Remove two screws (Figure 1, Item 6) and washers (Figure 1, Item 7) from sensor mounting flange (Figure 1, Item 8).

NOTE Note position of sensor assembly on bracket for installation. 4.

Remove three locknuts (Figure 1, Item 2), six washers (Figure 1, Item 3), three screws (Figure 1, Item 4), and sensor (Figure 1, Item 5) assembly from bracket (Figure 1, Item 1). Discard locknuts.

5.

Remove protective covering (Figure 1, Item 11) from cable (Figure 1, Item 15) of sensor (Figure 1, Item 5). 2,3,4

1

5

6,7 15 12,13,14 11

9,10

Figure 1.

8

M0248JCH

Steering System Wheel Sensor Removal.

0125-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

TM 10-3930-675-23-1

0125

REMOVAL - Continued 6.

Loosen four screws (Figure 2, Item 1) and remove cover (Figure 2, Item 2) from front (or rear) junction box (Figure 2, Item 3). 1

2

3

M0249JCH

Figure 2.

Steering System Wheel Sensor Removal.

0125-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

TM 10-3930-675-23-1

0125

REMOVAL - Continued

NOTE Tag wires for installation. 7.

Using a jeweler’s screwdriver, disconnect seven wires of cable (Figure 3, Item 3) from terminal blocks (Figure 3, Item 1) in junction box (Figure 3, Item 2).

8.

Loosen cable nut (Figure 3, Item 4) and slide cable nut and grommet (Figure 3, Item 5) back on cable (Figure 3, Item 3).

9.

Remove cable (Figure 3, Item 3) from junction box (Figure 3, Item 2).

NOTE Before removing, string may be tied to end of sensor cable to aid in installation. 10.

Remove sensor (Figure 1, Item 5) assembly with cable (Figure 1, Item 15) from vehicle. 1

5

Figure 3.

2

3

4

Steering System Wheel Sensor Removal.

END OF TASK

0125-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

M0250JCH

TM 10-3930-675-23-1

0125

INSTALLATION 1.

Position cable (Figure 4, Item 3) with sensor assembly in vehicle.

2.

Position cable (Figure 4, Item 3) in junction box (Figure 4, Item 2).

3.

Install grommet (Figure 4, Item 5) and cable nut (Figure 4, Item 4) in junction box (Figure 4, Item 2).

NOTE Use electrically conductive grease on wire connections before connections are made. 4.

Connect seven wires of cable (Figure 4, Item 3) to terminal blocks (Figure 4, Item 1) in junction box (Figure 4, Item 2) as follows: 1

5

2

3

4

Figure 4. Steering System Wheel Sensor Installation.

0125-5

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

M0251JCH

TM 10-3930-675-23-1

0125

INSTALLATION - Continued

Table 1.

Rear Junction Box X167 Wire Connections.

LEFT-REAR SENSOR

RIGHT-REAR SENSOR

Black No. 1 across from Brown

Black No. 1 across from Gray

Black No. 2 across from White

Black No. 2 across from Black

Black No. 3 across from Violet

Black No. 3 across from Red

Black No. 4 across from Orange

Black No. 4 across from Blue

Black No. 5 across from White/Black

Black No. 5 across from Yellow

Yellow/Green across from White/Red

Yellow/Green across from Green

Silver to Ground Terminal

Silver to Silver

Table 2.

Front Junction Box X192 Wire Connections.

LEFT-FRONT SENSOR

RIGHT-FRONT SENSOR

Black No. 1 across from Brown

Black No. 1 across from Gray

Black No. 2 across from White

Black No. 2 across from Black

Black No. 3 across from Violet

Black No. 3 across from Red

Black No. 4 across from Orange

Black No. 4 across from Blue

Black No. 5 across from White/Black

Black No. 5 across from Yellow

Yellow/Green across from White/Red

Yellow/Green across from Green

Silver to Ground Terminal

Silver to Silver

0125-6

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

TM 10-3930-675-23-1

0125

INSTALLATION - Continued 5.

Install cover (Figure 5, Item 2) on front (or rear) junction box (Figure 5, Item 3) and tighten four screws (Figure 5, Item 1). 1

2

3

M0252JCH

Figure 5. Steering System Wheel Sensor Installation.

0125-7

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

TM 10-3930-675-23-1

0125

INSTALLATION - Continued 6.

Install protective covering (Figure 6, Item 11) on cable (Figure 6, Item 15).

7.

Install sensor (Figure 6, Item 5) assembly on bracket (Figure 6, Item 1), in position noted during removal, with three screws (Figure 6, Item 4), six washers (Figure 6, Item 3), and three new locknuts (Figure 6, Item 2).

8.

Install sensor mounting flange (Figure 6, Item 8) with two washers (Figure 6, Item 7) and screws (Figure 6, Item 6).

9.

Install bracket (Figure 6, Item 1) on axle with two washers (Figure 6, Item 10) and screws (Figure 6, Item 9).

10.

Install clamp (Figure 6, Item 14) with washer (Figure 6, Item 13) and screw (Figure 6, Item 12).

11.

Install new tiedown straps as needed. 2,3,4

1

5

6,7 15 12,13,14 11

9,10

8

M0253JCH

Figure 6. Steering System Wheel Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE 1.

Install engine cover (Volume 2, WP 0185).

2.

Perform steering calibration (Volume 2, WP 0174).

END OF TASK END OF WORK PACKAGE

0125-8

03/15/2011 Rel(1.8) root(maintwp) wpno(M00090)

TM 10-3930-675-23-1

0126

FIELD MAINTENANCE SEAT WARNING BUZZER REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

REMOVAL 1.

Remove approximately eight plastic rivets (Figure 1, Item 1) from rubber bellows (Figure 1, Item 2) under seat (Figure 1, Item 3).

2.

Pull rubber bellows (Figure 1, Item 2) downward to access underside of seat (Figure 1, Item 3). 1

2

3

M0257JCH

Figure 1.

Seat Warning Buzzer Replacement.

