TM 5-2410-241-23-2

TECHNICAL MANUAL FIELD MAINTENANCE MANUAL

FOR

D7R SERIES II DOZER TYPE I WITH WINCH (NSN 2410-01-565-2605) D7R SERIES II DOZER TYPE II WITH RIPPER (NSN 2410-01-565-2603)

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

HEADQUARTERS, DEPARTMENT OF THE ARMY 29 FEBRUARY 2012

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Warning Summary

h TM 5-2410-241-23-2

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. In the event of injury, seek medical attention in accordance with FM 4-25.11. Also included in the summary are explanations of safety and hazardous materials icons used within the technical manual. EXPLANATION OF SAFETY WARNING ICONS EAR PROTECTION - headphones over ears show that noise level will harm ears.
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ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

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

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

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

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

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

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

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

PINCH POINT - Object crushing human figure shows that areas between vehicles or parts present a danger to life or limb.

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EXPLANATION OF SAFETY WARNING ICONS - CONTINUED SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a danger from falling.

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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.

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

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

HIGH-PRESSURE FLUID - high-pressure fluid spraying human hand 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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FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

GENERAL SAFETY WARNINGS DESCRIPTION
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WARNING

COMPRESSED AIR Compressed air for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to personnel.

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WARNING

HEARING PROTECTION Hearing protection is required when standing within 26 ft (8 m) of the machine while it is operating. Failure to wear hearing protection may result in hearing loss.

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WARNING

HOT COMPONENTS Components with metal parts can cause severe burns at operating temperature. Allow components to cool before performing maintenance on them. Wear insulated gloves, long sleeves, and eye protection when working with heated parts. MACHINE OPERATION Use of seat belt while operating machine is mandatory. Failure to follow this warning may result in injury or death to personnel in the event of an accident or machine overturn.

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GENERAL SAFETY WARNINGS DESCRIPTION - CONTINUED

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WARNING

PRESSURIZED COOLING SYSTEM DO NOT service cooling system unless engine has cooled. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. 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 cause injury to personnel.

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WARNING

SLAVE STARTING ENGINE When slave starting the engine: 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. DO NOT allow disabled machine and booster vehicle to come in contact with each other at any time during slave starting.

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Failure to follow these warnings may result in injury or death to personnel.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION

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WARNING

BATTERIES To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electric shock, 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 injury to personnel. EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately. SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 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. CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION - CONTINUED

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WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!!!! Carbon monoxide is a colorless, odorless, deadly poison, which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can result from severe exposure. Carbon monoxide occurs in the 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 the engine is operated. DO NOT operate engine in enclosed areas. DO NOT idle engine without adequate ventilation. BE ALERT for exhaust poisoning symptoms. They are: Headache Dizziness Sleepiness Loss of muscular control If you see another person with exhaust poisoning symptoms: Remove person from area. Expose to fresh air. Keep person warm. DO NOT permit physical exercise. Administer Cardiopulmonary Resuscitation (CPR) if necessary. Notify a medic. BE AWARE. The field protective mask for Chemical, Biological, Radiological, and Nuclear (CBRN) protection will not protect you from carbon monoxide poisoning.

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The Best Defense Against Carbon Monoxide Poisoning is Good Ventilation!

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION - CONTINUED

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WARNING

CARC PAINT Take the following precautions before grinding, cutting, or welding any equipment that has been CARC-coated: Wear protective equipment (e.g., goggles, gloves, apron) when grinding or sanding CARC-coated equipment. DO NOT leave any skin exposed. Use high-efficiency air-purifying respirators when grinding or sanding CARCcoated equipment. Never weld or cut CARC-coated equipment; grind or sand off CARC paint completely before welding. CARC paint contains isocyanate (HDI), which is highly irritating to the skin and respiratory system. High concentrations of HDI can produce itching and reddening of the skin, a burning sensation in the throat and nose, and watering of the eyes. In extreme concentrations, HDI can cause coughing, shortness of breath, pain during respiration, increased sputum production, and chest tightness.

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Failure to follow these warnings may result in injury or death to personnel.

WARNING

HAZARDOUS WASTE DISPOSAL When servicing this equipment, performing maintenance, or disposing of materials such as engine/ hydraulic oils, coolant, and fuel, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills. Failure to follow these warnings may result in injury to personnel.

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WARNING

HYDRAULIC SYSTEM PRESSURE DO NOT disconnect or remove any hydraulic system line or fitting unless the engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury or death to personnel. Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid from penetrating the skin. Failure to do so may cause injury or death to personnel.

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HAZARDOUS MATERIALS WARNINGS DESCRIPTION - CONTINUED

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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.

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WARNING

SOLVENT CLEANING COMPOUND Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel.

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WARNING
WORK SAFETY Improper cleaning methods and use of unauthorized cleaning liquids or solvents can injure personnel and damage equipment. To prevent this, refer to your units authorized cleaning and solvents list for further instructions. Solvents can burn easily, give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death to personnel, keep away from open fire and use in a well-ventilated area. If solvent gets on skin or clothing, wash immediately with soap and water.
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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: Zero in the Change No. column indicates an original page or work package. Date of issue for the original manual is: Original.... 29 February 2012 TOTAL NUMBER OF VOLUMES IS THREE. TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IN VOLUME II IS 62 AND TOTAL NUMBER OF WORK PACKAGES IS 140, CONSISTING OF THE FOLLOWING: Page/WP No. Change No. Page/WP No. Change No.

Volume II
Front Cover (2 pgs) . . . . . . . . . . . . . . . . 0 Warning Summary (8 pgs) . . . . . . . . . . . 0 TOC (32 pgs) . . . . . . . . . . . . . . . . . . . . 0 WP 0057 (66 pgs) . . . . . . . . . . . . . . . . . 0 WP 0058 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0059 (64 pgs) . . . . . . . . . . . . . . . . . 0 WP 0060 (20 pgs) . . . . . . . . . . . . . . . . . 0 WP 0061 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0062 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0063 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0064 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0065 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0066 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0067 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0068 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0069 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0070 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0071 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0072 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0073 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0074 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0075 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0076 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0077 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0078 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0079 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0080 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0081 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0082 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0083 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0084 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0085 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0086 (6 pgs) . . . . . . . . . . . . . . . . . . 0 A

WP 0087 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0088 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0089 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0090 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0091 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0092 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0093 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0094 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0095 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0096 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0097 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0098 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0099 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0100 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0101 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0102 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0103 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0104 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0105 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0106 (20 pgs) . . . . . . . . . . . . . . . . . 0 WP 0107 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0108 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0109 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0110 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0111 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0112 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0113 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0114 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0115 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0116 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0117 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0118 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0119 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0120 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0121 (4 pgs) . . . . . . . . . . . . . . . . . . 0

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Page/WP No.

Change No.

Page/WP No.

Change No.

WP 0122 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0123 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0124 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0125 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0126 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0127 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0128 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0129 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0130 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0131 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0132 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0133 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0134 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0135 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0136 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0137 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0138 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0139 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0140 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0141 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0142 (20 pgs) . . . . . . . . . . . . . . . . . 0 WP 0143 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0144 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0145 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0146 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0147 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0148 (28 pgs) . . . . . . . . . . . . . . . . . 0 WP 0149 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0150 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0151 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0152 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0153 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0154 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0155 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0156 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0157 (18 pgs) . . . . . . . . . . . . . . . . . 0 WP 0158 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0159 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0160 (14 pgs) . . . . . . . . . . . . . . . . . 0

WP 0161 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0162 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0163 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0164 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0165 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0166 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0167 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0168 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0169 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0170 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0171 (26 pgs) . . . . . . . . . . . . . . . . . 0 WP 0172 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0173 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0174 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0175 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0176 (18 pgs) . . . . . . . . . . . . . . . . . 0 WP 0177 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0178 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0179 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0180 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0181 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0182 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0183 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0184 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0185 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0186 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0187 (38 pgs) . . . . . . . . . . . . . . . . . 0 WP 0188 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0189 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0190 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0191 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0192 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0193 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0194 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0195 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0196 (8 pgs) . . . . . . . . . . . . . . . . . . 0 Index (6 pgs) . . . . . . . . . . . . . . . . . . . . . 0 Back Cover (2 pgs) . . . . . . . . . . . . . . . . 0

TM 5-2410-241-23-2
TECHNICAL MANUAL TM 5-2410-241-23-2 HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 29 February 2012

FIELD MAINTENANCE MANUAL FOR D7R Series II Dozer TYPE I WITH WINCH (NSN 2410-01-565-2605) D7R Series II Dozer TYPE II WITH RIPPER (NSN 2410-01-565-2603)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

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TABLE OF CONTENTS
WP Sequence No. Page No.
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How To Use This Technical Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxii Engine Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0057 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-2 Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-3 Torque Converter Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-4 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-5 Pump Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-6 Pump Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-7 Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-8 A/C Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-9 Starter Motor Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . 0057-10 Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-11 A/C Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-13 Platform Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-14 Hose Bundle Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-15 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-16 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-17 Engine Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-18 Front Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-19 Rear Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-20 Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-21 Secondary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-22 Starter Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-23 ECM Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-24 Receiver/Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-25 Harness and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-26 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-27 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-28 Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . 0057-29 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . 0057-30 Engine ECM, Spacers, and Isolators. . . . . . . . . . . . . . . . . . . . . . . 0057-31 Oil Dipstick Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-32 Engine Stand Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-33 Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-34 Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-35 Engine Stand Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-36 Oil Dipstick Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-37 Engine ECM, Spacers, and Isolators. . . . . . . . . . . . . . . . . . . . . . . 0057-38 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . 0057-39 Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . 0057-40 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-41 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-42 Harness and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-43 Receiver/Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-43 ECM Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057-44

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WP Sequence No. Page No. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18.
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Starter Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-45 Secondary Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-46 Engine Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-47 Engine Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-48 Rear Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-49 Front Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-50 Engine Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-51 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-51 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-52 Hose Bundle Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-53 Platform Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-54 A/C Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-55 Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-56 Starter Motor Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . .0057-57 A/C Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-58 Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-59 Pump Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-59 Pump Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-60 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-61 Torque Converter Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-62 Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-63 Torque Converter Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0057-64 Rear Engine Lifting Bracket Attachments. . . . . . . . . . . . . . . . . . . . .0058-2 Rear Engine Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0058-3 Rear Engine Lifting Bracket Attachments. . . . . . . . . . . . . . . . . . . . .0058-4 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-2 Line O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-3 Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-5 Alternator Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-6 A/C Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-7 Rear Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-8 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-9 Valve and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-10 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-11 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-12 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-13 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-14 Upper Compressor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-15 Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-16 Filter Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-17 Filter and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-18 Heater Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-19 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0059-20 iii

Engine Lift Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0058

Engine Replacement Transfer of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0059

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WP Sequence No. Page No. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63.
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Muffler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-21 Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-22 Pipe to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-23 Pipe to Air Cleaner Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-24 Alternator Ground Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-25 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-26 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-27 Air Cleaner Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-28 NATO Slave and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-29 Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-30 Coolant Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-31 Turbo Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-32 Transmission Cooler Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . 0059-33 Drain Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-34 Transmission Cooler Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . 0059-35 Turbo Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-36 Coolant Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-36 Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-37 NATO Slave and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-37 Air Cleaner Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-38 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-39 Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-40 Alternator Ground Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-41 Pipe to Air Cleaner Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-42 Pipe to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-43 Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-44 Muffler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-45 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-46 Heater Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-47 Filter and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-48 Filter Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-49 Fuel Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-50 Upper Compressor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-51 Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-52 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-53 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-54 Oil Cooler Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-55 Valve and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-56 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-57 Rear Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-58 A/C Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-59 Alternator Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-60 Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-61 Line O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-62 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059-63

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WP Sequence No. Page No.
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Ether Bottle, Valve, Bracket, and Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0060 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 1. Figure 2. Ether Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-2 Ether Bottle Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-3 Ether Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-4 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-5 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-6 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-7 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-8 Ether Valve Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-9 Ether Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-10 Ether Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-11 Ether Valve Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-12 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-13 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-14 Ether Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-15 Ether Bottle and Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-16 Ether Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-17 Ether Bottle Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-18 Ether Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0060-19 Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-2 Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-2 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-3 Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-4 Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-5 Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0061-5 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-1 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-2 Turbocharger Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-2 Line Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-3 Oil Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-4 Oil Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-5 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-6 Oil Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-7 Oil Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-8 Line Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-9 Turbocharger Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-10 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-10 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0062-11 Air Inlet Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0063-2 Air Inlet Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0063-3

Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0061

Turbocharger Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0062

Air Inlet Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0063

Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0064

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WP Sequence No. Page No. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1.
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Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064-2 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-2 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-3 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-4 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065-4 Turbocharger Inlet Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 0066-2 Exhaust Manifold and Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067-2 Rear Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-1 Rear Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-2 Rear Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-2 Front Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-3 Front Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-3 Aftercooler Housing Upper Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-4 Aftercooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-4 Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-5 Lower Aftercooler Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-6 Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-7 Aftercooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-8 Aftercooler Housing Upper Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-8 Front Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-9 Front Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-9 Rear Water Tube Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-10 Rear Water Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-10 Rear Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068-11 Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. Fuel Injection Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069-7

Fuel Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0065

Turbocharger Inlet Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0066 Exhaust Manifold Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0067 Aftercooler Housing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0068

Fuel Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0069

Fuel Manifold Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0070 Fuel Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070-2 Fuel Manifold O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070-3 Fuel Manifold O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070-4 Fuel Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070-5 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071-2

Primary Fuel Filter, Base and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0071

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WP Sequence No. Page No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.
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Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-3 Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-4 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-5 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-6 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-7 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-8 Prime Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-9 Prime Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-10 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-11 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-12 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-13 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-13 Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-14 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0071-15 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-2 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-3 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-4 Engine Enclosure Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-5 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-6 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-7 Filter and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-9 Filter Drain Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-10 Engine Enclosure Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-11 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-11 Filter Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-12 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0072-13 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-2 Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-3 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-4 Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-5 Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0073-6 Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0074-1 Temperature Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0074-2 Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0074-3 Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0075-2 Coolant Temperature Sensor O-ring. . . . . . . . . . . . . . . . . . . . . . . . .0075-3 Cooling Manifold Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0075-3 Cooling Manifold Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0075-4 Coolant Temperature Sensor O-ring. . . . . . . . . . . . . . . . . . . . . . . . .0075-4 Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0075-5

Secondary Fuel Filter, Base and Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0072

Fuel Transfer Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0073

Temperature Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0074

Cooling Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0075

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WP Sequence No. Page No.
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Water Pump Elbow Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0076 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Hoses to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-1 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-2 Fittings to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-3 Fittings to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-4 Water Pump Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-5 Hoses to Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076-6 Oil Cooler Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-2 Water Pump Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-3 Bypass Tube Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-4 Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-5 Bypass Tube Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-6 Water Pump Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-7 Oil Cooler Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077-8 Aftercooler Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078-2 Crankshaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-1 Seal O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-2 Seal O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-2 Crankshaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079-3 Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080-2 Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080-3 Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080-4 Front Housing Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081-2 Oil Filter Engine Base Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-1 Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-2 Adapters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-3 Oil Filter Engine Base Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082-4 Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-2 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-3 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-3 Filter Base Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-4 Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-5 Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-6 Filter Base Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-7 Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-8 Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083-9

Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0077

Aftercooler Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0078 Front Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0079

Crankshaft Damper, Pulley, and Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0080

Front Housing Cover Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0081 Oil Filter Engine Base Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0082

Engine Oil Filter, Base and Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0083

viii

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WP Sequence No. Page No. Figure 10. Figure 11. Figure 12. Figure 13. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 1. Figure 2. Figure 3. Figure 4.
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Filter Base Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-10 Guard Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-11 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-11 Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0083-12 Hose to Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-2 Oil Cooler Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-3 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-4 Oil Cooler Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-4 Oil Cooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-5 Cooler Core Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-6 Elbow O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-6 Cooler Core Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-7 Oil Cooler Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-8 Oil Cooler Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-9 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-9 Oil Cooler Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-10 Hose to Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0084-11 Cover and Retaining Hardware on Left Side of Flywheel Housing. .0085-1 O-ring on Left Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . .0085-2 Cover and Retaining Hardware on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-2 O-ring on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . .0085-3 Right Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-4 Left Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-5 Crankshaft Drive Gear and Idler Gears. . . . . . . . . . . . . . . . . . . . . .0085-6 Idler Gear and Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-7 Idler Gear and Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-8 Crankshaft Drive Gear and Idler Gears. . . . . . . . . . . . . . . . . . . . . .0085-9 Bearing Installation on Flywheel Housing. . . . . . . . . . . . . . . . . . . .0085-10 Bearing Installation on Hydraulic Pump Adapter. . . . . . . . . . . . . .0085-11 Left Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-12 Right Pump Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0085-13 O-ring on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . .0085-14 Cover and Retaining Hardware on Right Side of Flywheel Housing. 0085-14 O-ring on Left Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . .0085-15 Cover and Retaining Hardware on Left Side of Flywheel Housing. 0085-15 Oil Fill Tube and Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . .0086-2 Oil Fill Tube O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0086-3 Oil Tube O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0086-4 Oil Fill Tube and Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . .0086-5

Engine Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0084

Rear Gear Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0085

Oil Filler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0086

Dipstick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0087 ix

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WP Sequence No. Page No. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 1. Figure 2. Figure 3. Figure 1. Figure 1. Figure 2. Figure 3. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.
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Oil Level Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087-2 Oil Level Dipstick Tube and O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . 0087-3 Oil Level Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087-4 Oil Pump Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-1 Oil Pump and Elbow - On Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-2 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-3 Oil Pump and Elbow - Off Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-3 Oil Pump Elbow and Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-4 Oil Pump and Elbow - Off Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-5 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-6 Oil Pump and Elbow - On Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-7 Oil Pump Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088-8 Hose and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-2 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-3 Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-4 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-6 Hose and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089-7 Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090-1 Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090-2 Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091-1 Engine Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091-2 Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091-3 Air Inlet Manifold Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 0092-2 Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093-1 Camshaft Timing Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093-2 Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093-3 Engine Crankshaft Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 0094-2 Hub Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-1 Hub Upper Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-2 Hub Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-3 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-4 Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-5 Fan Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-6 Pulley and Shaft Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-7 Fan Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095-8 x

Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0088

Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0089

Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0090

Engine Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0091

Air Inlet Manifold Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0092 Camshaft Timing Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093

Engine Crankshaft Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0094 Fan Hub Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095

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WP Sequence No. Page No. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 1. Figure 2.
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Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-9 Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-10 Hub Pulley Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-11 Hub Upper Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-12 Hub Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0095-13 A/C Compressor V-Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . .0096-2 A/C Compressor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-3 A/C Compressor V-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-4 A/C Compressor V-Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-5 A/C Compressor Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . .0096-6 Compressor Adjusting Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-2 Compressor Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-3 A/C Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-4 A/C Compressor Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-5 Compressor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-6 Upper Compressor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-7 Compressor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-8 A/C Compressor Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-9 A/C Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-10 Compressor Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-11 Compressor Adjusting Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-12 Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0097-13 Alternator V-Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-2 Alternator Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-3 Alternator V-Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-4 Alternator Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098-5 Alternator, Wiring, and Retaining Hardware. . . . . . . . . . . . . . . . . . .0099-2 Alternator and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0099-3 Alternator, Brackets, and Retaining Hardware. . . . . . . . . . . . . . . . .0099-4 Alternator, Bracket, and Retaining Hardware. . . . . . . . . . . . . . . . . .0099-5 Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0099-5 Alternator and Bracket Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . .0099-6 Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0099-7 Alternator, Bracket, and Retaining Hardware. . . . . . . . . . . . . . . . . .0099-7 Alternator, Brackets, and Retaining Hardware. . . . . . . . . . . . . . . . .0099-8 Alternator and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0099-9 Alternator, Wiring, and Retaining Hardware. . . . . . . . . . . . . . . . . .0099-10 Flywheel and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . .0100-2 Flywheel, Guide Studs, and Retaining Hardware. . . . . . . . . . . . . . .0100-3 xi

V-Belt (A/C Compressor) Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0096

A/C Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0097

V-Belt Set (Alternator) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0098

Alternator and Brackets Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0099

Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0100

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WP Sequence No. Page No. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.
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Flywheel, Guide Studs, and Retaining Hardware. . . . . . . . . . . . . . . 0100-5 Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . 0101-2 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . . 0101-3 Engine ECM, Spacers, and Isolators. . . . . . . . . . . . . . . . . . . . . . . . 0101-4 Engine ECM, Ground Strap, and Retaining Hardware. . . . . . . . . . . 0101-5 Engine ECM and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . 0101-6 Crankshaft Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-1 Rear Crankshaft Seal, O-ring Seal, and Retaining Hardware. . . . . 0102-2 Rear Crankshaft Seal, O-ring Seal, Plastic Sleeve, and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-3 Bolt Tightening Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-4 Crankshaft Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102-4 Bracket and Retaining Hardware on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-2 Flywheel Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-3 Flywheel Housing and Retaining Hardware. . . . . . . . . . . . . . . . . . . 0103-5 Flywheel Housing and Retaining Hardware. . . . . . . . . . . . . . . . . . . 0103-7 Flywheel Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-8 Bracket and Retaining Hardware on Right Side of Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103-8 Flange and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104-1 Flange Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104-2 Flange and Retaining Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104-3 Crankshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-2 Camshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-3 Coolant Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-4 Fuel Temperature Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-5 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-6 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-7 ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-8 ECM Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-9 ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-10 Oil Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-11 Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-11 Fuel Temperature Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-12 Coolant Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-13 Camshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-14 Crankshaft Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105-15

Engine ECM Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0101

Rear Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0102

Flywheel Housing Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0103

Flange (Flywheel Housing) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0104 Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15.

Harness Assembly (ECM) Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0105

Valve Mechanism Cover, Base and Injector Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0106 xii

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WP Sequence No. Page No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14.
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Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-2 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-3 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-4 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-5 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-5 Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-6 Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-7 Valve Cover Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-8 Injector Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-9 Injector Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-10 Valve Cover Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-11 Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-12 Atmospheric Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-13 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-14 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-14 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-15 Valve Cover Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-16 Crankcase Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-17 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-18 Valve Cover Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0106-19 Rocker Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0107-2 Valve Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0107-2 Rocker Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0107-5 Valve Lash Adjustment No.1 TDC. . . . . . . . . . . . . . . . . . . . . . . . . .0107-7 Cylinder Head Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0108-2 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0108-3 Cylinder Head Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0108-4 Cylinder Head Bolts Torque Sequence. . . . . . . . . . . . . . . . . . . . . . .0108-5 Radiator Guard Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-3 Center Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-4 Center Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . .0109-4 Center Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-5 Center Radiator Core Bracket and Isolator. . . . . . . . . . . . . . . . . . . .0109-5 Outer Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-6 Outer Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . .0109-7 Outer Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-7 Outer Radiator Core Bracket and Isolator. . . . . . . . . . . . . . . . . . . . .0109-8 Outer Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-9 Outer Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . .0109-9 Outer Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-10 Outer Radiator Core Bracket and Isolator. . . . . . . . . . . . . . . . . . . .0109-11 Radiator Core Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0109-12 xiii

Rocker Arm Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0107

Cylinder Head Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0108

Radiator Core Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0109

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WP Sequence No. Page No.
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Figure 15. Radiator Core Lower Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-12 Figure 16. Radiator Core Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-13 Figure 17. Radiator Guard Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109-14 Lower Radiator Tank Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0110 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 1. Figure 2. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-2 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-3 Lower Radiator Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-4 Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-5 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-5 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-6 Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-7 Lower Radiator Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-8 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-9 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110-10 Air Cleaner Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-2 Air Filters Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-3 Air Cleaner Outlet Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-4 Air Cleaner Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-5 Air Cleaner Prescreener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-6 Air Cleaner Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-6 Air Cleaner Housing and Elements. . . . . . . . . . . . . . . . . . . . . . . . . . 0111-7 Air Cleaner Housing Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-8 Air Cleaner Housing and Elements. . . . . . . . . . . . . . . . . . . . . . . . . . 0111-9 Air Cleaner Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-10 Air Cleaner Prescreener. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-10 Air Cleaner Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-11 Air Cleaner Outlet Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-12 Air Filters Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-12 Air Cleaner Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111-13 Implement Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112-3 Implement Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112-5 Radiator Filler Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113-2 Coolant Drain Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113-3 Sight Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113-5 Oil Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114-2 Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114-3 Oil Filler and Dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114-4 Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115-1 Forcing Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115-2 xiv

Air Cleaner Assembly Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0111

Implement Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0112

Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0113

Engine Oil Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0114

Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0115

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WP Sequence No. Page No. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 1. Figure 1. Figure 2. Figure 3.
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O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-2 O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-3 Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0115-3 Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-1 Thrust Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-2 Outer Axle Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-3 Inner Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-3 Inner Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-4 Outer Axle Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-5 Thrust Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-5 Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0116-6 Main Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0117-1 U-Joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0117-2 Main Drive Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0117-3 Flange Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-3 Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-5 Threaded Fitting Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . .0118-7 Threaded Fitting Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . .0118-9 Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-11 Flange Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0118-12 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-2 Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-3 Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-4 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0119-5 Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-1 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-2 Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-2 Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-3 Couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-4 Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-4 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-5 Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0120-5 Transmission Mounting Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0121-2 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0122-2 Converter Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0122-3 Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0122-3

Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0116

Main Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0117

Powertrain Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0118

Powertrain Manifold Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0119

Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0120

Transmission Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0121 Torque Converter Output Speed Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0122

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WP Sequence No. Page No. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17.
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Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-4 Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-5 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122-6 Pressure Check Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-1 Torque Converter Output Relief Valve. . . . . . . . . . . . . . . . . . . . . . . 0123-2 Pressure Check Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-3 Test Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-4 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-5 Test Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123-6 Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0124-2 Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-1 Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-2 Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-3 Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-4 Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-5 Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125-6 Accumulator Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-1 Threaded Fitting Type Hydraulic Hose. . . . . . . . . . . . . . . . . . . . . . . 0126-2 Accumulator Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-3 Accumulator Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-4 Testing with Nitrogen Charging Kit. . . . . . . . . . . . . . . . . . . . . . . . . . 0126-5 Charging Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126-7 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-2 Adjuster Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-3 Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-3 Track Blocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-4 Track Separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-5 Track Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-6 Track Blocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-7 Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-8 Track Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-8 Track Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-9 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-9 Track Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-10 Loose Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-10 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-11 Adjuster Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-11 Track Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-12 Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127-12 xvi

Torque Converter Relief Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0123

Torque Converter Relief Valve Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0124 Equalizer Bar Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0125

Accumulator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0126

Track Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0127

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WP Sequence No. Page No.
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Figure 18. Track Tension Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-13 Figure 19. Adjuster Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0127-13 Track Shoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0128 Figure 1. Figure 1. Figure 1. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Track Shoe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0128-2 Track Shoe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0129-2 Trunnion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0130-2 Rear Strip Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0131-1 Front Strip Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0131-2 Rear Strip Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0131-3 Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-2 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-3 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-4 Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0132-5 Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-2 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-3 Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-4 Front and Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0133-5 Track Frame Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-2 Forcing Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-3 Front Idler and Adjuster Separation. . . . . . . . . . . . . . . . . . . . . . . . .0134-4 Front Idler and Adjuster Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .0134-5 Track Frame Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-6 Track Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-7 Track Adjuster Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-8 Track Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-9 Track Frame Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-10 Seals Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-11 Front Idler and Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-12 Guide Sealing Compound. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-13 Track Frame Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0134-13 Idler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0135-2 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0136-2 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0136-3 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0136-4 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0136-5 xvii Track Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0129 Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0130 Strip Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0131

Double Flange Track Roller Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0132

Single FLange Track Roller Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0133

Track Adjuster and Recoil Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0134

Idler Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0135 Final Drive Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0136

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WP Sequence No. Page No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.
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Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-5 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-6 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-7 Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-8 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-9 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-10 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-11 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136-12 Sprocket Segment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137-2 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-2 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-3 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-4 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-5 Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-5 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-6 Brake Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-7 Brake Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-8 Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-9 Final Drive Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-10 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-11 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-12 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-13 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138-14 Sliding Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-2 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-3 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-4 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-5 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-6 Brake Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-7 Housing O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-8 Brake Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-9 Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-10 Final Drive Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-11 Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-12 Cap and Sprocket Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139-13 Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140-2 Hydrostatic Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140-3 Forcing Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140-4 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140-5 Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140-6

Sprocket Segment Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0137 Brake and Planetary Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0138

Brake and Differential Drive Assembly Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0139

Hydrostatic Drive Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0140

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WP Sequence No. Page No. Figure 6. Figure 7. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 1. Figure 2. Figure 3. Figure 4.
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Hydrostatic Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-7 Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0140-8 Bell and Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-2 Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-3 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-3 Cab Lifting Device Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-4 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-5 O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-5 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-6 Pump O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-7 Pump O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-8 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-9 O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-10 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-10 Cab Lifting Device Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-11 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-11 Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-12 Bell and Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0141-13 Sliding Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-3 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-4 Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-5 Transmission Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-6 Transmission Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-7 Transmission Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-8 Transmission Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-9 Transmission Stand Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-10 Transmission Roller and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . .0142-11 Case O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-12 Case O-rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-13 Transmission Roller and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . .0142-13 Transmission Stand Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-14 Transmission Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-15 Transmission Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-16 Transmission Adapter Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-17 Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-18 Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-19 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0142-20 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0143-1 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0143-2 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0143-3 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0143-4 xix

Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0141

Transmission Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0142

Transmission Intermediate Speed Sensor One Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0143

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WP Sequence No. Page No. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19.
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Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-4 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143-5 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-1 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-2 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-3 Transmission Solenoid O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-4 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-5 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144-6 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145-1 Transmission Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145-3 Transmission Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . 0146-2 Control Valve Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-2 Control Valve Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-3 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-3 Secondary Brake Parking Valve and First Coil. . . . . . . . . . . . . . . . . 0147-4 Secondary Brake Parking Valve and First Coil. . . . . . . . . . . . . . . . . 0147-5 Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-6 Control Valve Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-6 Control Valve Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147-7 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-2 Transmission Cooler Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-3 Tube to Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . . . 0148-4 Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-4 Tube Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-5 Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-6 Outlet Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-7 Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-8 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-9 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-9 Cab Tool Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-10 Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-11 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-11 Torque Converter Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-12 Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-12 Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-13 Torque Converter and Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-14 Cab Tool Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-15 Torque Converter and Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . 0148-16 xx

Transmission Intermediate Speed Sensor Two Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0144

Transmission Clutch Solenoid Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0145

Transmission Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0146 Control Valve (Steering and Brake) Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0147

Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0148

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WP Sequence No. Page No. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 1. Figure 1. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6.
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Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-17 Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-18 Sensor Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-18 Torque Converter Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-19 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-19 Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-20 Cab Tool Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-21 Headliner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-21 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-22 Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-23 Outlet Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-23 Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-24 Tube Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-25 Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-26 Tube to Torque Converter Housing. . . . . . . . . . . . . . . . . . . . . . . .0148-26 Transmission Cooler Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-27 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0148-27 Final Drive Oil Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0149-2 Recoil Spring Compartment Oil Change. . . . . . . . . . . . . . . . . . . . . .0150-2 Transmission Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0151-2 Transmission Scavenge Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . .0151-3 Transmission System Oil Level Check. . . . . . . . . . . . . . . . . . . . . . .0151-4 Transmission Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0152-2 Transmission System Oil Level Check. . . . . . . . . . . . . . . . . . . . . . .0152-3 Transmission Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0153-2 Transmission Filter Base Isolators. . . . . . . . . . . . . . . . . . . . . . . . . .0153-3 Transmission Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . .0153-3 Transmission Filter Base Bypass Switch. . . . . . . . . . . . . . . . . . . . .0153-4 Transmission Filter Base Bypass Switch. . . . . . . . . . . . . . . . . . . . .0153-5 Transmission Filter Base Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . .0153-5 Transmission Filter Base Isolators. . . . . . . . . . . . . . . . . . . . . . . . . .0153-6 Transmission Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0153-7 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0154-1 Front Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0154-2 Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0154-3 Front Flood Lamp Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0154-4 Rear Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0154-5 Rear Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0154-6 xxi

Final Drive Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0149 Recoil Spring Compartment Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0150 Transmission System Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0151

Transmission System Oil Filter Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0152

Transmission System Oil Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0153

Flood Lamp Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0154

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WP Sequence No. Page No. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11.
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Rear Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-7 Front Flood Lamp Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-8 Front Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-9 Front Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-10 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154-11 Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-2 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-3 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-4 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-5 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-6 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-8 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-9 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-10 Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155-11 Battery Box Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-2 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-3 Battery Disconnect Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-4 Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-5 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-5 Battery Disconnect Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-6 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-6 Pivot Shaft Tank Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-7 Information Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-8 Pivot Shaft Tank Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-9 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-10 Battery Disconnect Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-10 Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-11 Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-11 Battery Disconnect Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-12 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-13 Battery Door Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156-14 Fuel Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-2 Fuel Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-3 Tank Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-4 Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-5 Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . . . 0157-6 Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . . . 0157-7 Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-8 Fuel Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-9 Fuel Drain Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-10 Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157-11 Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . . 0157-12 xxii

Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0155

Battery Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0156

Fuel Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0157

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WP Sequence No. Page No. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1.
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Fuel Line Retaining Straps and Spacers. . . . . . . . . . . . . . . . . . . .0157-13 Tank Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-14 Tank Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-15 Fuel Return Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-16 Fuel Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0157-17 Pivot Shaft Oil Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-2 Pivot Shaft Lubrication Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-3 Pivot Shaft Lubrication Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-4 Pivot Shaft Lubrication Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0158-6 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-2 Battery Positive Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-3 Battery Positive Cable to Junction Box. . . . . . . . . . . . . . . . . . . . . . .0159-4 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-6 Fuse Panel Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-7 Fuse Panel Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-8 Fuse Panel Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-9 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-10 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-11 Battery Positive Cable to Junction Box. . . . . . . . . . . . . . . . . . . . . .0159-12 Battery Positive Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-13 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0159-14 Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-2 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-3 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-4 Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-5 Switch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-6 Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-7 Ground Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-8 Switch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-9 Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-10 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-11 Arctic Kit Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-12 Arctic Kit Battery Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0160-13 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0161-2 Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0161-3 Battery Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0161-4 Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0161-5 Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0162-2 xxiii

Pivot Shaft Lubrication Line Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0158

Battery Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0159

Battery Ground Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0160

Battery Crossover Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0161

Battery Disconnect Switch, Receptacle and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0162

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WP Sequence No. Page No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 1. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8.
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Receptacle and Battery Disconnect Switch Connections. . . . . . . . . 0162-3 Receptacle Cable at Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . 0162-4 Receptacle and Battery Disconnect Switch Connections. . . . . . . . . 0162-6 Battery Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162-7 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-1 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-2 Fuse Panel Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-3 Alternator Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-4 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-5 Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-6 Alternator Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-7 Fuse Panel Alternator Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-8 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-9 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163-10 Starter Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-2 Starter Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-3 Starter Cable to Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-4 Starter Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-5 Starter Cable to Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-6 Starter Cable to Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-7 Starter Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164-8 Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165-2 Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166-2 Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-1 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-2 Light Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-3 Horn Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-4 Light Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-5 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-6 Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167-7 Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-1 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-2 Alarm Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-2 Alarm Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-3 Alarm Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-4 Alarm Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-4 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-5 Frame Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168-5 xxiv

Alternator Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0163

Starter Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0164

Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0165 Junction Block Replacement (With Arctic Kit Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0166 Front Lighting Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0167

Backup Alarm Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0168

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WP Sequence No. Page No.
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Transmission Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0169 Figure 1. Figure 2. Figure 3. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0169-1 Transmission Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0169-2 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0169-3 Fuel Tank Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0170-2 Fuel Tank Supply Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-2 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-3 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-4 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-5 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-6 Sending Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-7 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-8 Supply Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-9 Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-10 Fuel Tank Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-11 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-12 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-13 Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-14 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-15 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-16 Fuel Tank Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-17 Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-18 Supply Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-19 Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-20 Sending Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-21 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-22 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-23 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-23 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-24 Fuel Tank Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-25 Fuel Tank Supply Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0171-26 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-1 Chassis Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-2 Harness to Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-3 Temp Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-3 Temp Sensor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-4 Harness To Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-5 Chassis Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-6 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0172-7

Fuel Tank Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0170 Fuel Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0171

Chassis Harness Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0172

Transmission Sensor Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0173

xxv

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WP Sequence No. Page No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.
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Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-2 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-3 Speed Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-4 Control Solenoids Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-5 Transmission Harness Main Connector. . . . . . . . . . . . . . . . . . . . . . 0173-6 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-7 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-8 Transmission Harness Main Connector. . . . . . . . . . . . . . . . . . . . . . 0173-9 Control Solenoids Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-10 Speed Sensor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-11 Transmission Case. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-12 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173-13 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-1 Brake Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-2 Brake Switch Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-3 Instrument Panel Lower Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-4 Instrument Panel Upper Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-5 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-6 Brake Switch Harness Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-7 Brake Switch Harness Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-8 Harness Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-9 Instrument Panel Upper Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-10 Instrument Panel Lower Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-11 Brake Switch Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-12 Brake Switch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-13 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174-14 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-1 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-2 ECM (Powertrain). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-3 ECM (Powertrain). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-4 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-5 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175-5 Fuse Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-2 Starter and Main Relay Straps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-3 Main Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-4 Starter Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-5 Junction Block Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-6 Blower Motor Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-7 Fuse Block Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-8 Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-9 Alternator Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-10 Junction Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176-11 xxvi

Switch and Harness Assembly (Service Brake) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0174

ECM (Powertrain) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0175

Fuse Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0176

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TABLE OF CONTENTS - CONTINUED

WP Sequence No. Page No. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 1. Figure 2. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 1. Figure 2. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.
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Fuse Block Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-12 Blower Motor Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-13 Junction Block Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-14 Starter Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-15 Main Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-16 Starter and Main Relay Straps. . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-17 Fuse Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0176-18 Power Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0177-1 Power Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0177-2 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-1 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-2 Powertrain Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0178-3 Powertrain Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . .0178-4 Left Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-5 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0178-6 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-1 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-2 Switch Pod Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-2 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-3 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-4 Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-5 Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-6 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-7 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-8 Switch Pod Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-9 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-10 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0179-11 Winch Solenoid Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0180-2 Winch Solenoid Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0180-3 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0181-1 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0181-2 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0181-2 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0181-3 Left Hand Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0182-1 Horn Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0182-2 Horn and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0182-3 Horn and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0182-4 Horn Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0182-5 xxvii

Power Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0177

Wiring Harness Assembly (Steering Control) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0178

Right Cab Switch Panel Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0179

Winch Solenoid Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0180

Hydraulic Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0181

Horn Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0182

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WP Sequence No. Page No. Figure 6. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28.
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Left Hand Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182-6 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183-1 Backup Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183-2 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183-3 Hydraulic System Oil Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184-2 Hydraulic System Oil Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184-3 Hydraulic System Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185-3 Hydraulic Filter Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185-5 Hydraulic System Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185-6 Cab Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186-1 Hydraulic System Fill Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186-2 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-4 Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-5 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-6 Hydraulic Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-6 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-7 Hydraulic Tank Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-8 Hydraulic Tank Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-8 Hydraulic Tank Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-9 Hydraulic Tank Filler Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-9 Hydraulic Tank Rear Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . 0187-10 Hydraulic Tank Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-11 Hydraulic Tank Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . 0187-12 Hydraulic Tank T Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-13 Hydraulic Tank Front Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . 0187-14 Hydraulic Tank Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-15 Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-15 Hydraulic Tank Safety Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0187-16 Hydraulic Tank Pick-up Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-17 Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-18 Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-19 Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-20 Hydraulic Tank Internal Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-21 Hydraulic Tank Pick-up Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-22 Hydraulic Tank Safety Drain Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0187-23 Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-24 Hydraulic Tank Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187-24 xxviii

Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0183

Hydraulic Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0184

Hydraulic Oil Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0185

Hydraulic System Pressure Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0186

Hydraulic Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0187

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WP Sequence No. Page No. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7.
-

Hydraulic Tank Front Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . .0187-25 Hydraulic Tank T Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-26 Hydraulic Tank Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . .0187-27 Hydraulic Tank Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-28 Hydraulic Tank Rear Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . .0187-29 Hydraulic Tank Filler Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-30 Hydraulic Tank Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-30 Hydraulic Tank Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-31 Hydraulic Tank Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-31 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-32 Hydraulic Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-32 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-33 Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-34 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-35 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-36 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0187-37 Enclosure Bracket and Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-2 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-3 Information Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-4 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-5 Enclosure Bracket and Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0188-6 Upper Hydraulic Oil Cooler Line Elbow. . . . . . . . . . . . . . . . . . . . . . .0189-3 Upper Hydraulic Oil Cooler Line. . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-4 Upper Hydraulic Oil Cooler Line at Counterbalance Valve. . . . . . . .0189-5 Lower Hydraulic Oil Cooler Line Connector. . . . . . . . . . . . . . . . . . .0189-6 Clamps Under Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-7 Clamps Under Foot Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-8 Lower Hydraulic Oil Cooler Line at Hydraulic Tank. . . . . . . . . . . . .0189-9 Lower Hydraulic Oil Cooler Line at Hydraulic Tank. . . . . . . . . . . .0189-10 Clamps Under Foot Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-11 Clamps Under Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0189-12 Lower Hydraulic Oil Cooler Line Connector. . . . . . . . . . . . . . . . . .0189-13 Upper Hydraulic Oil Cooler Line at Counterbalance Valve. . . . . . .0189-14 Upper Hydraulic Oil Cooler Line. . . . . . . . . . . . . . . . . . . . . . . . . . .0189-15 Upper Hydraulic Oil Cooler Line Elbow. . . . . . . . . . . . . . . . . . . . . .0189-16 Upper Hydraulic Suction Line at Right Front Panel. . . . . . . . . . . . .0190-3 Lower Hydraulic Suction Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0190-4 Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0190-5 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0190-6 Right Front Panel Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0190-7 Upper Hydraulic Suction Line at Hydraulic Tank. . . . . . . . . . . . . . .0190-8 Right Front Panel Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0190-9 xxix

Hydraulic Tank Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0188

Hydraulic Oil Cooler Lines Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0189

Hydraulic Suction Line Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0190

TM 5-2410-241-23-2

TABLE OF CONTENTS - CONTINUED

WP Sequence No. Page No. Figure 8. Figure 9. Figure 10. Figure 11. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 1. Figure 2. Figure 3. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.
-

Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-10 Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-11 Lower Hydraulic Suction Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190-12 Upper Hydraulic Suction Line at Right Front Panel. . . . . . . . . . . . 0190-13 Implement Pump to Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . 0191-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-3 Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-4 Clamps at Filler Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-4 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-5 Clamps at Filler Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-6 Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-7 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191-7 Implement Pump to Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . 0191-8 Implement Pump to Steering Motor Tee. . . . . . . . . . . . . . . . . . . . . . 0192-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192-4 Implement Pump to Steering Motor Tee. . . . . . . . . . . . . . . . . . . . . . 0192-5 Implement Pump to Main Hydraulic Control Valve. . . . . . . . . . . . . . 0193-3 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193-3 Main Hydraulic Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193-4 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193-5 Implement Pump to Main Hydraulic Control Valve. . . . . . . . . . . . . . 0193-6 Implement Pump to Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . 0194-3 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-3 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-4 Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-5 Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-6 Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-7 Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194-8 Implement Pump to Pilot Accumulator. . . . . . . . . . . . . . . . . . . . . . . 0194-8 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-3 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-3 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-4 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-4 Steering Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-5 Steering Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-6 Hydraulic Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-7 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-7 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-8 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195-8 xxx

Hydraulic Implement Pump Tank Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0191

Hydraulic Implement Pump Steering Motor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0192

Hydraulic Implement Pump Main Control Valve Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0193

Hydraulic Implement Pump Pilot Accumulator Hose Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0194

Hydraulic Steering Motor/Tank Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0195

TM 5-2410-241-23-2

TABLE OF CONTENTS - CONTINUED

WP Sequence No. Page No.
-

Hydraulic Counterbalance Valve Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0196 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-3 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-4 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-4 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-6 Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-7 Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0196-7

xxxi

TM 5-2410-241-23-2

HOW TO USE THIS TECHNICAL MANUAL

This manual is designed to help you operate and maintain the D7R Dozer, Type I with Winch and Type II with Ripper. FEATURES OF THIS MANUAL 1. A Table of Contents is provided at the beginning of this manual. 2. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid.

WARNING
A WARNING indicates a hazard which can result in death or serious injury to personnel.

CAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment.

NOTE
A NOTE is a statement containing information that will make the procedure easier to perform. 3. Statements and words of particular importance are printed in CAPITAL LETTERS to create emphasis. 4. Instructions are located with illustrations that show the specific task on which the operator or mechanic is working. 5. Dashed leader lines used in illustrations indicate that called out items are not visible (i.e., they are located within the structure). Dashed leader lines in the Lubrication Chart indicate that lubrication is required on BOTH sides of the equipment. 6. Technical instructions include metric units in addition to standard units. A metric conversion chart is provided on the inside back cover. 7. An alphabetical index is provided at the end of the manual to assist in locating information not readily found in the Table of Contents. FOLLOW THESE GUIDELINES WHEN YOU USE THIS MANUAL 1. Read through this manual and become familiar with its contents before attempting to operate or maintain the dozer. 2. A Warning Summary is provided at the beginning of this manual and should be read before attempting to operate or maintain the dozer. 3. Within a chapter or work package, headings are used to help group the material to assist in quickly finding tasks. Read all preliminary information found at the beginning of each task.

xxxii

66 TM 5-2410-241-23-2 0057

FIELD MAINTENANCE ENGINE ASSEMBLY REPLACEMENT Engine Removal, Install Engine on Stand, Cleaning and Inspection, Remove Engine from Stand, Engine Installation
0 0 5 7

INITIAL SETUP Tools and Special Tools

0

Materials/Parts - Continued Sealing Compound 577 (WP 0303, Item 32) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Gasket Locknut (2) O-ring (23) Personnel Required Two References WP 0059 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) A/C system evacuated (WP 0263) Radiator guard removed (WP 0205) Main drive shaft removed (WP 0117) Pump coupling removed (WP 0120) Hydraulic oil drained (WP 0184) Torque converter drained (WP 0148) Ether bottle bracket removed (WP 0060) Air cleaner assembly removed (WP 0111) Arctic kit heater removed (WP 0291) Seat assembly removed (WP 0247) Estimated Time to Complete 34.5 Hr W/O Arctic Heater

Tool Kit, General Mechanics (WP 0302, Item 65) Adapter, Engine (WP 0302, Item 3) Wrench, Combination 1-1/8 (S0788) (WP 0302, Item 68) Wrench, Combination, 1-3/8 (S0791) (WP 0302, Item 68) Wrench, Combination 1-1/2 (S0793) (WP 0302, Item 68) Wrench, Combination 1-5/8 (S0794) (WP 0302, Item 68) Socket, 1/2 Drive, 6 Point, 1-1/8 (S0582) (WP 0302, Item 68) Socket, 1/2 Drive, 6 Point, Regular, 1-1/2 (S0588) (WP 0302, Item 68) Socket, 3/4 Drive, 1-5/8, 12 Point (S0392) (WP 0302, Item 68) Joint, Universal, 3/4 Drive (S0379) (WP 0302, Item 68) Light, Extension, Fluorescent (S0246) (WP 0302, Item 68) Engine Stand Adapter (WP 0302, Item 4) Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) Hoist, Chain (WP 0302, Item 33) Stand, Maintenance, Automotive Engine (WP 0302, Item 57) Lifting device 10,000-lb capacity
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24)

38.0 Hr W/ Arctic Heater

0

0057-1

TM 5-2410-241-23-2

0057

ENGINE REMOVAL

00057

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

1. Remove four bolts (Figure 1, Item 3), washers (Figure 1, Item 4), split flange clamp (Figure 1, Item 6), hose (Figure 1, Item 2), and O-ring (Figure 1, Item 5) from cooler line (Figure 1, Item 7). Discard O-ring. 2. Remove four bolts (Figure 1, Item 12), washers (Figure 1, Item 11), split flange clamp (Figure 1, Item 10), hose (Figure 1, Item 1), O-ring (Figure 1, Item 9), and screen (Figure 1, Item 13) from torque converter (Figure 1, Item 8). Discard O-ring.

Figure 1. Torque Converter Hoses.

0057

0057-2

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

3. Remove four bolts (Figure 2, Item 5), washers (Figure 2, Item 6), split flange clamp (Figure 2, Item 4), hose (Figure 2, Item 7) and O-ring (Figure 2, Item 3) from torque converter (Figure 2, Item 8). Discard O-ring. 4. Position spacer (Figure 2, Item 9) aside. 5. Loosen tube nut (Figure 2, Item 10) and remove hose (Figure 2, Item 2) and O-ring (Figure 2, Item 1) from torque converter (Figure 2, Item 8). Discard O-ring.

Figure 2. Torque Converter Hoses.

0057

0057-3

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

6. Loosen tube nut (Figure 3, Item 4) and remove hose (Figure 3, Item 5) and O-ring (Figure 3, Item 3) from fitting (Figure 3, Item 2) and torque converter output relief valve (Figure 3, Item 1). Place hose aside and discard Oring.

Figure 3. Torque Converter Hose.

0057

0057-4

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

7. Loosen tube nut (Figure 4, Item 3) and remove hose (Figure 4, Item 2) from tee fitting (Figure 4, Item 1). Set hose aside. 8. Remove O-ring (Figure 4, Item 4) from tee fitting (Figure 4, Item 1). Discard O-ring.

Figure 4. Hose.

0057

0057-5

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

9. Remove four bolts (Figure 5, Item 15), washers (Figure 5, Item 14), split flange clamp (Figure 5, Item 12), hose (Figure 5, Item 17), O-ring (Figure 5, Item 13), spacer (Figure 5, Item 10), and O-ring (Figure 5, Item 11) from pump (Figure 5, Item 9). Discard O-rings. 10. Position spacer (Figure 5, Item 10) and hose (Figure 5, Item 16) aside. 11. Loosen tube nut (Figure 5, Item 4) and remove hose (Figure 5, Item 3) from fitting (Figure 5, Item 5). Set hose aside. 12. Remove fitting (Figure 5, Item 5) and two O-rings (Figure 5, Item 6) from pump (Figure 5, Item 9). Discard Orings. 13. Loosen tube nut (Figure 5, Item 2) and remove hose (Figure 5, Item 1) from fitting (Figure 5, Item 8). Set hose aside. 14. Remove fitting (Figure 5, Item 8) and two O-rings (Figure 5, Item 7) from pump (Figure 5, Item 9). Discard Orings.

Figure 5. Pump Hoses.

0057

0057-6

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

15. Remove four bolts (Figure 6, Item 8), washers (Figure 6, Item 9), line (Figure 6, Item 7) and O-ring (Figure 6, Item 10) from pump (Figure 6, Item 6). Discard O-ring. 16. Position line (Figure 6, Item 7) aside. 17. Loosen tube nut (Figure 6, Item 2) and remove two tee fittings (Figure 6, Item 4) and hose (Figure 6, Item 5) from line (Figure 6, Item 1). Set hose and tee fittings aside. 18. Remove O-ring (Figure 6, Item 3) from tee fitting (Figure 6, Item 4). Discard O-ring.

Figure 6. Pump Lines.

0057

0057-7

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED 19. Close fuel shutoff valve (Figure 7, Item 1).

Figure 7. Fuel Shutoff Valve.

0057

0057-8

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

20. Loosen tube nut (Figure 8, Item 14), and remove hose (Figure 8, Item 12) and O-ring (Figure 8, Item 15) from secondary fuel filter base (Figure 8, Item 13). Discard O-ring. 21. Disconnect A/C quick connect (Figure 8, Item 8) from receiver/drier (Figure 8, Item 9). Position A/C hose (Figure 8, Item 6) aside. 22. Disconnect A/C quick connect (Figure 8, Item 10) from receiver/drier (Figure 8, Item 9). Position A/C hose (Figure 8, Item 11) aside. 23. Disconnect connector (Figure 8, Item 3) from work light (Figure 8, Item 4). 24. Disconnect connector (Figure 8, Item 1) from switch (Figure 8, Item 2). 25. Remove tiedown straps (Figure 8, Item 7) from harness (Figure 8, Item 5). Discard tiedown straps. 26. Position harness (Figure 8, Item 5) aside.

Figure 8. A/C Connections.

0057

0057-9

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Tag and mark all electrical connections to aid installation. 27. Remove nut (Figure 9, Item 2) and ground strap (Figure 9, Item 3) from starter (Figure 9, Item 1). 28. Loosely install nut (Figure 9, Item 2) on starter (Figure 9, Item 1).

Figure 9. Starter Motor Ground Connections.

0057

0057-10

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Tag and mark all hoses to aid installation. 29. Position boot (Figure 10, Item 6) aside and remove nut (Figure 10, Item 7) and positive battery cable (Figure 10, Item 1) from starter motor solenoid (Figure 10, Item 8). 30. Loosely install nut (Figure 10, Item 7) on starter motor solenoid (Figure 10, Item 8). 31. Remove tiedown straps (Figure 10, Item 2) from positive battery cable (Figure 10, Item 1). Discard tiedown straps. Place positive cable aside. 32. Remove tiedown straps (Figure 10, Item 4) and harness (Figure 10, Item 5) from frame (Figure 10, Item 3). Place harness aside. Discard tiedown straps.

Figure 10. Starter Motor.

0057

0057-11

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

33. Remove bolt (Figure 11, Item 7), washer (Figure 11, Item 9) and P-clip (Figure 11, Item 8) from hose (Figure 11, Item 6). 34. Remove bolt (Figure 11, Item 2), washer (Figure 11, Item 3) and plate (Figure 11, Item 4) from A/C compressor (Figure 11, Item 14). 35. Remove two hoses (Figure 11, Items 1 and 6) and O-rings (Figure 11, Item 5) from A/C compressor (Figure 11, Item 14) and machine. Discard O-rings.

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

36. Loosen tube nut (Figure 11, Item 11) and remove hose (Figure 11, Item 10) and O-ring (Figure 11, Item 12) from fitting (Figure 11, Item 13). Discard O-ring. Position hose aside.

0057-12

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

Figure 11. A/C Hose.

0057

0057-13

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Tag and mark all hoses to aid installation. Note location and quantity of tiedown straps to aid installation.

37. Remove tiedown straps (Figure 12, Item 2) from engine main harness connectors (Figure 12, Items 3 and 9). Discard tiedown straps. 38. Disconnect engine main harness connector (Figure 12, Item 7) from ether aid relay (Figure 12, Item 4). 39. Disconnect engine main harness connector (Figure 12, Item 9) from platform connector (Figure 12, Item 10). 40. Loosen bolt (Figure 12, Item 8) and disconnect engine main harness connector (Figure 12, Item 3) from platform connector (Figure 12, Item 1).

NOTE
Cap and plug all hoses, lines and tubes to prevent contamination and leaks. Tag and mark all hoses to aid installation.

41. Loosen two clamps (Figure 12, Item 5) from two heater hoses (Figure 12, Item 6). 42. Remove two heater hoses (Figure 12, Item 6) from cab.

Figure 12. Platform Harness Connections.

0057

0057-14

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED 43. Remove two bolts (Figure 13, Item 1), washers (Figure 13, Item 2) and clamp (Figure 13, Item 3) from hose bundle (Figure 13, Item 4). Position hose bundle aside.

Figure 13. Hose Bundle Clamps.

0057

0057-15

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Tag and mark all lines, hoses and electrical connections to aid installation. Note location and quantity of tiedown straps to aid installation.

44. Remove two locknuts (Figure 14, Item 12), washers (Figure 14, Item 11) and clamps (Figure 14, Item 13) from alternator cable (Figure 14, Item 10). Discard locknuts. 45. Remove bolt (Figure 14, Item 7), washer (Figure 14, Item 8), clamp (Figure 14, Item 9) and bracket (Figure 14, Item 6) from alternator bracket (Figure 14, Item 5). 46. Position boot (Figure 14, Item 4) aside. 47. Remove nut (Figure 14, Item 2), two washers (Figure 14, Item 3) and alternator cable (Figure 14, Item 10) from alternator (Figure 14, Item 1). Set cable aside.

Figure 14. Alternator Cable.

0057

0057-16

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED 48. Remove tiedown strap (Figure 15, Item 1) from alternator cable (Figure 15, Item 2). .

Figure 15. Alternator Cable.

0057

0057-17

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

WARNING

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

NOTE
The engine assembly weighs approximately 3,750 lb (1,700 kg). 49. Attach lever pull hoist (Figure 16, Item 1) and suitable lifting device on engine (Figure 16, Item 2). Support engine.

Figure 16. Engine Lifting Device.

0057

0057-18

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED 50. Remove two front engine mount bolts (Figure 17, Item 1) and washers (Figure 17, Item 2) from two front engine mounts (Figure 17, Item 3).

Figure 17. Front Engine Mounts.

0057

0057-19

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED 51. Remove four rear engine mount bolts (Figure 18, Item 1), washers (Figure 18, Item 2), and two caps (Figure 18, Item 3) from two rear engine mounts (Figure 18, Item 4).

Figure 18. Rear Engine Mounts.

0057

0057-20

TM 5-2410-241-23-2

0057

ENGINE REMOVAL CONTINUED

NOTE
Move engine forward then upward in order to clear the cab and powertrain oil cooler. 52. Remove engine (Figure 19, Item 1) from machine. 53. Remove two bolts (Figure 19, Item 3), washers (Figure 19, Item 4) and flange (Figure 19, Item 5) from torque converter housing (Figure 19, Item 2). 54. Remove two O-rings (Figure 19, Item 6) from flange (Figure 19, Item 5). Discard O-rings. 55. Position engine (Figure 19, Item 1) on suitable supports.

Figure 19. Engine Assembly. END OF TASK

0057

0057-21

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND 1. Engine removed, refer to this work package. 2. Remove secondary fuel filter (Figure 20, Item 2) from base (Figure 20, Item 1).

00057

Figure 20. Secondary Fuel Filter.

0057

0057-22

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED

NOTE
Tag and mark all cables to aid installation. 3. Remove nut (Figure 21, Item 2) and cable (Figure 21, Item 1) from starter motor solenoid (Figure 21, Item 4). 4. Remove nut (Figure 21, Item 5) and cable (Figure 21, Item 3) from starter motor solenoid (Figure 21, Item 4). 5. Remove nut (Figure 21, Item 8), and cable (Figure 21, Item 10) from starter (Figure 21, Item 6). Set cable aside. 6. Remove cable (Figure 21, Item 7) and cable (Figure 21, Item 9) from starter (Figure 21, Item 6). Set cables aside. 7. Remove nut (Figure 21, Item 11) and cable (Figure 21, Item 9) from engine.

Figure 21. Starter Connection.

0057

0057-23

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED

NOTE
Tag and mark all cables to aid installation. 8. Loosen two bolts (Figure 22, Item 1) and remove two connectors (Figure 22, Item 2) from engine ECM (Figure 22, Item 3).

Figure 22. ECM Connection.

0057

0057-24

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED

NOTE
Tag and mark all cables to aid installation. 9. Remove bolt (Figure 23, Item 7), washer (Figure 23, Item 6), clamp (Figure 23, Item 8), receiver/dryer (Figure 23, Item 9) and spacer (Figure 23, Item 5) from engine. 10. Remove bolt (Figure 23, Item 4), washer (Figure 23, Item 3), and clamp (Figure 23, Item 1). Position NATO slave cables (Figure 23, Item 2) aside.

Figure 23. Receiver/Dryer.

0057

0057-25

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED 11. Remove bolt (Figure 24, Item 1), washer (Figure 24, Item 2), and bracket (Figure 24, Item 3). Position harness (Figure 24, Item 4) aside.

Figure 24. Harness and Bracket.

0057

0057-26

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED

NOTE
Tag and mark all electrical connections to aid installation. 12. Disconnect engine oil pressure sensor connector (Figure 25, Item 1) from engine oil pressure sensor (Figure 25, Item 2). 13. Remove engine oil pressure sensor (Figure 25, Item 2) from elbow (Figure 25, Item 3). 14. Remove elbow (Figure 25, Item 3) from engine. 15. Remove two O-rings (Figure 25, Item 4) from elbow (Figure 25, Item 3). Discard O-rings.

Figure 25. Oil Pressure Sensor.

0057

0057-27

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED

WARNING

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

NOTE
Starter weighs approximately 80 lb (36 kg). 16. With assistance, remove three bolts (Figure 26, Item 2) and starter (Figure 26, Item 3) from engine. 17. Remove gasket (Figure 26, Item 1) from starter (Figure 26, Item 3). Discard gasket.

Figure 26. Starter.

0057

0057-28

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED 18. Remove special bolt (Figure 27, Item 6) and washer (Figure 27, Item 5) from ECM (Figure 27, Item 4). 19. Remove two bolts (Figure 27, Item 2) and washers (Figure 27, Item 1) from engine ECM (Figure 27, Item 4). 20. Remove three isolators (Figure 27, Item 3) from engine ECM (Figure 27, Item 4).

Figure 27. Engine ECM and Retaining Hardware.

0057

0057-29

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED

NOTE
Tag and mark ground strap to aid installation. 21. Remove bolt (Figure 28, Item 5), nut (Figure 28, Item 2), washer (Figure 28, Item 4), clamp (Figure 28, Item 1), ground strap (Figure 28, Item 3), special bolt (Figure 28, Item 7) and washer (Figure 28, Item 9) from engine ECM (Figure 28, Item 8). 22. Remove isolator (Figure 28, Item 6) from engine ECM (Figure 28, Item 8).

Figure 28. Engine ECM, Ground Strap, and Retaining Hardware.

0057

0057-30

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED 23. Remove engine ECM (Figure 29, Item 1), four spacers (Figure 29, Item 2) and isolators (Figure 29, Item 3) from engine (Figure 29, Item 4).

Figure 29. Engine ECM, Spacers, and Isolators.

0057

0057-31

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED

NOTE
Note position of oil dipstick mounting bracket. 24. Remove bolt (Figure 30, Item 4) and washer (Figure 30, Item 5) from engine. Position P-clip (Figure 30, Item 14) aside.

NOTE
Note position of oil dipstick mounting bracket and spacer. 25. Remove bolt (Figure 30, Item 10), washer (Figure 30, Item 9), P-clip (Figure 30, Item 12), and spacer (Figure 30, Item 8) from engine. Position P-clip and hose (Figure 30, Item 13) aside. 26. Remove bolt (Figure 30, Item 1), washer (Figure 30, Item 2), and oil dipstick tube (Figure 30, Item 3) from engine. 27. Remove O-ring (Figure 30, Item 11) from oil dipstick tube (Figure 30, Item 3). Discard O-ring. 28. Loosen bolt (Figure 30, Item 7) and position fuel hose (Figure 30, Item 6) up and aside.

Figure 30. Oil Dipstick Tube.

0057

0057-32

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED 29. Install engine stand mount (Figure 31, Item 3), three spacers (Figure 31, Item 1) and bolts (Figure 31, Item 2) on engine.

WARNING

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

NOTE
The engine assembly weighs approximately 3,750 lb (1,700 kg). 30. Attach suitable lifting device on engine, lift engine from supports.

Figure 31. Engine Stand Mount.

0057

0057-33

TM 5-2410-241-23-2

0057

INSTALL ENGINE ON STAND CONTINUED 31. Position engine stand (Figure 32, Item 4) on engine stand mount (Figure 32, Item 1), install eight bolts (Figure 32, Item 2) and four nuts (Figure 32, Item 3).

Figure 32. Engine Stand. 32. Remove lifting device from engine. 33. If installing new engine, refer to Engine Replacement Transfer of Parts (WP 0059). END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0057

00057

0057-34

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND

00057

WARNING

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

NOTE
The engine assembly weighs approximately 3,750 lb (1,700 kg). 1. If installing new engine refer to Engine Transfer Of Parts (WP 0059). 2. Attach lifting device on engine. 3. Remove eight bolts (Figure 33, Item 2), four nuts (Figure 33, Item 3) and engine stand (Figure 33, Item 4) from engine stand mount (Figure 33, Item 1). 4. Position engine on supports. 5. Remove lifting device from engine.

Figure 33. Engine Stand.

0057

0057-35

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED 6. Remove three bolts (Figure 34, Item 2), spacers (Figure 34, Item 1) and engine stand mount (Figure 34, Item 3) from engine.

Figure 34. Engine Stand Mount.

0057

0057-36

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED 7. Position fuel hose (Figure 35, Item 6) and tighten bolt (Figure 35, Item 7) on engine. 8. Install new O-ring (Figure 35, Item 11) on oil dipstick tube (Figure 35, Item 3). 9. Install oil dipstick tube (Figure 35, Item 3), washer (Figure 35, Item 2) and bolt (Figure 35, Item 1) on engine.

NOTE
Install spacer and oil dipstick mounting bracket as noted during removal. 10. Position hose (Figure 35, Item 13) and P-clip (Figure 35, Item 12) on engine. 11. Install spacer (Figure 35, Item 8), P-clip (Figure 35, Item 12), washer (Figure 35, Item 9), and bolt (Figure 35, Item 10) on engine.

NOTE
Install oil dipstick mounting bracket as noted during removal. 12. Position P-clip (Figure 35, Item 14) on engine. 13. Install washer (Figure 35, Item 5) and bolt (Figure 35, Item 4) on engine.

Figure 35. Oil Dipstick Tube.

0057

0057-37

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED 14. Install four isolators (Figure 36, Item 3), spacers (Figure 36, Item 2) and engine ECM (Figure 36, Item 1) on engine (Figure 36, Item 4).

Figure 36. Engine ECM, Spacers, and Isolators.

0057

0057-38

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED

NOTE
Install ground strap as noted during removal. 15. Install isolator (Figure 37, Item 6) on engine ECM (Figure 37, Item 8). 16. Install washer (Figure 37, Item 9), special bolt (Figure 37, Item 7), ground strap (Figure 37, Item 3), clamp (Figure 37, Item 1), washer (Figure 37, Item 4), nut (Figure 37, Item 2), and bolt (Figure 37, Item 5) on engine ECM (Figure 37, Item 8).

Figure 37. Engine ECM, Ground Strap, and Retaining Hardware.

0057

0057-39

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED 17. Install three isolators (Figure 38, Item 3) on engine ECM (Figure 38, Item 4). 18. Install two washers (Figure 38, Item 1) and bolts (Figure 38, Item 2) on engine ECM (Figure 38, Item 4). 19. Install washer (Figure 38, Item 5) and special bolt (Figure 38, Item 6) on ECM (Figure 38, Item 4).

Figure 38. Engine ECM and Retaining Hardware.

0057

0057-40

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED

WARNING

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

NOTE
Starter weighs approximately 80 lb (36 kg). 20. Install new gasket (Figure 39, Item 1) on starter (Figure 39, Item 3). 21. With assistance, install starter (Figure 39, Item 3) and three bolts (Figure 39, Item 2) on engine.

Figure 39. Starter.

0057

0057-41

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED 22. Install two new O-rings (Figure 40, Item 4) on elbow (Figure 40, Item 3). 23. Install elbow (Figure 40, Item 3) on engine. 24. Install engine oil pressure sensor (Figure 40, Item 2) on elbow (Figure 40, Item 3). 25. Connect engine oil pressure sensor connector (Figure 40, Item 1) on engine oil pressure sensor (Figure 40, Item 2).

Figure 40. Oil Pressure Sensor.

0057

0057-42

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED 26. Position harness (Figure 41, Item 4) and install bracket (Figure 41, Item 3), washer (Figure 41, Item 2) and bolt (Figure 41, Item 1).

Figure 41. Harness and Bracket.

0057

27. Position NATO slave cables (Figure 42, Item 2) and install clamp (Figure 42, Item 1), washer (Figure 42, Item 3) and bolt (Figure 42, Item 4). 28. Install clamp (Figure 42, Item 8), receiver dryer (Figure 42, Item 9), spacer (Figure 42, Item 5), washer (Figure 42, Item 6) and bolt (Figure 42, Item 7) on engine.

Figure 42. Receiver/Dryer.

0057

0057-43

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED

NOTE
Install cables as marked in removal. 29. Install two connectors (Figure 43, Item 2) and tighten two bolts (Figure 43, Item 1) on engine ECM (Figure 43, Item 3).

Figure 43. ECM Connection.

0057

0057-44

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED

NOTE
Install cables as marked in removal. 30. Install cable (Figure 44, Item 9) and nut (Figure 44, Item 11) on engine. 31. Install cable (Figure 44, Item 9) and cable (Figure 44, Item 7) on starter (Figure 44, Item 6). 32. Install cable (Figure 44, Item 10) and nut (Figure 44, Item 8) on starter (Figure 44, Item 6). 33. Install cable (Figure 44, Item 3) and nut (Figure 44, Item 5) on starter motor solenoid (Figure 44, Item 4). 34. Install cable (Figure 44, Item 1) and loosely install nut (Figure 44, Item 2) on starter motor solenoid (Figure 44, Item 4).

Figure 44. Starter Connection.

0057

0057-45

TM 5-2410-241-23-2

0057

REMOVE ENGINE FROM STAND CONTINUED 35. Install secondary fuel filter (Figure 45, Item 2) on base (Figure 45, Item 1).

Figure 45. Secondary Fuel Filter. 36. Install engine, refer to this work package. END OF TASK

0057

0057-46

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION

00057

WARNING

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

NOTE
The engine assembly weighs approximately 3,750 lb (1,700 kg). 1. Attach lever pull hoist (Figure 46, Item 1) and suitable lifting device to engine (Figure 46, Item 2).

Figure 46. Engine Lifting Device.

0057

0057-47

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Move engine downward then rearward in order to clear the cab and powertrain oil cooler. 2. Install engine (Figure 47, Item 1) on machine. 3. Install two new O-rings (Figure 47, Item 6) on flange (Figure 47, Item 5). 4. Install flange (Figure 47, Item 5), two washers (Figure 47, Item 4) and bolts (Figure 47, Item 3) on torque converter housing (Figure 47, Item 2).

Figure 47. Engine Assembly.

0057

0057-48

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED 5. Install two caps (Figure 48, Item 3), four washers (Figure 48, Item 2), and rear engine mount bolts (Figure 48, Item 1) on two rear engine mounts (Figure 48, Item 4).

Figure 48. Rear Engine Mounts.

0057

0057-49

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED 6. Install two washers (Figure 49, Item 2) and front engine mount bolts (Figure 49, Item 1) on two front engine mounts (Figure 49, Item 3).

Figure 49. Front Engine Mounts.

0057

0057-50

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED 7. Remove lifting device and lever pull hoist (Figure 50, Item 1) from engine (Figure 50, Item 2).

Figure 50. Engine Lifting Device. 8. Install tiedown strap (Figure 51, Item 1) on alternator cable (Figure 51, Item 2).

0057

Figure 51. Alternator Cable.

0057

0057-51

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Install hoses as tagged and marked during removal. Install tiedown straps as noted during removal.

9. Install alternator cable (Figure 52, Item 10), two washers (Figure 52, Item 3) and nut (Figure 52, Item 2) on alternator (Figure 52, Item 1). 10. Install boot (Figure 52, Item 4) on nut (Figure 52, Item 2). 11. Install bracket (Figure 52, Item 6), clamp (Figure 52, Item 9), washer (Figure 52, Item 8) and bolt (Figure 52, Item 7) on alternator bracket (Figure 52, Item 5). 12. Install two clamps (Figure 52, Item 13), washers (Figure 52, Item 11), and new locknuts (Figure 52, Item 12) on alternator cable (Figure 52, Item 10).

Figure 52. Alternator Cable.

0057

0057-52

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Install hoses as tagged and marked during removal. 13. Install clamp (Figure 53, Item 3), two washers (Figure 53, Item 2) and bolts (Figure 53, Item 1) on hose bundle (Figure 53, Item 4).

Figure 53. Hose Bundle Clamps.

0057

0057-53

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Caps and plugs removed from hoses, lines and tubes. Install hoses as tagged and marked during removal.

14. Install two heater hoses (Figure 54, Item 6) on cab. 15. install two clamps (Figure 54, Item 5) on heater hoses (Figure 54, Item 6).

NOTE
Install electrical connections and harness routing as noted during removal. Install tiedown straps as noted during removal.

16. Connect engine main harness connector (Figure 54, Item 3) and install bolt (Figure 54, Item 8) on platform connector (Figure 54, Item 1). 17. Connect engine main harness connector (Figure 54, Item 9) on platform connector (Figure 54, Item 10). 18. Connect engine main harness connector (Figure 54, Item 7) on ether aid relay (Figure 54, Item 4). 19. Install new tiedown straps (Figure 54, Item 2) on engine main harness connectors (Figure 54, Items 3 and 9).

Figure 54. Platform Harness Connections.

0057

0057-54

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Remove caps and plugs from all hoses, lines and tubes. Install all hoses as noted during removal.

20. Install new O-ring (Figure 55, Item 12), hose (Figure 55, Item 10), and tube nut (Figure 55, Item 11) on fitting (Figure 55, Item 13). 21. Install two new O-rings (Figure 55, Item 5) and hoses (Figure 55, Items 1 and 6) on A/C compressor (Figure 55, Item 14). 22. Install plate (Figure 55, Item 4), washer (Figure 55, Item 3), and bolt (Figure 55, Item 2) on A/C compressor (Figure 55, Item 14). 23. Install P-clip (Figure 55, Item 8), washer (Figure 55, Item 9), and bolt (Figure 55, Item 7) on hose (Figure 55, Item 6).

Figure 55. A/C Hose.

0057

0057-55

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Connect electrical connections as tagged and marked during removal. 24. Install harness (Figure 56, Item 5) and new tiedown straps (Figure 56, Item 4) on frame (Figure 56, Item 3). 25. Position positive cable (Figure 56, Item 1) on engine. 26. Install new tiedown straps (Figure 56, Item 2) on positive battery cable (Figure 56, Item 1). 27. Remove nut (Figure 56, Item 7) from starter motor solenoid (Figure 56, Item 8). 28. Install positive battery cable (Figure 56, Item 1) and nut (Figure 56, Item 7) on starter motor solenoid (Figure 56, Item 8). 29. Position boot (Figure 56, Item 6) over nut (Figure 56, Item 7).

Figure 56. Starter Motor.

0057

0057-56

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Connect electrical connections as tagged and marked during removal. 30. Remove nut (Figure 57, Item 2) on starter (Figure 57, Item 1). 31. Install ground strap (Figure 57, Item 3) and nut (Figure 57, Item 2) on starter (Figure 57, Item 1).

Figure 57. Starter Motor Ground Connections.

0057

0057-57

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Remove caps and plugs from hoses and ports. Install hoses as tagged and marked during removal.

32. Position harness (Figure 58, Item 5) on engine. 33. Install new tiedown straps (Figure 58, Item 7) on harness (Figure 58, Item 5). 34. Connect connector (Figure 58, Item 1) on switch (Figure 58, Item 2). 35. Connect connector (Figure 58, Item 3) on work light (Figure 58, Item 4). 36. Position A/C hose (Figure 58, Item 11) on receiver/drier (Figure 58, Item 9). 37. Connect A/C quick connect (Figure 58, Item 10) on receiver/drier (Figure 58, Item 9). 38. Position A/C hose (Figure 58, Item 6) on receiver/drier (Figure 58, Item 9). 39. Connect A/C quick connect (Figure 58, Item 8) on receiver/drier (Figure 58, Item 9). 40. Install new O-ring (Figure 58, Item 15), hose (Figure 58, Item 12), and tube nut (Figure 58, Item 14) on secondary fuel filter base (Figure 58, Item 13).

Figure 58. A/C Connections.

0057

0057-58

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED 41. Open fuel shutoff valve (Figure 59, Item 1).

Figure 59. Fuel Shutoff Valve.

0057

NOTE
Remove caps and plugs from all hoses, lines and tubes. Install all hoses as noted during removal.

42. Install new O-ring (Figure 60, Item 3) on tee fitting (Figure 60, Item 4). 43. Install hose (Figure 60, Item 5), two tee fittings (Figure 60, Item 4) and tube nut (Figure 60, Item 2) on line (Figure 60, Item 1). 44. Install new O-ring (Figure 60, Item 10), line (Figure 60, Item 7), four washers (Figure 60, Item 9), and bolts (Figure 60, Item 8) on pump (Figure 60, Item 6).

Figure 60. Pump Lines.

0057

0057-59

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Remove caps and plugs from all hoses, lines and tubes. Install all hoses as noted during removal.

45. Install two new O-rings (Figure 61, Item 7) and fitting (Figure 61, Item 8) on pump (Figure 61, Item 9). 46. Install hose (Figure 61, Item 1) and tube nut (Figure 61, Item 2) on fitting (Figure 61, Item 8). 47. Install two new O-rings (Figure 61, Item 6) and fitting (Figure 61, Item 5) on pump (Figure 61, Item 9). 48. Install hose (Figure 61, Item 3) and tube nut (Figure 61, Item 4) on fitting (Figure 61, Item 5). 49. Position spacer (Figure 61, Item 10) and hose (Figure 61, Item 16) on pump (Figure 61, Item 9). 50. Install new O-ring (Figure 61, Item 11), spacer (Figure 61, Item 10), new O-ring (Figure 61, Item 13), hose (Figure 61, Item 17), split flange clamp (Figure 61, Item 12), four washers (Figure 61, Item 14), and bolts (Figure 61, Item 15) on pump (Figure 61, Item 9).

Figure 61. Pump Hoses.

0057

0057-60

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Remove caps and plugs from all hoses, lines and tubes. Install all hoses as noted during removal.

51. Install new O-ring (Figure 62, Item 4) on tee fitting (Figure 62, Item 1). 52. Install hose (Figure 62, Item 2) and tube nut (Figure 62, Item 3) on tee fitting (Figure 62, Item 1).

Figure 62. Hose.

0057

0057-61

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Remove caps and plugs from all hoses, lines and tubes. Install all hoses as noted during removal.

53. Install new O-ring (Figure 63, Item 3), hose (Figure 63, Item 5), and tube nut (Figure 63, Item 4) on fitting (Figure 63, Item 2), and torque converter output relief valve (Figure 63, Item 1).

Figure 63. Torque Converter Hose.

0057

0057-62

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Remove caps and plugs from all hoses, lines and tubes. Install all hoses as noted during removal.

54. Install new O-ring (Figure 64, Item 1), hose (Figure 64, Item 2) and tube nut (Figure 64, Item 10) on torque converter (Figure 64, Item 8). 55. Position spacer (Figure 64, Item 9) on torque converter (Figure 64, Item 8). 56. Install new O-ring (Figure 64, Item 3), hose (Figure 64, Item 7), split flange clamp (Figure 64, Item 4), four washers (Figure 64, Item 6), and bolts (Figure 64, Item 5) on torque converter (Figure 64, Item 8).

Figure 64. Torque Converter Hoses.

0057

0057-63

TM 5-2410-241-23-2

0057

ENGINE INSTALLATION CONTINUED

NOTE
Remove caps and plugs from all hoses, lines and tubes. Install all hoses as noted during removal.

57. Install screen (Figure 65, Item 13), new O-ring (Figure 65, Item 9), hose (Figure 65, Item 1), split flange clamp (Figure 65, Item 10), four washers (Figure 65, Item 11), and bolts (Figure 65, Item 12) on torque converter (Figure 65, Item 8). 58. Install new O-ring (Figure 65, Item 5), hose (Figure 65, Item 2), split flange clamp (Figure 65, Item 6), four washers (Figure 65, Item 4), and bolts (Figure 65, Item 3) on cooler line (Figure 65, Item 7).

Figure 65. Torque Converter Hoses. END OF TASK

0057

0057-64

TM 5-2410-241-23-2

0057

FOLLOW-ON TASKS 1. Fill torque converter (WP 0148). 2. Fill hydraulic oil (WP 0184). 3. Install pump coupling (WP 0120). 4. Install main drive shaft (WP 0117). 5. Install radiator guard (WP 0205). 6. Charge A/C system (WP 0263). 7. Install ether bottle bracket (WP 0060). 8. Install arctic kit heater (WP 0291). 9. Install air cleaner assembly (WP 0111). 10. Install seat assembly (WP 0247). 11. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00057

0057-65/(66 blank)

4 TM 5-2410-241-23-2 0058

FIELD MAINTENANCE ENGINE LIFT BRACKETS REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 5 8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure left door guard removed (WP 0202) Engine enclosure right door guard removed (WP 0204)
0 0 0

Drawing Required
0

TM 5-2410-241-24P, Figure 13 Estimated Time to Complete 2.5 Hr

0058-1

TM 5-2410-241-23-2

0058

REMOVAL 1. Remove bolt (Figure 1, Item 12), washer (Figure 1, Item 11), and clamp (Figure 1, Item 13) from rear engine lifting bracket (Figure 1, Item 8).

00058

NOTE
Note position and location of tiedown straps to aid installation. 2. Remove tiedown straps (Figure 1, Item 14) from harness (Figure 1, Item 15). Discard tiedown straps and position harness aside. 3. Remove bolt (Figure 1, Item 1), washer (Figure 1, Item 2), clamp (Figure 1, Item 3), spacer (Figure 1, Item 18) and clamp (Figure 1, Item 17) from plate (Figure 1, Item 7). 4. Remove clamp (Figure 1, Item 3) from hose (Figure 1, Item 4). 5. Remove clamp (Figure 1, Item 17) from hose (Figure 1, Item 16). 6. Position hose (Figure 1, Item 16) and hose (Figure 1, Item 4) aside. 7. Remove two nuts (Figure 1, Item 9), washers (Figure 1, Item 10), bolts (Figure 1, Item 5), washers (Figure 1, Item 6) and plate (Figure 1, Item 7) from rear engine lifting bracket (Figure 1, Item 8).

Figure 1. Rear Engine Lifting Bracket Attachments.

0058

0058-2

TM 5-2410-241-23-2

0058

REMOVAL CONTINUED 8. Remove tiedown straps (Figure 2, Item 2) from harness (Figure 2, Item 3). Position harness aside. 9. Remove six bolts (Figure 2, Item 7), washers (Figure 2, Item 6), two clips (Figure 2, Item 1), lifting bracket (Figure 2, Item 4) and spacer (Figure 2, Item 5) from engine (Figure 2, Item 8).

Figure 2. Rear Engine Lifting Bracket. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install spacer (Figure 2, Item 5), lifting bracket (Figure 2, Item 4), two clips (Figure 2, Item 1), six washers (Figure 2, Item 6), and bolts (Figure 2, Item 7) on engine (Figure 2, Item 8). 2. Install tiedown straps (Figure 2, Item 2) on harness (Figure 2, Item 3).

0058

00058

00058

0058-3

TM 5-2410-241-23-2

0058

INSTALLATION CONTINUED 3. Install plate (Figure 3, Item 7), two washers (Figure 3, Item 6), bolts (Figure 3, Item 5), washers (Figure 3, Item 10), and nuts (Figure 3, Item 9) on rear engine lifting bracket (Figure 3, Item 8). 4. Position hose (Figure 3, Item 16) and hose (Figure 3, Item 4) on machine. 5. Install clamp (Figure 3, Item 17) on hose (Figure 3, Item 16). 6. Install clamp (Figure 3, Item 3) on hose (Figure 3, Item 4). 7. Install clamp (Figure 3, Item 17), spacer (Figure 3, Item 18), clamp (Figure 3, Item 3), washer (Figure 3, Item 2), and bolt (Figure 3, Item 1) on plate (Figure 3, Item 7).

NOTE
Install tiedown straps as noted during removal. 8. Install new tiedown straps (Figure 3, Item 14) on harness (Figure 3, Item 15). 9. Install clamp (Figure 3, Item 13), washer (Figure 3, Item 11), and bolt (Figure 3, Item 12) on rear engine lifting bracket (Figure 3, Item 8).

Figure 3. Rear Engine Lifting Bracket Attachments. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure right door guard (WP 0204). 2. Install engine enclosure left door guard (WP 0202). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0058

00058

0058-4

64 TM 5-2410-241-23-2 0059

FIELD MAINTENANCE
0 0 5 9

ENGINE REPLACEMENT TRANSFER OF PARTS Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) Sling, Multiple Leg (WP 0302, Item 54) Wrench, Combination 1-1/8 (S0788) (WP 0302, Item 68) Lifting Device (500-lb) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Sealing Compound 577 (WP 0303, Item 32) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36)
0

Materials/Parts - Continued O-ring (16)

References
0

WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Engine removed and on engine stand (WP 0057) Implement pump removed (WP 0112) Drawing Required TM 5-2410-241-24P, Figure 13 Estimated Time to Complete 37.5 Hr

0059-1

TM 5-2410-241-23-2

0059

REMOVAL 1. Remove four bolts (Figure 1, Item 14), washers (Figure 1, Item 13) from line (Figure 1, Item 7) and torque converter (Figure 1, Item 1).