0126-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00091)

TM 10-3930-675-23-1

0126

REMOVAL - Continued 3.

Loosen nut (Figure 2, Item 1) and screw (Figure 2, Item 2) on seat warning buzzer holder (Figure 2, Item 3).

4.

Pull seat warning buzzer (Figure 2, Item 4) downward from seat warning buzzer holder (Figure 2, Item 3). 1

2

3

4

M0258JCH

Figure 2.

Seat Warning Buzzer Replacement.

NOTE Tag wires for installation. 5.

Remove two nuts (Figure 3, Item 6) and washers (Figure 3, Item 7) and disconnect two wires (Figure 3, Items 1 and 2) from seat warning buzzer (Figure 3, Item 3).

NOTE Perform Step 6 to disconnect two connectors from seat warning buzzer switch. 6.

Disconnect two connectors (Figure 3, Item 5) from seat warning buzzer switch (Figure 3, Item 4).

END OF TASK

0126-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00091)

TM 10-3930-675-23-1

0126

INSTALLATION

NOTE Perform Step 1 to connect two connectors to seat warning buzzer switch. 1.

Connect two connectors (Figure 3, Item 5) to seat warning buzzer switch (Figure 3, Item 4).

2.

Connect two wires (Figure 3, Items 1 and 2) to seat warning buzzer (Figure 3, Item 3) with two washers (Figure 3, Item 7) and nuts (Figure 3, Item 6).

3.

Push seat warning buzzer (Figure 2, Item 4) upward into seat warning buzzer holder (Figure 2, Item 3).

4.

Tighten screw (Figure 2, Item 2) and nut (Figure 2, Item 1) on seat warning buzzer holder (Figure 2, Item 3). 1

3

2

4

5

6,7

M0259JCH

Figure 3.

Seat Warning Buzzer Replacement.

0126-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00091)

TM 10-3930-675-23-1

0126

INSTALLATION - Continued 5.

Pull rubber bellows (Figure 4, Item 2) upward to seat (Figure 4, Item 3).

6.

Install rubber bellows (Figure 4, Item 2) on seat (Figure 4, Item 3) with approximately eight plastic rivets (Figure 4, Item 1). 1

2

3

M0260JCH

Figure 4.

Seat Warning Buzzer Replacement.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check seat warning buzzer for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0126-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00091)

TM 10-3930-675-23-1

FIELD MAINTENANCE ELECTRIC HORN REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

0127-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00092)

0127

TM 10-3930-675-23-1

0127

REMOVAL

NOTE Tag wires for installation. 1.

Disconnect two connectors (Figure 1, Item 1) from rear of electric horn (Figure 1, Item 2).

2.

Remove screw (Figure 1, Item 4), washer (Figure 1, Item 5), and electric horn (Figure 1, Item 2) with bracket (Figure 1, Item 3) from vehicle.

END OF TASK INSTALLATION 1.

Install electric horn (Figure 1, Item 2) with bracket (Figure 1, Item 3) on vehicle with washer (Figure 1, Item 5) and screw (Figure 1, Item 4).

2.

Connect two connectors (Figure 1, Item 1) to rear of electric horn (Figure 1, Item 2). 2

1

3

4,5 M0254JCH

Figure 1. Electric Horn Replacement. END OF TASK

0127-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00092)

TM 10-3930-675-23-1

FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Test electric horn for proper operation (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0127-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00092)

0127

TM 10-3930-675-23-1

0128

FIELD MAINTENANCE BATTERY MAINTENANCE

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Apron, Utility (Volume 2, WP 0277, Table 1, Item 5) Battery Kit, Service (Volume 2, WP 0277, Table 1, Item 8) Gloves, Rubber, Industrial (Volume 2, WP 0277, Table 1, Item 32) Goggles, Industrial (Volume 2, WP 0277, Table 1, Item 34)

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 80) Qty: 4 References TB 9-6140-252-13 TM 10-3930-675-10 Equipment Condition Battery cables removed (WP 0129)

WARNING

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or serious injury to personnel. 1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. 2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. 4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0128-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00093)

TM 10-3930-675-23-1

0128

REMOVAL 1.

Remove four locknuts (Figure 1, Item 1), eight washers (Figure 1, Item 2), four bolts (Figure 1, Item 3), and two battery holddown straps (Figure 1, Item 4) from across top of batteries (Figure 1, Item 5). Discard locknuts.

NOTE Note position of batteries in battery compartment for installation. 2.

Remove four batteries (Figure 1, Item 5) from battery compartment (Figure 1, Item 6). 1,2,3

4

5

6

M0261JCH

Figure 1.

Battery Replacement.

END OF TASK SERVICE

WARNING

To avoid injury, wear eye protection when working around batteries. The gasses produced by a lead-acid battery can explode. Do not smoke, have open flames, or make a spark if filler caps are off. Remove all jewelry, such as rings, ID tags, watches, and bracelets. If jewelry contacts a battery terminal, a direct short will result in instant heating and may cause severe injury to personnel and/or damage equipment.

NOTE If battery compartment is corroded, it will be necessary to remove batteries and clean compartment to remove acid residues and corrosion. Buildup of dirt or corrosion on batteries can lead to electrical malfunctions.

0128-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00093)

TM 10-3930-675-23-1

0128

SERVICE - Continued Service batteries as follows: 1.

Access batteries (Figure 2, Item 2) inside battery box (Figure 2, Item 1) on left side of machine.

2.

Check battery hold-downs (Figure 2, Item 3) for looseness, corrosion or damage. Tighten if loose.

3.

Clean top of batteries (Figure 2, Item 2) with clean water and a rag. Flush batteries (Figure 2, Item 2), battery tray (Figure 2, Item 4) and battery box (Figure 2, Item 1) with water until clean of debris.

4.

Inspect batteries (Figure 2, Item 2) for evidence of cracks, dents, leaking or swelling of battery case and/or lid.

5.

Disconnect battery cables (WP 0129).

6.

As required, use a battery terminal cleaner or wire brush to remove any corrosion or acid film from battery post clamps.

7.

As required, use a battery terminal cleaner or wire brush to remove any corrosion or acid film from battery post.

8.

Test batteries using Pulsetech battery tester. Follow the on-screen instructions.

NOTE If a battery is suspect it may need follow-on testing or charging; refer to TB 9-6140-252-13. These follow-on tests may require the batteries to be removed from vehicle. 1

3

2

2

4

M1727JCH

Figure 2.

Battery Service.

END OF TASK

0128-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00093)

TM 10-3930-675-23-1

0128

INSTALLATION 1.

Position four batteries (Figure 3, Item 5) in battery compartment (Figure 3, Item 6) as noted during removal.

2.

Install two battery holddown straps (Figure 3, Item 4) across top of batteries (Figure 3, Item 5) with four bolts (Figure 3, Item 3), eight washers (Figure 3, Item 2), and four new locknuts (Figure 3, Item 1). 1,2,3

4

5

6

M0261JCH

Figure 3.

Battery Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Install battery cables (WP 0129).

2.

Connect battery cables (WP 0129).

END OF TASK END OF WORK PACKAGE

0128-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00093)

TM 10-3930-675-23-1

0129

FIELD MAINTENANCE BATTERY CABLES REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Apron, Utility (Volume 2, WP 0277, Table 1, Item 5) Battery Kit, Service (Volume 2, WP 0277, Table 1, Item 8)

Materials/Parts (cont.) Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63) Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 80)

Materials/Parts Grease, Automotive and Artillery, GAA (Volume 2, WP 0276, Table 1, Item 27) Rag, Wiping (Volume 2, WP 0276, Table 1, Item 50)

References WP 0130

WARNING

• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or serious injury to personnel. 1. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. 2. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 3. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. 4. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0129-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00094)

TM 10-3930-675-23-1

0129

REMOVAL

NOTE • Tag battery cables prior to removal to aid in installation. • Cut tiedown straps and remove protective covering from battery cables as necessary. • Perform Steps 1 thru 5 only to disconnect battery cables when performing any electrical maintenance task on vehicle. 1.

Remove each of four locking pins (Figure 1, Item 2) from studs of battery compartment (Figure 1, Item 1).

2.

Remove battery compartment cover (Figure 1, Item 3) from battery compartment (Figure 1, Item 1) and position aside to gain access to battery compartment. 1

2

3

2

Figure 1. 3.

M1723JCH

Battery Cables Replacement.

Inside battery compartment (Figure 2, Item 1), disconnect connector (Figure 2, Item 3) and wire (Figure 2, Item 2) of solar charger from connector (Figure 2, Item 4). 1

2

3

4

M0262JCH

Figure 2. Solar Charger Disconnect.

0129-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00094)

TM 10-3930-675-23-1

0129

REMOVAL - Continued

WARNING

Disconnect NEGATIVE battery cables first to avoid electrical shock. 4.

At end of two NEGATIVE battery cables (Figure 3, Item 17), raise plastic cap (Figure 3, Item 16) and loosen nut (Figure 3, Item 14) and screw (Figure 3, Item 15) on battery cable clamp.

5.

Disconnect NEGATIVE battery cables (Figure 3, Item 17) from two of four batteries (Figure 3, Item 13) and remove cables.

6.

Remove locknut (Figure 3, Item 3) and washer (Figure 3, Item 2) and disconnect four NEGATIVE cables (Figure 3, Item 1) from side of battery compartment (Figure 3, Item 4). Discard locknut.

7.

At ends of two battery cables (Figure 3, Item 8), raise plastic cap (Figure 3, Item 5) and loosen nut (Figure 3, Item 6) and screw (Figure 3, Item 7) on battery cable clamp.

8.

Remove two battery cables (Figure 3, Item 8) from four batteries (Figure 3, Item 13).

9.

At end of two POSITIVE battery cables (Figure 3, Item 9), raise plastic cap (Figure 3, Item 10) and loosen nut (Figure 3, Item 11) and screw (Figure 3, Item 12) on battery cable clamp.

10.

Disconnect POSITIVE battery cables (Figure 3, Item 9) from two of four batteries (Figure 3, Item 13).

11.

Disconnect POSITIVE battery cables (Figure 3, Item 9) from master battery switch (WP 0130) and remove. 1

2,3

5

4

6,7

8

9 1

10 17

11,12

16

Figure 3.

14,15

Battery Cables Replacement.

END OF TASK

0129-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00094)

8

13

M0269JCH

TM 10-3930-675-23-1

0129

CLEANING AND INSPECTION 1.

Clean batteries and battery posts with a wire brush. Wipe clean with rags.

2.

Inspect for corrosion or other damage.

END OF TASK INSTALLATION 1.

Connect two POSITIVE battery cables (Figure 4, Item 9) to master battery switch (WP 0130).

2.

Connect POSITIVE battery cables (Figure 4, Item 9) to two of four batteries (Figure 4, Item 13).

3.

At end of two POSITIVE battery cables (Figure 4, Item 9), raise plastic cap (Figure 4, Item 10) and tighten screw (Figure 4, Item 12) and nut (Figure 4, Item 11) on battery cable clamp.

4.

Install two battery cables (Figure 4, Item 9) on four batteries (Figure 4, Item 13).

5.

At ends of two battery cables (Figure 4, Item 8), raise plastic cap (Figure 4, Item 5) and tighten screw (Figure 4, Item 7) and nut (Figure 4, Item 6) on battery cable clamp.

6.

Connect four NEGATIVE cables (Figure 4, Item 1) to side of battery compartment (Figure 4, Item 4) with washer (Figure 4, Item 2) and new locknut (Figure 4, Item 3).

7.

Connect NEGATIVE battery cables (Figure 4, Item 17) to two of four batteries (Figure 4, Item 13).

8.