00059

2. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 3) from line (Figure 1, Item 12) and transmission oil cooler (Figure 1, Item 8). 3. Remove four bolts (Figure 1, Item 5), washers (Figure 1, Item 6) and split flanges (Figure 1, Item 4) from transmission oil cooler (Figure 1, Item 8). 4. Remove two bolts (Figure 1, Item 10), washers (Figure 1, Item 11), bracket (Figure 1, Item 9) and lines (Figure 1, Items 12 and 7) from torque converter (Figure 1, Item 1).

Figure 1. Lines.

0059

0059-2

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Note size and position of O-rings to aid installation. 5. Remove three O-rings (Figure 2, Item 1) from two lines (Figure 2, Item 2). Discard O-rings.

Figure 2. Line O-rings.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Tag hoses and electrical connectors to aid installation. 6. Loosen tube nut (Figure 3, Item 6) and remove hose (Figure 3, Item 7) from fitting (Figure 3, Item 5). 7. Remove fitting (Figure 3, Item 5) and two O-rings (Figure 3, Item 4) from engine (Figure 3, Item 11). Discard Orings. 8. Remove tiedown strap (Figure 3, Item 19) from connector (Figure 3, Item 18). Discard tiedown strap. 9. Disconnect connector (Figure 3, Item 18) from speed sensor (Figure 3, Item 13). 10. Disconnect connector (Figure 3, Item 14) from temperature sensor (Figure 3, Item 15). 11. Remove tiedown straps (Figure 3, Item 17) and harness (Figure 3, Item 16) from torque converter (Figure 3, Item 12). Position harness aside and discard tiedown straps. 12. Remove bolt (Figure 3, Item 2), washer (Figure 3, Item 3) and clip (Figure 3, Item 1) from torque converter (Figure 3, Item 12).

0059-4

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

WARNING

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

NOTE
Torque converter weighs approximately 320 lb (145 kg). Note position of bolts to aid installation.

13. Attach bracket link, bolt (Figure 3, Item 2) and lifting device to torque converter (Figure 3, Item 12). 14. Using lifting device, remove ten bolts (Figure 3, Item 9), washers (Figure 3, Item 10), clamp (Figure 3, Item 8), hose (Figure 3, Item 7) and torque converter (Figure 3, Item 12) from engine (Figure 3, Item 11). 15. Remove lifting device, bolt (Figure 3, Item 2) and bracket link from torque converter (Figure 3, Item 12). 16. Remove two O-rings (Figure 3, Item 20) from torque converter (Figure 3, Item 12). Discard O-rings.

Figure 3. Torque Converter.

0059

0059-5

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Note harness routing, mark, and tag all electrical connectors to aid installation. 17. Disconnect connector (Figure 4, Item 6) from alternator (Figure 4, Item 5). 18. Remove bolt (Figure 4, Item 8), washers (Figure 4, Item 7) and harness clip (Figure 4, Item 9) from alternator (Figure 4, Item 5). 19. Remove two nuts (Figure 4, Item 2), washers (Figure 4, Item 3) and harness clips (Figure 4, Item 4) from temperature regulator (Figure 4, Item 10). 20. Position harness (Figure 4, Item 1) aside.

Figure 4. Alternator Harness.

0059

0059-6

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Note harness routing, mark, and tag all electrical connectors to aid installation. 21. Disconnect connector (Figure 5, Item 2) from connector (Figure 5, Item 1). 22. Remove two bolts (Figure 5, Item 8), and washers (Figure 5, Item 7) from bracket (Figure 5, Item 6). 23. Position bracket (Figure 5, Item 6) and harness (Figure 5, Item 3) aside from muffler bracket (Figure 5, Item 4). 24. Remove tiedown straps (Figure 5, Item 5) from harness (Figure 5, Item 3). Position harness aside and discard tiedown straps.

Figure 5. A/C Harness.

0059

0059-7

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Note position and routing of harness to aid installation. 25. Remove three bolts (Figure 6, Item 4), washers (Figure 6, Item 3) and harness clips (Figure 6, Item 5) from engine (Figure 6, Item 8). 26. Remove tiedown straps (Figure 6, Item 1) and harness (Figure 6, Item 2) from engine (Figure 6, Item 8). Discard tiedown straps. 27. Remove fitting (Figure 6, Item 7) and O-ring (Figure 6, Item 6) from engine (Figure 6, Item 8). Discard O-ring.

Figure 6. Rear Engine Harness.

0059

0059-8

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 28. Remove nut (Figure 7, Item 1), washer (Figure 7, Item 8), bolt (Figure 7, Item 11), washer (Figure 7, Item 10) and two P-clips (Figure 7, Items 9 and 12) from line (Figure 7, Item 2). 29. Loosen clamp (Figure 7, Item 3) and remove hose (Figure 7, Item 7) from fitting (Figure 7, Item 4). Position hose aside.

NOTE
Note orientation of valve and fitting to aid installation. 30. Remove valve (Figure 7, Item 4) and fitting (Figure 7, Item 5) from water pump elbow (Figure 7, Item 6).

Figure 7. Water Pump Elbow.

0059

0059-9

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 31. Remove O-ring (Figure 8, Item 4) from valve (Figure 8, Item 1). Discard O-ring. 32. Remove O-ring (Figure 8, Item 3) from fitting (Figure 8, Item 2). Discard O-ring.

Figure 8. Valve and Fitting.

0059

0059-10

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Tag hoses to aid installation. 33. Remove nut (Figure 9, Item 2), washer (Figure 9, Item 3), and P-clip (Figure 9, Item 4) from two hoses (Figure 9, Items 8 and 5). 34. Remove bolt (Figure 9, Item 11), washer (Figure 9, Item 10) and bracket (Figure 9, Item 9) from engine. Position hose (Figure 9, Item 8) and bracket aside. 35. Loosen clamp (Figure 9, Item 13) and remove hose (Figure 9, Item 1) from fitting (Figure 9, Item 12). Position hose aside. 36. Loosen clamp (Figure 9, Item 6) and remove hose (Figure 9, Item 5) from valve (Figure 9, Item 7). Position hose aside.

Figure 9. Oil Cooler Hoses.

0059

0059-11

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 37. Remove bolt (Figure 10, Item 8), washer (Figure 10, Item 7) and bracket (Figure 10, Item 1) from engine.

NOTE
Note position and orientation of fittings, elbow and valve to aid installation. 38. Remove fitting (Figure 10, Item 6) from fitting (Figure 10, Item 5). 39. Remove fitting (Figure 10, Item 5) from elbow (Figure 10, Item 4). 40. Remove elbow (Figure 10, Item 4) from oil cooler (Figure 10, Item 2). 41. Remove valve (Figure 10, Item 3) from oil cooler (Figure 10, Item 2).

Figure 10. Oil Cooler Hoses.

0059

0059-12

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 42. Remove bolt (Figure 11, Item 3), washer (Figure 11, Item 4), P-clip (Figure 11, Item 2), spacer (Figure 11, Item 5), and P-clip (Figure 11, Item 1), from bracket (Figure 11, Item 6). 43. Remove three hoses (Figure 11, Item 7) from engine.

Figure 11. Oil Cooler Hoses.

0059

0059-13

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Note proper belt tension before loosening nuts. 44. Loosen nut (Figure 12, Item 4) and nut (Figure 12, Item 14) from block (Figure 12, Item 5). 45. Loosen nut (Figure 12, Item 9), and bolt (Figure 12, Item 3) from block (Figure 12, Item 5). 46. Loosen bolt (Figure 12, Item 16) and bolt (Figure 12, Item 6) from bracket (Figure 12, Item 8). 47. Remove belt (Figure 12, Item 1) from A/C compressor (Figure 12, Item 2). 48. Remove bolt (Figure 12, Item 10), washer (Figure 12, Item 11), shaft (Figure 12, Item 13), and washer (Figure 12, Item 12) from bracket (Figure 12, Item 8). 49. Remove bolt (Figure 12, Item 6), washer (Figure 12, Item 7), bolt (Figure 12, Item 16), washer (Figure 12, Item 15) and A/C compressor (Figure 12, Item 2) from bracket (Figure 12, Item 8).

Figure 12. Compressor.

0059

0059-14

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 50. Remove four bolts (Figure 13, Item 2), washers (Figure 13, Item 1) and upper bracket (Figure 13, Item 3) from machine.

Figure 13. Upper Compressor Bracket.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Cap and plug all lines, hoses and tubes to prevent contamination and leaks. Tag lines, hoses and fittings to aid installation.

51. Loosen tube nut (Figure 14, Item 2) and remove line (Figure 14, Item 3) from fitting (Figure 14, Item 1). 52. Loosen tube nut (Figure 14, Item 4) and remove line (Figure 14, Item 3) from fitting (Figure 14, Item 5). 53. Remove bolt (Figure 14, Item 8), washer (Figure 14, Item 9), P-clip (Figure 14, Item 10) and line (Figure 14, Item 3) from engine. 54. Remove fitting (Figure 14, Item 5) from injection pump (Figure 14, Item 7). 55. Remove O-ring (Figure 14, Item 6) from fitting (Figure 14, Item 5). Discard O-ring.

Figure 14. Fuel Line.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 56. Remove bolt (Figure 15, Item 1), washer (Figure 15, Item 2), and P-clip (Figure 15, Item 3) from engine.

Figure 15. Filter Drain Hose.

0059

0059-17

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 57. Remove five bolts (Figure 16, Item 2), washers (Figure 16, Item 3), and P-clip (Figure 16, Item 1) from air cleaner bracket (Figure 16, Item 4). Position hose (Figure 16, Item 9) aside. 58. Remove two bolts (Figure 16, Item 5), washers (Figure 16, Item 6), fuel filter base (Figure 16, Item 7), and bracket (Figure 16, Item 8) from engine.

Figure 16. Filter and Bracket.

0059

0059-18

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 59. Loosen clamp (Figure 17, Item 1) from hose (Figure 17, Item 4). 60. Remove hose (Figure 17, Item 4) from fitting (Figure 17, Item 2). 61. Remove fitting (Figure 17, Item 2) from engine. 62. Remove O-ring (Figure 17, Item 3) from fitting (Figure 17, Item 2). Discard O-ring.

Figure 17. Heater Hose.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 63. Loosen nut (Figure 18, Item 7) and clamp (Figure 18, Item 6) on muffler (Figure 18, Item 1). 64. Remove two bolts (Figure 18, Item 4), washer (Figure 18, Item 3) and muffler (Figure 18, Item 1) from bracket (Figure 18, Item 2) and exhaust elbow (Figure 18, Item 5).

Figure 18. Muffler.

0059

0059-20

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 65. Remove three bolts (Figure 19, Item 3), washers (Figure 19, Item 4) and muffler bracket (Figure 19, Item 1) from air cleaner bracket (Figure 19, Item 2).

Figure 19. Muffler Bracket.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Do not loosen clamps and hoses from pipe. Pipe assembly will remove with hoses attached. 66. Loosen clamp (Figure 20, Item 2) from hose (Figure 20, Item 3). 67. Remove hose (Figure 20, Item 3) from aftercooler (Figure 20, Item 1). 68. Loosen clamp (Figure 20, Item 4) from hose (Figure 20, Item 5). 69. Remove hose (Figure 20, Item 5) from water temperature regulator housing (Figure 20, Item 9). 70. Loosen clamp (Figure 20, Item 7) from hose (Figure 20, Item 6). 71. Remove hose (Figure 20, Item 6) from fitting (Figure 20, Item 8). Set hose aside.

Figure 20. Hose Clamps.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 72. Remove nut (Figure 21, Item 2), washer (Figure 21, Item 3), bolt (Figure 21, Item 4), and washer (Figure 21, Item 5) from pipe assembly (Figure 21, Item 1).

Figure 21. Pipe to Engine.

0059

0059-23

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Pipe assembly will remove with hoses attached. 73. Remove bolt (Figure 22, Item 2), washer (Figure 22, Item 3) and pipe assembly (Figure 22, Item 1) from engine.

Figure 22. Pipe to Air Cleaner Bracket.

0059

0059-24

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 74. Remove bolt (Figure 23, Item 5), washer (Figure 23, Item 6) and ground strap (Figure 23, Item 4) from engine. Position ground strap aside. 75. Remove bolt (Figure 23, Item 3), and washer (Figure 23, Item 2) from alternator (Figure 23, Item 1).

Figure 23. Alternator Ground Strap.

0059

0059-25

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 76. Position pulley (Figure 24, Item 3) to gain access to bolt (Figure 24, Item 2). 77. Remove three bolts (Figure 24, Items 5 and 2), washers (Figure 24, Item 6) from adjustment bracket (Figure 24, Item 4). 78. Remove bolt (Figure 24, Item 7), washer (Figure 24, Item 8), alternator (Figure 24, Item 1) and adjustment bracket (Figure 24, Item 4) from engine.

Figure 24. Alternator.

0059

0059-26

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 79. Position pulley (Figure 25, Item 3) to gain access to bolt (Figure 25, Item 2). 80. Remove bolt (Figure 25, Item 2), and washer (Figure 25, item 1) from hub (Figure 25, Item 6).

WARNING

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

NOTE
Fan hub pulley assembly weighs approximately 95 lb (43 kg). 81. Attach nylon lifting strap and lifting device to fan hub pulley assembly (Figure 25, Item 1). Support fan hub pulley assembly. 82. Using lifting device, remove two nuts (Figure 25, Item 4), washers (Figure 25, Item 5), and hub (Figure 25, Item 6) from engine. Place hub on flat level surface. 83. Remove nylon lifting strap and lifting device from fan hub pulley assembly (Figure 25, Item 1).

Figure 25. Hub.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 84. Remove three bolts (Figure 26, Item 1) and washers (Figure 26, Item 2) from aftercooler housing (Figure 26, Item 3). 85. Remove three bolts (Figure 26, Item 6), washers (Figure 26, Item 5), and air cleaner bracket (Figure 26, Item 4) from engine.

Figure 26. Air Cleaner Housing Bracket.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 86. Remove two bolts (Figure 27, Item 6), washers (Figure 27, Item 5), clamp (Figure 27, Item 3) and harness (Figure 27, Item 4) from bracket assembly (Figure 27, Item 1). 87. Remove bracket assembly (Figure 27, Item 1) and cables (Figure 27, Item 2) from engine.

Figure 27. NATO Slave and Cables.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED

NOTE
Step shows left side engine mounts. Follow the same procedure for right side engine mounts. 88. Remove six bolts (Figure 28, Item 1), washers (Figure 28, Item 2) and engine mount (Figure 28, Item 3) from engine.

Figure 28. Engine Mount.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 89. Remove fitting (Figure 29, Item 3) from water temperature regulator housing (Figure 29, Item 1). 90. Remove O-ring (Figure 29, Item 2) from fitting (Figure 29, Item 3). Discard O-ring.

Figure 29. Coolant Fitting.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 91. Remove three bolts (Figure 30, Item 3), washers (Figure 30, Item 2), bracket (Figure 30, Item 4) and shield (Figure 30, Item 1) from engine.

Figure 30. Turbo Heat Shield.

0059

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TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 92. Loosen clamp (Figure 31, Item 6) from hose (Figure 31, Item 4). 93. Remove hose (Figure 31, Item 4) from fitting (Figure 31, Item 7). 94. Remove fitting (Figure 31, Item 7) and O-ring (Figure 31, Item 8) from transmission cooler (Figure 31, Item 5). Discard O-ring. 95. Remove two bolts (Figure 31, Item 1), washers (Figure 31, Item 2) and brackets (Figure 31, Item 3) from engine. Position hose (Figure 31, Item 4) and brackets aside.

Figure 31. Transmission Cooler Drain Hose.

0059

0059-33

TM 5-2410-241-23-2

0059

REMOVAL CONTINUED 96. Remove bolt (Figure 32, Item 1), washer (Figure 32, Item 7) and bracket (Figure 32, Item 6) from engine. Position hose (Figure 32, Item 5) and bracket aside. 97. Remove two bolts (Figure 32, Item 2), washers (Figure 32, Item 4), coupling (Figure 32, Item 3) and drain hoses (Figure 32, Item 5) from engine.

WARNING

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

NOTE
The engine assembly weighs approximately 3,750 lb (1,700 kg). 98. Remove engine from engine stand and place on a flat surface.

Figure 32. Drain Hoses. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0059

00059

0059-34

TM 5-2410-241-23-2

0059

INSTALLATION

00059

WARNING

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

NOTE
The engine assembly weighs approximately 3,750 lb (1,700 kg). 1. Install new engine on engine stand. 2. Install drain hoses (Figure 32, Item 5), coupling (Figure 32, Item 3), two washers (Figure 32, Item 4), and bolts (Figure 32, Item 2) on engine. 3. Position hose (Figure 32, Item 5) and bracket (Figure 32, Item 6) on engine. 4. Install bracket (Figure 32, Item 6), washer (Figure 32, Item 7) and bolt (Figure 32, Item 1) on engine. 5. Position hose (Figure 33, Item 4) and two brackets (Figure 33, Item 3) on engine. 6. Install two brackets (Figure 33, Item 3), washers (Figure 33, Item 2), and bolts (Figure 33, Item 1) on engine. 7. Install new O-ring (Figure 33, Item 8) and fitting (Figure 33, Item 7) on transmission cooler (Figure 33, Item 5). 8. Install hose (Figure 33, Item 4) on fitting (Figure 33, Item 7). 9. Install clamp (Figure 33, Item 6) on hose (Figure 33, Item 4).

Figure 33. Transmission Cooler Drain Hose.

0059

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TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 10. Install shield (Figure 34, Item 1), bracket (Figure 34, Item 4), three washers (Figure 34, Item 2), and bolts (Figure 34, Item 3) on engine.

Figure 34. Turbo Heat Shield. 11. Install new O-ring (Figure 35, Item 2) on fitting (Figure 35, Item 3). 12. Install fitting (Figure 35, Item 3) on water temperature regulator housing (Figure 35, Item 1).

0059

Figure 35. Coolant Fitting.

0059

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TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Step shows left side engine mounts. Follow the same procedure for right side engine mounts. 13. Install engine mount (Figure 36, Item 3), six washers (Figure 36, Item 2), and bolts (Figure 36, Item 1) on engine.

Figure 36. Engine Mount. 14. Install cables (Figure 37, Item 2) and bracket assembly (Figure 37, Item 1) on engine. 15. Install harness (Figure 37, Item 4), clamp (Figure 37, Item 3), two washers (Figure 37, Item 5), and bolts (Figure 37, Item 6) on bracket assembly (Figure 37, Item 1).

0059

Figure 37. NATO Slave and Cables.

0059

0059-37

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 16. Install air cleaner bracket (Figure 38, Item 4), three washers (Figure 38, Item 5), and bolts (Figure 38, Item 6) on engine. 17. Install three washers (Figure 38, Item 2) and bolts (Figure 38, Item 1) on aftercooler housing (Figure 38, Item 3).

Figure 38. Air Cleaner Housing Bracket.

0059

0059-38

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

WARNING

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

NOTE
Fan hub pulley assembly weighs approximately 95 lb (43 kg). 18. Attach nylon lifting strap and lifting device to fan hub pulley assembly (Figure 39, Item 1). Support fan hub pulley assembly. 19. Using lifting device, install hub (Figure 39, Item 6), two washers (Figure 39, Item 5) and nuts (Figure 39, Item 4) on engine. 20. Position pulley (Figure 39, Item 3) to gain access for bolt (Figure 39, Item 2). 21. Install washer (Figure 39, item 1) and bolt (Figure 39, Item 2) on hub (Figure 39, Item 6). 22. Remove nylon lifting strap and lifting device from fan hub pulley assembly (Figure 39, Item 1).

Figure 39. Hub.

0059

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TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 23. Install adjustment bracket (Figure 40, Item 4), alternator (Figure 40, Item 1), washer (Figure 40, Item 8), and bolt (Figure 40, Item 7) on engine. 24. Position pulley (Figure 40, Item 3) to gain access for bolt (Figure 40, Item 2). 25. Install three washers (Figure 40, Item 6), and bolts (Figure 40, Items 5 and 2) on adjustment bracket (Figure 40, Item 4).

Figure 40. Alternator.

0059

0059-40

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 26. Install washer (Figure 41, Item 2) and bolt (Figure 41, Item 3) on alternator (Figure 41, Item 1). 27. Install ground strap (Figure 41, Item 4), washer (Figure 41, Item 6), and bolt (Figure 41, Item 5) on engine.

Figure 41. Alternator Ground Strap.

0059

0059-41

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Pipe assembly will install with hoses attached. Position hoses before installing bolt on pipe. 28. Install pipe assembly (Figure 42, Item 1), washer (Figure 42, Item 3), and bolt (Figure 42, Item 2) on engine.

Figure 42. Pipe to Air Cleaner Bracket.

0059

0059-42

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 29. Install washer (Figure 43, Item 5), bolt (Figure 43, Item 4), washer (Figure 43, Item 3), and nut (Figure 43, Item 2) on pipe assembly (Figure 43, Item 1).

Figure 43. Pipe to Engine.

0059

0059-43

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 30. Install hose (Figure 44, Item 6) on fitting (Figure 44, Item 8). 31. Install clamp (Figure 44, Item 7) on hose (Figure 44, Item 6). 32. Install hose (Figure 44, Item 5) on water temperature regulator housing (Figure 44, Item 9). 33. Install clamp (Figure 44, Item 4) on hose (Figure 44, Item 5). 34. Install hose (Figure 44, Item 3) on aftercooler (Figure 44, Item 1). 35. Install clamp (Figure 44, Item 2) on hose (Figure 44, Item 3).

Figure 44. Hose Clamps.

0059

0059-44

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 36. Install muffler bracket (Figure 45, Item 1), three washers (Figure 45, Item 4), and bolts (Figure 45, Item 3) on air cleaner bracket (Figure 45, Item 2).

Figure 45. Muffler Bracket.

0059

0059-45

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 37. Install muffler (Figure 46, Item 1), two washers (Figure 46, Item 3) and bolts (Figure 46, Item 4) on exhaust elbow (Figure 46, Item 5) and bracket (Figure 46, Item 2). 38. Install clamp (Figure 46, Item 6) and nut (Figure 46, Item 7) on muffler (Figure 46, Item 1).

Figure 46. Muffler.

0059

0059-46

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 39. Install new O-ring (Figure 47, Item 3) on fitting (Figure 47, Item 2). 40. Install fitting (Figure 47, Item 2) on engine. 41. Install hose (Figure 47, Item 4) on fitting (Figure 47, Item 2). 42. Install clamp (Figure 47, Item 1) on hose (Figure 47, Item 4).

Figure 47. Heater Hose.

0059

0059-47

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 43. Install bracket (Figure 48, Item 8), fuel filter base (Figure 48, Item 7), two washers (Figure 48, Item 6), and bolts (Figure 48, Item 5) on engine. 44. Position hose (Figure 48, Item 9) on air cleaner bracket (Figure 48, Item 4). 45. Install P-clip (Figure 48, Item 1), five washers (Figure 48, Item 3), and bolts (Figure 48, Item 2) on air cleaner bracket (Figure 48, Item 4).

Figure 48. Filter and Bracket.

0059

0059-48

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 46. Install P-clip (Figure 49, Item 3), washer (Figure 49, Item 2) and bolt (Figure 49, Item 1) on engine.

Figure 49. Filter Drain Hose.

0059

0059-49

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Remove all caps and plugs from all lines, hoses and tubes. 47. Install new O-ring (Figure 50, Item 6) on fitting (Figure 50, Item 5). 48. Install fitting (Figure 50, Item 5) on injection pump (Figure 50, Item 7). 49. Install line (Figure 50, Item 3), P-clip (Figure 50, Item 10), washer (Figure 50, Item 9), and bolt (Figure 50, Item 8) on engine. 50. Install line (Figure 50, Item 3) and tube nut (Figure 50, Item 4) on fitting (Figure 50, Item 5). 51. Install line (Figure 50, Item 3) and tube nut (Figure 50, Item 2) on fitting (Figure 50, Item 1).

Figure 50. Fuel Line.

0059

0059-50

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 52. Install upper bracket (Figure 51, Item 3), four washers (Figure 51, Item 1) and bolts (Figure 51, Item 2) on engine.

Figure 51. Upper Compressor Bracket.

0059

0059-51

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 53. Install A/C compressor (Figure 52, Item 2), washer (Figure 52, Item 15), bolt (Figure 52, Item 16), washer (Figure 52, Item 7), and bolt (Figure 52, Item 6) on bracket (Figure 52, Item 8). 54. Install washer (Figure 52, Item 12), shaft (Figure 52, Item 13), washer (Figure 52, Item 11), and bolt (Figure 52, Item 10) on bracket (Figure 52, Item 8). 55. Install belt (Figure 52, Item 1) on A/C compressor (Figure 52, Item 2).

NOTE
Note proper belt tension before tightening nuts. 56. Tighten nut (Figure 52, Item 14) on block (Figure 52, Item 5) until belt (Figure 52, Item 1) has tension. 57. Tighten nut (Figure 52, Item 4) on block (Figure 52, Item 5). 58. Tighten nut (Figure 52, Item 9), and bolt (Figure 52, Item 3) on block (Figure 52, Item 5). 59. Tighten bolt (Figure 52, Item 16) and bolt (Figure 52, Item 6) on bracket (Figure 52, Item 8).

Figure 52. Compressor.

0059

0059-52

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 60. Install three hoses (Figure 53, Item 7) on engine. 61. Install P-clip (Figure 53, Item 1), spacer (Figure 53, Item 5), P-clip (Figure 53, Item 2), washer (Figure 53, Item 4), and bolt (Figure 53, Item 3) on bracket (Figure 53, Item 6).

Figure 53. Oil Cooler Hoses.

0059

0059-53

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Install fittings, elbow and valve as noted during removal. 62. Install valve (Figure 54, Item 3) on oil cooler (Figure 54, Item 2). 63. Install elbow (Figure 54, Item 4) on oil cooler (Figure 54, Item 2). 64. Install fitting (Figure 54, Item 5) on elbow (Figure 54, Item 4). 65. Install fitting (Figure 54, Item 6) on fitting (Figure 54, Item 5). 66. Install bracket (Figure 54, Item 1), washer (Figure 54, Item 7), and bolt (Figure 54, Item 8) on engine.

Figure 54. Oil Cooler Hoses.

0059

0059-54

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 67. Install hose (Figure 55, Item 5) and clamp (Figure 55, Item 6) on valve (Figure 55, Item 7). 68. Install hose (Figure 55, Item 1) and clamp (Figure 55, Item 13) on fitting (Figure 55, Item 12). 69. Position hose (Figure 55, Item 8) and bracket (Figure 55, Item 9) on engine. 70. Install bracket (Figure 55, Item 9), washer (Figure 55, Item 10), and bolt (Figure 55, Item 11) on engine. 71. Install P-clip (Figure 55, Item 4), washer (Figure 55, Item 3), and nut (Figure 55, Item 2) on two hoses (Figure 55, Items 8 and 5).

Figure 55. Oil Cooler Hoses.

0059

0059-55

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 72. Install new O-ring (Figure 56, Item 3) on fitting (Figure 56, Item 2). 73. Install new O-ring (Figure 56, Item 4) on valve (Figure 56, Item 1).

Figure 56. Valve and Fitting.

0059

0059-56

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Install fitting and valve as noted during removal. 74. Install fitting (Figure 57, Item 5) and valve (Figure 57, Item 4) on water pump elbow (Figure 57, Item 6). 75. Install hose (Figure 57, Item 7) and clamp (Figure 57, Item 3) on fitting (Figure 57, Item 4). 76. Install two P-clips (Figure 57, Items 9 and 12), washer (Figure 57, Item 10), bolt (Figure 57, Item 11), washer (Figure 57, Item 8) and nut (Figure 57, Item 1) on line (Figure 57, Item 2).

Figure 57. Water Pump Elbow.

0059

0059-57

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 77. Install new O-ring (Figure 58, Item 6) and fitting (Figure 58, Item 7) on engine (Figure 58, Item 8).

NOTE
Install harness as noted during removal. 78. Install new tiedown straps (Figure 58, Item 1) and harness (Figure 58, Item 2) on engine (Figure 58, Item 8). Discard tiedown straps. 79. Install three harness clips (Figure 58, Item 5), washers (Figure 58, Item 3) and bolts (Figure 58, Item 4) on engine (Figure 58, Item 8).

Figure 58. Rear Engine Harness.

0059

0059-58

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Install harness and all electrical connectors as noted during removal. 80. Position harness (Figure 59, Item 3) on engine. 81. Install new tiedown straps (Figure 59, Item 5) on harness (Figure 59, Item 3). 82. Position harness (Figure 59, Item 5) and bracket (Figure 59, Item 6) on muffler bracket (Figure 59, Item 4). 83. Install two washers (Figure 59, Item 7) and bolts (Figure 59, Item 8) on bracket (Figure 59, Item 6). 84. Connect connector (Figure 59, Item 2) on connector (Figure 59, Item 1).

Figure 59. A/C Harness.

0059

0059-59

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Install harness and all electrical connectors as noted during removal. 85. Position harness (Figure 60, Item 1) on engine. 86. Install two harness clips (Figure 60, Item 4), washers (Figure 60, Item 3), and nuts (Figure 60, Item 2) on temperature regulator (Figure 60, Item 10). 87. Install harness clip (Figure 60, Item 9), washers (Figure 60, Item 7), and bolt (Figure 60, Item 8) on alternator (Figure 60, Item 5). 88. Connect connector (Figure 60, Item 6) on alternator (Figure 60, Item 5).

Figure 60. Alternator Harness. 89. Install two new O-rings (Figure 61, Item 20) on torque converter (Figure 61, Item 12).

0059

WARNING

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

0059-60

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Torque converter weighs approximately 320 lb (145 kg). Install bolts as noted during removal.

90. Attach bracket link and lifting device on torque converter (Figure 61, Item 12). 91. Using lifting device, position torque converter (Figure 61, Item 12), hose (Figure 61, Item 7), and clamp (Figure 61, Item 8), and install ten washers (Figure 61, Item 10) and bolts (Figure 61, Item 9) on engine (Figure 61, Item 11). 92. Remove lifting device and bracket link from torque converter (Figure 61, Item 12). 93. Install clip (Figure 61, Item 1), washer (Figure 61, Item 3), and bolt (Figure 61, Item 2) on torque converter (Figure 61, Item 12). 94. Install harness (Figure 61, Item 16) and new tiedown straps (Figure 61, Item 17) on torque converter (Figure 61, Item 12). 95. Connect connector (Figure 61, Item 14) on temperature sensor (Figure 61, Item 15). 96. Connect connector (Figure 61, Item 18) on speed sensor (Figure 61, Item 13). 97. Install new tiedown strap (Figure 61, Item 19) on connector (Figure 61, Item 18). 98. Install two new O-rings (Figure 61, Item 4) and fitting (Figure 61, Item 5) on engine (Figure 61, Item 11). 99. Install hose (Figure 61, Item 7) and tube nut (Figure 61, Item 6) on fitting (Figure 61, Item 5).

Figure 61. Torque Converter.

0059

0059-61

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED

NOTE
Note size and position of O-rings to aid installation. 100.Install three new O-rings (Figure 62, Item 1) on two lines (Figure 62, Item 2).

Figure 62. Line O-rings.

0059

0059-62

TM 5-2410-241-23-2

0059

INSTALLATION CONTINUED 101.Install lines (Figure 63, Items 12 and 7), bracket (Figure 63, Item 9), two washers (Figure 63, Item 11), and bolts (Figure 63, Item 10) on torque converter (Figure 63, Item 1). 102.Install split flanges (Figure 63, Item 4), four washers (Figure 63, Item 6) and bolts (Figure 63, Item 5) on transmission oil cooler (Figure 63, Item 8). 103.Install four washers (Figure 63, Item 3) and bolts (Figure 63, Item 2) on transmission oil cooler (Figure 63, Item 8) and line (Figure 63, Item 12). 104.Install four washers (Figure 63, Item 13) and bolts (Figure 63, Item 14) on line (Figure 63, Item 7) and torque converter (Figure 63, Item 1).

Figure 63. Lines. END OF TASK FOLLOW-ON TASKS 1. Install implement pump (WP 0112). 2. Remove engine from stand and install engine (WP 0057). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0059

00059

0059-63/(64 blank)

20 TM 5-2410-241-23-2 0060

FIELD MAINTENANCE ETHER BOTTLE, VALVE, BRACKET, AND RELAY REPLACEMENT Ether Bottle Removal, Ether Line Removal, Ether Valve Removal, Ether Valve and Bottle Support Bracket Removal, Ether Relay Removal, Cleaning and Inspection, Ether Relay Installation, Ether Valve and Bottle Support Bracket Installation, Ether Valve Installation, Ether Line Installation, Ether Bottle Installation
0 0 6 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) Gasket References TM 5-2410-241-10 WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10)

Drawing Required
0

TM 5-2410-241-24P, Figure 17 Estimated Time to Complete

1.0 Hr
0 0

0060-1

TM 5-2410-241-23-2

0060

ETHER BOTTLE REMOVAL 1. Loosen clamp (Figure 1, Item 2) from bottle (Figure 1, Item 1). 2. Remove bottle (Figure 1, Item 1) from ether valve (Figure 1, Item 3) and clamp (Figure 1, Item 2).

00060

Figure 1. Ether Bottle.

0060

0060-2

TM 5-2410-241-23-2

0060

ETHER BOTTLE REMOVAL CONTINUED 3. Remove gasket (Figure 2, Item 1) from ether valve (Figure 2, Item 2). Discard gasket.

Figure 2. Ether Bottle Gasket. END OF TASK

0060

0060-3

TM 5-2410-241-23-2

0060

ETHER LINE REMOVAL 1. Loosen tube nut (Figure 3, Item 3) and remove line (Figure 3, Item 4) from fitting (Figure 3, Item 2). 2. Remove fitting (Figure 3, Item 2) from aftercooler housing (Figure 3, Item 1). 3. Remove two bolts (Figure 3, Item 9), washers (Figure 3, Item 8), and clamps (Figure 3, Item 10) from line (Figure 3, Item 4). 4. Loosen tube nut (Figure 3, Item 7) and remove line (Figure 3, Item 4) from fitting (Figure 3, Item 6). 5. Remove fitting (Figure 3, Item 6) from ether valve (Figure 3, Item 5).

00060

Figure 3. Ether Line. END OF TASK

0060

0060-4

TM 5-2410-241-23-2

0060

ETHER VALVE REMOVAL 1. Loosen clamp (Figure 4, Item 2) from bottle (Figure 4, Item 1). 2. Remove bottle (Figure 4, Item 1) from ether valve (Figure 4, Item 3) and clamp (Figure 4, Item 2). 3. Loosen tube nut (Figure 4, Item 5) and remove line (Figure 4, Item 6) from fitting (Figure 4, Item 4).

00060

Figure 4. Ether Bottle and Line.

0060

0060-5

TM 5-2410-241-23-2

0060

ETHER VALVE REMOVAL CONTINUED 4. Remove tiedown strap (Figure 5, Item 11) and disconnect connector (Figure 5, Item 12) from connector (Figure 5, Item 13). Discard tiedown strap. 5. Remove two nuts (Figure 5, Item 8), washers (Figure 5, Item 9), clip (Figure 5, Item 10), and bracket (Figure 5, Item 7) from machine. 6. Remove gasket (Figure 5, Item 6) from valve (Figure 5, Item 14). Discard gasket. 7. Remove cap (Figure 5, Item 5) from housing (Figure 5, Item 1). 8. Remove screw (Figure 5, Item 2) and housing (Figure 5, Item 1) from bracket (Figure 5, Item 15). 9. Remove two bolts (Figure 5, Item 3), tether (Figure 5, Item 4), cap (Figure 5, Item 5), bracket (Figure 5, Item 15), and valve (Figure 5, Item 14) from bracket (Figure 5, Item 7). 10. Remove fitting (Figure 5, Item 16) from valve (Figure 5, Item 14).

Figure 5. Ether Valve. END OF TASK

0060

0060-6

TM 5-2410-241-23-2

0060

ETHER VALVE AND BOTTLE SUPPORT BRACKET REMOVAL 1. Loosen clamp (Figure 6, Item 4) from bottle (Figure 6, Item 5). 2. Remove bottle (Figure 6, Item 5) from ether valve (Figure 6, Item 7) and clamp (Figure 6, Item 4). 3. Loosen tube nut (Figure 6, Item 9) and remove line (Figure 6, Item 10) from fitting (Figure 6, Item 8). 4. Remove two bolts (Figure 6, Item 12), washers (Figure 6, Item 13), and clamps (Figure 6, Item 11) from line (Figure 6, Item 10). Position line aside. 5. Remove two bolts (Figure 6, Item 2), washers (Figure 6, Item 3), clip (Figure 6, Item 1), and clamp (Figure 6, Item 4) from bracket (Figure 6, Item 6). Position clip and harness (Figure 6, Item 14) aside.

00060

Figure 6. Ether Bottle and Line.

0060

0060-7

TM 5-2410-241-23-2

0060

ETHER VALVE AND BOTTLE SUPPORT BRACKET REMOVAL CONTINUED 6. Remove tiedown strap (Figure 7, Item 11) and disconnect connector (Figure 7, Item 12) from connector (Figure 7, Item 13). Discard tiedown strap. 7. Remove two nuts (Figure 7, Item 8), washers (Figure 7, Item 9), clip (Figure 7, Item 10), and bracket (Figure 7, Item 7) from machine. 8. Remove gasket (Figure 7, Item 6) from valve (Figure 7, Item 14). Discard gasket. 9. Remove cap (Figure 7, Item 5) from housing (Figure 7, Item 1). 10. Remove screw (Figure 7, Item 2) and housing (Figure 7, Item 1) from bracket (Figure 7, Item 15). 11. Remove two bolts (Figure 7, Item 3), tether (Figure 7, Item 4), cap (Figure 7, Item 5), bracket (Figure 7, Item 15), and valve (Figure 7, Item 14) from bracket (Figure 7, Item 7). 12. Remove fitting (Figure 7, Item 16) from valve (Figure 7, Item 14).

Figure 7. Ether Valve.

0060

0060-8

TM 5-2410-241-23-2

0060

ETHER VALVE AND BOTTLE SUPPORT BRACKET REMOVAL CONTINUED 13. Remove tiedown straps (Figure 8, Item 2) and harness (Figure 8, Item 6) from bracket (Figure 8, Item 1). Discard tiedown straps and position harness aside. 14. Remove three bolts (Figure 8, Item 5), washers (Figure 8, Item 4), one spacer (Figure 8, Item 3), and bracket (Figure 8, Item 1) from machine.

Figure 8. Ether Valve Mounting Bracket. END OF TASK

0060

0060-9

TM 5-2410-241-23-2

0060

ETHER RELAY REMOVAL 1. Disconnect engine harness connector (Figure 9, Item 5) from ether relay (Figure 9, Item 4). Position engine harness connector aside. 2. Remove bolt (Figure 9, Item 3), washer (Figure 9, Item 2), and ether relay (Figure 9, Item 4) from bracket (Figure 9, Item 1).

Figure 9. Ether Relay. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0060

00060

0060-10

TM 5-2410-241-23-2

0060

ETHER RELAY INSTALLATION 1. Install ether relay (Figure 10, Item 4), washer (Figure 10, Item 2), and bolt (Figure 10, Item 3) on bracket (Figure 10, Item 1). 2. Connect engine harness connector (Figure 10, Item 5) on ether relay (Figure 10, Item 4).

Figure 10. Ether Relay. END OF TASK

0060

0060-11

TM 5-2410-241-23-2

0060

ETHER VALVE AND BOTTLE SUPPORT BRACKET INSTALLATION 1. Install bracket (Figure 11, Item 1), spacer (Figure 11, Item 3), three washers (Figure 11, Item 4), and bolts (Figure 11, Item 5) on machine. 2. Install tiedown straps (Figure 11, Item 2) and harness (Figure 11, Item 6) on bracket (Figure 11, Item 1).

00060

Figure 11. Ether Valve Mounting Bracket.

0060

0060-12

TM 5-2410-241-23-2

0060

ETHER VALVE AND BOTTLE SUPPORT BRACKET INSTALLATION CONTINUED 3. Install fitting (Figure 12, Item 16) on valve (Figure 12, Item 14). 4. Install valve (Figure 12, Item 14), bracket (Figure 12, Item 15), cap (Figure 12, Item 5), tether (Figure 12, Item 4), and two bolts (Figure 12, Item 3) on bracket (Figure 12, Item 7). 5. Install housing (Figure 12, Item 1) and screw (Figure 12, Item 2) on bracket (Figure 12, Item 15). 6. Install cap (Figure 12, Item 5) on housing (Figure 12, Item 1). 7. Install new gasket (Figure 12, Item 6) on valve (Figure 12, Item 14). 8. Install bracket (Figure 12, Item 7), clip (Figure 12, Item 10), two washers (Figure 12, Item 9), and nuts (Figure 12, Item 8) on machine. 9. Connect connector (Figure 12, Item 12) to connector (Figure 12, Item 13). 10. Install new tiedown strap (Figure 12, Item 11) on connector (Figure 12, Item 13).

Figure 12. Ether Valve.

0060

0060-13

TM 5-2410-241-23-2

0060

ETHER VALVE AND BOTTLE SUPPORT BRACKET INSTALLATION CONTINUED 11. Position clip (Figure 13, Item 1) and harness (Figure 13, Item 14) on bracket (Figure 13, Item 6). 12. Install clamp (Figure 13, Item 4), clip (Figure 13, Item 1), two washers (Figure 13, Item 3), and bolts (Figure 13, Item 2) on bracket (Figure 13, Item 6). 13. Install clamps (Figure 13, Item 11), two washers (Figure 13, Item 13), and bolts (Figure 13, Item 12) on line (Figure 13, Item 10). 14. Install line (Figure 13, Item 10) and tube nut (Figure 13, Item 9) on fitting (Figure 13, Item 8). 15. Install bottle (Figure 13, Item 5) on clamp (Figure 13, Item 4) and ether valve (Figure 13, Item 7). 16. Tighten clamp (Figure 13, Item 4) on bottle (Figure 13, Item 5).

Figure 13. Ether Bottle and Line. END OF TASK

0060

0060-14

TM 5-2410-241-23-2

0060

ETHER VALVE INSTALLATION 1. Install fitting (Figure 14, Item 16) on valve (Figure 14, Item 14). 2. Install valve (Figure 14, Item 14), bracket (Figure 14, Item 15), cap (Figure 14, Item 5), tether (Figure 14, Item 4), and two bolts (Figure 14, Item 3) on bracket (Figure 14, Item 7). 3. Install housing (Figure 14, Item 1) and screw (Figure 14, Item 2) on bracket (Figure 14, Item 15). 4. Install cap (Figure 14, Item 5) on housing (Figure 14, Item 1). 5. Install new gasket (Figure 14, Item 6) on valve (Figure 14, Item 14).

00060

6. Install bracket (Figure 14, Item 7), clip (Figure 14, Item 10), two washers (Figure 14, Item 9), and nuts (Figure 14, Item 8) on machine. 7. Connect connector (Figure 14, Item 12) to connector (Figure 14, Item 13). 8. Install new tiedown strap (Figure 14, Item 11) on connector (Figure 14, Item 13).

Figure 14. Ether Valve.

0060

0060-15

TM 5-2410-241-23-2

0060

ETHER VALVE INSTALLATION CONTINUED 9. Install line (Figure 15, Item 6) and tube nut (Figure 15, Item 5) on fitting (Figure 15, Item 4). 10. Install bottle (Figure 15, Item 1) on clamp (Figure 15, Item 2) and ether valve (Figure 15, Item 3). 11. Tighten clamp (Figure 15, Item 2) on bottle (Figure 15, Item 1).

Figure 15. Ether Bottle and Line. END OF TASK

0060

0060-16

TM 5-2410-241-23-2

0060

ETHER LINE INSTALLATION 1. Install fitting (Figure 16, Item 6) on ether valve (Figure 16, Item 5). 2. Install line (Figure 16, Item 4) and tube nut (Figure 16, Item 7) on fitting (Figure 16, Item 6). 3. Install clamps (Figure 16, Item 10), two washers (Figure 16, Item 8), and bolts (Figure 16, Item 9) on line (Figure 16, Item 4). 4. Install fitting (Figure 16, Item 2) on aftercooler housing (Figure 16, Item 1). 5. Install line (Figure 16, Item 4) and tube nut (Figure 16, Item 3) on fitting (Figure 16, Item 2).

00060

Figure 16. Ether Line. END OF TASK

0060

0060-17

TM 5-2410-241-23-2

0060

ETHER BOTTLE INSTALLATION 1. Install new gasket (Figure 17, Item 1) on ether valve (Figure 17, Item 2).

00060

Figure 17. Ether Bottle Gasket.

0060

0060-18

TM 5-2410-241-23-2

0060

ETHER BOTTLE INSTALLATION CONTINUED 2. Install bottle (Figure 18, Item 1) on clamp (Figure 18, Item 2) and ether valve (Figure 18, Item 3). 3. Tighten clamp (Figure 18, Item 2) on bottle (Figure 18, Item 1).

Figure 18. Ether Bottle. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0060

00060

0060-19/(20 blank)

6 TM 5-2410-241-23-2 0061

FIELD MAINTENANCE STARTER REPLACEMENT Removal, Cleaning and Inspection, Installation

0 0 6 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Lifting Device (1000 lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure left door guard removed (WP 0202) Front and center bottom guards removed (WP 0199)
0 0 0

Personnel Required
0 0

Two Drawing Required TM 5-2410-241-24P, Figure 18 Estimated Time to Complete 3.0 Hr

0061-1

TM 5-2410-241-23-2

0061

REMOVAL

00061

NOTE
Tag and mark all cables to aid installation. 1. Position boot (Figure 1, Item 5) aside. 2. Remove nut (Figure 1, Item 1), cable (Figure 1, Item 4), and cable (Figure 1, Item 6) from starter (Figure 1, Item 7). Position cables aside. 3. Remove nut (Figure 1, Item 2) and cable (Figure 1, Item 3) from starter (Figure 1, Item 7). Position cables aside.

Figure 1. Power Cables.

0061

NOTE
Tag and mark all cables to aid installation. 4. Remove nut (Figure 2, Item 6), cable (Figure 2, Item 2), ground strap (Figure 2, Item 5), cable (Figure 2, Item 7), cable (Figure 2, Item 3), and cable (Figure 2, Item 4) from starter (Figure 2, Item 1). 5. Remove nut (Figure 2, Item 8) and cable (Figure 2, Item 7) from machine.

Figure 2. Ground Cables.

0061

0061-2

TM 5-2410-241-23-2

0061

REMOVAL CONTINUED

WARNING

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

NOTE
Starter weighs approximately 80 lb (36 kg). 6. Attach lifting device to starter (Figure 3, Item 2). 7. Using lifting device, remove three bolts (Figure 3, Item 1), starter (Figure 3, Item 2) and gasket (Figure 3, Item 3) from machine. Discard gasket. 8. Place starter (Figure 3, Item 2) on flat level surface and remove lifting device.

Figure 3. Starter. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0061

00061

0061-3

TM 5-2410-241-23-2

0061

INSTALLATION

00061

WARNING

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

NOTE
Starter weighs approximately 80 lb (36 kg). 1. Attach lifting device to starter (Figure 4, Item 2). 2. Using lifting device, install new gasket (Figure 4, Item 3), starter (Figure 4, Item 2) and three bolts (Figure 4, Item 1) on machine. 3. Remove lifting device from starter (Figure 4, Item 2).

Figure 4. Starter.

0061

0061-4

TM 5-2410-241-23-2

0061

INSTALLATION CONTINUED

NOTE
Install cables as noted during removal. 4. Install cable (Figure 5, Item 7) and nut (Figure 5, Item 8) on machine. 5. Install cable (Figure 5, Item 4), cable (Figure 5, Item 3), cable (Figure 5, Item 7), ground strap (Figure 5, Item 5), cable (Figure 5, Item 2), and nut (Figure 5, Item 6) on starter (Figure 5, Item 1).

Figure 5. Ground Cables.

0061

NOTE
Install cables as noted during removal. 6. Install cable (Figure 6, Item 3) and nut (Figure 6, Item 2) on starter (Figure 6, Item 7). 7. Install cable (Figure 6, Item 6), cable (Figure 6, Item 4), and nut (Figure 6, Item 1) on starter (Figure 6, Item 7). 8. Position boot (Figure 6, Item 5) over nut (Figure 6, Item 1).

Figure 6. Power Cables. END OF TASK

0061

0061-5

TM 5-2410-241-23-2

0061

FOLLOW-ON TASKS 1. Install engine enclosure left door guard (WP 0202). 2. Install front and center bottom guards (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00061

0061-6

12 TM 5-2410-241-23-2 0062

FIELD MAINTENANCE TURBOCHARGER REPLACEMENT Removal, Cleaning and Inspection, Installation

0 0 6 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket (4) Locknut (4) O-ring (5) Ring (2) References WP 0295 REMOVAL 1. Remove three bolts (Figure 1, Item 2) and washers (Figure 1, Item 3) from machine. 2. Position bracket (Figure 1, Item 4) and cable (Figure 1, Item 5) aside. 3. Remove guard (Figure 1, Item 1) from machine.
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Muffler removed (WP 0045) Engine enclosure right door guard removed (WP 0204) Drawing Required TM 5-2410-241-24P, Figure 19, 20 Estimated Time to Complete 3.0 Hr

00062

Figure 1. Guard.

0062

0062-1

TM 5-2410-241-23-2

0062

REMOVAL CONTINUED 4. Remove three bolts (Figure 2, Item 1), washers (Figure 2, Item 3) and plate (Figure 2, Item 2) from machine.

Figure 2. Guard Mount. 5. Remove four bolts (Figure 3, Item 5), washers (Figure 3, Item 6), and elbow (Figure 3, Item 2) from exhaust manifold (Figure 3, Item 7). 6. Remove coupler (Figure 3, Item 4) from turbocharger (Figure 3, Item 1). 7. Remove two rings (Figure 3, Item 3) from coupler (Figure 3, Item 4). Discard rings.

0062

Figure 3. Turbocharger Elbow.

0062

0062-2

TM 5-2410-241-23-2

0062

REMOVAL CONTINUED

NOTE
Tag lines to aid installation. 8. Remove nut (Figure 4, Item 4), bolt (Figure 4, Item 6), two washers (Figure 4, Item 5), and clamps (Figure 4, Item 1) from oil supply line (Figure 4, Item 2), and oil drain line (Figure 4, Item 3).

Figure 4. Line Clamp.

0062

0062-3

TM 5-2410-241-23-2

0062

REMOVAL CONTINUED 9. Remove two bolts (Figure 5, Item 2), washers (Figure 5, Item 3), spacers (Figure 5, Item 4), oil supply line (Figure 5, Item 6) and gasket (Figure 5, Item 5) from turbocharger (Figure 5, Item 1). Discard gasket. 10. Loosen tube nut (Figure 5, Item 9) and disconnect oil supply line (Figure 5, Item 6) from fitting (Figure 5, Item 8). 11. Remove fitting (Figure 5, Item 8), from engine (Figure 5, Item 10). 12. Remove O-ring (Figure 5, Item 7) from fitting (Figure 5, Item 8). Discard O-ring.

Figure 5. Oil Supply Line.

0062

0062-4

TM 5-2410-241-23-2

0062

REMOVAL CONTINUED 13. Remove two bolts (Figure 6, Item 5), washers (Figure 6, Item 4), spacers (Figure 6, Item 3) oil drain line (Figure 6, Item 6) and gasket (Figure 6, Item 1) from turbocharger (Figure 6, Item 2). Discard gasket. 14. Remove two bolts (Figure 6, Item 7) and fitting (Figure 6, Item 9) from engine (Figure 6, Item 10). 15. Remove fitting (Figure 6, Item 9) from oil drain line (Figure 6, Item 6). 16. Remove two O-rings (Figure 6, Item 8) from fitting (Figure 6, Item 9). Discard O-rings.

Figure 6. Oil Drain Line.

0062

0062-5

TM 5-2410-241-23-2

0062

REMOVAL CONTINUED 17. Loosen two clamps (Figure 7, Item 8) and remove elbow (Figure 7, Item 7) from machine. 18. Remove two clamps (Figure 7, Item 8) from elbow (Figure 7, Item 7). 19. Remove four bolts (Figure 7, Item 4), washers (Figure 7, Item 3), elbow (Figure 7, Item 2) and gasket (Figure 7, Item 1) from machine. Discard gasket. 20. Remove two O-rings (Figure 7, Item 10) from elbow (Figure 7, Item 2). Discard O-rings. 21. Remove four locknuts (Figure 7, Item 5) from turbocharger (Figure 7, Item 9). Discard locknuts. 22. Remove turbocharger (Figure 7, Item 9) and gasket (Figure 7, Item 6) from machine. Discard gasket.

Figure 7. Elbow. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install turbocharger (Figure 7, Item 9) and gasket (Figure 7, Item 6) on machine. 2. Install four new locknuts (Figure 7, Item 5) on turbocharger (Figure 7, Item 9). 3. Install two new O-rings (Figure 7, Item 10) on elbow (Figure 7, Item 2).

0062

00062

00062

4. Install new gasket (Figure 7, Item 1), elbow (Figure 7, Item 2), four washers (Figure 7, Item 3) and bolts (Figure 7, Item 4) on machine. 5. Install two clamps (Figure 7, Item 8) on elbow (Figure 7, Item 7). 6. Install elbow (Figure 7, Item 7) on machine and tighten two clamps (Figure 7, Item 8).

0062-6

TM 5-2410-241-23-2

0062

INSTALLATION CONTINUED

NOTE
Install lines as tagged during removal. 7. Install two new O-rings (Figure 8, Item 8) on fitting (Figure 8, Item 9). 8. Install fitting (Figure 8, Item 9) on oil drain line (Figure 8, Item 6). 9. Install fitting (Figure 8, Item 9) and two bolts (Figure 8, Item 7) on engine (Figure 8, Item 10). 10. Install new gasket (Figure 8, Item 1), oil drain line (Figure 8, Item 6), two spacers (Figure 8, Item 3), washers (Figure 8, Item 4) and bolts (Figure 8, Item 5) on turbocharger (Figure 8, Item 2).

Figure 8. Oil Drain Line.

0062

0062-7

TM 5-2410-241-23-2

0062

INSTALLATION CONTINUED 11. Install new O-ring (Figure 9, Item 7) on fitting (Figure 9, Item 8). 12. Install fitting (Figure 9, Item 8) on engine (Figure 9, Item 10). 13. Connect oil supply line (Figure 9, Item 6) on fitting (Figure 9, Item 8). Tighten tube nut (Figure 9, Item 9). 14. Install new gasket (Figure 9, Item 5), oil supply line (Figure 9, Item 6), two spacers (Figure 9, Item 4), washers (Figure 9, Item 3) and bolts (Figure 9, Item 2) on turbocharger (Figure 9, Item 1).

Figure 9. Oil Supply Line.

0062

0062-8

TM 5-2410-241-23-2

0062

INSTALLATION CONTINUED 15. Install clamps (Figure 10, Item 1) on oil supply line (Figure 10, Item 2) and oil drain line (Figure 10, Item 3). Install two washers (Figure 10, Item 5), bolt (Figure 10, Item 6) and nut (Figure 10, Item 4).

Figure 10. Line Clamp.

0062

0062-9

TM 5-2410-241-23-2

0062

INSTALLATION CONTINUED 16. Install two new rings (Figure 11, Item 3) on coupler (Figure 11, Item 4). 17. Install coupler (Figure 11, Item 4) on turbocharger (Figure 11, Item 1). 18. Install elbow (Figure 11, Item 2), four washers (Figure 11, Item 6) and bolts (Figure 11, Item 5) on exhaust manifold (Figure 11, Item 7).

Figure 11. Turbocharger Elbow. 19. Install plate (Figure 12, Item 2), three washers (Figure 12, Item 3) and bolts (Figure 12, Item 1) on machine.

0062

Figure 12. Guard Mount.

0062

0062-10

TM 5-2410-241-23-2

0062

INSTALLATION CONTINUED 20. Install guard (Figure 13, Item 1) on machine. 21. Position bracket (Figure 13, Item 4) and cable (Figure 13, Item 5). 22. Install three washers (Figure 13, Item 3) and bolts (Figure 13, Item 2) on machine.

Figure 13. Guard. END OF TASK FOLLOW-ON TASKS 1. Install muffler (WP 0045). 2. Install engine enclosure right door guard (WP 0204). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0062

00062

0062-11/(12 blank)

4 TM 5-2410-241-23-2 0063

FIELD MAINTENANCE
0 0 6 3

AIR INLET TEMPERATURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure right door guard removed (WP 0204) Drawing Required TM 5-2410-241-24P, Figure 15 Estimated Time to Complete 1.0 Hr

0063-1

TM 5-2410-241-23-2

0063

REMOVAL

00063

NOTE
Tag electrical connectors to aid installation. 1. Disconnect connector (Figure 1, Item 1) from air inlet temperature sensor (Figure 1, Item 2). 2. Remove air inlet temperature sensor (Figure 1, Item 2) from aftercooler (Figure 1, Item 3). 3. Remove O-ring (Figure 1, Item 4) from air inlet temperature sensor (Figure 1, Item 2). Discard O-ring.

Figure 1. Air Inlet Temperature Sensor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0063

00063

0063-2

TM 5-2410-241-23-2

0063

INSTALLATION

00063

NOTE
Install electrical connectors as tagged during removal. 1. Install new O-ring (Figure 2, Item 4) on air inlet temperature sensor (Figure 2, Item 2). 2. Install air inlet temperature sensor (Figure 2, Item 2) on aftercooler (Figure 2, Item 3). 3. Connect connector (Figure 2, Item 1) on air inlet temperature sensor (Figure 2, Item 2).

Figure 2. Air Inlet Temperature Sensor. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure right door guard (WP 0204). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0063

00063

0063-3/(4 blank)

4 TM 5-2410-241-23-2 0064

FIELD MAINTENANCE
0 0 6 4

COOLANT TEMPERATURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Drawing Required

Tool Kit, General Mechanics (WP 0302, Item 65) Socket, 3/8 Drive, 6 Point, Long, 7/8 (S0541) (WP 0302, Item 68)
0 0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring

TM 5-2410-241-24P, Figure 15 Estimated Time to Complete 3.0 Hr

0064-1

TM 5-2410-241-23-2

0064

REMOVAL

00064

NOTE
Tag electrical connectors to aid installation. 1. Disconnect connector (Figure 1, Item 2) from coolant temperature sensor (Figure 1, Item 1). 2. Remove coolant temperature sensor (Figure 1, Item 1) from engine (Figure 1, Item 3). 3. Remove O-ring (Figure 1, Item 4) from coolant temperature sensor (Figure 1, Item 1). Discard O-ring.

Figure 1. Coolant Temperature Sensor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0064

00064

00064

NOTE
Install electrical connectors as tagged during removal. 1. Install new O-ring (Figure 1, Item 4) on coolant temperature sensor (Figure 1, Item 1). 2. Install coolant temperature sensor (Figure 1, Item 1) on engine (Figure 1, Item 3). 3. Connect connector (Figure 1, Item 2) on coolant temperature sensor (Figure 1, Item 1). END OF TASK

0064-2

TM 5-2410-241-23-2

0064

FOLLOW-ON TASKS 1. Fill cooling system (WP 0113). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00064

0064-3/(4 blank)

4 TM 5-2410-241-23-2 0065

FIELD MAINTENANCE
0 0 6 5

FUEL TEMPERATURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 15
0

Estimated Time to Complete

0

0.5 Hr
0 0

0065-1

TM 5-2410-241-23-2

0065

REMOVAL

00065

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, glove, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

1. Close fuel valve (Figure 1, Item 1) on machine.

Figure 1. Fuel Valve.

0065

0065-2

TM 5-2410-241-23-2

0065

REMOVAL CONTINUED

NOTE
Tag electrical connectors to aid installation. 2. Disconnect connector (Figure 2, Item 4) from fuel temperature sensor (Figure 2, Item 3). 3. Remove fuel temperature sensor (Figure 2, Item 3) from filter base (Figure 2, Item 2). 4. Remove O-ring (Figure 2, Item 1) from fuel temperature sensor (Figure 2, Item 3). Discard O-ring.

Figure 2. Fuel Temperature Sensor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0065

00065

0065-3

TM 5-2410-241-23-2

0065

INSTALLATION

00065

NOTE
Install electrical connectors as tagged during removal. 1. Install new O-ring (Figure 4, Item 1) on fuel temperature sensor (Figure 4, Item 3). 2. Install fuel temperature sensor (Figure 4, Item 3) on filter base (Figure 4, Item 2). 3. Connect connector (Figure 4, Item 4) on fuel temperature sensor (Figure 4, Item 3).

Figure 3. Fuel Temperature Sensor. 4. Open fuel valve (Figure 4, Item 1) on machine.

0065

Figure 4. Fuel Valve. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0065

00065

0065-4

4 TM 5-2410-241-23-2 0066

FIELD MAINTENANCE
0 0 6 6

TURBOCHARGER INLET PRESSURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 11
0 0

Estimated Time to Complete 0.5 Hr

0066-1

TM 5-2410-241-23-2

0066

REMOVAL

00066

NOTE
Tag electrical connectors to aid installation. 1. Remove tiedown strap (Figure 1, Item 5) from connector (Figure 1, Item 6). Discard tiedown strap. 2. Disconnect connector (Figure 1, Item 4) from connector (Figure 1, Item 6). 3. Remove turbocharger inlet pressure sensor (Figure 1, Item 7) from fitting (Figure 1, Item 2). 4. Remove O-ring (Figure 1, Item 3) from fitting (Figure 1, Item 2). Discard O-ring. 5. Remove fitting (Figure 1, Item 2) from air cleaner housing (Figure 1, Item 1).

Figure 1. Turbocharger Inlet Pressure Sensor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0066

00066

0066-2

TM 5-2410-241-23-2

0066

INSTALLATION

00066

NOTE
Install electrical connectors as tagged during removal. 1. Install fitting (Figure 1, Item 2) on air cleaner housing (Figure 1, Item 1). 2. Install new O-ring (Figure 1, Item 3) on fitting (Figure 1, Item 2). 3. Install turbocharger inlet pressure sensor (Figure 1, Item 7) on fitting (Figure 1, Item 2). 4. Connect connector (Figure 1, Item 4) on connector (Figure 1, Item 6). 5. Install new tiedown strap (Figure 1, Item 5) on connector (Figure 1, Item 6). END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
00066

0066-3/(4 blank)

4 TM 5-2410-241-23-2 0067

FIELD MAINTENANCE EXHAUST MANIFOLD REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 6 7

INITIAL SETUP Tools and Special Tools

0

Equipment Condition Machine parked (TM 5-2410-241-10) Turbocharger removed (WP 0062) Engine oil filter, base and lines removed (WP 0083) Drawing Required TM 5-2410-241-24P, Figure 21 Estimated Time to Complete 6.5 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73)
0 0

Materials/Parts Antiseize Compound (WP 0303, Item 2) Rag, Wiping (WP 0303, Item 24) Gasket (6) Locknut (12) References WP 0295

0067-1

TM 5-2410-241-23-2

0067

REMOVAL 1. Remove 12 locknuts (Figure 1, Item 6), washers (Figure 1, Item 5), and spacers (Figure 1, Item 4) from exhaust manifold (Figure 1, Item 1). Discard locknuts.

00067

2. Remove exhaust manifold (Figure 1, Item 1) and six gaskets (Figure 1, Item 2) from machine. Discard gaskets. 3. Remove four studs (Figure 1, Item 8) from exhaust manifold (Figure 1, Item 1). 4. Remove 12 studs (Figure 1, Item 7) from the engine (Figure 1, Item 3).

Figure 1. Exhaust Manifold and Gaskets. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0067

00067

0067-2

TM 5-2410-241-23-2

0067

INSTALLATION

00067

NOTE
Apply liberal amount of antiseize on studs. 1. Install 12 studs (Figure 1, Item 7) on engine (Figure 1, Item 3). Tighten studs to 26 lb-ft (35 Nm). 2. Install four studs (Figure 1, Item 8) on exhaust manifold (Figure 1, Item 1). Tighten studs to 26 lb-ft (35 Nm). 3. Install six new gaskets (Figure 1, Item 2) and exhaust manifold (Figure 1, Item 1) on machine. 4. Install 12 spacers (Figure 1, Item 4), washers (Figure 1, Item 5) and new locknuts (Figure 1, Item 6) on exhaust manifold (Figure 1, Item 1). Tighten locknuts to 41 lb-ft (55 Nm). END OF TASK FOLLOW-ON TASKS 1. Install engine oil filter, base and lines (WP 0083). 2. Install turbocharger (WP 0062). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
00067

0067-3/(4 blank)

12 TM 5-2410-241-23-2 0068

FIELD MAINTENANCE AFTERCOOLER HOUSING SERVICE Removal, Cleaning and Inspection, Installation
0 0 6 8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Gasket (7) O-ring (7) References WP 0295 Equipment Condition
0

Equipment Condition - Continued

Arctic kit heater removed, if equipped (WP 0291) Ether valve, line and bracket removed (WP 0060) Air cleaner housing bracket removed (WP 0111) Water temperature regulator outlet hose and pipe removed (WP 0051) Rear engine lifting brackets removed (WP 0058) Exhaust manifold removed (WP 0067)
0 0 0 0 0 0

Drawing Required
0

TM 5-2410-241-24P, Figure 22 Estimated Time to Complete 7.5 Hr W/O Arctic, 11 Hr W/Arctic Heater

Machine parked (TM 5-2410-241-10) Engine enclosure right door guard removed (WP 0204)
0 0

REMOVAL 1. Remove two clamps (Figure 1, Item 2) and hose (Figure 1, Item 3), from tube (Figure 1, Item 1).

00068

Figure 1. Rear Coolant Hose.

0068

0068-1

TM 5-2410-241-23-2

0068

REMOVAL CONTINUED 2. Remove four bolts (Figure 2, Item 1), washers (Figure 2, Item 2), tube (Figure 2, Item 5) from aftercooler housing (Figure 2, Item 3). 3. Remove O-ring (Figure 2, Item 4) from tube (Figure 2, Item 5). Discard O-ring.

Figure 2. Rear Water Tube. 4. Remove spacer (Figure 3, Item 2) from housing (Figure 3, Item 3). 5. Remove gasket (Figure 3, Item 1) from spacer (Figure 3, Item 2). Discard gasket.

0068

Figure 3. Rear Water Tube Spacer.

0068

0068-2

TM 5-2410-241-23-2

0068

REMOVAL CONTINUED 6. Remove four bolts (Figure 4, Item 3), washers (Figure 4, Item 2), tube (Figure 4, Item 4) from aftercooler housing (Figure 4, Item 1). 7. Remove O-ring (Figure 4, Item 5) from tube (Figure 4, Item 4). Discard O-ring.

Figure 4. Front Water Tube. 8. Remove spacer (Figure 5, Item 2) from housing (Figure 5, Item 1). 9. Remove gasket (Figure 5, Item 3) from spacer (Figure 5, Item 2). Discard gasket.

0068

Figure 5. Front Water Tube Spacer.

0068

0068-3

TM 5-2410-241-23-2

0068

REMOVAL CONTINUED

NOTE
Note position of bolts and clips to aid installation. 10. Remove 24 bolts (Figure 6, Item 1), 22 washers (Figure 6, Item 7), two clips (Figure 6, Item 3), wiring harness (Figure 6, Item 6) and aftercooler housing cover (Figure 6, Item 2) from aftercooler lower housing (Figure 6, Item 5). Set harness aside. 11. Remove gasket (Figure 6, Item 4) from aftercooler housing cover (Figure 6, Item 2). Discard gasket.

Figure 6. Aftercooler Housing Upper Cover. 12. Remove aftercooler core (Figure 7, Item 1) from aftercooler lower housing (Figure 7, Item 4). 13. Remove two O-rings (Figure 7, Item 2) and gasket (Figure 7, Item 3) from aftercooler core (Figure 7, Item 1). Discard O-rings and gasket.

0068

Figure 7. Aftercooler Core.

0068

0068-4

TM 5-2410-241-23-2

0068

REMOVAL CONTINUED

NOTE
Mark, tag, and note routing of harness to aid installation. 14. Remove tiedown strap (Figure 8, Item 6) from harness (Figure 8, Item 5). Discard tiedown strap. 15. Disconnect connector (Figure 8, Item 7) from connector (Figure 8, Item 8). 16. Remove sensor (Figure 8, Item 1) from fitting (Figure 8, Item 2). 17. Remove fitting (Figure 8, Item 2) from aftercooler housing (Figure 8, Item 3). 18. Remove two O-rings (Figure 8, Item 4) from fitting (Figure 8, Item 2). Discard O-rings.

Figure 8. Pressure Sensor.

0068

0068-5

TM 5-2410-241-23-2

0068

REMOVAL CONTINUED

NOTE
Mark, tag, and note routing of harness to aid installation. 19. Disconnect connector (Figure 9, Item 1) from sensor (Figure 9, Item 2). 20. Remove air inlet temperature sensor (Figure 9, Item 2) from aftercooler (Figure 9, Item 3). 21. Remove O-ring (Figure 9, Item 7) from sensor (Figure 9, Item 2). Discard O-ring. 22. Remove 12 bolts (Figure 9, Item 6), washers (Figure 9, Item 5), aftercooler lower housing (Figure 9, Item 3), and three gaskets (Figure 9, Item 4) from machine. Discard gaskets.

Figure 9. Lower Aftercooler Housing. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0068

00068

0068-6

TM 5-2410-241-23-2

0068

INSTALLATION 1. Install 3 new gaskets (Figure 9, Item 4), aftercooler lower housing (Figure 9, Item 3), 12 washers (Figure 9, Item 5) and bolts (Figure 9, Item 6) on machine. 2. Install new O-ring (Figure 9, Item 7) on sensor (Figure 9, Item 2). 3. Install sensor (Figure 9, Item 2) on aftercooler lower housing (Figure 9, Item 3).

00068

NOTE
Install harness and connector as noted during removal. 4. Connect connector (Figure 9, Item 1) on sensor (Figure 9, Item 2).

NOTE
Install harness and connector as noted during removal. 5. Install two new O-rings (Figure 10, Item 4) on fitting (Figure 10, Item 2). 6. Install fitting (Figure 10, Item 2) on aftercooler housing (Figure 10, Item 3). 7. Install sensor (Figure 10, Item 1) on fitting (Figure 10, Item 2). 8. Connect connector (Figure 10, Item 7) on connector (Figure 10, Item 8). 9. Install new tiedown strap (Figure 10, Item 6) on harness (Figure 10, Item 5).

Figure 10. Pressure Sensor.

0068

0068-7

TM 5-2410-241-23-2

0068

INSTALLATION CONTINUED 10. Install new gasket (Figure 11, Item 3) and two new O-rings (Figure 11, Item 2) on aftercooler core (Figure 11, Item 1). 11. Install aftercooler core (Figure 11, Item 1) on aftercooler lower housing (Figure 11, Item 4).

Figure 11. Aftercooler Core.

0068

NOTE
Install clips and bolts as noted during removal. 12. Install new gasket (Figure 12, Item 4) on aftercooler housing cover (Figure 12, Item 2). 13. Install aftercooler housing cover (Figure 12, Item 2), wiring harness (Figure 12, Item 6), two clips (Figure 12, Item 3), 22 washers (Figure 12, Item 7), and 24 bolts (Figure 12, Item 1) on aftercooler lower housing (Figure 12, Item 5).

Figure 12. Aftercooler Housing Upper Cover.

0068

0068-8

TM 5-2410-241-23-2

0068

INSTALLATION CONTINUED 14. Install new gasket (Figure 13, Item 3) on spacer (Figure 13, Item 2). 15. Install spacer (Figure 13, Item 2) on housing (Figure 13, Item 1).

Figure 13. Front Water Tube Spacer. 16. Install new O-ring (Figure 14, Item 5) on tube (Figure 14, Item 4). 17. Install tube (Figure 14, Item 4), four washers (Figure 14, Item 2), and bolts (Figure 14, Item 3) on aftercooler housing (Figure 14, Item 1).

0068

Figure 14. Front Water Tube.

0068

0068-9

TM 5-2410-241-23-2

0068

INSTALLATION CONTINUED 18. Install new gasket (Figure 15, Item 1) on spacer (Figure 15, Item 2). 19. Install spacer (Figure 15, Item 2) on housing (Figure 15, Item 3).

Figure 15. Rear Water Tube Spacer. 20. Install new O-ring (Figure 16, Item 4) on tube (Figure 16, Item 5). 21. Install tube (Figure 16, Item 5), four washers (Figure 16, Item 2), and bolts (Figure 16, Item 1) on aftercooler housing (Figure 16, Item 3).

0068

Figure 16. Rear Water Tube.

0068

0068-10

TM 5-2410-241-23-2

0068

INSTALLATION CONTINUED 22. Install hose (Figure 17, Item 3) and two clamps (Figure 17, Item 2) on tube (Figure 17, Item 1).

Figure 17. Rear Coolant Hose. END OF TASK FOLLOW-ON TASKS 1. Install exhaust manifold (WP 0067). 2. Install rear engine lifting brackets (WP 0058). 3. Install water temperature regulator outlet hose and pipe (WP 0051). 4. Install air cleaner housing bracket (WP 0111). 5. Install ether valve, line and bracket (WP 0060). 6. Install arctic kit heater, if equipped (WP 0291). 7. Install engine enclosure right door guard (WP 0204). 8. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0068

00068

0068-11/(12 blank)

8 TM 5-2410-241-23-2 0069

FIELD MAINTENANCE FUEL INJECTOR REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 6 9

INITIAL SETUP Tools and Special Tools

0

References WP 0295 WP 0017 Equipment Condition Machine parked (TM 5-2410-241-10) Rocker arm assembly removed (WP 0107) Drawing Required

Tool Kit, General Mechanics (WP 0302, Item 65) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73)
0 0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Hold-down bolt O-ring (3)

TM 5-2410-241-24P, Figure 26 Estimated Time to Complete 23.5 Hr

REMOVAL

00069

NOTE
The following procedure will remove one fuel injector. Follow the same steps for each additional fuel injector. 1. Remove plug (Figure 1, Item 2) from manifold (Figure 1, Item 1).

Figure 1. Fuel Injection Manifold.

0069

0069-1

TM 5-2410-241-23-2

0069

REMOVAL CONTINUED

NOTE
Mark location and orientation of valve bridges for installation. Tag and mark electrical connectors to aid with installation.

2. Remove valve bridge assemblies (Figure 2, Item 7) from cylinder head (Figure 2, Item 6). 3. Loosen nuts (Figure 2, Item 2) and disconnect harness connector (Figure 2, Item 1) from fuel injector (Figure 2, Item 3).

NOTE
Mark injector location for installation. 4. Remove fuel injector hold-down bolt (Figure 2, Item 4) and spacer (Figure 2, Item 5). Discard hold-down bolt. 5. Pry fuel injector (Figure 2, Item 3) out of cylinder head assembly (Figure 2, Item 6).

Figure 2. Fuel Injection Manifold.

0069

0069-2

TM 5-2410-241-23-2

0069

REMOVAL CONTINUED

NOTE
Note position and orientation of clamp to aid installation. Clamp is stamped THIS SIDE UP.

6. Remove three O-rings (Figure 3, Item 2) and clamp (Figure 3, Item 3) from each fuel injector (Figure 3, Item 1). Discard O-rings.

Figure 3. Fuel Injection Manifold. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0069

00069

0069-3

TM 5-2410-241-23-2

0069

INSTALLATION

00069

NOTE
The following procedure will install one fuel injector. Follow the same steps for each additional fuel injector. If replacement fuel injector is to be installed, record fuel injector code prior to installation.

1. If a replacement fuel injector is to be installed, correct injector trim file must be programmed into electronic control module (ECM) (WP 0017). Record fuel injector code (Figure 4, Item 1) to obtain injector trim file.

Figure 4. Fuel Injection Manifold.

0069

0069-4

TM 5-2410-241-23-2

0069

INSTALLATION CONTINUED

NOTE
Install clamp as noted during removal. Clamp is stamped THIS SIDE UP.

2. Install clamp (Figure 5, Item 3) and three new O-ring seals (Figure 5, Item 2) on each fuel injector (Figure 5, Item 1).

Figure 5. Fuel Injection Manifold.

0069

0069-5

TM 5-2410-241-23-2

0069

INSTALLATION CONTINUED

NOTE
Install fuel injectors as marked during removal. 3. Install fuel injector (Figure 6, Item 3) on cylinder head assembly (Figure 6, Item 6). 4. Install spacer (Figure 6, Item 5) and new fuel injector hold down bolt (Figure 6, Item 4) on cylinder head (Figure 6, Item 6). Tighten fuel injector hold down bolt to 22 lb-ft (30 Nm). 5. Connect harness connector (Figure 6, Item 1) to fuel injector (Figure 6, Item 3) and tighten nuts (Figure 6, Item 2).

NOTE
Install valve bridges as marked during removal. Tag and mark electrical connectors to aid with installation.

6. Install valve bridge assemblies (Figure 6, Item 7) on cylinder head (Figure 6, Item 6).

Figure 6. Fuel Injection Manifold.

0069

0069-6

TM 5-2410-241-23-2

0069

INSTALLATION CONTINUED 7. Install plug (Figure 7, Item 2) on manifold (Figure 7, Item 1).

Figure 7. Fuel Injection Manifold. END OF TASK FOLLOW-ON TASKS Install rocker arm assembly (WP 0107). END OF TASK END OF WORK PACKAGE

0069

00069

0069-7/(8 blank)

6 TM 5-2410-241-23-2 0070

FIELD MAINTENANCE FUEL MANIFOLD REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 7 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (10) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Primary fuel filter bracket removed (WP 0071) Secondary fuel filter removed (WP 0072) Drawing Required TM 5-2410-241-24P, Figure 23 Estimated Time to Complete 4.0 Hr

0070-1

TM 5-2410-241-23-2

0070

REMOVAL

00070

1. Remove bolt (Figure 1, Item 7), washer (Figure 1, Item 6), and clip (Figure 1, Item 5) from fuel manifold (Figure 1, Item 1).

NOTE
Tag electrical connectors to aid installation. 2. Disconnect connector (Figure 1, Item 2) from engine (Figure 1, Item 4) and position harness (Figure 1, Item 3) aside. 3. Remove four bolts (Figure 1, Item 9), washers (Figure 1, Item 8), and fuel manifold (Figure 1, Item 1) from engine (Figure 1, Item 4).

Figure 1. Fuel Manifold.

0070

0070-2

TM 5-2410-241-23-2

0070

REMOVAL CONTINUED 4. Remove three plugs (Figure 2, Item 3), and O-rings (Figure 2, Item 2), from fuel manifold (Figure 2, Item 1). Discard O-rings. 5. Remove plug (Figure 2, Item 5), and O-ring (Figure 2, Item 4), from fuel manifold (Figure 2, Item 1). Discard Oring. 6. Remove six O-rings (Figure 2, Item 6) from fuel manifold (Figure 2, Item 1). Discard O-rings.

Figure 2. Fuel Manifold O-rings. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0070

00070

0070-3

TM 5-2410-241-23-2

0070

INSTALLATION 1. Install six new O-rings (Figure 3, Item 6) on fuel manifold (Figure 3, Item 1). 2. Install new O-ring (Figure 3, Item 4) and plug (Figure 3, Item 5) on fuel manifold (Figure 3, Item 1). 3. Install three new O-rings (Figure 3, Item 2) and plugs (Figure 3, Item 3) on fuel manifold (Figure 3, Item 1).

00070

Figure 3. Fuel Manifold O-rings.

0070

0070-4

TM 5-2410-241-23-2

0070

INSTALLATION CONTINUED 4. Install fuel manifold (Figure 4, Item 1), four washers (Figure 4, Item 8) and bolts (Figure 4, Item 9) on engine (Figure 1, Item 4).

NOTE
Install electrical connectors as tagged during removal. 5. Position harness (Figure 4, Item 3) and connect connector (Figure 4, Item 2) on engine (Figure 4, Item 4). 6. Install clip (Figure 4, Item 5), washer (Figure 4, Item 6) and bolt (Figure 4, Item 7) on fuel manifold (Figure 4, Item 1).

Figure 4. Fuel Manifold. END OF TASK

0070

0070-5

TM 5-2410-241-23-2

0070

FOLLOW-ON TASKS 1. Install secondary fuel filter (WP 0072). 2. Install primary fuel filter bracket (WP 0071). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00070

0070-6

16 TM 5-2410-241-23-2 0071

FIELD MAINTENANCE PRIMARY FUEL FILTER, BASE AND BRACKET REPLACEMENT Primary Fuel Filter Removal, Filter Base and Mounting Plate Removal, Cleaning and Inspection, Filter Base and Mounting Plate Installation, Primary Fuel Filter Installation
0 0 7 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Pan, drain (S0255) (WP 0302, Item 68) Wrench, oil filter, strap (S0982) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket O-ring (12)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Arctic kit fuel metering pump hose and fitting removed (WP 0293)
0 0

Drawing Required
0

TM 5-2410-241-24P, Figure 25 Estimated Time to Complete 2.5 Hr

0071-1

TM 5-2410-241-23-2

0071

PRIMARY FUEL FILTER REMOVAL

00071

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

CAUTION
Wipe area clean around fuel filter. Contamination of fuel system could result in premature failure. 1. Close fuel valve (Figure 1, Item 1) on machine.

Figure 1. Fuel Valve.

0071

0071-2

TM 5-2410-241-23-2

0071

PRIMARY FUEL FILTER REMOVAL CONTINUED 2. Remove three bolts (Figure 2, Item 3), washers (Figure 2, Item 2) and cover (Figure 2, Item 1) from machine. 3. Position drain pan to drain hose (Figure 2, Item 5) and turn drain valve (Figure 2, Item 6) to drain fluid from filter (Figure 2, Item 4).

Figure 2. Filter Drain.

0071

0071-3

TM 5-2410-241-23-2

0071

PRIMARY FUEL FILTER REMOVAL CONTINUED 4. Loosen clamp (Figure 3, Item 6) and remove hose (Figure 3, Item 7) from water separator (Figure 3, Item 5). 5. Remove filter (Figure 3, Item 1), gasket (Figure 3, Item 3) and water separator (Figure 3, Item 5) from filter base (Figure 3, Item 2). 6. Remove water separator (Figure 3, Item 5) and two O-rings (Figure 3, Item 4) from filter (Figure 3, Item 1). Discard O-rings.