At end of two NEGATIVE battery cables (Figure 4, Item 17), raise plastic cap (Figure 4, Item 16) and tighten screw (Figure 4, Item 15) and nut (Figure 4, Item 14) on battery cable clamp. 1

2,3

5

4

6,7

8

9 1

10 17

11,12

16

Figure 4.

14,15

Battery Cables Replacement.

0129-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00094)

8

13

M0269JCH

TM 10-3930-675-23-1

0129

INSTALLATION - Continued 9.

Position battery compartment cover close enough to battery compartment (Figure 5, Item 1) to allow connection of solar charger connector (Figure 5, Item 3) and wire (Figure 5, Item 2) to vehicle connector (Figure 5, Item 4). 1

3

2

4

M0262JCH

Figure 5.

Solar Charger Connection.

10.

Install battery compartment cover (Figure 6, Item 3) on battery compartment (Figure 6, Item 1).

11.

Install each of four locking pins (Figure 6, Item 2) on studs of battery compartment (Figure 6, Item 1). 1

2

3

2

Figure 6.

M1723JCH

Battery Cables Replacement.

END OF TASK END OF WORK PACKAGE

0129-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00094)

TM 10-3930-675-23-1

0130

FIELD MAINTENANCE MASTER BATTERY SWITCH REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85) Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66) Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 86) Qty: 2

Equipment Condition Battery compartment door open (TM 10-3930-675-10) NEGATIVE battery cables disconnected (WP 0129)

WARNING

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 personnel injury or death. REMOVAL 1.

Remove handle (Figure 1, Item 2) from master battery switch (Figure 1, Item 1). 1 2

M0273JCH

Figure 1.

Master Battery Switch Replacement.

0130-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00095)

TM 10-3930-675-23-1

0130

REMOVAL - Continued

NOTE Note orientation of master battery switch prior to removal to ensure correct installation. 2.

Remove two locknuts (Figure 2, Item 2), washers (Figure 2, Item 3), screws (Figure 2, Item 4), and master battery switch (Figure 2, Item 5) from mounting plate (Figure 2, Item 1). Discard locknuts. 1

5

2,3,4

M0274JCH

Figure 2.

Master Battery Switch Replacement.

NOTE Tag cables prior to disconnection to ensure proper connection on installation. Also note switch terminal to which cables are connected. 3.

Pull back two rubber boots (Figure 3, Item 5) and remove two nuts (Figure 3, Item 3), washers (Figure 3, Item 4), and four cables (Figure 3, Item 1) from terminals of master battery switch (Figure 3, Item 2).

0130-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00095)

TM 10-3930-675-23-1

0130

REMOVAL - Continued 1

2

5

3,4 M0275JCH

Figure 3.

Master Battery Switch Replacement.

END OF TASK INSTALLATION 1.

Install four cables (Figure 3, Item 1), two washers (Figure 3, Item 4), and nuts (Figure 3, Item 3) on terminals of master battery switch (Figure 3, Item 2). Install two rubber boots (Figure 3, Item 5).

2.

Position master battery switch (Figure 2, Item 5) with shaft through opening in mounting plate (Figure 2, Item 1). Install two screws (Figure 2, Item 4), washers (Figure 2, Item 3), and new locknuts (Figure 2, Item 2).

3.

Install boot and handle (Figure 1, Item 2) on shaft of master battery switch (Figure 1, Item 1).

END OF TASK FOLLOW-ON MAINTENANCE 1.

Connect NEGATIVE battery cables (WP 0129).

2.

Close battery compartment door (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0130-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00095)

TM 10-3930-675-23-1

FIELD MAINTENANCE AMBIENT TEMPERATURE SENSOR REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

0131-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00098)

0131

TM 10-3930-675-23-1

0131

REMOVAL

NOTE If necessary, remove and discard tiedown straps. 1.

Disconnect connector (Figure 1, Item 6) of ambient temperature sensor (Figure 1, Item 5) from connector of cab wiring harness (Figure 1, Item 1).

2.

Remove screw (Figure 1, Item 2), clip (Figure 1, Item 3), and ambient temperature sensor (Figure 1, Item 5) from bracket (Figure 1, Item 4).

1

2,3,4

6

5

Figure 1. Ambient Temperature Sensor Removal. END OF TASK

0131-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00098)

M0202JCH

TM 10-3930-675-23-1

0131

INSTALLATION

NOTE If removed, use new tiedown straps during installation. 1.

Install ambient temperature sensor (Figure 2, Item 5) on bracket (Figure 2, Item 4) with clip (Figure 2, Item 3). Install screw (Figure 2, Item 2).

2.

Connect connector (Figure 2, Item 6) of ambient temperature sensor (Figure 2, Item 5) to connector of cab wiring harness (Figure 2, Item 1).

1

2,3,4

6

5

Figure 2. Ambient Temperature Sensor Installation. END OF TASK FOLLOW-ON MAINTENANCE Turn master battery switch to ON position (TM 10-3930-675-10). END OF TASK END OF WORK PACKAGE

0131-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00098)

M0203JCH

TM 10-3930-675-23-1

0132

FIELD MAINTENANCE FUEL LEVEL SENDING UNIT REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts O-Ring (Volume 2, WP 0278, Table 1, Item 172) Transmitter, Liquid Quantity (Volume 2, WP 0278, Table 1, Item 172)

REMOVAL 1.

Trace cable (Figure 1, Item 1) of fuel level sending unit (Figure 1, Item 3) back to point of connection, at rear corner of fuel tank (Figure 1, Item 2). 2

1

3

M0213JCH

Figure 1.

Fuel Level Sending Unit Connector Removal.

0132-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 10-3930-675-23-1

0132

REMOVAL - Continued 2.

Disconnect connector (Figure 3, Item 1) of fuel level sending unit (Figure 3, Item 4) from wiring harness connector (Figure 2, Item 2).

1

2

M0214JCH

Figure 2. Fuel Level Sending Unit Removal. 3.

Remove two clamps (Figure 3, Item 1) and release cable (Figure 3, Item 2) from top of fuel tank (Figure 3, Item 3).

4.