Figure 3. Filter. END OF TASK

0071

0071-4

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE REMOVAL

00071

CAUTION
Wipe area clean around fuel filter. Contamination of fuel system could result in premature failure. 1. Close fuel valve (Figure 4, Item 1) on machine.

Figure 4. Fuel Valve.

0071

0071-5

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE REMOVAL CONTINUED 2. Remove three bolts (Figure 5, Item 3), washers (Figure 5, Item 2) and cover (Figure 5, Item 1) from machine. 3. Position drain pan to drain hose (Figure 5, Item 5) and turn drain valve (Figure 5, Item 6) to drain fluid from filter (Figure 5, Item 4).

Figure 5. Filter Drain.

0071

0071-6

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE REMOVAL CONTINUED

NOTE
Tag hoses to aid installation. 4. Loosen clamp (Figure 6, Item 2) and remove hose (Figure 6, Item 1) from water separator (Figure 6, Item 3). 5. Remove bolt (Figure 6, Item 10), washer (Figure 6, Item 9), clamp (Figure 6, Item 11) and hose (Figure 6, Item 1) from machine. 6. Remove bolt (Figure 6, Item 6), washer (Figure 6, Item 5), clamp (Figure 6, Item 4) from bracket (Figure 6, Item 8) and line (Figure 6, Item 7).

Figure 6. Filter Drain Tube.

0071

0071-7

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE REMOVAL CONTINUED

NOTE
Cap and plug all lines, hoses and tubes to prevent contamination and leaks. 7. Loosen tube nut (Figure 7, Item 13) and remove hose (Figure 7, Item 12) from fitting (Figure 7, Item 14). Position hose aside. 8. Remove fitting (Figure 7, Item 14) from filter base (Figure 7, Item 1). 9. Remove two O-rings (Figure 7, Item 15) from fitting (Figure 7, Item 14). Discard O-rings. 10. Loosen tube nut (Figure 7, Item 9) and remove line (Figure 7, Item 10) from fitting (Figure 7, Item 8). Position line aside. 11. Remove fitting (Figure 7, Item 8) from filter base (Figure 7, Item 1). 12. Remove two O-rings (Figure 7, Item 7) from fitting (Figure 7, Item 8). Discard O-rings. 13. Loosen water separator (Figure 7, Item 16) from filter (Figure 7, Item 11). 14. Loosen filter (Figure 7, Item 11) from filter base (Figure 7, Item 1). 15. Remove two bolts (Figure 7, Item 6), washers (Figure 7, Item 5) and filter base (Figure 7, Item 1) from bracket (Figure 7, Item 2). 16. Remove seven bolts (Figure 7, Item 3), washers (Figure 7, Item 4) and bracket (Figure 7, Item 2) from machine.

Figure 7. Filter and Base.

0071

0071-8

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE REMOVAL CONTINUED 17. Remove filter (Figure 8, Item 9), O-ring (Figure 8, Item 8) and water separator (Figure 8, Item 11) from filter base (Figure 8, Item 5). Discard O-ring. 18. Remove water separator (Figure 8, Item 11) and O-ring (Figure 8, Item 10) from filter (Figure 8, Item 9). Discard O-ring.

NOTE
Note size and position of bolts to aid installation. 19. Remove two bolts (Figure 8, Item 2), washers (Figure 8, Item 3), prime pump (Figure 8, Item 1) and gasket (Figure 8, Item 4) from filter base (Figure 8, Item 5). Discard gasket. 20. Remove four plugs (Figure 8, Item 6) and O-rings (Figure 8, Item 7) from filter base (Figure 8, Item 5). Discard O-rings.

Figure 8. Prime Pump. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0071

00071

0071-9

TM 5-2410-241-23-2

0071

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.
00071

FILTER BASE AND MOUNTING PLATE INSTALLATION

CAUTION
Wipe area clean around fuel filter. Contamination of fuel system could result in premature failure. 1. Install four new O-rings (Figure 9, Item 5) and plugs (Figure 9, Item 6) on filter base (Figure 9, Item 7).

NOTE
Install bolts in positions as noted during removal. 2. Install new gasket (Figure 9, Item 4), prime pump (Figure 9, Item 3), two washers (Figure 9, Item 2), and bolts (Figure 9, Item 1) on filter base (Figure 9, Item 7). 3. Install new O-ring (Figure 9, Item 11) and water separator (Figure 9, Item 10) on filter (Figure 9, Item 9). 4. Install water separate (Figure 9, Item 10), new O-ring (Figure 9, Item 8) and filter (Figure 9, Item 9), on filter base (Figure 9, Item 7).

Figure 9. Prime Pump.

0071

0071-10

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE INSTALLATION CONTINUED 5. Install bracket (Figure 10, Item 2), seven washers (Figure 10, Item 4) and bolts (Figure 10, Item 3) on machine. 6. Install filter base (Figure 10, Item 1), two washers (Figure 10, Item 5) and bolts (Figure 10, Item 6) on bracket (Figure 10, Item 2). 7. Install filter (Figure 10, Item 11) on filter base (Figure 10, Item 1). 8. Install water separator (Figure 10, Item 16) on filter (Figure 10, Item 11). 9. Install new O-ring (Figure 10, Item 7), and fitting (Figure 10, Item 8) on filter base (Figure 10, Item 1). 10. Install line (Figure 10, Item 10) and tube nut (Figure 10, Item 9) on fitting (Figure 10, Item 8). 11. Install new O-rings (Figure 10, Item 15), and fitting (Figure 10, Item 14) on filter base (Figure 10, Item 1). 12. Install hose (Figure 10, Item 12) and tube nut (Figure 10, Item 13) on fitting (Figure 10, Item 14).

Figure 10. Filter and Base.

0071

0071-11

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE INSTALLATION CONTINUED 13. Install clamp (Figure 11, Item 4), washer (Figure 11, Item 5) and bolt (Figure 11, Item 6) on line (Figure 11, Item 7) and bracket (Figure 11, Item 8).

NOTE
Install hoses as tagged during removal. 14. Install hose (Figure 11, Item 1), clamp (Figure 11, Item 11), washer (Figure 11, Item 9), and bolt (Figure 11, Item 10) on machine. 15. Install hose (Figure 11, Item 6) and clamp (Figure 11, Item 2) on water separator (Figure 11, Item 3).

Figure 11. Filter Drain Tube.

0071

0071-12

TM 5-2410-241-23-2

0071

FILTER BASE AND MOUNTING PLATE INSTALLATION CONTINUED 16. Shut off drain valve (Figure 12, Item 6) on filter (Figure 12, Item 4) and remove drain pan from drain hose (Figure 12, Item 5). 17. Install cover (Figure 12, Item 1), three washers (Figure 12, Item 2), and bolts (Figure 12, Item 3) on machine.

Figure 12. Filter Drain. 18. Open fuel valve (Figure 13, Item 1) on machine.

0071

Figure 13. Fuel Valve. END OF TASK

0071

0071-13

TM 5-2410-241-23-2

0071

PRIMARY FUEL FILTER INSTALLATION

00071

CAUTION
Wipe area clean around fuel filter. Contamination of fuel system could result in premature failure. 1. Install two new O-rings (Figure 14, Item 4) and water separator (Figure 14, Item 5) on filter (Figure 14, Item 1). 2. Install water separator (Figure 14, Item 5), new gasket (Figure 14, Item 3) and filter (Figure 14, Item 1) on filter base (Figure 14, Item 2). 3. Install hose (Figure 14, Item 7) and clamp (Figure 14, Item 6) on water separator (Figure 14, Item 5).

Figure 14. Filter.

0071

0071-14

TM 5-2410-241-23-2

0071

PRIMARY FUEL FILTER INSTALLATION CONTINUED 4. Open fuel valve (Figure 15, Item 1) on machine.

Figure 15. Fuel Valve. END OF TASK FOLLOW-ON TASKS 1. Install arctic kit fuel metering pump hose and fitting (WP 0293). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0071

00071

0071-15/(16 blank)

14 TM 5-2410-241-23-2 0072

FIELD MAINTENANCE SECONDARY FUEL FILTER, BASE AND HOSE REPLACEMENT Secondary Fuel Filter Removal, Secondary Filter Hose and Base Removal, Cleaning and Inspection, Secondary Filter Hose and Base Installation, Secondary Fuel Filter Installation
0 0 7 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Pan, Drain (S0255) (WP 0302, Item 68) Wrench, Oil Filter (S0981) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34)
0

Materials/Parts - Continued Gasket O-ring (14) References

WP 0087 WP 0295 Equipment Condition

Machine parked (TM 5-2410-241-10)

0

Drawing Required
0

TM 5-2410-241-24P, Figure 23
0 0

Estimated Time to Complete 1.5 Hr

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, glove, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

0072-1

TM 5-2410-241-23-2

0072

SECONDARY FUEL FILTER REMOVAL

00072

CAUTION
Wipe area clean around fuel filter. Contamination of fuel system could result in premature failure. 1. Close fuel valve (Figure 1, Item 1) on machine.

Figure 1. Fuel Valve.

0072

0072-2

TM 5-2410-241-23-2

0072

SECONDARY FUEL FILTER REMOVAL CONTINUED 2. Remove three bolts (Figure 2, Item 3), washers (Figure 2, Item 2) and cover (Figure 2, Item 1) from machine. 3. Position drain pan under filter (Figure 2, Item 4) and remove filter (Figure 2, Item 4) from base (Figure 2, Item 5).

Figure 2. Filter Drain. END OF TASK

0072

0072-3

TM 5-2410-241-23-2

0072

SECONDARY FILTER HOSE AND BASE REMOVAL

00072

CAUTION
Wipe area clean around fuel line connections. Contamination of fuel system could result in premature failure. 1. Close fuel valve (Figure 3, Item 1) on machine.

Figure 3. Fuel Valve.

0072

0072-4

TM 5-2410-241-23-2

0072

SECONDARY FILTER HOSE AND BASE REMOVAL CONTINUED 2. Remove three bolts (Figure 4, Item 3), washers (Figure 4, Item 2) and cover (Figure 4, Item 1) from machine.

Figure 4. Engine Enclosure Left.

0072

0072-5

TM 5-2410-241-23-2

0072

SECONDARY FILTER HOSE AND BASE REMOVAL CONTINUED

NOTE
Tag electrical connectors and hoses to aid installation. Cap all lines and hoses to prevent contamination.

3. Remove dipstick tube (WP 0087). 4. Disconnect electrical connector (Figure 5, Item 1) from filter base (Figure 5, Item 2). 5. Loosen filter (Figure 5, Item 19) from filter base (Figure 5, Item 2). 6. Disconnect hose (Figure 5, Item 18) from filter base (Figure 5, Item 2). Position hose aside. 7. Remove bolt (Figure 5, Item 13), washer (Figure 5, Item 12), clamp (Figure 5, Item 11), spacer (Figure 5, Item 10) from engine (Figure 5, Item 20) and hose (Figure 5, Item 6). 8. Remove nut (Figure 5, Item 9), washer (Figure 5, Item 8) clamp (Figure 5, Item 7) from engine (Figure 5, Item 20) and hose (Figure 5, Item 6). 9. Loosen tube nut (Figure 5, Item 5) and remove hose (Figure 5, Item 6) from fitting (Figure 5, Item 3). 10. Remove fitting (Figure 5, Item 3) and O-ring (Figure 5, Item 4) from filter base (Figure 5, Item 2). Discard Oring. 11. Loosen tube nut (Figure 5, Item 15) and remove hose (Figure 5, Item 6) from fitting (Figure 5, Item 16). 12. Remove fitting (Figure 5, Item 16) from fitting (Figure 5, Item 17). 13. Remove fitting (Figure 5, Item 17) and O-ring (Figure 5, Item 14) from engine (Figure 5, Item 20). Discard Oring. 14. Remove hose (Figure 5, Item 6) and filter (Figure 5, Item 19) from engine (Figure 5, Item 20) and filter base (Figure 5, Item 2).

Figure 5. Filter Drain Tube.

0072

0072-6

TM 5-2410-241-23-2

0072

SECONDARY FILTER HOSE AND BASE REMOVAL CONTINUED

NOTE
Pin (Figure 6, Item 6) comes assembled to spacer (Figure 6, Item 4). Do not remove pin. 15. Remove two bolts (Figure 6, Item 12) washers (Figure 6, Item 7), filter base (Figure 6, Item 18), O-ring (Figure 6, Item 3), spacer (Figure 6, Item 4) and two O-rings (Figure 6, Item 5) from fuel manifold (Figure 6, Item 2). Discard O-rings.

NOTE
Note position and location of bolts to aid in assembly. 16. Remove two bolts (Figure 6, Item 15), washers (Figure 6, Item 14), cover (Figure 6, Item 16) and gasket (Figure 6, Item 17) from filter base (Figure 6, Item 18). Discard gasket. 17. Remove plug (Figure 6, Item 21), cap (Figure 6, Item 1), fitting (Figure 6, Item 22) and three O-rings (Figure 6, Items 19, 20 and 23) from filter base (Figure 6, Item 18). Discard O-rings. 18. Remove fuel temperature sensor (Figure 6, Item 9) and O-ring (Figure 6, Item 8) from filter base (Figure 6, Item 18). Discard O-ring. 19. Remove plug (Figure 6, Item 10) and O-ring (Figure 6, Item 11) from filter base (Figure 6, Item 18). Discard Oring. 20. Remove fitting (Figure 6, Item 13) from filter base (Figure 6, Item 18).

Figure 6. Filter and Base. END OF TASK

0072

0072-7

TM 5-2410-241-23-2

0072

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

00072

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, glove, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.
00072

SECONDARY FILTER HOSE AND BASE INSTALLATION

CAUTION
Wipe area clean around fuel line connections. Contamination of fuel system could result in premature failure. 1. Install fitting (Figure 7, Item 13) on filter base (Figure 7, Item 18). 2. Install new O-ring (Figure 7, Item 11) and plug (Figure 7, Item 10) on filter base (Figure 7, Item 18). 3. Install new O-ring (Figure 7, Item 8) and fuel temperature sensor (Figure 7, Item 9) on filter base (Figure 7, Item 18). 4. Install new three new O-rings (Figure 7, Items 19, 20 and 23), fitting (Figure 7, Item 22), cap (Figure 7, Item 1), and plug (Figure 7, Item 21) on filter base (Figure 7, Item 18). 5. Install new gasket (Figure 7, Item 17), cover (Figure 7, Item 16), two washers (Figure 7, Item 14), and bolts (Figure 7, Item 15) on filter base (Figure 7, Item 18).

0072-8

TM 5-2410-241-23-2

0072

SECONDARY FILTER HOSE AND BASE INSTALLATION CONTINUED

NOTE
Ensure pin (Figure 7, Item 6) is installed in spacer (Figure 7, Item 4) as noted during removal. 6. Install two new O-rings (Figure 7, Item 5), spacer (Figure 7, Item 4), new O-ring (Figure 7, Item 3), filter base (Figure 7, Item 18), two washers (Figure 7, Item 7) and bolts (Figure 7, Item 12) on fuel manifold (Figure 7, Item 2).

Figure 7. Filter and Base.

0072

0072-9

TM 5-2410-241-23-2

0072

SECONDARY FILTER HOSE AND BASE INSTALLATION CONTINUED

NOTE
Install electrical connectors and hoses as tagged during removal. 7. Loosely install filter (Figure 8, Item 19) on filter base (Figure 8, Item 2). 8. Position hose (Figure 8, Item 6) on engine (Figure 8, Item 20). 9. Install new O-ring (Figure 8, Item 14) and fitting (Figure 8, Item 17) on engine (Figure 8, Item 20). 10. Install fitting (Figure 8, Item 16) on fitting (Figure 8, Item 17). 11. Install hose (Figure 8, Item 6) and tighten tube nut (Figure 8, Item 15) on fitting (Figure 8, Item 16). 12. Install new O-ring (Figure 8, Item 4) and fitting (Figure 8, Item 3) on filter base (Figure 8, Item 2). 13. Install hose (Figure 8, Item 6) and tighten tube nut (Figure 8, Item 5) on fitting (Figure 8, Item 3). 14. Install clamp (Figure 8, Item 7), washer (Figure 8, Item 8) and nut (Figure 8, Item 9) on hose (Figure 8, Item 6) and engine (Figure 8, Item 20). 15. Install spacer (Figure 8, Item 10), clamp (Figure 8, Item 11), washer (Figure 8, Item 12), and bolt (Figure 8, Item 13) on hose (Figure 8, Item 6) and engine (Figure 8, Item 20). 16. Connect hose (Figure 8, Item 18) to filter base (Figure 8, Item 2). 17. Tighten filter (Figure 8, Item 19) on filter base (Figure 8, Item 2). 18. Connect electrical connector (Figure 8, Item 1) to filter base (Figure 8, Item 2). 19. Install dipstick tube (WP 0087).

Figure 8. Filter Drain Tube.

0072

0072-10

TM 5-2410-241-23-2

0072

SECONDARY FILTER HOSE AND BASE INSTALLATION CONTINUED 20. Install cover (Figure 9, Item 1), three washers (Figure 9, Item 2) and bolts (Figure 9, Item 3) on machine.

Figure 9. Engine Enclosure Left. 21. Open fuel valve (Figure 10, Item 1) on machine.

0072

Figure 10. Fuel Valve. END OF TASK

0072

0072-11

TM 5-2410-241-23-2

0072

SECONDARY FUEL FILTER INSTALLATION

00072

CAUTION
Wipe area clean around fuel filter. Contamination of fuel system could result in premature failure. 1. Tighten filter (Figure 11, Item 4) on base (Figure 11, Item 5). 2. Install cover (Figure 11, Item 1), three washers (Figure 11, Item 2) and bolts (Figure 11, Item 3) on machine.

Figure 11. Filter Drain.

0072

0072-12

TM 5-2410-241-23-2

0072

SECONDARY FUEL FILTER INSTALLATION CONTINUED 3. Open fuel valve (Figure 12, Item 1) on machine.

Figure 12. Fuel Valve. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0072

00072

0072-13/(14 blank)

6 TM 5-2410-241-23-2 0073

FIELD MAINTENANCE FUEL TRANSFER PUMP REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 7 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket O-ring (3)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Front bottom guards removed (WP 0199) Drawing Required TM 5-2410-241-24P, Figure 27 Estimated Time to Complete 3.0 Hr

0073-1

TM 5-2410-241-23-2

0073

REMOVAL

00073

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

1. Close fuel valve (Figure 1, Item 1) on machine.

Figure 1. Fuel Valve.

0073

0073-2

TM 5-2410-241-23-2

0073

REMOVAL CONTINUED

NOTE
Tag lines to aid installation. 2. Remove two bolts (Figure 2, Item 9), washers (Figure 2, Item 8), transfer pump cover (Figure 2, Item 3) and gasket (Figure 2, Item 4) from front housing (Figure 2, Item 2). Discard gasket. 3. Disconnect line (Figure 2, Item 13) from fitting (Figure 2, Item 12). 4. Disconnect line (Figure 2, Item 10) from fitting (Figure 2, Item 11). 5. Remove two bolts (Figure 2, Item 1), washers (Figure 2, Item 7), and transfer pump (Figure 2, Item 6) from front housing (Figure 2, Item 2). 6. Remove O-ring (Figure 2, Item 5) from transfer pump (Figure 2, Item 6). Discard O-ring.

Figure 2. Fuel Transfer Pump.

0073

0073-3

TM 5-2410-241-23-2

0073

REMOVAL CONTINUED 7. Remove two fittings (Figure 3, Item 2) from transfer pump (Figure 3, Item 1). 8. Remove and discard two O-rings (Figure 3, Item 3) from fittings (Figure 3, Item 2).

Figure 3. Fittings. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0073

00073

0073-4

TM 5-2410-241-23-2

0073

INSTALLATION

00073

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel filter. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

1. Install two new O-rings (Figure 3, Item 3) on fittings (Figure 3, Item 2). 2. Install two fittings (Figure 3, Item 2) on transfer pump (Figure 3, Item 1).

NOTE
Install lines as tagged during removal. 3. Install new O-ring (Figure 4, Item 5) on transfer pump (Figure 4, Item 6). 4. Install transfer pump (Figure 4, Item 6), two washers (Figure 4, Item 7) and bolts (Figure 4, Item 1) on front housing (Figure 4, Item 2). 5. Connect line (Figure 4, Item 10) on fitting (Figure 4, Item 11). 6. Connect line (Figure 4, Item 13) on fitting (Figure 4, Item 12). 7. Install new gasket (Figure 4, Item 4), transfer pump cover (Figure 4, Item 3), two washers (Figure 4, Item 8), and bolts (Figure 4, Item 9) on front housing (Figure 4, Item 2).

Figure 4. Fuel Transfer Pump.

0073

0073-5

TM 5-2410-241-23-2

0073

INSTALLATION CONTINUED 8. Open fuel valve (Figure 5, Item 1) on machine.

Figure 5. Fuel Valve. END OF TASK FOLLOW-ON TASKS 1. Install front bottom guards (WP 0199). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0073

00073

0073-6

4 TM 5-2410-241-23-2 0074

FIELD MAINTENANCE
0 0 7 4

TEMPERATURE REGULATOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket Lip Seal (2) O-ring (4)
0

References WP 0295

Equipment Condition
0 0

Machine parked (TM 5-2410-241-10) Cooling system drained (WP 0113) Drawing Required

TM 5-2410-241-24P, Figure 28
0 0

Estimated Time to Complete 4.0 Hr

REMOVAL

00074

NOTE
Tag hoses to aid installation. 1. Remove two nuts (Figure 1, Item 8), washers (Figure 1, Item 7) and clips (Figure 1, Item 6) from housing (Figure 1, Item 9). 2. Position harness (Figure 1, Item 1) aside from housing (Figure 1, Item 9). 3. Loosen clamp (Figure 1, Item 2) and remove hose (Figure 1, Item 3) from housing (Figure 1, Item 9). 4. Remove six bolts (Figure 1, Item 4), washers (Figure 1, Item 5) and housing (Figure 1, Item 9) from engine (Figure 1, Item 10).

Figure 1. Housing.

0074

0074-1

TM 5-2410-241-23-2

0074

REMOVAL CONTINUED 5. Remove gasket (Figure 2, Item 4) from coolant manifold (Figure 2, Item 5). Discard gasket.

NOTE
Note orientation of temperature regulators and lip seals to aid installation. 6. Remove two temperature regulators (Figure 2, Item 2) and lip seals (Figure 2, Item 3) from housing (Figure 2, Item 1). Discard lip seals. 7. Remove cap (Figure 2, Item 14) from fitting (Figure 2, Item 13). 8. Remove fitting (Figure 2, Item 13), O-ring (Figure 2, Item 12), fitting (Figure 2, Item 11) and O-ring (Figure 2, Item 10) from housing (Figure 2, Item 1). Discard O-rings. 9. Remove plug (Figure 2, Item 9) and O-ring (Figure 2, Item 8) from housing (Figure 2, Item 1). Discard O-ring. 10. Remove plug (Figure 2, Item 7) and O-ring (Figure 2, Item 6) from housing (Figure 2, Item 1). Discard O-ring.

Figure 2. Temperature Regulator. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0074

00074

0074-2

TM 5-2410-241-23-2

0074

INSTALLATION 1. Install new O-ring (Figure 2, Item 6) and plug (Figure 2, Item 7) on housing (Figure 2, Item 1). 2. Install new O-ring (Figure 2, Item 8) and plug (Figure 2, Item 9) on housing (Figure 2, Item 1). 3. Install new O-ring (Figure 2, Item 10), fitting (Figure 2, Item 11), new O-ring (Figure 2, Item 12) and fitting (Figure 2, Item 13) on housing (Figure 2, Item 1). 4. Install cap (Figure 2, Item 14) on fitting (Figure 2, Item 13).

00074

NOTE
Install lip seals and temperature regulators as noted during removal. If equipped with arctic heater, install arctic temperature regulators.

5. Install two new lip seals (Figure 2, Item 3) and temperature regulators (Figure 2, Item 2) on housing (Figure 2, Item 1). 6. Install new gasket (Figure 2, Item 4) on coolant manifold (Figure 2, Item 5). 7. Install housing (Figure 3, Item 9), six washers (Figure 3, Item 5), and bolts (Figure 3, Item 4) on engine (Figure 3, Item 10).

NOTE
Install hoses as tagged during removal. 8. Install hose (Figure 3, Item 3) and clamp (Figure 3, Item 2) on housing (Figure 3, Item 9). 9. Position harness (Figure 3, Item 1) on housing (Figure 3, Item 9). 10. Install two clips (Figure 3, Item 6), washers (Figure 3, Item 7), and nuts (Figure 3, Item 8) on housing (Figure 3, Item 9).

Figure 3. Housing. END OF TASK

0074

0074-3

TM 5-2410-241-23-2

0074

FOLLOW-ON TASKS 1. Fill cooling system (WP 0113). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00074

0074-4

6 TM 5-2410-241-23-2 0075

FIELD MAINTENANCE COOLING MANIFOLD REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 7 5

INITIAL SETUP Tools and Special Tools

0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Aftercooler housing removed (WP 0068) Water temperature regulator removed (WP 0074) Drawing Required

Tool Kit, General Mechanics (WP 0302, Item 65) Socket, 3/8 Drive, 6 Points, Long, 3/8 (S0533) (WP 0302, Item 68)
0 0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (6) Gasket (5)

TM 5-2410-241-24P, Figure 15, 28, 29

0

Estimated Time to Complete 5.0 Hr

0075-1

TM 5-2410-241-23-2

0075

REMOVAL

00075

NOTE
Tag electrical connectors to aid installation. 1. Disconnect connector (Figure 1, Item 1) from coolant temperature sensor (Figure 1, Item 10). 2. Remove coolant temperature sensor (Figure 1, Item 10) from cooling manifold (Figure 1, Item 11). 3. Remove plug (Figure 1, Item 4) and O-ring (Figure 1, Item 5) from cooling manifold (Figure 1, Item 11). Discard O-ring. 4. Remove fitting (Figure 1, Item 3) from fitting (Figure 1, Item 2). 5. Remove fitting (Figure 1, Item 2) from cooling manifold (Figure 1, Item 11).

NOTE
Note location and size of bolts to aid in installation. 6. Remove eight bolts (Figure 1, Item 6), washers (Figure 1, Item 7), clip (Figure 1, Item 8), and cooling manifold (Figure 1, Item 11) from engine (Figure 1, Item 12). Position harness (Figure 1, Item 9) aside.

Figure 1. Coolant Temperature Sensor.

0075

0075-2

TM 5-2410-241-23-2

0075

REMOVAL CONTINUED 7. Remove O-ring (Figure 2, Item 6) from coolant temperature sensor (Figure 2, Item 5). Discard O-ring. 8. Remove O-ring (Figure 2, Item 2) from fitting (Figure 2, Item 1). Discard O-ring. 9. Remove O-ring (Figure 2, Item 4) from fitting (Figure 2, Item 3). Discard O-ring.

Figure 2. Coolant Temperature Sensor O-ring. 10. Remove four gaskets (Figure 3, Item 2) from cooling manifold (Figure 3, Item 1). Discard gaskets.

0075

11. Remove two bolts (Figure 3, Item 3), washers (Figure 3, Item 4), pipe (Figure 3, Item 6), and gasket (Figure 3, Item 5) from cooling manifold (Figure 3, Item 1). Discard gasket. 12. Remove two O-rings (Figure 3, Item 7) from pipe (Figure 3, Item 6). Discard O-rings.

Figure 3. Cooling Manifold Gaskets. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0075

00075

0075-3

TM 5-2410-241-23-2

0075

INSTALLATION 1. Install two new O-rings (Figure 4, Item 7) on pipe (Figure 4, Item 6).

00075

2. Install new gasket (Figure 4, Item 5), pipe (Figure 4, Item 6), two washers (Figure 4, Item 4), and bolts (Figure 4, Item 3) on cooling manifold (Figure 4, Item 1). 3. Install four new gaskets (Figure 4, Item 2) on cooling manifold (Figure 4, Item 1).

Figure 4. Cooling Manifold Gaskets. 4. Install new O-ring (Figure 5, Item 4) on fitting (Figure 5, Item 3). 5. Install new O-ring (Figure 5, Item 2) on fitting (Figure 5, Item 1). 6. Install new O-ring (Figure 5, Item 6) on coolant temperature sensor (Figure 5, Item 5).

0075

Figure 5. Coolant Temperature Sensor O-ring.

0075

0075-4

TM 5-2410-241-23-2

0075

INSTALLATION CONTINUED 7. Position harness (Figure 6, Item 9) on machine.

NOTE
Install bolts as noted during removal. 8. Install cooling manifold (Figure 6, Item 11), clip (Figure 6, Item 8), eight washers (Figure 6, Item 7), and bolts (Figure 6, Item 6) on engine (Figure 6, Item 12). 9. Install fitting (Figure 6, Item 2) on cooling manifold (Figure 6, Item 11). 10. Install fitting (Figure 6, Item 3) on fitting (Figure 6, Item 2). 11. Install O-ring (Figure 6, Item 5) and plug (Figure 6, Item 4) on cooling manifold (Figure 6, Item 11). 12. Install coolant temperature sensor (Figure 6, Item 10) on cooling manifold (Figure 6, Item 11).

NOTE
Install electrical connectors as tagged during removal. 13. Connect connector (Figure 6, Item 1) on coolant temperature sensor (Figure 6, Item 10).

Figure 6. Coolant Temperature Sensor. END OF TASK FOLLOW-ON TASKS 1. Install water temperature regulator (WP 0074). 2. Install aftercooler housing (WP 0068). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0075

00075

0075-5/(6 blank)

6 TM 5-2410-241-23-2 0076

FIELD MAINTENANCE WATER PUMP ELBOW REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 7 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket O-ring (4) References WP 0295 REMOVAL
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure right door guard removed (WP 0204) Cooling system drained (WP 0113) Drawing Required TM 5-2410-241-24P, Figure 5, 29, 101 Estimated Time to Complete 4.0 Hr

00076

NOTE
Tag and note routing and position of hoses to aid installation. 1. Loosen clamp (Figure 1, Item 1) and remove hose (Figure 1, Item 2) from elbow (Figure 1, Item 5). 2. Remove clamp (Figure 1, Item 1) from hose (Figure 1, Item 2). Position hose aside. 3. Loosen clamp (Figure 1, Item 4) and remove hose (Figure 1, Item 3) from fitting (Figure 1, Item 5). 4. Remove clamp (Figure 1, Item 4) from hose (Figure 1, Item 3). Position hose aside. 5. Loosen clamp (Figure 1, Item 7) and remove hose (Figure 1, Item 8) from valve (Figure 1, Item 6). 6. Remove clamp (Figure 1, Item 7) from hose (Figure 1, Item 8). Position hose aside.

Figure 1. Hoses to Elbow.

0076

0076-1

TM 5-2410-241-23-2

0076

REMOVAL CONTINUED 7. Remove two bolts (Figure 2, Item 5), washers (Figure 2, Item 3), elbow (Figure 2, Item 4) and gasket (Figure 2, Item 2) from water pump (Figure 2, Item 1). Discard gasket.

Figure 2. Water Pump Elbow.

0076

NOTE
Note position and orientation of fittings to aid installation. 8. Loosen jam nut (Figure 3, Item 12) and remove valve (Figure 3, Item 1) from fitting (Figure 3, Item 2). 9. Remove O-ring (Figure 3, Item 3) from valve (Figure 3, Item 1). Discard O-ring. 10. Loosen jam nut (Figure 3, Item 10) and remove fitting (Figure 3, Item 2) from water pump elbow (Figure 3, Item 11). 11. Remove O-ring (Figure 3, Item 4) from fitting (Figure 3, Item 2). Discard O-ring. 12. Loosen jam nut (Figure 3, Item 9) and remove elbow (Figure 3, Item 5) from fitting (Figure 3, Item 7). 13. Remove O-ring (Figure 3, Item 6) from fitting (Figure 3, Item 5). Discard O-ring. 14. Remove fitting (Figure 3, Item 7) from water pump elbow (Figure 3, Item 11). 15. Remove O-ring (Figure 3, Item 8) from fitting (Figure 3, Item 7). Discard O-ring.

0076-2

TM 5-2410-241-23-2

0076

REMOVAL CONTINUED

Figure 3. Fittings to Elbow. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0076

00076

0076-3

TM 5-2410-241-23-2

0076

INSTALLATION

00076

NOTE
Note position and orientation of fittings to aid installation. 1. Install new O-ring (Figure 4, Item 8) on fitting (Figure 4, Item 7). 2. Install fitting (Figure 4, Item 7) on water pump elbow (Figure 4, Item 11). 3. Install new O-ring (Figure 4, Item 6) on fitting (Figure 4, Item 5). 4. Install elbow (Figure 4, Item 5) and jam nut (Figure 4, Item 9) on fitting (Figure 4, Item 7). 5. Install new O-ring (Figure 4, Item 4) on fitting (Figure 4, Item 2). 6. Install fitting (Figure 4, Item 2) and jam nut (Figure 4, Item 10) on water pump elbow (Figure 4, Item 11). 7. Install new O-ring (Figure 4, Item 3) on valve (Figure 4, Item 1). 8. Install valve (Figure 4, Item 1) and jam nut (Figure 4, Item 12) on fitting (Figure 4, Item 2).

Figure 4. Fittings to Elbow.

0076

0076-4

TM 5-2410-241-23-2

0076

INSTALLATION CONTINUED 9. Install new gasket (Figure 5, Item 2), elbow (Figure 5, Item 4), two washers (Figure 5, Item 3), and bolts (Figure 5, Item 5) on water pump (Figure 5, Item 1).

Figure 5. Water Pump Elbow.

0076

0076-5

TM 5-2410-241-23-2

0076

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 10. Install clamp (Figure 6, Item 7) on hose (Figure 6, Item 8). 11. Install hose (Figure 6, Item 8) and clamp (Figure 6, Item 7) on valve (Figure 6, Item 6). 12. Install clamp (Figure 6, Item 4) on hose (Figure 6, Item 3). 13. Install hose (Figure 6, Item 3) and clamp (Figure 6, Item 4) on fitting (Figure 6, Item 5). 14. Install clamp (Figure 6, Item 1) on hose (Figure 6, Item 2). 15. Install hose (Figure 6, Item 2) and clamp (Figure 6, Item 1) on elbow (Figure 6, Item 5).

Figure 6. Hoses to Elbow. END OF TASK FOLLOW-ON TASKS 1. Fill cooling system (WP 0113). 2. Install engine enclosure right door guard (WP 0204). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0076

00076

0076-6

10 TM 5-2410-241-23-2 0077

FIELD MAINTENANCE WATER PUMP REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 7 7

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket (2) O-ring (4) References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Engine enclosure right door guard removed (WP 0204) Engine oil filter removed (WP 0083) Alternator and bracket removed (WP 0099) Water pump elbow removed (WP 0076) Drawing Required

TM 5-2410-241-24P, Figure 30, 35

0

Estimated Time to Complete 7.0 Hr

0077-1

TM 5-2410-241-23-2

0077

REMOVAL

00077

NOTE
Tag hoses to aid installation. 1. Loosen two clamps (Figure 1, Item 2) from hose (Figure 1, Item 3). 2. Remove two bolts (Figure 1, Item 4), and washers (Figure 1, Item 5) from water pump elbow (Figure 1, Item 7) from water pump (Figure 1, Item 9). 3. Remove three bolts (Figure 1, Item 10), and washers (Figure 1, Item 11) from oil cooler housing cap (Figure 1, Item 1). 4. Remove hose (Figure 1, Item 3), water pump elbow (Figure 1, Item 7) and oil cooler housing cap (Figure 1, Item 1) from machine. 5. Remove O-ring (Figure 1, Item 6) from oil cooler housing cap (Figure 1, Item 1). Discard O-ring. 6. Remove gasket (Figure 1, Item 8) from water pump elbow (Figure 1, Item 7). Discard gasket. 7. Remove hose (Figure 1, Item 3) from water pump elbow (Figure 1, Item 7) and oil cooler housing cap (Figure 1, Item 1). 8. Remove two clamps (Figure 1, Item 2) from hose (Figure 1, Item 3).

Figure 1. Oil Cooler Connection.

0077

0077-2

TM 5-2410-241-23-2

0077

REMOVAL CONTINUED 9. Remove bolt (Figure 2, Item 2), and washer (Figure 2, Item 3) from water pump (Figure 2, Item 1). 10. Remove bolt (Figure 2, Item 4), and washer (Figure 2, Item 5) from water pump (Figure 2, Item 1).

Figure 2. Water Pump Bolts.

0077

0077-3

TM 5-2410-241-23-2

0077

REMOVAL CONTINUED 11. Remove two bolts (Figure 3, Item 4), washers (Figure 3, Item 3), water pump (Figure 3, Item 6), water pump bypass tube (Figure 3, Item 5), gasket (Figure 3, Item 2), and O-ring (Figure 3, Item 7) from temperature regulator housing (Figure 3, Item 1). Discard gasket and O-ring.

Figure 3. Bypass Tube Bolts.

0077

0077-4

TM 5-2410-241-23-2

0077

REMOVAL CONTINUED 12. Remove bypass tube (Figure 4, Item 1), and O-ring (Figure 4, Item 4) from water pump (Figure 4, Item 3). Discard O-ring. 13. Remove O-ring (Figure 4, Item 2) from water pump (Figure 4, Item 3). Discard O-ring.

Figure 4. Water Pump. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install new O-ring (Figure 4, Item 2) on water pump (Figure 4, Item 3). 2. Install new O-ring (Figure 4, Item 4) and bypass tube (Figure 4, Item 1) on water pump (Figure 4, Item 3).

0077

00077

00077

0077-5

TM 5-2410-241-23-2

0077

INSTALLATION CONTINUED 3. Install new O-ring (Figure 5, Item 7), new gasket (Figure 5, Item 2), water pump bypass tube (Figure 5, Item 5), water pump (Figure 5, Item 6), two washers (Figure 5, Item 3), and bolts (Figure 5, Item 4) on temperature regulator housing (Figure 5, Item 1).

Figure 5. Bypass Tube Bolts.

0077

0077-6

TM 5-2410-241-23-2

0077

INSTALLATION CONTINUED 4. Install washer (Figure 6, Item 5) and bolt (Figure 6, Item 4) on water pump (Figure 6, Item 1). 5. Install washer (Figure 6, Item 3) and bolt (Figure 6, Item 2) on water pump (Figure 6, Item 1).

Figure 6. Water Pump Bolts.

0077

0077-7

TM 5-2410-241-23-2

0077

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 6. Install two clamps (Figure 7, Item 2) on hose (Figure 7, Item 3). 7. Install hose (Figure 7, Item 3) on water pump elbow (Figure 7, Item 7) and oil cooler housing cap (Figure 7, Item 1). 8. Install new gasket (Figure 7, Item 8) on water pump elbow (Figure 7, Item 7). 9. Install new O-ring (Figure 7, Item 6) on oil cooler housing cap (Figure 7, Item 1). 10. Install oil cooler housing cap (Figure 7, Item 1), water pump elbow (Figure 7, Item 7) and hose (Figure 7, Item 3) on machine. 11. Install three washers (Figure 7, Item 11) and bolts (Figure 7, Item 10) on oil cooler housing cap (Figure 7, Item 1). 12. Install two washers (Figure 7, Item 5) and bolts (Figure 7, Item 4) on water pump elbow (Figure 7, Item 7) on water pump (Figure 7, Item 9). 13. Tighten two clamps (Figure 7, Item 2) on hose (Figure 7, Item 3).

Figure 7. Oil Cooler Connection. END OF TASK

0077

0077-8

TM 5-2410-241-23-2

0077

FOLLOW-ON TASKS 1. Install water pump elbow (WP 0076). 2. Install alternator and bracket (WP 0099). 3. Install engine oil filter (WP 0083). 4. Fill cooling system (WP 0113). 5. Install engine enclosure right door guard (WP 0204). 6. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00077

0077-9/(10 blank)

4 TM 5-2410-241-23-2 0078

FIELD MAINTENANCE
0 0 7 8

AFTERCOOLER WATER PUMP REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Engine enclosure left door guard removed (WP 0202)
0 0 0

Drawing Required TM 5-2410-241-24P, Figure 30 Estimated Time to Complete 6.0 Hr

0078-1

TM 5-2410-241-23-2

0078

REMOVAL

00078

NOTE
Tag hoses to aid installation. 1. Loosen two clamps (Figure 1, Item 3) from hose (Figure 1, Item 2). 2. Remove hose (Figure 1, Item 2) from water pump (Figure 1, Item 1). 3. Loosen clamp (Figure 1, Item 8) from hose (Figure 1, Item 9). 4. Remove hose (Figure 1, Item 9) from water pump (Figure 1, Item 1). 5. Remove fuel drain hose (Figure 1, Item 10) from clamp (Figure 1, Item 7). Place fuel drain hose aside.

NOTE
Note position and location of bolts and clamp to aid installation. 6. Remove three bolts (Figure 1, Item 6), washers (Figure 1, Item 5), clamp (Figure 1, Item 7), water pump (Figure 1, Item 1) and gasket (Figure 1, Item 4) from machine. Discard gasket.

Figure 1. Aftercooler Pump. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0078

00078

0078-2

TM 5-2410-241-23-2

0078

INSTALLATION 1. Install new gasket (Figure 1, Item 4), water pump (Figure 1, Item 1), clamp (Figure 1, Item 7), three washers (Figure 1, Item 5) and bolts (Figure 1, Item 6) on machine.

00078

NOTE
Install hoses as tagged during removal. 2. Install fuel drain hose (Figure 1, Item 10) on clamp (Figure 1, Item 7). 3. Install hose (Figure 1, Item 9) on water pump (Figure 1, Item 1). 4. Tighten clamps (Figure 1, Item 8) on hose (Figure 1, Item 9). 5. Install hose (Figure 1, Item 2) on water pump (Figure 1, Item 1). 6. Tighten two clamps (Figure 1, Item 3) on hose (Figure 1, Item 2). END OF TASK FOLLOW-ON TASKS 1. Fill cooling system (WP 0113). 2. Install engine enclosure left door guard (WP 0202). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
00078

0078-3/(4 blank)

4 TM 5-2410-241-23-2 0079

FIELD MAINTENANCE
0 0 7 9

FRONT CRANKSHAFT SEAL REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring Seal References WP 0295 REMOVAL 1. Remove five nuts (Figure 1, Item 3), washers (Figure 1, Item 4), and crankshaft seal (Figure 1, Item 2) from engine (Figure 1, Item 1).
0

Equipment Condition Machine parked (TM 5-2410-241-10) Trunnion assembly removed (WP 0048) Drawing Required TM 5-2410-241-24P, Figure 31 Estimated Time to Complete 5.5 Hr

00079

Figure 1. Crankshaft Seal.

0079

0079-1

TM 5-2410-241-23-2

0079

REMOVAL CONTINUED 2. Remove O-ring (Figure 2, Item 2) from crankshaft seal (Figure 2, Item 1). Discard O-ring and crankshaft seal.

Figure 2. Seal O-ring. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0079

00079

00079

NOTE
Do not remove protective sleeve until after installation on engine. Install crankshaft seal dry.

1. Install new O-ring (Figure 3, Item 2) on new crankshaft seal (Figure 3, Item 1).

Figure 3. Seal O-ring.

0079

0079-2

TM 5-2410-241-23-2

0079

INSTALLATION CONTINUED

NOTE
Tighten down nuts evenly in order to push protective sleeve off the seal. 2. Install crankshaft seal (Figure 4, Item 2), five washers (Figure 4, Item 4), and nuts (Figure 4, Item 3) on engine (Figure 4, Item 1). 3. Remove protective sleeve (Figure 4, Item 5) from crankshaft seal (Figure 4, Item 2). Discard protective sleeve.

Figure 4. Crankshaft Seal. END OF TASK FOLLOW-ON TASKS 1. Install trunnion assembly (WP 0048). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0079

00079

0079-3/(4 blank)

4 TM 5-2410-241-23-2 0080

FIELD MAINTENANCE
0 0 8 0

CRANKSHAFT DAMPER, PULLEY, AND ADAPTER REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) V-belt (A/C compressor) removed (WP 0096) V-belt set (alternator) removed (WP 0098) Front bottom guard removed (WP 0199) Cooling fan removed (WP 0050) Drawing Required

Tool Kit, General Mechanics (WP 0302, Item 65) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) Lifting Device (1,000-lb capacity)
0 0 0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Gasket Sealing washer (2) Personnel Required Two

TM 5-2410-241-24P, Figure 31
0

Estimated Time to Complete

0

3.5 Hr

0080-1

TM 5-2410-241-23-2

0080

REMOVAL

00080

WARNING

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

NOTE
Crankshaft damper weighs approximately 70 lb (32 kg). 1. Attach lifting device to crankshaft damper (Figure 1, Item 1). 2. Remove six bolts (Figure 1, Item 4), washers (Figure 1, Item 3), crankshaft damper (Figure 1, Item 1) and adapter (Figure 1, Item 2) from engine (Figure 1, Item 5). 3. Place crankshaft damper (Figure 1, Item 1) on flat level surface and remove lifting device.

Figure 1. Front Housing Cover.

0080

0080-2

TM 5-2410-241-23-2

0080

REMOVAL CONTINUED 4. Remove eight bolts (Figure 2, Item 2) and washers (Figure 2, Item 3) from crankshaft damper (Figure 2, Item 1). 5. Remove crankshaft damper (Figure 2, Item 1) from crankshaft pulley (Figure 2, Item 5). 6. Remove adapter (Figure 2, Item 4) from crankshaft pulley (Figure 2, Item 5).

Figure 2. Front Housing Cover. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install adapter (Figure 2, Item 4) on crankshaft pulley (Figure 2, Item 5). 2. Install crankshaft damper (Figure 2, Item 1) on crankshaft pulley (Figure 2, Item 5). 3. Install eight washers (Figure 2, Item 3) and bolts (Figure 2, Item 2) on crankshaft damper (Figure 2, Item 1). Tighten bolts to 41 lb-ft (55 Nm).

0080

00080

00080

0080-3

TM 5-2410-241-23-2

0080

INSTALLATION CONTINUED

WARNING

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

NOTE
Crankshaft damper weighs approximately 70 lb (32 kg). 1. Attach lifting device to crankshaft damper (Figure 3, Item 1). 2. Install adapter (Figure 3, Item 2), crankshaft damper (Figure 3, Item 1), six washers (Figure 3, Item 3), and bolts (Figure 3, Item 4) on engine (Figure 3, Item 5). 3. Remove lifting device from crankshaft damper (Figure 3, Item 1).

Figure 3. Front Housing Cover. END OF TASK FOLLOW-ON TASKS 1. Install cooling fan (WP 0050). 2. Install front bottom guard (WP 0199). 3. Install V-belt set (alternator) (WP 0098). 4. Install V-belt (A/C compressor) (WP 0096). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0080

00080

0080-4

4 TM 5-2410-241-23-2 0081

FIELD MAINTENANCE
0 0 8 1

FRONT HOUSING COVER ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Gasket (2) Sealing washer (2) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Alternator and bracket removed (WP 0099) Front crankshaft seal removed (WP 0079) Fuel transfer pump removed (WP 0073) Drawing Required TM 5-2410-241-24P, Figure 32 Estimated Time to Complete 7.0 Hr

0081-1

TM 5-2410-241-23-2

0081

REMOVAL

00081

1. Remove two bolts (Figure 1, Item 9), washers (Figure 1, Item 8), cover (Figure 1, Item 7), and gasket (Figure 1, Item 10) from front cover (Figure 1, Item 5). Discard gasket. 2. Remove two sealing washers (Figure 1, Item 2) and studs (Figure 1, Item 1) from front cover (Figure 1, Item 5). Discard sealing washers. 3. Remove 23 bolts (Figure 1, Item 4), washers (Figure 1, Item 3), front cover (Figure 1, Item 5) and gasket (Figure 1, Item 6) from machine. Discard gasket.

Figure 1. Front Housing Cover. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install new gasket (Figure 1, Item 6), front cover (Figure 1, Item 5), 23 washers (Figure 1, Item 3) and bolts (Figure 1, Item 4) on machine.

0081

00081

00081

2. install two studs (Figure 1, Item 1) and new sealing washers (Figure 1, Item 2) on front cover (Figure 1, Item 5). 3. Install new gasket (Figure 1, Item 10), cover (Figure 1, Item 7), two washers (Figure 1, Item 8), and bolts (Figure 1, Item 9) on front cover (Figure 1, Item 5). END OF TASK

0081-2

TM 5-2410-241-23-2

0081

FOLLOW-ON TASKS 1. Install fuel transfer pump (WP 0073). 2. Install front crankshaft seal (WP 0079). 3. Install alternator and bracket (WP 0099). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00081

0081-3/(4 blank)

4 TM 5-2410-241-23-2 0082

FIELD MAINTENANCE OIL FILTER ENGINE BASE ASSEMBLY REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 0 8 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Sealing Compound (WP 0303, Item 29) O-ring (14) References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10) Oil filter base removed (WP 0083) Oil cooler removed (WP 0084) Drawing Required TM 5-2410-241-24P, Figure 34 Estimated Time to Complete 5.0 Hr

00082

1. Remove six bolts (Figure 1, Item 4), washers (Figure 1, Item 3) and oil filter engine base (Figure 1, Item 2) from engine (Figure 1, Item 1). 2. Remove three O-rings (Figure 1, Item 5) from oil filter engine base (Figure 1, Item 2). Discard O-rings.

Figure 1. Oil Filter Engine Base Mount. END OF TASK

0082

0082-1

TM 5-2410-241-23-2

0082

DISASSEMBLY 1. Remove adapter (Figure 2, Item 5) from oil filter base (Figure 2, Item 12). Remove O-ring (Figure 2, Item 4) from adapter. Discard O-ring. 2. Remove two adapters (Figure 2, Items 9 and 10) from oil filter base (Figure 2, Item 12). Remove two O-rings (Figure 2, Item 11) from adapter (Figure 2, Item 10). Discard O-ring.

00082

3. Remove fitting (Figure 2, Item 7) from adapter (Figure 2, Item 9). Remove two O-rings (Figure 2, Items 6 and 8) from fitting. Discard O-rings. 4. Remove fitting (Figure 2, Item 2) from adapter (Figure 2, Item 10). Remove two O-rings (Figure 2, Items 1 and 3) from fitting. Discard O-rings.

Figure 2. Adapters. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0082

00082

0082-2

TM 5-2410-241-23-2

0082

ASSEMBLY

00082

1. Install two new O-rings (Figure 3, Items 1 and 3) on fitting (Figure 3, Item 2). Install fitting on adapter (Figure 3, Item 10). 2. Install two new O-rings (Figure 3, Items 6 and 8) on fitting (Figure 3, Item 7). Install fitting on adapter (Figure 3, Item 9). 3. Install two new O-rings (Figure 3, Item 11) on adapter (Figure 3, Item 10). Install two adapters (Figure 3, Items 10 and 9) on oil filter base (Figure 3, Item 12). 4. Install new O-ring (Figure 3, Item 4) on adapter (Figure 3, Item 5). Install adapter on oil filter base (Figure 3, Item 12).

Figure 3. Adapters. END OF TASK

0082

0082-3

TM 5-2410-241-23-2

0082

INSTALLATION 1. Install three new O-rings (Figure 4, Item 5) on oil filter engine base (Figure 4, Item 2). 2. Install oil filter engine base (Figure 4, Item 2), six washers (Figure 4, Item 3), and bolts (Figure 4, Item 4) on engine (Figure 4, Item 1).

00082

Figure 4. Oil Filter Engine Base Mount. END OF TASK FOLLOW-ON TASKS 1. Install oil cooler (WP 0084). 2. Install oil filter base (WP 0083). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0082

00082

0082-4

12 TM 5-2410-241-23-2 0083

FIELD MAINTENANCE ENGINE OIL FILTER, BASE AND LINES REPLACEMENT Oil Filter Removal, Oil Filter Base and Lines Removal, Cleaning and Inspection, Oil Filter Base and Lines Installation, Oil Filter Installation
0 0 8 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Pan, Drain (S0255) (WP 0302, Item 68) Wrench, Oil Filter (S0981) (WP 0302, Item 68) Wrench, Combination 1-5/8 (S0794) (WP 0302, Item 68) Wrench, Open End, 1 1/2 and 1 5/8 (S0853) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34)
0

Materials/Parts - Continued O-ring (4)

References
0

WP 0295 Equipment Condition

Machine parked (TM 5-2410-241-10) Oil drained (WP 0114) Engine enclosure right door guard removed (WP 0204) Drawing Required

TM 5-2410-241-24P, Figure 34 Estimated Time to Complete 3.0 Hr

0083-1

TM 5-2410-241-23-2

0083

OIL FILTER REMOVAL

00083

WARNING

Lubricating/hydraulic oils used in the performance of maintenance can be very slippery. Immediately wipe up any spills. Wear protective eye covering and gloves. Failure to follow these warnings may result in injury to personnel.

1. Place container under filter (Figure 1, Item 1). 2. Remove filter (Figure 1, Item 1) from base (Figure 1, Item 2).

Figure 1. Access Panel. END OF TASK

0083

0083-2

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES REMOVAL 1. Remove three bolts (Figure 2, Item 2) and washers (Figure 2, Item 3) from machine. 2. Position bracket (Figure 2, Item 4) and cable (Figure 2, Item 5) aside. 3. Remove guard (Figure 2, Item 1) from machine.

00083

Figure 2. Guard. 4. Remove three bolts (Figure 3, Item 1), washers (Figure 3, Item 3), and plate (Figure 3, Item 2) from machine.

0083

Figure 3. Guard Mount.

0083

0083-3

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES REMOVAL CONTINUED

NOTE
Tag and note routing and orientation of fittings and lines to aid installation. 5. Remove nut (Figure 4, Item 6), bolt (Figure 4, Item 4), two washers (Figure 4, Item 5) and clamps (Figure 4, Item 3) from lines (Figure 4, Items 7 and 2). 6. Remove nut (Figure 4, Item 8), bolt (Figure 4, Item 11), two washers (Figure 4, Item 9) and clamp (Figure 4, Item 10) from line (Figure 4, Item 7). 7. Loosen tube nut (Figure 4, Item 12) and remove line (Figure 4, Item 7) from engine filter base (Figure 4, Item 13). 8. Loosen tube nut (Figure 4, Item 1) and remove line (Figure 4, Item 2) from engine filter base (Figure 4, Item 13).

Figure 4. Filter Base Lines.

0083

0083-4

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES REMOVAL CONTINUED 9. Remove filter (Figure 5, Item 5) from filter base (Figure 5, Item 4). 10. Loosen tube nut (Figure 5, Item 2) and remove line (Figure 5, Item 1) from fitting (Figure 5, Item 3) on filter base (Figure 5, Item 4). 11. Loosen tube nut (Figure 5, Item 7) and remove line (Figure 5, Item 6) from fitting (Figure 5, Item 8) on filter base (Figure 5, Item 4).

Figure 5. Filter Base.

0083

0083-5

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES REMOVAL CONTINUED

NOTE
Note orientation of fittings to aid installation. 12. Loosen nut (Figure 6, Item 3) and remove fitting (Figure 6, Item 1) from filter base (Figure 6, Item 4). 13. Remove two O-rings (Figure 6, Item 2) from fitting (Figure 6, Item 1). Discard O-rings. 14. Remove fitting (Figure 6, Item 6) from filter base (Figure 6, Item 4). 15. Remove two O-rings (Figure 6, Item 5) from fitting (Figure 6, Item 6). Discard O-rings. 16. Remove four bolts (Figure 6, Item 7), washers (Figure 6, Item 8), one clip (Figure 6, Item 9), and filter base (Figure 6, Item 10) from filter base bracket (Figure 6, Item 11).

Figure 6. Filter Base Fittings.

0083

0083-6

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES REMOVAL CONTINUED 17. Remove three bolts (Figure 7, Item 2), four washers (Figure 7, Item 3), one ground strap (Figure 7, Item 4), and filter base bracket (Figure 7, Item 1) from machine.

Figure 7. Filter Base Bracket. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0083

00083

0083-7

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES INSTALLATION

00083

WARNING

Lubricating/hydraulic oils used in the performance of maintenance can be very slippery. Immediately wipe up any spills. Wear protective eye covering and gloves. Failure to follow these warnings may result in injury to personnel.

1. Install filter base bracket (Figure 7, Item 1), four washers (Figure 7, Item 3), one ground strap (Figure 7, Item 4) and three bolts (Figure 7, Item 2) on machine.

NOTE
Install fittings and lines as noted during removal. 2. Install filter base (Figure 8, Item 10), four washers (Figure 8, Item 8), one clip (Figure 8, Item 9) and four bolts (Figure 8, Item 7) on filter base bracket (Figure 8, Item 11). 3. Install two new O-rings (Figure 8, Item 5) on fitting (Figure 8, Item 6). 4. Install fitting (Figure 8, Item 6) on filter base (Figure 8, Item 4). 5. Install two new O-rings (Figure 8, Item 2) on fitting (Figure 8, Item 1). 6. Install fitting (Figure 8, Item 1) on filter base (Figure 8, Item 4). Tighten nut (Figure 8, Item 3).

Figure 8. Filter Base Fittings.

0083

0083-8

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES INSTALLATION CONTINUED 7. Install line (Figure 9, Item 6) on fitting (Figure 9, Item 8) on filter base (Figure 9, Item 4). Tighten tube nut (Figure 9, Item 7). 8. Install line (Figure 9, Item 1) on fitting (Figure 9, Item 3) on filter base (Figure 9, Item 4). Tighten tube nut (Figure 9, Item 2). 9. Install filter (Figure 9, Item 5) on filter base (Figure 9, Item 4).

Figure 9. Filter Base.

0083

0083-9

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES INSTALLATION CONTINUED

NOTE
Orient fittings and lines as noted during removal. 10. Install line (Figure 10, Item 2) on engine filter base (Figure 10, Item 13). Tighten tube nut (Figure 10, Item 1). 11. Install line (Figure 10, Item 7) on engine filter base (Figure 10, Item 13). Tighten tube nut (Figure 10, Item 12). 12. Install clamp (Figure 10, Item 10), two washers (Figure 10, Item 9), bolt (Figure 10, Item 11), and nut (Figure 10, Item 8) on line (Figure 10, Item 7). 13. Install clamps (Figure 10, Item 3), two washers (Figure 10, Item 5), bolt (Figure 10, Item 4), and nut (Figure 10, Item 6) on lines (Figure 10, Items 7 and 2).

Figure 10. Filter Base Lines.

0083

0083-10

TM 5-2410-241-23-2

0083

OIL FILTER BASE AND LINES INSTALLATION CONTINUED 14. Install plate (Figure 11, Item 2), three washers (Figure 11, Item 3), and bolts (Figure 11, Item 1) on machine.

Figure 11. Guard Mount. 15. Install guard (Figure 12, Item 1) on machine. 16. Position cable (Figure 12, Item 5) and bracket (Figure 12, Item 4) on guard (Figure 12, Item 1). 17. Install three washers (Figure 12, Item 3) and bolts (Figure 12, Item 2) on machine.

0083

Figure 12. Guard. END OF TASK

0083

0083-11

TM 5-2410-241-23-2

0083

OIL FILTER INSTALLATION 1. Install new filter (Figure 13, Item 1) on base (Figure 13, Item 2). 2. Remove container from under filter (Figure 13, Item 1).

00083

Figure 13. Access Panel. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure right door guard (WP 0204). 2. Fill oil (WP 0114). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0083

00083

0083-12

12 TM 5-2410-241-23-2 0084

FIELD MAINTENANCE ENGINE OIL COOLER REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 8 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket (2) O-ring (7) References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10)
0

Equipment Condition - Continued

Engine enclosure right door guard removed (WP 0204) Cooling system drained (WP 0113) Oil filter base removed (WP 0083) Personnel Required Two Drawing Required TM 5-2410-241-24P, Figure 35, 101, 153 Estimated Time to Complete 6.5 Hr

0084-1

TM 5-2410-241-23-2

0084

REMOVAL

00084

NOTE
Tag and note routing and position of hoses to aid installation. 1. Loosen two clamps (Figure 1, Item 7) on hose (Figure 1, Item 3). 2. Remove three bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from oil cooler bonnet (Figure 1, Item 9). 3. Remove two bolts (Figure 1, Item 4) and washers (Figure 1, Item 5) from cooler elbow (Figure 1, Item 6). 4. Push oil cooler bonnet (Figure 1, Item 9) from oil cooler (Figure 1, Item 10). 5. Remove cooler bonnet (Figure 1, Item 9), hose (Figure 1, Item 3), and cooler elbow (Figure 1, Item 6) from water pump (Figure 1, Item 8).

Figure 1. Hose to Water Pump.

0084

0084-2

TM 5-2410-241-23-2

0084

REMOVAL CONTINUED 6. Remove O-ring (Figure 2, Item 2) from cooler bonnet (Figure 2, Item 1). Discard O-ring. 7. Remove gasket (Figure 2, Item 9) from cooler elbow (Figure 2, Item 8). Discard gasket. 8. Remove cooler bonnet (Figure 2, Item 1) from hose (Figure 2, Item 7). 9. Remove plug (Figure 2, Item 5) from cooler bonnet (Figure 2, Item 1). 10. Remove two clamps (Figure 2, Item 6) from hose (Figure 2, Item 7). 11. Remove hose (Figure 2, Item 7) from cooler elbow (Figure 2, Item 8). 12. Remove plug (Figure 2, Item 4) and O-ring (Figure 2, Item 3) from cooler elbow (Figure 2, Item 8). Discard Oring.

Figure 2. Oil Cooler Adapter.

0084

0084-3

TM 5-2410-241-23-2

0084

REMOVAL CONTINUED 13. Remove two bolts (Figure 3, Item 2) and washers (Figure 3, Item 1) from machine. 14. Position hoses and bracket (Figure 3, Item 3) aside on machine.

Figure 3. Hose Bracket. 15. Loosen clamp (Figure 4, Item 5) and remove hose (Figure 4, Item 4) from valve (Figure 4, Item 6). Position hose aside. 16. Loosen clamp (Figure 4, Item 2) and remove hose (Figure 4, Item 1) from nipple (Figure 4, Item 3). Position hose aside.

0084

Figure 4. Oil Cooler Valve.

0084

0084-4

TM 5-2410-241-23-2

0084

REMOVAL CONTINUED 17. Remove three bolts (Figure 5, Item 2) and washers (Figure 5, Item 4) from elbow (Figure 5, Item 1). 18. Remove four bolts (Figure 5, Item 8) and washers (Figure 5, Item 7) from oil cooler core (Figure 5, Item 3). 19. Remove oil cooler core (Figure 5, Item 3), two O-rings (Figure 5, Item 6) from oil filter base (Figure 5, Item 9) and elbow (Figure 5, Item 1). Discard O-rings. 20. Remove O-ring (Figure 5, Item 5) from elbow (Figure 5, Item 1). Discard O-ring.

Figure 5. Oil Cooler Core.

0084

0084-5

TM 5-2410-241-23-2

0084

REMOVAL CONTINUED 21. Remove six bolts (Figure 6, Item 4), washers (Figure 6, Item 3), clamp (Figure 6, Item 2), cooler core elbow (Figure 6, Item 1) and gasket (Figure 6, Item 5) from machine. Discard gasket. 22. Remove nipple (Figure 6, Item 8), adapter (Figure 6, Item 7) and elbow (Figure 6, Item 6) from cooler core elbow (Figure 6, Item 1).

Figure 6. Cooler Core Elbow.

0084

23. Remove fitting (Figure 7, Item 3) and two O-rings (Figure 7, Item 2) from cooler core elbow (Figure 7, Item 1). Discard O-rings. 24. Remove valve (Figure 7, Item 4) from cooler core elbow (Figure 7, Item 1).

Figure 7. Elbow O-rings. END OF TASK

0084

0084-6

TM 5-2410-241-23-2

0084

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install valve (Figure 7, Item 4) on elbow (Figure 7, Item 1). 2. Install two new O-rings (Figure 7, Item 2) and fitting (Figure 7, Item 3) on elbow (Figure 7, Item 1). 3. Install elbow (Figure 8, Item 6), adapter (Figure 8, Item 7) and nipple (Figure 8, Item 8) on cooler core elbow (Figure 8, Item 1). 4. Install new gasket (Figure 8, Item 5), cooler core elbow (Figure 8, Item 1), clamp (Figure 8, Item 2), six washers (Figure 8, Item 3) and bolts (Figure 8, Item 4) on machine.

00084

00084

Figure 8. Cooler Core Elbow.

0084

0084-7

TM 5-2410-241-23-2

0084

INSTALLATION CONTINUED 5. Install new O-ring (Figure 9, Item 5) on cooler core elbow (Figure 9, Item 1). 6. Install two new O-rings (Figure 9, Item 6) and oil cooler core (Figure 9, Item 3) on oil filter base (Figure 9, Item 9) and cooler core elbow (Figure 9, Item 1). 7. Install four washers (Figure 9, Item 7) and bolts (Figure 9, Item 8) on oil cooler core (Figure 9, Item 3). 8. Install three washers (Figure 9, Item 4) and bolts (Figure 9, Item 2) on cooler core elbow (Figure 9, Item 1).

Figure 9. Oil Cooler Core.

0084

0084-8

TM 5-2410-241-23-2

0084

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 9. Install hose (Figure 10, Item 1) and clamp (Figure 10, Item 2) on nipple (Figure 10, Item 3). 10. Install hose (Figure 10, Item 4) and clamp (Figure 10, Item 5) on valve (Figure 10, Item 6).

Figure 10. Oil Cooler Valve.

0084

11. Install bracket and hoses (Figure 11, Item 3), two washers (Figure 11, Item 1) and bolts (Figure 11, Item 2) on machine.

Figure 11. Hose Bracket.

0084

0084-9

TM 5-2410-241-23-2

0084

INSTALLATION CONTINUED 12. Install new O-ring (Figure 12, Item 3) and plug (Figure 12, Item 4) on cooler elbow (Figure 12, Item 8). 13. Install hose (Figure 12, Item 7) on cooler elbow (Figure 12, Item 8). 14. Install two clamps (Figure 12, Item 6) on hose (Figure 12, Item 7). 15. Install plug (Figure 12, Item 5) on cooler bonnet (Figure 12, Item 1). 16. Install cooler bonnet (Figure 12, Item 1) on hose (Figure 12, Item 7). 17. Install new gasket (Figure 12, Item 9) on cooler elbow (Figure 12, Item 8). 18. Install new O-ring (Figure 12, Item 2) on cooler bonnet (Figure 12, Item 1).

Figure 12. Oil Cooler Adapter.

0084

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TM 5-2410-241-23-2

0084

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 19. Install cooler elbow (Figure 13, Item 6), hose (Figure 13, Item 3), and cooler bonnet (Figure 13, Item 9) on water pump (Figure 13, Item 8). 20. Install oil cooler bonnet (Figure 13, Item 9) on oil cooler (Figure 13, Item 10). 21. Install two washers (Figure 13, Item 5) and bolts (Figure 13, Item 4) on cooler elbow (Figure 13, Item 6). 22. Install three washers (Figure 13, Item 2) and bolts (Figure 13, Item 1) on oil cooler bonnet (Figure 13, Item 9). 23. Tighten two clamps (Figure 13, Item 7) on hose (Figure 13, Item 3).

Figure 13. Hose to Water Pump. END OF TASK FOLLOW-ON TASKS 1. Install oil filter base (WP 0083). 2. Fill cooling system (WP 0113). 3. Install engine enclosure right door guard (WP 0204). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0084

00084

0084-11/(12 blank)

16 TM 5-2410-241-23-2 0085

FIELD MAINTENANCE REAR GEAR ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 8 5

INITIAL SETUP Tools and Special Tools

0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Implement pump removed (WP 0112) Flange removed (WP 0104) Flywheel removed (WP 0100) Drawing Required TM 5-2410-241-24P, Figure 38, 43 Estimated Time to Complete 6.0 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Wrench, Torque, Click, Ratcheting, 1/2 Drive, 250 lb-ft (WP 0302, Item 71) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73)
0 0 0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Bearings (4) O-ring (4)

REMOVAL 1. Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2) and cover (Figure 1, Item 3) from flywheel housing (Figure 1, Item 4).

00085

Figure 1. Cover and Retaining Hardware on Left Side of Flywheel Housing.

0085

0085-1

TM 5-2410-241-23-2

0085

REMOVAL CONTINUED 2. Remove O-ring (Figure 2, Item 1) from flywheel housing (Figure 2, Item 2). Discard O-ring.

Figure 2. O-ring on Left Side of Flywheel Housing. 3. Remove two bolts (Figure 3, Item 3), washers (Figure 3, Item 2) and cover (Figure 3, Item 4) from flywheel housing (Figure 3, Item 1).

0085

Figure 3. Cover and Retaining Hardware on Right Side of Flywheel Housing.

0085

0085-2

TM 5-2410-241-23-2

0085

REMOVAL CONTINUED 4. Remove O-ring (Figure 4, Item 2) from flywheel housing (Figure 4, Item 1). Discard O-ring.

Figure 4. O-ring on Right Side of Flywheel Housing.

0085

0085-3

TM 5-2410-241-23-2

0085

REMOVAL CONTINUED

NOTE
Note orientation of hydraulic pump adapter and gear. 5. Remove six bolts (Figure 5, Item 7), washers (Figure 5, Item 8), clip (Figure 5, Item 9), hydraulic pump adapter (Figure 5, Item 6), O-ring (Figure 5, Item 5), and pump drive gear (Figure 5, Item 3) from flywheel housing (Figure 5, Item 2). Discard O-ring. 6. Remove bearing (Figure 5, Item 4) from hydraulic pump adapter (Figure 5, Item 6). Discard bearing. 7. Remove bearing (Figure 5, Item 1) from flywheel housing (Figure 5, Item 2). Discard bearing.

Figure 5. Right Pump Drive Gear.

0085

0085-4

TM 5-2410-241-23-2

0085

REMOVAL CONTINUED

NOTE
Note orientation of hydraulic pump adapter and gear. 8. Remove six bolts (Figure 6, Item 9), washers (Figure 6, Item 8), bracket (Figure 6, Item 7), hydraulic pump adapter (Figure 6, Item 6), O-ring (Figure 6, Item 5), and pump drive gear (Figure 6, Item 3) from flywheel housing (Figure 6, Item 2). Discard O-ring. 9. Remove bearing (Figure 6, Item 4) from hydraulic pump adapter (Figure 6, Item 6). Discard bearing. 10. Remove bearing (Figure 6, Item 1) from flywheel housing (Figure 6, Item 2). Discard bearing.

Figure 6. Left Pump Drive Gear.

0085

0085-5

TM 5-2410-241-23-2

0085

REMOVAL CONTINUED

NOTE
Note position and location of gears to aid installation. 11. Remove crankshaft drive gear (Figure 7, Item 5) from two idler gears (Figure 7, Item 1). 12. Remove six bolts (Figure 7, Item 2), two idler gear shafts (Figure 7, Item 3), and idler gears (Figure 7, Item 1) from flywheel housing (Figure 7, Item 4).

Figure 7. Crankshaft Drive Gear and Idler Gears.

0085

0085-6

TM 5-2410-241-23-2

0085

REMOVAL CONTINUED

NOTE
The following step removes bearing from one idler gear. Repeat procedure to remove bearing from other idler gear. 13. Remove bearing (Figure 8, Item 1) from idler gear (Figure 8, Item 2).

Figure 8. Idler Gear and Bearing. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0085

00085

0085-7

TM 5-2410-241-23-2

0085

INSTALLATION

00085

CAUTION
When installed, center of relief grooves on bearing must not be more than two degrees off center of relief grooves on idler gear. When installed, bearing must be flush with idler gear face on both sides of idler gear. Failure to follow these cautions may result in damage to equipment.

NOTE
The following step installs bearing on one idler gear. Repeat procedure to install bearing on other idler gear. 1. Install bearing (Figure 9, Item 1) on idler gear (Figure 9, Item 2) with relief grooves (Figure 9, Item 3) on bearing centered with relief joints (Figure 9, Item 4) on idler gear.

Figure 9. Idler Gear and Bearing.

0085

0085-8

TM 5-2410-241-23-2

0085

INSTALLATION CONTINUED

NOTE
Install gears as noted during removal. 2. Install two idler gears (Figure 10, Item 1), idler gear shafts (Figure 10, Item 3), and six bolts (Figure 10, Item 2) on flywheel housing (Figure 10, Item 4). Tighten bolts to 74 15 lb-ft (100 20 Nm).

CAUTION
Make sure gears do not bind. Failure to follow this caution may result in damage to equipment. 3. Install crankshaft drive gear (Figure 10, Item 5) on two idler gears (Figure 10, Item 1).

Figure 10. Crankshaft Drive Gear and Idler Gears.

0085

0085-9

TM 5-2410-241-23-2

0085

INSTALLATION CONTINUED

CAUTION
When installed, bearing joint must not be more than 15 degrees off center of bottom of bore on flywheel housing. Failure to follow this caution may result in damage to equipment.

NOTE
Step 4 installs one bearing on flywheel housing. Repeat procedure to install other bearing on flywheel housing. 4. Install bearing (Figure 11, Item 2) with joint (Figure 11, Item 1) at bottom of bore (Figure 11, Item 4) on flywheel housing (Figure 11, Item 3).

Figure 11. Bearing Installation on Flywheel Housing.

0085

0085-10

TM 5-2410-241-23-2

0085

INSTALLATION CONTINUED

CAUTION
When installed, bearing joint must not be more than 15 degrees off center of bottom of bore on hydraulic pump adapter. Failure to follow this caution may result in damage to equipment.

NOTE
Step 5 installs bearing on one hydraulic pump adapter. Repeat procedure to install bearing on other hydraulic pump adapter. 5. Position oil passage (Figure 12, Item 4) on hydraulic pump adapter (Figure 12, Item 1) downward. 6. Install new bearing (Figure 12, Item 2) with joint (Figure 12, Item 3) at bottom of bore (Figure 12, Item 6) on hydraulic pump adapter (Figure 12, Item 1). 7. Recess bearing (Figure 12, Item 2) 0.138 0.020 in. (3.5 0.5 mm) from inside edge of bore (Figure 12, Item 5) on hydraulic pump adapter (Figure 12, Item 1).

Figure 12. Bearing Installation on Hydraulic Pump Adapter.

0085

0085-11

TM 5-2410-241-23-2

0085

INSTALLATION CONTINUED

CAUTION
Make sure gears do not bind. Failure to follow this caution may result in damage to equipment.

NOTE
Install gear and hydraulic pump adapter as noted during removal. 8. Install pump drive gear (Figure 13, Item 2), new O-ring (Figure 13, Item 3), hydraulic pump adapter (Figure 13, Item 4), bracket (Figure 13, Item 5), six washers (Figure 13, Item 6) and bolts (Figure 13, Item 7) on flywheel housing (Figure 13, Item 1). Tighten bolts to 41 9 lb-ft (55 12 Nm).

Figure 13. Left Pump Drive Gear.

0085

0085-12

TM 5-2410-241-23-2

0085

INSTALLATION CONTINUED

CAUTION
Make sure gears do not bind. Failure to follow this caution may result in damage to equipment.

NOTE
Install gear and hydraulic pump adapter as noted during removal. 9. Install pump drive gear (Figure 14, Item 2), new O-ring (Figure 14, Item 3), hydraulic pump adapter (Figure 14, Item 4), clip (Figure 14, Item 7), six washers (Figure 14, Item 6) and bolts (Figure 14, Item 5) on flywheel housing (Figure 14, Item 1). Tighten bolts to 41 9 lb-ft (55 12 Nm).

Figure 14. Right Pump Drive Gear.

0085

0085-13

TM 5-2410-241-23-2

0085

INSTALLATION CONTINUED 10. Install new O-ring (Figure 15, Item 2) on flywheel housing (Figure 15, Item 1).

Figure 15. O-ring on Right Side of Flywheel Housing. 11. Install cover (Figure 16, Item 4), two washers (Figure 16, Item 2), and bolts (Figure 16, Item 3) on flywheel housing (Figure 16, Item 1). Tighten bolts to 177 30 lb-ft (240 40 Nm).

0085

Figure 16. Cover and Retaining Hardware on Right Side of Flywheel Housing.

0085

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TM 5-2410-241-23-2

0085

INSTALLATION CONTINUED 12. Install new O-ring (Figure 17, Item 1) on flywheel housing (Figure 17, Item 2).

Figure 17. O-ring on Left Side of Flywheel Housing. 13. Install cover (Figure 18, Item 3), two washers (Figure 18, Item 2), and bolts (Figure 18, Item 1) on flywheel housing (Figure 18, Item 4). Tighten bolts to 74 15 lb-ft (100 20 Nm).

0085

Figure 18. Cover and Retaining Hardware on Left Side of Flywheel Housing. END OF TASK

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TM 5-2410-241-23-2

0085

FOLLOW-ON TASKS 1. Install flywheel (WP 0100). 2. Install flange (WP 0104). 3. Install implement pump (WP 0112). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

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0085-16

6 TM 5-2410-241-23-2 0086

FIELD MAINTENANCE OIL FILLER REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 8 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure left door guard removed (WP 0202)
0 0

Drawing Required TM 5-2410-241-24P, Figure 37 Estimated Time to Complete 0.5 Hr

0086-1

TM 5-2410-241-23-2

0086

REMOVAL

00086

CAUTION
Wipe area clean around oil fill tube. Contamination of engine oil could result in premature failure. 1. Remove two nuts (Figure 1, Item 2), bolts (Figure 1, Item 3), and four washers (Figure 1, Item 4) from engine bracket (Figure 1, Item 6). 2. Move hose bracket (Figure 1, Item 5) aside. 3. Remove two bolts (Figure 1, Item 9) and washers (Figure 1, Item 8) from fill tube (Figure 1, Item 10). 4. Move bracket (Figure 1, Item 7) aside, and remove fill tube (Figure 1, Item 1) from machine.

Figure 1. Oil Fill Tube and Mounting Bolts.

0086

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TM 5-2410-241-23-2

0086

REMOVAL CONTINUED 5. Remove O-ring (Figure 2, Item 2) from fill tube (Figure 2, Item 1). Discard O-ring.

Figure 2. Oil Fill Tube O-ring. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0086

00086

0086-3

TM 5-2410-241-23-2

0086

INSTALLATION 1. Install new O-ring (Figure 3, Item 2) on fill tube (Figure 3, Item 1).

00086

Figure 3. Oil Tube O-ring.

0086

0086-4

TM 5-2410-241-23-2

0086

INSTALLATION CONTINUED 2. Install fill tube (Figure 4, Item 1) on machine. 3. Position bracket (Figure 4, Item 8) on fill tube (Figure 4, Item 11). 4. Install two washers (Figure 4, Item 9) and bolts (Figure 4, Item 10) on fill tube (Figure 4, Item 11). 5. Align oil fill tube bracket (Figure 4, Item 2) and hose bracket (Figure 4, Item 6) on engine bracket (Figure 4, Item 7). 6. Install four washers (Figure 4, Item 5), two bolts (Figure 4, Item 4), and nuts (Figure 4, Item 3) on engine bracket (Figure 4, Item 7).

Figure 4. Oil Fill Tube and Mounting Bolts. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure left door guard (WP 0202). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0086

00086

0086-5/(6 blank)

4 TM 5-2410-241-23-2 0087

FIELD MAINTENANCE DIPSTICK REPLACEMENT Removal, Cleaning and Inspection, Installation

0 0 8 7

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure left door guard removed (WP 0202)
0 0

Drawing Required TM 5-2410-241-24P, Figure 36 Estimated Time to Complete 0.5 Hr

0087-1

TM 5-2410-241-23-2

0087

REMOVAL 1. Remove dipstick (Figure 1, Item 1) from dipstick tube (Figure 1, Item 4).

00087

2. Remove three bolts (Figure 1, Item 3), washers (Figure 1, Item 6), spacer (Figure 1, Item 5), and dipstick tube (Figure 1, Item 4) from engine (Figure 1, Item 2).

Figure 1. Oil Level Dipstick.

0087

0087-2

TM 5-2410-241-23-2

0087

REMOVAL CONTINUED 3. Remove O-ring (Figure 2, Item 1) from dipstick tube (Figure 2, Item 2). Discard O-ring.

Figure 2. Oil Level Dipstick Tube and O-ring. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install new O-ring (Figure 2, Item 1) on dipstick tube (Figure 2, Item 2).

0087

00087

00087

0087-3

TM 5-2410-241-23-2

0087

INSTALLATION CONTINUED 2. Install dipstick tube (Figure 3, Item 4), spacer (Figure 3, Item 5), three washers (Figure 3, Item 6), and bolts (Figure 3, Item 3) on engine (Figure 3, Item 2). 3. Install dipstick (Figure 3, Item 1) on dipstick tube (Figure 3, Item 4).

Figure 3. Oil Level Dipstick. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure left door guard (WP 0202). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0087

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8 TM 5-2410-241-23-2 0088

FIELD MAINTENANCE OIL PUMP REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 8 8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) O-ring (8) References WP 0114 WP 0295 REMOVAL 1. Remove two bolts (Figure 1, Item 2) and washers (Figure 1, Item 3) from oil pump (Figure 1, Item 1).
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine bottom guard removed (WP 0199) Engine enclosure right door guard removed (WP 0204) Drawing Required TM 5-2410-241-24P, Figure 40 Estimated Time to Complete 4.5 Hr

00088

Figure 1. Oil Pump Mounting Bolts.

0088

0088-1

TM 5-2410-241-23-2

0088

REMOVAL CONTINUED

NOTE
Remove oil pump and elbow from engine as an assembly. 2. Remove four bolts (Figure 2, Item 4), washers (Figure 2, Item 5), oil pump (Figure 2, Item 2) and elbow (Figure 2, Item 1) from engine (Figure 2, Item 3).

Figure 2. Oil Pump and Elbow - On Engine.

0088

0088-2

TM 5-2410-241-23-2

0088

REMOVAL CONTINUED 3. Remove tube (Figure 3, Item 2) from oil filter base (Figure 3, Item 1). 4. Remove and discard O-ring (Figure 3, Item 3) from tube (Figure 3, Item 2).

Figure 3. Tube. 5. Remove elbow (Figure 4, Item 1) from oil pump (Figure 4, Item 2). 6. Remove and discard O-ring (Figure 4, Item 3) from oil pump (Figure 4, Item 2).

0088

Figure 4. Oil Pump and Elbow - Off Engine.

0088

0088-3

TM 5-2410-241-23-2

0088

REMOVAL CONTINUED

NOTE
Note size and position of O-rings to aid installation. Note size and position of couplings to aid installation.

7. Remove two couplings (Figure 5, Item 4) and six O-rings (Figure 5, Items 3 and 1) from elbow (Figure 5, Item 2). Discard O-rings.