Rotate fuel level sending unit (Figure 3, Item 4) counterclockwise to remove from top of fuel tank (Figure 3, Item 3). Remove and discard O-ring.

END OF TASK

0132-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 10-3930-675-23-1

0132

INSTALLATION

NOTE Replacement fuel level sending unit comes with two new O-rings. During installation, ensure sending unit is positioned in pipe at bottom of fuel tank. 1.

Install fuel level sending unit (Figure 3, Item 4) with new O-ring in top of fuel tank (Figure 3, Item 3).

2.

Connect connector (Figure 2, Item 1) of fuel level sending unit (Figure 3, Item 4) to wiring harness connector (Figure 2, Item 2).

3.

Secure cable (Figure 3, Item 2) to frame and fuel tank (Figure 3, Item 3) with two clamps (Figure 3, Item 1). 1

3

2

4

M0215JCH

Figure 3.

Fuel Level Sending Unit Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn on master switch (TM 10-3930-675-10).

2.

Check for proper operation of fuel sending unit (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0132-3/4 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00099)

TM 10-3930-675-23-1

0133

FIELD MAINTENANCE BACKUP ALARM REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10)

Materials/Parts Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 80) Qty: 2 Strap, Tiedown Electrical Components (Volume 2, WP 0276, Table 1, Item 63)

REMOVAL

NOTE Remove and discard tiedown straps as necessary. 1.

Disconnect connector (Figure 1, Item 2) of backup alarm (Figure 1, Item 1) from connector (Figure 1, Item 3) of wiring harness.

2.

Remove two locknuts (Figure 1, Item 4), four washers (Figure 1, Item 5), two screws (Figure 1, Item 6), and backup alarm (Figure 1, Item 1) from right rear light bracket (Figure 1, Item 7). Discard locknuts. 3

2

1

4,5,6 7

M0255JCH

Figure 1.

Backup Alarm Removal.

END OF TASK

0133-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00100)

TM 10-3930-675-23-1

0133

INSTALLATION 1.

Install backup alarm (Figure 2, Item 1) on right rear light bracket (Figure 2, Item 7) with two screws (Figure 2, Item 6), four washers (Figure 2, Item 5), and two new locknuts (Figure 2, Item 4).

2.

Connect connector (Figure 2, Item 2) of backup alarm (Figure 2, Item 1) to connector (Figure 2, Item 3) of wiring harness. 3

2

1

4,5,6 7

M0256JCH

Figure 2.

Backup Alarm Installation.

END OF TASK FOLLOW-ON MAINTENANCE 1.

Turn master battery switch to ON position (TM 10-3930-675-10).

2.

Check operation of backup alarm (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0133-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00100)

TM 10-3930-675-23-1

0134

FIELD MAINTENANCE SLAVE STARTING RECEPTACLE REPLACEMENT

INITIAL SETUP: Tools and Special Tools Tool Kit, General Mechanics (Volume 2, WP 0277, Table 1, Item 85)

Materials/Parts (cont.) Nut, Self-Locking, Clinch (Volume 2, WP 0278, Table 1, Item 86) Qty: 8 Nut, Self-Locking, Hexagon (Volume 2, WP 0278, Table 1, Item 88) Qty: 4

Materials/Parts Tag, Marker (Volume 2, WP 0276, Table 1, Item 66)

Equipment Condition Master battery switch in OFF position (TM 10-3930-675-10) NEGATIVE battery cables disconnected (WP 0129)

RIGHT SLAVE STARTING RECEPTACLE REMOVAL 1.

Remove cap (Figure 1, Item 1) from slave starting receptacle (Figure 1, Item 2).

2.

Remove four locknuts (Figure 1, Item 3), eight washers (Figure 1, Item 4), four screws (Figure 1, Item 5), and bracket (Figure 1, Item 6) from vehicle. Pull bracket downward to access rear of slave starting receptacle (Figure 1, Item 2). Discard locknuts. 1,2

3,4,5

6

M0276JCH

Figure 1. Right Slave Starting Receptacle Replacement.

0134-1

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

TM 10-3930-675-23-1

0134

RIGHT SLAVE STARTING RECEPTACLE REMOVAL - Continued 3.

Remove four locknuts (Figure 2, Item 1), eight washers (Figure 2, Item 2), four screws (Figure 2, Item 3), slave starting receptacle (Figure 2, Item 8), and cord of cap (Figure 2, Item 7) from bracket (Figure 1, Item 6). Discard locknuts.

4.

Remove two screws (Figure 2, Item 4), lockwashers (Figure 2, Item 5), and two cables (Figure 2, Item 6) from rear of slave starting receptacle (Figure 2, Item 8). 1,2,3

6

4,5

8

7

M0277JCH

Figure 2. Right Slave Starting Receptacle Replacement. END OF TASK

0134-2

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

TM 10-3930-675-23-1

0134

RIGHT SLAVE STARTING RECEPTACLE INSTALLATION

NOTE New slave starting receptacle comes with new lockwashers. 1.

Position slave starting receptacle (Figure 2, Item 8) on bracket (Figure 1, Item 6) and install two cables (Figure 2, Item 6) on rear of slave starting receptacle with two new lockwashers (Figure 2, Item 5) and screws (Figure 2, Item 4).

2.

Install slave starting receptacle (Figure 2, Item 8) and cord of cap (Figure 2, Item 7) on bracket (Figure 1, Item 6) with four screws (Figure 2, Item 3), eight washers (Figure 2, Item 2), and four new locknuts (Figure 2, Item 1).

3.

Install bracket (Figure 3, Item 6) on vehicle with four screws (Figure 3, Item 5), eight washers (Figure 3, Item 4), and four new locknuts (Figure 3, Item 3).

4.

Install cap (Figure 3, Item 1) on slave starting receptacle (Figure 3, Item 2). 1,2

3,4,5

6

M0278JCH

Figure 3. Right Slave Starting Receptacle Replacement. END OF TASK

0134-3

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

TM 10-3930-675-23-1

0134

LEFT SLAVE STARTING RECEPTACLE REMOVAL 1.

Remove two screws (Figure 4, Item 8), lockwashers (Figure 4, Item 9), and cables (Figure 4, Item 1) from rear of slave starting receptacle (Figure 4, Item 2). Discard lockwashers.

2.

Remove cap (Figure 4, Item 3) from slave starting receptacle (Figure 4, Item 2).

3.

Remove four locknuts (Figure 4, Item 4), eight washers (Figure 4, Item 5), four screws (Figure 4, Item 6), slave starting receptacle (Figure 4, Item 2), and cord of cap (Figure 4, Item 3) from mounting plate (Figure 4, Item 7). Discard locknuts. 2

3

1

10

8,9

4,5,6

7

Figure 4. Left Slave Starting Receptacle Replacement. END OF TASK

0134-4

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

M0279JCH

TM 10-3930-675-23-1

0134

LEFT SLAVE STARTING RECEPTACLE INSTALLATION 1.

Install slave starting receptacle (Figure 5, Item 2) and cord of cap (Figure 5, Item 3) on mounting plate (Figure 5, Item 7) with four screws (Figure 5, Item 6), eight washers (Figure 5, Item 5), and four new locknuts (Figure 5, Item 4).

2.

Install cap (Figure 5, Item 3) on slave starting receptacle (Figure 5, Item 2).

3.

Connect two cables (Figure 5, Item 1) to rear of slave starting receptacle (Figure 5, Item 2) with two new lockwashers (Figure 5, Item 9) and screws (Figure 5, Item 8). 2

3

1

10

8,9

4,5,6

7

Figure 5. Left Slave Starting Receptacle Replacement. END OF TASK FOLLOW-ON MAINTENANCE 1.

Connect NEGATIVE battery cables (WP 0129).

2.

Close battery compartment door (TM 10-3930-675-10).

END OF TASK END OF WORK PACKAGE

0134-5/6 blank

03/15/2011 Rel(1.8) root(maintwp) wpno(M00101)

M0279JCH

TM 10-3930-675-23-1

INDEX Subject

WP Sequence No.-Page No.

A ALTERNATOR DRIVE BELT MAINTENANCE................................................................. ALTERNATOR REPLACEMENT...................................................................................... AMBIENT TEMPERATURE SENSOR REPLACEMENT.................................................. AUXILIARY PUMP TROUBLESHOOTING....................................................................... AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING.............................................

WP 0092-1 WP 0091-1 WP 0131-1 WP 0036-1 WP 0031-1

B BACKUP ALARM REPLACEMENT.................................................................................. BACKUP LIGHT AND WORK LIGHT MAINTENANCE.................................................... BATTERY CABLES REPLACEMENT.............................................................................. BATTERY MAINTENANCE.............................................................................................. BLACKOUT LIGHT MAINTENANCE................................................................................ BOOM ANGLE SENSOR REPLACEMENT...................................................................... BOOM EXTENSION SENSOR REPLACEMENT............................................................. BOOM IN/OUT TROUBLESHOOTING............................................................................. BOOM LIFTING/LOWERING TROUBLESHOOTING....................................................... BOOM WIRING HARNESSES REPLACEMENT.............................................................. BRAKE SYSTEM TROUBLESHOOTING.........................................................................

WP 0133-1 WP 0110-1 WP 0129-1 WP 0128-1 WP 0111-1 WP 0121-1 WP 0122-1 WP 0040-1 WP 0039-1 WP 0107-1 WP 0030-1

C CAB INTERIOR LIGHT MAINTENANCE.......................................................................... CAB POSITION PROXIMITY SWITCHES REPLACEMENT............................................ CIRCUIT BREAKERS AND RELAYS REPLACEMENT................................................... COOLANT FILTER AND FILTER HEAD REPLACEMENT.............................................. COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING................... COOLING SYSTEM EXPANSION TANK MAINTENANCE.............................................. COOLING SYSTEM HOSES REPLACEMENT................................................................ CYLINDER HEAD REPLACEMENT.................................................................................

WP 0114-1 WP 0105-1 WP 0103-1 WP 0090-1 WP 0009-1 WP 0082-1 WP 0083-1 WP 0052-1

D DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE............................ DRAINING AND FILLING RADIATOR ASSEMBLY.........................................................

WP 0112-1 WP 0080-1

E ECS DISPLAY SCREEN REPLACEMENT....................................................................... ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING............................................ ELECTRIC HORN REPLACEMENT................................................................................. ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING......... ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING...... ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT.............................................. ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT................................................ ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT............... ENGINE AIR CLEANER MAINTENANCE........................................................................ ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT........................................ ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING...................................................................................................... ENGINE ASSEMBLY REPLACEMENT............................................................................ ENGINE BATTERY VOLTAGE CIRCUITS TROUBLESHOOTING..................................

Index-1

03/15/2011 Rel(1.8) root(aindx) wpno(Paper_Index)

WP 0096-1 WP 0013-1 WP 0127-1 WP 0012-1 WP 0015-1 WP 0100-1 WP 0101-1 WP 0102-1 WP 0071-1 WP 0072-1 WP 0021-1 WP 0050-1 WP 0024-1

TM 10-3930-675-23-1

Subject

WP Sequence No.-Page No.

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING............... ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT................................. ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING........................................ ENGINE FUEL PRESSURE SENSORS AND CIRCUITS TROUBLESHOOTING........... ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT.................................... ENGINE OIL AND OIL FILTER REPLACEMENT............................................................. ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT.......................... ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING........................................... ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING................................... ENGINE PRESSURE SENSOR TROUBLESHOOTING.................................................. ENGINE SENSORS REPLACEMENT.............................................................................. ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING.............. ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING................................. EQUIPMENT DESCRIPTION AND DATA........................................................................ ERROR CODE REFERENCES........................................................................................ ETHER COLD START SYSTEM MAINTENANCE........................................................... EXHAUST MANIFOLD REPLACEMENT..........................................................................