Figure 5. Oil Pump Elbow and Couplings. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0088

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0088-4

TM 5-2410-241-23-2

0088

INSTALLATION

00088

NOTE
Lubricate O-rings with clean engine oil. Install O-rings as noted at removal. Install couplings as noted at removal.

1. Install four new O-rings (Figure 5, Item 3) on two couplings (Figure 5, Item 4). 2. Install two couplings (Figure 5, Item 4) on elbow (Figure 5, Item 2). 3. Install two new O-rings (Figure 5, Item 1) on elbow (Figure 5, Item 2). 4. Install new O-ring (Figure 6, Item 3) on oil pump (Figure 6, Item 2). 5. Install elbow (Figure 6, Item 1) on oil pump (Figure 6, Item 2).

Figure 6. Oil Pump and Elbow - Off Engine.

0088

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TM 5-2410-241-23-2

0088

INSTALLATION CONTINUED 6. Install new O-ring (Figure 7, Item 3) on tube (Figure 7, Item 2). 7. Install tube (Figure 7, Item 2) on oil filter base (Figure 7, Item 1).

Figure 7. Tube.

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TM 5-2410-241-23-2

0088

INSTALLATION CONTINUED

NOTE
Install oil pump and elbow as an assembly. 8. Install oil pump (Figure 8, Item 2), elbow (Figure 8, Item 1), four washers (Figure 8, Item 5), and bolts (Figure 8, Item 4) on engine (Figure 8, Item 3). Do not tighten bolts at this time.

Figure 8. Oil Pump and Elbow - On Engine.

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TM 5-2410-241-23-2

0088

INSTALLATION CONTINUED 9. Install two washers (Figure 9, Item 3) and bolts (Figure 9, Item 2) on oil pump (Figure 9, Item 1). Tighten all bolts.

Figure 9. Oil Pump Mounting Bolts. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure right door guard (WP 0204). 2. Install engine bottom guard (WP 0199). 3. Check engine oil level (WP 0114). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0088

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0088-8

8 TM 5-2410-241-23-2 0089

FIELD MAINTENANCE OIL PAN REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 8 9

INITIAL SETUP Tools and Special Tools

0

Materials/Parts - Continued O-ring References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Engine oil drained (WP 0114) Engine removed (WP 0057) Drawing Required

Tool Kit, General Mechanics (WP 0302, Item 65) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Pan, Drain (S0255) (WP 0302, Item 68)
0 0 0 0 0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Gasket (Sealing Compound) (WP 0303, Item 10) Gasket Gasket, oil pan

TM 5-2410-241-24P, Figure 1, 39
0

Estimated Time to Complete 38.0 Hr

0089-1

TM 5-2410-241-23-2

0089

REMOVAL

00089

WARNING

Engine oil pan may drop when bolts are removed. Support engine oil pan when removing bolts. Failure to follow these procedures may result in death or injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids properly. 1. Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2) and brackets (Figure 1, Item 3) from engine (Figure 1, Item 4). 2. Set brackets (Figure 1, Item 3) with hose aside.

Figure 1. Hose and Brackets.

0089

0089-2

TM 5-2410-241-23-2

0089

REMOVAL CONTINUED 3. Remove bolt (Figure 2, Item 6), washer (Figure 2, Item 5), clamp (Figure 2, Item 7), washer (Figure 2, Item 4) and isolator (Figure 2, Item 2) from oil pan (Figure 2, Item 1). 4. Set harness (Figure 2, Item 3) aside.

Figure 2. Harness.

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TM 5-2410-241-23-2

0089

REMOVAL CONTINUED 5. Remove 13 bolts (Figure 3, Item 1), washers (Figure 3, Item 17), isolators (Figure 3 Item 18) and oil pan (Figure 3, Item 2) from engine. 6. Remove gasket (Figure 3, Item 16) and 14 sleeves (Figure 3, Item 19) from oil pan (Figure 3, Item 2). Discard gasket. 7. Remove four bolts (Figure 3, Items 11 and 15), washers (Figure 3, Items 10 and 14), two spacers (Figure 3, Item 13) and oil pickup (Figure 3, Item 12) from engine. 8. Remove O-ring (Figure 3, Item 9) from oil pickup tube (Figure 3, Item 12). Discard O-ring. 9. Remove two plugs (Figure 3, Item 7) and washers (Figure 3, Item 8) from oil pan (Figure 3, Item 2). 10. Remove two pipe plugs (Figure 3, Item 3) from oil pan (Figure 3, Item 2). 11. Remove two bolts (Figure 3, Item 6), one adapter (Figure 3, Item 5), and gasket (Figure 3, Item 4) from oil pan (Figure 3, Item 2). Discard gasket.

Figure 3. Oil Pan. END OF TASK CLEANING AND INSPECTION Clean and inspect all components IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0089

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TM 5-2410-241-23-2

0089

INSTALLATION 1. Install new gasket (Figure 3, Item 4), adapter (Figure 3, Item 5), and two bolts (Figure 3, Item 6) on oil pan (Figure 3, Item 2). 2. Install two pipe plugs (Figure 3, Item 3) on oil pan (Figure 3, Item 2). 3. Install two washers (Figure 3, Item 8) and plugs (Figure 3, Item 7) on oil pan (Figure 3, Item 2). 4. Install new O-ring (Figure 3, Item 9) on oil pickup tube (Figure 3, Item 12). 5. Install oil pickup tube (Figure 3, Item 12), two spacers (Figure 3, Item 13), washers (Figure 3, Item 14), and bolts (Figure 3, Item 15) on engine. 6. Align oil pickup tube (Figure 3, Item 12) and install two washers (Figure 3, Item 10) and bolts (Figure 3, Item 11) on machine.

00089

WARNING

Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 7. Apply gasket (sealing compound) on sealing surface of oil pan, connecting joints of front plate, oil pan gasket, cylinder block, and flywheel housing. 8. Install 14 sleeves (Figure 3, Item 19) and new gasket (Figure 3, Item 16) on oil pan (Figure 3, Item 2). 9. Install oil pan (Figure 3, Item 2) on machine. 10. Align gasket (Figure 3, Item 16), oil pan (Figure 3, Item 2) and install 13 isolators (Figure 3, Item 18), washers (Figure 3, Item 17) and bolts (Figure 3, Item 1) on oil pan. Torque bolts to 41 lb-ft (55 Nm).

0089-5

TM 5-2410-241-23-2

0089

INSTALLATION CONTINUED 11. Position harness (Figure 4, Item 3) at mounting location on oil pan (Figure 4, Item 1). 12. Install isolator (Figure 4, Item 2), washer (Figure 4, Item 4), clamp (Figure 4, Item 7), washer (Figure 4, Item 5) and bolt (Figure 4, Item 6) on oil pan (Figure 4, Item 1).

Figure 4. Harness.

0089

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TM 5-2410-241-23-2

0089

INSTALLATION CONTINUED 13. Position brackets (Figure 5, Item 3) at mounting location on engine (Figure 5, Item 4). 14. Install two brackets (Figure 5, Item 3), washers (Figure 5, Item 2) and bolts (Figure 5, Item 1) on engine (Figure 5, Item 4).

Figure 5. Hose and Brackets. END OF TASK FOLLOW-ON TASKS 1. Install engine (WP 0057). 2. Fill engine with oil (WP 0114). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0089

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2 TM 5-2410-241-23-2 0090

FIELD MAINTENANCE
0 0 9 0

ATMOSPHERIC PRESSURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10)

Drawing Required
0

TM 5-2410-241-24P, Figure 15 Estimated Time to Complete

0.5 Hr
0 0

00090

NOTE
Tag electrical connectors to aid installation. 1. Disconnect connector (Figure 1, Item 1) from pressure sensor (Figure 1, Item 2). 2. Remove pressure sensor (Figure 1, Item 2) from engine (Figure 1, Item 4). 3. Remove O-ring (Figure 1, Item 3) from pressure sensor (Figure 1, Item 2). Discard O-ring.

Figure 1. Atmospheric Pressure Sensor. END OF TASK

0090

0090-1

TM 5-2410-241-23-2

0090

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00090

00090

NOTE
Install electrical connectors as tagged during removal. 1. Install new O-ring (Figure 2, Item 3) on pressure sensor (Figure 2, Item 2). 2. Install pressure sensor (Figure 2, Item 2) on engine (Figure 2, Item 4). 3. Connect connector (Figure 2, Item 1) on pressure sensor (Figure 2, Item 2).

Figure 2. Atmospheric Pressure Sensor. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0090

00090

0090-2

4 TM 5-2410-241-23-2 0091

FIELD MAINTENANCE
0 0 9 1

ENGINE OIL PRESSURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10)

Drawing Required
0

TM 5-2410-241-24P, Figure 15 Estimated Time to Complete

0.5 Hr
0 0

00091

1. Remove three bolts (Figure 1, Item 3), washers (Figure 1, Item 2) and cover (Figure 1, Item 1) from machine.

Figure 1. Access Panel.

0091

0091-1

TM 5-2410-241-23-2

0091

REMOVAL CONTINUED

NOTE
Tag electrical connectors to aid installation. 2. Disconnect connector (Figure 2, Item 1) from engine oil pressure sensor (Figure 2, Item 2). 3. Remove engine oil pressure sensor (Figure 2, Item 2) and O-ring (Figure 2, Item 3) from fitting (Figure 2, Item 4). Discard O-ring. 4. Remove fitting (Figure 2, Item 4) from engine (Figure 2, Item 5).

Figure 2. Engine Oil Pressure Sensor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0091

00091

00091

NOTE
Install electrical connectors as tagged during removal. 1. Install fitting (Figure 2, Item 4) on engine (Figure 2, Item 5). 2. Install new O-ring (Figure 2, Item 3) and engine oil pressure sensor (Figure 2, Item 2) on fitting (Figure 2, Item 4). 3. Connect connector (Figure 2, Item 1) on engine oil pressure sensor (Figure 2, Item 2).

0091-2

TM 5-2410-241-23-2

0091

INSTALLATION CONTINUED 4. Install cover (Figure 3, Item 1), three washers (Figure 3, Item 2), and bolts (Figure 3, Item 3) on machine.

Figure 3. Access Door. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0091

00091

0091-3/(4 blank)

4 TM 5-2410-241-23-2 0092

FIELD MAINTENANCE
0 0 9 2

AIR INLET MANIFOLD PRESSURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (2)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 15
0 0

Estimated Time to Complete 0.5 Hr

0092-1

TM 5-2410-241-23-2

0092

REMOVAL

00092

NOTE
Tag electrical connectors to aid installation. 1. Remove tiedown strap (Figure 1, Item 2) from aftercooler housing (Figure 1, Item 6). Discard tiedown strap. 2. Disconnect connector (Figure 1, Item 7) from connector (Figure 1, Item 1). 3. Remove air inlet manifold pressure sensor (Figure 1, Item 5) from fitting (Figure 1, Item 4). 4. Remove fitting (Figure 1, Item 4) from aftercooler housing (Figure 1, Item 6). 5. Remove two O-rings (Figure 1, Item 3) from fitting (Figure 1, Item 4). Discard O-rings.

Figure 1. Air Inlet Manifold Pressure Sensor. END OF TASK

0092

0092-2

TM 5-2410-241-23-2

0092

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00092

00092

NOTE
Install electrical connectors as tagged during removal. 1. Install two new O-rings (Figure 1, Item 3) on fitting (Figure 1, Item 4). 2. Install fitting (Figure 1, Item 4) on aftercooler housing (Figure 1, Item 6). 3. Install air inlet manifold pressure sensor (Figure 1, Item 5) on fitting (Figure 1, Item 4). 4. Connect connector (Figure 1, Item 7) on connector (Figure 1, Item 1). 5. Install new tiedown strap (Figure 1, Item 2) on aftercooler housing (Figure 1, Item 6). END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
00092

0092-3/(4 blank)

4 TM 5-2410-241-23-2 0093

FIELD MAINTENANCE
0 0 9 3

CAMSHAFT TIMING SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10)

Drawing Required
0

TM 5-2410-241-24P, Figure 15 Estimated Time to Complete

1.0 Hr
0 0

00093

1. Remove three bolts (Figure 1, Item 3), washers (Figure 1, Item 2) and cover (Figure 1, Item 1) from machine.

Figure 1. Access Panel.

0093

0093-1

TM 5-2410-241-23-2

0093

REMOVAL CONTINUED

NOTE
Tag electrical connectors to aid installation. 2. Disconnect connector (Figure 2, Item 6) from camshaft timing sensor (Figure 2, Item 4). 3. Remove bolt (Figure 2, Item 3), washer (Figure 2, Item 2), clamp (Figure 2, Item 1) and camshaft timing sensor (Figure 2, Item 4) from engine (Figure 2, Item 5). 4. Remove O-ring (Figure 2, Item 5) from camshaft timing sensor (Figure 2, Item 4). Discard O-ring.

Figure 2. Camshaft Timing Sensor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0093

00093

0093-2

TM 5-2410-241-23-2

0093

INSTALLATION 1. Install new O-ring (Figure 2, Item 5) on cam shaft timing sensor (Figure 2, Item 4). 2. Install camshaft timing sensor (Figure 2, Item 4), clamp (Figure 2, Item 1), washer (Figure 2, Item 2) and bolt (Figure 2, Item 3) on engine (Figure 2, Item 5).

00093

NOTE
Install electrical connectors as tagged during removal. 3. Connect connector (Figure 2, Item 6) on cam shaft timing sensor (Figure 2, Item 4). 4. Install cover (Figure 3, Item 1), three washers (Figure 3, Item 2) and bolts (Figure 3, Item 3) on machine.

Figure 3. Access Door. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0093

00093

0093-3/(4 blank)

4 TM 5-2410-241-23-2 0094

FIELD MAINTENANCE
0 0 9 4

ENGINE CRANKSHAFT POSITION SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Front bottom guards removed (WP 0199) Drawing Required TM 5-2410-241-24P, Figure 15 Estimated Time to Complete

1.0 Hr
0 0

0094-1

TM 5-2410-241-23-2

0094

REMOVAL

00094

CAUTION
Do not disconnect jumper harness from sensor. Sensor damage will occur. 1. Do not disconnect connector (Figure 1, Item 3) from engine crankshaft position sensor (Figure 1, Item 1).

NOTE
Tag electrical connectors to aid installation. 2. Remove tiedown strap (Figure 1, Item 11) and disconnect connector (Figure 1, Item 10) from harness (Figure 1, Item 12). Discard tiedown strap. 3. Remove bolt (Figure 1, Item 8), washer (Figure 1, Item 7) and clamp (Figure 1, Item 9) from engine (Figure 1, Item 13). 4. Remove bolt (Figure 1, Item 5), washer (Figure 1, Item 4), clamp (Figure 1, Item 6) and engine crankshaft position sensor (Figure 1, Item 1) from engine (Figure 1, Item 13). 5. Remove O-ring (Figure 1, Item 2) from engine crankshaft position sensor (Figure 1, Item 1). Discard O-ring.

Figure 1. Engine Crankshaft Position Sensor. END OF TASK

0094

0094-2

TM 5-2410-241-23-2

0094

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00094

00094

CAUTION
Do not disconnect jumper harness from sensor. Sensor damage will occur. 1. Do not disconnect connector (Figure 1, Item 3) from engine crankshaft position sensor (Figure 1, Item 1). 2. Install new O-ring (Figure 1, Item 2) on engine crankshaft position sensor (Figure 1, Item 1). 3. Install engine crankshaft position sensor (Figure 1, Item 2), clamp (Figure 1, Item 6), washer (Figure 1, Item 4) and bolt (Figure 1, Item 5) on engine (Figure 1, Item 13). 4. Install clamp (Figure 1, Item 9) washer (Figure 1, Item 7) and bolt (Figure 1, Item 8) from engine (Figure 1, Item 13).

NOTE
Install electrical connectors as tagged during removal. 5. Connect connector (Figure 1, Item 10) and install new tiedown strap (Figure 1, Item 11) on harness (Figure 1, Item 12). END OF TASK FOLLOW-ON TASKS 1. Install front bottom guards (WP 0199). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
00094

0094-3/(4 blank)

14 TM 5-2410-241-23-2 0095

FIELD MAINTENANCE FAN HUB PULLEY REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 9 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Lifting Device (500 lb capacity) Sling, Multiple Leg (WP 0302, Item 54) Materials/Parts Rag, Wiping (WP 0303, Item 24) Emery Cloth Locknut (2) Roll Pin Seal Personnel Required Two REMOVAL 1. Remove two locknuts (Figure 1, Item 1) and washers (Figure 1, Item 2) from plate (Figure 1, Item 3). Discard locknuts.
0

References WP 0295

Equipment Condition
0 0

Machine parked (TM 5-2410-241-10) Cooling fan removed (WP 0050) V-belt set (Alternator) removed (WP 0098) V-belt (A/C compressor) removed (WP 0096) Hood removed (WP 0200) Drawing Required

TM 5-2410-241-24P, Figure 6, 7
0

Estimated Time to Complete

0 0

4.0 Hr

00095

Figure 1. Hub Lower Mount.

0095

0095-1

TM 5-2410-241-23-2

0095

REMOVAL CONTINUED

WARNING

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

NOTE
Fan hub pulley assembly weighs approximately 95 lb (43 kg). 2. Attach lifting device to fan hub pulley assembly (Figure 2, Item 1). Support fan hub pulley assembly. 3. Using lifting device, remove five bolts (Figure 2, Item 2), washers (Figure 2, Item 3), bracket (Figure 2, Item 4), and fan hub pulley assembly (Figure 2, Item 1) from machine. Set fan hub pulley assembly on flat level surface. 4. Remove lifting device from fan hub pulley assembly (Figure 2, Item 1).

Figure 2. Hub Upper Mount.

0095

0095-2

TM 5-2410-241-23-2

0095

REMOVAL CONTINUED 5. Remove bolt (Figure 3, Item 3), plate (Figure 3, Item 4), and hub (Figure 3, Item 2) from pulley (Figure 3, Item 1).

Figure 3. Hub Pulley Assembly.

0095

0095-3

TM 5-2410-241-23-2

0095

REMOVAL CONTINUED 6. Remove bearing (Figure 4, Item 7), cup (Figure 4, Item 6), and spacer (Figure 4, Item 5) from hub (Figure 4, Item 4).

NOTE
Note position and orientation of seal to aid installation. 7. Remove seal (Figure 4, Item 1), bearing (Figure 4, Item 2), and cup (Figure 4, Item 3), from hub (Figure 4, Item 4). Discard seal.

Figure 4. Hub.

0095

0095-4

TM 5-2410-241-23-2

0095

REMOVAL CONTINUED

WARNING

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

NOTE
Pulley weighs approximately 60 lb (27 kg). 8. With assistance, remove pulley (Figure 5, Item 2) from bracket (Figure 5, Item 1).

Figure 5. Pulley.

0095

0095-5

TM 5-2410-241-23-2

0095

REMOVAL CONTINUED 9. Remove spacer (Figure 6, Item 5), roll pin (Figure 6, Item 3), fitting (Figure 6, Item 4) and shaft (Figure 6, Item 2) from bracket (Figure 6, Item 1). Discard roll pin.

Figure 6. Fan Shaft. END OF TASK

0095

0095-6

TM 5-2410-241-23-2

0095

CLEANING AND INSPECTION 1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect pulley (Figure 7, Item 1) for the following: a. Pulley grooves (Figure 7, Item 4) for burrs or nicks. Remove burrs or nicks with emery cloth. b. Pulley grooves (Figure 7, Item 4) for deformed groove walls. c.

00095

Inspect pulley (Figure 7, Item 1) for cracks, breaks, wear, or damage around bolt holes (Figure 7, Item 3).

d. Replace pulley if conditions in b or c above are found. 3. Inspect shaft (Figure 7, Item 2) for wear, pitting, grooving, or damage to threads. Replace shaft if found. 4. Inspect bearings, cups, and spacers from hub IAW Mechanical General Maintenance Instructions (WP 0295).

Figure 7. Pulley and Shaft Inspection. END OF TASK

0095

0095-7

TM 5-2410-241-23-2

0095

INSTALLATION 1. Install shaft (Figure 8, Item 2), fitting (Figure 8, Item 4), new roll pin (Figure 8, Item 3), and spacer (Figure 8, Item 5) on bracket (Figure 8, Item 1).

00095

Figure 8. Fan Shaft.

0095

0095-8

TM 5-2410-241-23-2

0095

INSTALLATION CONTINUED

WARNING

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

NOTE
Pulley weighs approximately 60 lb (27 kg). 2. With assistance, install pulley (Figure 9, Item 2) on bracket (Figure 9, Item 1).

Figure 9. Pulley.

0095

0095-9

TM 5-2410-241-23-2

0095

INSTALLATION CONTINUED

NOTE
Install seal as noted during removal. 3. Install cup (Figure 10, Item 3), bearing (Figure 10, Item 2), and new seal (Figure 10, Item 1) on hub (Figure 10, Item 4). 4. Install spacer (Figure 10, Item 5), cup (Figure 10, Item 6) and bearing (Figure 10, Item 7) on hub (Figure 10, Item 4).

Figure 10. Hub.

0095

0095-10

TM 5-2410-241-23-2

0095

INSTALLATION CONTINUED 5. Install hub (Figure 11, Item 2), plate (Figure 11, Item 4), and bolt (Figure 11, Item 3) on pulley (Figure 11, Item 1).

Figure 11. Hub Pulley Assembly.

0095

0095-11

TM 5-2410-241-23-2

0095

INSTALLATION CONTINUED

WARNING

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

NOTE
Fan hub pulley assembly weighs approximately 95 lb (43 kg). 6. Attach lifting device to fan hub pulley assembly (Figure 12, Item 1). 7. Using lifting device, install fan hub pulley assembly (Figure 12, Item 1), bracket (Figure 12, Item 4), five washers (Figure 12, Item 3), and bolts (Figure 12, Item 2) on machine. 8. Remove lifting device from fan hub pulley assembly (Figure 12, Item 1).

Figure 12. Hub Upper Mount.

0095

0095-12

TM 5-2410-241-23-2

0095

INSTALLATION CONTINUED 9. Install two washers (Figure 13, Item 2) and new locknuts (Figure 13, Item 1) on plate (Figure 13, Item 3).

Figure 13. Hub Lower Mount. END OF TASK FOLLOW-ON TASKS 1. Install hood (WP 0200). 2. Install V-belt (A/C compressor) (WP 0096). 3. Install V-belt set (alternator) (WP 0098). 4. Install cooling fan (WP 0050). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0095

00095

0095-13/(14 blank)

6 TM 5-2410-241-23-2 0096

FIELD MAINTENANCE V-BELT (A/C COMPRESSOR) REPLACEMENT Inspection, Removal, Cleaning and Inspection, Installation
0 0 9 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Tensioner, Dial Indicating (WP 0302, Item 61) Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Alternator V-belts removed (WP 0098) Drawing Required

TM 5-2410-241-24P, Figure 41 Estimated Time to Complete 1.0 Hr

0096-1

TM 5-2410-241-23-2

0096

INSPECTION

00096

NOTE
If belt is worn or damaged, replace belt. 1. Inspect belt (Figure 1, Item 1) for damage, cracking, or excessive wear. 2. Use belt tension gauge to check deflection on belt (Figure 1, Item 1). Belt deflection should not be more than 0.58 to 0.81 in. (14 to 20 mm) with 25 lb (110 N) of force.

Figure 1. A/C Compressor V-Belt Inspection. END OF TASK

0096

0096-2

TM 5-2410-241-23-2

0096

REMOVAL 1. Loosen two bolts (Figure 2, Item 2) on A/C compressor mounting bracket (Figure 2, Item 1).

00096

Figure 2. A/C Compressor Mounting Bolts.

0096

0096-3

TM 5-2410-241-23-2

0096

REMOVAL CONTINUED 2. Loosen bolt (Figure 3, Item 5) from adjusting rod (Figure 3, Item 6). 3. Loosen nut (Figure 3, Item 3) and bolt (Figure 3, Item 8) from A/C compressor (Figure 3, Item 2). 4. Loosen two adjusting nuts (Figure 3, Items 1 and 4) and move A/C compressor (Figure 3, Item 2) down until belt (Figure 3, Item 7) can be removed. 5. Remove belt (Figure 3, Item 7) from machine.

Figure 3. A/C Compressor V-Belt. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0096

00096

0096-4

TM 5-2410-241-23-2

0096

INSTALLATION

00096

NOTE
If new belt is installed, check belt adjustment after 30 minutes of operation. 1. Install belt (Figure 4, Item 7) on machine. 2. While holding belt (Figure 4, Item 7) in position, move A/C compressor (Figure 4, Item 2) upward and tighten adjusting nut (Figure 4, Item 4) until correct belt tension is achieved. 3. Use belt tension gauge to check deflection on belt (Figure 4, Item 7). Belt deflection should not be more than 0.58 to 0.81 in. (14 to 20 mm) with 25 lb (110 N) of force. 4. Once correct belt tension is achieved, tighten adjusting nut (Figure 4, Item 1). 5. Tighten nut (Figure 4, Item 3) and bolt (Figure 4, Item 8) on A/C compressor (Figure 4, Item 2). 6. Tighten bolt (Figure 4, Item 5) on adjusting rod (Figure 4, Item 6).

Figure 4. A/C Compressor V-Belt.

0096

0096-5

TM 5-2410-241-23-2

0096

INSTALLATION CONTINUED 7. Tighten two bolts (Figure 5, Item 2) on A/C compressor bracket (Figure 5, Item 1).

Figure 5. A/C Compressor Mounting Bolts. END OF TASK FOLLOW-ON TASKS 1. Install alternator belts (WP 0098). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0096

00096

0096-6

14 TM 5-2410-241-23-2 0097

FIELD MAINTENANCE A/C COMPRESSOR REPLACEMENT Removal, Cleaning and Inspection, Installation
0 0 9 7

INITIAL SETUP Tools and Special Tools Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Oil, Lubricating, Refrigerant Compressor (WP 0303, Item 22) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (3) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Refrigerant recovered from A/C system (WP 0263) Air cleaner assembly removed (WP 0111) Personnel Required

91C Drawing Required

TM 5-2410-241-24P, Figure 41
0 0

Estimated Time to Complete 4.0 Hr

0097-1

TM 5-2410-241-23-2

0097

REMOVAL

00097

NOTE
Tag and mark electrical connectors to aid installation. 1. Remove tiedown strap (Figure 1, Item 4) and disconnect connector (Figure 1, Item 3) from connector (Figure 1, Item 2). Discard tiedown strap. 2. Position harness (Figure 1, Item 5) and harness (Figure 1, Item 6) aside.

NOTE
Note proper belt tension before loosening nuts. 3. Loosen nut (Figure 1, Item 1) and nut (Figure 1, Item 14) from block (Figure 1, Item 15). 4. Remove nut (Figure 1, Item 8), washer (Figure 1, Item 9), bolts (Figure 1, Item 16) and washer (Figure 1, Item 17) from block (Figure 1, Item 15). 5. Remove bolt (Figure 1, Item 10), washer (Figure 1, Item 11), shaft (Figure 1, Item 13) and washer (Figure 1, Item 12) from A/C compressor (Figure 1, Item 7). 6. Remove nut (Figure 1, Item 1), block (Figure 1, Item 15), and nut (Figure 1, Item 14) from shaft (Figure 1, Item 13).

Figure 1. Compressor Adjusting Shaft.

0097

0097-2

TM 5-2410-241-23-2

0097

REMOVAL CONTINUED

CAUTION
Cap all A/C lines and fittings during removal to protect against contamination. Failure to follow this caution may result in equipment damage.

NOTE
Tag lines to aid installation. 7. Loosen bolt (Figure 2, Item 4), plate (Figure 2, Item 3) and remove line (Figure 2, Item 2) and line (Figure 2, Item 8) from A/C compressor (Figure 2, Item 1). Position lines aside.

NOTE
Tag and mark electrical connectors to aid installation. 8. Disconnect connector (Figure 2, Item 6) from connector (Figure 2, Item 7). 9. Position harness (Figure 2, Item 5) aside.

Figure 2. Compressor Lines.

0097

0097-3

TM 5-2410-241-23-2

0097

REMOVAL CONTINUED 10. Loosen bolt (Figure 3, Item 3) and bolt (Figure 3, Item 6) from bracket (Figure 3, Item 5). 11. Remove belt (Figure 3, Item 2) from A/C compressor (Figure 3, Item 1). 12. Remove bolt (Figure 3, Item 3), washer (Figure 3, Item 4), bolt (Figure 3, Item 6), washer (Figure 3, Item 7) and A/C compressor (Figure 3, Item 1) from bracket (Figure 3, Item 5).

Figure 3. A/C Compressor.

0097

0097-4

TM 5-2410-241-23-2

0097

REMOVAL CONTINUED 13. Remove bolt (Figure 4, Item 2), washer (Figure 4, Item 15), bracket (Figure 4, Item 1) from compressor (Figure 4, Item 9).

NOTE
Tag and mark electrical connectors to aid installation. 14. Disconnect connector (Figure 4, Item 4) from switch (Figure 4, Item 3). 15. Remove tiedown strap (Figure 4, Item 6) from harness (Figure 4, Item 5). Position harness aside. 16. Remove switch (Figure 4, Item 3) from compressor (Figure 4, Item 9).

NOTE
Note position and orientation of bolts, nuts and brackets to aid installation. Note clearance of nut to A/C pulley.

17. Remove five nuts (Figure 4, Item 12), washers (Figure 4, Item 11), bolts (Figure 4, Item 10), washer (Figure 4, Item 13), one harness clip (Figure 4, Item 7), two mounting brackets (Figure 4, Item 8) and one adjustment bracket (Figure 4, Item 14) from compressor (Figure 4, Item 9).

Figure 4. A/C Compressor Mounts.

0097

0097-5

TM 5-2410-241-23-2

0097

REMOVAL CONTINUED

NOTE
Tag electrical connectors to aid installation. 18. Remove tiedown strap (Figure 5, Item 4) from harness (Figure 5, Item 3). Discard tiedown strap. 19. Disconnect connector (Figure 5, Item 13) from connector (Figure 5, Item 12). 20. Remove harness (Figure 5, Item 3) from compressor (Figure 5, Item 5). 21. Remove two nuts (Figure 5, Item 2), washers (Figure 5, Item 1), bolts (Figure 5, Item 9), washers (Figure 5, Item 10) and brackets (Figure 5, Item 11) from compressor (Figure 5, Item 5). 22. Remove O-ring (Figure 5, Item 6) from fitting (Figure 5, Item 7). Discard O-ring. 23. Remove two O-rings (Figure 5, Item 8) from compressor (Figure 5, Item 5). Discard O-rings.

Figure 5. Compressor Harness.

0097

0097-6

TM 5-2410-241-23-2

0097

REMOVAL CONTINUED 24. Remove four bolts (Figure 6, Item 2), washers (Figure 6, Item 1) and upper bracket (Figure 6, Item 3) from machine.

Figure 6. Upper Compressor Bracket. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0097

00097

0097-7

TM 5-2410-241-23-2

0097

INSTALLATION

00097

NOTE
Install electrical connectors as tagged during removal. 1. Install upper bracket (Figure 7, Item 3), four washers (Figure 7, Item 1) and bolts (Figure 7, Item 2) on machine. 2. Lubricate new O-rings (Figure 7, Item 8) with clean refrigerant oil. 3. Install two new O-rings (Figure 7, Item 8) on compressor (Figure 7, Item 5). 4. Lubricate new O-ring (Figure 7, Item 6) with clean refrigerant oil. 5. Install new O-ring (Figure 7, Item 6) on fitting (Figure 7, Item 7). 6. Install two brackets (Figure 7, Item 11), washers (Figure 7, Item 10), bolts (Figure 7, Item 9), washers (Figure 7, Item 1), and nuts (Figure 7, Item 2) on compressor (Figure 7, Item 5). 7. Install harness (Figure 7, Item 3) on compressor (Figure 7, Item 5). 8. Connect connector (Figure 7, Item 13) on connector (Figure 7, Item 12). 9. Install new tiedown strap (Figure 7, Item 4) on harness (Figure 7, Item 3).

Figure 7. Compressor Harness.

0097

0097-8

TM 5-2410-241-23-2

0097

INSTALLATION CONTINUED

NOTE
Install bolts, nuts and brackets as noted during removal. Install pulley with same clearance as noted during removal.

10. Install adjustment bracket (Figure 8, Item 14), two mounting brackets (Figure 8, Item 8), one harness clip (Figure 8, Item 7), five washer (Figure 8, Item 13), bolts (Figure 8, Item 10), washers (Figure 8, Item 11), and nuts (Figure 8, Item 12) on compressor (Figure 8, Item 9). 11. Install switch (Figure 8, Item 3) on compressor (Figure 8, Item 9). 12. Install new tiedown strap (Figure 8, Item 6) on harness (Figure 8, Item 5).

NOTE
Tag and mark electrical connectors to aid installation. 13. Connect connector (Figure 8, Item 4) on switch (Figure 8, Item 3). 14. Install plate (Figure 8, Item 1), washer (Figure 8, Item 15), and bolt (Figure 8, Item 2) on compressor (Figure 8, Item 9).

Figure 8. A/C Compressor Mounts.

0097

0097-9

TM 5-2410-241-23-2

0097

INSTALLATION CONTINUED 15. Install A/C compressor (Figure 9, Item 1), washer (Figure 9, Item 7), bolt (Figure 9, Item 6), washer (Figure 9, Item 4), and bolt (Figure 9, Item 3) on bracket (Figure 9, Item 5). 16. Do not tighten bolt (Figure 9, Item 3) and bolt (Figure 9, Item 6) on bracket (Figure 9, Item 5). 17. Install belt (Figure 9, Item 2) on A/C compressor (Figure 9, Item 1).

Figure 9. A/C Compressor.

0097

0097-10

TM 5-2410-241-23-2

0097

INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. 18. Position harness (Figure 10, Item 5) on machine. 19. Connect connector (Figure 10, Item 6) on connector (Figure 10, Item 7).

NOTE
Install lines as tagged during removal. 20. Install line (Figure 10, Item 8), line (Figure 10, Item 2), position plate (Figure 10, Item 3) as shown and tighten bolt (Figure 10, Item 4) on A/C compressor (Figure 10, Item 1).

Figure 10. Compressor Lines.

0097

0097-11

TM 5-2410-241-23-2

0097

INSTALLATION CONTINUED 21. Install nut (Figure 11, Item 14), block (Figure 11, Item 15), and nut (Figure 11, Item 1) on shaft (Figure 11, Item 13). 22. Install washer (Figure 11, Item 12), shaft (Figure 11, Item 13), washer (Figure 11, Item 11), and bolt (Figure 11, Item 10) on A/C compressor (Figure 11, Item 7). 23. Install washer (Figure 11, Item 17), bolts (Figure 11, Item 16), washer (Figure 11, Item 9), and nut (Figure 11, Item 8) on block (Figure 11, Item 15). Do not tighten bolt and nut.

NOTE
Ensure belt is aligned on pulleys. Adjust belt with nuts as noted during removal.

24. Adjust nut (Figure 11, Item 1), block (Figure 11, Item 15) and nut (Figure 11, Item 14) on shaft (Figure 11, Item 13).

NOTE
Install electrical connectors as noted during removal. 25. Position harness (Figure 11, Item 5) and harness (Figure 11, Item 6) on A/C compressor (Figure 11, Item 7). 26. Connect connector (Figure 11, Item 3) on connector (Figure 11, Item 2). 27. Install new tiedown strap (Figure 11, Item 4) on connector (Figure 11, Item 2).

Figure 11. Compressor Adjusting Shaft.

0097

0097-12

TM 5-2410-241-23-2

0097

INSTALLATION CONTINUED 28. Tighten nut (Figure 12, Item 2) and bolts (Figure 12, Item 8) on block (Figure 12, Item 9). 29. Tighten bolt (Figure 12, Item 5) on shaft (Figure 12, Item 6). 30. Tighten nut (Figure 12, Item 7) and nut (Figure 12, Item 1) on block (Figure 12, Item 9). 31. Tighten two bolts (Figure 12, Item 3) on bracket (Figure 12, Item 4).

Figure 12. Fasteners. END OF TASK FOLLOW-ON TASKS 1. Install air cleaner assembly (WP 0111). 2. Charge refrigerant on A/C system (WP 0263). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0097

00097

0097-13/(14 blank)

6 TM 5-2410-241-23-2 0098

FIELD MAINTENANCE 0098V-BELT SET (ALTERNATOR) REPLACEMENT Inspection, Removal, Cleaning and Inspection, Installation INITIAL SETUP Tools and Special Tools 0 Equipment Condition 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Tensioner, Dial Indicating (WP 0302, Item 61)0 Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295 0 0 0 0

Machine parked (TM 5-2410-241-10) 0 Engine enclosure right door guard removed (WP 0204) 0 A/C condenser removed (WP 0044) 0 Drawing Required TM 5-2410-241-24P, Figure 7, 42 Estimated Time to Complete 2.5 Hr 0 0 0 0

0098-1

TM 5-2410-241-23-2

0098

INSPECTION

00098

NOTE
If one belt is worn or damaged, replace both belts. 1. Inspect belts (Figure 1, Item 1) for damage, cracking, or excessive wear. 2. Use belt tension gauge to check deflection on both belts (Figure 1, Item 1). Belt deflection should not be more than 0.58 to 0.81 in. (14 to 20 mm) with 25 lb (110 N) of force.

Figure 1. Alternator V-Belt Inspection. END OF TASK

0098

0098-2

TM 5-2410-241-23-2

0098

REMOVAL 1. Loosen two bolts (Figure 2, Item 2) on alternator (Figure 2, Item 1).

00098

Figure 2. Alternator Mounting Bolts.

0098

0098-3

TM 5-2410-241-23-2

0098

REMOVAL CONTINUED 2. Loosen bolt (Figure 3, Item 1) from shaft (Figure 3, Item 2). 3. Loosen nut (Figure 3, Item 5) and bolt (Figure 3, Item 7) from alternator (Figure 3, Item 8). 4. Loosen two adjusting nuts (Figure 3, Items 4 and 6) and move alternator (Figure 3, Item 8) inward until belts (Figure 3, Item 3) can be removed. 5. Remove two belts (Figure 3, Item 3) from machine.

Figure 3. Alternator V-Belts. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0098

00098

0098-4

TM 5-2410-241-23-2

0098

INSTALLATION

00098

NOTE
If new belts are installed, check belt adjustment after 30 minutes of operation. If equipped with arctic heater, install arctic belts.

1. Install two belts (Figure 3, Item 3) on machine. 2. While holding belts (Figure 3, Item 3) in position, move alternator (Figure 3, Item 8) outward and tighten nut (Figure 3, Item 4) until correct belt tension is achieved. 3. Once correct belt tension is achieved, tighten nut (Figure 3, Item 6). 4. Tighten bolt (Figure 3, Item 7) and nut (Figure 3, Item 5) on alternator (Figure 3, Item 8). 5. Tighten bolt (Figure 3, Item 1) on shaft (Figure 3, Item 2). 6. Tighten two bolts (Figure 4, Item 2) on alternator (Figure 4, Item 1).

Figure 4. Alternator Mounting Bolts. END OF TASK FOLLOW-ON TASKS 1. Install A/C condenser (WP 0044). 2. Install engine enclosure right door guard (WP 0204). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0098

00098

0098-5/(6 blank)

12 TM 5-2410-241-23-2 0099

FIELD MAINTENANCE
0 0 9 9

ALTERNATOR AND BRACKETS REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

References WP 0098 WP 0295 Equipment Condition

Tool Kit, General Mechanics (WP 0302, Item 65) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) Wrench, Torque, Click, Ratcheting, 1/2 Drive, 250 lb-ft (WP 0302, Item 71) Wrench, Torque, Dial, 3/8 Drive, 300 lb-in. (WP 0302, Item 74)
0 0 0 0

Machine parked (TM 5-2410-241-10) Engine enclosure right door guard removed (WP 0204) Drawing Required TM 5-2410-241-24P, Figure 42 Estimated Time to Complete 2.5 Hr

Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Lockwasher

0099-1

TM 5-2410-241-23-2

0099

REMOVAL

00099

NOTE
Tag and mark wiring harnesses to aid installation. 1. Position boot (Figure 1, Item 13) aside. 2. Remove nut (Figure 1, Item 12), lockwasher (Figure 1, Item 10), washer (Figure 1, Item 11), and harness connector (Figure 1, Item 14) from alternator (Figure 1, Item 8). Discard lockwasher. 3. Disconnect wire (Figure 1, Item 9) from alternator (Figure 1, Item 8). 4. Remove bolt (Figure 1, Item 5), two washers (Figure 1, Item 7), and ground strap (Figure 1, Item 6) from alternator (Figure 1, Item 8). Position ground strap aside. 5. Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and three clips (Figure 1, Item 3) from bracket (Figure 1, Item 4). Position wiring harnesses (Figure 1, Items 15 and 16) aside.

Figure 1. Alternator, Wiring, and Retaining Hardware.

099

0099-2

TM 5-2410-241-23-2

0099

REMOVAL CONTINUED 6. Loosen nut (Figure 2, Item 6), block (Figure 2, Item 8), and nut (Figure 2, Item 11) from rod (Figure 2, Item 7). 7. Remove nut (Figure 2, Item 4), washer (Figure 2, Item 5), bolt (Figure 2, Item 9), washer (Figure 2, Item 10), and washer (Figure 2, Item 3) from alternator (Figure 2, Item 2). 8. Remove bolt (Figure 2, Item 13), washer (Figure 2, Item 12), and rod (Figure 2, Item 7) from bracket (Figure 2, Item 1).

Figure 2. Alternator and Retaining Hardware.

099

0099-3

TM 5-2410-241-23-2

0099

REMOVAL CONTINUED 9. Remove two bolts (Figure 3, Item 1), washers (Figure 3, Item 5), guard (Figure 3, Item 4) and alternator (Figure 3, Item 2) from bracket (Figure 3, Item 3). 10. Remove two bolts (Figure 3, Item 13), washers (Figure 3, Item 12) and bracket (Figure 3, Item 11) from engine (Figure 3, Item 10).

NOTE
Align hole in fan pulley with bolt to remove bolt from top of bracket. 11. Remove three bolts (Figure 3, Item 7) and bracket (Figure 3, Item 6) from bracket (Figure 3, Item 3) and from engine (Figure 3, Item 10). 12. Remove four bolts (Figure 3, Item 8), washers (Figure 3, Item 9), and bracket (Figure 3, Item 3) from engine (Figure 3, Item 10).

Figure 3. Alternator, Brackets, and Retaining Hardware.

099

0099-4

TM 5-2410-241-23-2

0099

REMOVAL CONTINUED 13. Remove three bolts (Figure 4, Item 1), washers (Figure 4, Item 2), one bracket (Figure 4, Item 3), rear cover (Figure 4, Item 4) and rear guards (Figure 4, Item 5) from alternator (Figure 4, Item 6).

Figure 4. Alternator, Bracket, and Retaining Hardware. 14. Remove nut (Figure 5, Item 3), washer (Figure 5, Item 4), and pulley (Figure 5, Item 1) from alternator (Figure 5, Item 2).

099

Figure 5. Pulley. END OF TASK

099

0099-5

TM 5-2410-241-23-2

0099

CLEANING AND INSPECTION 1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect inside pulley (Figure 6, Item 5) for wear or out of round. Replace pulley if worn.

00099

3. Inspect shaft threads (Figure 6, Item 1) for damage or excessive wear. Replace alternator (Figure 6, Item 3) if damaged or has excessive wear. 4. Turn alternator shaft (Figure 6, Item 2) by hand. Shaft should turn easily with no grinding sound. If noisy, bearings are worn, replace alternator (Figure 6, Item 3). 5. Inspect bracket (Figure 6, Item 4) for cracks, wear or deformities. Replace bracket if worn.

Figure 6. Alternator and Bracket Inspection. END OF TASK

099

0099-6

TM 5-2410-241-23-2

0099

INSTALLATION 1. Install pulley (Figure 7, Item 1), washer (Figure 7, Item 4), and nut (Figure 7, Item 3) on alternator (Figure 7, Item 2). Tighten nut to 94 7 lb-ft (127 10 Nm).

00099

Figure 7. Pulley. 2. Install rear guards (Figure 8, Item 5), rear cover, (Figure 8, Item 4), one bracket (Figure 8, Item 3), three washers (Figure 8, Item 2), and bolts (Figure 8, Item 1) on alternator (Figure 8, Item 6).

099

Figure 8. Alternator, Bracket, and Retaining Hardware.

099

0099-7

TM 5-2410-241-23-2

0099

INSTALLATION CONTINUED 3. Install bracket (Figure 9, Item 3), four washers (Figure 9, Item 9), and bolts (Figure 9, Item 8) on engine (Figure 9, Item 10).

NOTE
Align hole in fan pulley with bolt hole on engine to install bolt at top of bracket. 4. Install bracket (Figure 9, Item 6) and three bolts (Figure 9, Item 7) on bracket (Figure 9, Item 3) and engine (Figure 9, Item 10). 5. Install bracket (Figure 9, Item 11), two washers (Figure 9, Item 12), and bolts (Figure 9, Item 13) on engine (Figure 9, Item 10).

NOTE
Bolts on alternator and tension adjuster should be finger tight until after belts are adjusted. 6. Install alternator (Figure 9, Item 2), guard (Figure 9, Item 4), two washers (Figure 9, Item 5) and bolts (Figure 9, Item 1) on bracket (Figure 9, Item 3).

Figure 9. Alternator, Brackets, and Retaining Hardware.

099

0099-8

TM 5-2410-241-23-2

0099

INSTALLATION CONTINUED 7. Install rod (Figure 10, Item 7), washer (Figure 10, Item 12), and bolt (Figure 10, Item 13) on bracket (Figure 10, Item 1). 8. Install washer (Figure 10, Item 3), block (Figure 10, Item 8), washer (Figure 10, Item 10), bolt (Figure 10, Item 9), washer (Figure 10, Item 5), and nut (Figure 10, Item 4) on alternator (Figure 10, Item 2). 9. Tighten nut (Figure 10, Item 11), block (Figure 10, Item 8), and nut (Figure 10, Item 6) on rod (Figure 10, Item 7).

Figure 10. Alternator and Retaining Hardware.

099

0099-9

TM 5-2410-241-23-2

0099

INSTALLATION CONTINUED 10. Install three clips (Figure 11, Item 3), two washers (Figure 11, Item 2), and bolts (Figure 11, Item 1) on bracket (Figure 11, Item 4) to secure wiring harness (Figure 11, Items 15 and 16).

NOTE
Install wiring harnesses as noted during removal. 11. Install ground strap (Figure 11, Item 6), washer (Figure 11, Item 7), and bolt (Figure 11, Item 5) on alternator (Figure 11, Item 8). Tighten bolt to 39 9 lb-in. (4.4 1 Nm). 12. Connect wire (Figure 11, Item 9) on alternator (Figure 11, Item 8). 13. Install harness connector (Figure 11, Item 14), washer (Figure 11, Item 11), new lockwasher (Figure 11, Item 10), and nut (Figure 11, Item 12) on alternator (Figure 11, Item 8). Tighten nut to 13 2 lb-ft (18.2 2.7 Nm). 14. Install boot (Figure 11, Item 13) on alternator (Figure 11, Item 8). 15. Apply proper belt tension (WP 0098). 16. Tighten all mounting hardware.

Figure 11. Alternator, Wiring, and Retaining Hardware. END OF TASK

099

0099-10

TM 5-2410-241-23-2

0099

FOLLOW-ON TASKS 1. Install engine enclosure right door guard (WP 0204). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00099

0099-11/(12 blank)

6 TM 5-2410-241-23-2 0100

FIELD MAINTENANCE FLYWHEEL ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 0 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Stud, Guide, 1/2 X 20 (WP 0302, Item 58) (2) Wrench, Torque, Click, Ratcheting, 1/2 Drive, 250 lb-ft (WP 0302, Item 71) Materials/Parts Rag, Wiping (WP 0303, Item 24) Sealing Compound (WP 0303, Item 29) 0 0 0 0 0 0 0 0 0 Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Engine removed (WP 0057) Torque converter removed (WP 0148) Drawing Required TM 5-2410-241-24P, Figure 44 Estimated Time to Complete 38.0 Hr 0 0 0 0 0 0 0 0 0 0 0 0

0100-1

TM 5-2410-241-23-2

0100

REMOVAL 1. Remove two bolts (Figure 1, Item 3) and washers (Figure 1, Item 4) retaining flywheel (Figure 1, Item 1) on crankshaft (Figure 1, Item 2).

000100

Figure 1. Flywheel and Retaining Hardware.

0100

0100-2

TM 5-2410-241-23-2

0100

REMOVAL CONTINUED 2. Install two guide studs (Figure 2, Item 2) on crankshaft (Figure 2, Item 3) through bolt holes (Figure 2, Item 7). 3. Remove six remaining bolts (Figure 2, Item 5) and washers (Figure 2, Item 6) retaining flywheel (Figure 2, Item 1) on crankshaft (Figure 2, Item 3).

WARNING

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

NOTE
Flywheel weighs approximately 125 lb (57 kg). 4. With assistance, remove flywheel (Figure 2, Item 1) from flywheel housing (Figure 2, Item 4). Lower flywheel onto flat surface.

NOTE
Crankshaft drive gear may be loose. If necessary set drive gear aside, if loose. 5. Remove two guide studs (Figure 2, Item 2) from crankshaft (Figure 2, Item 3).

Figure 2. Flywheel, Guide Studs, and Retaining Hardware. END OF TASK

0100

0100-3

TM 5-2410-241-23-2

0100

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000100

000100

NOTE
If crankshaft drive gear was loose, position drive gear on engine. 1. Install two guide studs (Figure 3, Item 2) on crankshaft (Figure 3, Item 3).

WARNING

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

NOTE
Flywheel weighs approximately 125 lb (57 kg). 2. With assistance, install flywheel (Figure 3, Item 1) on flywheel housing (Figure 3, Item 4).

WARNING

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

0100-4

TM 5-2410-241-23-2

0100

INSTALLATION CONTINUED 3. Apply sealing compound on threads of eight bolts (Figure 3, Item 5). 4. Install six washers (Figure 3, Item 6) and bolts (Figure 3, Item 5) retaining flywheel (Figure 3, Item 1) on crankshaft (Figure 3, Item 3). 5. Remove two guide studs (Figure 3, Item 2) from crankshaft (Figure 3, Item 3). 6. Install two remaining washers (Figure 3, Item 6) and bolts (Figure 3, Item 5) retaining flywheel (Figure 3, Item 1) on crankshaft (Figure 3, Item 3). Tighten bolts to 220 30 lb-ft (300 40 Nm).

Figure 3. Flywheel, Guide Studs, and Retaining Hardware. END OF TASK FOLLOW-ON TASKS 1. Install torque converter (WP 0148). 2. Install engine (WP 0057). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0100

000100

0100-5/(6 blank)

6 TM 5-2410-241-23-2 0101

FIELD MAINTENANCE ENGINE ECM SERVICE Removal, Cleaning and Inspection, Installation
0 1 0 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) References WP 0017 WP 0295 0 0 0 0 0 0 0 0 Equipment Condition 0

Machine parked (TM 5-2410-241-10) 0 Engine enclosure left door guard removed (WP 0202) 0 Drawing Required TM 5-2410-241-24P, Figure 16 Estimated Time to Complete 1.5 Hr 0 0 0 0

0101-1

TM 5-2410-241-23-2

0101

REMOVAL 1. Record all diagnostic codes and save engine ECM configuration data (WP 0017).

000101

NOTE
Tag and mark electrical connectors to aid installation. 2. Loosen two screws (Figure 1, Item 9) and disconnect harness connectors (Figure 1, Item 1) from engine ECM (Figure 1, Item 5). Position harness connectors aside. 3. Remove special bolt (Figure 1, Item 8) and washer (Figure 1, Item 7). 4. Remove two bolts (Figure 1, Item 3) and washers (Figure 1, Item 2) retaining engine ECM (Figure 1, Item 5), on engine (Figure 1, Item 6). 5. Remove three isolators (Figure 1, Item 4) from engine ECM (Figure 1, Item 5).

Figure 1. Engine ECM and Retaining Hardware.

0101

0101-2

TM 5-2410-241-23-2

0101

REMOVAL CONTINUED

NOTE
Tag and mark ground strap to aid installation. 6. Remove nut (Figure 2, Item 3), washer (Figure 2, Item 4), clamp (Figure 2, Item 1), ground strap (Figure 2, Item 7), washer (Figure 2, Item 9), special bolt (Figure 2, Item 2) and two washers (Figure 2, Item 10) from engine ECM (Figure 2, Item 8). 7. Remove screw (Figure 2, Item 5) and ground strap (Figure 2, Item 7) from engine ECM (Figure 2, Item 8). 8. Remove isolator (Figure 2, Item 6) from engine ECM (Figure 2, Item 8).

Figure 2. Engine ECM, Ground Strap, and Retaining Hardware.

0101

0101-3

TM 5-2410-241-23-2

0101

REMOVAL CONTINUED 9. Remove engine ECM (Figure 3, Item 1) from engine (Figure 3, Item 4). 10. Remove four spacers (Figure 3, Item 2) and isolators (Figure 3, Item 3) from engine ECM (Figure 3, Item 1).

Figure 3. Engine ECM, Spacers, and Isolators. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0101

000101

000101

NOTE
Verify isolators remain seated on engine ECM after installing spacers. 1. Install four isolators (Figure 3, Item 3) and spacers (Figure 3, Item 2) on engine ECM (Figure 3, Item 1). 2. Position engine ECM (Figure 3, Item 1) on engine (Figure 3, Item 4).

0101-4

TM 5-2410-241-23-2

0101

INSTALLATION CONTINUED

NOTE
Install ground strap as noted during removal. 3. Install isolator (Figure 4, Item 6) on engine ECM (Figure 4, Item 8). 4. Install two washers (Figure 4, Item 10) and special bolt (Figure 4, Item 2) on engine ECM (Figure 4, Item 8). 5. Install ground strap (Figure 4, Item 7) and screw (Figure 4, Item 5) on engine ECM (Figure 4, Item 8). 6. Install washer (Figure 4, Item 9), ground strap (Figure 4, Item 7), clamp (Figure 4, Item 1), washer (Figure 4, Item 4), and nut (Figure 4, Item 3) on special bolt (Figure 4, Item 2).

Figure 4. Engine ECM, Ground Strap, and Retaining Hardware.

0101

0101-5

TM 5-2410-241-23-2

0101

INSTALLATION CONTINUED 7. Install three isolators (Figure 5, Item 4) on engine ECM (Figure 5, Item 5). 8. Install two washers (Figure 5, Item 2) and bolts (Figure 5, Item 3) retaining engine ECM (Figure 5, Item 5) on engine (Figure 5, Item 6). 9. Install washer (Figure 5, Item 7) and special bolts (Figure 5, Item 8).

NOTE
Install electrical connectors as noted during removal. 10. Connect two harness connectors (Figure 5, Item 1) on engine ECM (Figure 5, Item 5) and tighten screws (Figure 5, Item 9).

Figure 5. Engine ECM and Retaining Hardware. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure left door guard (WP 0202). 2. Program machine ECM (WP 0017). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0101

000101

0101-6

4 TM 5-2410-241-23-2 0102

FIELD MAINTENANCE
0 1

REAR CRANKSHAFT SEAL REPLACEMENT Removal, Cleaning and Inspection, Installation

0 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-40 (WP 0303, Item 20) Oil, Lubricating OE/HDO 15/40 (WP 0303, Item 21) Rag, Wiping (WP 0303, Item 24) Sealing Compound (WP 0303, Item 29) REMOVAL 1. Remove crankshaft drive gear (Figure 1, Item 2) from idler gears (Figure 1, Item 1). 0 0 0 0 0 0 0 0 0 0 Materials/Parts - Continued O-ring Rear Crankshaft Seal References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Flywheel removed (WP 0100) Drawing Required TM 5-2410-241-24P, Figure 43 Estimated Time to Complete 36.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0

000102

Figure 1. Crankshaft Drive Gear.

0102

0102-1

TM 5-2410-241-23-2

0102

REMOVAL CONTINUED

NOTE
Once removed, rear crankshaft seal must be replaced. 2. Remove nine bolts (Figure 2, Item 5), washers (Figure 2, Item 4), rear crankshaft seal (Figure 2, Item 3), and O-ring (Figure 2, Item 2) from flywheel housing (Figure 2, Item 1). Discard rear crankshaft seal and O-ring.

Figure 2. Rear Crankshaft Seal, O-ring Seal, and Retaining Hardware. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0102

000102

000102

CAUTION
Do not install rear crankshaft seal without plastic sleeve. Seal damage and oil leakage may result. Do not lubricate rear crankshaft seal or crankshaft flange. Rear crankshaft seal must be installed dry or oil leakage may result.

NOTE
Replacement rear crankshaft seal includes plastic sleeve, which protects seal lip during installation. Do not remove plastic sleeve, it will be forced off during installation. Ensure mounting flange is clean, dry, and free from damage. Ensure plastic sleeve is squarely installed within new rear crankshaft seal.

0102-2

TM 5-2410-241-23-2

0102

INSTALLATION CONTINUED 1. Apply lubricating oil on new O-ring (Figure 3, Item 2). 2. Install O-ring (Figure 3, Item 2) on new rear crankshaft seal (Figure 3, Item 3). 3. Align bolt holes (Figure 3, Items 7 and 8) and push rear crankshaft seal (Figure 3, Item 3) squarely on flywheel housing (Figure 3, Item 1). Plastic sleeve (Figure 3, Item 6) will be forced out of rear crankshaft seal. Discard plastic sleeve.

Figure 3. Rear Crankshaft Seal, O-ring Seal, Plastic Sleeve, and Retaining Hardware.

0102

WARNING

Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 4. Apply sealing compound on threads of nine bolts (Figure 3, Item 5). 5. Install nine washers (Figure 3, Item 4) and bolts (Figure 3, Item 5) retaining rear crankshaft seal (Figure 3, Item 3) on flywheel housing (Figure 3, Item 1).

0102-3

TM 5-2410-241-23-2

0102

INSTALLATION CONTINUED 6. Tighten nine bolts in sequence shown (Figure 4).

Figure 4. Bolt Tightening Sequence. 7. Install crankshaft drive gear (Figure 5, Item 2) on idler gears (Figure 5, Item 1).

0102

Figure 5. Crankshaft Drive Gear. END OF TASK FOLLOW-ON TASKS 1. Install flywheel (WP 0100). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0102

000102

0102-4

10 TM 5-2410-241-23-2 0103

FIELD MAINTENANCE
0 1 0 3

FLYWHEEL HOUSING ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Sling, Multiple Leg (WP 0302, Item 54) Stud, Guide, M12 X 1.75 (WP 0302, Item 59) (2) Lifting Device (1,000-lb capacity) Materials/Parts Gasket (Sealing Compound) (WP 0303, Item 10) Rag, Wiping (WP 0303, Item 24) Sealing Compound (WP 0303, Item 29) Gasket O-ring (6) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Starter removed (WP 0061) Rear gear assembly removed (WP 0085) Rear crankshaft seal removed (WP 0102) Rear engine mounts removed (WP 0046) Drawing Required TM 5-2410-241-24P, Figure 43 Estimated Time to Complete 38.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0103-1

TM 5-2410-241-23-2

0103

REMOVAL

000103

1. Remove bolt (Figure 1, Item 3), washer (Figure 1, Item 2), and bracket (Figure 1, Item 4) from flywheel housing (Figure 1, Item 1).

Figure 1. Bracket and Retaining Hardware on Right Side of Flywheel Housing.

0103

0103-2

TM 5-2410-241-23-2

0103

REMOVAL CONTINUED 2. Remove two bolts (Figure 2, Item 4) and washers (Figure 2, Item 3) from bracket (Figure 2, Item 2) and flywheel housing (Figure 2, Item 1).

Figure 2. Flywheel Housing Bracket.

0103

0103-3

TM 5-2410-241-23-2

0103

REMOVAL CONTINUED 3. Install lifting device on flywheel housing (Figure 3, Item 6).

NOTE
Note size and position of bolts to aid installation. 4. Remove two bolts (Figure 3, Item 11) and washers (Figure 3, Item 12) retaining flywheel housing (Figure 3, Item 6) on engine (Figure 3, Item 7). 5. Install two guide studs (Figure 3, Item 10) on engine (Figure 3, Item 7) through bolt holes (Figure 3, Item 1).

NOTE
Note size and position of bolts to aid installation. 6. Remove 11 remaining bolts (Figure 3, Items 11 and 9) and washers (Figure 3, Items 12 and 8) retaining flywheel housing (Figure 3, Item 6) on engine (Figure 3, Item 7).

WARNING

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

NOTE
Flywheel housing weighs approximately 210 lb (95 kg).

0103-4

TM 5-2410-241-23-2

0103

REMOVAL CONTINUED 7. Using lifting device and assistance, remove flywheel housing (Figure 3, Item 6) from engine (Figure 3, Item 7). Lower flywheel housing onto flat surface. 8. Remove lifting device from flywheel housing (Figure 3, Item 6). 9. Remove two guide studs (Figure 3, Item 10) from engine (Figure 3, Item 7). 10. Remove plug (Figure 3, Item 2) and gasket (Figure 3, Item 3) from flywheel housing (Figure 3, Item 6). Discard gasket. 11. Remove six plugs (Figure 3, Item 4) and O-rings (Figure 3, Item 5) from flywheel housing (Figure 3, Item 6). Discard O-rings.

Figure 3. Flywheel Housing and Retaining Hardware. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0103

000103

0103-5

TM 5-2410-241-23-2

0103

INSTALLATION 1. Install lifting device on flywheel housing (Figure 4, Item 6). 2. Install six new O-rings (Figure 4, Item 5) and plugs (Figure 4, Item 4) on flywheel housing (Figure 4, Item 6). 3. Install new gasket (Figure 4, Item 3) and plug (Figure 4, Item 2) on flywheel housing (Figure 4, Item 6).

000103

WARNING

Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 4. Apply gasket sealant on engine mounting surface (Figure 4, Item 7). 5. Install two guide studs (Figure 4, Item 10) on engine (Figure 4, Item 7).

WARNING

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

NOTE
Flywheel housing weighs approximately 210 lb (92 kg). 6. Using lifting device and assistance, install flywheel housing (Figure 4, Item 6) on engine (Figure 4, Item 7).

WARNING

Use caution when using adhesives and sealants. Prolonged inhalation of vapors can cause lung irritation. Contact with skin can cause dermatitis. Wear gloves and safety goggles and use product in a well-ventilated area away from open flame. If ingested, keep individual calm and seek medical attention. DO NOT induce vomiting. If contact with skin or eyes is made, flush thoroughly with water. Dispose of cleanup rags IAW local policy and ordinances. Failure to follow this warning may cause injury to personnel. 7. Apply sealing compound on threads of 13 bolts (Figure 4, Items 11 and 9).

0103-6

TM 5-2410-241-23-2

0103

INSTALLATION CONTINUED

NOTE
Install bolts as noted during removal. 8. Install 11 washers (Figure 4, Items 12 and 8) and bolts (Figure 4, Items 11 and 9) retaining flywheel housing (Figure 4, Item 6) on engine (Figure 4, Item 7). 9. Remove two guide studs (Figure 4, Item 10) from engine (Figure 4, Item 7) through bolt holes (Figure 4, Item 1).

NOTE
Install bolts as noted during removal. 10. Install two remaining washers (Figure 4, Item 12) and bolts (Figure 4, Item 11) retaining flywheel housing (Figure 4, Item 6) on engine (Figure 4, Item 7). 11. Remove lifting device from flywheel housing (Figure 4, Item 6).

Figure 4. Flywheel Housing and Retaining Hardware.

0103

0103-7

TM 5-2410-241-23-2

0103

INSTALLATION CONTINUED 12. Install two washers (Figure 5, Item 3) and bolts (Figure 5, Item 4) to bracket (Figure 5, Item 2) and flywheel housing (Figure 5, Item 1).

Figure 5. Flywheel Housing Bracket. 13. Install bracket (Figure 6, Item 4), washer (Figure 6, Item 2) and bolt (Figure 6, Item 3) on flywheel housing (Figure 6, Item 1).

0103

Figure 6. Bracket and Retaining Hardware on Right Side of Flywheel Housing. END OF TASK

0103

0103-8

TM 5-2410-241-23-2

0103

FOLLOW-ON TASKS 1. Install rear engine mounts (WP 0046). 2. Install rear crankshaft seal (WP 0102). 3. Install rear gear assembly (WP 0085). 4. Install starter (WP 0061). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000103

0103-9/(10 blank)

4 TM 5-2410-241-23-2 0104

FIELD MAINTENANCE FLANGE (FLYWHEEL HOUSING) REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 1 0 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Lip seal O-ring References WP 0295 REMOVAL Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and flange (Figure 1, Item 3) from adapter (Figure 1, Item 4). 0 0 0 0 0 0 0 0
000104

Equipment Condition Machine parked (TM 5-2410-241-10) Coupling removed (WP 0120) Drawing Required TM 5-2410-241-24P, Figure 50 Estimated Time to Complete 3.0 Hr

0 0 0 0 0 0 0

Figure 1. Flange and Retaining Hardware. END OF TASK

00104

0104-1

TM 5-2410-241-23-2

0104

DISASSEMBLY Remove O-ring (Figure 2, Item 6), retaining ring (Figure 2, Item 5), flange (Figure 2, Item 1), bearing (Figure 2, Item 4), and lip seal (Figure 2, Item 3) from housing (Figure 2, Item 2). Discard O-ring and lip seal.

000104

Figure 2. Flange Components. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY

00104

000104

000104

Install new lip seal (Figure 2, Item 3), bearing (Figure 2, Item 4), flange (Figure 2, Item 1), retaining ring (Figure 2, Item 5), and new O-ring (Figure 2, Item 6) on housing (Figure 2, Item 2). END OF TASK

0104-2

TM 5-2410-241-23-2

0104

INSTALLATION

000104

Install flange (Figure 3, Item 3), two washers (Figure 3, Item 2), and bolts (Figure 3, Item 1) on adapter (Figure 3, Item 4).

Figure 3. Flange and Retaining Hardware. END OF TASK FOLLOW-ON TASKS 1. Install pump coupling (WP 0120). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00104

000104

0104-3/(4 blank)

16 TM 5-2410-241-23-2 0105

FIELD MAINTENANCE
0 1 0 5

HARNESS ASSEMBLY (ECM) REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295 0 0 0 0 0 0 0 0 Equipment Condition 0

Machine parked (TM 5-2410-241-10) 0 Front bottom guard removed (WP 0199) 0 Engine enclosure left door guard removed (WP 0202) 0 Drawing Required TM 5-2410-241-24P, Figure 15 Estimated Time to Complete 4.0 Hr 0 0 0 0

0105-1

TM 5-2410-241-23-2

0105

REMOVAL

000105

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

1. Remove tiedown straps (Figure 1, Item 2) from harness (Figure 1, Item 4). Discard tiedown strap. 2. Disconnect connector (Figure 1, Item 1) from connector (Figure 1, Item 3). Position harness (Figure 1, Item 4) aside.

Figure 1. Crankshaft Sensor Harness.

00105

0105-2

TM 5-2410-241-23-2

0105

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

3. Remove tiedown straps from harness (Figure 2, Item 1). Discard tiedown strap. 4. Disconnect connector (Figure 2, Item 2) from camshaft speed sensor (Figure 2, Item 3). Position harness (Figure 2, Item 1) aside.

Figure 2. Camshaft Sensor Harness.

00105

0105-3

TM 5-2410-241-23-2

0105

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

5. Remove tiedown straps (Figure 3, Item 6) from harness (Figure 3, Item 5). Discard tiedown straps. 6. Remove five bolts (Figure 3, Item 2), washers (Figure 3, Item 4) and clamps (Figure 3, Item 3) from harness (Figure 3, Item 5). 7. Disconnect harness (Figure 3, Item 5) from coolant temperature sensor (Figure 3, Item 1). Position harness aside.

Figure 3. Coolant Sensor Harness.

00105

0105-4

TM 5-2410-241-23-2

0105

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

8. Remove tiedown straps (Figure 4, Item 3) from harness (Figure 4, Item 1). Discard tiedown straps. 9. Disconnect ether aid connector (Figure 4, Item 4) from connector (Figure 4, Item 5). 10. Disconnect connector (Figure 4, Item 2) from air inlet manifold pressure connector (Figure 4, Item 6). Position harness (Figure 4, Item 1) aside.

Figure 4. Fuel Temperature Harness.

00105

0105-5

TM 5-2410-241-23-2

0105

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

11. Remove tiedown straps from harness (Figure 5, Item 1). Discard tiedown strap. 12. Disconnect connector (Figure 5, Item 3) from fuel temperature sensor (Figure 5, Item 2). Position harness (Figure 5, Item 1) aside.

Figure 5. Fuel Temperature Sensor.

00105

0105-6

TM 5-2410-241-23-2

0105

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

13. Remove tiedown straps from harness (Figure 6, Item 1). Discard tiedown strap. 14. Disconnect connector (Figure 6, Item 3) from oil pressure sensor (Figure 6, Item 2). Position harness (Figure 6, Item 1) aside.

Figure 6. Oil Pressure Sensor.

00105

0105-7

TM 5-2410-241-23-2

0105

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

15. Loosen bolt (Figure 7, Item 3) and disconnect connector (Figure 7, Item 1) from ECM (Figure 7, Item 2).

Figure 7. ECM Connector.

00105

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note location of tiedown straps to aid installation.

16. Disconnect connector (Figure 8, Item 1) from engine (Figure 8, Item 2). 17. Remove bolt (Figure 8, Item 6), washer (Figure 8, Item 7) and clamp (Figure 8, Item 5) from harness (Figure 8, Item 4). 18. Remove tiedown straps (Figure 8, Item 3) and harness (Figure 8, Item 4) from engine (Figure 8, Item 2). Discard tiedown straps.

0105-8

TM 5-2410-241-23-2

0105

REMOVAL CONTINUED

Figure 8. ECM Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

00105

000105

000105

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 1. Install harness (Figure 8, Item 4) and new tiedown straps (Figure 8, Item 3) on engine (Figure 8, Item 2). 2. Install clamp (Figure 8, Item 5), washer (Figure 8, Item 7) and bolt (Figure 8, Item 6) on harness (Figure 8, Item 4). 3. Connect connector (Figure 8, Item 1) on engine (Figure 8, Item 2).

0105-9

TM 5-2410-241-23-2

0105

INSTALLATION CONTINUED

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 4. Connect connector (Figure 9, Item 1) and tighten bolt (Figure 9, Item 3) on ECM (Figure 9, Item 2).

Figure 9. ECM Connector.

00105

0105-10

TM 5-2410-241-23-2

0105

INSTALLATION CONTINUED

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 5. Connect connector (Figure 10, Item 3) on oil pressure sensor (Figure 10, Item 2). 6. Install new tiedown straps on harness (Figure 10, Item 1).

Figure 10. Oil Pressure Sensor.

00105

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 7. Connect connector (Figure 11, Item 3) on fuel temperature sensor (Figure 11, Item 2). 8. Install new tiedown straps on harness (Figure 11, Item 1).

Figure 11. Fuel Temperature Sensor.

00105

0105-11

TM 5-2410-241-23-2

0105

INSTALLATION CONTINUED

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 9. Connect connector (Figure 12, Item 2) on air inlet manifold pressure connector (Figure 12, Item 6). 10. Connect ether aid connector (Figure 12, Item 4) on connector (Figure 12, Item 5). 11. Install new tiedown straps (Figure 12, Item 3) on harness (Figure 12, Item 1).

Figure 12. Fuel Temperature Harness.

00105

0105-12

TM 5-2410-241-23-2

0105

INSTALLATION CONTINUED

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 12. Connect harness (Figure 13, Item 5) to coolant temperature sensor (Figure 13, Item 1). 13. Install five clamps (Figure 13, Item 3), washers (Figure 13, Item 4) and bolts (Figure 13, Item 2) on harness (Figure 13, Item 5). 14. Install new tiedown straps (Figure 13, Item 6) on harness (Figure 13, Item 5).

Figure 13. Coolant Sensor Harness.

00105

0105-13

TM 5-2410-241-23-2

0105

INSTALLATION CONTINUED

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 15. Connect connector (Figure 14, Item 2) on camshaft speed sensor (Figure 14, Item 3). 16. Install new tiedown straps on harness (Figure 14, Item 1).

Figure 14. Camshaft Sensor Harness.

00105

0105-14

TM 5-2410-241-23-2

0105

INSTALLATION CONTINUED

NOTE
Install electrical connections, harness routing and tiedown straps as noted during removal. 17. Connect connector (Figure 15, Item 1) on connector (Figure 15, Item 3). 18. Install new tiedown straps (Figure 15, Item 2) on harness (Figure 15, Item 4).

Figure 15. Crankshaft Sensor Harness. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure left door guard (WP 0202). 2. Install front bottom guard (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00105

000105

0105-15/(16 blank)

20 TM 5-2410-241-23-2 0106

FIELD MAINTENANCE VALVE MECHANISM COVER, BASE AND INJECTOR HARNESS REPLACEMENT Valve Mechanism Covers Removal, Crankcase Breather Removal, Valve Mechanism Base and Injector Harness Removal, Cleaning and Inspection, Valve Mechanism Base and Injector Harness Installation, Crankcase Breather Installation, Valve Mechanism Covers Installation
0 1 0 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket (9) O-ring References WP 0295 0 0 0 0 0
0

0 0 1 0

0 1

Equipment Condition

Machine parked (TM 5-2410-241-10) 0 Air cleaner bracket removed (WP 0111) 0 NATO slave removed (WP 0053) 0 Arctic kit heater and bracket removed (if equipped) (WP 0291) 0 Drawing Required TM 5-2410-241-24P, Figure 45, 46 Estimated Time to Complete 5.0 Hr W/O Arctic Heater 8.5 Hr W/Arctic Heater 0 0 0 0 0

0 0 0

0106-1

TM 5-2410-241-23-2

0106

VALVE MECHANISM COVERS REMOVAL

000106

NOTE
Note position of harness and clips to aid installation. 1. Remove 16 bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and 3 harness clips (Figure 1, Item 5) from valve mechanism covers (Figure 1, Item 3). 2. Remove three valve mechanism covers (Figure 1, Item 3) and gaskets (Figure 1, Item 4) from valve mechanism cover base (Figure 1, Item 6). Discard gaskets.

Figure 1. Valve Cover. END OF TASK

00106

0106-2

TM 5-2410-241-23-2

0106

CRANKCASE BREATHER REMOVAL 1. Loosen clamp (Figure 2, Item 6) and remove hose (Figure 2, Item 7) from crankcase breather (Figure 2, Item 1). 2. Remove four bolts (Figure 2, Item 2), washers (Figure 2, Item 3), crankcase breather (Figure 2, Item 1) and gasket (Figure 2, Item 4) from valve cover base (Figure 2, Item 5). Discard gasket.

000106

Figure 2. Crankcase Breather. END OF TASK

00106

0106-3

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS REMOVAL

000106

NOTE
Note position of harness and clips to aid installation. 1. Remove 16 bolts (Figure 3, Item 1), washers (Figure 3, Item 2), and 3 harness clips (Figure 3, Item 5) from valve mechanism covers (Figure 3, Item 3). 2. Remove three valve mechanism covers (Figure 3, Item 3) and gaskets (Figure 3, Item 4) from valve mechanism cover base (Figure 3, Item 6). Discard gaskets.

Figure 3. Valve Cover.

00106

0106-4

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS REMOVAL CONTINUED

000106

NOTE
Tag and mark electrical connector to aid installation. 3. Disconnect connector (Figure 4, Item 1) from valve cover base (Figure 4, Item 2). Position connector aside.

Figure 4. Harness Connector. 4. Loosen clamp (Figure 5, Item 6) and remove hose (Figure 5, Item 7) from crankcase breather (Figure 5, Item 1). 5. Remove four bolts (Figure 5, Item 2), washers (Figure 5, Item 3), crankcase breather (Figure 5, Item 1) and gasket (Figure 5, Item 4) from valve cover base (Figure 5, Item 5). Discard gasket.

00106

Figure 5. Crankcase Breather.

00106

0106-5

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS REMOVAL CONTINUED

000106

NOTE
Tag and mark all electrical connectors to aid installation. 6. Disconnect connector (Figure 6, Item 1) from pressure sensor (Figure 6, Item 2). 7. Remove pressure sensor (Figure 6, Item 2) from valve mechanism cover base (Figure 6, Item 3). 8. Remove O-ring (Figure 6, Item 8) from pressure sensor (Figure 6, Item 2). Discard O-ring. 9. Remove three bolts (Figure 6, Item 7), washers (Figure 6, Item 5), and harness clips (Figure 6, Item 6) from valve mechanism cover base (Figure 6, Item 3). 10. Remove three harness clips (Figure 6, Item 6) from harness (Figure 6, Item 4). 11. Position harness (Figure 6, Item 4) aside.

Figure 6. Atmospheric Pressure Sensor.

00106

0106-6

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS REMOVAL CONTINUED

000106

NOTE
Tag and mark all electrical connectors to aid installation. 12. Remove 12 nuts (Figure 7, Item 3) and 6 connectors (Figure 7, Item 1) from 6 injectors (Figure 7, Item 2). Position connectors (Figure 7, Item 1) aside.

Figure 7. Injectors.

00106

0106-7

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS REMOVAL CONTINUED

000106

NOTE
Remove bolts in sequence shown in (Figure 8). 13. Remove eight bolts (Figure 8, Item 1), washers (Figure 8, Item 6), isolators (Figure 8, Item 5), sleeves (Figure 8, Item 4), and valve mechanism cover base (Figure 8, Item 2) from machine. 14. Remove gasket (Figure 8, Item 3) from valve mechanism cover base (Figure 8, Item 2). Discard gasket.

Figure 8. Valve Cover Base.

00106

0106-8

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS REMOVAL CONTINUED 15. Remove two bolts (Figure 9, Item 7), washers (Figure 9, Item 8), and connector (Figure 9, Item 5) from valve mechanism cover base (Figure 9, Item 6). Position connector (Figure 9, Item 5) aside.

000106

NOTE
Note position of harness clips and harness routing to aid installation. 16. Remove seven bolts (Figure 9, Item 2), three crimp style clips (Figure 9, Item 3), four harness clips (Figure 9, Item 4), and harness (Figure 9, Item 1) from valve mechanism cover base (Figure 9, Item 6). 17. Remove three crimp style clips (Figure 9, Item 3), and four harness clips (Figure 9, Item 4) from harness (Figure 9, Item 1).

Figure 9. Injector Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

00106

000106

0106-9

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS INSTALLATION

000106

NOTE
Note position of harness clips and harness routing to aid installation. 1. Install four harness clips (Figure 10, Item 4) and three crimp style clips (Figure 10, Item 3) on harness (Figure 10, Item 1). 2. Install harness (Figure 10, Item 1), four harness clips (Figure 10, Item 4), three crimp style clips (Figure 10, Item 3), and seven bolts (Figure 10, Item 2) on valve mechanism cover base (Figure 10, Item 6). 3. Install connector (Figure 10, Item 5) two washers (Figure 10, Item 8), and bolts (Figure 10, Item 7) on valve mechanism cover base (Figure 10, Item 6).

Figure 10. Injector Harness.

00106

0106-10

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS INSTALLATION CONTINUED

000106

NOTE
Tighten bolts in sequence shown in (Figure 11). 4. Install new gasket (Figure 11, Item 3) on valve mechanism cover base (Figure 11, Item 2). 5. Install valve mechanism cover base (Figure 11, Item 2), eight sleeves (Figure 11, Item 4), isolators (Figure 11, Item 5), washers (Figure 11, Item 6), and bolts (Figure 11, Item 1) on machine. Tighten bolts in sequence shown in (Figure 11) to 21 lb-ft (28 Nm).

Figure 11. Valve Cover Base.

00106

0106-11

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS INSTALLATION

000106

NOTE
Install electrical connectors as noted from removal. 6. Install 6 connectors (Figure 12, Item 1) and 12 nuts (Figure 12, Item 3) on 6 injectors (Figure 12, Item 2).

Figure 12. Injectors.

00106

0106-12

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS INSTALLATION 7. Position harness (Figure 13, Item 4) on machine. 8. Install three harness clips (Figure 13, Item 6) on harness (Figure 13, Item 4). 9. Install harness clips (Figure 13, Item 6), three washers (Figure 13, Item 5), and bolts (Figure 13, Item 7) on valve mechanism cover base (Figure 13, Item 3). 10. Install new O-ring (Figure 13, Item 8) on pressure sensor (Figure 13, Item 2). 11. Install pressure sensor (Figure 13, Item 2) on valve mechanism cover base (Figure 13, Item 3).

000106

NOTE
Install electrical connectors as noted during removal. 12. Connect connector (Figure 13, Item 1) on pressure sensor (Figure 13, Item 2).

Figure 13. Atmospheric Pressure Sensor.

00106

0106-13

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS INSTALLATION 13. Install new gasket (Figure 14, Item 4), crankcase breather (Figure 14, Item 1), four washers (Figure 14, Item 3), and bolts (Figure 14, Item 2) on valve cover base (Figure 14, Item 5). 14. Install hose (Figure 14, Item 7) and clamp (Figure 14, Item 6) on crankcase breather (Figure 14, Item 1).

000106

Figure 14. Crankcase Breather.

00106

NOTE
Install electrical connector as noted during removal. 15. Connect connector (Figure 15, Item 1) on valve cover base (Figure 15, Item 2).

Figure 15. Harness Connector.

00106

0106-14

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS INSTALLATION 16. Install three new gaskets (Figure 16, Item 4) and valve mechanism covers (Figure 16, Item 3) on valve mechanism cover base (Figure 16, Item 6).

000106

NOTE
Install harness and clips as noted during removal. 17. Install 3 harness clips (Figure 16, Item 5), 16 washers (Figure 16, Item 2), and bolts (Figure 16, Item 1) on valve mechanism covers (Figure 16, Item 3).

Figure 16. Valve Cover.

00106

0106-15

TM 5-2410-241-23-2

0106

VALVE MECHANISM BASE AND INJECTOR HARNESS INSTALLATION

000106

NOTE
Tighten bolts in sequence shown (Figure 17). 18. Tighten bolts (Figure 17, Item 1) in sequence shown (Figure 17) to 9 lb-ft (12 Nm).

Figure 17. Valve Cover Torque. END OF TASK

00106

0106-16

TM 5-2410-241-23-2

0106

CRANKCASE BREATHER INSTALLATION 1. Install new gasket (Figure 18, Item 4), crankcase breather (Figure 18, Item 1), four washers (Figure 18, Item 3), and bolts (Figure 18, Item 2) on valve cover base (Figure 18, Item 5). 2. Install hose (Figure 18, Item 7) and clamp (Figure 18, Item 6) on crankcase breather (Figure 18, Item 1).