WP 0017-1 WP 0099-1 WP 0007-1 WP 0023-1 WP 0051-1 WP 0059-1 WP 0061-1 WP 0019-1 WP 0018-1 WP 0022-1 WP 0118-1 WP 0020-1 WP 0008-1 WP 0002-1 WP 0004-1 WP 0077-1 WP 0063-1

F FLYWHEEL ASSEMBLY REPLACEMENT...................................................................... FORDING WATER LEVEL SENSOR REPLACEMENT................................................... FRONT GEAR COVER REPLACEMENT......................................................................... FRONT MAIN OIL SEAL REPLACEMENT....................................................................... FUEL FILTER/WATER SEPARATOR REPLACEMENT.................................................. FUEL HOSES, LINES, AND FITTINGS REPLACEMENT................................................ FUEL INJECTOR REPLACEMENT.................................................................................. FUEL LEVEL SENDING UNIT REPLACEMENT.............................................................. FUEL PUMP ASSEMBLY REPLACEMENT..................................................................... FUEL SOLENOID SHUTOFF VALVE REPLACEMENT................................................... FUEL SUPPLY AND RETURN HOSES REPLACEMENT................................................ FUEL TANK REPLACEMENT..........................................................................................

WP 0054-1 WP 0116-1 WP 0065-1 WP 0066-1 WP 0076-1 WP 0069-1 WP 0067-1 WP 0132-1 WP 0068-1 WP 0070-1 WP 0075-1 WP 0074-1

G GENERAL INFORMATION...............................................................................................

WP 0001-1

H HEADLIGHT MAINTENANCE.......................................................................................... HYDRAULIC COOLING FAN MAINTENANCE................................................................ HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT..................................... HYDRAULIC FILTER INDICATORS TROUBLESHOOTING............................................ HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING...................................... HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT............ HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING......................................................................................................

WP 0109-1 WP 0089-1 WP 0119-1 WP 0038-1 WP 0037-1 WP 0124-1 WP 0035-1

I INFRARED (IR) LIGHTS REPLACEMENT....................................................................... INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING...................................................................................................... INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT............................................................................................................... INTAKE MANIFOLD REPLACEMENT..............................................................................

Index-2

03/15/2011 Rel(1.8) root(aindx) wpno(Paper_Index)

WP 0115-1 WP 0016-1 WP 0094-1 WP 0064-1

TM 10-3930-675-23-1

Subject

WP Sequence No.-Page No.

INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING....

WP 0029-1

M MASTER BATTERY SWITCH REPLACEMENT.............................................................. MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING.............. MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING.......................... MUFFLER AND EXHAUST PIPE REPLACEMENT.........................................................

WP 0130-1 WP 0033-1 WP 0028-1 WP 0079-1

O OIL FILTER HEAD AND OIL COOLER MAINTENANCE................................................. OIL PAN REPLACEMENT................................................................................................ OIL SAMPLING VALVES AND HOSES REPLACEMENT................................................ OVERLOAD PROTECTION TROUBLESHOOTING........................................................

WP 0060-1 WP 0058-1 WP 0062-1 WP 0010-1

P PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)............................... PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Introduction...........

WP 0048-1 WP 0047-1

R RADIATOR ASSEMBLY MAINTENANCE........................................................................ RADIATOR FILL COVER PLATE REPLACEMENT......................................................... RADIATOR SPLASH SHIELD REPLACEMENT.............................................................. RADIATOR TOP GRATING REPLACEMENT.................................................................. REAR MAIN OIL SEAL REPLACEMENT......................................................................... ROCKER ARM ASSEMBLY MAINTENANCE.................................................................. ROCKER ARM COVER AND GASKET REPLACEMENT................................................

WP 0081-1 WP 0086-1 WP 0084-1 WP 0085-1 WP 0055-1 WP 0056-1 WP 0057-1

S SEAT WARNING BUZZER REPLACEMENT................................................................... SERVICE UPON RECEIPT.............................................................................................. SLAVE STARTING RECEPTACLE REPLACEMENT...................................................... SOLAR CHARGER REPLACEMENT (IF EQUIPPED)..................................................... STARTER MOTOR REPLACEMENT............................................................................... STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING...................................................................................................... STEERING SENSOR TROUBLESHOOTING.................................................................. STEERING SYSTEM WHEEL SENSOR REPLACEMENT.............................................. STEERING VALVE CIRCUIT TROUBLESHOOTING......................................................

WP 0126-1 WP 0049-1 WP 0134-1 WP 0106-1 WP 0093-1 WP 0014-1 WP 0034-1 WP 0125-1 WP 0032-1

T THEORY OF OPERATION............................................................................................... THERMOSTAT REPLACEMENT..................................................................................... THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT.............. TOPHANDLER ANGLE SENSOR REPLACEMENT........................................................ TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING...................................................................................................... TOPHANDLER JUNCTION BOX MAINTENANCE........................................................... TOPHANDLER LEVELING TROUBLESHOOTING.......................................................... TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT................. TOPHANDLER PROXIMITY SWITCHES REPLACEMENT............................................. TOPHANDLER SIDESHIFT TROUBLESHOOTING......................................................... TOPHANDLER SLEWING TROUBLESHOOTING...........................................................

Index-3

03/15/2011 Rel(1.8) root(aindx) wpno(Paper_Index)

WP 0003-1 WP 0087-1 WP 0078-1 WP 0123-1 WP 0011-1 WP 0097-1 WP 0043-1 WP 0098-1 WP 0104-1 WP 0044-1 WP 0041-1

TM 10-3930-675-23-1

Subject

WP Sequence No.-Page No.

TOPHANDLER SPREADER TROUBLESHOOTING........................................................ TOPHANDLER TILT TROUBLESHOOTING.................................................................... TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING......... TOPHANDLER WIRING HARNESSES REPLACEMENT................................................ TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT................. TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING.......................................... TRANSMISSION SENSORS REPLACEMENT................................................................ TRANSMISSION SPEED SENSORS TROUBLESHOOTING.......................................... TRANSMISSION TEMPERATURE TROUBLESHOOTING............................................. TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)....................................... TROUBLESHOOTING SYMPTOM INDEX....................................................................... TURBOCHARGER REPLACEMENT................................................................................ TWISTLOCK INDICATOR LIGHTS MAINTENANCE.......................................................

WP 0045-1 WP 0042-1 WP 0046-1 WP 0108-1 WP 0095-1 WP 0027-1 WP 0120-1 WP 0026-1 WP 0025-1 WP 0006-1 WP 0005-1 WP 0073-1 WP 0113-1

V VIBRATION DAMPER REPLACEMENT..........................................................................

WP 0053-1

W WATER PUMP REPLACEMENT...................................................................................... WHEEL TEMPERATURE SENSOR REPLACEMENT.....................................................

Index-4

03/15/2011 Rel(1.8) root(aindx) wpno(Paper_Index)

WP 0088-1 WP 0117-1

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE Date you filled out this form.

TO (Forward to proponent of publication or form) (Include ZIP Code)

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command

Your mailing address

ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER

TM Number ITEM

PAGE

PARAGRAPH

LINE

FIGURE TABLE NO.

DATE

TITLE

Date of the TM

Title of the TM

RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)

0007-3

Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer.

0018-2

Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).

SAMPLE

TYPED NAME, GRADE OR TITLE

Your Name DA FORM 2028, FEB 74

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

Your Phone Number

SIGNATURE

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

Date you filled out

Your Address

this form

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER

DATE

Date of the TM

TM Number PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK NUMBER

TITLE

Title of the TM

TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED

RECOMMENDED ACTION

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

TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

Your Phone Number

Your Signature APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field Maintenance 01 October 2012 TM 10-3930-675-23-1 Manual PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field 01 October 2012 TM 10-3930-675-23-1 Maintenance Manual PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

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

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field Maintenance 01 October 2012 TM 10-3930-675-23-1 Manual ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field 01 October 2012 TM 10-3930-675-23-1 Maintenance Manual PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III – REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field Maintenance 01 October 2012 TM 10-3930-675-23-1 Manual ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field 01 October 2012 TM 10-3930-675-23-1 Maintenance Manual PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

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

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is OAASA

TO (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

FROM (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field Maintenance 01 October 2012 TM 10-3930-675-23-1 Manual ITEM

PAGE

PARAGRAPH

TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74

LINE

FIGURE TABLE NO.

RECOMMENDED CHANGES AND REASON

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication)

FROM (Activity and location) (Include ZIP Code)

DATE

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE PUBLICATION/FORM NUMBER DATE Rough Terrain Container Handler (RTCH) Field 01 October 2012 TM 10-3930-675-23-1 Maintenance Manual PAGE NO.

COLM NO.

LINE NO.

NATIONAL STOCK NUMBER

REFERENCE FIGURE ITEM NO. NO. NO.

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

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

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

By Order of the Secretary of the Army:

RAYMOND T. ODIERNO General, United States Army Chief of Staff

Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 1224104

By Order of the Marine Corps: MARK T. BRINKMAN Program Manager, Infantry Weapons (PMM-132) Marine Corps Systems Command

MICHAEL W. HAGEE. Commandant of the Marine Corps

Distribution: To be distributed in accordance with the initial distribution number (IDN) 391061 requirements for TM 10-3930-675-23-1.

MARINE CORPS PCN: 184 110783 00

THE METRIC SYSTEM AND EQUIVALENTS Square Measure

Linear Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles Inches 1 Kilometer = 1000 Meters = 0.621 Miles Cubic Measure Weights 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature 5/9 (∞F - 32) = ∞C 212∞Fahrenheit is equivalent to 100∞Celsius 90∞Fahrenheit is equivalent to 32.2∞Celsius 32∞Fahrenheit is equivalent to 0∞Celsius 9/5 ∞C +32 = ∞F

APPROXIMATE CONVERSION FACTORS To Change

To

Multiply By

To Change

To

Multiply By

Inches

Centimeters

2.540

Centimeters

Inches

0.394

Feet

Meters

0.305

Meters

Feet

3.280

Yards

Meters

0.914

Meters

Yards

1.094

Miles

Kilometers

1.609

Kilometers

Miles

0.621

Sq Inches

Sq Centimeters

6.451

Sq Centimeters

Sq Inches

0.155

Sq Feet

Sq Meters

0.093

Sq Meters

Sq Feet

10.764

Sq Yards

Sq Meters

0.836

Sq Meters

Sq Yards

1.196

Sq Miles

Sq Kilometers

2.590

Sq Kilometers

Sq Miles

0.386

Acres

Sq Hectometers

0.405

Sq Hectometers

Acres

2.471

Cubic Feet

Cubic Meters

0.028

Cubic Meters

Cubic Feet

35.315

Cubic Yards

Cubic Meters

0.765

Cubic Meters

Cubic Yards

1.308

Fluid Ounces

Milliliters

29.573

Milliliters

Fluid Ounces

0.034

Pints

Liters

0.473

Liters

Pints

2.113

Quarts

Liters

0.946

Liters

Quarts

1.057

Gallons

Liters

3.785

Liters

Gallons

0.264

Ounces

Grams

28.349

Grams

Ounces

0.035

Pounds

Kilograms

0.454

Kilograms

Pounds

2.205

Short Tons

Metric Tons

0.907

Metric Tons

Short Tons

1.102

Pound-Feet

Newton-Meters

1.356

Newton-Meters

Pound-Feet

0.738

Pounds per Sq Inch

Kilopascals

6.895

Kilopascals

Pounds per Sq Inch

0.145

Miles per Gallon

Kilometers per Liter

0.425

Kilometers per Liter

Miles per Gallon

2.354

Miles per Hour

Kilometers per Hour 1.609

Kilometers per Hour Miles per Hour

0.621

PIN: 087211-000