000106

Figure 18. Crankcase Breather. END OF TASK

00106

0106-17

TM 5-2410-241-23-2

0106

VALVE MECHANISM COVERS INSTALLATION 1. Install three new gaskets (Figure 19, Item 4) and valve mechanism covers (Figure 19, Item 3) on valve mechanism cover base (Figure 19, Item 6).

000106

NOTE
Install harness and clips as noted during removal. 2. Install three harness clips (Figure 19, Item 5), 16 washers (Figure 19, Item 2), and bolts (Figure 19, Item 1) on valve mechanism covers (Figure 19, Item 3).

Figure 19. Valve Cover.

00106

0106-18

TM 5-2410-241-23-2

0106

VALVE MECHANISM COVERS INSTALLATION CONTINUED

000106

NOTE
Tighten bolts in sequence shown (Figure 20). 3. Tighten bolts (Figure 20, Item 1) in sequence shown (Figure 20) to 9 lb-ft (12 Nm).

Figure 20. Valve Cover Torque. END OF TASK FOLLOW-ON TASKS 1. Install NATO slave (WP 0053). 2. Install air cleaner bracket (WP 0111). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00106

000106

0106-19/(20 blank)

8 TM 5-2410-241-23-2 0107

FIELD MAINTENANCE ROCKER ARM ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation, Electronic Unit Injector Adjustment, Valve Lash Adjustment
0 1 0 7

INITIAL SETUP Tools and Special Tools 0 References WP 0023 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Valve mechanism cover removed (WP 0106) Drawing Required 0 0 0 TM 5-2410-241-24P, Figure 46 Estimated Time to Complete 12.5 Hr 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Hammer, Soft Face 1 (S0226) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) 0 Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) Rag, Wiping (WP 0303, Item 24) 0

0107-1

TM 5-2410-241-23-2

0107

REMOVAL

000107

NOTE
This procedure removes one set of rocker arms, push rods, and valve bridge. Follow the same procedure for each additional set of rocker arms, push rods, and valve bridge. Note and mark location of each rocker arm, push rod, and valve bridge to aid installation.

1. Remove two bolts (Figure 1, Item 1) and rocker arm assembly (Figure 1, Item 2) from head (Figure 1, Item 4). 2. Remove three push rods (Figure 1, Item 3) from head (Figure 1, Item 4).

Figure 1. Rocker Arm. 3. Remove valve bridge (Figure 2, Item 1) from head (Figure 2, Item 2).

00107

Figure 2. Valve Bridge. END OF TASK

00107

0107-2

TM 5-2410-241-23-2

0107

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000107

000107

NOTE
This procedure installs one set of rocker arms, push rods, and valve bridge. Follow the same procedure for each additional set of rocker arms, push rods, and valve bridge. Install each rocker arm, push rod, and valve bridge in its original location as noted during removal. Lubricate all parts with clean engine oil.

1. Install valve bridge (Figure 2, Item 1) on head (Figure 2, Item 2). 2. Install three push rods (Figure 1, Item 3) on head (Figure 1, Item 4). 3. Install rocker arm assembly (Figure 1, Item 2) and two bolts (Figure 1, Item 1) on head (Figure 1, Item 4). END OF TASK

0107-3

TM 5-2410-241-23-2

0107

ELECTRONIC UNIT INJECTOR ADJUSTMENT

000107

NOTE
Electronic unit injectors on cylinders 3, 5, and 6 can be adjusted with No.1 cylinder at top center position on the compression stroke. 1. Put No.1 cylinder at top center position on the compression stroke. Refer to Engine Mechanical Tests, Inspections, and Adjustments (WP 0023). 2. Adjust electronic unit injector (Figure 3, Item 1) at cylinders 3, 5, and 6.

NOTE
Steps a - i will adjust one electronic unit injector. Follow steps a - i to adjust additional electronic unit injector. (a) Loosen nut (Figure 3, Item 2) on rocker arm adjustment screw (Figure 3, Item 3). (b) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise until contact is made on electronic unit injector (Figure 3, Item 1). (c) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise two additional turns. (d) Turn rocker arm adjustment screw (Figure 3, Item 3) counter clockwise three turns. (e) Push rocker arm (Figure 3, Item 3) so contact is made on pushrod (Figure 3, Item 4). (f) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise until contact is made on electronic unit injector (Figure 3, Item 1). (g) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise 1/2 turn (180 degrees). (h) Hold rocker arm adjustment screw (Figure 3, Item 3) in this position. (i) Tighten nut (Figure 3, Item 2) on rocker arm adjustment screw (Figure 3, Item 3). Tighten nut to 41 lb-ft (55 Nm).

NOTE
Electronic unit injectors on cylinders 1, 2, and 4 can be adjusted with No.1 cylinder at top center position on the exhaust stroke. 3. Put No.1 cylinder at top center position on the exhaust stroke. Refer to Engine Mechanical Tests, Inspections, and Adjustments (WP 0023). 4. Adjust electronic unit injector (Figure 3, Item 1) at cylinders 1, 2, and 4.

0107-4

TM 5-2410-241-23-2

0107

ELECTRONIC UNIT INJECTOR ADJUSTMENT CONTINUED

000107

NOTE
Steps a - i will adjust one electronic unit injector. Follow steps a - i to adjust additional electronic unit injector. (a) Loosen nut (Figure 3, Item 2) on rocker arm adjustment screw (Figure 3, Item 3). (b) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise until contact is made on electronic unit injector (Figure 3, Item 1). (c) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise two additional turns. (d) Turn rocker arm adjustment screw (Figure 3, Item 3) counter clockwise three turns. (e) Push rocker arm (Figure 3, Item 3) so contact is made on pushrod (Figure 3, Item 4). (f) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise until contact is made on electronic unit injector (Figure 3, Item 1). (g) Turn rocker arm adjustment screw (Figure 3, Item 3) clockwise 1/2 turn (180 degrees). (h) Hold rocker arm adjustment screw (Figure 3, Item 3) in this position. (i) Tighten nut (Figure 3, Item 2) on rocker arm adjustment screw (Figure 3, Item 3). Tighten nut to 41 lb-ft (55 Nm).

Figure 3. Rocker Arm. END OF TASK

00107

0107-5

TM 5-2410-241-23-2

0107

VALVE LASH ADJUSTMENT

000107

CAUTION
Intake valves at cylinders 1, 2, and 4 must be adjusted with No.1 at top center position on compression stroke. Exhaust valves at cylinders 1, 3, and 5 must be adjusted with No.1 at top center position on compression stroke. Intake valves at cylinders 3, 5, and 6 must be adjusted with No. 6 at top center position on compression stroke. Exhaust valves at cylinders 2, 4, and 6 must be adjusted with No. 6 at top center position on compression stroke.

1. Put No.1 cylinder at top center position on the compression stroke. Refer to Engine Mechanical Tests Inspections, and Adjustments (WP 0023). 2. Adjust valve lash of intake valves at cylinders 1, 2, and 4. Adjust valve lash of exhaust valves at cylinders 1, 3, and 5. 3. Lightly tap top of rocker arms (Figure 4, Item 1) with soft mallet. 4. Adjust valve lash of intake valves setting to 0.015 0.003 in (0.38 0.08 mm).

NOTE
Steps a - g will adjust one intake valve. Follow steps a - g to adjust additional intake valves. (a) Place feeler gage between rocker arm (Figure 4, Item 1) and valve bridge (Figure 4, Item 4). (b) Loosen nut (Figure 4, Item 2) on rocker arm adjustment screw (Figure 4, Item 3). (c) Continued to slide feeler gage between rocker arm (Figure 4, Item 1) and valve bridge (Figure 4, Item 4). (d) Turn rocker arm adjustment screw (Figure 4, Item 3) until slight drag is felt on feeler gage. (e) Remove feeler gage between rocker arm (Figure 4, Item 1) and valve bridge (Figure 4, Item 4). (f) Hold rocker arm adjustment screw (Figure 4, Item 3) in this position. (g) Tighten nut (Figure 4, Item 2) on rocker arm adjustment screw (Figure 4, Item 3). Tighten nut to 22 lb-ft (30 Nm). 5. Adjust valve lash of exhaust valves setting to 0.025 0.003 in (0.64 0.08 mm).

NOTE
Steps a - g will adjust one exhaust valve. Follow steps a - g to adjust additional exhaust valves. (a) Place feeler gage between rocker arm (Figure 4, Item 1) and valve bridge (Figure 4, Item 4). (b) Loosen nut (Figure 4, Item 2) on rocker arm adjustment screw (Figure 4, Item 3). (c) Continued to slide feeler gage between rocker arm (Figure 4, Item 1) and valve bridge (Figure 4, Item 4). (d) Turn rocker arm adjustment screw (Figure 4, Item 3) until slight drag is felt on feeler gage. (e) Remove feeler gage between rocker arm (Figure 4, Item 1) and valve bridge (Figure 4, Item 4).

0107-6

TM 5-2410-241-23-2

0107

VALVE LASH ADJUSTMENT CONTINUED (f) Hold rocker arm adjustment screw (Figure 4, Item 3) in this position. (g) Tighten nut (Figure 4, Item 2) on rocker arm adjustment screw (Figure 4, Item 3). Tighten nut to 22 b-ft (30 Nm). 6. Put No.6 cylinder at top center position on the compression stroke by rotating engine 360 degrees. Refer to Engine Mechanical Tests Inspections, and Adjustments (WP 0023). 7. Repeat steps 3 - 5 until all intake valves at cylinders 3, 5, and 6 and exhaust valves at cylinders 2, 4, and 6 have been adjusted.

000107

Figure 4. Valve Lash Adjustment No.1 TDC. END OF TASK FOLLOW-ON TASKS 1. Install valve mechanism cover (WP 0106). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

00107

000107

0107-7/(8 blank)

6 TM 5-2410-241-23-2 0108

FIELD MAINTENANCE CYLINDER HEAD ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation
0 1 0 8

INITIAL SETUP Tools and Special Tools 0 Equipment Condition 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Bracket, Link (3/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 11) 0 Handle, Ratchet 1/2 drive 10 long (S0563) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Lifting device (500 lb capacity) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Gasket Head Bolt (33) O-ring (6) References WP 0295 0 0 0 0 0 0 0

Machine parked (TM 5-2410-241-10) 0 Ether bracket removed (WP 0060) 0 Air cleaner bracket removed (WP 0111) 0 Aftercooler housing removed (WP 0068) 0 Cooling manifold removed (WP 0075) 0 Fuel injectors removed (WP 0069) 0 Water lines removed (WP 0049) 0 Water temperature regulator removed (WP 0074) 0 Exhaust manifold removed (WP 0067) 0 Fuel manifold removed (WP 0070) 0 Valve mechanism cover base removed (WP 0106) 0 Rocker arm assemblies removed (WP 0107) 0 Drawing Required TM 5-2410-241-24P, Figure 14, 47 Estimated Time to Complete 31.0 Hr 0 0 0 0

0108-1

TM 5-2410-241-23-2

0108

REMOVAL

000108

NOTE
Note position of bolts and washers to aid installation. 1. Remove 33 bolts (Figure 1, Item 2) and 26 washers (Figure 1, Item 3) from cylinder head (Figure 1, Item 1). Discard bolts. 2. Install two bracket links (Figure 1, Item 4) on cylinder head (Figure 1, Item 1) .

Figure 1. Cylinder Head Bolts.

0108

WARNING

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

NOTE
Cylinder head weighs approximately 300 lb (135 kg). 3. Attach lifting device to cylinder head (Figure 2, Item 1).

NOTE
O-rings may stay in block when cylinder head is removed. 4. Using lifting device, remove cylinder head (Figure 2, Item 1), cylinder head gasket (Figure 2, Item 2) and six Orings (Figure 2, Item 3) from engine (Figure 2, Item 4). Discard six O-rings and gasket. 5. Place cylinder head (Figure 2, Item 1) on flat level surface. Remove lifting device from cylinder head.

0108-2

TM 5-2410-241-23-2

0108

REMOVAL CONTINUED

Figure 2. Cylinder Head. CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0108

000108

000108

WARNING

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

NOTE
Cylinder head weighs approximately 300 lb (135 kg). 1. Attach lifting device to cylinder head (Figure 2, Item 1). 2. Using lifting device install six new O-rings (Figure 2, Item 3), new cylinder head gasket (Figure 2, Item 2) and cylinder head (Figure 2, Item 1) on engine (Figure 2, Item 4). 3. Remove lifting device from cylinder head (Figure 2, Item 1).

0108-3

TM 5-2410-241-23-2

0108

INSTALLATION CONTINUED 4. Remove two bracket links (Figure 3, Item 4) from cylinder head (Figure 3, Item 1).

NOTE
Install washers and bolts in position noted during removal. 5. Install 33 new bolts (Figure 3, Item 2) and 26 washers (Figure 3, Item 3) on cylinder head (Figure 3, Item 1). Do not tighten bolts.

Figure 3. Cylinder Head Bolts.

0108

0108-4

TM 5-2410-241-23-2

0108

INSTALLATION CONTINUED 6. Tighten 33 bolts on cylinder head (Figure 4) as follows: a. Tighten bolts 1-26 in sequence to 120 lb-ft (160 Nm). b. Tighten bolts 1-26 again in sequence to 120 lb-ft (160 Nm). c. Tighten bolts 1-26 in sequence plus an additional 1/4 turn (90 degrees). d. Loosen bolts 1-26 in sequence until washers are loose. e. Tighten bolts 1-26 in sequence to 120 lb-ft (160 Nm). f. Tighten bolts 1-26 again in sequence to 120 lb-ft (160 Nm). g. Tighten bolts 1-26 in sequence plus an additional 1/4 turn (90 degrees). h. Tighten bolts 27-33 in sequence to 20 lb-ft (28 Nm).

Figure 4. Cylinder Head Bolts Torque Sequence. END OF TASK FOLLOW-ON TASKS 1. Install fuel injectors (WP 0069). 2. Install rocker arm assemblies (WP 0107). 3. Install valve mechanism cover base (WP 0106). 4. Install fuel manifold (WP 0070). 5. Install exhaust manifold (WP 0067). 6. Install water lines (WP 0049). 7. Install water temperature regulator (WP 0074). 8. Install after cooler housing (WP 0068). 9. Install cooling manifold (WP 0068). 10. Install air cleaner bracket (WP 0111). 11. Install ether bracket (WP 0060). 12. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0108

000108

0108-5/(6 blank)

16 TM 5-2410-241-23-2 0109

FIELD MAINTENANCE RADIATOR CORE SERVICE Center Radiator Core Removal, Outer Position Radiator Core Removal, Cleaning and Inspection, Outer Position Radiator Core Installation, Center Radiator Core Installation
0 1 0 9

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Sling, Multiple Leg (WP 0302, Item 54) Lifting Device (500 lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Emery Cloth Gasket (2) 0 0 0 0 0 0 0 0 0 Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Coolant drained (WP 0113) Drawing Required TM 5-2410-241-24P, Figure 2 Estimated Time to Complete 1.5 Hr 0 0 0 0 0 0 0 0 0 0 0

0109-1

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE REMOVAL

000109

WARNING

Components with metal parts can cause severe burns at operating temperature. Allow components to cool before performing maintenance on them. Wear insulated gloves, long sleeves, and eye protection when working with heated parts.

NOTE
There are nine radiator cores in the radiator assembly. The seven center cores will all remove the same way. The following procedure will remove the left side outer most position center radiator core. Follow the same steps for each of six additional center radiator cores. If removing radiator core in center most position, two radiator cores will need to be removed. 1. Remove eight bolts (Figure 1, Item 2) and washers (Figure 1, Item 3) from door (Figure 1, Item 1). 2. Open door (Figure 1, Item 1) on hinge (Figure 1, Item 4).

WARNING

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

NOTE
Door weighs approximately 120 lb (54 kg). 3. Attach lifting strap, and lifting device on door (Figure 1, Item 1). 4. With assistance using lifting device, remove door (Figure 1, Item 1) from hinge (Figure 1, Item 4). Place door on flat level surface. 5. Remove lifting device and strap from door (Figure 1, Item 1). 6. Open second door (Figure 1, Item 1) on hinge (Figure 1, Item 4). 7. Attach lifting strap and lifting device on door (Figure 1, Item 1). 8. With assistance using lifting device, remove door (Figure 1, Item 1) from hinge (Figure 1, Item 4). Place door on flat level surface. 9. Remove lifting device and strap from door (Figure 1, Item 1).

0109-2

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE REMOVAL CONTINUED

Figure 1. Radiator Guard Doors.

0109

0109-3

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE REMOVAL CONTINUED

NOTE
Tag and note position, location and routing of each hose to aid installation. 10. Loosen two clamps (Figure 2, Item 2) from hoses (Figure 2, Item 1). 11. Remove two hoses (Figure 2, Item 1) from radiator core (Figure 2, Item 3). 12. Remove two bolts (Figure 2, Item 5) and washers (Figure 2, Item 4) from radiator core (Figure 2, Item 3).

Figure 2. Center Radiator Core Hoses. 13. Pry radiator core (Figure 3, Item 1) up from radiator tank (Figure 3, Item 2). 14. With assistance, remove radiator core (Figure 3, Item 1) from machine.

0109

Figure 3. Center Radiator Core Lower Mount.

0109

0109-4

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE REMOVAL CONTINUED 15. Remove gasket (Figure 4, Item 1) from radiator tank (Figure 4, Item 2). Discard gasket.

Figure 4. Center Radiator Core Gasket.

0109

16. Remove upper mounting bracket (Figure 5, Item 2), and isolator (Figure 5, Item 1) from radiator core (Figure 5, Item 3).

Figure 5. Center Radiator Core Bracket and Isolator. END OF TASK

0109

0109-5

TM 5-2410-241-23-2

0109

OUTER POSITION RADIATOR CORE REMOVAL

000109

NOTE
The following procedure will remove left side outer position radiator core. Follow the same steps for right side outer position core removal. Note position, location and routing of each hose to aid installation.

1. Remove left side outer most position center radiator core. Refer to Center Radiator Core Removal in this work package. 2. Loosen clamp (Figure 6, Item 2) from hose (Figure 6, Item 1). 3. Remove hose (Figure 6, Item 1) from radiator core (Figure 6, Item 3). 4. Remove bolt (Figure 6, Item 5) and washer (Figure 6, Item 4) from radiator core (Figure 6, Item 3).

Figure 6. Outer Radiator Core Hoses.

0109

0109-6

TM 5-2410-241-23-2

0109

OUTER POSITION RADIATOR CORE REMOVAL CONTINUED 5. Pry radiator core (Figure 7, Item 1) up from radiator tank (Figure 7, Item 2). 6. With assistance, remove radiator core (Figure 7, Item 1) from machine.

Figure 7. Outer Radiator Core Lower Mount. 7. Remove gasket (Figure 8, Item 1) from radiator tank (Figure 8, Item 2). Discard gasket.

0109

Figure 8. Outer Radiator Core Gasket.

0109

0109-7

TM 5-2410-241-23-2

0109

OUTER POSITION RADIATOR CORE REMOVAL CONTINUED 8. Remove clamp (Figure 9, Item 4) and cap (Figure 9, Item 3) from radiator core (Figure 9, Item 5). 9. Remove upper mounting bracket (Figure 9, Item 2), and isolator (Figure 9, Item 1) from radiator core (Figure 9, Item 5).

Figure 9. Outer Radiator Core Bracket and Isolator. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK OUTER POSITION RADIATOR CORE INSTALLATION

0109

000109

000109

NOTE
The following procedure will install left side outer position radiator core. Follow the same steps for right side outer position core installation. 1. Install isolator (Figure 9, Item 1) and upper mounting bracket (Figure 9, Item 2) on radiator core (Figure 9, Item 5). 2. Install cap (Figure 9, Item 3) and clamp (Figure 9, Item 4) on radiator core (Figure 9, Item 5).

0109-8

TM 5-2410-241-23-2

0109

OUTER POSITION RADIATOR CORE INSTALLATION CONTINUED 3. Install new gasket (Figure 10, Item 1) on radiator tank (Figure 10, Item 2).

Figure 10. Outer Radiator Core Gasket. 4. With assistance, install radiator core (Figure 11, Item 1) on machine. 5. Push radiator core (Figure 11, Item 1) down on radiator tank (Figure 11, Item 2).

0109

Figure 11. Outer Radiator Core Lower Mount.

0109

0109-9

TM 5-2410-241-23-2

0109

OUTER POSITION RADIATOR CORE INSTALLATION CONTINUED

NOTE
When installing multiple radiator cores, align all radiator cores before tightening bolts. 6. Install washer (Figure 12, Item 4) and bolt (Figure 12, Item 5) on radiator core (Figure 12, Item 3).

NOTE
Install hoses as noted during removal. 7. Install hose (Figure 12, Item 1) on radiator core (Figure 12, Item 3). 8. Install clamp (Figure 12, Item 2) on hose (Figure 12, Item 1). 9. Install left side outer most position center radiator core. Refer to Center Radiator Core Installation in this work package.

Figure 12. Outer Radiator Core Hoses. END OF TASK

0109

0109-10

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE INSTALLATION

000109

NOTE
There are nine radiator cores in the radiator assembly. The seven center cores will all install the same way. The following procedure will install the left side outer most position center radiator core. Follow the same steps for each of six additional center radiator cores. If installing radiator core in center most position, two radiator cores will need to be installed. 1. Install isolator (Figure 13, Item 1) and upper mounting bracket (Figure 13, Item 2) on radiator core (Figure 13, Item 3).

Figure 13. Outer Radiator Core Bracket and Isolator.

0109

0109-11

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE INSTALLATION CONTINUED 2. Install new gasket (Figure 14, Item 1) on radiator tank (Figure 14, Item 2).

Figure 14. Radiator Core Gasket. 3. Install radiator core (Figure 15, Item 1) on machine. 4. Push radiator core (Figure 15, Item 1) down on radiator tank (Figure 15, Item 2).

0109

Figure 15. Radiator Core Lower Mount.

0109

0109-12

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE INSTALLATION CONTINUED

NOTE
When installing multiple radiator cores, align all radiator cores before tightening bolts. 5. Install two washers (Figure 16, Item 4) and bolts (Figure 16, Item 5) on radiator core (Figure 16, Item 3).

NOTE
Install hoses as noted during removal. 6. Install two hoses (Figure 16, Item 1) on radiator core (Figure 16, Item 3). 7. Tighten two clamps (Figure 16, Item 2) on hoses (Figure 16, Item 1).

Figure 16. Radiator Core Hoses.

0109

0109-13

TM 5-2410-241-23-2

0109

CENTER RADIATOR CORE INSTALLATION CONTINUED

WARNING

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

NOTE
Door weighs approximately 120 lb (54 kg). 8. Attach lifting strap, and lifting device on door (Figure 17, Item 1). 9. With assistance using lifting device, install door (Figure 17, Item 1) on hinge (Figure 17, Item 4). 10. Remove lifting device and strap from door (Figure 17, Item 1). 11. Close door (Figure 17, Item 1) on hinge (Figure 17, Item 4). 12. Attach lifting strap, and lifting device on second door (Figure 17, Item 1). 13. With assistance using lifting device, install door (Figure 17, Item 1) on hinge (Figure 17, Item 4). 14. Remove lifting device and strap from door (Figure 17, Item 1). 15. Close door (Figure 17, Item 1) on hinge (Figure 17, Item 4). 16. Install eight washers (Figure 17, Item 3) and bolts (Figure 17, Item 2) on door (Figure 17, Item 1).

Figure 17. Radiator Guard Doors. END OF TASK

0109

0109-14

TM 5-2410-241-23-2

0109

FOLLOW-ON TASKS 1. Fill cooling system (WP 0113). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000109

0109-15/(16 blank)

10 TM 5-2410-241-23-2 0110

FIELD MAINTENANCE INSTRUCTIONS LOWER RADIATOR TANK REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 1 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Socket, 1/2 Drive, 6 point, 1-1/8 (S0582) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket (2) O-ring Personnel Required Two 0 0 0 0 0 Drawing Required
0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Bottom guard removed (WP 0199) Radiator cores removed (WP 0109)

0 0 0 0 0 0 0 0 0 0

0 0 0 0

TM 5-2410-241-24P, Figure 2, 86 Estimated Time to Complete 4.5 Hr

0110-1

TM 5-2410-241-23-2

0110

REMOVAL

000110

WARNING

Components with metal parts can cause severe burns at operating temperature. Allow components to cool before performing maintenance on them. Wear insulated gloves, long sleeves, and eye protection when working with heated parts.

NOTE
Tag hoses to aid installation. 1. Loosen clamp (Figure 1, Item 2) and disconnect hose (Figure 1, Item 1) from lower radiator tank (Figure 1, Item 9). 2. Loosen clamp (Figure 1, Item 3) and disconnect hose (Figure 1, Item 4) from lower radiator tank (Figure 1, Item 9). 3. Loosen clamp (Figure 1, Item 5) and disconnect hose (Figure 1, Item 6) from lower radiator tank (Figure 1, Item 9). 4. Loosen clamp (Figure 1, Item 7) and disconnect hose (Figure 1, Item 8) from lower radiator tank (Figure 1, Item 9).

Figure 1. Hoses.

0110

0110-2

TM 5-2410-241-23-2

0110

REMOVAL CONTINUED 5. Remove bolt (Figure 2, Item 5), washer (Figure 2, Item 4) and two clips (Figure 2, Item 6) from bracket (Figure 2, Item 7). 6. Remove bolt (Figure 2, Item 3), washer (Figure 2, Item 2) and bracket (Figure 2, Item 7) from lower radiator tank (Figure 2, Item 1).

Figure 2. Bracket.

0110

0110-3

TM 5-2410-241-23-2

0110

REMOVAL CONTINUED

WARNING

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

NOTE
Weight of lower radiator tank is approximately 105 lb (41 kg). 7. With assistance, remove four bolts (Figure 3, Item 1), washers (Figure 3, Item 2) and lower radiator tank (Figure 3, Item 3) from machine.

Figure 3. Lower Radiator Tank.

0110

0110-4

TM 5-2410-241-23-2

0110

REMOVAL CONTINUED 8. Remove eight bolts (Figure 4, Item 4), two elbows (Figure 4, Item 3) and two gaskets (Figure 4, Item 5) from lower radiator tank (Figure 4, Item 6). Discard gaskets. 9. Remove fitting (Figure 4, Item 2) from lower radiator tank (Figure 4, Item 6). 10. Remove O-ring (Figure 4, Item 1) from fitting (Figure 4, Item 2). Discard O-ring. 11. Remove six bolts (Figure 4, Item 7), washers (Figure 4, Item 8) and baffle (Figure 4, Item 9) from lower radiator tank (Figure 4, Item 6).

Figure 4. Elbows. 12. Remove four bolts (Figure 5, Item 1), washers (Figure 5, Item 2) and two plates (Figure 5, Item 3) from machine.

0110

Figure 5. Plates. END OF TASK

0110

0110-5

TM 5-2410-241-23-2

0110

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install two plates (Figure 6, Item 3), four washers (Figure 6, Item 2) and bolts (Figure 6, Item 1) on machine.

000110

000110

Figure 6. Plates.

0110

0110-6

TM 5-2410-241-23-2

0110

INSTALLATION CONTINUED 2. Install baffle (Figure 7, Item 9), six washers (Figure 7, Item 8) and bolts (Figure 7, Item 7) on lower radiator tank (Figure 7, Item 6). 3. Install new O-ring (Figure 7, Item 1) on fitting (Figure 7, Item 2). 4. Install fitting (Figure 7, Item 2) on lower radiator tank (Figure 7, Item 6). 5. Install two new gaskets (Figure 7, Item 5), elbows (Figure 7, Item 3) and eight bolts (Figure 7, Item 4) on lower radiator tank (Figure 7, Item 6).

Figure 7. Elbows.

0110

0110-7

TM 5-2410-241-23-2

0110

INSTALLATION CONTINUED

WARNING

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

NOTE
Weight of lower radiator tank is approximately 105 lb (41 kg). 6. With assistance, install lower radiator tank (Figure 8, Item 3), four washers (Figure 8, Item 2) and bolts (Figure 8, Item 1) on machine.

Figure 8. Lower Radiator Tank.

0110

0110-8

TM 5-2410-241-23-2

0110

INSTALLATION CONTINUED 7. Install bracket (Figure 9, Item 7), washer (Figure 9, Item 2) and bolt (Figure 9, Item 3) on lower radiator tank (Figure 9, Item 1). 8. Install two clips (Figure 9, Item 6), washer (Figure 9, Item 4) and bolt (Figure 9, Item 5) on bracket (Figure 9, Item 7).

Figure 9. Bracket.

0110

0110-9

TM 5-2410-241-23-2

0110

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 9. Connect hose (Figure 10, Item 8) on lower radiator tank (Figure 10, Item 9) and tighten clamp (Figure 10, Item 7). 10. Connect hose (Figure 10, Item 6) on lower radiator tank (Figure 10, Item 9) and tighten clamp (Figure 10, Item 5). 11. Connect hose (Figure 10, Item 4) on lower radiator tank (Figure 10, Item 9) and tighten clamp (Figure 10, Item 3). 12. Connect hose (Figure 10, Item 1) on lower radiator tank (Figure 10, Item 9) and tighten clamp (Figure 10, Item 2).

Figure 10. Hoses. END OF TASK FOLLOW-ON TASKS 1. Install radiator cores (WP 0109). 2. Install bottom guard (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0110

000110

0110-10

14 TM 5-2410-241-23-2 0111

FIELD MAINTENANCE
0 1 1 1

AIR CLEANER ASSEMBLY SERVICE

Air Cleaner Element Removal, Air Cleaner Assembly Removal, Air Cleaner Housing Bracket Removal, Cleaning and Inspection, Air Cleaner Housing Bracket Installation, Air Cleaner Assembly Installation, Air Cleaner Element Installation INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Seal References WP 0045 WP 0051 0 0
0

References - Continued WP 0066 WP 0071 WP 0097 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 49 Estimated Time to Complete 2.0 Hr

0 0 0 0 0 0 0 0 0 0 0

0 0 0
0

0 0 0 0

0111-1

TM 5-2410-241-23-2

0111

WARNING

If CBRN exposure is suspected, personnel wearing protective equipment should handle all air cleaner media. Consult your CBRN Officer NCO for appropriate handling or disposal procedures. Refer to FM 3-11.3, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Contamination Avoidance and FM 3-11.5, Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Decontamination. Allow engine to cool off before performing maintenance on air cleaner. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Failure to follow these warnings may cause injury or death to personnel.
000111

AIR CLEANER ELEMENTS REMOVAL 1. Open left side access door (TM 5-2410-241-10). 2. Open clips (Figure 1, Item 3) and remove cover (Figure 1, Item 1) from housing (Figure 1, Item 2).

Figure 1. Air Cleaner Cover.

0111

0111-2

TM 5-2410-241-23-2

0111

AIR CLEANER ELEMENTS REMOVAL CONTINUED 3. Remove primary filter element (Figure 2, Item 1) from housing (Figure 2, Item 2). 4. Remove secondary filter element (Figure 2, Item 3) from housing (Figure 2, Item 2).

Figure 2. Air Filters Elements. END OF TASK

0111

0111-3

TM 5-2410-241-23-2

0111

AIR CLEANER ASSEMBLY REMOVAL 1. Open right side engine access door (TM 5-2410-241-10). 2. Remove turbocharger inlet pressure sensor (WP 0066).

000111

NOTE
Tag hoses to aid installation. 3. Loosen two clamps (Figure 3, Item 3) and remove hose (Figure 3, Item 4) from air cleaner housing (Figure 3, Item 1) and turbo (Figure 3, Item 2). 4. Remove two clamps (Figure 3, Item 3) from hose (Figure 3, Item 4).

Figure 3. Air Cleaner Outlet Hose.

0111

0111-4

TM 5-2410-241-23-2

0111

AIR CLEANER ASSEMBLY REMOVAL CONTINUED 5. Loosen two clamps (Figure 4, Item 3) and remove hose (Figure 4, Item 4) from prescreener (Figure 4, Item 2) and muffler (Figure 4, Item 5). 6. Remove two clamps (Figure 4, Item 3) from hose (Figure 4, Item 4). 7. Loosen two clamps (Figure 4, Item 1) and remove hose (Figure 4, Item 6) from prescreener (Figure 4, Item 2) and air cleaner housing (Figure 4, Item 7). 8. Remove two clamps (Figure 4, Item 1) from hose (Figure 4, Item 6).

Figure 4. Air Cleaner Boot.

0111

0111-5

TM 5-2410-241-23-2

0111

AIR CLEANER ASSEMBLY REMOVAL CONTINUED 9. Remove nut (Figure 5, Item 6), bolt (Figure 5, Item 5), clamp (Figure 5, Item 4) and prescreener (Figure 5, Item 2) from precleaner body (Figure 5, Item 3). 10. Remove four bolts (Figure 5, Item 8), washers (Figure 5, Item 7) and precleaner body (Figure 5, Item 3) from hood (Figure 5, Item 1).

Figure 5. Air Cleaner Prescreener.

0111

NOTE
Note position and location of bolts. 11. Remove four bolts (Figure 6, Item 2), washers (Figure 6, Item 3) and air cleaner housing (Figure 6, Item 1) from bracket (Figure 6, Item 4).

Figure 6. Air Cleaner Housing.

0111

0111-6

TM 5-2410-241-23-2

0111

AIR CLEANER ASSEMBLY REMOVAL CONTINUED 12. Open clips (Figure 7, Item 6) and remove cover (Figure 7, Item 2) from housing (Figure 7, Item 1). 13. Remove seal (Figure 7, Item 3) from cover (Figure 7, Item 2). Discard seal. 14. Remove primary filter element (Figure 7, Item 4) and secondary filter element (Figure 7, Item 5) from housing (Figure 7, Item 1).

Figure 7. Air Cleaner Housing and Elements. END OF TASK

0111

0111-7

TM 5-2410-241-23-2

0111

AIR CLEANER HOUSING BRACKET REMOVAL 1. Remove muffler bracket (WP 0045). 2. Remove A/C compressor bracket (WP 0097). 3. Remove water temperature regulator outlet pipe removed (WP 0051). 4. Remove primary fuel filter and base (WP 0071). 5. Remove air cleaner housing (in this work package). 6. Remove eight bolts (Figure 8, Item 2), washers (Figure 8, Item 3), and plate (Figure 8, Item 1) from machine.

000111

7. Remove seven bolts (Figure 8, Item 9), washers (Figure 8, Item 8), and plate (Figure 8, Item 4) from machine. 8. Remove two bolts (Figure 8, Item 6), washers (Figure 8, Item 7), and plate (Figure 8, Item 5) from machine.

Figure 8. Air Cleaner Housing Bracket. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0111

000111

0111-8

TM 5-2410-241-23-2

0111

AIR CLEANER HOUSING BRACKET INSTALLATION 1. Install plate (Figure 8, Item 5), two washers (Figure 8, Item 7) and bolts (Figure 8, Item 6) on machine. 2. Install plate (Figure 8, Item 4), seven washers (Figure 8, Item 8) and bolts (Figure 8, Item 9) on machine. 3. Install plate (Figure 8, Item 1), eight washers (Figure 8, Item 3) and bolts (Figure 8, Item 2) on machine. 4. Install air cleaner housing (in this work package). 5. Install primary fuel filter and base (WP 0071). 6. Install water temperature regulator outlet pipe (WP 0051). 7. Install A/C compressor bracket (WP 0097). 8. Install muffler bracket (WP 0045). END OF TASK AIR CLEANER ASSEMBLY INSTALLATION 1. Install secondary filter element (Figure 9, Item 5) and primary filter element (Figure 9, Item 4) on housing (Figure 9, Item 1). 2. Install new seal (Figure 9, Item 3) on cover (Figure 9, Item 2). 3. Install cover (Figure 9, Item 2) and clips (Figure 9, Item 6) on housing (Figure 9, Item 1).

000111

000111

Figure 9. Air Cleaner Housing and Elements.

0111

0111-9

TM 5-2410-241-23-2

0111

AIR CLEANER ASSEMBLY INSTALLATION CONTINUED

NOTE
Install bolts as noted during removal. 4. Install air cleaner housing (Figure 10, Item 1), four washers (Figure 10, Item 3), and bolts (Figure 10, Item 2) on bracket (Figure 10, Item 4).

Figure 10. Air Cleaner Housing. 5. Install precleaner body (Figure 11, Item 3), four washers (Figure 11, Item 7) and bolts (Figure 11, Item 8) on hood (Figure 11, Item 1). 6. Install prescreener (Figure 11, Item 2), clamp (Figure 11, Item 4), bolt (Figure 11, Item 5) and nut (Figure 11, Item 6) on precleaner body (Figure 11, Item 3).

0111

Figure 11. Air Cleaner Prescreener.

0111

0111-10

TM 5-2410-241-23-2

0111

AIR CLEANER ASSEMBLY INSTALLATION CONTINUED 7. Install two clamps (Figure 12, Item 1) on hose (Figure 12, Item 6). 8. Install hose (Figure 12, Item 6) and two clamps (Figure 12, Item 1) on prescreener (Figure 12, Item 2) and air cleaner housing (Figure 12, Item 7). 9. Install two clamps (Figure 12, Item 3) on hose (Figure 12, Item 4). 10. Install hose (Figure 12, Item 4) and two clamps (Figure 12, Item 3) on prescreener (Figure 12, Item 2) and muffler (Figure 12, Item 5).

Figure 12. Air Cleaner Boot.

0111

0111-11

TM 5-2410-241-23-2

0111

AIR CLEANER ASSEMBLY INSTALLATION CONTINUED 11. Install two clamps (Figure 13, Item 3) on hose (Figure 13, Item 4). 12. Install hose (Figure 13, Item 4) and two clamps (Figure 13, Item 3) on air cleaner housing (Figure 13, Item 1) and turbo (Figure 13, Item 2). 13. Install turbo charger inlet pressure sensor (WP 0066). 14. Close right engine access door (TM 5-2410-241-10).

Figure 13. Air Cleaner Outlet Hose. END OF TASK AIR CLEANER ELEMENTS INSTALLATION 1. Install secondary filter element (Figure 14, Item 3) on housing (Figure 14, Item 2). 2. Install primary filter element (Figure 14, Item 1) on housing (Figure 14, Item 2).

0111

000111

Figure 14. Air Filters Elements.

0111

0111-12

TM 5-2410-241-23-2

0111

AIR CLEANER ELEMENTS INSTALLATION CONTINUED 3. Install cover (Figure 15, Item 1) and clips (Figure 15, Item 3) on housing (Figure 15, Item 2). 4. Close left side access door (TM 5-2410-241-10).

Figure 15. Air Cleaner Cover. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0111

000111

0111-13/(14 blank)

6 TM 5-2410-241-23-2 0112

FIELD MAINTENANCE INSTRUCTIONS IMPLEMENT PUMP REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 1 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Lifting Device (500 lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring (3) References WP 0295 0 0 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Engine removed (WP 0057) Drawing Required TM 5-2410-241-24P, Figure 51 Estimated Time to Complete 35.5 Hr 0 0 0 0 0 0 0

0112-1

TM 5-2410-241-23-2

0112

REMOVAL 1. Loosen tube nut (Figure 1, Item 10) and remove line (Figure 1, Item 3) from fitting (Figure 1, Item 12).

000112

2. Remove bolt (Figure 1, Item 8), washer (Figure 1, Item 6), clamp (Figure 1, Item 9) and line (Figure 1, Item 3) from bracket (Figure 1, Item 7).

NOTE
Note orientation and position of fitting to aid installation. 3. Loosen nut (Figure 1, Item 13) and remove fitting (Figure 1, Item 12) from implement pump (Figure 1, Item 2). 4. Remove two O-rings (Figure 1, Items 11 and 14) from fitting (Figure 1, Item 12). Discard O-rings.

WARNING

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

0112-2

TM 5-2410-241-23-2

0112

REMOVAL CONTINUED

NOTE
Implement pump weighs approximately 150 lb (68 kg). 5. Attach suitable lifting device to implement pump (Figure 1, Item 2). 6. Using lifting device, remove two bolts (Figure 1, Item 15), washers (Figure 1, Item 16) and implement pump (Figure 1, Item 2) from engine (Figure 1, Item 1). 7. Place implement pump (Figure 1, Item 2) on flat level surface. Remove lifting device from implement pump. 8. Remove O-ring (Figure 1, Item 17) from implement pump (Figure 1, Item 2). Discard O-ring. 9. Remove bolt (Figure 1, Item 4), washer (Figure 1, Item 5) and bracket (Figure 1, Item 7) from engine (Figure 1, Item 1).

Figure 1. Implement Pump. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0112

000112

0112-3

TM 5-2410-241-23-2

0112

INSTALLATION 1. Install bracket (Figure 2, Item 7), washer (Figure 2, Item 5), and bolt (Figure 2, Item 4) on engine (Figure 2, Item 1). 2. Install new O-ring (Figure 2, Item 17) on implement pump (Figure 2, Item 2).

000112

WARNING

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

NOTE
Implement pump weighs approximately 150 lb (68 kg). 3. Attach suitable lifting device on implement pump (Figure 2, Item 2). 4. Using lifting device, install implement pump (Figure 2, Item 2), two washers (Figure 2, Item 16) and bolts (Figure 2, Item 15) on engine (Figure 2, Item 1). 5. Remove lifting device from implement pump (Figure 2, Item 2). 6. Install two new O-rings (Figure 2, Items 11 and 14) on fitting (Figure 2, Item 12).

0112-4

TM 5-2410-241-23-2

0112

INSTALLATION CONTINUED

NOTE
Install fitting as noted during removal. 7. Install fitting (Figure 2, Item 12) and nut (Figure 2, Item 13) on implement pump (Figure 2, Item 2). 8. Install line (Figure 2, Item 3), clamp (Figure 2, Item 9), washer (Figure 2, Item 6), and bolt (Figure 2, Item 8) on bracket (Figure 2, Item 7). 9. Install line (Figure 2, Item 3) and tube nut (Figure 2, Item 10) on fitting (Figure 2, Item 12).

Figure 2. Implement Pump. END OF TASK FOLLOW ON TASKS 1. Install engine (WP 0057). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0112

000112

0112-5/(6 blank)

6 TM 5-2410-241-23-2 0113

FIELD MAINTENANCE COOLING SYSTEM SERVICE Drain and Flushing Procedure, Coolant Level Check
0 1 1 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Pan, Drain (S0255) (WP 0302, Item 68) Materials/Parts Antifreeze, Permanent, Ethylene Glycol, Inhibited (WP 0303, Item 1) Rag, Wiping (WP 0303, Item 24) 0 0
0

References WP 0039 WP 0199 Equipment Condition Machine parked (TM 5-2410-241-10)

0 0 0 0 0 0 0

0 0 0

Estimated Time to Complete 2.5 Hr

0 0

0113-1

TM 5-2410-241-23-2

0113

DRAIN AND FLUSHING PROCEDURE

000113

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 when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns. Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury to personnel.

1. Drain coolant at required interval. Refer to PMCS (WP 0039). Drain coolant whenever it is dirty or when foaming is observed. The radiator filler (Figure 1, Item 1) cap is beneath the access door (Figure 1, Item 2) on the top left side of radiator guard (Figure 1, Item 3). 2. Inspect radiator core for debris, if necessary clean radiator core. Use compressed air or high pressure water to remove dirt and debris from radiator core. Refer to PMCS (WP 0039 Item #1 Radiator Core - Clean). 3. Open access door (Figure 1, Item 2) and slowly loosen radiator filler cap (Figure 1, Item 1) to relieve system pressure. Remove radiator filler cap.

Figure 1. Radiator Filler Cap.

0113

0113-2

TM 5-2410-241-23-2

0113

DRAIN AND FLUSHING PROCEDURE CONTINUED

NOTE
Access panel (WP 0014) can be removed as an alternative to removing front bottom guard for reaching coolant drain valves. 4. Remove front bottom guard (WP 0199). 5. Position coolant drain hose in suitable drain pan. 6. Open coolant drain valves (Figure 2, Item 1). Allow coolant to drain into a suitable drain pan. 7. Close coolant drain valves (Figure 2, Item 1). 8. Fill cooling system with clean water. 9. Start engine (TM 5-2410-241-10). Run engine for 90 minutes. 10. Stop engine (TM 5-2410-241-10). Open coolant drain valves and drain water into a suitable drain pan. 11. If contamination is present, flush system with water. Flush system until draining water is clear. 12. Close coolant drain valves (Figure 2, Item 1).

Figure 2. Coolant Drain Valves.

0113

0113-3

TM 5-2410-241-23-2

0113

DRAIN AND FLUSHING PROCEDURE CONTINUED

CAUTION
Do not add water to pre-mixed antifreeze. If water is added to pre-mixed antifreeze, it will be diluted and will not provide proper engine protection and engine and/or cooling system damage may occur. Be sure to identify the type of antifreeze being added, or engine and/or cooling system damage may occur.

NOTE
Some antifreeze is pre-mixed and requires no water. Traditional antifreeze requires mixing with an equal amount of water. Mix antifreeze and water before adding to machine cooling system to ensure proper 1:1 ratio is used. It is allowable to mix traditional and pre-mix antifreeze types in the same cooling system. The cooling system capacity is 19.8 gal. (75 L).

13. Add correct type and amount of antifreeze. 14. Start engine TM 5-2410-241-10. Run engine without radiator filler cap until the thermostat opens and coolant level stabilizes. 15. Check coolant level. Make necessary adjustments to coolant level. 16. Inspect radiator filler cap seal for debris, foreign material, or damage. Clean radiator filler cap with a clean cloth. Replace radiator filler cap if damaged. 17. Install radiator filler cap and close access door. 18. Stop engine (TM 5-2410-241-10). 19. Install bottom guards (WP 0199). END OF TASK

0113-4

TM 5-2410-241-23-2

0113

COOLANT LEVEL CHECK

000113

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 when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may cause serious burns. Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may cause injury to personnel.

The surge tank has a radiator filler cap and a sight glass (Figure 3, Item 1). It is not necessary to remove radiator filler cap in order to check coolant level. The sight glass is inside the engine compartment on the front left side of machine. The radiator filler cap is beneath the access door on the top left side of radiator guard.

Figure 3. Sight Glass.

0113

0113-5

TM 5-2410-241-23-2

0113

COOLANT LEVEL CHECK CONTINUED 1. Inspect radiator core for debris, if necessary clean radiator core. Use compressed air or high pressure water to remove dirt and debris from radiator core, refer to PMCS WP 0039 Item #1 Radiator Core - Clean. 2. Open left front access door and observe sight glass to check level of coolant. If coolant completely fills the sight glass, coolant level is okay. If coolant level can be seen in the sight glass, coolant level is low.

CAUTION
Do not add water to pre-mixed antifreeze. If water is added to pre-mixed antifreeze, it will be diluted and will not provide proper engine protection and engine and/or cooling system damage may occur. Be sure to identify the type of antifreeze being added, or engine and/or cooling system damage may occur.

NOTE
Some antifreeze is pre-mixed and requires no water. Traditional antifreeze requires mixing with an equal amount of water. Mix antifreeze and water before adding to machine cooling system to ensure proper 1:1 ratio is used. It is allowable to mix traditional and pre-mix antifreeze types in the same cooling system.

3. If it is necessary to add antifreeze, open access door and slowly loosen radiator filler cap to relieve system pressure. Remove radiator filler cap. 4. Fill cooling system to bottom of filler tube. Adding coolant above the bottom of the filler tube will cause coolant to overflow cooling system. 5. Maintain coolant level between top of sight glass and the bottom of filler tube. Close left front access door. 6. Inspect radiator filler cap seal for debris, foreign material, or damage. Clean radiator filler cap with a clean cloth. Replace radiator filler cap if damaged. 7. Install radiator filler cap and close access door. END OF TASK END OF WORK PACKAGE

0113-6

4 TM 5-2410-241-23-2 0114

FIELD MAINTENANCE INSTRUCTIONS ENGINE OIL SERVICE Changing Engine Oil and Filter
0 1 1 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Drain Pan (S0255) (WP 0302, Item 68) Filter Wrench (S0981) (WP 0302, Item 68) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) 0.75 inch (19.0 mm) pipe with 3/4-14 NPTF pipe thread Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-40 (WP 0303, Item 20) 0 0 0 0
0

Materials/Parts - Continued Oil, Lubricating OE/HDO 15/40 (WP 0303, Item 21) Rag, Wiping (WP 0303, Item 24) Oil filter References LO 5-2410-241-13 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required

0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0

TM 5-2410-241-24P, Figure 34 Estimated Time to Complete 0.5 Hr

0114-1

TM 5-2410-241-23-2

0114

CHANGING ENGINE OIL AND FILTER

000114

WARNING

Engine oil should be warm to ensure it drains completely from crankcase. Use caution to protect against burns, when draining oil. Contact with engine oil can damage skin. Wear gloves when handling engine oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

1. Remove two bolts (Figure 1, Item 2) and plate (Figure 1, Item 1) from bottom guard (Figure 1, Item 3). 2. Install a 0.75 in (19.0 mm) pipe into drain (Figure 1, Item 4). Pipe requires a 3/4-14 NPTF pipe thread. 3. Open drain valve (Figure 1, Item 5). Allow oil to drain into a suitable container. A drain hose may be attached to the pipe to aid in draining. 4. When oil has completed draining from crankcase, close drain valve (Figure 1, Item 5). Remove pipe from drain (Figure 1, Item 4). 5. Install access cover (Figure 1, Item 1) and two bolts (Figure 1, Item 2) on bottom guard (Figure 1, Item 3).

Figure 1. Oil Drain.

0114

0114-2

TM 5-2410-241-23-2

0114

CHANGING ENGINE OIL AND FILTER CONTINUED 6. Open right engine access door. Remove three bolts and cover from lower access cover. 7. Remove engine oil filter element (Figure 2, Item 2) from oil filter base (Figure 2, Item 1). Discard engine oil filter element. Make sure all old filter seal is removed from filter base. 8. Apply a thin coat of oil to seal on new filter element. Install new engine oil filter element (Figure 2, Item 2) on oil filter base (Figure 2, Item 1) by hand. When gasket contacts oil filter base, tighten filter element by an additional 3/4 turn (270 degrees). Rotation index marks are on new filter element. These rotation index marks are spaced at 90 degree intervals. Use these rotation index marks as a guide for proper tightening. 9. Install cover and three bolts on lower access cover. Close right engine access door.

Figure 2. Oil Filter.

0114

0114-3

TM 5-2410-241-23-2

0114

CHANGING ENGINE OIL AND FILTER CONTINUED 10. Open left engine access door. Remove oil filler cap (Figure 3, Item 1). Refer to LO 5-2410-241-13 for correct amount and type of engine oil. Fill crankcase with new oil. Measure oil level with dipstick (Figure 3, Item 2). With engine oil cold, remove dipstick and check ENGINE STOPPED side of dipstick while engine is stopped. Maintain oil level between LOW mark and FULL mark. Install dipstick, start engine, remove dipstick and check LOW IDLE side of dipstick while engine is running. With oil at operating temperature, maintain oil level between ADD mark and FULL mark. Install dipstick. 11. Clean and install oil filler cap (Figure 3, Item 1). 12. Close left engine access door.

Figure 3. Oil Filler and Dipstick. END OF TASK FOLLOW-ON TASKS 1. Start engine and check for leaks. 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0114

000114

0114-4

4 TM 5-2410-241-23-2 0115

FIELD MAINTENANCE ADAPTER REPLACEMENT Removal, Cleaning and Inspection, Installation

0 1 1 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) 3/8 x 16 forcing screw (3) O-ring References WP 0295 REMOVAL 0 0 0 0 0 0 0 0
000115

Equipment Condition

Machine parked (TM 5-2410-241-10) 0 Hydrostatic drive motor removed (WP 0140) 0 Drawing Required TM 5-2410-241-24P, Figure 67 Estimated Time to Complete 8.1 Hr 0 0 0 0

NOTE
Note orientation of adapter in hydrostatic drive motor before removal. Adapter must be oriented the same for installation. 1. Remove six bolts (Figure 1, Item 1) from adapter (Figure 1, Item 2).

Figure 1. Adapter.

0115

0115-1

TM 5-2410-241-23-2

0115

REMOVAL CONTINUED 2. Evenly install three forcing screws (Figure 2, Item 2) in adapter (Figure 2, Item 1) and remove adapter from hydrostatic drive motor (Figure 2, Item 3). 3. Remove forcing screws (Figure 2, Item 2) from adapter (Figure 2, Item 1).

Figure 2. Forcing Screws. 4. Remove O-ring (Figure 3, Item 1) from adapter (Figure 3, Item 2). Discard O-ring.

0115

Figure 3. O-ring. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0115

000115

0115-2

TM 5-2410-241-23-2

0115

INSTALLATION 1. Install new O-ring (Figure 4, Item 1) on adapter (Figure 4, Item 2).
.

000115

Figure 4. O-ring.

0115

NOTE
Install adapter in same orientation it was removed. 2. Install adapter (Figure 5, Item 2) and six bolts (Figure 5, Item 1) on hydrostatic drive motor.

Figure 5. Adapter. END OF TASK

0115

0115-3

TM 5-2410-241-23-2

0115

FOLLOW-ON TASKS 1. Install hydrostatic drive motor (WP 0140). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000115

0115-4

6 TM 5-2410-241-23-2 0116

FIELD MAINTENANCE AXLE REPLACEMENT Removal, Cleaning and Inspection, Installation

0 1 1 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Adapter Assembly, Axle Removal (WP 0302, Item 1) Axle Removal Tool (WP 0302, Item 9) Materials/Parts Rag, Wiping (WP 0303, Item 24) O-ring REMOVAL 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 54, 64 Estimated Time to Complete 1.0 Hr 0 0 0 0 0 0 0 0

000116

NOTE
The following procedure will remove left side axle shaft. Follow the same steps for right side axle shaft. 1. Remove three bolts (Figure 1, Item 3), washers (Figure 1, Item 4), cap (Figure 1, Item 2), and O-ring (Figure 1, Item 5) from drive assembly (Figure 1, Item 1). Discard O-ring.

Figure 1. Axle Cap.

0116

0116-1

TM 5-2410-241-23-2

0116

REMOVAL CONTINUED 2. Remove thrust washer (Figure 2, Item 2) from drive assembly (Figure 2, Item 1).

Figure 2. Thrust Washer.

0116

0116-2

TM 5-2410-241-23-2

0116

REMOVAL CONTINUED

NOTE
Note orientation and position of axle shaft to aid installation. 3. Using adapter (Figure 3, Item 2), remove outer axle shaft (Figure 3, Item 3) from drive assembly (Figure 3, Item 1).

Figure 3. Outer Axle Shaft.

0116

NOTE
Inner axle shaft can only be removed from left side. Note orientation and position of axle shaft to aid installation.

4. Using installer (Figure 4, Item 2) remove inner axle shaft (Figure 4, Item 3) from drive assembly (Figure 4, Item 1).

Figure 4. Inner Axle Cap. END OF TASK

0116

0116-3

TM 5-2410-241-23-2

0116

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000116

000116

NOTE
The following procedure will install left side axle shaft. Follow the same steps for right side axle shaft. Inner axle shaft can only be installed from left side. Install axle shafts as noted during removal.

1. Using installer (Figure 5, Item 2), install inner axle shaft (Figure 5, Item 3) in drive assembly (Figure 5, Item 1).

Figure 5. Inner Axle Cap.

0116

0116-4

TM 5-2410-241-23-2

0116

INSTALLATION CONTINUED 2. Using adapter (Figure 6, Item 2), install outer axle shaft (Figure 6, Item 3) in drive assembly (Figure 6, Item 1).

Figure 6. Outer Axle Shaft. 3. Install thrust washer (Figure 7, Item 2) on drive assembly (Figure 7, Item 1).

0116

Figure 7. Thrust Washer.

0116

0116-5

TM 5-2410-241-23-2

0116

INSTALLATION CONTINUED 4. Install new O-ring (Figure 8, Item 5), cap (Figure 8, Item 2), three washers (Figure 8, Item 4) and bolts (Figure 8, Item 3) on drive assembly (Figure 8, Item 1).

Figure 8. Axle Cap. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0116

000116

0116-6

4 TM 5-2410-241-23-2 0117

FIELD MAINTENANCE MAIN DRIVE SHAFT REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 1 7

INITIAL SETUP Tools and Special Tools 0 Equipment Condition Machine parked (TM 5-2410-241-10) Middle bottom guards removed (WP 0199) Drawing Required TM 5-2410-241-24P, Figure 55 Estimated Time to Complete 2.0 Hr 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295 REMOVAL 0 0 0 0

000117

NOTE
Note position of bolts and washers to aid installation. 1. Remove eight bolts (Figure 1, Item 3), washers (Figure 1, Item 1) and main drive shaft (Figure 1, Item 2) from machine.

Figure 1. Main Drive Shaft.

0117

0117-1

TM 5-2410-241-23-2

0117

REMOVAL CONTINUED 2. Remove eight bolts (Figure 2, Item 1), washers (Figure 2, Item 2) and two universal joints (Figure 2, Item 4) from main drive shaft (Figure 2, Item 3).

Figure 2. U-Joint. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install two universal joints (Figure 2, Item 4), eight washers (Figure 2, Item 2), and bolts (Figure 2, Item 1) on main drive shaft (Figure 2, Item 3). Tighten bolts to 40 lb-ft (54 Nm).

0117

000117

000117

0117-2

TM 5-2410-241-23-2

0117

INSTALLATION CONTINUED

NOTE
Install washers and bolts as noted during removal. 2. Install main drive shaft (Figure 3, Item 2), eight washers (Figure 3, Item 1), and bolts (Figure 3, Item 3), on machine. Tighten bolts to 40 lb-ft (54 Nm).

Figure 3. Main Drive Shaft. END OF TASK FOLLOW-ON TASKS 1. Install middle bottom guards (WP 0199). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0117

000117

0117-3/(4 blank)

14 TM 5-2410-241-23-2 0118

FIELD MAINTENANCE POWERTRAIN LINES REPLACEMENT Flange Type Hose Removal, Flange and Threaded Fitting Type Hose Removal, Threaded Fitting Type Hose Removal, Cleaning and Inspection, Threaded Fitting Type Hose Installation, Flange and Threaded Fitting Type Hose Installation, Flange Type Hose Installation
0 1 1 8

INITIAL SETUP Tools and Special Tools 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Bottom guards removed (WP 0199) Front floor plate removed (WP 0230) Rear floor plate removed (WP 0231) Hydraulic system drained (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 52 Estimated Time to Complete 5.6 Hr 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Crowfoot Attachment, Socket Wrench, 1-3/8 (1/2 drive) (WP 0302, Item 19) 0 Crowfoot Attachment, Socket Wrench, 1-5/8 (1/2 drive) (WP 0302, Item 20) 0 Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) 0 Wrench, Open End, 1-1/2 and 1-5/8 (S0853) (WP 0302, Item 68) 0
0

Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (11)

0 0 0 0 0 0

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering and gloves. Lubricating/hydraulic oils used in performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow these warnings may result in injury or death to personnel.

0118-1

TM 5-2410-241-23-2

0118

CAUTION
Cap all hydraulic hose ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment. FLANGE TYPE HOSE REMOVAL
000118

NOTE
Hydraulic hoses, tubes, fittings, and clamps are all removed in generally the same method. This procedure covers removal of one hydraulic hose, and fitting from machine. Tag and mark all hoses, tubes, lines, and fittings to aid installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Note routing of hoses and tubes to aid installation. Cap all hydraulic hose ends along with component connections during removal to protect against contamination. This procedure will remove one hose with flange at each end. Follow the same procedure for additional hoses with flanges at each end.

1. Remove eight bolts (Figure 1, Item 5), washers (Figure 1, Item 4), and hose (Figure 1, Item 1) from machine. 2. Remove four flanges (Figure 1, Item 3) and two O-rings (Figure 1, Item 2) from hose (Figure 1, Item 1). Discard O-rings.

0118-2

TM 5-2410-241-23-2

0118

FLANGE TYPE HOSE REMOVAL CONTINUED

Figure 1. Flange Type Hydraulic Hose. END OF TASK

0118

0118-3

TM 5-2410-241-23-2

0118

FLANGE AND THREADED FITTING TYPE HOSE REMOVAL

000118

NOTE
Hydraulic hoses, tubes, fittings, and clamps are all removed in generally the same method. This procedure covers removal of one hydraulic hose and fitting from machine. Tag and mark all hoses, tubes, lines, and fittings to aid installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Note routing of hoses and tubes to aid installation. Cap all hydraulic hose ends along with component connections during removal to protect against contamination. This procedure will remove one hose with flange at one end and threaded fitting at other end. Follow the same procedure for additional hoses with flanges at one end and threaded fitting at other end.

1. Remove four bolts (Figure 2, Item 12), washers (Figure 2, Item 11), and hose (Figure 2, Item 5) from pump (Figure 2, Item 13). Position hose aside. 2. Remove two flanges (Figure 2, Item 10) and O-rings (Figure 2, Item 9) from hose (Figure 2, Item 5). Discard Orings. 3. Loosen tube nut (Figure 2, Item 4) and remove hose (Figure 2, Item 5) from fitting (Figure 2, Item 2). 4. Remove fitting (Figure 2, Item 2) and two O-rings (Figure 2, Items 1 and 3) from filter base (Figure 2, Item 14). Discard O-rings. 5. Remove two bolts (Figure 2, Item 6), washers (Figure 2, Item 7) and clamps (Figure 2, Item 8) from hose (Figure 2, Item 5). 6. Remove hose (Figure 2, Item 5) from machine.

0118-4

TM 5-2410-241-23-2

0118

FLANGE AND THREADED FITTING TYPE HOSE REMOVAL CONTINUED

Figure 2. Hydraulic Hose. END OF TASK

0118

0118-5

TM 5-2410-241-23-2

0118

THREADED FITTING TYPE HOSE REMOVAL

000118

NOTE
Hydraulic hoses, tubes, fittings, and clamps are all removed in generally the same method. This procedure covers removal of one hydraulic hose and fitting from machine. Tag and mark all hoses, tubes, lines, and fittings, to aid installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Note routing of hoses and tubes to aid installation. Cap all hydraulic hose ends along with component connections during removal to protect against contamination. This procedure will remove one hose with threaded fitting at each end. Follow the same procedure for additional hoses with threaded fittings at each end.

1. Loosen tube nut (Figure 3, Item 4) and remove hose (Figure 3, Item 11) from fitting (Figure 3, Item 1). 2. Loosen tube nut (Figure 3, Item 10) and remove hose (Figure 3, Item 11) from fitting (Figure 3, Item 6). 3. Remove bolt (Figure 3, Item 12), washer (Figure 3, Item 13) and clamp (Figure 3, Item 14) from hose (Figure 2, Item 11). 4. Remove hose (Figure 3, Item 11) from machine. 5. Remove fitting (Figure 3, Item 6) and two O-rings (Figure 3, Items 8 and 7) from filter base (Figure 3, Item 9). Discard O-rings. 6. Loosen tube nut (Figure 3, Item 3) and remove hose (Figure 3, Item 5) from fitting (Figure 3, Item 1). 7. Remove fitting (Figure 3, Item 1) and three O-rings (Figure 3, Items 2 and 16) from fuel tank (Figure 3, Item 15). Discard O-rings.

0118-6

TM 5-2410-241-23-2

0118

THREADED FITTING TYPE HOSE REMOVAL CONTINUED

Figure 3. Threaded Fitting Type Hydraulic Hose. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0118

000118

0118-7

TM 5-2410-241-23-2

0118

THREADED FITTING TYPE HOSE INSTALLATION

000118

NOTE
Hydraulic hoses, fittings, and clamps are all installed in generally the same method. This procedure covers installation of one hydraulic hose assembly on machine. This procedure will install one hose with threaded fitting at each end. Follow the same procedure for additional hoses with threaded fittings at each end. Install hoses and fittings as noted during removal.

1. Install three new O-rings (Figure 4, Items 2 and 16) and fitting (Figure 4, Item 1) on fuel tank (Figure 4, Item 15). 2. Install hose (Figure 4, Item 5) and tube nut (Figure 4, Item 3) on fitting (Figure 4, Item 1). 3. Install two new O-rings (Figure 4, Items 8 and 7) and fitting (Figure 4, Item 6) on filter base (Figure 4, Item 9). 4. Install hose (Figure 4, Item 11) on machine. 5. Install clamp (Figure 4, Item 14), washer (Figure 4, Item 13) and bolt (Figure 4, Item 12) on hose (Figure 4, Item 11). 6. Install hose (Figure 4, Item 11) and tube nut (Figure 4, Item 10) on fitting (Figure 4, Item 6). 7. Install hose (Figure 4, Item 11) and tube nut (Figure 4, Item 4) on fitting (Figure 4, Item 1).

0118-8

TM 5-2410-241-23-2

0118

THREADED FITTING TYPE HOSE INSTALLATION CONTINUED

Figure 4. Threaded Fitting Type Hydraulic Hose. END OF TASK

0118

0118-9

TM 5-2410-241-23-2

0118

FLANGE AND THREADED FITTING TYPE HOSE INSTALLATION

000118

NOTE
Hydraulic hoses, fittings, and clamps are all installed in generally the same method. This procedure covers installation of one hydraulic hose assembly on machine. This procedure will install one hose with flange at one end and threaded fitting at other end. Follow the same procedure for additional hoses with flanges at one end and threaded fitting at other end. Install lines and hoses as noted during removal.

1. Install hose (Figure 5, Item 5) on machine. 2. Install two clamps (Figure 5, Item 8), washers (Figure 5, Item 7), and bolts (Figure 5, Item 6) on hose (Figure 5, Item 5). 3. Install two new O-rings (Figure 5, Items 1 and 3) and fitting (Figure 5, Item 2) on filter base (Figure 5, Item 14). 4. Install hose (Figure 5, Item 5) and tube nut (Figure 5, Item 4) on fitting (Figure 5, Item 2). 5. Install new O-ring (Figure 5, Item 9) and two flanges (Figure 5, Item 10) on hose (Figure 5, Item 5). 6. Install hose (Figure 5, Item 5), four washers (Figure 5, Item 11), and bolts (Figure 5, Item 12) on pump (Figure 5, Item 13).

0118-10

TM 5-2410-241-23-2

0118

FLANGE AND THREADED FITTING TYPE HOSE INSTALLATION CONTINUED

Figure 5. Hydraulic Hose. END OF TASK

0118

0118-11

TM 5-2410-241-23-2

0118

FLANGE TYPE HOSE INSTALLATION

000118

NOTE
Hydraulic hoses, fittings, and clamps are all installed in generally the same method. This procedure covers installation of one hydraulic hose assembly on machine. This procedure will install one hose with flange at each end. Follow the same procedure for additional hoses with flange at each end. Install lines and hoses as noted during removal.

1. Install two O-rings (Figure 6, Item 2) and four flanges (Figure 6, Item 3) on hose (Figure 6, Item 1). 2. Install hose (Figure 6, Item 1), eight washers (Figure 6, Item 4), and bolts (Figure 6, Item 5) on machine.

Figure 6. Flange Type Hydraulic Hose. END OF TASK

0118

0118-12

TM 5-2410-241-23-2

0118

FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Install bottom guards (WP 0199). 3. Install rear floor plate (WP 0231). 4. Install front floor plate (WP 0230). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000118

0118-13/(14 blank)

6 TM 5-2410-241-23-2 0119

FIELD MAINTENANCE
0 1 1 9

POWERTRAIN MANIFOLD REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Transmission oil drained (WP 0151) Drawing Required TM 5-2410-241-24P, Figure 52 Estimated Time to Complete 2.5 Hr 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Pliers Set, Retaining Ring (S0260) (WP 0302, Item 68) 0 Wrench, Open End, 1-1/2 x 1-5/8 (S0853) (WP 0302, Item 68) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (10) 0 0 0 0

0119-1

TM 5-2410-241-23-2

0119

REMOVAL

000119

NOTE
Tag and mark all hoses to aid installation. 1. Remove 12 bolts (Figure 1, Item 6), washers (Figure 1, Item 7), 6 flanges (Figure 1, Item 8), and 3 hoses (Figure 1, Item 5) from manifold (Figure 1, Item 2). 2. Remove three O-rings (Figure 1, Item 9) from hoses (Figure 1, Item 5). Discard O-rings. 3. Loosen tube nut (Figure 1, Item 13) and remove hose (Figure 1, Item 14) from manifold (Figure 1, Item 2). 4. Remove O-ring (Figure 1, Item 12) from fitting (Figure 1, Item 11). Discard O-ring. 5. Remove fitting (Figure 1, Item 11) and O-ring (Figure 1, Item 10) from manifold (Figure 1, Item 2). Discard O-ring. 6. Remove four bolts (Figure 1, Item 3), washers (Figure 1, Item 4), and manifold (Figure 1, Item 2) from chassis (Figure 1, Item 1).

Figure 1. Manifold.

0119

0119-2

TM 5-2410-241-23-2

0119

REMOVAL CONTINUED

NOTE
Note size and position of O-rings to aid installation. 7. Remove three O-rings (Figure 2, Item 5) from manifold (Figure 2, Item 1). Discard O-rings. 8. Remove cap (Figure 2, Item 4), fitting (Figure 2, Item 3), and O-ring (Figure 2, Item 2) from manifold (Figure 2, Item 1). Discard O-ring. 9. Remove retaining ring (Figure 2, Item 6), retainer (Figure 2, Item 7), valve (Figure 2, Item 8), and O-ring (Figure 2, Item 9) from manifold (Figure 2, Item 1). Discard O-ring.

Figure 2. Valve. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0119

000119

0119-3

TM 5-2410-241-23-2

0119

INSTALLATION 1. Install new O-ring (Figure 3, Item 9), valve (Figure 3, Item 8), retainer (Figure 3, Item 7), and retaining ring (Figure 3, Item 6) on manifold (Figure 3, Item 1).

000119

2. Install new O-ring (Figure 3, Item 2), fitting (Figure 3, Item 3), and cap (Figure 3, Item 4) on manifold (Figure 3, Item 1).

NOTE
Install O-rings as noted during removal. 3. Install three new O-rings (Figure 3, Item 5) on manifold (Figure 3, Item 1).

Figure 3. Valve.

0119

0119-4

TM 5-2410-241-23-2

0119

INSTALLATION CONTINUED

NOTE
Install all hoses as noted during removal. 4. Install manifold (Figure 4, Item 2), four washers (Figure 4, Item 4), and bolts (Figure 4, Item 3) on chassis (Figure 4, Item 1). 5. Install O-ring (Figure 4, Item 10) and fitting (Figure 4, Item 11) on manifold (Figure 4, Item 2). 6. Install new O-ring (Figure 4, Item 12) on fitting (Figure 1, Item 11). 7. Install hose (Figure 4, Item 14) and tube nut (Figure 4, Item 13) on manifold (Figure 4, Item 2). 8. Install three new O-rings (Figure 4, Item 9) on hoses (Figure 4, Item 5). 9. Install 3 hoses (Figure 4, Item 5), 6 flanges (Figure 4, Item 8), 12 washers (Figure 4, Item 7), and bolts (Figure 4, Item 6) on manifold (Figure 4, Item 2).

Figure 4. Manifold. END OF TASK FOLLOW-ON TASKS 1. Install transmission oil (WP 0151). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0119

000119

0119-5/(6 blank)

6 TM 5-2410-241-23-2 0120

FIELD MAINTENANCE COUPLING REPLACEMENT Removal, Cleaning and Inspection, Installation

0 1 2 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Light, Extension, Fluorescent (S0246) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) References WP 0295 0 0 0 Personnel Required 0 0 0 0 0 Two Drawing Required TM 5-2410-241-24P, Figure 56 Estimated Time to Complete 4.5 Hr
000120

Equipment Condition Machine parked (TM 5-2410-241-10) Bottom guards removed (WP 0199) Front floor plate removed (WP 0230)

0 0 0 0 0 0 0 0 0 0

REMOVAL 1. Remove two bolts (Figure 1, Item 3), washers (Figure 1, Item 4) and clamp (Figure 1, Item 2) from plate (Figure 1, Item 5). Position hoses (Figure 1, Item 1) aside.

Figure 1. Hydraulic Hose.

0120

0120-1

TM 5-2410-241-23-2

0120

REMOVAL CONTINUED 2. Remove tiedown straps (Figure 2, Item 2) from bracket (Figure 2, Item 5). Discard tiedown straps. 3. Disconnect connector (Figure 2, Item 3) from connector (Figure 2, Item 4). Position harness (Figure 2, Item 1) aside.

Figure 2. Harness.

0120

4. Remove six bolts (Figure 3, Item 2), washers (Figure 3, Item 1), and two guards (Figure 3, Item 3) from bracket (Figure 3, Item 4). 5. Remove four bolts (Figure 3, Item 5), washers (Figure 3, Item 6), and bracket (Figure 3, Item 4) from machine.

Figure 3. Guards.

0120

0120-2

TM 5-2410-241-23-2

0120

REMOVAL CONTINUED

NOTE
Note orientation and location of bolts to aid installation. 6. Remove six bolts (Figure 4, Item 2), washers (Figure 4, Item 3), and shaft (Figure 4, Item 1) from machine. 7. Remove six bolts (Figure 4, Item 6), washers (Figure 4, Item 5), and two couplings (Figure 4, Item 4) from shaft (Figure 4, Item 1).

Figure 4. Couplings. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0120

000120

0120-3

TM 5-2410-241-23-2

0120

INSTALLATION

000120

NOTE
Install bolts as noted during removal. 1. Install two couplings (Figure 5, Item 4), six washers (Figure 5, Item 5), and bolts (Figure 5, Item 6) on shaft (Figure 5, Item 1). 2. Install shaft (Figure 5, Item 1), six washers (Figure 5, Item 3), and bolts (Figure 5, Item 2) on machine.

Figure 5. Couplings. 3. Install bracket (Figure 6, Item 4), four washers (Figure 6, Item 6), and bolts (Figure 6, Item 5) on machine. 4. Install two guards (Figure 6, Item 3), six washers (Figure 6, Item 1), and bolts (Figure 6, Item 2) on bracket (Figure 6, Item 4).

0120

Figure 6. Guards.

0120

0120-4

TM 5-2410-241-23-2

0120

INSTALLATION CONTINUED 5. Position harness (Figure 7, Item 1) and connect connector (Figure 7, Item 4) to connector (Figure 7, Item 3). 6. Install new tiedown straps (Figure 7, Item 2) on harness (Figure 7, Item 1) and bracket (Figure 7, Item 5).

Figure 7. Harness.

0120

7. Install clamp (Figure 8, Item 2), two washers (Figure 8, Item 4) and bolts (Figure 8, Item 3) on hoses (Figure 8, Item 1) and plate (Figure 8, Item 5).

Figure 8. Hydraulic Hose. END OF TASK

0120

0120-5

TM 5-2410-241-23-2

0120

FOLLOW-ON TASKS 1. Install bottom guards (WP 0199). 2. Install front floor plate (WP 0230). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000120

0120-6

4 TM 5-2410-241-23-2 0121

FIELD MAINTENANCE INSTRUCTIONS

0 1 2 1

TRANSMISSION MOUNTING REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Locknut (4) References WP 0295 0 0 0 0 0 0 Personnel Required Two Equipment Condition Machine parked (TM 5-2410-241-10) Transmission removed (WP 0142) Drawing Required TM 5-2410-241-24P, Figure 69 Estimated Time to Complete 14.0 Hr 0 0 0 0 0 0 0 0 0

0121-1

TM 5-2410-241-23-2

0121

REMOVAL 1. Remove four locknuts (Figure 1, Item 1), washers (Figure 1, Item 2), bolts (Figure 1, Item 7), and washers (Figure 1, Item 8) from two tube assemblies (Figure 1, Item 3). Discard locknuts. 2. Remove two tube assemblies (Figure 1, Item 3) from machine.

000121

3. Remove spring pin (Figure 1, Item 4), two washers (Figure 1, Item 5), and springs (Figure 1, Item 6) from tube assembly (Figure 1, Item 3). 4. Repeat step 3 for other tube assembly.

Figure 1. Transmission Mounting Tubes. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0121

000121

0121-2

TM 5-2410-241-23-2

0121

INSTALLATION 1. Install two springs (Figure 1, Item 6), washers (Figure 1, Item 5), and spring pin (Figure 1, Item 4) on tube assembly (Figure 1, Item 3). 2. Repeat step 1 for other tube assembly. 3. Install two tube assemblies (Figure 1, Item 3) on machine. 4. Install four washers (Figure 1, Item 8), bolts (Figure 1, Item 7), washers (Figure 1, Item 2), and new locknuts (Figure 1, Item 1) on two tube assemblies (Figure 1, Item 3). END OF TASK FOLLOW-ON TASKS 1. Install transmission (WP 0142). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000121

000121

0121-3/(4 blank)

6 TM 5-2410-241-23-2 0122

FIELD MAINTENANCE
0 1 2 2

TORQUE CONVERTER OUTPUT SPEED SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation, Adjustment

INITIAL SETUP Tools and Special Tools 0 References WP 0295 WP 0298 Equipment Condition Machine parked (TM 5 2410-241-10) Front floor plate removed (WP 0230) Drawing Required TM 5-2410-241-24P, Figure 11 Estimated Time to Complete 2.0 Hr 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Crowfoot Attachment, 3/8 Drive, 3/4 (S0168) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) 0 0 0 0

0122-1

TM 5-2410-241-23-2

0122

REMOVAL

000122

NOTE
Tag and mark all electrical connections to aid installation. 1. Remove tiedown strap (Figure 1, Item 2) from connector (Figure 1, Item 1). 2. Disconnect connector (Figure 1, Item 3) from connector (Figure 1, Item 1).

Figure 1. Harness Connector.

0122

0122-2

TM 5-2410-241-23-2

0122

REMOVAL CONTINUED 3. Loosen nut (Figure 2, Item 2) and remove sensor (Figure 2, Item 3) from housing (Figure 2, Item 1).

Figure 2. Converter Sensor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Center gear tooth (Figure 3, Item 5) to align with sensor (Figure 3, Item 1). 2. Install sensor (Figure 3, Item 1) until sensor tip (Figure 3, Item 4) touches gear tooth (Figure 3, Item 5). 3. Set gap between sensor tip (Figure 3, Item 4) and gear tooth (Figure 3, Item 5) by turning sensor (Figure 3, Item 1) 180 degrees counterclockwise. 4. Hold sensor (Figure 3, Item 1) and tighten jam nut (Figure 3, Item 2) to 18 lb-ft (25 Nm) on housing (Figure 3, Item 3). Refer to Torque Limits (WP 0298).

0122

000122

000122

Figure 3. Sensor Adjustment.

0122

0122-3

TM 5-2410-241-23-2

0122

INSTALLATION CONTINUED

NOTE
Install electrical connections as noted during removal. 5. Connect connector (Figure 4, Item 3) on connector (Figure 4, Item 1). 6. Install new tiedown strap (Figure 4, Item 2) on connector (Figure 4, Item 1).

Figure 4. Harness Connector. END OF TASK

0122

0122-4

TM 5-2410-241-23-2

0122

ADJUSTMENT

000122

NOTE
Tag and mark all electrical connections to aid installation. Refer to Torque Limits (WP 0298).

1. Remove tiedown strap (Figure 4, Item 2) from connector (Figure 4, Item 1). 2. Disconnect connector (Figure 4, Item 3) from connector (Figure 4, Item 1). 3. Loosen nut (Figure 5, Item 2) and remove sensor (Figure 5, Item 1) from housing (Figure 5, Item 3). 4. Center gear tooth (Figure 5, Item 5) to align with sensor (Figure 5, Item 1). 5. Install sensor (Figure 5, Item 1) until sensor tip (Figure 5, Item 4) touches gear tooth (Figure 5, Item 5). 6. Set gap between sensor tip (Figure 5, Item 4) and gear tooth (Figure 5, Item 5) by turning sensor (Figure 5, Item 1) 180 degrees counterclockwise. 7. Hold sensor (Figure 5, Item 1) and tighten jam nut (Figure 5, Item 2) to 18 lb-ft (25 Nm) on housing (Figure 5, Item 3).

Figure 5. Sensor Adjustment.

0122

0122-5

TM 5-2410-241-23-2

0122

ADJUSTMENT CONTINUED

NOTE
Install electrical connections as noted during removal. 8. Connect connector (Figure 6, Item 3) on connector (Figure 6, Item 1). 9. Install new tiedown strap (Figure 6, Item 2) on connector (Figure 6, Item 1).

Figure 6. Harness Connector. END OF TASK FOLLOW-ON TASKS 1. Install front floor plate (WP 0230). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0122

000122

0122-6

6 TM 5-2410-241-23-2 0123

FIELD MAINTENANCE TORQUE CONVERTER RELIEF VALVE SERVICE Removal, Cleaning and Inspection, Installation, Test and Adjustment
0 1 2 3

INITIAL SETUP Tools and Special Tools 0 Materials/Parts - Continued 5M-9623 SHIM (0.9-MM THK) References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Middle bottom guards removed (WP 0199) Front floor plate removed (WP 0230) Drawing Required TM 5-2410-241-24P, Figure 52 Estimated Time to Complete 4.5 Hr REMOVAL
000123

0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Gauge, Pressure, Dial Indicating (5,800 psi) (WP 0302, Item 29) 0 Gauge Kit, Pressure, Dial Indicating (WP 0302, Item 28) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (6) 0 0 0 0 0

NOTE
Tag and mark all hoses to aid installation. 1. Loosen tube nut (Figure 1, Item 3) and remove hose (Figure 1, Item 4) from fitting (Figure 1, Item 1). 2. Remove O-ring (Figure 1, Item 2) from fitting (Figure 1, Item 1). Discard O-ring.

Figure 1. Pressure Check Hose.

0123

0123-1

TM 5-2410-241-23-2

0123

REMOVAL CONTINUED

NOTE
Tag and mark all electrical connections to aid installation. 3. Remove tiedown straps (Figure 2, Item 8) from harness (Figure 2, Item 4). Discard tiedown straps. 4. Disconnect connector (Figure 2, Item 7) from temperature sensor (Figure 2, Item 9). 5. Position harness (Figure 2, Item 4) aside. 6. Remove four bolts (Figure 2, Item 13) and washers (Figure 2, Item 14) from line (Figure 2, Item 12). 7. Loosen line (Figure 2, Item 12) from torque converter output relief valve (Figure 2, Item 5). 8. Remove three bolts (Figure 2, Item 2), washers (Figure 2, Item 1), clips (Figure 2, Item 3), and torque converter outlet relief valve (Figure 2, Item 5) from machine. 9. Remove three O-rings (Figure 2, Item 6) from torque converter outlet relief valve (Figure 2, Item 5) and line (Figure 2, Item 12). Discard O-rings.

NOTE
Note position and orientation of fitting to aid installation. 10. Remove fitting (Figure 2, Item 10) and O-ring (Figure 2, Item 11) from torque converter outlet relief valve (Figure 2, Item 5). Discard O-ring.

Figure 2. Torque Converter Output Relief Valve. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0123

000123

0123-2

TM 5-2410-241-23-2

0123

INSTALLATION

000123

NOTE
Install fitting as noted during removal. Install electrical connections as noted during removal.

1. Install new O-ring (Figure 2, Item 11) and fitting (Figure 2, Item 10) on torque converter outlet relief valve (Figure 2, Item 5). 2. Install three new O-rings (Figure 2, Item 6) on torque converter outlet relief valve (Figure 2, Item 5). 3. Install torque converter outlet relief valve (Figure 2, Item 5), three clips (Figure 2, Item 3), washers (Figure 2, Item 1) and bolts (Figure 2, Item 2) on machine. 4. Install line (Figure 2, Item 12), four washers (Figure 2, Item 14), and bolts (Figure 2, Item 13), on torque converter output relief valve (Figure 2, Item 5).

NOTE
Install electrical connections and harness as noted during removal. 5. Position harness (Figure 2, Item 4) on machine. 6. Connect connector (Figure 2, Item 7) on temperature sensor (Figure 2, Item 9). 7. Install new tiedown straps (Figure 2, Item 8) on harness (Figure 2, Item 4).

NOTE
Install hoses as noted during. 8. Install new O-ring (Figure 3, Item 2) on fitting (Figure 3, Item 1). 9. Install hose (Figure 3, Item 4) and tube nut (Figure 3, Item 3) on fitting (Figure 3, Item 1).

Figure 3. Pressure Check Hose. END OF TASK

0123

0123-3

TM 5-2410-241-23-2

0123

TEST AND ADJUSTMENT 1. Remove cap (Figure 4, Item 2) from fitting (Figure 4, Item 1). 2. Install pressure gauge on fitting (Figure 4, Item 1). 3. Start engine. Powertrain oil must be at operating temperature. 4. With park brake disengaged and steering control lever in the NEUTRAL position, run engine at HIGH IDLE (2100 RPM). 5. Pressure gauge should read 75 10 psi (515 70 kPa). 6. With park brake disengaged and steering control lever in the NEUTRAL position, run engine at LOW IDLE (800 RPM). 7. Pressure gauge should read 55 10 psi (380 70 kPa).

000123

Figure 4. Test Port.

0123

NOTE
One shim changes pressure setting by 2.4 psi (16.5 kPa). Adding shims will raise pressure. Removing shims will lower pressure. 8. Park machine (TM 5-2410-241-10).

WARNING

Hot oil and hot components can cause injury. Do not allow hot oil or hot components to contact skin. Failure to follow this warning may result in injury to personnel. 9. If the pressure is incorrect, adjust pressure by removing or adding shims (Figure 5, Item 11) as follows:

NOTE
Tag and mark all electrical connections. a. Remove tiedown strap (Figure 5, Item 3) and disconnect connector (Figure 5, Item 4) from harness (Figure 5, Item 2). Position harness aside.

0123-4

TM 5-2410-241-23-2

0123

TEST AND ADJUSTMENT CONTINUED

NOTE
There will be spring tension on the cap. b. Remove two bolts (Figure 5, Item 9), washers (Figure 5, Item 10), cap (Figure 5, Item 8), and O-ring (Figure 5, Item 12) from torque converter relief valve (Figure 5, Item 1). Discard O-ring.

NOTE
c. One shim changes pressure setting by 2.4 psi (16.5 kPa). Adding shims will raise pressure. Removing shims will lower pressure. Note number of shims removed from valve.

Remove valve (Figure 5, Item 7), shims (Figure 5, Item 11), spring (Figure 5, Item 6), and spring (Figure 5, Item 5) from torque converter relief valve (Figure 5, Item 1).

d. If pressure is low, shims (Figure 5, Item 11) must be added. e. If pressure is high, shims (Figure 5, Item 11) must be taken out.

NOTE
f. One shim changes pressure setting by 2.4 psi (16.5 kPa). Adding shims will raise pressure. Removing shims will lower pressure. Install shims as needed for proper torque converter outlet pressure.

Install spring (Figure 5, Item 5), spring (Figure 5, Item 6), shims (Figure 5, Item 11), and valve (Figure 5, Item 7) on torque converter relief valve (Figure 5, Item 1).

g. Install new O-ring (Figure 5, Item 12), cap (Figure 5, Item 8), two washers (Figure 5, Item 10), and bolts (Figure 5, Item 9) on torque converter relief valve (Figure 5, Item 1).

NOTE
Install electrical connections as noted during removal. h. Connect connector (Figure 5, Item 4) and install new tiedown strap (Figure 5, Item 3) on harness (Figure 5, Item 2).

Figure 5. Adjustment.

0123

0123-5

TM 5-2410-241-23-2

0123

TEST AND ADJUSTMENT CONTINUED 10. Start engine. Powertrain oil must be at operating temperature. 11. With park brake disengaged and steering control lever in the NEUTRAL position, run engine at HIGH IDLE (2100 RPM). 12. Pressure gauge should read 75 10 psi (515 70 kPa). 13. With park brake disengaged and steering control lever in the NEUTRAL position, run engine at LOW IDLE (800 RPM). 14. Pressure gauge should read 55 10 psi (380 70 kPa). 15. If pressures are incorrect, repeat steps 8 thru 14. 16. Remove pressure gauge from fitting (Figure 6, Item 1). 17. Install cap (Figure 6, Item 2) on fitting (Figure 6, Item 1).

Figure 6. Test Port. END OF TASK FOLLOW-ON TASKS 1. Verify correct operation of machine (TM 5-2410-241-10). 2. Install front floor plate (WP 0230). 3. Install middle bottom guards (WP 0199). END OF TASK END OF WORK PACKAGE

0123

000123

0123-6

4 TM 5-2410-241-23-2 0124

FIELD MAINTENANCE
0 1 2 4

TORQUE CONVERTER RELIEF VALVE TEMPERATURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Middle bottom guards removed (WP 0199) Front floor plate removed (WP 0230) Drawing Required TM 5-2410-241-24P, Figure 52 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0 0 0 0

0124-1

TM 5-2410-241-23-2

0124

REMOVAL

000124

NOTE
Tag and mark all electrical connections to aid installation. 1. Remove tiedown strap (Figure 1, Item 4) from connector (Figure 1, Item 5). Discard tiedown straps. 2. Disconnect connector (Figure 1, Item 5) from temperature sensor (Figure 1, Item 1). 3. Remove temperature sensor (Figure 1, Item 1) and O-ring (Figure 1, Item 2) from torque converter relief valve (Figure 1, Item 3). Discard O-ring.

Figure 1. Temperature Sensor. END OF TASK

0124

NOTE
CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK
000124

0124-2

TM 5-2410-241-23-2

0124

INSTALLATION

000124

NOTE
Install electrical connections as noted during removal. 1. Install new O-ring (Figure 1, Item 2) and temperature sensor (Figure 1, Item 1) on torque converter relief valve (Figure 1, Item 3). 2. Connect connector (Figure 1, Item 5) on temperature sensor (Figure 1, Item 1). 3. Install new tiedown strap (Figure 1, Item 4) on connector (Figure 1, Item 5). END OF TASK FOLLOW-ON TASKS 1. Verify correct operation of machine (TM 5-2410-241-10). 2. Install front floor plate (WP 0230). 3. Install middle bottom guards (WP 0199). END OF TASK END OF WORK PACKAGE
000124

0124-3/(4 blank)

6 TM 5-2410-241-23-2 0125

FIELD MAINTENANCE EQUALIZER BAR PAD REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 2 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Wood Block 12 x 12 x 24 Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295 REMOVAL 0 0 0 0 0 0 0
000125

Equipment Condition Machine parked (TM 5-2410-241-10) Bottom guards removed (WP 0199) Drawing Required TM 5-2410-241-24P, Figure 57 Estimated Time to Complete 5.5 Hr

0 0 0 0 0 0 0

NOTE
Procedure will remove right side equalizer bar pad. Follow same procedure for left side equalizer bar pads. Lifting track on one side allows maximum clearance between frame and equalizer bar on opposite side.

1. Position left side of track (Figure 1, Item 1) on blocks (Figure 1, Item 2).

Figure 1. Blocks.

0125

0125-1

TM 5-2410-241-23-2

0125

REMOVAL CONTINUED

NOTE
Note location and size of bolts to aid installation. 2. Remove two nuts (Figure 2, Item 3), bolts (Figure 2, Item 11), and four washers (Figure 2, Item 10) from outside edge of lower pad (Figure 2, Item 9) and upper pad (Figure 2, Item 4). 3. Loosen two nuts (Figure 2, Item 5), bolts (Figure 2, Item 8), four washers (Figure 2, Item 7), and two spacers (Figure 2, Item 6) from inside edge of lower pad (Figure 2, Item 9) and upper pad (Figure 2, Item 4). 4. Remove two bolts (Figure 2, Item 2) and washers (Figure 2, Item 1) from equalizer bar (Figure 2, Item 12). 5. Remove lower pad (Figure 2, Item 9). 6. Remove upper pad (Figure 2, Item 4). 7. Remove two nuts (Figure 2, Item 5), bolts (Figure 2, Item 8), four washers (Figure 2, Item 7), and two spacers (Figure 2, Item 6) from upper pad (Figure 2, Item 4).

Figure 2. Pads.

0125

0125-2

TM 5-2410-241-23-2

0125

REMOVAL CONTINUED 8. Remove left side of track (Figure 3, Item 1) from blocks (Figure 3, Item 2).

Figure 3. Blocks. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0125

000125

0125-3

TM 5-2410-241-23-2

0125

INSTALLATION

000125

NOTE
Procedure will install right side equalizer bar pad. Follow the same procedure for left side equalizer bar pads. Lifting track on one side allows maximum clearance between frame and equalizer bar on opposite side.

1. Position left side of track (Figure 4, Item 1) on blocks (Figure 4, Item 2).

Figure 4. Blocks.

0125

0125-4

TM 5-2410-241-23-2

0125

INSTALLATION CONTINUED

NOTE
Install bolts as noted during removal. 2. Loosely install two spacers (Figure 5, Item 6), four washers (Figure 5, Item 7), two bolts (Figure 5, Item 8), and nuts (Figure 5, Item 5) on upper pad (Figure 5, Item 4). 3. While holding upper pad (Figure 5, Item 4) in installed position, slide lower pad (Figure 5, Item 9) below it so two slots engage with spacers (Figure 5, Item 6) on upper pad. 4. Install two washers (Figure 5, Item 1) and bolts (Figure 5, Item 2) on equalizer bar (Figure 5, Item 12). 5. Install four washers (Figure 5, Item 10), bolts (Figure 5, Item 11), and two nuts (Figure 5, Item 3) on outside edge of lower pad (Figure 5, Item 9) and upper pad (Figure 5, Item 4). 6. Tighten two spacers (Figure 5, Item 6), four washers (Figure 5, Item 7), two bolts (Figure 5, Item 8), and nuts (Figure 5, Item 5) on inside edge of lower pad (Figure 5, Item 9) and upper pad (Figure 5, Item 4).

Figure 5. Pads.

0125

0125-5

TM 5-2410-241-23-2

0125

INSTALLATION CONTINUED 7. Remove left side of track (Figure 6, Item 1) from blocks (Figure 6, Item 2).

Figure 6. Blocks. END OF TASK FOLLOW-ON TASKS 1. Install bottom guards (WP 0199). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0125

000125

0125-6

8 TM 5-2410-241-23-2 0126

FIELD MAINTENANCE ACCUMULATOR SERVICE Removal, Cleaning and Inspection, Installation, Test, Charge Accumulator
0 1 2 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Charging Kit, Pressuring (Nitrogen) (WP 0302, Item 16) Crowfoot Attachment, Socket Wrench, 1-5/8 (1/2 drive) (WP 0302, Item 20) Gauge, Pressure, Dial Indicating (5,800 psi) (WP 0302, Item 29) Goggles (S0209) (WP 0302, Item 68) Wrench, Combination, 1-7/8 (S0798) (WP 0302, Item 68) Wrench, Combination, 1-3/8 (S0791) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Nitrogen, Technical, Dry Cylinder (WP 0303, Item 39) 0 0 0 References 0 0 0 0 0 0 0 0 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Rear floor plate removed (WP 0231) Drawing Required TM 5-2410-241-24P, Figure 52 Estimated Time to Complete 4.0 Hr 0 0 0 0 0 0 0 0 0 Materials/Parts - Continued Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (5) 0 0 0 0

0126-1

TM 5-2410-241-23-2

0126

REMOVAL 1. Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and clamps (Figure 1, Item 4) from accumulator (Figure 1, Item 3).

000126

Figure 1. Accumulator Bolts.

0126

0126-2

TM 5-2410-241-23-2

0126

REMOVAL CONTINUED

NOTE
Tag and mark hoses and lines to aid installation. Cap and plug all open hoses and ports to avoid contamination.

2. Loosen two tube nuts (Figure 2, Item 3) and remove hose (Figure 2, Item 5) from tee (Figure 2, Item 1) and elbow (Figure 2, Item 7). 3. Loosen tube nut (Figure 2, Item 4) and remove hose (Figure 2, Item 10) from tee (Figure 2, Item 1). 4. Remove tee (Figure 2, Item 1) and three O-rings (Figure 2, Items 2 and 11) from machine. Discard O-rings. 5. Remove accumulator (Figure 2, Item 6) from machine.

NOTE
Note orientation of elbow to aid installation. 6. Remove elbow (Figure 2, Item 7) and two O-rings (Figure 2, Items 8 and 9) from accumulator (Figure 2, Item 6). Discard O-rings.

Figure 2. Threaded Fitting Type Hydraulic Hose. END OF TASK

0126

0126-3

TM 5-2410-241-23-2

0126

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000126

000126

NOTE
A new accumulator must be charged before installation. Refer to Charge Accumulator in this work package. Install hoses and lines as noted during removal.

1. Charge new accumulator (Figure 2, Item 6). 2. Install two new O-rings (Figure 2, Items 8 and 9) and elbow (Figure 2, Item 7) on accumulator (Figure 2, Item 6).

NOTE
Install hose on elbow as noted during removal. 3. Install accumulator (Figure 2, Item 6) on machine. 4. Install three new O-rings (Figure 2, Items 2 and 11) and tee (Figure 2, Item 1) on machine. 5. Install hose (Figure 2, Item 10) and tube nut (Figure 2, Item 4) on tee (Figure 2, Item 1). 6. Install hose (Figure 2, Item 5) and two tube nuts (Figure 2, Item 3) on tee (Figure 2, Item 1) and elbow (Figure 2, Item 7). 7. Install two clamps (Figure 3, Item 4), washers (Figure 3, Item 2), and bolts (Figure 3, Item 1) on accumulator (Figure 3, Item 3).

Figure 3. Accumulator Bolts. END OF TASK

0126

0126-4

TM 5-2410-241-23-2

0126

TEST

000126

NOTE
The following steps will determine if accumulator is charged to appropriate pressure. 1. Move machine to a smooth horizontal location. 2. Lower all implements (TM 5-2410-241-10). 3. Engage parking brake and shut down engine (TM 5-2410-241-10). 4. Allow machine to sit for two minutes before attaching gauges to allow pressure and temperature to stabilize. 5. Remove two bolts (Figure 4, Item 3) and protective strap (Figure 4, Item 1) from accumulator (Figure 4, Item 2). 6. Remove protective cap (Figure 4, Item 5) from valve (Figure 4, Item 4) on accumulator (Figure 4, Item 2).

Figure 4. Accumulator Pressure.

0126

0126-5

TM 5-2410-241-23-2

0126

TEST CONTINUED

WARNING
Dry nitrogen is the only gas approved for use in accumulator. Any other gas may cause failure of accumulator or injury to personnel.

NOTE
Accumulator charge pressure should be 245-265 psi (1690-1827 kPa) when oil temperature is 70F (20C). 7. Ensure valve handle on nitrogen chuck (Figure 5, Item 8) is closed. 8. Attach nitrogen chuck (Figure 5, Item 8) to valve (Figure 5, Item 5). 9. Ensure that needle valve (Figure 5, Item 7) is closed. 10. Open valve handle on nitrogen chuck (Figure 5, Item 8). 11. Check accumulator pressure on pressure gauge (Figure 5, Item 1). Accumulator charge pressure should be 245-265 psi (1690-1827 kPa) when oil temperature is 70F (20C). 12. If accumulator pressure is not within acceptable range, replace accumulator (Figure 5, Item 3). 13. Remove nitrogen chuck (Figure 5, Item 8) from valve (Figure 5, Item 5). 14. Install protective cap (Figure 5, Item 6) on valve (Figure 5, Item 5). 15. Install protective strap (Figure 5, Item 2) and two bolts (Figure 5, Item 4) on accumulator (Figure 5, Item 3).

Figure 5. Testing with Nitrogen Charging Kit. END OF TASK

0126

0126-6

TM 5-2410-241-23-2

0126

CHARGE ACCUMULATOR

000126

WARNING
Dry nitrogen is the only gas approved for use in accumulator. Any other gas may cause failure of accumulator or injury to personnel.

NOTE
A new accumulator should be charged before installation. Do not charge accumulator that is connected to powertrain system. Pressure from the powertrain oil may interfere with charging procedure. 1. Connect nitrogen charging kit regulator fitting (Figure 6, Item 4) to nitrogen cylinder. 2. Make sure that needle valve (Figure 6, Item 1) is closed and then open valve of nitrogen cylinder. 3. Remove two bolts (Figure 6, Item 6) and protective strap (Figure 6, Item 7) from accumulator (Figure 6, Item 9). 4. Remove protective cap (Figure 6, Item 5) from valve (Figure 6, Item 8). 5. Install nitrogen chuck (Figure 6, Item 12) on valve (Figure 6, Item 8). 6. Open valve handle on nitrogen chuck (Figure 6, Item 12). 7. Adjust screw (Figure 6, Item 11) on regulator (Figure 6, Item 10) until pressure gauge (Figure 6, Item 3) reads 245-265 psi (1690-1827 kPa) when oil temperature is 70F (20C). 8. Open needle valve (Figure 6, Item 1) and allow nitrogen to flow into accumulator (Figure 6, Item 9). 9. When pressure on pressure gauge (Figure 6, Item 2) matches pressure on pressure gauge (Figure 6, Item 3), close screw (Figure 6, Item 11) on regulator (Figure 6, Item 10). 10. Wait 60 seconds to ensure that pressure remains stable. If pressure decreases, repeat steps 7 through 9 until pressure remains stable. 11. Close valve on nitrogen cylinder. 12. Close needle valve (Figure 6, Item 1) and valve on nitrogen charging chuck (Figure 6, Item 12). 13. Remove nitrogen charging chuck (Figure 6, Item 12) from valve (Figure 6, Item 8) on accumulator (Figure 6, Item 9) 14. Install protective cap (Figure 6, Item 5) on valve (Figure 6, Item 8). 15. Install protective strap (Figure 6, Item 7) and two bolts (Figure 6, Item 6) on accumulator (Figure 6, Item 9). 16. Remove nitrogen charging kit regulator fitting (Figure 6, Item 4) from nitrogen cylinder.

0126-7

TM 5-2410-241-23-2

0126

CHARGE ACCUMULATOR CONTINUED

Figure 6. Charging Accumulator. END OF TASK FOLLOW-ON TASKS 1. Verify correct operation of machine (TM 5-2410-241-10). 2. Install rear floor plate (WP 0231). END OF TASK END OF WORK PACKAGE

0126

000126

0126-8

14 TM 5-2410-241-23-2 0127

FIELD MAINTENANCE TRACK SERVICE Removal, Cleaning and Inspection, Installation, Track Tension Measurement, Loose Track Adjustment, Tight Track Adjustment
0 1 2 7

INITIAL SETUP Tools and Special Tools

0

Materials/Parts

Tool Kit, General Mechanics (WP 0302, Item 65) Goggles (S0209) (WP 0302, Item 68) Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) Jack Stands (2) Consisting of: Pin, Shoulder, Headless, Jack Stand (WP 0302, Item 42) Repair Tool, Special Purpose (Tube), Jack Stand (WP 0302, Item 49) Saddle Assembly, Lifting Block, Jack Stand (WP 0302, Item 50) Stand Assembly, Jack Stand (WP 0302, Item 56) Socket, 3/4 Drive, 1-5/16, 12 Point (S0387) (WP 0302, Item 68) Wrench, Electric Impact, 3/4 Square Drive, 1,200 lb-ft (S0730) (WP 0302, Item 68) Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) Lifting Device (10,000-lb capacity) Wood Block 4 x 4 x 12 (2)
0 0 0 0 0 0 0 0 0 0 0 0 0

Antifreeze, Permanent, Ethylene Glycol, Inhibited (WP 0303, Item 1) Grease, Automotive and Artillery (GAA) (WP 0303, Item 12) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) O-ring (3) String (12 ft)
0 0 0 0 0 0

Personnel Required Two References WP 0129 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 58, 63 Estimated Time to Complete 2.5 Hr

0127-1

TM 5-2410-241-23-2

0127

REMOVAL

000127

NOTE
The following procedure is for one track master separation. Use the same procedure for additional track master separation. 1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 3), cap (Figure 1, Item 1), and O-ring (Figure 1, Item 4) from track frame (Figure 1, Item 5). Discard O-ring.

Figure 1. Adjuster Cap.

0127

0127-2

TM 5-2410-241-23-2

0127

REMOVAL CONTINUED

WARNING

Loosen relief valve one turn only. Grease inside adjuster is under high pressure. Failure to follow this warning may cause injury to personnel. 2. Loosen relief valve (Figure 2, Item 1) one turn (360 degrees) on adjuster (Figure 2, Item 2). Allow grease to escape. 3. Tighten relief valve (Figure 2, Item 1) on adjuster (Figure 2, Item 2).

Figure 2. Adjuster Release.

0127

4. Lift and support blade (Figure 3, Item 2) on machine allowing clearance for track (Figure 3, Item 1) to separate. 5. Lift and support machine allowing track to hang.

Figure 3. Blade.

0127

0127-3

TM 5-2410-241-23-2

0127

REMOVAL CONTINUED 6. Position master link (Figure 4, Item 2) to align with center of rear idler (Figure 4, Item 3).

NOTE
Track should be firmly against blocking. 7. Install suitable blocking (Figure 4, Item 5) against track (Figure 4, Item 4) to support tracks.

WARNING

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

NOTE
Track shoe weighs approximately 85 lb (40 kg). Note position and size of bolts to aid installation.

8. With assistance, remove four bolts (Figure 4, Item 6) and track shoe (Figure 4, Item 1) from machine.

Figure 4. Track Blocking.

0127

0127-4

TM 5-2410-241-23-2

0127

REMOVAL CONTINUED

WARNING

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

NOTE
Track weighs approximately 5,750 lb (2,600 kg). 9. Install lifting device on upper track (Figure 5, Item 1). 10. Using lifting device, separate track links (Figure 5, Item 4). 11. Turn final drive (Figure 5, Item 2) forward while supporting track (Figure 5, Item 1) with lifting device. 12. Using lifting device, allow lower track (Figure 5, Item 1) to slowly fall rearward. 13. Using lifting device, move upper track (Figure 5, Item 1) forward and flat in front of machine. 14. Remove blocking (Figure 5, Item 3) from track. 15. Using lifting device, pull track (Figure 5, Item 1) from under front or rear of machine. 16. Remove lifting device from track (Figure 5, Item 1).

Figure 5. Track Separation. END OF TASK CLEANING AND INSPECTION Clean and inspect all components IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0127

000127

0127-5

TM 5-2410-241-23-2

0127

INSTALLATION

000127

WARNING

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

NOTE
Track weighs approximately 5,750 lb (2,600 kg). 1. Install lifting device to upper track (Figure 6, Item 1). 2. Align track to rollers and pull track (Figure 6, Item 1) on from front or back of machine.

NOTE
Track should be firmly against blocking. 3. Install blocking (Figure 6, Item 3) on lower track (Figure 6, Item 1). 4. Using lifting device, install upper track (Figure 6, Item 1) on final drive (Figure 6, Item 2). 5. Turn final drive (Figure 6, Item 2) in reverse while supporting track (Figure 6, Item 1) with lifting device. 6. Connect track links (Figure 6, Item 4). 7. Remove lifting device from track (Figure 6, Item 1).

Figure 6. Track Connection.

0127

0127-6

TM 5-2410-241-23-2

0127

INSTALLATION CONTINUED

WARNING

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

NOTE
Track shoe weighs approximately 85 lb (40 kg). 8. With assistance, install track shoe (Figure 7, Item 1) and four bolts (Figure 7, Item 6) on master link (Figure 7, Item 2). Tighten bolts to 250 lb-ft (340 Nm). Then tighten bolts 180 degrees. 9. Remove blocking (Figure 7, Item 5) from lower track (Figure 7, Item 4) and rear idler (Figure 7, Item 3).

Figure 7. Track Blocking.

0127

0127-7

TM 5-2410-241-23-2

0127

INSTALLATION CONTINUED 10. Remove supports and lower machine on tracks (Figure 8, Item 1). 11. Remove supports and lower blade (Figure 8, Item 2) on machine.

Figure 8. Blade. 12. Move machine forward. Allow the machine to stop without use of brakes. 13. Install string (Figure 9, Item 1) on track (Figure 9, Item 3) near sprocket segment (Figure 9, Item 4).

0127

14. Install other end of string (Figure 9, Item 1) on track (Figure 9, Item 3) near front idler (Figure 9, Item 2). String should be tight. 15. Measure from track shoe tip (Figure 9, Item 3) to string (Figure 9, Item 1) at lowest point. Correct adjustment is 4.5 in. (115 mm).

Figure 9. Track Adjustment.

0127

0127-8

TM 5-2410-241-23-2

0127

INSTALLATION CONTINUED 16. Add grease through valve (Figure 10, Item 2) on track adjuster (Figure 10, Item 1) until track is at specification of 4.5 in. (115 mm).

Figure 10. Track Tension Adjustment. 17. Install new O-ring (Figure 11, Item 4), cap (Figure 11, Item 1), four washers (Figure 11, Item 3), and bolts (Figure 11, Item 2) on adjuster (Figure 11, Item 5).

0127

Figure 11. Adjuster Cap. END OF TASK

0127

0127-9

TM 5-2410-241-23-2

0127

TRACK TENSION MEASUREMENT 1. Move machine forward. Allow the machine to stop without use of brakes. 2. Install string (Figure 12, Item 1) on track (Figure 12, Item 3) near sprocket segment (Figure 12, Item 4). 3. Install other end of string (Figure 12, Item 1) on track (Figure 12, Item 3) near front idler (Figure 12, Item 2). String should be tight.

000127

4. Measure from track shoe tip (Figure 12, Item 3) to string (Figure 12, Item 1) at lowest point. Correct adjustment is 4.5 in. (115 mm). 5. Loosen or tighten track to meet specification.

Figure 12. Track Adjustment. END OF TASK LOOSE TRACK ADJUSTMENT 1. Measure between points on front track roller frame (Figure 13, Item 1) and rear track roller frame (Figure 13, Item 2). If measurement is over 5.4 in. (138 mm) do not adjust. Replace track chain (WP 0129).

0127

000127

Figure 13. Loose Track.

0127

0127-10

TM 5-2410-241-23-2

0127

LOOSE TRACK ADJUSTMENT CONTINUED 2. Remove four bolts (Figure 14, Item 2), washers (Figure 14, Item 3), cap (Figure 14, Item 1), and O-ring (Figure 14, Item 4) from adjuster (Figure 14, Item 5). Discard O-ring.

Figure 14. Adjuster Cap.

0127

WARNING

Loosen relief valve one turn only. Grease inside adjuster is under high pressure. Failure to follow this warning may cause injury to personnel. 3. Loosen relief valve (Figure 15, Item 1) one turn (360 degrees) from adjuster (Figure 15, Item 2). Allow grease to escape. 4. Tighten relief valve (Figure 15, Item 1) on adjuster (Figure 15, Item 2).

Figure 15. Adjuster Release.

0127

0127-11

TM 5-2410-241-23-2

0127

LOOSE TRACK ADJUSTMENT CONTINUED 5. Add grease through valve (Figure 16, Item 2) on track adjuster (Figure 16, Item 1) until track adjustment meets specification of 4.5 in. (115 mm).

Figure 16. Track Tension Adjustment. 6. Install new O-ring (Figure 17, Item 4), cap (Figure 17, Item 1), four washers (Figure 17, Item 3), and bolts (Figure 17, Item 2) on adjuster (Figure 17, Item 5).

0127

Figure 17. Adjuster Cap. END OF TASK

0127

0127-12

TM 5-2410-241-23-2

0127

TIGHT TRACK ADJUSTMENT 1. Remove four bolts (Figure 17, Item 2), washers (Figure 17, Item 3), cap (Figure 17, Item 1), and O-ring (Figure 17, Item 4) from adjuster (Figure 17, Item 5). Discard O-ring.

000127

2. Add grease through valve (Figure 18, Item 2) on track adjuster (Figure 18, Item 1) until track adjustment meets specification of 4.5 in. (115 mm).

Figure 18. Track Tension Adjustment. 3. Install new O-ring (Figure 19, Item 4), cap (Figure 19, Item 1), four washers (Figure 19, Item 3), and bolts (Figure 19, Item 2) on adjuster (Figure 19, Item 5).

0127

Figure 19. Adjuster Cap. END OF TASK

0127

0127-13

TM 5-2410-241-23-2

0127

FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000127

0127-14

4 TM 5-2410-241-23-2 0128

FIELD MAINTENANCE TRACK SHOE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 2 8

INITIAL SETUP Tools and Special Tools 0 Personnel Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 58 Estimated Time to Complete 1.0 Hr 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) 0 Handle, Sliding T, 3/4 Drive, 17 Long (S0374) (WP 0302, Item 68) 0 Socket, 3/4 Drive, 12 Point, 1-5/16 (S0387) (WP 0302, Item 68) 0 Socket, Impact, 3/4 Drive, 6 Point, 1 5/16 (S0974) (WP 0302, Item 68) 0 Wrench, Electric Impact, 3/4 Square Drive, 1,200 lb-ft (S0730) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) 0 0

0128-1

TM 5-2410-241-23-2

0128

REMOVAL

000128

WARNING

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

NOTE
This procedure will remove one track shoe. Follow the same procedure for additional track shoes. Track shoe weighs approximately 85 lb (40 kg).

With assistance, remove four bolts (Figure 1, Item 1), nuts (Figure 1, Item 2), and track shoe (Figure 1, Item 3) from machine.

Figure 1. Track Shoe. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0128

000128

0128-2

TM 5-2410-241-23-2

0128

INSTALLATION

000128

WARNING

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

NOTE
This procedure will install one track shoe. Follow the same procedure for additional track shoes. Track shoe weighs approximately 85 lb (40 kg).

With assistance, install track shoe (Figure 1, Item 3), four nuts (Figure 1, Item 2), and bolts (Figure 1, Item 1) on machine. Tighten bolts to 250 lb-ft (340 Nm). Tighten bolts additional 120 degrees. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000128

0128-3/(4 blank)

4 TM 5-2410-241-23-2 0129

FIELD MAINTENANCE TRACK LINK REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 2 9

INITIAL SETUP Tools and Special Tools 0 Personnel Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Track separated (WP 0127) Drawing Required TM 5-2410-241-24P, Figure 58 Estimated Time to Complete 8.0 Hr 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) 0 Handle, Sliding T, 3/4 Drive, 17 Long (S0374) (WP 0302, Item 68) 0 Socket, 3/4 Drive, 12 Point, 1-5/16 (S0387) (WP 0302, Item 68) 0 Socket, Impact, 3/4 Drive, 6 Point, 1 5/16 (S0974) (WP 0302, Item 68) 0 Wrench, Electric Impact, 3/4 Square Drive, 1200 lb-ft (S0730) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) 0 0

0129-1

TM 5-2410-241-23-2

0129

REMOVAL

000129

WARNING

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

NOTE
This procedure will replace one track. Follow the same procedure for additional track. Track shoe weighs approximately 85 lb (40 kg).

With assistance, remove 156 bolts (Figure 1, Item 1), nuts (Figure 1, Item 2), and 39 track shoes (Figure 1, Item 3) from track link assembly (Figure 1, Item 4).

Figure 1. Track Shoe. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0129

000129

0129-2

TM 5-2410-241-23-2

0129

INSTALLATION

000129

WARNING

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

NOTE
This procedure will replace one track. Follow the same procedure for additional track. Track shoe weighs approximately 85 lb (40 kg).

With assistance, install 39 track shoes (Figure 1, Item 3), 156 nuts (Figure 1, Item 2), and bolts (Figure 1, Item 1) on track link (Figure 1, Item 4). Tighten bolts to 250 lb-ft (340 Nm). Tighten bolts additional 120 degrees. END OF TASK FOLLOW-ON TASKS 1. Connect track (WP 0127). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000129

0129-3/(4 blank)

4 TM 5-2410-241-23-2 0130

FIELD MAINTENANCE TRUNNION REPLACEMENT Removal, Cleaning and Inspection, Installation

0 1 3 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Personnel Required Two References WP 0295
0

Equipment Condition Blade removed (WP 0268) Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 132 Estimated Time to Complete 2.5 Hr

0130-1

TM 5-2410-241-23-2

0130

REMOVAL

000130

WARNING

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

NOTE
Procedure will remove one trunnion. Follow the same procedure for other trunnion. Trunnion weighs approximately 60 lb (27 kg).

1. With assistance, remove 16 bolts (Figure 1, Item 3), washers (Figure 1, Item 2), and trunnion (Figure 1, Item 4) from track roller frame (Figure 1, Item 1). 2. Place trunnion on flat level surface.

Figure 1. Trunnion. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0130

000130

0130-2

TM 5-2410-241-23-2

0130

INSTALLATION

000130

WARNING

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

NOTE
Trunnion weighs approximately 60 lb (27 kg). With assistance, install trunnion (Figure 1, Item 4), 16 washers (Figure 1, Item 2), and bolts (Figure 1, Item 3) on track roller frame (Figure 1, Item 1). END OF TASK FOLLOW-ON TASKS 1. Install blade (WP 0268). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000130

0130-3/(4 blank)

4 TM 5-2410-241-23-2 0131

FIELD MAINTENANCE INSTRUCTIONS STRIP PLATE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 3 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295 REMOVAL 0 0 0 0 0 0
000131

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 63 Estimated Time to Complete 1.0 Hr

0 0 0 0 0 0

NOTE
Procedure will remove four strip plates from right track roller frame. Follow the same procedure to remove four strip plates from left track roller frame. 1. Remove six bolts (Figure 1, Item 3), washers (Figure 1, Item 4), and two strip plates (Figure 1, Item 1) from track roller frame (Figure 1, Item 2).

Figure 1. Rear Strip Plate.

0131

0131-1

TM 5-2410-241-23-2

0131

REMOVAL CONTINUED 2. Remove six bolts (Figure 2, Item 3), washers (Figure 2, Item 4), and two strip plates (Figure 2, Item 1) from track roller frame (Figure 2, Item 2).

Figure 2. Front Strip Plate. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions WP 0295). END OF TASK INSTALLATION

0131

000131

000131

NOTE
Procedure will install four strip plates on right track roller frame. Follow the same procedure to install four strip plates on left track roller frame. 1. Install two strip plates (Figure 2, Item 1), six washers (Figure 2, Item 4), and bolts (Figure 2, Item 3) on track roller frame (Figure 2, Item 2).

0131-2

TM 5-2410-241-23-2

0131

INSTALLATION CONTINUED 2. Install two strip plates (Figure 3, Item 1), six washers (Figure 3, Item 4), and bolts (Figure 3, Item 3) on track roller frame (Figure 3, Item 2).

Figure 3. Rear Strip Plate. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0131

000131

0131-3/(4 blank)

6 TM 5-2410-241-23-2 0132

FIELD MAINTENANCE
0 1 3 2

DOUBLE FLANGE TRACK ROLLER REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Track tension released (WP 0127) Drawing Required TM 5-2410-241-24P, Figure 60 Estimated Time to Complete 4.5 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Fork Assembly, Roller Lifting (WP 0302, Item 26) Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) Jack Stand Consisting of: Pin, Shoulder, Headless, Jack Stand (WP 0302, Item 42) Repair Tool, Special Purpose (Tube), Jack Stand (WP 0302, Item 49) Saddle Assembly, Lifting Block, Jack Stand (WP 0302, Item 50) Stand Assembly, Jack Stand (WP 0302, Item 56) Socket, 3/4 Drive, 12 Point 1-5/16 (S0387) (WP 0302, Item 68) Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) Lifting device (1,000-lb capacity) Wood block 12 x 12 x 24 (2)
0 0 0 0 0 0 0 0 0 0 0 0

0132-1

TM 5-2410-241-23-2

0132

REMOVAL

000132

WARNING

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

NOTE
Bulldozer weighs approximately 67,000 lb (30,390 kg). Track roller weighs approximately 150 lb (68 kg). This procedure is for one track roller. Use same procedure for remaining track rollers.

1. Raise and support front of machine (Figure 1, Item 2) with jack stand (Figure 1, Item 1), and rear of machine (Figure 1, Item 4) with two wooden blocks (Figure 1, Item 3) to allow bottom track to hang free.

Figure 1. Front and Rear Support.

0132

0132-2

TM 5-2410-241-23-2

0132

REMOVAL CONTINUED 2. Using lifting device and roller lifting fork, support track roller (Figure 2, Item 1). 3. Remove four bolts (Figure 2, Item 4), washers (Figure 2, Item 3), and track roller (Figure 2, Item 1) from track frame (Figure 2, Item 2). Place track roller on flat level surface. 4. Remove lifting device and roller lifting fork from track roller (Figure 2, Item 1).

Figure 2. Track Roller. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0132

000132

0132-3

TM 5-2410-241-23-2

0132

INSTALLATION

000132

WARNING

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

NOTE
Bulldozer weighs approximately 67,000 lb (30,390 kg). Track roller weighs approximately 150 lb (68 kg). This procedure is for one track roller. Use same procedure for remaining track rollers.

1. Using lifting device and roller lifting fork, install track roller (Figure 3, Item 1), four washers (Figure 3, Item 3), and bolts (Figure 3, Item 4) on track frame (Figure 3, Item 2). Tighten bolts to 391 lb-ft (530 Nm). 2. Remove lifting device and roller lifting fork from track roller (Figure 3, Item 1).

Figure 3. Track Roller.

0132

0132-4

TM 5-2410-241-23-2

0132

INSTALLATION CONTINUED 3. Using lifting device, raise rear of machine (Figure 4, Item 4) and remove two wooden blocks (Figure 4, Item 3). Lower rear of machine. 4. Using lifting device, raise front of machine (Figure 4, Item 2) and remove jack stand (Figure 4, Item 1). Lower front of machine.

Figure 4. Front and Rear Support. END OF TASK FOLLOW-ON TASKS 1. Adjust track tension (WP 0127). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0132

000132

0132-5/(6 blank)

6 TM 5-2410-241-23-2 0133

FIELD MAINTENANCE
0 1 3 3

SINGLE FLANGE TRACK ROLLER REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Wood block (2) Personnel Required Two References WP 0132 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Track tension released (WP 0127) Drawing Required TM 5-2410-241-24P, Figure 59 Estimated Time to Complete 4.5 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Fork Assembly, Roller Lifting (WP 0302, Item 26) Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) Jack Stand Consisting of: Pin, Shoulder, Headless, Jack Stand (WP 0302, Item 42) Repair Tool, Special Purpose (Tube), Jack Stand (WP 0302, Item 49) Saddle Assembly, Lifting Block, Jack Stand (WP 0302, Item 50) Stand Assembly, Jack Stand (WP 0302, Item 56) Socket, 3/4 Drive, 1-5/16, 12 Point (S0387) (WP 0302, Item 68) Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) Lifting device (1,000-lb capacity) Wood block 12 x 12 x 24 (2)
0 0 0 0 0 0 0 0 0 0 0 0

0133-1

TM 5-2410-241-23-2

0133

REMOVAL

000133

WARNING

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

NOTE
Bulldozer weighs approximately 67,000 lb (30,390 kg). 1. Raise and support front of machine (Figure 1, Item 2) with jack stand (Figure 1, Item 1) and rear of machine (Figure 1, Item 4) with two wooden blocks (Figure 1, Item 3) to allow bottom track to hang free.

Figure 1. Front and Rear Support.

0133

0133-2

TM 5-2410-241-23-2

0133

REMOVAL CONTINUED

NOTE
If removing front or rear roller, the double flange roller next to it must be removed first (WP 0132). Track roller weighs approximately 143 lb (65 kg). This procedure is for one track roller. Use same procedure for remaining track rollers.

2. Using lifting device and roller lifting fork, support track roller (Figure 2, Item 1). 3. Remove four bolts (Figure 2, Item 4), washers (Figure 2, Item 3), and track roller (Figure 2, Item 1) from track frame (Figure 2, Item 2). Place track roller on flat level surface. 4. Remove lifting device and roller lifting fork from track roller (Figure 2, Item 1).

Figure 2. Track Roller. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0133

000133

0133-3

TM 5-2410-241-23-2

0133

INSTALLATION

000133

WARNING

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

NOTE
Bulldozer weighs approximately 67,000 lb (30,390 kg). Track roller weighs approximately 143 lb (65 kg). This procedure is for one track roller. Use same procedure for remaining track rollers. If double flange roller was removed, install after installing single roller (WP 0132).

1. Using lifting device and roller lifting fork, install track roller (Figure 3, Item 1), four washers (Figure 3, Item 3), and bolts (Figure 3, Item 4) on track frame (Figure 3, Item 2). Tighten bolts to 391 lb-ft (530 Nm). 2. Remove lifting device and roller lifting fork from track roller (Figure 3, Item 1).

Figure 3. Track Roller.

0133

0133-4

TM 5-2410-241-23-2

0133

INSTALLATION CONTINUED 3. Using lifting device, raise rear of machine (Figure 4, Item 4) and remove two wooden blocks (Figure 4, Item 3). Lower rear of machine. 4. Using lifting device, raise front of machine (Figure 4, Item 2) and remove jack stand (Figure 4, Item 1). Lower front of machine.

Figure 4. Front and Rear Support. END OF TASK FOLLOW-ON TASKS 1. Adjust track tension (WP 0127). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0133

000133

0133-5/(6 blank)

14 TM 5-2410-241-23-2 0134

FIELD MAINTENANCE TRACK ADJUSTER AND RECOIL ASSEMBLY SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 1 3 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Hoist, Chain (WP 0302, Item 33) Pan, Drain (S0255) (WP 0302, Item 68) Seal Guard (WP 0302, Item 51) Sling, Multiple Leg (WP 0302, Item 54) Lifting Device (2,000-lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Sealing Compound (Gasket Maker) (WP 0303, Item 30) Bearing O-ring (2) Screw, 2 1/2-13 X 1/2 (2) Seal (2) 0 0
0

Personnel Required Two References WP 0135 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Track separated (WP 0127) Drawings Required TM 5-2410-241-24P, Figure 62, 63 Estimated Time to Complete 8.0 Hr

0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0

0134-1

TM 5-2410-241-23-2

0134

REMOVAL

000134

NOTE
This procedure will remove one track adjuster and recoil assembly. Follow same procedure for additional track adjuster and recoil assembly. Guides are located both inside and outside of track frame.

1. Remove 12 bolts (Figure 1, Item 2) and washers (Figure 1, Item 3) from 2 guides (Figure 1, Item 1).

Figure 1. Track Frame Guide.

0134

0134-2

TM 5-2410-241-23-2

0134

REMOVAL CONTINUED

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. Wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. 2. Install two bolts (Figure 2, Item 2) at locations (Figure 2, Item 3) to remove both inner and outer guides (Figure 2, Item 1) from track frame (Figure 2, Item 4). 3. Remove two bolts (Figure 2, Item 2) from guides (Figure 2, Item 1) as guides are removed.

Figure 2. Forcing Screws.

0134

0134-3

TM 5-2410-241-23-2

0134

REMOVAL CONTINUED

WARNING

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

NOTE
Track adjuster assembly weighs approximately 1,100 lb (499 kg). 4. Attach lifting device on track adjuster (Figure 3, Item 1). 5. Using lifting device, pull track adjuster (Figure 3, Item 1) out from track frame (Figure 3, Item 2). Do not fully disengage track adjuster (Figure 3, Item 1) from track frame (Figure 3, Item 2). 6. Remove lifting device from track adjuster (Figure 3, Item 1).

Figure 3. Front Idler and Adjuster Separation.

0134

0134-4

TM 5-2410-241-23-2

0134

REMOVAL CONTINUED

WARNING

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

NOTE
Track adjuster assembly weighs approximately 1,100 lb (499 kg). 7. Attach lifting device and nylon sling on track adjuster (Figure 4, Item 2). 8. Using lifting device, remove track adjuster (Figure 4, Item 2) from track frame (Figure 4, Item 1). 9. Remove track adjuster (Figure 4, Item 2) from machine. 10. Remove front idler (WP 0135).

Figure 4. Front Idler and Adjuster Removal.

0134

0134-5

TM 5-2410-241-23-2

0134

REMOVAL CONTINUED

NOTE
Note orientation and position of seal, retaining rings and bearing to aid installation. 11. Remove retaining ring (Figure 5, Item 4), seal (Figure 5, Item 3), retaining ring (Figure 5, Item 2), and bearing (Figure 5, Item 1) from track frame (Figure 5, Item 5). Discard seal and bearing.

Figure 5. Track Frame Seals. END OF TASK

0134

0134-6

TM 5-2410-241-23-2

0134

DISASSEMBLY

000134

WARNING

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

NOTE
Track adjuster weighs approximately 95 lb (43 kg). 1. Remove four bolts (Figure 6, Item 4), washers (Figure 6, Item 3), and two stops (Figure 6, Item 5) from track adjuster frame (Figure 6, Item 2). 2. With assistance, remove track adjuster (Figure 6, Item 1) from track adjuster frame (Figure 6, Item 2). Place track adjuster on flat level surface.

Figure 6. Track Adjuster.

0134

0134-7

TM 5-2410-241-23-2

0134

DISASSEMBLY CONTINUED

WARNING

Compressed air for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi (207 kPa). Wear protective clothing (goggles/shield, gloves, etc.) and use caution to avoid injury to personnel. Air under 100 psi (690 kPa) is used in the operation of the air brake system. Serious injury or death can result if precautions are not taken.

3. Use compressed air in fill valve (Figure 7, Item 8) and carefully remove piston (Figure 7, Item 6) from track adjuster cylinder (Figure 7, Item 4).

NOTE
Note orientation and position of seal to aid installation. 4. Remove seal (Figure 7, Item 5) from track adjuster cylinder (Figure 7, Item 4). Discard seal. 5. Remove plug (Figure 7, Item 9) and O-ring (Figure 7, Item 10) from track adjuster cylinder (Figure 7, Item 4). Discard O-ring. 6. Remove two bolts (Figure 7, Item 2), washers (Figure 7, Item 1), and plate (Figure 7, Item 7) from track adjuster cylinder (Figure 7, Item 4). 7. Remove fill valve (Figure 7, Item 8), relief valve (Figure 7, Item 3), and O-ring (Figure 7, Item 11) from track adjuster cylinder (Figure 7, Item 4). Discard O-ring.

Figure 7. Track Adjuster Cylinder. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0134

000134

0134-8

TM 5-2410-241-23-2

0134

ASSEMBLY

000134

NOTE
Install seal as noted during removal. 1. Install new seal (Figure 7, Item 5) on track adjuster cylinder (Figure 7, Item 4). 2. Install piston (Figure 7, Item 6) on track adjuster cylinder (Figure 7, Item 4). 3. Install new O-ring (Figure 7, Item 11), relief valve (Figure 7, Item 3), and fill valve (Figure 7, Item 8) on track adjuster cylinder (Figure 7, Item 4). 4. Install plate (Figure 7, Item 7), two washers (Figure 7, Item 1), and bolts (Figure 7, Item 2) on track adjuster cylinder (Figure 7, Item 4). 5. Install new O-ring (Figure 7, Item 10) and plug (Figure 7, Item 9) on track adjuster cylinder (Figure 7, Item 4).

WARNING

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

NOTE
Track adjuster weighs approximately 95 lb (43 kg). 6. With assistance, install track adjuster (Figure 8, Item 1) on track adjuster frame (Figure 8, Item 2). 7. Install two stops (Figure 8, Item 5), four washers (Figure 8, Item 3), and bolts (Figure 8, Item 4) on track adjuster frame (Figure 8, Item 2).

Figure 8. Track Adjuster.

0134

0134-9

TM 5-2410-241-23-2

0134

END OF TASK INSTALLATION

000134

NOTE
This procedure will install one track adjuster and recoil assembly. Follow same procedure for additional track adjuster and recoil assembly. Install bearing, retaining rings and seal as noted during removal.

1. Install new bearing (Figure 9, Item 1), retaining ring (Figure 9, Item 2), new seal (Figure 9, Item 3), and retaining ring (Figure 9, Item 4) on track frame (Figure 9, Item 5).

Figure 9. Track Frame Seals.

0134

0134-10

TM 5-2410-241-23-2

0134

INSTALLATION CONTINUED 2. Install seal guard (Figure 10, Item 1) on seal (Figure 10, Item 4).

NOTE
Track adjuster assembly weighs approximately 1,100 lb (499 kg). 3. Attach lifting device and nylon sling on track adjuster (Figure 10, Item 2). 4. Partially install track adjuster (Figure 10, Item 2) on machine. Remove and discard seal guard. 5. Using lifting device, install track adjuster (Figure 10, Item 2) on track frame (Figure 10, Item 3).

Figure 10. Seals Guard. 6. Install front Idler (WP 0135).

0134

0134-11

TM 5-2410-241-23-2

0134

INSTALLATION CONTINUED

WARNING

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

NOTE
Track adjuster assembly weighs approximately 1,100 lb (499 kg). 7. Attach horizontal lifting device on track frame (Figure 11, Item 1) and track adjuster (Figure 11, Item 2). 8. Using lifting device, pull track adjuster (Figure 11, Item 2) into track frame (Figure 11, Item 1). Fully engage track adjuster (Figure 11, Item 2) on track frame (Figure 11, Item 1). 9. Remove horizontal lifting device from track frame (Figure 11, Item 1) and track adjuster (Figure 11, Item 2).

Figure 11. Front Idler and Adjuster.

0134

0134-12

TM 5-2410-241-23-2

0134

INSTALLATION CONTINUED 10. Apply a bead of sealing compound around the inside edge (Figure 12, Item 2) of two guides (Figure 12, Item 1).

Figure 12. Guide Sealing Compound. 11. Install 2 guides (Figure 13, Item 1), 12 washers (Figure 13, Item 3), and bolts (Figure 13, Item 2) on track frame.

0134

Figure 13. Track Frame Guide. END OF TASK

0134

0134-13

TM 5-2410-241-23-2

0134

FOLLOW-ON TASKS 1. Connect track (WP 0127). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000134

0134-14

4 TM 5-2410-241-23-2 0135

FIELD MAINTENANCE
0 1 3 5

IDLER ASSEMBLY SERVICE

Removal, Cleaning and Inspection, Installation INITIAL SETUP Tools and Special Tools 0 Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM-5-2410-241-10) Track separated and positioned aside (WP 0127) Drawing Required TM 5-2410-241-24P, Figure 61, 62 Estimated Time to Complete 4.5 Hr 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) 0 Sling, Multiple Leg (WP 0302, Item 54) 0 Socket, Impact, 3/4 Drive, 6 point, 1-5/16 (S0974) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Lifting Device (500 lb capacity) 0 Lifting Device (3,000 lb capacity) 0 Materials/Parts Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) REMOVAL 0 0 0

000135

WARNING

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

NOTE
The following procedure covers removal of one idler assembly. Follow same procedure when removing other idler assemblies. Idler assembly weighs approximately 420 lb (186 kg).

0135-1

TM 5-2410-241-23-2

0135

REMOVAL CONTINUED 1. Attach lifting device on idler assembly (Figure 1, Item 7).

NOTE
Shims may or may not be present due to build variation. Note quantity and position of shims to aid installation. Note position and alignment of spring pin to idler shaft and lower cap.

2. Using lifting device and assistance, remove four bolts (Figure 1, Item 5), washers (Figure 1, Item 6), two caps (Figure 1, Item 4), spring pins (Figure 1, Item 3), idler (Figure 1, Item 7), blocks (Figure 1, Item 2), and shims (Figure 1, Item 1) from machine. 3. Set idler assembly (Figure 1, Item 7) on flat level surface. 4. Remove lifting device from idler assembly (Figure 1, Item 7).

Figure 1. Idler. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0135

000135

0135-2

TM 5-2410-241-23-2

0135

INSTALLATION

000135

WARNING

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

NOTE
The following procedure covers installation of one idler assembly. Follow same procedure when removing other idler assemblies. Idler assembly weighs approximately 420 lb (186 kg).

1. Attach lifting device on idler assembly (Figure 1, Item 7).

NOTE
Shims may or may not be present due to build variation. Install shims as noted during removal. Install spring pin as noted during removal.

2. Using lifting device and assistance, install shims (Figure 1, Item 1), two blocks (Figure 1, Item 2), idler (Figure 1, Item 7), spring pins (Figure 1, Item 3), two caps (Figure 1, Item 4), four washers (Figure 1, Item 6), and bolts (Figure 1, Item 5) on machine. Tighten bolts to 420 lb-ft (570 Nm). 3. Remove lifting device from idler assembly (Figure 1, Item 7). END OF TASK FOLLOW-ON TASKS 1. Connect track (WP 0127). 2. Verify correct operation of machine (TM 5-2410-240-10). END OF TASK END OF WORK PACKAGE
000135

0135-3/(4 blank)

14 TM 5-2410-241-23-2 0136

FIELD MAINTENANCE FINAL DRIVE ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation
0 1 3 6

INITIAL SETUP Tools and Special Tools 0 Materials/Parts - Continued Nut (3/4 in. x 10) (2) O-ring Washer (3/4) (4) Personnel Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Track separated (WP 0127) Final drive oil drained (WP 0149) Axle removed (WP 0116) ROPS removed (WP 0225) Battery box removed (WP 0289) if removing left final drive assembly on machine equipped with arctic heater Drawing Required TM 5-2410-241-24P, Figure 64 Estimated Time to Complete 7.0 Hr 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) 0 Extension, 3/4 Drive, 4 Long (S3076) (WP 0302, Item 68) 0 Handle, Ratchet, 3/4 Drive, 17 Long (S0374) (WP 0302, Item 68) 0 Lifting Bracket (WP 0302, Item 75) 0 Shackle, 1 (WP 0302, Item 52) 0 Socket, 3/4 Drive, 12 Point, 1 1/8 (S0385) (WP 0302, Item 68) 0 Socket, Impact 3/4 Drive, 6 Point 1-1/8 (S0972) (WP 0302, Item 68) 0 Wrench, Combination, 1 1/8 (S0788) (WP 0302, Item 68) 0 Wrench, Electric Impact, 3/4 Square Drive, 1200 lb-ft (S0730) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Lifting Device (2,000-lb capacity) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Bolt (3/4 in. x 10 x 5 1/2) (2) 0 0 0

0 0 0 0 0

0136-1

TM 5-2410-241-23-2

0136

REMOVAL

000136

NOTE
This procedure will remove one final drive assembly. Follow same procedure for additional final drive assembly. 1. Install cap (Figure 1, Item 8), three washers (Figure 1, Item 7), and bolts (Figure 1, Item 6) on final drive assembly (Figure 1, Item 1). 2. Remove two nuts (Figure 1, Item 3), bolts (Figure 1, Item 5), and washers (Figure 1, Item 4) from sprocket segment (Figure 1, Item 2).

Figure 1. Cap and Sprocket Bolts.

0136

0136-2

TM 5-2410-241-23-2

0136

REMOVAL CONTINUED 3. Loosen three nuts (Figure 2, Item 2) and bracket (Figure 2, Item 1) from lifting bracket (Figure 2, Item 4). 4. Position bracket (Figure 2, Item 1) 1.5 in. (38 mm) from end of lifting bracket (Figure 2, Item 4). 5. Tighten three nuts (Figure 2, Item 2) and bracket (Figure 2, Item 1) on lifting bracket (Figure 2, Item 4).

WARNING

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

NOTE
Final drive weighs approximately 1,377 lb (625 kg). 6. Install shackle (Figure 2, Item 3) and lifting device on lifting bracket (Figure 2, Item 4). 7. With assistance using lifting device, install lifting bracket (Figure 2, Item 1), two washers (Figure 2, Item 5), bolts (Figure 2, Item 6), washers (Figure 2, Item 8), and nuts (Figure 2, Item 7) on final drive assembly (Figure 2, Item 9).

Figure 2. Lifting Bracket.

0136

0136-3

TM 5-2410-241-23-2

0136

REMOVAL CONTINUED 8. Do not remove bolts (Figure 3, Item 6) from machine. 9. Remove two bolts (Figure 3, Item 5) and washers (Figure 3, Item 4) from machine.

WARNING

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

NOTE
Final drive weighs approximately 1,377 lb (625 kg). 10. Using lifting device, support final drive (Figure 3, Item 1). 11. Remove 26 bolts (Figure 3, Item 2) and washers (Figure 3, Item 3) from final drive (Figure 3, Item 1).

Figure 3. Final Drive Bolts.

0136

0136-4

TM 5-2410-241-23-2

0136

REMOVAL CONTINUED 12. With assistance and using lifting device, remove final drive (Figure 4, Item 1) and O-ring (Figure 4, Item 2) from machine (Figure 4, Item 3). Discard O-ring. 13. Place final drive (Figure 4, Item 1) on flat level surface.

Figure 4. Final Drive. 14. Using lifting device, remove two nuts (Figure 5, Item 2), washers (Figure 5, Item 3), bolts (Figure 5, Item 1), washers (Figure 5, Item 5), and lifting bracket (Figure 5, Item 4) from final drive assembly (Figure 5, Item 6).

0136

Figure 5. Final Drive Lifting Device.

0136

0136-5

TM 5-2410-241-23-2

0136

REMOVAL CONTINUED 15. Install two washers (Figure 6, Item 4), bolts (Figure 6, Item 5), and nuts (Figure 6, Item 3) on sprocket segment (Figure 6, Item 2) and final drive (Figure 6, Item 1).

Figure 6. Sprocket Bolts. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0136

000136

0136-6

TM 5-2410-241-23-2

0136

INSTALLATION

000136

NOTE
This procedure will install one final drive assembly. Follow same procedure for additional final drive assembly. 1. Remove two nuts (Figure 7, Item 3), bolts (Figure 7, Item 5), and washers (Figure 7, Item 4) from sprocket segment (Figure 7, Item 2) and final drive (Figure 7, Item 1).

Figure 7. Sprocket Bolts.

0136

0136-7

TM 5-2410-241-23-2

0136

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,377 lb (625 kg). 2. Install shackle and lifting device on lifting bracket (Figure 8, Item 4). 3. With assistance and using lifting device, install lifting bracket (Figure 8, Item 4), two washers (Figure 8, Item 5), bolts (Figure 8, Item 1), washers (Figure 8, Item 3), and nuts (Figure 8, Item 2) on final drive assembly (Figure 8, Item 6).

Figure 8. Final Drive Lifting Device.

0136

0136-8

TM 5-2410-241-23-2

0136

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,377 lb (625 kg). 4. Install new O-ring (Figure 9, Item 2) on machine (Figure 9, Item 3). 5. Position final drive (Figure 9, Item 1) on machine (Figure 9, Item 3).

Figure 9. Final Drive.

0136

0136-9

TM 5-2410-241-23-2

0136

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,377 lb (625 kg). 6. Install 26 washers (Figure 10, Item 3) and bolts (Figure 10, Item 2) on final drive (Figure 10, Item 1). 7. Install two washers (Figure 10, Item 4) and bolts (Figure 10, Item 5) on machine. 8. Do not remove bolts (Figure 10, Item 6) from machine.

Figure 10. Final Drive Bolts.

0136

0136-10

TM 5-2410-241-23-2

0136

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,377 lb (625 kg). 9. With assistance and using lifting device, remove two nuts (Figure 11, Item 6), washers (Figure 11, Item 5), bolts (Figure 11, Item 4), washers (Figure 11, Item 3), and lifting bracket (Figure 11, Item 2) from final drive assembly (Figure 11, Item 7). 10. Remove lifting device and shackle (Figure 11, Item 1) from lifting bracket (Figure 11, Item 2).

Figure 11. Lifting Bracket.

0136

0136-11

TM 5-2410-241-23-2

0136

INSTALLATION CONTINUED 11. Install two washers (Figure 12, Item 4), bolts (Figure 12, Item 5), and nuts (Figure 12, Item 3) on sprocket segment (Figure 12, Item 2). 12. Tighten nuts (Figure 12, Item 3) to 221 lb-ft (300 Nm). 13. Tighten nuts (Figure 12, Item 3) an additional 1/3 turn. 14. Check torque on nuts (Figure 12, Item 3). Minimum torque on nuts to 420 lb-ft (570 Nm). 15. Remove three bolts (Figure 12, Item 6), washers (Figure 12, Item 7), and cap (Figure 12, Item 8) from final drive assembly (Figure 12, Item 1).
.

Figure 12. Cap and Sprocket Bolts. END OF TASK

0136

0136-12

TM 5-2410-241-23-2

0136

FOLLOW-ON TASKS 1. Install ROPS (WP 0225). 2. Connect track (WP 0127). 3. Install axle (WP 0116). 4. Fill final drive oil (WP 0149). 5. If installing left final drive assembly on machine equipped with arctic heater, install battery box (WP 0289). 6. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000136

0136-13/(14 blank)

4 TM 5-2410-241-23-2 0137

FIELD MAINTENANCE SPROCKET SEGMENT REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 3 7

INITIAL SETUP Tools and Special Tools 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 64 Estimated Time to Complete 0.8 Hr 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Extension, 3/4 Drive, 4" Long (S0376) (WP 0302, Item 68) 0 Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) 0 Socket, Impact, 3/4 Drive, 6 point, 1-1/8 (S0972) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0

0137-1

TM 5-2410-241-23-2

0137

REMOVAL

000137

NOTE
This procedure will remove one sprocket segment. Follow the same procedure for additional sprocket segments. 1. Move machine forward or backward to position sprocket segment (Figure 1, Item 2) down. 2. Remove five nuts (Figure 1, Item 3) and sprocket segment (Figure 1, Item 2) from final drive (Figure 1, Item 1). 3. Remove five bolts (Figure 1, Item 5) and washers (Figure 1, Item 4) from final drive (Figure 1, Item 1).

Figure 1. Sprocket Segment. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0137

000137

0137-2

TM 5-2410-241-23-2

0137

INSTALLATION

000137

NOTE
This procedure will install one sprocket segment. Follow same procedure for additional sprocket segments. 1. Install five washers (Figure 1, Item 4) and bolts (Figure 1, Item 5) on final drive (Figure 1, Item 1). 2. Install sprocket segment (Figure 1, Item 2) and five nuts (Figure 1, Item 3) on final drive (Figure 1, Item 1). 3. Tighten nuts (Figure 1, Item 3) to 221 lb-ft (300 Nm). 4. Tighten nuts (Figure 1, Item 3) an additional 1/3 turn. 5. Check torque on nuts (Figure 1, Item 3). Minimum torque on nuts is 420 lb-ft (570 Nm). END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000137

0137-3/(4 blank)

14 TM 5-2410-241-23-2 0138

FIELD MAINTENANCE
0 1 3 8

BRAKE AND PLANETARY ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Bolt (3/4 in. x 10 x 5 1/2) (2) Bolt (5/8 in. x 10 x 2) (3) Nut (3/4 in. x 10) (2) O-ring (3) Washer (3/4) (4) Personnel Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Track separated (WP 0127) Final drive oil drained (WP 0149) Axles removed (WP 0116) ROPS removed (WP 0225) Drawing Required TM 5-2410-241-24P, Figure 65 Estimated Time to Complete 7.0 Hr 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Bracket, Link (3/8 in.; 2,250 lb [1,000 kg]) (WP 0302, Item 10) 0 Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) 0 Extension, 3/4 Drive, 4 Long (S3076) (WP 0302, Item 68) 0 Handle, Ratchet, 3/4 Drive, 17 Long (S0375) (WP 0302, Item 68) 0 Lifting Bracket (WP 0302, Item 75) 0 Shackle, 1 (WP 0302, Item 52) 0 Socket, 3/4 Drive, 12 Point, 1 1/8 (S0385) (WP 0302, Item 68) 0 Socket, Impact 3/4 Drive, 6 Point 1-1/8 (S0972) (WP 0302, Item 68) 0 Wrench, Combination, 1 1/8 (S0788) (WP 0302, Item 68) 0 Wrench, Electric Impact, 3/4 Square Drive, 1,200 lb-ft (S0730) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Lifting Device (2,000-lb capacity) 0

0138-1

TM 5-2410-241-23-2

0138

REMOVAL 1. Install cap (Figure 1, Item 8), three washers (Figure 1, Item 7), and bolts (Figure 1, Item 6) on final drive assembly (Figure 1, Item 1). 2. Remove two nuts (Figure 1, Item 3), bolts (Figure 1, Item 5), and washers (Figure 1, Item 4) from sprocket segment (Figure 1, Item 2).

000138

Figure 1. Cap and Sprocket Bolts.

0138

0138-2

TM 5-2410-241-23-2

0138

REMOVAL CONTINUED 3. Loosen three nuts (Figure 2, Item 2) and bracket (Figure 2, Item 1) on lifting bracket (Figure 2, Item 4). 4. Position bracket (Figure 2, Item 1) at end of lifting bracket (Figure 2, Item 4). 5. Tighten three nuts (Figure 2, Item 2) and bracket (Figure 2, Item 1) on lifting bracket (Figure 2, Item 4).

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 6. Install shackle (Figure 2, Item 3) and lifting device on lifting bracket (Figure 2, Item 4). 7. With assistance and using lifting device, install lifting bracket (Figure 2, Item 1), two washers (Figure 2, Item 6), bolts (Figure 2, Item 5), washers (Figure 2, Item 7), and nuts (Figure 2, Item 8) on final drive assembly (Figure 2, Item 9).

Figure 2. Lifting Bracket.

0138

0138-3

TM 5-2410-241-23-2

0138

REMOVAL CONTINUED 8. Do not remove bolts (Figure 3, Item 5) from machine. 9. Remove two bolts (Figure 3, Item 4) from machine.

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 10. Using lifting device, support final drive (Figure 3, Item 3). 11. Remove 26 bolts (Figure 3, Item 1) and washers (Figure 3, Item 2) from final drive (Figure 3, Item 3).

Figure 3. Final Drive Bolts.

0138

0138-4

TM 5-2410-241-23-2

0138

REMOVAL CONTINUED 12. With assistance and using lifting device, remove final drive (Figure 4, Item 1) and three O-rings (Figure 4, Item 2) from machine. Discard O-rings. 13. Place final drive (Figure 4, Item 1) face down on flat level surface.

Figure 4. Final Drive. 14. With assistance, remove two nuts (Figure 5, Item 2), washers (Figure 5, Item 3), bolts (Figure 5, Item 1), washers (Figure 5, Item 5), and lifting bracket (Figure 5, Item 4) from final drive assembly (Figure 5, Item 6).

0138

Figure 5. Final Drive Lifting Device.

0138

0138-5

TM 5-2410-241-23-2

0138

REMOVAL CONTINUED 15. Install two washers (Figure 6, Item 4), bolts (Figure 6, Item 5), and nuts (Figure 6, Item 3) on sprocket segment (Figure 6, Item 2) and final drive (Figure 6, Item 1).

Figure 6. Sprocket Bolts.

0138

WARNING

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

NOTE
Planetary assembly weighs approximately 300 lb (136 kg).

0138-6

TM 5-2410-241-23-2

0138

REMOVAL CONTINUED 16. Attach bracket links (Figure 7, Item 3), bolts (Figure 7, Item 2), and lifting device on planetary assembly (Figure 7, Item 1). Support final drive. 17. Remove two bolts (Figure 7, Item 4) and washers (Figure 7, Item 5) from final drive (Figure 7, Item 6). 18. Using lifting device, remove planetary assembly (Figure 7, Item 1) from final drive (Figure 7, Item 6). Set planetary assembly on flat level surface. 19. Remove lifting device, bolts (Figure 7, Item 2), and bracket links (Figure 7, Item 3) from planetary assembly (Figure 7, Item 1).

Figure 7. Brake Planetary END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0138

000138

0138-7

TM 5-2410-241-23-2

0138

INSTALLATION

000138

WARNING

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

NOTE
Planetary assembly weighs approximately 300 lb (136 kg). 1. Attach bracket links (Figure 8, Item 3), bolts (Figure 8, Item 2), and lifting device on planetary assembly (Figure 8, Item 1). Support final drive. 2. Using lifting device, install planetary assembly (Figure 8, Item 1) on final drive (Figure 8, Item 6). 3. Install two washers (Figure 8, Item 5) and bolts (Figure 8, Item 4) on final drive (Figure 8, Item 6). 4. Remove lifting device, bolts (Figure 8, Item 2), and bracket links (Figure 8, Item 3) from planetary assembly (Figure 8, Item 1).

Figure 8. Brake Planetary

0138

0138-8

TM 5-2410-241-23-2

0138

INSTALLATION CONTINUED 5. Remove two nuts (Figure 9, Item 3), bolts (Figure 9, Item 5), and washers (Figure 9, Item 4) from sprocket segment (Figure 9, Item 2) and final drive (Figure 9, Item 1).

Figure 9. Sprocket Bolts.

0138

0138-9

TM 5-2410-241-23-2

0138

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 6. Install shackle and lifting device on lifting bracket (Figure 10, Item 4). 7. With assistance and using lifting device, install lifting bracket (Figure 10, Item 4), two washers (Figure 10, Item 5), bolts (Figure 10, Item 1), washers (Figure 10, Item 3), and nuts (Figure 10, Item 2) on final drive assembly (Figure 10, Item 6).

Figure 10. Final Drive Lifting Device.

0138

0138-10

TM 5-2410-241-23-2

0138

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 8. Install three new O-rings (Figure 11, Item 2) and position final drive (Figure 11, Item 1) on machine.

Figure 11. Final Drive.

0138

0138-11

TM 5-2410-241-23-2

0138

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 9. Install 26 washers (Figure 12, Item 2) and bolts (Figure 12, Item 1) on final drive (Figure 12, Item 3). 10. Install two bolts (Figure 12, Item 4) on machine. 11. Ensure bolts (Figure 12, Item 5) are tight on machine.

Figure 12. Final Drive Bolts.

0138

0138-12

TM 5-2410-241-23-2

0138

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 12. With assistance and using lifting device, remove two nuts (Figure 13, Item 6), washers (Figure 13, Item 5), bolts (Figure 13, Item 4), washers (Figure 13, Item 3), and lifting bracket (Figure 13, Item 2) from final drive assembly (Figure 13, Item 7). 13. Remove lifting device and shackle (Figure 13, Item 1) from lifting bracket (Figure 13, Item 2).

Figure 13. Lifting Bracket.

0138

0138-13

TM 5-2410-241-23-2

0138

INSTALLATION CONTINUED 14. Install two washers (Figure 14, Item 4), bolts (Figure 14, Item 5), and nuts (Figure 14, Item 3) on sprocket segment (Figure 14, Item 2). 15. Tighten nuts (Figure 14, Item 3) to 221 lb-ft (300 Nm). 16. Tighten nuts (Figure 14, Item 3) an additional 1/3 turn. 17. Check torque on nuts (Figure 14, Item 3). Minimum torque on nuts to 420 lb-ft (570 Nm). 18. Remove three bolts (Figure 14, Item 6), washers (Figure 14, Item 7), and cap (Figure 14, Item 8) from final drive assembly (Figure 14, Item 1).

Figure 14. Cap and Sprocket Bolts. END OF TASK FOLLOW-ON TASKS 1. Install ROPS (WP 0225). 2. Connect track (WP 0127). 3. Install axles (WP 0116). 4. Fill final drive oil (WP 0149). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0138

000138

0138-14

14 TM 5-2410-241-23-2 0139

FIELD MAINTENANCE
0 1 3 9

BRAKE AND DIFFERENTIAL DRIVE ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Bolt (3/4 in. x 10 x 5 1/2) (2) Bolt (5/8 in. x 10 x 2) (3) Nut (3/4 in. x 10) (2) O-ring (4) Washer (3/4) (4) Personnel Two References WP 0295 Equipment Condition 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Adapter Assembly, Axle Removal (WP 0302, Item 1) 0 Axle Removal Tool (WP 0302, Item 9) 0 Bracket, Link (3/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 11) 0 Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) 0 Extension, 3/4 Drive, 4 Long (S3076) (WP 0302, Item 68) 0 Handle, Ratchet, 3/4 Drive, 17 Long (S0375) (WP 0302, Item 68) 0 Lifting Bracket (WP 0302, Item 75) 0 Shackle, 1 (WP 0302, Item 52) 0 Socket, 3/4 Drive, 12 Point, 1 1/8 (S0385) (WP 0302, Item 68) 0 Socket, Impact 3/4 Drive, 6 Point 1-1/8 (S0972) (WP 0302, Item 68) 0 Wrench, Combination, 1 1/8 (S0788) (WP 0302, Item 68) 0 Wrench, Electric Impact, 3/4 Square Drive, 1,200 lb-ft (S0730) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Lifting Device (2,000-lb capacity) 0

Machine parked (TM 5-2410-241-10) 0 Track separated (WP 0127) 0 Axles removed (WP 0116) 0 Adapter removed (WP 0115) 0 Final drive oil drained (WP 0149) 0 ROPS removed (WP 0225) 0 Battery box removed (WP 0289) if machine equipped with arctic heater 0 Drawing Required TM 5-2410-241-24P, Figure 66 Estimated Time to Complete 8.0 Hr 0 0 0 0

0139-1

TM 5-2410-241-23-2

0139

REMOVAL 1. Insert axle removal tool and adapter (Figure 1, Item 1) 37 in. (940 mm) in final drive (Figure 1, Item 2). 2. Rotate axle removal tool and adapter (Figure 1, Item 1) 180 degrees. 3. Pull axle removal tool and adapter (Figure 1, Item 1) until sliding carrier stops. 4. Rotate axle removal tool and adapter (Figure 1, Item 1) 180 degrees. 5. Remove axle removal tool and adapter (Figure 1, Item 1) 37 in. (940 mm) from final drive (Figure 1, Item 2).

000139

Figure 1. Sliding Carrier.

0139

0139-2

TM 5-2410-241-23-2

0139

REMOVAL CONTINUED 6. Install cap (Figure 2, Item 8), three washers (Figure 2, Item 7), and bolts (Figure 2, Item 6) on final drive assembly (Figure 2, Item 1). 7. Remove two nuts (Figure 2, Item 3), bolts (Figure 2, Item 5), and washers (Figure 2, Item 4) from sprocket segment (Figure 2, Item 2).

Figure 2. Cap and Sprocket Bolts.

0139

0139-3

TM 5-2410-241-23-2

0139

REMOVAL CONTINUED 8. Loosen three nuts (Figure 3, Item 4) and bracket (Figure 3, Item 3) from lifting bracket (Figure 3, Item 1). 9. Position bracket (Figure 3, Item 3) at far end on lifting bracket (Figure 3, Item 1). 10. Tighten three nuts (Figure 3, Item 4) and bracket (Figure 3, Item 3) on lifting bracket (Figure 3, Item 1).

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 11. Install shackle (Figure 3, Item 2) and lifting device on lifting bracket (Figure 3, Item 1). 12. With assistance using lifting device, install lifting bracket (Figure 3, Item 1), two washers (Figure 3, Item 5), bolts (Figure 3, Item 6), washers (Figure 3, Item 8), and nuts (Figure 3, Item 7) on final drive assembly (Figure 3, Item 9).

Figure 3. Lifting Bracket.

0139

0139-4

TM 5-2410-241-23-2

0139

REMOVAL CONTINUED 13. Do not remove bolts (Figure 4, Item 3) from machine. 14. Remove two bolts (Figure 4, Item 4) from machine.

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 15. Using lifting device, support final drive (Figure 4, Item 5). 16. Remove 26 bolts (Figure 4, Item 1) and washers (Figure 4, Item 2) from final drive (Figure 4, Item 5).

Figure 4. Final Drive Bolts.

0139

0139-5

TM 5-2410-241-23-2

0139

REMOVAL CONTINUED 17. With assistance and using lifting device, remove final drive (Figure 5, Item 6) and three O-rings (Figure 5, Item 7) from machine. Discard O-rings. 18. Place final drive (Figure 5, Item 6) flat level surface. 19. Remove two nuts (Figure 5, Item 2), washers (Figure 5, Item 3), bolts (Figure 5, Item 1), washers (Figure 5, Item 5), and lifting bracket (Figure 5, Item 4) from final drive (Figure 5, Item 6).

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 20. Attach bracket link and lifting device on brake and differential assembly (Figure 5, Item 8). 21. Using lifting device, position final drive (Figure 5, Item 6) face down. 22. Remove lifting device and bracket link from brake and differential assembly (Figure 5, Item 8).

Figure 5. Final Drive.

0139

0139-6

TM 5-2410-241-23-2

0139

REMOVAL CONTINUED

WARNING

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

NOTE
Brake housing weighs approximately 440 lb (198 kg). 23. Install three bracket links (Figure 6, Item 3), bolts (Figure 6, Item 2), and lifting device on brake housing (Figure 6, Item 1). 24. With assistance, remove two bolts (Figure 6, Item 5), washers (Figure 6, Item 6), and brake housing (Figure 6, Item 1) from final drive housing (Figure 6, Item 4). Place brake housing on its side on flat level surface. 25. Remove lifting device, three bolts (Figure 6, Item 2), and bracket links (Figure 6, Item 3) from brake housing (Figure 6, Item 1).

Figure 6. Brake Housing.

0139

0139-7

TM 5-2410-241-23-2

0139

REMOVAL CONTINUED 26. Remove O-ring (Figure 7, Item 2) from brake housing (Figure 7, Item 1). Discard O-ring.

Figure 7. Housing O-ring. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install new O-ring (Figure 7, Item 2) on brake housing (Figure 7, Item 1).

0139

000139

000139

0139-8

TM 5-2410-241-23-2

0139

INSTALLATION CONTINUED

WARNING

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

NOTE
Brake housing weighs approximately 440 lb (198 kg). 2. Install three bracket links (Figure 8, Item 3), bolts (Figure 8, Item 2), and lifting device on brake housing (Figure 8, Item 1). 3. Using lifting device, install brake housing (Figure 8, Item 1), two washers (Figure 8, Item 6), and bolts (Figure 8, Item 5) on final drive housing (Figure 8, Item 4). 4. Remove lifting device, three bolts (Figure 8, Item 2), and bracket links (Figure 8, Item 3) from brake housing (Figure 8, Item 1).

Figure 8. Brake Housing.

0139

0139-9

TM 5-2410-241-23-2

0139

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 5. Attach bracket link and lifting device on brake and differential assembly (Figure 9, Item 8). 6. Using lifting device, position final drive (Figure 9, Item 6) on its side. 7. Remove lifting device and bracket link from brake and differential assembly (Figure 9, Item 8). 8. Install lifting bracket (Figure 9, Item 4), washers, (Figure 9, Item 5), bolts (Figure 9, Item 1), washers, (Figure 9, Item 3), and two nuts (Figure 9, Item 2) on final drive (Figure 9, Item 6). 9. Install three new O-rings (Figure 9, Item 7) on final drive (Figure 9, Item 6). 10. Using lifting device, position final drive (Figure 9, Item 6) on machine.

Figure 9. Final Drive.

0139

0139-10

TM 5-2410-241-23-2

0139

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,377 lb (625 kg). 11. Install 26 washers (Figure 10, Item 2) and bolts (Figure 10, Item 1) on final drive (Figure 10, Item 5). 12. Install two bolts (Figure 10, Item 4) on machine. 13. Ensure bolts (Figure 10, Item 3) are tight on machine.

Figure 10. Final Drive Bolts.

0139

0139-11

TM 5-2410-241-23-2

0139

INSTALLATION CONTINUED

WARNING

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

NOTE
Final drive weighs approximately 1,875 lb (850 kg). 14. Using lifting device, remove two nuts (Figure 11, Item 5), washers (Figure 11, Item 6), bolts (Figure 11, Item 4), washers (Figure 11, Item 3), and lifting bracket (Figure 11, Item 1) from final drive assembly (Figure 11, Item 7). 15. Remove lifting device and shackle (Figure 11, Item 2) from lifting bracket (Figure 11, Item 1).

Figure 11. Lifting Bracket.

0139

0139-12

TM 5-2410-241-23-2

0139

INSTALLATION CONTINUED 16. Install two washers (Figure 12, Item 4), bolts (Figure 12, Item 5), and nuts (Figure 12, Item 3) on sprocket segment (Figure 12, Item 2). 17. Tighten nuts (Figure 12, Item 3) to 221 lb-ft (300 Nm). 18. Tighten nuts (Figure 12, Item 3) an additional 1/3 turn. 19. Check torque on nuts (Figure 12, Item 3). Minimum torque on nuts to 420 lb-ft (570 Nm). 20. Remove three bolts (Figure 12, Item 6), washers (Figure 12, Item 7), and cap (Figure 12, Item 8) from final drive assembly (Figure 12, Item 1).

Figure 12. Cap and Sprocket Bolts. END OF TASK

0139

0139-13

TM 5-2410-241-23-2

0139

FOLLOW-ON TASKS 1. Install ROPS (WP 0225). 2. Install adapter (WP 0115). 3. Install axles (WP 0116). 4. Fill final drive oil (WP 0149). 5. Connect track (WP 0127). 6. If machine equipped with arctic heater, install battery box (WP 0289). 7. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000139

0139-14

8 TM 5-2410-241-23-2 0140

FIELD MAINTENANCE HYDROSTATIC DRIVE MOTOR SERVICE Removal, Cleaning and Inspection, Installation
0 1 4 0

INITIAL SETUP Tools and Special Tools 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Bottom guards removed (WP 0199) Counterbalance valve removed (WP 0217) Drawing Required TM 5-2410-241-24P, Figure 67 Estimated Time to Complete 11.5 Hr 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Forcing Screw, 3/8 X 16 (WP 0302, Item 25) 0 Hoist, Chain (WP 0302, Item 33) 0 Shackle, 7/8, 6.5 Ton (WP 0302, Item 53) 0 Sling, Multiple Leg (WP 0302, Item 54) 0 Socket, 1/2 Drive 6 Point 1-1/8 (S0582) (WP 0302, Item 68) 0 Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (4) 0 0 0 0 0

0140-1

TM 5-2410-241-23-2

0140

REMOVAL

000140

NOTE
Tag and mark lines and hoses to aid installation. Cap and plug all lines and hoses to prevent contamination and leaks.

1. Loosen nut (Figure 1, Item 3) and remove tee (Figure 1, Item 2) from elbow fitting (Figure 1, Item 4). Position two hoses (Figure 1, Item 1) aside. 2. Loosen tube nut (Figure 1, Item 6) and remove hose (Figure 1, Item 5) from hydrostatic drive pump (Figure 1, Item 7). Position hose aside.

Figure 1. Hydraulic Hoses.

0140

0140-2

TM 5-2410-241-23-2

0140

REMOVAL CONTINUED

WARNING

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

NOTE
Hydrostatic drive motor weighs approximately 70 lb (32 kg). 3. Attach lifting device on hydrostatic drive motor (Figure 2, Item 1). Support hydrostatic drive motor. 4. Remove two bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and hydrostatic drive motor (Figure 2, Item 1) from machine.

Figure 2. Hydrostatic Drive Motor.

0140

0140-3

TM 5-2410-241-23-2

0140

REMOVAL CONTINUED 5. Install forcing screw (Figure 3, Item 1) in drive motor (Figure 3, Item 2) and remove motor from machine.

Figure 3. Forcing Screw.

0140

0140-4

TM 5-2410-241-23-2

0140

REMOVAL CONTINUED 6. Position hydrostatic drive motor (Figure 4, Item 5) on flat level surface. 7. Remove lifting device and forcing screw from hydrostatic drive motor (Figure 4, Item 5). 8. Remove fitting (Figure 4, Item 1) from hydrostatic drive motor (Figure 4, Item 5). 9. Remove two O-rings (Figure 4, Item 2) from fitting (Figure 4, Item 1). Discard O-rings. 10. Remove fitting (Figure 4, Item 4) from hydrostatic drive motor (Figure 4, Item 5). 11. Remove two O-rings (Figure 4, Item 3) from fitting (Figure 4, Item 4). Discard O-rings.

Figure 4. Fittings. CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0140

000140

0140-5

TM 5-2410-241-23-2

0140

INSTALLATION 1. Install two new O-rings (Figure 5, Item 3) on fitting (Figure 5, Item 4). 2. Install fitting (Figure 5, Item 4) on hydrostatic drive motor (Figure 5, Item 5). 3. Install two new O-rings (Figure 5, Item 2) on fitting (Figure 5, Item 1). 4. Install fitting (Figure 5, Item 1) on hydrostatic drive motor (Figure 5, Item 5).

000140

Figure 5. Fittings.

0140

0140-6

TM 5-2410-241-23-2

0140

INSTALLATION CONTINUED

WARNING

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

NOTE
Hydrostatic drive motor weighs approximately 70 lb (32 kg). 5. Attach lifting device to hydrostatic drive motor (Figure 6, Item 1). Support hydrostatic drive motor. 6. Install hydrostatic drive motor (Figure 6, Item 1), two washers (Figure 6, Item 3), and bolts (Figure 6, Item 2) on machine. 7. Remove lifting device from hydrostatic drive motor (Figure 6, Item 1).

Figure 6. Hydrostatic Drive Motor.

0140

0140-7

TM 5-2410-241-23-2

0140

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 8. Install hose (Figure 7, Item 5) on hydrostatic drive pump (Figure 7, Item 7) and tighten tube nut (Figure 7, Item 6). 9. Position two hoses (Figure 7, Item 1) and install tee (Figure 7, Item 2) on elbow fitting (Figure 7, Item 4). Tighten nut (Figure 7, Item 3).

Figure 7. Hydraulic Hoses. END OF TASK FOLLOW-ON TASKS 1. Install counterbalance valve (WP 0217). 2. Install bottom guards (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0140

000140

0140-8

14 TM 5-2410-241-23-2 0141

FIELD MAINTENANCE
0 1 4 1

GEAR PUMP SERVICE

Removal, Cleaning and Inspection, Installation INITIAL SETUP Tools and Special Tools 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Transmission drained (WP 0151) Main drive shaft removed (WP 0117) Coupling removed (WP 0120) Drawing Required TM 5-2410-241-24P, Figure 52, 68 Estimated Time to Complete 8.0 Hr 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Hoist, Chain (WP 0302, Item 33) 0 Lifting Link (1/2 in.; 4,000 lb [1,800 kg]) (WP 0302, Item 36) (2) 0 Sling, Multiple Leg (WP 0302, Item 54) 0 Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (10) 0 0 0 0 0

0141-1

TM 5-2410-241-23-2

0141

REMOVAL

000141

CAUTION
Cap all hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag all hoses, tubes, and fittings to aid installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Note routing of hoses and lines to aid installation.

1. Remove four bolts (Figure 1, Item 7), washers (Figure 1, Item 8), and bell and tube (Figure 1, Item 2) from transmission (Figure 1, Item 9). 2. Remove two bolts (Figure 1, Item 3), washers (Figure 1, Item 4), and bell and tube (Figure 1, Item 2) from pump (Figure 1, Item 1). 3. Remove four O-rings (Figure 1, Items 5 and 6) from bell and tube (Figure 1, Item 2). Discard O-rings.

Figure 1. Bell and Tube.

0141

0141-2

TM 5-2410-241-23-2

0141

REMOVAL CONTINUED

NOTE
Tag electrical connectors to aid installation. 4. Disconnect temperature sensor connector (Figure 2, Item 3) from wiring harness (Figure 2, Item 4). 5. Remove temperature sensor probe (Figure 2, Item 2) from pump (Figure 2, Item 1). 6. Remove and discard O-ring (Figure 2, Item 5) from temperature sensor probe (Figure 2, Item 2).

Figure 2. Temperature Sensor. 7. Remove four bolts (Figure 3, Item 1) and plate (Figure 3, Item 2) from headliner (Figure 3, Item 3). 8. Remove mirror (Figure 3, Item 4) from bracket (Figure 3, Item 7).

0141

9. Remove two bolts (Figure 3, Item 5), washers (Figure 3, Item 6), and bracket (Figure 3, Item 7) from headliner (Figure 3, Item 3).

Figure 3. Headliner.

0141

0141-3

TM 5-2410-241-23-2

0141

REMOVAL CONTINUED 10. Install bracket links on cab (Figure 4, Item 1). 11. Install chain hoist on bracket links.

Figure 4. Cab Lifting Device Setup.

0141

CAUTION
Cap all hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag all hoses, tubes, and fittings to aid installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Note routing of hoses and lines to aid installation.

0141-4

TM 5-2410-241-23-2

0141

REMOVAL CONTINUED 12. Remove twelve bolts (Figure 5, Item 4), washers (Figure 5, Item 5) and three hoses (Figure 5, Items 2, 3 and 6) from pump (Figure 5, Item 1).

Figure 5. Hoses.

0141

13. Remove six flanges (Figure 6, Item 1) and three O-rings (Figure 6, Item 3) from three hoses (Figure 6, Item 2). Discard O-rings.

Figure 6. O-rings.

0141

0141-5

TM 5-2410-241-23-2

0141

REMOVAL CONTINUED

WARNING

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

NOTE
Gear pump weighs approximately 90 lb (41 kg). 14. Attach sling and chain hoist to pump (Figure 7, Item 1). 15. Remove slack from sling. 16. Remove two nuts (Figure 7, Item 4) and washers (Figure 7, Item 5) from pump (Figure 7, Item 1). 17. Using chain hoist, remove two bolts (Figure 7, Item 2), washers (Figure 7, Item 3), and pump (Figure 7, Item 1) from machine. Place pump on flat level surface. 18. Remove chain hoist and sling from pump (Figure 7, Item 1).

Figure 7. Pump.

0141

0141-6

TM 5-2410-241-23-2

0141

REMOVAL CONTINUED 19. Remove and discard two O-rings (Figure 8, Items 1 and 2) from pump (Figure 8, Item 3).

Figure 8. Pump O-rings. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0141

000141

0141-7

TM 5-2410-241-23-2

0141

INSTALLATION 1. Install two new O-rings (Figure 9, Items 1 and 2) on pump (Figure 9, Item 3).

000141

Figure 9. Pump O-rings.

0141

0141-8

TM 5-2410-241-23-2

0141

INSTALLATION CONTINUED

WARNING

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

NOTE
Gear pump weighs approximately 90 lb (41 kg). 2. Attach sling and chain hoist to pump (Figure 10, Item 1). 3. Using chain hoist, install pump (Figure 10, Item 1), two washers (Figure 10, Item 3), and bolts (Figure 10, Item 2) on machine. 4. Install two washers (Figure 10, Item 5) and nuts (Figure 10, Item 4) on pump (Figure 10, Item 1). 5. Remove sling and chain hoist from pump (Figure 10, Item 1).

Figure 10. Pump.

0141

0141-9

TM 5-2410-241-23-2

0141

INSTALLATION CONTINUED 6. Install three new O-rings (Figure 11, Item 3) and six flanges (Figure 11, Item 1) on three hoses (Figure 11, Item 2).

Figure 11. O-rings.

0141

NOTE
Install hoses, tubes and fittings as noted during removal. 7. Install 3 hoses (Figure 12, Items 2, 3 and 6), 12 washers (Figure 12, Item 5), and bolts (Figure 12, Item 4) on pump (Figure 12, Item 1).

Figure 12. Hoses.

0141

0141-10

TM 5-2410-241-23-2

0141

INSTALLATION CONTINUED 8. Remove chain hoist from bracket links. 9. Remove bracket links from cab (Figure 13, Item 1).

Figure 13. Cab Lifting Device Setup.

0141

10. Install bracket (Figure 14, Item 7), two washers (Figure 14, Item 6), and bolts (Figure 14, Item 5) on headliner (Figure 14, Item 3). 11. Install mirror (Figure 14, Item 4) on bracket (Figure 14, Item 7). 12. Install plate (Figure 14, Item 2) and four bolts (Figure 14, Item 1) on headliner (Figure 14, Item 3).

Figure 14. Headliner.

0141

0141-11

TM 5-2410-241-23-2

0141

INSTALLATION CONTINUED 13. Install new O-ring (Figure 15, Item 5) on temperature sensor probe (Figure 15, Item 2). 14. Install temperature sensor probe (Figure 15, Item 2) on pump (Figure 15, Item 1). 15. Connect temperature sensor connector (Figure 15, Item 3) to wiring harness (Figure 15, Item 4).

Figure 15. Temperature Sensor.

0141

0141-12

TM 5-2410-241-23-2

0141

INSTALLATION CONTINUED

NOTE
Install hoses, tubes and fittings as noted during removal. 16. Install four new O-rings (Figure 16, Items 5 and 6) on bell and tube (Figure 16, Item 2). 17. Install bell and tube (Figure 16, Item 2), two washers (Figure 16, Item 4), and bolts (Figure 16, Item 3) on pump (Figure 16, Item 1). 18. Install bell and tube (Figure 16, Item 2), four washers (Figure 16, Item 8), and bolts (Figure 16, Item 7) on transmission (Figure 16, Item 9).

Figure 16. Bell and Tube. END OF TASK FOLLOW-ON TASKS 1. Install coupling (WP 0120). 2. Install main drive shaft (WP 0117). 3. Fill transmission (WP 0151). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0141

000141

0141-13/(14 blank)

20 TM 5-2410-241-23-2 0142

FIELD MAINTENANCE INSTRUCTIONS TRANSMISSION ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation
0 1 4 2

INITIAL SETUP Tools and Special Tools 0 Personnel Required Two References WP 0184 WP 0295 Equipment Condition 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Adapter Assembly, Axle Removal (WP 0302, Item 1) 0 Adapter, Transmission (WP 0302, Item 7) 0 Axle Removal Tool (WP 0302, Item 9) 0 Bracket, Link (3/8 in.; 2,250 lb [1,000 kg]) (WP 0302, Item 10) (2) 0 Crowfoot Attachment, Socket Wrench, 1-3/8 (1/2 drive) (WP 0302, Item 19) 0 Crowfoot Attachment, Socket Wrench, 1-5/8 (1/2 drive) (WP 0302, Item 20) 0 Jack Stand (4910-00-251-8013) (WP 0302, Item 68) 0 Socket, 1/2 Drive, 6 point, Long, 1-3/16 (S0625) (WP 0302, Item 68) 0 Wrench Open End 1-3/8 and 1-7/16 (S0852) (WP 0302, Item 68) 0 Wrench Open End, 1-1/2 and 1-5/8 (S0853) (WP 0302, Item 68) 0 Lifting device (2,000-lb capacity) 0 Materials/Parts Cap Set, Protective (WP 0303, Item 4) Tag, Marker (WP 0303, Item 34) Bolts (5/8 x 10) (2) Bolts (1/2 x 13) (2) O-ring (8) Safety Wire 0 0 0 0 0 0 0

Machine parked (TM 5-2410-241-10) 0 Main drive shaft removed (WP 0117) 0 With ripper equipped - ripper frame removed (WP 0279) 0 With winch equipped - winch removed (WP 0272) 0 Transmission fluid drained (WP 0151) 0 Rear bottom guard removed (WP 0199) 0 Ripper control valve removed (WP 0213) 0 Axles removed (WP 0116) 0 Drawing Required TM 5-2410-241-24P, Figure 70 Estimated Time to Complete 8.5 Hr 0 0 0 0

0142-1

TM 5-2410-241-23-2

0142

REMOVAL 1. Install adapter (Figure 1, Item 3) on axle removal tool (Figure 1, Item 1). 2. Insert axle removal tool and adapter (Figure 1, Item 1) 37 in. (940 mm) in left final drive (Figure 1, Item 2). 3. Rotate axle removal tool and adapter (Figure 1, Item 1) 180 degrees. 4. Pull axle removal tool and adapter (Figure 1, Item 1) until sliding carrier stops. 5. Rotate axle removal tool and adapter (Figure 1, Item 1) 180 degrees. 6. Remove axle removal tool and adapter (Figure 1, Item 1) 37 in. (940 mm) from final drive (Figure 1, Item 2).

000142

Figure 1. Sliding Carrier.

0142

0142-2

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED 7. Remove four bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and guard (Figure 2, Item 1) from transmission case (Figure 2, Item 7). 8. Remove four bolts (Figure 2, Item 5), washers (Figure 2, Item 4), and two brackets (Figure 2, Item 6) from machine.

Figure 2. Plate.

0142

0142-3

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED

NOTE
Tag and mark all hose and line connections to aid installation. Cap and plug all hose connections. 9. Loosen two tube nuts (Figure 3, Item 3) and disconnect two tube assemblies (Figure 3, Item 2) from fitting (Figure 3, Item 5). 10. Remove two O-rings (Figure 3, Item 4) from fitting (Figure 3, Item 5). Discard O-rings.

NOTE
Tag electrical connectors to aid installation. 11. Remove safety wire (Figure 3, Item 8) from connector (Figure 3, Item 1). Discard safety wire. 12. Twist lock (Figure 3, Item 7) and disconnect electrical connector (Figure 3, Item 1) from transmission case (Figure 3, Item 6).

Figure 3. Connections.

0142

0142-4

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED 13. Remove the yoke (Figure 4, Item 6) from transmission. 14. Remove four bolts (Figure 4, Item 1), washers (Figure 4, Item 2) and retainer (Figure 4, Item 4) from transmission and bevel gear case (Figure 4, Item 5). 15. Remove O-ring (Figure 4, Item 3) from the transmission and bevel gear case (Figure 4, Item 5). Discard O-ring.

Figure 4. Retainer.

0142

0142-5

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED 16. Remove six bolts (Figure 5, Item 2) and cover (Figure 5, Item 1) from transmission case (Figure 5, Item 4). 17. Install Adapter FT-1897 (Figure 5, Item 3) and six bolts (Figure 5, Item 2) on transmission case (Figure 5, Item 4).

Figure 5. Transmission Tool.

0142

0142-6

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED

NOTE
Note location of bolts to aid installation. 18. Remove 19 bolts (Figure 6, Item 5) and washers (Figure 6, Item 4) from transmission case (Figure 6, Item 6). 19. Remove three bolts (Figure 6, Item 3), washers (Figure 6, Item 1), and one bracket (Figure 6, Item 2) from top transmission case (Figure 6, Item 6). Position bracket aside.

Figure 6. Transmission Mounting Bolts.

0142

0142-7

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED

WARNING

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

NOTE
Transmission weighs approximately 825 lb (375 kg). 20. Attach lifting device on adapter (Figure 7, Item 3). Support transmission (Figure 7, Item 2).

NOTE
Remove a 12-point bolt from each side of transmission case. Install forcing bolts in the location of removed 12-point bolts. 21. Remove two 12-point bolts (Figure 7, Item 1) from the transmission case (Figure 7, Item 2). 22. Evenly install two forcing bolts 1/2 x 13 (Figure 7, Item 4) on transmission case (Figure 7, Item 2). 23. Using lifting device, support transmission case (Figure 7, Item 2) and evenly install forcing bolts (Figure 7, Item 4) on transmission case (Figure 7, Item 2). 24. Remove two forcing bolts 1/2 x 13 (Figure 7, Item 4) and install two 12-point bolts (Figure 7, Item 1) on the transmission case (Figure 7, Item 2).

Figure 7. Transmission Tool.

0142

0142-8

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED

WARNING

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

NOTE
Transmission weighs approximately 825 lb (375 kg). 25. Using lifting device, keep transmission case (Figure 8, Item 1) level. 26. Slide transmission case (Figure 8, Item 1) from machine until roller (Figure 8, Item 2) contacts stop (Figure 8, Item 3).

Figure 8. Transmission Roller.

0142

0142-9

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED

WARNING

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

NOTE
Transmission weighs approximately 825 lb (375 kg). 27. Install jack stand under rear of transmission case (Figure 9, Item 1). 28. Remove lifting device from adapter (Figure 9, Item 5). 29. Remove six bolts (Figure 9, Item 4) and adapter (Figure 9, Item 5) from case (Figure 9, Item 1). 30. Install original plate and six bolts (Figure 9, Item 4) on case (Figure 9, Item 1). 31. Install two bracket links (Figure 9, Item 2) and bolts (Figure 9, Item 3) on transmission case (Figure 9, Item 1). 32. Attach lifting device on bracket links (Figure 9, Item 2). 33. Using lifting device, remove transmission case (Figure 9, Item 1) from machine. Place transmission case on flat level surface.

Figure 9. Transmission Stand Support.

0142

0142-10

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED 34. Remove lifting device from bracket links (Figure 10, Item 3). 35. Remove two bolts (Figure 10, Item 4) and bracket links (Figure 10, Item 3) from transmission case (Figure 10, Item 5). 36. Remove O-ring (Figure 10, Item 6) from transmission case (Figure 10, Item 5). Discard O-ring. 37. Remove fitting (Figure 10, Item 1) and O-ring (Figure 10, Item 2) from transmission case (Figure 10, Item 5). Discard O-ring. 38. Remove four bolts (Figure 10, Item 9), washers (Figure 10, Item 8), and two roller brackets (Figure 10, Item 7) from transmission case (Figure 10, Item 5).

Figure 10. Transmission Roller and Fitting.

0142

0142-11

TM 5-2410-241-23-2

0142

REMOVAL CONTINUED 39. Remove three O-rings (Figure 11, Item 2) from gear case (Figure 11, Item 1). Discard O-rings.

Figure 11. Case O-rings. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0142

000142

0142-12

TM 5-2410-241-23-2

0142

INSTALLATION 1. Install three new O-rings (Figure 12, Item 2) on gear case (Figure 12, Item 1).

000142

Figure 12. Case O-rings.

0142

2. Install two roller brackets (Figure 13, Item 7), four washers (Figure 13, Item 8), and bolts (Figure 13, Item 9) on transmission case (Figure 13, Item 5). 3. Install new O-ring (Figure 13, Item 2) and fitting (Figure 13, Item 1) on transmission case (Figure 13, Item 5). 4. Install new O-ring (Figure 13, Item 6) on transmission case (Figure 13, Item 5). 5. Install two bracket links (Figure 13, Item 3) and bolts (Figure 13, Item 4) on transmission case (Figure 13, Item 5).

Figure 13. Transmission Roller and Fitting.

0142

0142-13

TM 5-2410-241-23-2

0142

INSTALLATION CONTINUED

WARNING

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

NOTE
Transmission weighs approximately 825 lb (375 kg). 6. Attach lifting device on bracket links (Figure 14, Item 2). 7. Using lifting device, position transmission case (Figure 14, Item 1) on machine. 8. Install jack stand under rear of transmission case (Figure 14, Item 1). 9. Remove lifting device from bracket links (Figure 14, Item 2). 10. Remove two bolts (Figure 14, Item 3) and bracket links (Figure 14, Item 2) from transmission case (Figure 14, Item 1). 11. Remove six bolts (Figure 14, Item 4) and plate from case (Figure 14, Item 1). 12. Install adapter (Figure 14, Item 5) and six bolts (Figure 14, Item 4) on case (Figure 14, Item 1). 13. Install lifting device on adapter (Figure 14, Item 5).

Figure 14. Transmission Stand Support.

0142

0142-14

TM 5-2410-241-23-2

0142

INSTALLATION CONTINUED

WARNING

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

NOTE
Transmission weighs approximately 825 lb (375 kg). 14. Using lifting device, keep transmission case (Figure 15, Item 1) level. 15. Slowly slide transmission case (Figure 15, Item 1) and rollers (Figure 15, Item 2) in machine and away from stops (Figure 15, Item 3).

Figure 15. Transmission Roller.

0142

0142-15

TM 5-2410-241-23-2

0142

INSTALLATION CONTINUED

NOTE
Install bolts as noted during removal. Start and evenly tighten all bolts.

16. Install one bracket (Figure 16, Item 2), three washers (Figure 16, Item 1), and bolts (Figure 16, Item 3) on top transmission case (Figure 16, Item 6). 17. Install 19 washers (Figure 16, Item 4) and bolts (Figure 16, Item 5) on transmission case (Figure 16, Item 6).

Figure 16. Transmission Mounting Bolts.

0142

0142-16

TM 5-2410-241-23-2

0142

INSTALLATION CONTINUED 18. Remove lifting device from adapter (Figure 17, Item 3). 19. Remove six bolts (Figure 17, Item 2) and adapter (Figure 17, Item 3) from transmission case (Figure 17, Item 4). 20. Install cover (Figure 17, Item 1) and six bolts (Figure 17, Item 2) on transmission case (Figure 17, Item 4).

Figure 17. Transmission Adapter Tool.

0142

0142-17

TM 5-2410-241-23-2

0142

INSTALLATION CONTINUED 21. Install new O-ring (Figure 18, Item 3) on transmission and bevel gear case (Figure 18, Item 5). 22. Install retainer (Figure 18, Item 4), four washers (Figure 18, Item 2), and bolts (Figure 18, Item 1) on transmission and bevel gear case (Figure 18, Item 5). 23. Install yoke (Figure 18, Item 6) on transmission.

Figure 18. Retainer.

0142

0142-18

TM 5-2410-241-23-2

0142

INSTALLATION CONTINUED

NOTE
Install electrical connectors as tagged during removal. 24. Connect electrical connector (Figure 19, Item 1) and twist lock (Figure 19, Item 7) on transmission case (Figure 19, Item 6). 25. Install new safety wire (Figure 19, Item 8) on connector (Figure 19, Item 1).

NOTE
Remove caps and plugs from all hose and line connections. Install hoses and lines as noted during removal.

26. Install two new O-rings (Figure 19, Item 4) on fitting (Figure 19, Item 5). 27. Install two tube assembly (Figure 19, Item 2) and tube nuts (Figure 19, Item 3) on fitting (Figure 19, Item 5).

Figure 19. Connections.

0142

0142-19

TM 5-2410-241-23-2

0142

INSTALLATION CONTINUED 28. Install two brackets (Figure 20, Item 6), four washers (Figure 20, Item 4), and bolts (Figure 20, Item 5) on machine. 29. Install guard (Figure 20, Item 1), four washers (Figure 20, Item 3), and bolts (Figure 20, Item 2) on transmission case (Figure 20, Item 7).

Figure 20. Plate. END OF TASK FOLLOW-ON TASKS 1. Install rear bottom guard (WP 0199). 2. Fill transmission and bevel gear case with oil (WP 0151). 3. Install axles (WP 0116). 4. With winch - install winch (WP 0272). 5. Install ripper control valve (WP 0213). 6. With ripper - install ripper frame (WP 0279). 7. Install main drive shaft (WP 0117). 8. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0142

000142

0142-20

6 TM 5-2410-241-23-2 0143

FIELD MAINTENANCE
0 1 4 3

TRANSMISSION INTERMEDIATE SPEED SENSOR ONE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket O-ring References WP 0295 REMOVAL 1. Remove six bolts (Figure 1, Item 4), washers (Figure 1, Item 3), and plate (Figure 1, Item 1) from gear case (Figure 1, Item 2). 0 0 0 0 0 0 0 0 0
000143

Equipment Condition

Machine parked (TM 5-2410-241-10) 0 Transmission assembly removed (WP 0142) 0 Drawing Required TM 5-2410-241-24P, Figure 70, 71 Estimated Time to Complete 9.0 Hr 0 0 0 0

Figure 1. Plate.

0143

0143-1

TM 5-2410-241-23-2

0143

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

2. Disconnect connector (Figure 2, Item 2) from transmission intermediate speed sensor one (Figure 2, Item 6). 3. Remove bolt (Figure 2, Item 4), washer (Figure 2, Item 5), and one harness clip (Figure 2, Item 3) from transmission intermediate speed sensor one (Figure 2, Item 6). Position harness (Figure 2, Item 1) and harness clip aside. 4. Remove transmission intermediate speed sensor one (Figure 2, Item 6) and hold down bracket (Figure 2, Item 7) from gear case (Figure 2, Item 8). 5. Remove gasket (Figure 2, Item 9) from gear case (Figure 2, Item 8). Discard gasket.

Figure 2. Transmission Solenoid.

0143

0143-2

TM 5-2410-241-23-2

0143

REMOVAL CONTINUED 6. Remove O-ring (Figure 3, Item 2) from transmission intermediate speed sensor one (Figure 3, Item 1). Discard O-ring.

Figure 3. Transmission Solenoid O-ring. END OF TASK

0143

NOTE
CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK
000143

0143-3

TM 5-2410-241-23-2

0143

INSTALLATION 1. Install new O-ring (Figure 4, Item 2) on transmission intermediate speed sensor one (Figure 4, Item 1).

000143

Figure 4. Transmission Solenoid O-ring.

0143

2. Install hold down bracket (Figure 5, Item 7) and transmission intermediate speed sensor one (Figure 5, Item 6) on transmission (Figure 5, Item 8). 3. Position harness (Figure 5, Item 1) and install harness clip (Figure 5, Item 3), washer (Figure 5, Item 5), and bolt (Figure 5, Item 4) on transmission intermediate speed sensor one (Figure 5, Item 6). 4. Connect connector (Figure 5, Item 2) on transmission intermediate speed sensor one (Figure 5, Item 6). 5. Install new gasket (Figure 5, Item 9) on gear case (Figure 5, Item 8).

Figure 5. Transmission Solenoid.

0143

0143-4

TM 5-2410-241-23-2

0143

INSTALLATION CONTINUED

NOTE
6. Install plate (Figure 6, Item 1), six washers (Figure 6, Item 3), and bolts (Figure 6, Item 4) on gear case (Figure 6, Item 2).

Figure 6. Plate. END OF TASK FOLLOW-ON TASKS 1. Install transmission assembly (WP 0142). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0143

000143

0143-5/(6 blank)

6 TM 5-2410-241-23-2 0144

FIELD MAINTENANCE
0 1 4 4

TRANSMISSION INTERMEDIATE SPEED SENSOR TWO REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket O-ring References WP 0295 REMOVAL 1. Remove six bolts (Figure 1, Item 4), washers (Figure 1, Item 3), and plate (Figure 1, Item 1) from gear case (Figure 1, Item 2).
0

Equipment Condition Machine parked (TM 5-2410-241-10) Transmission assembly removed (WP 0142) Drawing Required TM 5-2410-241-24P, Figure 70, 71 Estimated Time to Complete 9.0 Hr

000144

Figure 1. Plate.

0144

0144-1

TM 5-2410-241-23-2

0144

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

2. Disconnect connector (Figure 2, Item 5) from transmission intermediate speed sensor two (Figure 2, Item 1). Position harness (Figure 2, Item 6) aside. 3. Remove bolt (Figure 2, Item 4) and washer (Figure 2, Item 3) from transmission intermediate speed sensor two (Figure 2, Item 1). 4. Remove transmission intermediate speed sensor two (Figure 2, Item 1) and hold down bracket (Figure 2, Item 2) from gear case (Figure 2, Item 7). 5. Remove gasket (Figure 2, Item 8) from gear case (Figure 2, Item 7). Discard gasket.

Figure 2. Transmission Solenoid.

0144

0144-2

TM 5-2410-241-23-2

0144

REMOVAL CONTINUED 6. Remove O-ring (Figure 3, Item 2) from transmission intermediate speed sensor two (Figure 3, Item 1). Discard O-ring.

Figure 3. Transmission Solenoid O-ring. END OF TASK

0144

NOTE
CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK
000144

0144-3

TM 5-2410-241-23-2

0144

INSTALLATION 1. Install new O-ring (Figure 4, Item 2) on transmission intermediate speed sensor two (Figure 4, Item 1).

000144

Figure 4. Transmission Solenoid O-ring.

0144

0144-4

TM 5-2410-241-23-2

0144

INSTALLATION CONTINUED 2. Install hold down bracket (Figure 5, Item 2) and transmission intermediate speed sensor two (Figure 5, Item 1) and) on transmission (Figure 5, Item 7). 3. Install washer (Figure 5, Item 3) and bolt (Figure 5, Item 4) on transmission intermediate speed sensor two (Figure 5, Item 1). 4. Position harness (Figure 5, Item 6) and connect connector (Figure 5, Item 5) on transmission intermediate speed sensor two (Figure 5, Item 1). 5. Install new gasket (Figure 5, Item 8) on gear case (Figure 5, Item 7).

Figure 5. Transmission Solenoid.

0144

0144-5

TM 5-2410-241-23-2

0144

INSTALLATION CONTINUED

NOTE
6. Install plate (Figure 6, Item 1), six washers (Figure 6, Item 3), and bolts (Figure 6, Item 4) on gear case (Figure 6, Item 2).

Figure 6. Plate. END OF TASK FOLLOW-ON TASKS 1. Install transmission assembly (WP 0142). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0144

000144

0144-6

4 TM 5-2410-241-23-2 0145

FIELD MAINTENANCE
0 1 4 5

TRANSMISSION CLUTCH SOLENOID REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring References WP 0295 REMOVAL 0 0 0 0 0 0 0 0
000145

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 71 Estimated Time to Complete 0.5 Hr

0 0 0 0 0 0

NOTE
The following procedure will remove one transmission clutch solenoid. Follow same procedure to remove additional transmission clutch solenoids. 1. Remove four bolts (Figure 1, Item 7), washers (Figure 1, Item 6), and guard (Figure 1, Item 1) from machine. 2. Remove two bolts (Figure 1, Item 5) and guard (Figure 1, Item 4) from machine. 3. Remove 15 bolts (Figure 1, Item 3) and plate (Figure 1, Item 2) from machine.

Figure 1. Plate.

0145

0145-1

TM 5-2410-241-23-2

0145

REMOVAL CONTINUED 4. Remove O-ring (Figure 2, Item 5) from manifold. Discard O-ring.

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

5. Disconnect connector (Figure 2, Item 1) from transmission clutch solenoid (Figure 2, Item 7).

NOTE
Note location and position of harness clips. Not all solenoids will have a harness and harness clips to position aside. 6. Remove two bolts (Figure 2, Item 3), washers (Figure 2, Item 2), and one harness clip (Figure 2, Item 4) from transmission clutch solenoid (Figure 2, Item 7). Position harness (Figure 2, Item 8) and harness clip aside. 7. Remove transmission clutch solenoid (Figure 2, Item 7) from transmission control valve (Figure 2, Item 6).

Figure 2. Transmission Solenoid. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0145

000145

0145-2

TM 5-2410-241-23-2

0145

INSTALLATION

000145

NOTE
The following procedure will remove one transmission clutch solenoid. Follow same procedure to remove additional transmission clutch solenoids. 1. Position transmission clutch solenoid (Figure 2, Item 7) on transmission control valve (Figure 2, Item 6).

NOTE
Note location and position of harness clips. Not all solenoids will have a harness and harness clips to position aside. 2. Position harness (Figure 2, Item 8) and install one harness clip (Figure 2, Item 4), two washers (Figure 2, Item 2), and bolts (Figure 2, Item 3) on transmission clutch solenoid (Figure 2, Item 7).

NOTE
Install electrical connections and harness routing as noted during removal. 3. Connect connector (Figure 2, Item 1) on transmission clutch solenoid (Figure 2, Item 7). 4. Install new O-ring (Figure 2, Item 5) on manifold. 5. Install plate (Figure 3, Item 2) and 15 bolts (Figure 3, Item 3) on machine. 6. Install guard (Figure 3, Item 4) and two bolts (Figure 3, Item 5) on machine. 7. Install guard (Figure 3, Item 1), four washers (Figure 3, Item 6), and bolts (Figure 3, Item 7) on machine.

Figure 3. Plate. END OF TASK

0145

0145-3

TM 5-2410-241-23-2

0145

FOLLOW-ON TASKS 1. Calibrate modulating valves. 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000145

0145-4

4 TM 5-2410-241-23-2 0146

FIELD MAINTENANCE
0 1 4 6

TRANSMISSION TEMPERATURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) O-ring (1) References WP 0295 0 0 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Middle bottom guard removed (WP 0199) Drawing Required TM 5-2410-241-24P, Figure 71 Estimated Time to Complete 3.0 Hr 0 0 0 0 0 0 0

0146-1

TM 5-2410-241-23-2

0146

REMOVAL 1. Remove tiedown strap (Figure 1, Item 4) and harness (Figure 1, Item 5) from bracket (Figure 1, Item 3). Discard tiedown strap. 2. Disconnect transmission temperature sensor (Figure 1, Item 1) from harness (Figure 1, Item 5). 3. Remove transmission temperature sensor (Figure 1, Item 1) from transmission (Figure 1, Item 6). 4. Remove O-ring (Figure 1, Item 2) from transmission temperature sensor (Figure 1, Item 1). Discard O-ring. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install new O-ring (Figure 1, Item 2) on transmission temperature sensor (Figure 1, Item 1). 2. Install transmission temperature sensor (Figure 1, Item 1) on transmission (Figure 1, Item 6). 3. Connect transmission temperature sensor (Figure 1, Item 1) on harness (Figure 1, Item 5). 4. Install harness (Figure 1, Item 5) and new tiedown strap (Figure 1, Item 4) on bracket (Figure 1, Item 3).

000146

000146

000146

Figure 1. Transmission Temperature Sensor. END OF TASK

0146

0146-2

TM 5-2410-241-23-2

0146

FOLLOW ON TASKS 1. Install middle bottom guard (WP 0199). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000146

0146-3/(4 blank)

8 TM 5-2410-241-23-2 0147

FIELD MAINTENANCE INSTRUCTIONS CONTROL VALVE (STEERING AND BRAKE) SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 1 4 7

INITIAL SETUP Tools and Special Tools 0 Materials/Parts - Continued O-ring (10) References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Front floor plate removed (WP 0230) Rear floor plate removed (WP 0231) Drawing Required TM 5-2410-241-24P, Figure 72 Estimated Time to Complete 3.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Adaptor, 3/8 Drive Male to 1/2 Drive Female (S0957) (WP 0302, Item 68) 0 Socket, 1/2 Drive, 6 Point, Long, 1 1/8 (S0624) (WP 0302, Item 68) 0 Wrench, Combination, 1-1/8 (S0788) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) 0 Wrench, Torque, Dial, 3/8 Drive, 300 lb-in. (WP 0302, Item 74) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) 0 0 0 0

0147-1

TM 5-2410-241-23-2

0147

REMOVAL

000147

NOTE
Tag harness to aid installation. Clean exterior of component to prevent contamination. Plug all lines, hoses and tubes to prevent contamination and leaks.

1. Remove tiedown straps (Figure 1, Item 9) and disconnect three connectors (Figure 1, Item 10) from three solenoid valve connectors (Figure 1, Item 11). Position three harnesses (Figure 1, Item 3) aside from control valve (Figure 1, Item 8). 2. Loosen tube nut (Figure 1, Item 5) and remove hose (Figure 1, Item 1) from fitting (Figure 1, Item 7). 3. Remove fitting (Figure 1, Item 7) and two O-rings (Figure 1, Item 6) from control valve (Figure 1, Item 8). 4. Remove four bolts (Figure 1, Item 4), washers (Figure 1, Item 12), and control valve (Figure 1, Item 8) from chassis (Figure 1, Item 2).

Figure 1. Control Valve Harness.

0147

0147-2

TM 5-2410-241-23-2

0147

REMOVAL CONTINUED 5. Remove four O-rings (Figure 2, Item 2) from control valve (Figure 2, Item 1). Discard O-rings.

Figure 2. Control Valve Seals. 6. Remove nut (Figure 3, Item 5), washer (Figure 3, Item 6), and coil (Figure 3, Item 7) from spool assembly (Figure 3, Item 4). 7. Remove spool assembly (Figure 3, Item 4) from manifold (Figure 3, Item 1). 8. Remove O-rings (Figure 3, Item 2) and O-ring (Figure 3, Item 3) from spool assembly (Figure 3, Item 4). Discard O-rings.

0147

Figure 3. Solenoid Valve.

0147

0147-3

TM 5-2410-241-23-2

0147

REMOVAL CONTINUED 9. Remove two nuts (Figure 4, Item 6), washers (Figure 4, Item 5), and coils (Figure 4, Item 7) from spool assembly (Figure 4, Item 2). 10. Remove two spool assemblies (Figure 4, Item 2) from manifold (Figure 4, Item 1). 11. Remove O-rings (Figure 4, Item 3) and O-ring (Figure 4, Item 4) from each spool assembly (Figure 4, Item 2). Discard O-rings
.

Figure 4. Secondary Brake Parking Valve and First Coil. END OF TASK CLEANING AND INSPECTION

0147

000147

NOTE
After cleaning, allow parts to air dry. Do not use rags. Rags may cause lint to be deposited on parts. Perform cleaning and inspection and assembly on a clean surface. Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0147-4

TM 5-2410-241-23-2

0147

INSTALLATION 1. Install new O-ring (Figure 5, Item 3) and new O-ring (Figure 5, Item 4) on two spool assemblies (Figure 5, Item 2).

000147

2. Install two spool assemblies (Figure 5, Item 2) on manifold (Figure 5, Item 1). Tighten spool to 37 lb-ft (50 Nm). 3. Install two coils (Figure 5, Item 7), washers (Figure 5, Item 5), and nuts (Figure 5, Item 6) on spool assembly (Figure 5, Item 2). Tighten nut to 85 lb-in. (9.5 Nm).
.

Figure 5. Secondary Brake Parking Valve and First Coil.

0147

0147-5

TM 5-2410-241-23-2

0147

INSTALLATION CONTINUED 4. Install O-rings (Figure 6, Item 2) and O-ring (Figure 6, Item 3) on spool assembly (Figure 6, Item 4). 5. Install spool assembly (Figure 6, Item 4) on manifold (Figure 6, Item 1). Tighten spool to 37 lb-ft (50 Nm). 6. Install coil (Figure 6, Item 7), washer (Figure 6, Item 6), and nut (Figure 6, Item 5) on spool assembly (Figure 6, Item 4). Tighten nut to 85 lb-in. (9.5 Nm).

Figure 6. Solenoid Valve. 7. Install four new O-rings (Figure 7, Item 2) on control valve (Figure 7, Item 1).

0147

Figure 7. Control Valve Seals.

0147

0147-6

TM 5-2410-241-23-2

0147

INSTALLATION CONTINUED

NOTE
Install harness as noted during removal. Clean exterior of component to prevent contamination. Remove plugs from all lines, hoses and tubes.

8. Install control valve (Figure 8, Item 8), four washers (Figure 8, Item 12), and bolts (Figure 8, Item 4) on chassis (Figure 8, Item 2). Tighten bolts to 22 lb-ft (30 Nm). 9. Install two O-rings (Figure 8, Item 6) and fitting (Figure 8, Item 7) on control valve (Figure 8, Item 8). 10. Install hose (Figure 8, Item 1) and tube nut (Figure 8, Item 5) on fitting (Figure 8, Item 7). 11. Position three harnesses (Figure 8, Item 3) on control valve (Figure 8, Item 8). 12. Connect three connectors (Figure 8, Item 10) and install new tiedown straps (Figure 8, Item 9) on three solenoid valve connectors (Figure 8, Item 11).

Figure 8. Control Valve Harness. END OF TASK FOLLOW-ON TASKS 1. Install rear floor plate (WP 0231). 2. Install front floor plate (WP 0230). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0147

000147

0147-7/(8 blank)

28 TM 5-2410-241-23-2 0148

FIELD MAINTENANCE INSTRUCTIONS TORQUE CONVERTER REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 4 8

INITIAL SETUP Tools and Special Tools 0 References WP 0295 Personnel Required Two Equipment Condition Machine parked (TM 5-2410-241-10) Rear and middle bottom guards removed (WP 0199) Main drive shaft removed (WP 0117) Front floor plate removed (WP 0230) Drawing Required 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Bracket, Link (3/8 in.; 2,250 lb [1,000 kg]) (WP 0302, Item 10) 0 Crowfoot attachment, 3/8 drive, 3/4 (S016) (WP 0302, Item 68) 0 Drain, Pan (S0255) (WP 0302, Item 68) 0 Gloves, Rubber (S0208) (WP 0302, Item 68) 0 Goggles (S0209) (WP 0302, Item 68) 0 Hoist, Chain (WP 0302, Item 33) 0 Lifting Link (1/2 in.; 4,000 lb [1,800 kg]) (WP 0302, Item 36) 0 Screwdriver attachment, Torx, 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) 0 Wrench, Open End, 1-1/2 and 1-5/8 (S0853) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) 0 Wrench, Torque, Click, Ratcheting, 1/2 Drive, 250 lb-ft (WP 0302, Item 71) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (9) Seal (4) 0 0 0 0 0 0

TM 5-2410-241-24P, Figure 52, 73, 106, 108 0 Estimated Time to Complete 10.5 Hr 0 0

0148-1

TM 5-2410-241-23-2

0148

REMOVAL

000148

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Tag and mark hoses to aid installation.

1. Position drain pan under torque converter housing (Figure 1, Item 6). 2. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 3), two flanges (Figure 1, Item 4), and hose (Figure 1, Item 1) from torque converter housing (Figure 1, Item 6). 3. Remove O-ring (Figure 1, Item 5) from hose (Figure 1, Item 1). Discard O-ring and position hose aside.

Figure 1. Hose.

0148

0148-2

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED

NOTE
Tag tubes to aid installation. 4. Remove four bolts (Figure 2, Item 5), washers (Figure 2, Item 6), and two flanges (Figure 2, Item 7) from lower transmission cooler tube (Figure 2, Item 4).

NOTE
Clearance does not allow bolts to remove from tube. Bolts will be removed with tube. 5. Loosen four bolts (Figure 2, Item 1) and washers (Figure 2, Item 2) from upper transmission cooler tube (Figure 2, Item 3). 6. Loosen upper transmission cooler tube (Figure 2, Item 3) and lower transmission cooler tube (Figure 2, Item 4) from transmission oil cooler (Figure 2, Item 8).

Figure 2. Transmission Cooler Tubes.

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0148-3

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 7. Remove four bolts (Figure 3, Item 1) and washers (Figure 3, Item 2) from transmission cooler tube assembly (Figure 3, Item 3). 8. Loosen transmission cooler tube assembly (Figure 3, Item 3) from outlet relief valve (Figure 3, Item 4).

Figure 3. Tube to Torque Converter Housing.

0148

NOTE
Tag and mark hoses to aid installation. 9. Position drain pan under hose (Figure 4, Item 9). 10. Remove four bolts (Figure 4, Item 8), washers (Figure 4, Item 7), two flanges (Figure 4, Item 1), and hose (Figure 4, Item 9) from upper transmission cooler tube (Figure 4, Item 2). 11. Remove seal (Figure 4, Item 10) from hose (Figure 4, Item 9). Discard seal and position hose aside. 12. Remove two bolts (Figure 4, Item 6), washers (Figure 4, Item 5), bracket (Figure 4, Item 4), lower transmission cooler tube (Figure 4, Item 3), and upper transmission cooler tube (Figure 4, Item 2) from machine.

Figure 4. Tube Assembly.

0148

0148-4

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 13. Remove four bolts (Figure 5, Item 3) and washers (Figure 5, Item 2) from transmission cooler tube (Figure 5, Item 4).

NOTE
Note size and position of seals to aid installation. 14. Remove three seals (Figure 5, Item 1) from two transmission cooler tubes (Figure 5, Item 4). Discard seals.

Figure 5. Tube Seals.

0148

0148-5

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED

NOTE
Tag hoses to aid installation. 15. Loosen tube nut (Figure 6, Item 12) and remove hose (Figure 6, Item 1) from torque converter housing (Figure 6, Item 11). 16. Remove O-ring (Figure 6, Item 2) from hose (Figure 6, Item 1). Discard O-ring. 17. Remove four bolts (Figure 6, Item 5), washers (Figure 6, Item 6), two flanges (Figure 6, Item 4), hose (Figure 6, Item 10), spacer (Figure 6, Item 8), and O-ring (Figure 6, Item 9) from torque converter housing (Figure 6, Item 11). Discard O-ring. 18. Position spacer and line (Figure 6, Item 3) aside. 19. Remove O-ring (Figure 6, Item 7) from hose (Figure 6, Item 10). Discard O-ring.

Figure 6. Hose Assemblies.

0148

0148-6

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED

NOTE
Tag hoses to aid installation. 20. Remove hose (Figure 7, Item 1) from torque converter outlet relief valve (Figure 7, Item 3). 21. Remove O-ring (Figure 7, Item 2) from hose (Figure 7, Item 1). Discard O-ring.

Figure 7. Outlet Relief Valve.

0148

0148-7

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED

NOTE
Note location of tiedown straps to aid installation. Tag wiring harness to aid installation.

22. Remove tiedown straps (Figure 8, Item 1) from harness (Figure 8, Item 2). Discard tiedown straps. 23. Disconnect connector (Figure 8, Item 8) from temperature sensor (Figure 8, Item 9). 24. Disconnect connector (Figure 8, Item 3) from speed sensor (Figure 8, Item 7). 25. Position harness (Figure 8, Item 2) aside. 26. Remove bolt (Figure 8, Item 4), washer (Figure 8, Item 5), and bracket (Figure 8, Item 6) from torque converter housing (Figure 8, Item 10).

Figure 8. Wiring Harness.

0148

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TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 27. Remove two bolts (Figure 9, Item 1), washers (Figure 9, Item 2), seal (Figure 9, Item 3), elbow (Figure 9, Item 4), sleeve (Figure 9, Item 5) and two O-rings (Figure 9, Item 7) from torque converter (Figure 9, Item 6). Discard seal and O-rings.

Figure 9. Elbow. 28. Remove four bolts (Figure 10, Item 1) and plate (Figure 10, Item 2) from headliner (Figure 10, Item 3). 29. Remove mirror (Figure 10, Item 4) from bracket (Figure 10, Item 7). 30. Remove two bolts (Figure 10, Item 5), washers (Figure 10, Item 6), and bracket (Figure 10, Item 7) from headliner (Figure 10, Item 3).

0148

Figure 10. Headliner.

0148

0148-9

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED

NOTE
Adjust chain to necessary length. 31. Install bracket links on cab (Figure 11, Item 1). 32. Install lifting device on bracket links.

Figure 11. Cab Tool Setup.

0148

WARNING

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

NOTE
Torque converter weighs approximately 320 lb (145 kg). Install bracket link toward engine.

0148-10

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 33. Install bracket link (Figure 12, Item 4), washer (Figure 12, Item 5), and bolt (Figure 12, Item 6) on torque converter housing (Figure 12, Item 3). 34. Connect lifting device to bracket link (Figure 12, Item 4). 35. Remove 10 bolts (Figure 12, Item 1) and washers (Figure 12, Item 2) and clamp (Figure 12, Item 7) from torque converter housing (Figure 12, Item 3). 36. With assistance and using lifting device, remove torque converter housing (Figure 12, Item 3) from engine (Figure 12, Item 9).

NOTE
Oil will be in torque converter. 37. Lower torque converter (Figure 12, Item 3) and remove from bottom of machine. 38. Remove O-ring seal (Figure 12, Item 8) from torque converter housing (Figure 12, Item 3). Discard O-ring.

Figure 12. Torque Converter Housing. 39. Remove retaining ring (Figure 13, Item 3) and gear (Figure 13, Item 2) from flywheel (Figure 13, Item 1).

0148

Figure 13. Gear.

0148

0148-11

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 40. Remove three bolts (Figure 14, Item 5), washers (Figure 14, Item 4), bracket links (Figure 14, Item 3), and torque converter relief valve (Figure 14, Item 2) from torque converter housing (Figure 14, Item 1).

Figure 14. Torque Converter Relief Valve. 41. Remove bolt (Figure 15, Item 3), washer (Figure 15, Item 4), O-ring (Figure 15, Item 5), yoke (Figure 15, Item 6), and seal (Figure 15, Item 7) from torque converter (Figure 15, Item 2). Discard O-ring and seal. 42. Remove two bolts (Figure 15, Item 11), washers (Figure 15, Item 10), plate (Figure 15, Item 9), and gasket (Figure 15, Item 8) from torque converter housing (Figure 15, Item 1). Discard gasket.

0148

Figure 15. Yoke.

0148

0148-12

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 43. Loosen nut (Figure 16, Item 1) and remove speed sensor (Figure 16, Item 2) from torque converter housing (Figure 16, Item 3).

Figure 16. Speed Sensor.

0148

0148-13

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 44. Remove fitting (Figure 17, Item 3) and O-ring (Figure 17, Item 2) from torque converter housing (Figure 17, Item 1). Discard O-ring.

WARNING

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

NOTE
Torque converter housing weighs 144 lb (195.2 Nm). Torque converter weighs 172 lb (233.2 Nm). Mark position and alignment of torque converter to torque converter housing.

45. With assistance, remove eight bolts (Figure 17, Item 5), washers (Figure 17, Item 6), and torque converter housing (Figure 17, Item 1) from torque converter (Figure 17, Item 4). 46. Remove O-ring (Figure 17, Item 7) from torque converter (Figure 17, Item 4). Discard O-ring. 47. Remove bolt (Figure 17, Item 10), washer (Figure 17, Item 9), and bracket link (Figure 17, Item 8) from torque converter housing (Figure 17, Item 1).

Figure 17. Torque Converter and Housing.

0148

0148-14

TM 5-2410-241-23-2

0148

REMOVAL CONTINUED 48. Remove lifting device from bracket links. 49. Remove bracket links from cab (Figure 18, Item 1).

Figure 18. Cab Tool Setup. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install bracket links on cab (Figure 18, Item 1). 2. Install lifting device on bracket links. 3. Install bracket link (Figure 17, Item 8), washer (Figure 17, Item 9), and bolt (Figure 17, Item 10) on torque converter housing (Figure 17, Item 1). 4. Install new O-ring (Figure 17, Item 7) on torque converter (Figure 17, Item 4)

0148

000148

000148

0148-15

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED

WARNING

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

NOTE
Torque converter weighs 172 lb (233.2 Nm). Torque converter housing weighs 144 lb (195.2 Nm). Install torque converter housing to torque converter as noted during removal. Hand tighten all bolts before tightening bolts.

5. With assistance, install torque converter housing (Figure 19, Item 1), eight washers (Figure 19, Item 6), and bolts (Figure 19, Item 5) on torque converter (Figure 19, Item 4). 6. Install new O-ring (Figure 19, Item 2) and fitting (Figure 19, Item 3) on torque converter housing (Figure 19, Item 1).

Figure 19. Torque Converter and Housing.

0148

0148-16

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED 7. Install speed sensor (Figure 20, Item 2) and nut (Figure 20, Item 1) on torque converter housing (Figure 20, Item 3).

Figure 20. Speed Sensor.

0148

0148-17

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED 8. Install new gasket (Figure 21, Item 8), plate (Figure 21, Item 9), two washers (Figure 21, Item 10), and bolts (Figure 21, Item 11) on torque converter housing (Figure 21, Item 1). 9. Install new seal (Figure 21, Item 7), yoke (Figure 21, Item 6), new O-ring (Figure 21, Item 5), washer (Figure 21, Item 4), and bolt (Figure 21, Item 3) on torque converter (Figure 21, Item 2). Tighten bolt to 85 lb-ft (115 Nm).

Figure 21. Yoke. 10. Loosen nut (Figure 22, Item 2) and remove sensor (Figure 22, Item 1) from housing (Figure 22, Item 3). 11. Center gear tooth (Figure 22, Item 5) to align with sensor (Figure 22, Item 1). 12. Install sensor (Figure 22, Item 1) until sensor tip (Figure 22, Item 4) touches gear tooth (Figure 22, Item 5). 13. Set gap between sensor tip (Figure 22, Item 4) and gear tooth (Figure 22, Item 5) by turning sensor 180 degrees (Figure 22, Item 1) counterclockwise. 14. Hold sensor (Figure 22, Item 1) and tighten jam nut (Figure 22, Item 2) to 18 lb-ft (25 Nm) on housing (Figure 22, Item 3).

0148

Figure 22. Sensor Adjustment.

0148

0148-18

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED 15. Install torque converter relief valve (Figure 23, Item 2), three brackets (Figure 23, Item 3), washers (Figure 23, Item 4), and bolts (Figure 23, Item 5) on torque converter housing (Figure 23, Item 1).

Figure 23. Torque Converter Relief Valve. 16. Install gear (Figure 24, Item 2) and clip (Figure 24, Item 3) on flywheel (Figure 24, Item 1).

0148

Figure 24. Gear.

0148

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TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED

WARNING

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

NOTE
Torque converter weighs approximately 320 lb (145 kg). 17. Install new O-ring seal (Figure 25, Item 8) on torque converter housing (Figure 25, Item 3). 18. Attach lifting device on bracket link (Figure 25, Item 4) and torque converter housing (Figure 25, Item 3). 19. Using lifting device, position torque converter housing (Figure 25, Item 3) under bottom of machine. 20. With assistance and using lifting device, install torque converter housing (Figure 25, Item 3) on engine (Figure 25, Item 9). 21. Install clamp (Figure 25, Item 7), 10 washers (Figure 25, Item 2) and bolts (Figure 25, Item 1) on torque converter housing (Figure 25, Item 3). 22. Remove lifting device from bracket link (Figure 25, Item 4). 23. Remove bolt (Figure 25, Item 6), washer (Figure 25, Item 5), and bracket link (Figure 25, Item 4) from torque converter housing (Figure 25, Item 3).

Figure 25. Torque Converter Housing.

0148

0148-20

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED 24. Remove lifting device from bracket links. 25. Remove bracket links from cab (Figure 26, Item 1).

Figure 26. Cab Tool Setup. 26. Install bracket (Figure 27, Item 7), two washers (Figure 27, Item 6) and bolts (Figure 27, Item 5) on headliner (Figure 27, Item 3). 27. Install mirror (Figure 27, Item 4) on bracket (Figure 27, Item 7). 28. Install plate (Figure 27, Item 2) and four bolts (Figure 27, Item 1) on headliner (Figure 27, Item 3).

0148

Figure 27. Headliner.

0148

0148-21

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED 29. Install two new O-rings (Figure 28, Item 7), sleeve (Figure 28, Item 5), new O-ring (Figure 28, Item 3), elbow (Figure 28, Item 4), two washers (Figure 28, Item 2), and bolts (Figure 28, Item 1) on torque converter (Figure 28, Item 6).

Figure 28. Elbow.

0148

NOTE
Install wiring harness as noted during removal. Install tiedown straps as noted during removal.

30. Install bracket (Figure 29, Item 6), washer (Figure 29, Item 5), and bolt (Figure 29, Item 4) on torque converter housing (Figure 29, Item 10). 31. Position harness (Figure 29, Item 2) on torque converter housing (Figure 29, Item 10). 32. Connect connector (Figure 29, Item 3) on speed sensor (Figure 29, Item 7). 33. Connect connector (Figure 29, Item 8) on temperature sensor (Figure 29, Item 9). 34. Install new tiedown straps (Figure 29, Item 1) on harness (Figure 29, Item 2).

0148-22

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED

Figure 29. Wiring Harness.

0148

NOTE
Install hoses as tagged during removal. 35. Install new O-ring (Figure 30, Item 2) and hose assembly (Figure 30, Item 1) on torque converter outlet relief valve (Figure 30, Item 3).

Figure 30. Outlet Relief Valve.

0148

0148-23

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 36. Install new O-ring (Figure 31, Item 7) on hose (Figure 31, Item 10). 37. Position line (Figure 31, Item 3) and spacer (Figure 31, Item 8) on torque converter housing (Figure 31, Item 11). 38. Install new O-ring (Figure 31, Item 9), spacer (Figure 6, Item 8), hose (Figure 31, Item 10), two split clamps (Figure 31, Item 4), four washers (Figure 31, Item 6), and bolts (Figure 31, Item 5) on torque converter housing (Figure 31, Item 11). 39. Install new O-ring (Figure 31, Item 2) on hose (Figure 31, Item 1). 40. Install hose (Figure 31, Item 1) and tube nut (Figure 31, Item 12) on torque converter housing (Figure 31, Item 11).

Figure 31. Hose Assemblies.

0148

0148-24

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED

NOTE
Install seals as noted during removal. 41. Install three new seals (Figure 32, Item 1) on two transmission cooler tubes (Figure 32, Item 4).

NOTE
Clearance does not allow bolts to install with transmission cooler tube on machine. Bolts will be installed with transmission cooler tube. 42. Position four washers (Figure 32, Item 2) and bolts (Figure 32, Item 3) on transmission cooler tube (Figure 32, Item 4).

Figure 32. Tube Seals.

0148

0148-25

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 43. Install upper transmission cooler tube (Figure 33, Item 2), lower transmission cooler tube (Figure 33, Item 3), bracket (Figure 33, Item 4), two washers (Figure 33, Item 5), and bolts (Figure 33, Item 6) on machine. 44. Install new seal (Figure 33, Item 10) on hose (Figure 33, Item 9). 45. Install hose (Figure 33, Item 9), two flanges (Figure 33, Item 1), four washers (Figure 33, Item 7), and bolts (Figure 33, Item 8) on upper transmission cooler tube (Figure 33, Item 2).

Figure 33. Tube Assembly. 46. Install transmission cooler tube assembly (Figure 34, Item 3), four washers (Figure 34, Item 2), and bolts (Figure 34, Item 1) on outlet relief valve (Figure 34, Item 4).

0148

Figure 34. Tube to Torque Converter Housing.

0148

0148-26

TM 5-2410-241-23-2

0148

INSTALLATION CONTINUED

NOTE
Install tubes as tagged during removal. 47. Install upper transmission cooler tube (Figure 35, Item 3), four washers (Figure 35, Item 2), and bolts (Figure 35, Item 1) on transmission oil cooler (Figure 35, Item 8). 48. Install lower transmission cooler tube (Figure 35, Item 4), two flanges (Figure 35, Item 7), four washers (Figure 35, Item 6), and bolts (Figure 35, Item 5) on transmission oil cooler (Figure 35, Item 8).

Figure 35. Transmission Cooler Lines. 49. Install new O-ring (Figure 36, Item 5) on hose (Figure 36, Item 1). 50. Install hose (Figure 36, Item 1), two flanges (Figure 36, Item 4), four washers (Figure 36, Item 3), and bolts (Figure 36, Item 2) on torque converter housing (Figure 36, Item 6).

0148

Figure 36. Hose. END OF TASK

0148

0148-27

TM 5-2410-241-23-2

0148

FOLLOW-ON TASKS 1. Install main drive shaft (WP 0117). 2. Install rear and middle bottom guards (WP 0199). 3. Install front floor plates (WP 0230). 4. Start engine. Check for leaks and correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000148

0148-28

2 TM 5-2410-241-23-2 0149

FIELD MAINTENANCE INSTRUCTIONS

0 1 4 9

FINAL DRIVE OIL SERVICE Changing Final Drive Oil

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Drain, Pan (S0255) (WP 0302, Item 68) Gloves, Rubber (S0208) (WP 0302, Item 68) Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) CHANGING FINAL DRIVE OIL 0 0 0 0 0 0 0 0
000149

Materials/Parts - Continued Oil, Lubricating OE/HDO 15/40 (WP 0303, Item 21) Rag, Wiping (WP 0303, Item 24) O-ring (4) References LO 5-2410-241-13 Equipment Condition Machine parked (TM 5-2410-241-10) Estimated Time to Complete 0.5 Hr

0 0 0 0 0 0 0 0 0 0

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

0149-1

TM 5-2410-241-23-2

0149

CHANGING FINAL DRIVE OIL CONTINUED 1. Position one final drive (Figure 1, Item 6) so oil level mark (Figure 1, Item 1) is horizontal. Drain plug (Figure 1, Item 4) will be positioned at the bottom of final drive. 2. Remove drain plug (Figure 1, Item 4) and O-ring (Figure 1, Item 5) from final drive (Figure 1, Item 6). Discard O-ring. Allow oil to drain into a suitable container. 3. Install new O-ring (Figure 1, Item 5) and drain plug (Figure 1, Item 4) on final drive (Figure 1, Item 6). 4. Remove oil fill plug (Figure 1, Item 3) and O-ring (Figure 1, Item 2) from final drive (Figure 1, Item 6). Discard O-ring. 5. Refer to LO 5-2410-241-13 for correct amount and type of oil. Fill final drive (Figure 1, Item 6) to bottom of filler plug (Figure 1, Item 3) opening. 6. Clean and inspect oil fill plug (Figure 1, Item 3) for damage, replace plug if damaged. 7. Install new O-ring (Figure 1, Item 2) and oil fill plug (Figure 1, Item 3) on final drive (Figure 1, Item 6). 8. Repeat steps for other final drive.

Figure 1. Final Drive Oil Change. END OF TASK END OF WORK PACKAGE

0149

0149-2

2 TM 5-2410-241-23-2 0150

FIELD MAINTENANCE INSTRUCTIONS

0 1 5 0

RECOIL SPRING COMPARTMENT OIL SERVICE Changing Recoil Spring Compartment Oil

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Pan, Drain (S0255) (WP 0302, Item 68) Pump, Lubricant Manual (S0272) (WP 0302, Item 68) Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Oil, Lubricating OE/HDO-40 (WP 0303, Item 20) CHANGING RECOIL SPRING COMPARTMENT OIL 0 0 0 0 0 0 0 0 0 Materials/Parts - Continued Rag, Wiping (WP 0303, Item 24) Clean fluid container (20 gallon capacity) O-ring (2) Equipment Condition Machine parked (TM 5-2410-241-10) Reference LO 5-2410-241-13 Drawing Required TM 5-2410-241-24P, Figure 63 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0

000150

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns, when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

0150-1

TM 5-2410-241-23-2

0150

CHANGING RECOIL SPRING COMPARTMENT OIL CONTINUED 1. Clean area around cover plate (Figure 1, Item 3) on top of track roller (Figure 1, Item 4). 2. Remove four bolts (Figure 1, Item 1), washers (Figure 1, Item 2), cover plate (Figure 1, Item 3) and O-ring (Figure 1, Item 5) from track roller (Figure 1, Item 4). Discard O-ring. 3. Pump oil out of track roller (Figure 1, Item 4). 4. Refer to LO 5-2410-241-13 for correct amount and type of oil. Fill track roller with oil. Maintain oil level to the FULL mark. 5. Install new O-ring (Figure 1, Item 5), cover plate (Figure 1, Item 3), four washers (Figure 1, Item 2), and bolts (Figure 1, Item 1) on track roller (Figure 1, Item 4). 6. Repeat steps for other recoil spring compartment.

Figure 1. Recoil Spring Compartment Oil Change. END OF TASK END OF WORK PACKAGE

0150

0150-2

4 TM 5-2410-241-23-2 0151

FIELD MAINTENANCE INSTRUCTIONS TRANSMISSION SYSTEM OIL SERVICE Transmission Oil Change, Transmission Scavenge Screen Service, Transmission Fluid Level Check and Fill
0 1 5 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Drain, Pan (S0255) (WP 0302, Item 68) Gloves, Rubber (S0208) (WP 0302, Item 68) Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) 1 NPT Nipple Gasket TRANSMISSION OIL CHANGE 0 0 0 0 0 0 0 0 0 0 0 Materials/Parts - Continued O-ring References LO 5-2410-241-13 WP 0039 WP 0152 WP 0199 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 98 Estimated Time to Complete 1.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0 0

000151

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns, when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

0151-1

TM 5-2410-241-23-2

0151

TRANSMISSION OIL CHANGE CONTINUED 1. Remove rear bottom guard (WP 0199). 2. Remove plug (Figure 1, Item 1) from machine. 3. Remove O-ring (Figure 1, Item 2) from plug (Figure 1, Item 1). Discard O-ring.

NOTE
Transmission holds 34 gallons (128.7 liters). 4. Install 1 NPT nipple to depress valve (Figure 1, Item 3) and drain oil into suitable container. 5. Remove 1 NPT nipple from machine. 6. Install new O-ring (Figure 1, Item 2) on plug (Figure 1, Item 1). 7. Install plug (Figure 1, Item 1) on machine. 8. Install rear bottom guard (WP 0199).

Figure 1. Transmission Drain Plug. END OF TASK

0151

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns, when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

0151-2

TM 5-2410-241-23-2

0151

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.
000151

TRANSMISSION SCAVENGE SCREEN SERVICE 1. Remove four bolts (Figure 2, Item 1) and transmission scavenge screen cover (Figure 2, Item 2) from transmission (Figure 2, Item 3). Drain oil into suitable container. 2. Remove gasket (Figure 2, Item 5) from transmission scavenge screen cover (Figure 2, Item 2). Discard gasket. 3. Wash screen (Figure 2, Item 4) and transmission scavenge screen cover (Figure 2, Item 2) in nonflammable solvent. 4. Install new gasket (Figure 2, Item 5) on transmission scavenge screen cover (Figure 2, Item 2). 5. Install screen (Figure 2, Item 4), transmission scavenge screen cover (Figure 2, Item 2), and four bolts (Figure 2, Item 1) on transmission (Figure 2, Item 3).

Figure 2. Transmission Scavenge Screen. 6. Clean transmission magnetic screen - clean in PMCS (WP 0039). 7. Clean torque converter scavenge screen - clean in PMCS (WP 0039). 8. Change transmission oil filter (WP 0152). 9. Check and fill transmission fluid level per this work package. END OF TASK

0151

0151-3

TM 5-2410-241-23-2

0151

TRANSMISSION FLUID LEVEL CHECK AND FILL

000151

CAUTION
Check correct side of gauge. Over- or under-filled transmission may cause transmission to overheat, not perform properly, or damage system components.

NOTE
Transmission oil level gauge has oil level markings on both sides. One side is for checking when fluid is cold with engine stopped, the other side is for checking when fluid is hot with engine at idle and transmission in NEUTRAL. Checking fluid when hot is preferred and more accurate. Checking fluid when cold should be used for reference only.

1. Open right side upper access cover. 2. Clean area around transmission oil level gauge (Figure 3, Item 1) and oil filler cap (Figure 3, Item 2). 3. Remove transmission oil level gauge (Figure 3, Item 1), wipe it clean then reinstall. 4. Refer to LO 5-2410-241-13 for correct amount and type of transmission oil. Remove transmission oil level gauge (Figure 3, Item 1) and check level. Maintain oil within OPR ZONE (operating zone) markings. Maintain cold level first, then hot level. 5. Remove oil filler cap (Figure 3, Item 2), and add transmission oil in accordance with LO 5-2410-241-13 through filler tube. 6. Install oil filler cap (Figure 3, Item 2). 7. Close right side upper access cover.

Figure 3. Transmission System Oil Level Check. END OF TASK END OF WORK PACKAGE

0151

0151-4

4 TM 5-2410-241-23-2 0152

FIELD MAINTENANCE INSTRUCTIONS TRANSMISSION SYSTEM OIL FILTER SERVICE Transmission Oil Filter Change, Transmission Fluid Level Check and Fill
0 1 5 2

INITIAL SETUP Tools and Special Tools 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Filter Element O-ring References LO 5-2410-241-13 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 53 0 0 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Drain, Pan (S0255) (WP 0302, Item 68) 0 Gloves, Rubber (S0208) (WP 0302, Item 68) 0 Wrench, Open End, 1-1/2 and 1-5/8 (S0842) (WP 0302, Item 68) 0 Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) TRANSMISSION OIL FILTER CHANGE 0 0

000152

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns, when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

0152-1

TM 5-2410-241-23-2

0152

TRANSMISSION OIL FILTER CHANGE CONTINUED 1. Open right side access cover. 2. Remove filter element cover assembly (Figure 1, Item 4) from base (Figure 1, Item 1). 3. Remove filter element (Figure 1, Item 2) from filter element cover assembly (Figure 1, Item 4). Discard element. 4. Remove O-ring (Figure 1, Item 3) from base (Figure 1, Item 4). Discard O-ring. 5. Clean filter element cover assembly (Figure 1, Item 4) with a clean rag. 6. Install new O-ring (Figure 1, Item 3) on base (Figure 1, Item 4). 7. Install new filter element (Figure 1, Item 2) on filter element cover assembly (Figure 1, Item 4). 8. Install new filter element (Figure 1, Item 2) and filter element cover assembly (Figure 1, Item 4) on base (Figure 1, Item 1). 9. Close right side access cover. 10. Check and fill transmission fluid level in this work package.

Figure 1. Transmission Oil Filter. END OF TASK

0152

0152-2

TM 5-2410-241-23-2

0152

TRANSMISSION FLUID LEVEL CHECK AND FILL

000152

CAUTION
Check correct side of gauge. Over- or under-filled transmission may cause transmission to overheat, not perform properly, or damage system components.

NOTE
Transmission oil level gauge has oil level markings on both sides. One side is for checking when fluid is cold with engine stopped, the other side is for checking when fluid is hot with engine at idle and transmission in NEUTRAL. Checking fluid when hot is preferred and more accurate. Checking fluid when cold should be used for reference only.

1. Open right side upper access cover. 2. Clean area around transmission oil level gauge (Figure 2, Item 1) and oil filler cap (Figure 2, Item 2). 3. Remove transmission oil level gauge (Figure 2, Item 1), wipe it clean, and reinstall. 4. Refer to LO 5-2410-241-13 for correct amount and type of transmission oil. Remove transmission oil level gauge (Figure 2, Item 1) and check level. Maintain oil within OPR ZONE (operating zone) markings. Maintain cold level first, then hot level. 5. Remove oil filler cap (Figure 2, Item 2), add transmission oil in accordance with LO 5-2410-241-13 through filler tube. 6. Install oil filler cap (Figure 2, Item 2). 7. Close right side upper access cover.

Figure 2. Transmission System Oil Level Check. END OF TASK END OF WORK PACKAGE

0152

0152-3/(4 blank)

8 TM 5-2410-241-23-2 0153

FIELD MAINTENANCE INSTRUCTIONS

0 1 5 3

TRANSMISSION SYSTEM OIL FILTER BASE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools 0 Materials/Parts - Continued Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (9) References LO 5-2410-241-13 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Transmission oil filter removed (WP 0152) Drawing Required TM 5-2410-241-24P, Figure 53 0 0 0 Estimated Time to Complete 1.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Drain, Pan (S0255) (WP 0302, Item 68) 0 Gloves, Rubber (S0208) (WP 0302, Item 68) 0 Wrench, Open End, 1-1/2 and 1-5/8 (S0853) (WP 0302, Item 68) 0 Wrench, Open End, 1-7/8 and 2 (S0855) (WP 0302, Item 68) 0 Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) REMOVAL 0 0

000153

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns, when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow these warnings may cause injury to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

0153-1

TM 5-2410-241-23-2

0153

REMOVAL CONTINUED

NOTE
Tag electrical connectors and lines to aid installation. 1. Remove tiedown strap (Figure 1, Item 4) from connector (Figure 1, Item 5). 2. Disconnect connector (Figure 1, Item 6) from connector (Figure 1, Item 5) and position harness (Figure 1, Item 1) aside. 3. Loosen two tube nuts (Figure 1, Item 8) and lines (Figure 1, Item 7) from fittings (Figure 1, Item 9). 4. Remove three bolts (Figure 1, Item 12), washers (Figure 1, Item 11), large washers (Figure 1, Item 10), filter base (Figure 1, Item 2), and large washers (Figure 1, Item 3) from machine.

Figure 1. Transmission Filter Base.

0153

0153-2

TM 5-2410-241-23-2

0153

REMOVAL CONTINUED 5. Remove three upper isolators (Figure 2, Item 2) and lower isolators (Figure 2, Item 3) from bracket (Figure 2, Item 1).

Figure 2. Transmission Filter Base Isolators. 6. Remove two fittings (Figure 3, Item 2) and four O-rings (Figure 3, Item 3) from filter base (Figure 3, Item 1). Discard O-rings.

0153

Figure 3. Transmission Filter Base Fittings.

0153

0153-3

TM 5-2410-241-23-2

0153

REMOVAL CONTINUED 7. Remove cap (Figure 4, Item 9), fitting (Figure 4, Item 10), and O-ring (Figure 4, Item 11) from filter base (Figure 4, Item 1). Discard O-ring. 8. Remove valve (Figure 4, Item 12), O-ring (Figure 4, Item 13), fitting (Figure 4, Item 14), and O-ring (Figure 4, Item 15) from filter base (Figure 4, Item 1). Discard O-rings. 9. Remove bypass switch (Figure 4, Item 8) and O-ring (Figure 4, Item 7) from filter base (Figure 4, Item 1). Discard O-ring. 10. Remove fitting (Figure 4, Item 6), O-ring (Figure 4, Item 5), springs (Figure 4, Items 4 and 3), and spool valve (Figure 4, Item 2) from filter base (Figure 4, Item 1). Discard O-ring.

Figure 4. Transmission Filter Base Bypass Switch. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0153

000153

0153-4

TM 5-2410-241-23-2

0153

INSTALLATION

000153

1. Install spool valve (Figure 5, Item 2), springs (Figure 5, Items 3 and 4), new O-ring (Figure 5, Item 5), and fitting (Figure 5, Item 6) on filter base (Figure 5, Item 1). 2. Install new O-ring (Figure 5, Item 7) and bypass switch (Figure 5, Item 8) on filter base (Figure 5, Item 1). 3. Install new O-ring (Figure 5, Item 15), fitting (Figure 5, Item 14), new O-ring (Figure 5, Item 13), and valve (Figure 5, Item 12) on filter base (Figure 5, Item 1). 4. Install new O-ring (Figure 5, Item 11), fitting (Figure 5, Item 10), and cap (Figure 5, Item 9) on filter base (Figure 5, Item 1).

Figure 5. Transmission Filter Base Bypass Switch. 5. Install four new O-rings (Figure 6, Item 3) and two fittings (Figure 6, Item 2) on from filter base (Figure 6, Item 1).

0153

Figure 6. Transmission Filter Base Fittings.

0153

0153-5

TM 5-2410-241-23-2

0153

INSTALLATION CONTINUED 6. Install three lower isolators (Figure 7, Item 3) and upper isolators (Figure 7, Item 2) on bracket (Figure 7, Item 1).

Figure 7. Transmission Filter Base Isolators. 7. Install three large washers (Figure 8, Item 3), filter base (Figure 8, Item 2), three large washers (Figure 8, Item 10), washers (Figure 8, Item 11), and bolts (Figure 8, Item 12) on machine.

0153

NOTE
Install electrical connectors and lines as tagged during removal. 8. Install two lines (Figure 8, Item 7) and tube nuts (Figure 8, Item 8) on fittings (Figure 8, Item 9). 9. Position harness (Figure 8, Item 1) on machine.

0153-6

TM 5-2410-241-23-2

0153

INSTALLATION CONTINUED 10. Connect connector (Figure 8, Item 6) on connector (Figure 8, Item 5). 11. Install new tiedown strap (Figure 8, Item 4) on connector (Figure 8, Item 5).

Figure 8. Transmission Filter Base. END OF TASK FOLLOW-ON TASKS 1. Install transmission oil filter (WP 0152). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0153

000153

0153-7/(8 blank)

12 TM 5-2410-241-23-2 0154

FIELD MAINTENANCE INSTRUCTIONS

0 1 5 4

FLOOD LAMP HARNESS REPLACEMENT

Front Flood Lamp Harness Removal, Rear Flood Lamp Harness Removal, Cleaning and Inspection, Rear Flood Lamp Harness Installation, Front Flood Lamp Harness Installation INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295 FRONT FLOOD LAMP HARNESS REMOVAL 0 0 0 0 0 0 0 0
000154

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 121 Estimated Time to Complete 1.0 Hr

0 0 0 0 0 0

NOTE
This procedure will remove one front flood lamp harness. Follow same procedure for additional front flood lamp harness. 1. Remove eight bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and open two doors (Figure 1, Item 1) on hinges (Figure 1, Item 4).

Figure 1. Doors. 0154-1

0154

TM 5-2410-241-23-2

0154

FRONT FLOOD LAMP HARNESS REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation Mark location and number of tiedown straps before removal.

2. Remove tiedown strap (Figure 2, Item 5) from connector (Figure 2, Item 6). Discard tiedown strap. 3. Disconnect connector (Figure 2, Item 4) from connector (Figure 2, Item 6). 4. Remove tiedown strap (Figure 2, Item 3) and grommet (Figure 2, Item 1) from radiator guard (Figure 2, Item 7). Discard tiedown strap. 5. Remove grommet (Figure 2, Item 1) from harness (Figure 2, Item 2). 6. Position harness (Figure 2, Item 2) and connector (Figure 2, Item 4) from inside of radiator guard (Figure 2, Item 7).

Figure 2. Front Connector.

0154

0154-2

TM 5-2410-241-23-2

0154

FRONT FLOOD LAMP HARNESS REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation. Mark location and number of tiedown straps before removal.

7. Remove tiedown straps (Figure 3, Item 5) from harness (Figure 3, Item 6). Discard tiedown straps. 8. Disconnect connector (Figure 3, Item 3) from light (Figure 3, Item 4). 9. Remove grommet (Figure 3, Item 2) from bracket (Figure 3, Item 1). 10. Remove grommet (Figure 3, Item 2) from harness (Figure 3, Item 6). 11. Position harness (Figure 3, Item 6) and connector (Figure 3, Item 3) through bracket (Figure 3, Item 1).

Figure 3. Front Flood Lamp.

0154

0154-3

TM 5-2410-241-23-2

0154

FRONT FLOOD LAMP HARNESS REMOVAL CONTINUED 12. Remove three nuts (Figure 4, Item 6), washers (Figure 4, Item 5), clamps (Figure 4, Item 4), bolts (Figure 4, Item 2), washers (Figure 4, Item 3), and harness (Figure 4, Item 1) from machine. 13. Remove three clamps (Figure 4, Item 4), from harness (Figure 4, Item 1). 14. Remove harness (Figure 4, Item 1) from machine.

Figure 4. Front Flood Lamp Harness. END OF TASK

0154

0154-4

TM 5-2410-241-23-2

0154

REAR FLOOD LAMP HARNESS REMOVAL

000154

NOTE
This procedure will remove one rear flood lamp harness. Follow same procedure for additional rear flood lamp harness. Tag and mark electrical connectors to aid installation. Note harness routing to aid installation.

1. Disconnect connector (Figure 5, Item 2) from light harness (Figure 5, Item 1).

Figure 5. Rear Connector.

0154

0154-5

TM 5-2410-241-23-2

0154

REAR FLOOD LAMP HARNESS REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation. Mark location and number of tiedown straps before removal.

2. Remove tiedown straps (Figure 6, Item 3) from harness (Figure 6, Item 5). Discard tiedown straps. 3. Disconnect two connectors (Figure 6, Item 1) from two lights (Figure 6, Item 2). 4. Remove grommet (Figure 6, Item 4) from bracket (Figure 6, Item 6). 5. Remove grommet (Figure 6, Item 4) from harness (Figure 6, Item 5). 6. Position harness (Figure 6, Item 5) from bracket (Figure 6, Item 6). 7. Remove harness (Figure 6, Item 5) from machine.

Figure 6. Rear Flood Lamp. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0154

000154

0154-6

TM 5-2410-241-23-2

0154

REAR FLOOD LAMP HARNESS INSTALLATION

000154

NOTE
This procedure will install one rear flood lamp harness. Follow same procedure for additional rear flood lamp harness. Install electrical connectors as noted during removal. Install harness as noted during removal.

1. Position harness (Figure 6, Item 5) on machine. 2. Position harness (Figure 6, Item 5) on bracket (Figure 6, Item 6). 3. Install grommet (Figure 6, Item 4) on harness (Figure 6, Item 5). 4. Install grommet (Figure 6, Item 4) on bracket (Figure 6, Item 6). 5. Connect two connectors (Figure 6, Item 1) on two lights (Figure 6, Item 2).

NOTE
Install tiedown straps as noted during removal. 6. Install new tiedown straps (Figure 6, Item 3) on harness (Figure 6, Item 5). 7. Connect connector (Figure 7, Item 2) on light harness (Figure 7, Item 1).

Figure 7. Rear Connector. END OF TASK

0154

0154-7

TM 5-2410-241-23-2

0154

FRONT FLOOD LAMP HARNESS INSTALLATION

000154

NOTE
This procedure will install one front flood lamp harness. Follow same procedure for additional front flood lamp harness. 1. Install three clamps (Figure 8, Item 4) on harness (Figure 8, Item 1). 2. Install harness (Figure 8, Item 1), three washers (Figure 8, Item 3), bolts (Figure 8, Item 2), clamps (Figure 8, Item 4), washers (Figure 8, Item 5), and nuts (Figure 8, Item 6) on machine.

Figure 8. Front Flood Lamp Harness.

0154

0154-8

TM 5-2410-241-23-2

0154

FRONT FLOOD LAMP HARNESS INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. Install harness as noted during removal. Install tiedown straps as noted during removal.

3. Position connector (Figure 9, Item 3) and harness (Figure 9, Item 6) on bracket (Figure 9, Item 1). 4. Install grommet (Figure 9, Item 2) on harness (Figure 9, Item 6). 5. Install grommet (Figure 9, Item 2) on bracket (Figure 9, Item 1). 6. Connect connector (Figure 9, Item 3) on light (Figure 9, Item 4). 7. Install new tiedown straps (Figure 9, Item 5) on harness (Figure 9, Item 6).

Figure 9. Front Flood Lamp.

0154

0154-9

TM 5-2410-241-23-2

0154

FRONT FLOOD LAMP HARNESS INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. Install harness as noted during removal.

8. Position connector (Figure 10, Item 4) and harness (Figure 10, Item 2) on inside radiator guard (Figure 10, Item 7). 9. Install grommet (Figure 10, Item 1) on harness (Figure 10, Item 2). 10. Install grommet (Figure 10, Item 1) and new tiedown strap (Figure 10, Item 3) on radiator guard (Figure 10, Item 7). 11. Connect connector (Figure 10, Item 4) on connector (Figure 10, Item 6). 12. Install new tiedown strap (Figure 10, Item 5) on connector (Figure 10, Item 6).

Figure 10. Front Connector.

0154

0154-10

TM 5-2410-241-23-2

0154

FRONT FLOOD LAMP HARNESS INSTALLATION CONTINUED 13. Close two doors (Figure 11, Item 1) on machine. 14. With assistance, slightly lift doors (Figure 11, Item 1) up from hinges (Figure 11, Item 4). 15. Install eight washers (Figure 11, Item 3) and bolts (Figure 11, Item 2) on machine.

Figure 11. Doors. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0154

000154

0154-11/(12 blank)

12 TM 5-2410-241-23-2 0155

FIELD MAINTENANCE INSTRUCTIONS BATTERY REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 5 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Personnel Required Two REMOVAL 0 0 0 0 0 0 0 0 0
000155

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 91, 96, 154 Estimated Time to Complete 1.5 Hr

0 0 0 0 0 0 0 0

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 electric shock, 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 injury to personnel. EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately. SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 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. CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0155-1

TM 5-2410-241-23-2

0155

REMOVAL CONTINUED

NOTE
Steps 1 - 4 apply to machine equipped with arctic kit. 1. Open two latches (Figure 1, Item 2) and with assistance remove cover (Figure 1, Item 1) from machine.

Figure 1. Arctic Kit Battery Cover.

0155

0155-2

TM 5-2410-241-23-2

0155

REMOVAL CONTINUED

NOTE
Steps 1 - 4 apply to machine equipped with arctic kit. 2. Position cover (Figure 2, Item 1) aside. 3. Loosen nut (Figure 2, Item 2) and remove clamp (Figure 2, Item 3) from battery (Figure 2, Item 5). 4. Position negative cable (Figure 2, Item 4) aside.

Figure 2. Arctic Kit Battery Cable.

0155

0155-3

TM 5-2410-241-23-2

0155

REMOVAL CONTINUED 5. Release two rubber latches (Figure 3, Item 2) and open battery cover (Figure 3, Item 1) on battery box.

Figure 3. Battery Box.

0155

0155-4

TM 5-2410-241-23-2

0155

REMOVAL CONTINUED

NOTE
Tag cables to aid installation. 6. Position two covers (Figure 4, Item 8) aside. 7. Loosen two nuts (Figure 4, Item 6), and remove two clamps (Figure 4, Item 7) from batteries (Figure 4, Item 10). 8. Position battery ground cable (Figure 4, Item 9) aside. 9. Position six covers (Figure 4, Item 2) aside. 10. Loosen six nuts (Figure 4, Item 3) and remove six clamps (Figure 4, Item 1) from batteries (Figure 4, Item 10). 11. Remove two crossover cables (Figure 4, Items 5 and 11) from machine. 12. Position battery power cable (Figure 4, Item 4) aside.

Figure 4. Batteries.

0155

0155-5

TM 5-2410-241-23-2

0155

REMOVAL CONTINUED 13. Loosen latch (Figure 5, Item 1) on door (Figure 5, Item 2). 14. Remove five bolts (Figure 5, Item 4), washers (Figure 5, Item 3), door (Figure 5, Item 2), and plate (Figure 5, Item 5) from machine. 15. Remove four bolts (Figure 5, Item 6), washers (Figure 5, Item 7), and hold down bracket (Figure 5, Item 8) from batteries (Figure 5, Item 9).

WARNING

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

NOTE
Each battery weighs 58 lb (26 kg). 16. With assistance remove four batteries (Figure 5, Item 9) from machine.

Figure 5. Batteries. END OF TASK

0155

0155-6

TM 5-2410-241-23-2

0155

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000155

000155

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 electric shock, 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 injury to personnel. EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately. SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 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. CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

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

NOTE
Each battery weighs 58 lb (26 kg). 1. With assistance install four batteries (Figure 5, Item 9) on machine. 2. Install hold down bracket (Figure 5, Item 8), four washers (Figure 5, Item 7), and bolts (Figure 5, Item 6) on batteries (Figure 5, Item 9). 3. Install plate (Figure 5, Item 5), door (Figure 5, Item 2), five washers (Figure 5, Item 3), and bolts (Figure 5, Item 4) on machine. 4. Tighten latch (Figure 5, Item 1) on door (Figure 5, Item 2).

0155-7

TM 5-2410-241-23-2

0155

INSTALLATION CONTINUED

NOTE
Install cables as tagged during removal. 5. Install battery power cable (Figure 6, Item 4) on batteries (Figure 6, Item 10). 6. Install two crossover cables (Figure 6, Items 5 and 11) on batteries (Figure 6, Item 10). 7. Install six clamps (Figure 6, Item 1) and tighten nuts (Figure 6, Item 3) on batteries (Figure 6, Item 10). 8. Position six covers (Figure 6, Item 2) on clamps (Figure 6, Item 1). 9. Install battery ground cable (Figure 6, Item 9) on batteries (Figure 6, Item 10). 10. Install two clamps (Figure 6, Item 7) and tighten nuts (Figure 6, Item 6) on batteries (Figure 6, Item 10). 11. Position two covers (Figure 6, Item 8) on clamps (Figure 6, Item 7).

Figure 6. Batteries.

0155

0155-8

TM 5-2410-241-23-2

0155

INSTALLATION CONTINUED 12. Close battery cover (Figure 7, Item 1) and close two rubber latches (Figure 7, Item 2) on machine.

Figure 7. Battery Box.

0155

0155-9

TM 5-2410-241-23-2

0155

INSTALLATION CONTINUED

NOTE
Steps 13 - 16 apply to machine equipped with arctic kit. 13. Position negative cable (Figure 8, Item 4) on battery (Figure 8, Item 5). 14. Install clamp (Figure 8, Item 3) and tighten nut (Figure 8, Item 2) on battery (Figure 8, Item 5). 15. Position cover (Figure 8, Item 1) over clamp (Figure 8, Item 3).

Figure 8. Arctic Kit Battery Cable.

0155

0155-10

TM 5-2410-241-23-2

0155

INSTALLATION CONTINUED

NOTE
Steps 13 - 16 apply to machine equipped with arctic kit. 16. With assistance, install cover (Figure 9, Item 1) and close two latches (Figure 9, Item 2) on machine.

Figure 9. Arctic Kit Battery Cover. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0155

000155

0155-11/(12 blank)

14 TM 5-2410-241-23-2 0156

FIELD MAINTENANCE INSTRUCTIONS BATTERY BOX REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 5 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Blind Fastener, Installation (S0700) (WP 0302, Item 68) Drill-driver, Battery Operated (S0188) (WP 0302, Item 68) Drill Set, Twist 1/16 to 1/2 (S0194) (WP 0302, Item 68) Extension, 3/8 Drive, 6" long (S0496) (WP 0302, Item 68) Extension, 3/8 Drive, 10" long (S0497) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Cotter Pin (4) Lockwasher (4) Rivet (8) Speed nut (2) 0 0 0 0 0 0 0 0 0 0 0 0 0 Personnel Required Two References WP 0295 Equipment Condition 0 0 0 0 0

Machine parked (TM 5-2410-241-10) 0 Batteries removed (WP 0155) 0 (With Arctic Kit) Arctic kit battery box removed (WP 0289) 0 Washer bottle removed (WP 0224) 0 Pivot tank removed (WP 0158) 0 Drawing Required TM 5-2410-241-24P, Figure 91, 96 Estimated Time to Complete 7.5 Hr 0 0 0 0

0156-1

TM 5-2410-241-23-2

0156

REMOVAL

000156

1. Remove two speed nuts (Figure 1, Item 1), pins (Figure 1, Item 3), and latches (Figure 1, Item 2) from battery box door (Figure 1, Item 4). Discard speed nuts.

Figure 1. Battery Box Door.

0156

0156-2

TM 5-2410-241-23-2

0156

REMOVAL CONTINUED 2. With assistance, remove two cotter pins (Figure 2, Item 4), washers (Figure 2, Item 3) and prop plate (Figure 2, Item 2) from door (Figure 2, Item 1) and battery box (Figure 2, Item 5). Discard cotter pins. 3. Remove nine bolts (Figure 2, Item 7), washers (Figure 2, Item 6), and hinge (Figure 2, Item 8) from door (Figure 2, Item 1) and battery box (Figure 2, Item 5). 4. With assistance remove door (Figure 2, Item 1) from battery box (Figure 2, Item 5).

Figure 2. Door.

0156

0156-3

TM 5-2410-241-23-2

0156

REMOVAL CONTINUED 5. Remove bolt (Figure 3, Item 21), two washers (Figure 3, Item 22), nuts (Figure 3, Item 25), and key strap (Figure 3, Item 7) from bracket (Figure 3, Item 23). 6. Remove key (Figure 3, Item 3) from battery disconnect switch (Figure 3, Item 8). 7. Remove receptacle cable cover (Figure 3, Item 26) from receptacle cable (Figure 3, Item 15). 8. Remove bolt (Figure 3, Item 20), washer (Figure 3, Item 19), receptacle cable cover strap (Figure 3, Item 18), receptacle cable cover (Figure 3, Item 26), and bracket (Figure 3, Item 23) from front battery box cover (Figure 3, Item 24). 9. Remove bolt (Figure 3, Item 11), washer (Figure 3, Item 12), and ladder clip (Figure 3, Item 14) from front battery box cover (Figure 3, Item 24). 10. Remove four bolts (Figure 3, Item 16), washers (Figure 3, Item 17), and receptacle cable (Figure 3, Item 15) from front battery box cover (Figure 3, Item 24). 11. Remove nut (Figure 3, Item 4), two lockwashers (Figure 3, Item 5), and battery disconnect switch (Figure 3, Item 8) from front battery box cover (Figure 3, Item 24). Discard lockwashers.

Figure 3. Battery Disconnect Connections.

0156

NOTE
Decals can not be re-used, new decal must be installed if battery box is being replaced. Note location and orientation to aid installation. 12. Note location of decal (Figure 3, Item 6) on front battery box cover (Figure 3, Item 24).

NOTE
Arctic kit cable shown for machines equipped with arctic kit. Step 13 is for machines equipped with arctic kit. Go to step 14 if arctic kit is not installed. 13. Position arctic kit junction block cable (Figure 3, Item 13) aside. 14. Remove two nuts (Figure 3, Item 1), lockwashers (Figure 3, Item 2), and bolts (Figure 3, Item 9), and electrical post (Figure 3, Item 10) from front battery box cover (Figure 3, Item 24). Discard lockwashers.

0156-4

TM 5-2410-241-23-2

0156

REMOVAL CONTINUED 15. Remove three bolts (Figure 4, Item 1) and washers (Figure 4, Item 2) from inside front battery box cover (Figure 4, Item 3).

Figure 4. Inside Front Cover.

0156

16. Remove two bolts (Figure 5, Item 3), washers (Figure 5, Item 2), and front battery box cover (Figure 5, Item 1) from machine.

Figure 5. Front Cover.

0156

0156-5

TM 5-2410-241-23-2

0156

REMOVAL CONTINUED 17. Remove cotter pin (Figure 6, Item 1) and washer (Figure 6, Item 4) from knob (Figure 6, Item 2). Discard cotter pin. 18. Remove knob (Figure 6, Item 2) from battery disconnect door (Figure 6, Item 3).

Figure 6. Battery Disconnect Door.

0156

19. Remove three bolts (Figure 7, Item 3) and washers (Figure 7, Item 4) from inside battery box (Figure 7, Item 5). 20. Remove three bolts (Figure 7, Item 1), washers (Figure 7, Item 2), and battery box (Figure 7, Item 5) from fender.

Figure 7. Battery Box.

0156

0156-6

TM 5-2410-241-23-2

0156

REMOVAL CONTINUED 21. Remove roll pin (Figure 8, Item 4) and latch (Figure 8, Item 5) from stud (Figure 8, Item 3). Discard roll pin. 22. Remove knob (Figure 8, Item 1) and stud (Figure 8, Item 3) from pivot shaft tank door (Figure 8, Item 2). 23. Remove roll pin (Figure 8, Item 6) and knob (Figure 8, Item 1) from stud (Figure 8, Item 3). Discard roll pin.

Figure 8. Pivot Shaft Tank Door.

0156

0156-7

TM 5-2410-241-23-2

0156

REMOVAL CONTINUED

NOTE
Steps 24 and 25 remove the information plates for replacement of battery box panels. Do not remove information plates if panels are not being replaced. 24. Remove four rivets (Figure 9, Item 3) and information plates (Figure 9, Item 2) from side battery box panel (Figure 9, Item 1). Discard rivets. 25. Remove four rivets (Figure 9, Item 5) and information plates (Figure 9, Item 6) from front battery box panel (Figure 9, Item 4). Discard rivets.

Figure 9. Information Plates. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0156

000156

000156

NOTE
Steps 1 and 2 install the information plates for replacement of battery box panels. Information plates should not be removed if battery box panels are re-used. 1. Install information plate (Figure 9, Item 6) and four new rivets (Figure 9, Item 5) on front battery box panel (Figure 9, Item 4). 2. Install information plate (Figure 9, Item 2) and four new rivets (Figure 9, Item 3) on side battery box panel (Figure 9, Item 1).

0156-8

TM 5-2410-241-23-2

0156

INSTALLATION CONTINUED 3. Install knob (Figure 10, Item 1) and new roll pin (Figure 10, Item 6) on stud (Figure 10, Item 3). 4. Install stud (Figure 10, Item 3) and knob (Figure 10, Item 1) on pivot shaft tank door (Figure 10, Item 2). 5. Install latch (Figure 10, Item 5) and new roll pin (Figure 10, Item 4) on stud (Figure 10, Item 3).

Figure 10. Pivot Shaft Tank Door.

0156

0156-9

TM 5-2410-241-23-2

0156

INSTALLATION CONTINUED 6. Install battery box (Figure 11, Item 5), three washers (Figure 11, Item 2), and bolts (Figure 11, Item 1) on fender. 7. Install three washers (Figure 11, Item 4) and bolts (Figure 11, Item 3) inside battery box (Figure 11, Item 5).

Figure 11. Battery Box. 8. Install knob (Figure 12, Item 2) on battery disconnect door (Figure 12, Item 3). 9. Install washer (Figure 12, Item 4) and new cotter pin (Figure 12, Item 1) on knob (Figure 12, Item 2).

0156

Figure 12. Battery Disconnect Door.

0156

0156-10

TM 5-2410-241-23-2

0156

INSTALLATION CONTINUED 10. Install front battery box cover (Figure 13, Item 1), two washers (Figure 13, Item 2), and bolts (Figure 13, Item 3) on machine.

Figure 13. Front Cover.

0156

11. Install three washers (Figure 14, Item 2) and bolts (Figure 14, Item 1) on front battery cover (Figure 14, Item 3).

Figure 14. Inside Front Cover.

0156

0156-11

TM 5-2410-241-23-2

0156

INSTALLATION CONTINUED 12. Install electrical post (Figure 15, Item 10), two bolts (Figure 15, Item 9), new lockwashers (Figure 15, Item 2), and nuts (Figure 15, Item 1) on front battery box cover (Figure 15, Item 24).

NOTE
Arctic kit cable shown for machines equipped with arctic kit. Step 13 is for machines equipped with arctic kit. Go to step 14 if arctic kit is not installed. 13. Position arctic kit junction block cable (Figure 15, Item 13) on electrical post (Figure 15, Item 10).

NOTE
Decals can not be re-used. New decal must be installed if battery box is being replaced. Install new decals as noted during removal. 14. Install new decal (Figure 15, Item 6) on front battery box cover (Figure 15, Item 24). 15. Install battery disconnect switch (Figure 15, Item 8), two new lockwashers (Figure 15, Item 5), and nut (Figure 15, Item 4) on front battery box cover (Figure 15, Item 24). 16. Install receptacle cable (Figure 15, Item 15), four washers (Figure 15, Item 17), and bolts (Figure 15, Item 16) on front battery box cover (Figure 15, Item 24). 17. Install ladder clip (Figure 15, Item 14), washer (Figure 15, Item 12), and bolt (Figure 15, Item 11) on front battery box cover. (Figure 15, Item 24). 18. Install bracket (Figure 15, Item 23), receptacle cable cover (Figure 15, Item 26), receptacle cable cover strap (Figure 15, Item 18), washer (Figure 15, Item 19), and bolt (Figure 15, Item 20) on front battery box cover (Figure 15, Item 24). 19. Install receptacle cable cover (Figure 15, Item 26) on receptacle cable (Figure 15, Item 15). 20. Install key (Figure 15, Item 3) on battery disconnect switch (Figure 15, Item 8). 21. Install key strap (Figure 15, Item 7), two washers (Figure 15, Item 22), bolt (Figure 15, Item 21), and nuts (Figure 15, Item 25), on bracket (Figure 15, Item 23).

Figure 15. Battery Disconnect Connections.

0156

0156-12

TM 5-2410-241-23-2

0156

INSTALLATION CONTINUED 22. With assistance, install door (Figure 16, Item 1) on battery box (Figure 16, Item 5). 23. Install hinge (Figure 16, Item 8), nine washers (Figure 16, Item 6), and bolts (Figure 16, Item 7) on door (Figure 16, Item 1) and battery box (Figure 16, Item 5). 24. With assistance, install prop plate (Figure 16, Item 2), two washers (Figure 16, Item 3), and new cotter pins (Figure 16, Item 4) on door (Figure 16, Item 1) and battery box (Figure 16, Item 5).

Figure 16. Door.

0156

0156-13

TM 5-2410-241-23-2

0156

INSTALLATION CONTINUED 25. Install two latches (Figure 17, Item 2), new cotter pins (Figure 17, Item 3), and new speed nuts (Figure 17, Item 1) on battery box door (Figure 17, Item 4).

Figure 17. Battery Door Latch. END OF TASK FOLLOW-ON TASKS 1. Install pivot tank (WP 0158). 2. Install batteries (WP 0155). 3. Install washer bottle (WP 0224). 4. (With Arctic Kit) Install arctic kit battery box (WP 0289). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0156

000156

0156-14

18 TM 5-2410-241-23-2 0157

FIELD MAINTENANCE FUEL LINE REPLACEMENT Fuel Supply and Return Line Removal, Fuel Drain Line Removal, Cleaning and Inspection, Fuel Drain Line Installation, Fuel Supply and Return Line Installation
0 1 5 7

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Wrench, Combination, 1-1/8 (S0788) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (14) References WP 0171
0

References - Continued WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Front floor plates removed (WP 0230) Rear floor plates removed (WP 0231) Engine enclosure left door guard removed (WP 0202) Fuel drained (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 84 Estimated Time to Complete 7.0 Hr

0157-1

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE REMOVAL

000157

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel lines. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

NOTE
Note position and orientation of fittings to aid in installation. 1. Loosen tube nut (Figure 1, Item 8) and remove hose (Figure 1, Item 2) and O-ring (Figure 1, Item 9) from filter base (Figure 1, Item 1). Discard O-ring. 2. Remove nut (Figure 1, Item 4), washer (Figure 1, Item 3), two retaining straps (Figure 1, Items 6 and 7) from bracket (Figure 1, Item 5). 3. Remove retaining strap (Figure 1, Item 7) from hose (Figure 1, Item 2).

Figure 1. Fuel Supply Line.

0157

0157-2

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE REMOVAL CONTINUED 4. Loosen tube nut (Figure 2, Item 3), and remove hose (Figure 2, Item 4) and O-ring (Figure 2, Item 2) from filter base (Figure 2, Item 1). Discard O-ring. 5. Remove two bolts (Figure 2, Item 6), washers (Figure 2, Item 7), and retaining straps (Figure 2, Item 5) from machine. 6. Remove two retaining straps (Figure 2, Item 5) from two hoses (Figure 2, Item 4).

Figure 2. Fuel Return Line.

0157

0157-3

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE REMOVAL CONTINUED

NOTE
Note position and orientation of fittings to aid in installation. 7. Loosen tube nut (Figure 3, Item 3) and remove hose (Figure 3, Item 2) and O-ring (Figure 3, Item 4) from fitting (Figure 3, Item 5). Discard O-ring. 8. Remove fitting (Figure 3, Item 5) and O-ring (Figure 3, Item 6) from valve (Figure 3, Item 7). Discard O-ring. 9. Remove valve (Figure 3, Item 7) and O-ring (Figure 3, Item 8) from fitting (Figure 3, Item 9). Discard O-ring. 10. Remove fitting (Figure 3, Item 9) and O-ring (Figure 3, Item 10) from tank (Figure 3, Item 1). Discard O-ring.

Figure 3. Tank Supply Line.

0157

0157-4

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE REMOVAL CONTINUED

NOTE
Note position and orientation of fittings to aid in installation. 11. Loosen tube nut (Figure 4, Item 5) and remove hose (Figure 4, Item 2) and O-ring (Figure 4, Item 4) from elbow fitting (Figure 4, Item 3). Discard O-ring. 12. Loosen tube nut (Figure 4, Item 7) and remove elbow fitting (Figure 4, Item 3) and O-ring (Figure 4, Item 6) from hose (Figure 4, Item 1). Discard O-ring.

Figure 4. Tank Return Line.

0157

0157-5

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE REMOVAL CONTINUED

NOTE
Note position of retaining straps and routing of hoses to aid installation. 13. Remove bolt (Figure 5, Item 8), washer (Figure 5, Item 7), two retaining straps (Figure 5, Items 9 and 3), and spacer (Figure 5, Item 4) from two hoses (Figure 5, Items 2 and 1). 14. Position two connector clips (Figure 5, Item 5) and connectors (Figure 5, Item 6) aside.

Figure 5. Fuel Line Retaining Straps and Spacers.

0157

0157-6

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE REMOVAL CONTINUED

NOTE
Note position of retaining straps and routing of hoses to aid installation. 15. Remove two bolts (Figure 6, Item 1), washers (Figure 6, Item 2), one wire clip (Figure 6, Item 5), two retaining straps (Figure 6, Item 4), and hoses (Figure 6, Item 3) from machine. 16. Position wire clip (Figure 6, Item 5) and harness (Figure 6, Item 6) aside. 17. Remove two retaining straps (Figure 6, Item 4) from hoses (Figure 6, Item 3).

Figure 6. Fuel Line Retaining Straps and Spacers.

0157

0157-7

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE REMOVAL CONTINUED

NOTE
Note position of retaining straps and routing of hoses to aid installation. 18. Remove fuel tank (WP 0171). 19. Remove two bolts (Figure 7, Item 5), washers (Figure 7, Item 6), and P clips (Figure 7, Item 4) from hose (Figure 7, Item 3). 20. Loosen tube nut (Figure 7, Item 2) and remove hose (Figure 7, Item 3) from elbow (Figure 7, Item 1). 21. Remove elbow (Figure 7, Item 1) and two O-rings (Figure 7, Item 8) from tank (Figure 7, Item 7). Discard O-rings.

Figure 7. Tank Return Line. END OF TASK

0157

0157-8

TM 5-2410-241-23-2

0157

FUEL DRAIN LINE REMOVAL 1. Loosen retaining strap (Figure 8, Item 2) and remove hose (Figure 8, Item 5) from fitting (Figure 8, Item 6).

000157

2. Remove valve (Figure 8, Item 3) and O-ring (Figure 8, Item 10) from fitting (Figure 8, Item 4). Discard O-ring. 3. Remove fitting (Figure 8, Item 6) and O-ring (Figure 8, Item 7) from fitting (Figure 8, Item 8). Discard O-ring. 4. Remove fitting (Figure 8, Item 8) and O-ring (Figure 8, Item 9) from valve (Figure 8, Item 3). Discard O-ring. 5. Remove fitting (Figure 8, Item 4) and O-ring (Figure 8, Item 11) from tank (Figure 8, Item 1). Discard O-ring.

Figure 8. Fuel Drain Line. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0157

000157

0157-9

TM 5-2410-241-23-2

0157

FUEL DRAIN LINE INSTALLATION 1. Install new O-ring (Figure 9, Item 11) and fitting (Figure 9, Item 4) on tank (Figure 9, Item 1). 2. Install new O-ring (Figure 9, Item 9) and fitting (Figure 9, Item 8) on valve (Figure 9, Item 3). 3. Install new O-ring (Figure 9, Item 7) and fitting (Figure 9, Item 6) on fitting (Figure 9, Item 8). 4. Install new O-ring (Figure 9, Item 10) and valve (Figure 9, Item 3) on fitting (Figure 9, Item 4). 5. Install hose (Figure 9, Item 5) and retaining strap (Figure 9, Item 2) on fitting (Figure 9, Item 6).

000157

Figure 9. Fuel Drain Line. END OF TASK

0157

0157-10

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE INSTALLATION

000157

NOTE
Install retaining straps and hoses as noted during removal. 1. Install two new O-rings (Figure 10, Item 8) and fitting (Figure 10, Item 1) on tank (Figure 10, Item 7). 2. Install hose (Figure 10, Item 3) and tube nut (Figure 10, Item 2) on fitting (Figure 10, Item 1). 3. Install two P clips (Figure 10, Item 4), washers (Figure 10, Item 6), and bolts (Figure 10, Item 5) on hose (Figure 10, Item 3). 4. Install fuel tank (WP 0171).

Figure 10. Tank Return Line.

0157

0157-11

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE INSTALLATION CONTINUED

NOTE
Install retaining straps and hoses as noted during removal. 5. Install two retaining straps (Figure 11, Item 4) on hoses (Figure 11, Item 3). 6. Position wire clip (Figure 11, Item 5) and harness (Figure 11, Item 6) on machine. 7. Install two hoses (Figure 11, Item 3), retaining straps (Figure 11, Item 4), wire clip (Figure 11, Item 5), two washers (Figure 11, Item 2), and bolts (Figure 11, Item 1) on machine.

Figure 11. Fuel Line Retaining Straps and Spacers.

0157

0157-12

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE INSTALLATION CONTINUED

NOTE
Install retaining straps and hoses as noted during removal. 8. Position two connector clips (Figure 12, Item 5) and connectors (Figure 12, Item 6) on machine. 9. Install spacer (Figure 12, Item 4), two retaining straps (Figure 12, Items 9 and 3), washer (Figure 12, Item 7), and bolt (Figure 12, Item 8), on two hoses (Figure 12, Items 2 and 1).

Figure 12. Fuel Line Retaining Straps and Spacers.

0157

0157-13

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE INSTALLATION CONTINUED

NOTE
Install fittings as noted during removal. 10. Install new O-ring (Figure 13, Item 6), elbow fitting (Figure 13, Item 3), and tube nut (Figure 13, Item 7) on hose (Figure 13, Item 1). 11. Install new O-ring (Figure 13, Item 4), hose (Figure 13, Item 2), and tube nut (Figure 13, Item 5) on elbow fitting (Figure 13, Item 3).

Figure 13. Tank Return Line.

0157

0157-14

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE INSTALLATION CONTINUED

NOTE
Install fittings as noted during removal. 12. Install new O-ring (Figure 14, Item 10) and fitting (Figure 14, Item 9) on tank (Figure 14, Item 1). 13. Install new O-ring (Figure 14, Item 8) and valve (Figure 14, Item 7) on fitting (Figure 14, Item 9). 14. Install new O-ring (Figure 14, Item 6) and fitting (Figure 14, Item 5) on valve (Figure 14, Item 7). 15. Install new O-ring (Figure 14, Item 4), hose (Figure 14, Item 2) and tube nut (Figure 14, Item 3) on fitting (Figure 14, Item 5).

Figure 14. Tank Supply Line.

0157

0157-15

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE INSTALLATION CONTINUED 16. Install two retaining straps (Figure 15, Item 5) on two hoses (Figure 15, Item 4). 17. Install two retaining straps (Figure 15, Item 5), washers (Figure 15, Item 7), and bolts (Figure 15, Item 6) on machine. 18. Install new O-ring (Figure 15, Item 2), hose (Figure 15, Item 4), and tube nut (Figure 15, Item 3) on filter base (Figure 15, Item 1).

Figure 15. Fuel Return Line.

0157

0157-16

TM 5-2410-241-23-2

0157

FUEL SUPPLY AND RETURN LINE INSTALLATION CONTINUED 19. Install retaining strap (Figure 16, Item 7) on hose (Figure 16, Item 2). 20. Install two retaining straps (Figure 16, Items 6 and 7), washer (Figure 16, Item 3), and nut (Figure 16, Item 4) on bracket (Figure 16, Item 5).

NOTE
Install fittings as noted during removal. 21. Install O-ring (Figure 16, Item 9), hose (Figure 16, Item 2), and tube nut (Figure 16, Item 8) on filter base (Figure 16, Item 1).

Figure 16. Fuel Supply Line. END OF TASK FOLLOW-ON TASKS 1. Install rear floor plates (WP 0231). 2. Install front floor plates (WP 0230). 3. Install engine enclosure left door guard (WP 0202). 4. Fill fuel (TM 5-2410-241-10). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE 0157-17/(18 blank)

0157

000157

6 TM 5-2410-241-23-2 0158

FIELD MAINTENANCE INSTRUCTIONS

0 1 5 8

PIVOT SHAFT LUBRICATION LINE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Pan, Drain (S0255) (WP 0302, Item 68) Wrench, Combination 1 3/8 (S0791) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO 15/40 (WP 0303, Item 21) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) REMOVAL
0

Materials/Parts - Continued Tag, Marker (WP 0303, Item 34) O-ring (5) References

LO 5-2410-241-13 WP 0295 Equipment Condition

Machine parked (TM 5-2410-241-10) Rear bottom guards removed (WP 0199) Washer bottle removed (WP 0224) Drawing Required

TM 5-2410-241-24P, Figure 90
0

Estimated Time to Complete 3.5 Hr

000158

WARNING

Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Failure to follow this warning may cause injury to personnel. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Perform disassembly on a clean surface. Clean exterior of component to prevent contamination. Cap and plug all lines, hoses and tubes to prevent contamination and leaks. Tag and mark all hoses and lines to aid installation.

0158-1

TM 5-2410-241-23-2

0158

REMOVAL CONTINUED 1. Place drain pan under pivot shaft housing (Figure 1, Item 1). 2. Remove drain plug (Figure 1, Item 2) and O-ring (Figure 1, Item 3) from pivot shaft housing (Figure 1, Item 1). Drain oil into drain pan. Discard O-ring. 3. Install new O-ring (Figure 1, Item 3) and drain plug (Figure 1, Item 2) on pivot shaft housing (Figure 1, Item 1).

Figure 1. Pivot Shaft Oil Drain.

0158

0158-2

TM 5-2410-241-23-2

0158

REMOVAL CONTINUED 4. Loosen tube nut (Figure 2, Item 2) and remove line (Figure 2, Item 1) from fitting (Figure 2, Item 3). 5. Remove two bolts (Figure 2, Item 8), washers (Figure 2, Item 7) from oil tank (Figure 2, Item 4). 6. Remove bolt (Figure 2, Item 6) and cap (Figure 2, Item 5) from oil tank (Figure 2, Item 4). 7. Remove oil tank (Figure 2, Item 4) from machine. 8. Remove fitting (Figure 2, Item 3) and two O-rings (Figure 2, Item 9) from oil tank (Figure 2, Item 4). Discard O-rings.

Figure 2. Pivot Shaft Lubrication Tank.

0158

0158-3

TM 5-2410-241-23-2

0158

REMOVAL CONTINUED

NOTE
Note line routing, clamp position and orientation to aid installation. 9. Remove four bolts (Figure 3, Item 2), washers (Figure 3, Item 3), and clamps (Figure 3, Item 4) from line (Figure 3, Item 1). 10. Loosen tube nut (Figure 3, Item 5) and remove line (Figure 3, Item 1) from fitting (Figure 3, Item 6). 11. Remove line (Figure 3, Item 1) from machine.

NOTE
Note orientation of elbow fitting to aid installation. 12. Remove elbow fitting (Figure 3, Item 6) and two O-rings (Figure 3, Item 7) from pivot shaft housing (Figure 3, Item 8). Discard O-rings.

Figure 3. Pivot Shaft Lubrication Line. END OF TASK

0158

0158-4

TM 5-2410-241-23-2

0158

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000158

000158

WARNING

Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Failure to follow this warning may cause injury to personnel. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Remove plugs and caps from all lines, hoses and tubes. Install hoses and lines as noted during removal.

1. Install two new O-rings (Figure 3, Item 7) and elbow fitting (Figure 3, Item 6) on pivot shaft housing (Figure 3, Item 8). 2. Install line (Figure 3, Item 1) on machine. 3. Install line (Figure 3, Item 1) and tighten tube nut (Figure 3, Item 5) on fitting (Figure 3, Item 6).

NOTE
Install clamps and line as noted during removal. 4. Install four clamps (Figure 3, Item 4), washers (Figure 3, Item 3), and bolts (Figure 3, Item 2) on line (Figure 3, Item 1).

0158-5

TM 5-2410-241-23-2

0158

INSTALLATION CONTINUED 5. Install two new O-rings (Figure 4, Item 9) and fitting (Figure 4, Item 3) on oil tank (Figure 4, Item 4). 6. Install oil tank (Figure 4, Item 4) on machine. 7. Install cap (Figure 4, Item 5) and bolt (Figure 4, Item 6) on oil tank (Figure 4, Item 4). 8. Install two washers (Figure 4, Item 7) and bolts (Figure 4, Item 8) on oil tank (Figure 4, Item 4). 9. Install line (Figure 4, Item 1) and tube nut (Figure 4, Item 2) on fitting (Figure 4, Item 3). 10. Fill oil tank (Figure 4, Item 4). For correct quantity and type of oil, see LO 5-2410-241-13.

Figure 4. Pivot Shaft Lubrication Tank. END OF TASK FOLLOW-ON TASKS 1. Install washer bottle (WP 0224). 2. Install rear bottom guards (WP 0199). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0158

000158

0158-6

14 TM 5-2410-241-23-2 0159

FIELD MAINTENANCE BATTERY POWER CABLE REPLACEMENT Battery Positive to Junction Block Removal, Junction Block to Fuse Panel Power Cable Removal, Cleaning and Inspection, Junction Block to Fuse Panel Power Cable Installation, Battery Positive to Junction Block Installation
0 1 5 9

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Locknut (2)
0

References WP 0155 WP 0295 Equipment Condition

Machine parked (TM 5-2410-241-10) Front floor plates removed (WP 0230) Drawing Required TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 2.5 Hr

BATTERY POSITIVE TO JUNCTION BLOCK REMOVAL

000159

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 electric shock, 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 injury to personnel. EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately. SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 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. CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0159-1

TM 5-2410-241-23-2

0159

BATTERY POSITIVE TO JUNCTION BLOCK REMOVAL CONTINUED 1. Release two rubber latches (Figure 1, Item 2) and open battery cover (Figure 1, Item 1) on battery box.

Figure 1. Battery Box.

0159

0159-2

TM 5-2410-241-23-2

0159

BATTERY POSITIVE TO JUNCTION BLOCK REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

2. Position two covers (Figure 2, Item 4) aside. 3. Loosen two nuts (Figure 2, Item 5) and remove two clamps (Figure 2, Item 3) from batteries (Figure 2, Item 2). 4. Position positive battery cable (Figure 2, Item 1) aside.

Figure 2. Battery Positive Cable.

0159

0159-3

TM 5-2410-241-23-2

0159

BATTERY POSITIVE TO JUNCTION BLOCK REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

5. Position cover (Figure 3, Item 8) aside. 6. Remove nut (Figure 3, Item 7), washer (Figure 3, Item 6), and positive battery cable (Figure 3, Item 4) from junction box (Figure 3, Item 5).

NOTE
Note position of clamps to aid installation. 7. Remove two nuts (Figure 3, Item 2), washers (Figure 3, Item 3), and clamps (Figure 3, Item 1) from positive battery cable (Figure 3, Item 4). 8. Remove positive battery cable (Figure 3, Item 4) from machine.

Figure 3. Battery Positive Cable to Junction Box. END OF TASK

0159

0159-4

TM 5-2410-241-23-2

0159

JUNCTION BLOCK TO FUSE PANEL POWER CABLE REMOVAL 1. Remove batteries (WP 0155).

000159

NOTE
Note cable routing to aid installation. 2. Remove nut (Figure 4, Item 2), washer (Figure 4, Item 3), and two clamps (Figure 4, Item 4) from two cables (Figure 4, Item 1).

Figure 4. Clamps.

0159

0159-5

TM 5-2410-241-23-2

0159

JUNCTION BLOCK TO FUSE PANEL POWER CABLE REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. 3. Remove two nuts (Figure 5, Item 5), washers (Figure 5, Item 4), and two clamps (Figure 5, Item 6) from two cables (Figure 5, Item 7). 4. Remove two bolts (Figure 5, Item 2), washers (Figure 5, Item 3), and cover (Figure 5, Item 1) from fuse panel (Figure 5, Item 8).

Figure 5. Cover.

0159

0159-6

TM 5-2410-241-23-2

0159

JUNCTION BLOCK TO FUSE PANEL POWER CABLE REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

5. Remove bolt (Figure 6, Item 3), washers (Figure 6, Item 2) and positive battery cable (Figure 6, Item 4) from fuse panel (Figure 6, Item 1). 6. Position positive battery cable (Figure 6, Item 4) aside.

Figure 6. Fuse Panel Cable.

0159

0159-7

TM 5-2410-241-23-2

0159

JUNCTION BLOCK TO FUSE PANEL POWER CABLE REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

7. Remove locknut (Figure 7, Item 2), washer (Figure 7, Item 1), and clamp (Figure 7, Item 3) from junction block power cable (Figure 7, Item 4). Discard locknut. 8. Remove locknut (Figure 7, Item 7) and washer (Figure 7, Item 8) from machine. Discard locknut and position clamp (Figure 7, Item 6) aside. 9. Remove clamp (Figure 7, Item 5) from junction block power cable (Figure 7, Item 4). 10. Position cover (Figure 7, Item 9) aside. 11. Remove nut (Figure 7, Item 10), washers (Figure 7, Item 11), and junction block power cable (Figure 7, Item 4) from junction box (Figure 7, Item 12). 12. Remove junction block power cable (Figure 7, Item 4) from machine.

Figure 7. Fuse Panel Cable. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0159

000159

0159-8

TM 5-2410-241-23-2

0159

JUNCTION BLOCK TO FUSE PANEL POWER CABLE INSTALLATION

000159

NOTE
Install electrical connections and cables as noted during removal. 1. Install junction block power cable (Figure 7, Item 4) on machine. 2. Install junction block power cable (Figure 7, Item 4), washers (Figure 7, Item 11), and nut (Figure 7, Item 10) on junction box (Figure 7, Item 12). 3. Position cover (Figure 7, Item 9) over nut (Figure 7, Item 10). 4. Install clamp (Figure 7, Item 5) on junction block power cable (Figure 7, Item 4). 5. Install clamp (Figure 7, Item 6), washer (Figure 7, Item 8), and new locknut (Figure 7, Item 7) on machine. 6. Install clamp (Figure 7, Item 3), washer (Figure 7, Item 1), and new locknut (Figure 7, Item 2) on junction block power cable (Figure 7, Item 4).

NOTE
Route and install cables as noted during removal. Install electrical connections as marked during removal.

7. Position positive battery cable (Figure 8, Item 4) on fuse panel (Figure 8, Item 1). 8. Install positive battery cable (Figure 8, Item 4), washers (Figure 8, Item 3), and bolt (Figure 8, Item 2), on fuse panel (Figure 8, Item 1).

Figure 8. Fuse Panel Cable.

0159

0159-9

TM 5-2410-241-23-2

0159

JUNCTION BLOCK TO FUSE PANEL POWER CABLE INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 9. Install cover (Figure 9, Item 1), two washers (Figure 9, Item 3), and bolts (Figure 9, Item 2) on fuse panel (Figure 9, Item 8). 10. Install two clamps (Figure 9, Item 6), washers (Figure 9, Item 4), and nuts (Figure 9, Item 5) on two cables (Figure 9, Item 7).

Figure 9. Cover.

0159

0159-10

TM 5-2410-241-23-2

0159

JUNCTION BLOCK TO FUSE PANEL POWER CABLE INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 11. Install two clamps (Figure 10, Item 4), washer (Figure 10, Item 3), and nut (Figure 10, Item 2) on two cables (Figure 10, Item 1). 12. Install batteries (WP 0155).

Figure 10. Clamps. END OF TASK

0159

0159-11

TM 5-2410-241-23-2

0159

BATTERY POSITIVE TO JUNCTION BLOCK INSTALLATION

000159

NOTE
Install clamps as noted during removal. 1. Install positive battery cable (Figure 11, Item 4) on machine. 2. Install two clamps (Figure 11, Item 1), washers (Figure 11, Item 3), and nuts (Figure 11, Item 2) on positive battery cable (Figure 11, Item 4).

NOTE
Install electrical connections and cable as noted during removal. 3. Install positive battery cable (Figure 11, Item 4), washer (Figure 11, Item 6), and nut (Figure 11, Item 7) on junction box (Figure 11, Item 5). 4. Position cover (Figure 11, Item 8) over nut (Figure 11, Item 7).

Figure 11. Battery Positive Cable to Junction Box.

0159

0159-12

TM 5-2410-241-23-2

0159

BATTERY POSITIVE TO JUNCTION BLOCK INSTALLATION CONTINUED

NOTE
Install cable as noted during removal. 5. Install positive battery cable (Figure 12, Item 1) on batteries (Figure 12, Item 2). 6. Install two clamps (Figure 12, Item 3) and nuts (Figure 12, Item 5) on batteries (Figure 12, Item 2). 7. Position two covers (Figure 12, Item 4) over nuts (Figure 12, Item 5).

Figure 12. Battery Positive Cable.

0159

0159-13

TM 5-2410-241-23-2

0159

BATTERY POSITIVE TO JUNCTION BLOCK INSTALLATION CONTINUED 8. Close battery cover (Figure 13, Item 1) and secure two rubber latches (Figure 13, Item 2) on battery box.

Figure 13. Battery Box. END OF TASK FOLLOW-ON TASKS 1. Install front floor plates (WP 0230). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0159

000159

0159-14

14 TM 5-2410-241-23-2 0160

FIELD MAINTENANCE BATTERY GROUND CABLE REPLACEMENT Battery Ground to Disconnect Switch Cable Removal, Disconnect Switch to Machine Ground Cable Removal, Cleaning and Inspection, Disconnect Switch to Machine Ground Cable Installation, Battery Ground to Disconnect Switch Cable Installation
0 1 6 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Glove, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) WP 0155 WP 0230 0 0 0 0 0 0 0 0 0 References - Continued WP 0295 Personnel Required Two Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 2.0 Hr 0 0 0 0 0 0 0 0 0 0
000160

BATTERY GROUND TO DISCONNECT SWITCH CABLE REMOVAL

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 electric shock, 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 injury to personnel. EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately. SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 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. CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0160-1

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE REMOVAL CONTINUED

NOTE
Steps 1 - 4 apply to machine equipped with arctic kit. 1. Open two latches (Figure 1, Item 2) and with assistance remove cover (Figure 1, Item 1) from machine.

Figure 1. Arctic Kit Battery Cover.

0160

0160-2

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE REMOVAL CONTINUED

NOTE
Steps 1 - 4 apply to machine equipped with arctic kit. 2. Position cover (Figure 2, Item 1) aside 3. Loosen nut (Figure 2, Item 2) and remove clamp (Figure 2, Item 3) from battery (Figure 2, Item 5). 4. Position negative cable (Figure 2, Item 4) aside.

Figure 2. Arctic Kit Battery Cable.

0160

0160-3

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE REMOVAL CONTINUED 5. Release two rubber latches (Figure 3, Item 2) and open battery cover (Figure 3, Item 1) on battery box.

Figure 3. Battery Box.

0160

0160-4

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

6. Position two covers (Figure 4, Item 2) aside. 7. Loosen two nuts (Figure 4, Item 3) end remove two clamps (Figure 4, Item 4) from batteries (Figure 4, Item 1). 8. Position battery ground cable (Figure 4, Item 5) aside. 9. Position cover (Figure 4, Item 6) aside. 10. Remove nut (Figure 4, Item 9), washer (Figure 4, Item 8), and battery ground cable (Figure 4, Item 5) from battery disconnect switch (Figure 4, Item 7).

Figure 4. Battery Cable. END OF TASK

0160

0160-5

TM 5-2410-241-23-2

0160

DISCONNECT SWITCH TO MACHINE GROUND CABLE REMOVAL 1. Remove batteries (WP 0155). 2. Remove front floor plates (WP 0230).

000160

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

3. Remove tiedown strap (Figure 5, Item 3) from receptacle cable (Figure 5, Item 4). Discard tiedown strap. 4. Remove nut (Figure 5, Item 1), washer (Figure 5, Item 2), receptacle cable (Figure 5, Item 4), and ground cable (Figure 5, Item 5) from battery disconnect switch (Figure 5, Item 10). Position cables aside.

NOTE
Note position and orientation of cables and clamp to aid installation. 5. Remove nut (Figure 5, Item 6), washer (Figure 5, Item 7), and clamp (Figure 5, Item 8) from ground cable (Figure 5, Item 5) and receptacle power cable (Figure 5, Item 9).

Figure 5. Switch Cable.

0160

0160-6

TM 5-2410-241-23-2

0160

DISCONNECT SWITCH TO MACHINE GROUND CABLE REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

6. Remove nut (Figure 6, Item 4), washer (Figure 6, Item 3), clamp (Figure 6, Item 1), and clamp (Figure 6, Item 2) from machine. 7. Remove clamp (Figure 6, Item 2) from ground cable (Figure 6, Item 5). 8. Remove bolt (Figure 6, Item 7) and washer (Figure 6, Item 6) from machine. 9. Position cable (Figure 6, Item 8) aside. 10. Remove ground cable (Figure 6, Item 5) from machine.

Figure 6. Ground Cable. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0160

000160

0160-7

TM 5-2410-241-23-2

0160

DISCONNECT SWITCH TO MACHINE GROUND CABLE INSTALLATION

000160

NOTE
Install electrical connections and route cable as noted during removal. 1. Install ground cable (Figure 7, Item 5) on machine. 2. Position cable (Figure 7, Item 8) on machine. 3. Install washer (Figure 7, Item 6) and bolt (Figure 7, Item 7) on machine. 4. Install clamp (Figure 7, Item 2) on ground cable (Figure 7, Item 5). 5. Install clamp (Figure 7, Item 2), clamp (Figure 7, Item 1), washer (Figure 7, Item 3), and nut (Figure 7, Item 4) on machine.

Figure 7. Ground Cable.

0160

0160-8

TM 5-2410-241-23-2

0160

DISCONNECT SWITCH TO MACHINE GROUND CABLE INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 6. Install clamp (Figure 8, Item 8), washer (Figure 8, Item 7), and nut (Figure 8, Item 6) on ground cable (Figure 8, Item 5) and receptacle power cable (Figure 8, Item 9). 7. Install ground cable (Figure 8, Item 5), receptacle cable (Figure 8, Item 4), washer (Figure 8, Item 2), and nut (Figure 8, Item 1) on battery disconnect switch (Figure 8, Item 10). 8. Install new tiedown strap (Figure 8, Item 3) on receptacle cable (Figure 8, Item 4). 9. Install front floor plates (WP 0230). 10. Install batteries (WP 0155).

Figure 8. Switch Cable. END OF TASK

0160

0160-9

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE INSTALLATION

000160

NOTE
Install electrical connections and route cable as noted during removal. 1. Install battery ground cable (Figure 9, Item 5), washer (Figure 9, Item 8), and nut (Figure 9, Item 9) on battery disconnect switch (Figure 9, Item 7). 2. Position cover (Figure 9, Item 6) over nut (Figure 9, Item 9). 3. Position battery ground cable (Figure 9, Item 5) on batteries (Figure 9, Item 1). 4. Install two clamps (Figure 9, Item 4) and tighten nuts (Figure 9, Item 3) on batteries (Figure 9, Item 1). 5. Position two covers (Figure 9, Item 2) on clamps (Figure 9, Item 4).

Figure 9. Battery Cable.

0160

0160-10

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE INSTALLATION CONTINUED 6. Close battery cover (Figure 10, Item 1) and secure two rubber latches (Figure 10, Item 2) on battery box.

Figure 10. Battery Box.

0160

0160-11

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE INSTALLATION CONTINUED

NOTE
Steps 7 - 10 apply to machine equipped with arctic kit. 7. Position negative cable (Figure 11, Item 4) on battery (Figure 11, Item 5). 8. Install clamp (Figure 11, Item 3) and tighten nut (Figure 11, Item 2) on battery (Figure 11, Item 5). 9. Position cover (Figure 11, Item 1) over clamp (Figure 11, Item 3).

Figure 11. Arctic Kit Battery Cable.

0160

0160-12

TM 5-2410-241-23-2

0160

BATTERY GROUND TO DISCONNECT SWITCH CABLE INSTALLATION CONTINUED 10. With assistance, install cover (Figure 12, Item 1) and secure two latches (Figure 12, Item 2) on machine.

Figure 12. Arctic Kit Battery Cover. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0160

000160

0160-13/(14 blank)

6 TM 5-2410-241-23-2 0161

FIELD MAINTENANCE
0 1 6 1

BATTERY CROSSOVER CABLE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) REMOVAL 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0 0

000161

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 electric shock, 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 injury to personnel. EYES. Flush with cold water for no less than 15 minutes and seek medical attention immediately. SKIN. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. 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. CLOTHING/EQUIPMENT. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0161-1

TM 5-2410-241-23-2

0161

REMOVAL CONTINUED 1. Release two rubber latches (Figure 1, Item 2) and open battery cover (Figure 1, Item 1) on battery box.

Figure 1. Battery Box.

0161

0161-2

TM 5-2410-241-23-2

0161

REMOVAL CONTINUED

NOTE
Steps 2 - 4 will remove one battery crossover cable. Follow same steps for additional battery crossover cable. Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

2. Position two covers (Figure 2, Item 1) aside. 3. Loosen two nuts (Figure 2, Item 3) on clamps (Figure 2, Item 4). 4. Loosen clamps (Figure 2, Item 4) and remove cable (Figure 2, Item 2) from batteries (Figure 2, Item 5).

Figure 2. Battery Cable. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0161

000161

0161-3

TM 5-2410-241-23-2

0161

INSTALLATION

000161

NOTE
Steps 1 - 4 will install one battery crossover cable. Follow same steps for additional battery crossover cable. Install electrical connections and cable as noted during removal.

1. Install cable (Figure 3, Item 2) on batteries (Figure 3, Item 5). 2. Install clamps (Figure 3, Item 4) on batteries (Figure 3, Item 5). 3. Tighten two nuts (Figure 3, Item 3) on clamps (Figure 3, Item 4). 4. Position two covers (Figure 3, Item 1) on clamps (Figure 3, Item 4).

Figure 3. Battery Cable.

0161

0161-4

TM 5-2410-241-23-2

0161

INSTALLATION CONTINUED 5. Close battery cover (Figure 4, Item 1) and secure two rubber latches (Figure 4, Item 2) on battery box.

Figure 4. Battery Box. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0161

000161

0161-5/(6 blank)

8 TM 5-2410-241-23-2 0162

FIELD MAINTENANCE INSTRUCTIONS

0 1 6 2

BATTERY DISCONNECT SWITCH, RECEPTACLE AND CABLE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Locknut Lockwasher (5)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Batteries removed (WP 0155) Front floor plates removed (WP 0230) Drawing Required TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 3.5 Hr

0162-1

TM 5-2410-241-23-2

0162

REMOVAL 1. Remove key (Figure 1, Item 5) from battery disconnect switch (Figure 1, Item 3). 2. Remove nut (Figure 1, Item 1), two lockwashers (Figure 1, Item 2), and battery disconnect switch (Figure 1, Item 3) from front battery box cover (Figure 1, Item 4). Discard lockwashers. 3. Remove receptacle cover (Figure 1, Item 6) from receptacle (Figure 1, Item 7).

000162

Figure 1. Battery Disconnect Switch.

0162

0162-2

TM 5-2410-241-23-2

0162

REMOVAL CONTINUED 4. Position boot (Figure 2, Item 2) on negative battery cable (Figure 2, Item 1) aside.

NOTE
Arctic kit negative battery cable shown for machines equipped with arctic kit. Tag cables to aid installation.

5. Remove nut (Figure 2, Item 4), lockwasher (Figure 2, Item 3), negative battery cable (Figure 2, Item 1) and arctic kit ground battery cable (Figure 2, Item 16) from battery disconnect switch (Figure 2, Item 5). Discard lockwasher. 6. Remove tiedown strap (Figure 2, Item 8) from receptacle ground cable (Figure 2, Item 9). Discard tiedown strap. 7. Remove nut (Figure 2, Item 7), lockwasher (Figure 2, Item 6), receptacle ground cable (Figure 2, Item 9) and ground cable (Figure 2, Item 10) from battery disconnect switch (Figure 2, Item 5). Discard lockwasher. 8. Remove battery disconnect switch (Figure 2, Item 5) from machine. 9. Remove four bolts (Figure 2, Item 13), washers (Figure 2, Item 14), receptacle ground cable (Figure 2, Item 9) and junction block power cable (Figure 2, Item 11) from front battery box cover (Figure 2, Item 15).

Figure 2. Receptacle and Battery Disconnect Switch Connections.

0162

0162-3

TM 5-2410-241-23-2

0162

REMOVAL CONTINUED

NOTE
Note cable and clamp routing to aid installation. 10. Remove locknut (Figure 3, Item 4), washer (Figure 3, Item 3), and clamp (Figure 3, Item 2) from receptacle ground cable (Figure 3, Item 1) and junction block power cable (Figure 3, Item 5). Discard locknut. 11. Position boot (Figure 3, Item 7) aside.

NOTE
Arctic kit power battery cable shown for machines equipped with arctic kit. Note cable and clamp routing to aid installation.

12. Remove nut (Figure 3, Item 8), lockwasher (Figure 3, Item 9), fuse panel power cable (Figure 3, Item 6), arctic kit power battery cable (Figure 3, Item 10), and junction block power cable (Figure 3, Item 5) from junction block (Figure 3, Item 11). Discard lockwasher. 13. Remove junction block power cable (Figure 3, Item 5) from machine.

Figure 3. Receptacle Cable at Junction Block. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0162

000162

0162-4

TM 5-2410-241-23-2

0162

INSTALLATION

000162

NOTE
Arctic kit power battery cable shown for machines equipped with arctic kit. Route cables as noted during removal.

1. Install junction block power cable (Figure 3, Item 5) on machine. 2. Install junction block power cable (Figure 3, Item 5), arctic kit power battery cable (Figure 3, Item 10), fuse panel power cable (Figure 3, Item 6), new lockwasher (Figure 3, Item 9), and nut (Figure 3, Item 8) on junction block (Figure 3, Item 11). 3. Position boot (Figure 3, Item 7) on nut (Figure 3, Item 8).

NOTE
Install clamps as noted during removal. 4. Install clamp (Figure 3, Item 2), washer (Figure 3, Item 3), and new locknut (Figure 3, Item 4) on receptacle ground cable (Figure 3, Item 1) and junction block power cable (Figure 3, Item 5).

0162-5

TM 5-2410-241-23-2

0162

INSTALLATION CONTINUED

NOTE
Install cables as tagged during removal. 5. Install junction block power cable (Figure 4, Item 11), receptacle ground cable (Figure 4, Item 9), four washers (Figure 4, Item 14), and bolts (Figure 4, Item 13) on front battery box cover (Figure 4, Item, 15). 6. Install battery disconnect switch (Figure 4, Item 5) on machine. 7. Install ground cable (Figure 4, Item 10), receptacle ground cable (Figure 4, Item 9), new lockwasher (Figure 4, Item 6), and nut (Figure 4, Item 7) on battery disconnect switch (Figure 4, Item 5). 8. Install new tiedown strap (Figure 4, Item 8) on receptacle ground cable (Figure 4, Item 9).

NOTE
Arctic kit negative battery cable shown for machines equipped with arctic kit. Install cables as noted during removal.

9. Install arctic kit ground battery cable (Figure 4, Item 16), negative battery cable (Figure 4, Item 1), new lockwasher (Figure 4, Item 4), and nut (Figure 4, Item 3) on battery disconnect switch (Figure 4, Item 5). 10. Position boot (Figure 4, Item 2) on negative battery cable (Figure 4, Item 1).

Figure 4. Receptacle and Battery Disconnect Switch Connections.

0162

0162-6

TM 5-2410-241-23-2

0162

INSTALLATION CONTINUED 11. Install battery disconnect switch (Figure 5, Item 3), two new lockwashers (Figure 5, Item 2), and nut (Figure 5, Item 1) on front battery box cover (Figure 5, Item 4). 12. Install key (Figure 5, Item 5) in battery disconnect switch (Figure 5, Item 3). 13. Install receptacle cover (Figure 5, Item 7) on receptacle (Figure 5, Item 6).

Figure 5. Battery Disconnect Switch. END OF TASK FOLLOW-ON TASKS 1. Install front floor plates (WP 0230). 2. Install batteries (WP 0155). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0162

000162

0162-7/(8 blank)

10 TM 5-2410-241-23-2 0163

FIELD MAINTENANCE
0 1 6 3

ALTERNATOR POWER CABLE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles, (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10) Front floor plates removed (WP 0230) Batteries removed (WP 0155) Air cleaner hose removed (WP 0111) Drawing Required TM 5-2410-241-24P, Figure 11

Estimated Time to Complete 5.5 Hr

000163

NOTE
Note cable routing to aid installation. 1. Remove nut (Figure 1, Item 3), washer (Figure 1, Item 4), and two clamps (Figure 1, Item 5) from alternator cable (Figure 1, Item 1) and fuse panel cable (Figure 1, Item 2).

Figure 1. Clamps.

0163

0163-1

TM 5-2410-241-23-2

0163

REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. 2. Remove two nuts (Figure 2, Item 5), washers (Figure 2, Item 4), and two clamps (Figure 2, Item 6) from alternator cable (Figure 2, Item 7) and fuse panel cable (Figure 2, Item 8). 3. Remove two bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and cover (Figure 2, Item 1) from fuse panel (Figure 2, Item 9).

Figure 2. Cover.

0163

0163-2

TM 5-2410-241-23-2

0163

REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

4. Remove bolt (Figure 3, Item 3), washer (Figure 3, Item 2), and alternator cable (Figure 3, Item 4) from fuse panel (Figure 3, Item 1). 5. Position alternator cable (Figure 3, Item 4) aside.

Figure 3. Fuse Panel Alternator Cable.

0163

0163-3

TM 5-2410-241-23-2

0163

REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. 6. Remove two nuts (Figure 4, Item 2), washers (Figure 4, Item 3), and clamps (Figure 4, Item 1) from alternator cable (Figure 4, Item 4) and starter cable (Figure 4, Item 8). 7. Remove two nuts (Figure 4, Item 6), washers (Figure 4, Item 7), and clamps (Figure 4, Item 5) from alternator cable (Figure 4, Item 4). 8. Position alternator cable (Figure 4, Item 4) aside.

Figure 4. Alternator Cable to Chassis.

0163

0163-4

TM 5-2410-241-23-2

0163

REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

9. Remove tiedown strap (Figure 5, Item 5) from alternator cable (Figure 5, Item 1). Discard tiedown strap. 10. Remove nut (Figure 5, Item 3), washer (Figure 5, Item 4), and alternator cable (Figure 5, Item 1) from alternator (Figure 5, Item 2). 11. Position alternator cable (Figure 5, Item 1) aside. 12. Remove two nuts (Figure 5, Item 7), washers (Figure 5, Item 6) and clamps (Figure 5, Item 8) from alternator cable (Figure 5, Item 1). 13. Remove alternator cable (Figure 5, Item 1) from machine.

Figure 5. Alternator Cable. END OF TASK

0163

0163-5

TM 5-2410-241-23-2

0163

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000163

000163

NOTE
Install electrical connections and cable as noted during removal. 1. Install alternator cable (Figure 6, Item 1) on machine. 2. Install two clamps (Figure 6, Item 8), washers (Figure 6, Item 6), and nuts (Figure 6, Item 7) on alternator cable (Figure 6, Item 1). 3. Position alternator cable (Figure 6, Item 1) on machine. 4. Install alternator cable (Figure 6, Item 1), washer (Figure 6, Item 4), and nut (Figure 6, Item 3) on alternator (Figure 6, Item 2). 5. Install new tiedown strap (Figure 6, Item 5) on alternator cable (Figure 6, Item 1).

Figure 6. Alternator Cable.

0163

0163-6

TM 5-2410-241-23-2

0163

INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 6. Position alternator cable (Figure 7, Item 4) on machine. 7. Install two clamps (Figure 7, Item 5), washers (Figure 7, Item 7), and nuts (Figure 7, Item 6) on alternator cable (Figure 7, Item 4). 8. Install two clamps (Figure 7, Item 1), washers (Figure 7, Item 3), and nuts (Figure 7, Item 2) on alternator cable (Figure 7, Item 4) and starter cable (Figure 7, Item 8).

Figure 7. Alternator Cable to Chassis.

0163

0163-7

TM 5-2410-241-23-2

0163

INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 9. Position alternator cable (Figure 8, Item 4) on machine. 10. Install alternator cable (Figure 8, Item 4), washer (Figure 8, Item 2), and bolt (Figure 8, Item 3) on fuse panel (Figure 8, Item 1).

Figure 8. Fuse Panel Alternator Cable.

0163

0163-8

TM 5-2410-241-23-2

0163

INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 11. Install cover (Figure 9, Item 1), two washers (Figure 9, Item 3), and bolts (Figure 9, Item 2) on fuse panel (Figure 9, Item 9). 12. Install two clamps (Figure 9, Item 6), washers (Figure 9, Item 4), and nuts (Figure 9, Item 5) on alternator cable (Figure 9, Item 7) and fuse panel cable (Figure 9, Item 8).

Figure 9. Cover.

0163

0163-9

TM 5-2410-241-23-2

0163

INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 13. Install two clamps (Figure 10, Item 5), washer (Figure 10, Item 3) and nut (Figure 10, Item 4) on alternator cable (Figure 10, Item 1) and fuse panel cable (Figure 10, Item 2).

Figure 10. Clamps. END OF TASK FOLLOW-ON TASKS 1. Install front floor plates (WP 0230). 2. Install batteries (WP 0155). 3. Install air cleaner hose (WP 0111). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0163

000163

0163-10

8 TM 5-2410-241-23-2 0164

FIELD MAINTENANCE
0 1 6

STARTER POWER CABLE REPLACEMENT Removal, Cleaning and Inspection, Installation

4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Front floor plates removed (WP 0230) Battery disconnect switch to OFF (TM 5-2410241-10) Engine enclosure left door guard removed (WP 0202)
0 0 0 0

Drawing Required TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 3.5 Hr

0164-1

TM 5-2410-241-23-2

0164

REMOVAL

000164

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

1. Position boot (Figure 1, Item 8) on starter cable (Figure 1, Item 3) aside. 2. Remove nut (Figure 1, Item 9), washer (Figure 1, Item 10), and starter cable (Figure 1, Item 3) from junction block (Figure 1, Item 11). 3. Remove nut (Figure 1, Item 6), washer (Figure 1, Item 7), clamp (Figure 1, Item 1), clamp (Figure 1, Item 4), fuse panel cable (Figure 1, Item 2), and starter cable (Figure 1, Item 3) from stud (Figure 1, Item 5). 4. Position starter cable (Figure 1, Item 3) aside.

Figure 1. Starter Cable.

0164

0164-2

TM 5-2410-241-23-2

0164

REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

5. Remove two nuts (Figure 2, Item 1), washers (Figure 2, Item 2), clamps (Figure 2, Item 9), starter cable (Figure 2, Item 7) and alternator cable (Figure 2, Item 8) from stud (Figure 2, Item 10). 6. Remove nut (Figure 2, Item 5), washer (Figure 2, Item 3), clamp (Figure 2, Item 6), and starter cable (Figure 2, Item 7) from stud (Figure 2, Item 4). 7. Position starter cable (Figure 2, Item 7) aside.

Figure 2. Starter Cable to Chassis.

0164

0164-3

TM 5-2410-241-23-2

0164

REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

8. Position cover (Figure 3, Item 3) aside. 9. Remove nut (Figure 3, Item 4) and starter cable (Figure 3, Item 2) from starter (Figure 3, Item 1). 10. Position starter cable (Figure 3, Item 2) aside.

Figure 3. Starter Cable to Starter.

0164

0164-4

TM 5-2410-241-23-2

0164

REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections to aid installation.

11. Remove tiedown straps (Figure 4, Item 2) from starter cable (Figure 4, Item 1). Discard tiedown straps. 12. Remove starter cable (Figure 4, Item 1) from machine.

Figure 4. Starter Cable. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0164

000164

0164-5

TM 5-2410-241-23-2

0164

INSTALLATION

000164

NOTE
Install electrical connections and cable as noted during removal. 1. Install starter cable (Figure 4, Item 1) on machine. 2. Install new tiedown straps (Figure 4, Item 2) on starter cable (Figure 4, Item 1).

NOTE
Install electrical connections and cable as noted during removal. 3. Position starter cable (Figure 5, Item 2) on machine. 4. Install starter cable (Figure 5, Item 2) and nut (Figure 5, Item 4) on starter (Figure 5, Item 1). 5. Position cover (Figure 5, Item 3) on nut (Figure 5, Item 4).

Figure 5. Starter Cable to Starter.

0164

0164-6

TM 5-2410-241-23-2

0164

INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 6. Position starter cable (Figure 6, Item 7) on machine. 7. Install clamp (Figure 6, Item 6), washer (Figure 6, Item 3), nut (Figure 6, Item 5), and starter cable (Figure 6, Item 7) on stud (Figure 6, Item 4). 8. Install two clamps (Figure 6, Item 9), washers (Figure 6, Item 2), nuts (Figure 6, Item 1), alternator cable (Figure 6, Item 8), and starter cable (Figure 6, Item 7) on stud (Figure 6, Item 10).

Figure 6. Starter Cable to Chassis.

0164

0164-7

TM 5-2410-241-23-2

0164

INSTALLATION CONTINUED

NOTE
Install electrical connections and cable as noted during removal. 9. Position starter cable (Figure 7, Item 3) on machine. 10. Install clamp (Figure 7, Item 4), clamp (Figure 7, Item 1), fuse panel cable (Figure 7, Item 2), starter cable (Figure 7, Item 3), washer (Figure 7, Item 7), and nut (Figure 7, Item 6) on stud (Figure 7, Item 5). 11. Install starter cable (Figure 7, Item 3), washer (Figure 7, Item 10), and nut (Figure 7, Item 9) on junction block (Figure 7, Item 11). 12. Position boot (Figure 7, Item 8) on starter cable (Figure 7, Item 3).

Figure 7. Starter Cable. END OF TASK FOLLOW-ON TASKS 1. Install front floor plates (WP 0230). 2. Install engine enclosure left door guard (WP 0202). 3. Turn on battery disconnect switch (TM 5-2410-241-10). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0164

000164

0164-8

4 TM 5-2410-241-23-2 0165

FIELD MAINTENANCE INSTRUCTIONS JUNCTION BLOCK REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 6 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Lockwasher (3) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Battery disconnect switch OFF (TM 5-2410-241-10) Front floor plates removed (WP 0230) Drawing Required

TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 1.5 Hr

0165-1

TM 5-2410-241-23-2

0165

REMOVAL

000165

NOTE
Note cable and clamp locations and routing to aid installation. 1. Position three covers (Figure 1, Item 3) aside. 2. Remove three nuts (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and four cables (Figure 1, Item 2) from junction block (Figure 1, Item 1). Discard lockwashers. 3. Remove three bolts (Figure 1, Item 6), washers (Figure 1, Item 7), and junction block (Figure 1, Item 1) from machine.

Figure 1. Junction Block. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0165

000165

0165-2

TM 5-2410-241-23-2

0165

INSTALLATION

000165

NOTE
Install cables and clamps as noted during removal. 1. Install junction block (Figure 1, Item 1), three washers (Figure 1, Item 7), and bolts (Figure 1, Item 6) on machine. 2. Install four cables (Figure 1, Item 2), three new lockwashers (Figure 1, Item 5), and nuts (Figure 1, Item 4) on junction block (Figure 1, Item 1). 3. Position three covers (Figure 1, Item 3) over nuts (Figure 1, Item 4). END OF TASK FOLLOW-ON TASKS 1. Install front floor plates (WP 0230). 2. Battery disconnect switch ON (TM 5-2410-241-10). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000165

0165-3/(4 blank)

4 TM 5-2410-241-23-2 0166

FIELD MAINTENANCE
0 1 6 6

JUNCTION BLOCK REPLACEMENT (WITH ARCTIC KIT HEATER) Removal, Cleaning and Inspection, Installation Effectivity Notice (With Arctic Heater)

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Lockwasher (3) References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Battery disconnect switch OFF (TM 5-2410241-10) Front floor plates removed (WP 0230)
0 0 0

Drawing Required
0

TM 5-2410-241-24P, Figure 96
0

Estimated Time to Complete

0 0

1.5 Hr

0166-1

TM 5-2410-241-23-2

0166

REMOVAL

000166

NOTE
Note cable and clamp locations and routing to aid installation. 1. Position three covers (Figure 1, Item 3) aside. 2. Remove three nuts (Figure 1, Item 4), lockwashers (Figure 1, Item 5), and five cables (Figure 1, Item 2) from junction block (Figure 1, Item 1). Discard lockwashers. 3. Remove three bolts (Figure 1, Item 6), washers (Figure 1, Item 7), and junction block (Figure 1, Item 1) from machine.

Figure 1. Junction Block. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0166

000166

0166-2

TM 5-2410-241-23-2

0166

INSTALLATION

000166

NOTE
Install cables and clamps as noted during removal. 1. Install junction block (Figure 1, Item 1), three washers (Figure 1, Item 7), and bolts (Figure 1, Item 6) on machine. 2. Install five cables (Figure 1, Item 2), three new lockwashers (Figure 1, Item 5), and nuts (Figure 1, Item 4) on junction block (Figure 1, Item 1). 3. Position three covers (Figure 1, Item 3) over nuts (Figure 1, Item 4). END OF TASK FOLLOW-ON TASKS 1. Install front floor plates (WP 0230). 2. Turn on battery disconnect switch (TM 5-2410-241-10). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000166

0166-3/(4 blank)

8 TM 5-2410-241-23-2 0167

FIELD MAINTENANCE
0 1 6 7

FRONT LIGHTING HARNESS REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10) Lefts side engine enclosure door guard removed (WP 0202) Drawing Required TM 5-2410-241-24P, Figure 86, 96 Estimated Time to Complete 3.5 Hr

000167

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation.

1. Remove tiedown straps (Figure 1, Item 3) from harness (Figure 1, Item 4). Discard tiedown straps. 2. Disconnect connector (Figure 1, Item 1) from connector (Figure 1, Item 2). 3. Position harness (Figure 1, Item 4) aside.

Figure 1. Frame Connector.

0167

0167-1

TM 5-2410-241-23-2

0167

REMOVAL CONTINUED 4. Remove eight bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and open two doors (Figure 2, Item 1) on hinges (Figure 2, Item 4).

Figure 2. Doors.

0167

0167-2

TM 5-2410-241-23-2

0167

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation. Two connectors are on top of radiator behind each door.

5. Remove tiedown straps (Figure 3, Item 1) from harness (Figure 3, Item 4). Discard tiedown straps. 6. Disconnect two connectors (Figure 3, Item 3) from connectors (Figure 3, Item 2) and harness (Figure 3, Item 4). 7. Position harness (Figure 3, Item 4) aside.

Figure 3. Light Connectors.

0167

0167-3

TM 5-2410-241-23-2

0167

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation.

8. Remove tiedown strap (Figure 4, Item 4) from harness (Figure 4, Item 3). Discard tiedown strap. 9. Disconnect connector (Figure 4, Item 1) from horn (Figure 4, Item 2). 10. Disconnect connector (Figure 4, Item 5) from horn (Figure 4, Item 6). 11. Remove harness (Figure 4, Item 3) from machine.

Figure 4. Horn Connector. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0167

000167

0167-4

TM 5-2410-241-23-2

0167

INSTALLATION

000167

NOTE
Install connectors as noted during removal. Route harness as noted during removal.

1. Install harness (Figure 4, Item 3) on machine. 2. Connect connector Figure 4, Item 5) on horn (Figure 4, Item 6). 3. Connect connector (Figure 4, Item 1) on horn (Figure 4, Item 2). 4. Install new tiedown strap (Figure 4, Item 4) on harness (Figure 4, Item 3).

NOTE
Install connectors as noted during removal. Route harness as noted during removal.

5. Position harness (Figure 5, Item 4) on machine. 6. Connect two connectors (Figure 5, Item 2) on connectors (Figure 5, Item 3) and harness (Figure 5, Item 4). 7. Install new tiedown straps (Figure 5, Item 1) on harness (Figure 5, Item 4).

Figure 5. Light Connectors.

0167

0167-5

TM 5-2410-241-23-2

0167

INSTALLATION CONTINUED 8. Close two doors (Figure 6, Item 1) on hinges (Figure 6, Item 4). 9. Install eight washers (Figure 6, Item 3) and bolts (Figure 6, Item 2) on doors (Figure 6, Item 1).

Figure 6. Doors.

0167

0167-6

TM 5-2410-241-23-2

0167

INSTALLATION CONTINUED

NOTE
Install connectors as noted during removal. Route harness as noted during removal.

10. Position harness (Figure 7, Item 4) on machine. 11. Connect connector (Figure 7, Item 1) on connector (Figure 7, Item 2). 12. Install new tiedown straps (Figure 7, Item 3) on harness (Figure 7, Item 4).

Figure 7. Frame Connector. END OF TASK FOLLOW-ON TASKS 1. Install left side engine enclosure door guard (WP 0202). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0167

000167

0167-7/(8 blank)

6 TM 5-2410-241-23-2 0168

FIELD MAINTENANCE
0 1 6

BACKUP ALARM HARNESS REPLACEMENT Removal, Cleaning and Inspection, Installation

8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 96
0

Estimated Time to Complete 0.5 Hr REMOVAL

000168

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation. Mark location and number of tiedown straps before removal.

1. Remove tiedown straps (Figure 1, Item 1) from harness (Figure 1, Item 4). Discard tiedown straps. 2. Disconnect connector (Figure 1, Item 2) from connector (Figure 1, Item 3). 3. Position harness (Figure 1, Item 4) aside.

Figure 1. Frame Connector. 0168-1

0168

TM 5-2410-241-23-2

0168

REMOVAL CONTINUED 4. Remove three bolts (Figure 2, Item 1), washers (Figure 2, Item 2), and cover (Figure 2, Item 3) from machine.

Figure 2. Cover.

0168

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation.

5. Remove tiedown strap (Figure 3, Item 2) from connector (Figure 3, Item 3). Discard tiedown strap. 6. Disconnect connector (Figure 3, Item 1) from connector (Figure 3, Item 3).

Figure 3. Alarm Connector.

0168

0168-2

TM 5-2410-241-23-2

0168

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation.

7. Remove tiedown strap (Figure 4, Item 3) from harness (Figure 4, Item 2). Discard tiedown strap. 8. Remove grommet (Figure 4, Item 1) from harness (Figure 4, Item 2). 9. Remove harness (Figure 4, Item 2) from machine.

Figure 4. Alarm Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0168

000168

0168-3

TM 5-2410-241-23-2

0168

INSTALLATION

000168

NOTE
Install connectors as noted during removal. Route harness as noted during removal.

1. Install harness (Figure 5, Item 2) on machine. 2. Install grommet (Figure 5, Item 1) on harness (Figure 5, Item 2). 3. Install new tiedown strap (Figure 5, Item 3) on harness (Figure 5, Item 2).

Figure 5. Alarm Harness.

0168

NOTE
Install connectors as noted during removal. Route harness as noted during removal.

4. Connect connector (Figure 6, Item 1) to connector (Figure 6, Item 3). 5. Install new tiedown strap (Figure 6, Item 2) on connector (Figure 6, Item 3).

Figure 6. Alarm Connector.

0168

0168-4

TM 5-2410-241-23-2

0168

INSTALLATION CONTINUED 6. Install cover (Figure 7, Item 3), three washers (Figure 7, Item 2), and bolts (Figure 7, Item 1) on machine.

Figure 7. Cover.

0168

NOTE
Install connectors as noted during removal. Route harness as noted during removal. Install tiedown straps as noted during removal.

7. Position harness (Figure 8, Item 4) on machine. 8. Connect connector (Figure 8, Item 2) on connector (Figure 8, Item 3). 9. Install new tiedown straps (Figure 8, Item 1) on harness (Figure 8, Item 4).

Figure 8. Frame Connector. END OF TASK

0168

0168-5

TM 5-2410-241-23-2

0168

FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000168

0168-6

4 TM 5-2410-241-23-2 0169

FIELD MAINTENANCE
0 1 6 9

TRANSMISSION HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Tiedown Wire
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 96
0 0

Estimated Time to Complete 0.5 Hr

REMOVAL

000169

1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and guard (Figure 1, Item 1) from machine.

Figure 1. Guard.

0169

0169-1

TM 5-2410-241-23-2

0169

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

2. Remove tiedown wire (Figure 2, Item 4) from connector (Figure 2, Item 5). Discard tiedown wire. 3. Disconnect connector (Figure 2, Item 5) from connector (Figure 2, Item 3). 4. Remove tiedown straps (Figure 2, Item 2) from harness (Figure 2, Item 6). Discard tiedown straps. 5. Disconnect two connectors (Figure 2, Item 1) and remove harness (Figure 2, Item 6) from machine.

Figure 2. Transmission Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0169

000169

0169-2

TM 5-2410-241-23-2

0169

INSTALLATION

000169

NOTE
Install electrical connections and harness routing as noted during removal. 1. Install harness (Figure 2, Item 6) and connect two connectors (Figure 2, Item 1) on machine. 2. Install new tiedown straps (Figure 2, Item 2) on harness (Figure 2, Item 6). 3. Connect connector (Figure 2, Item 5) on connector (Figure 2, Item 3). 4. Install new tiedown wire (Figure 2, Item 4) on connector (Figure 2, Item 5). 5. Install guard (Figure 3, Item 1), four washers (Figure 3, Item 3), and bolts (Figure 3, Item 2) on machine.

Figure 3. Guard. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0169

000169

0169-3/(4 blank)

4 TM 5-2410-241-23-2 0170

FIELD MAINTENANCE
0 1 7 0

FUEL TANK HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Fuel tank removed (WP 0171) Drawing Required TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 2.5 Hr

0170-1

TM 5-2410-241-23-2

0170

REMOVAL

000170

NOTE
Tag and mark electrical connectors to aid installation. Note harness routing to aid installation.

1. Disconnect connector (Figure 1, Item 1) from fuel sending unit (Figure 1, Item 2). 2. Remove two connectors (Figure 1, Item 9) from clips (Figure 1, Item 6). 3. Remove bolt (Figure 1, Item 8), washer (Figure 1, Item 7), and two clips (Figure 1, Item 6) from fuel tank (Figure 1, Item 5).

NOTE
Note location and quantity of tiedown straps to aid installation. 4. Remove tiedown straps (Figure 1, Item 3) and fuel tank harness (Figure 1, Item 4) from fuel tank (Figure 1, Item 5). Discard tiedown straps.

Figure 1. Fuel Tank Harness. END OF TASK

0170

0170-2

TM 5-2410-241-23-2

0170

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000170

000170

NOTE
Install connectors as noted during removal. Install tiedown straps as noted in removal. Route harness as noted during removal.

1. Install fuel tank harness (Figure 1, Item 4) and new tiedown straps (Figure 1, Item 3) on fuel tank (Figure 1, Item 5). 2. Install two clips (Figure 1, Item 6), washer (Figure 1, Item 7), and bolt (Figure 1, Item 8) on fuel tank (Figure 1, Item 5). 3. Install two connectors (Figure 1, Item 9) on clips (Figure 1, Item 6). 4. Connect connector (Figure 1, Item 1) to fuel sending unit (Figure 1, Item 2). END OF TASK FOLLOW-ON TASKS 1. Install fuel tank (WP 0171) 2. Fill fuel tank (TM 5-2410-241-10). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000170

0170-3/(4 blank)

26 TM 5-2410-241-23-2 0171

FIELD MAINTENANCE FUEL TANK REPLACEMENT Removal, Sending Unit Disassembly, Strainer Disassembly, Supply Valve Disassembly, Drain Valve Disassembly, Fuel Tank Harness Disassembly, Fuel Tank Return Hose Disassembly, Plates Disassembly, Mounts Disassembly, Cleaning and Inspection, Mounts Assembly, Plates Assembly, Fuel Tank Return Hose Assembly, Fuel Tank Harness Assembly, Drain Valve Assembly, Supply Valve Assembly, Strainer Assembly, Sending Unit Assembly, Installation
0 1 7 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Lifting Link (1/2 in.; 4,000 lb [1,800 kg]) (WP 0302, Item 36) Pan, Drain (S0255) (WP 0302, Item 68) Socket, Socket wrench 1/2 Drive, 6 Point Regular 1 3/16 (S0583) (WP 0302, Item 68) Wrench, Combination 1 1/16 (S0787) (WP 0302, Item 68) Wrench, Combination 1 1/8 (S0788) (WP 0302, Item 68) Lifting Device (1,000 lb capacity) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24)
0

Materials/Parts - Continued Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Gasket O-ring (13) References

WP 0295 Equipment Condition

Machine parked (TM 5-2410-241-10) Fuel drained (TM 5-2410-241-10)

0

Personnel Required Two

Drawing Required
0

TM 5-2410-241-24P, Figure 84, 96, 97 Estimated Time to Complete

2.5 Hr
0 0

0171-1

TM 5-2410-241-23-2

0171

REMOVAL

000171

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel system. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

NOTE
Cap and plug all hose connections to prevent contamination. Tag and mark all connections to aid installation. Note position and orientation of fittings to aid in installation.

1. Loosen tube nut (Figure 1, Item 2) and remove supply hose (Figure 1, Item 1) and O-ring (Figure 1, Item 3) from drain valve (Figure 1, Item 4). Discard O-ring.

Figure 1. Fuel Tank Supply Hose.

0171

0171-2

TM 5-2410-241-23-2

0171

REMOVAL CONTINUED

NOTE
Cap and plug all hose connections to prevent contamination. Tag and mark all connections to aid installation. Note position and orientation of fittings to aid in installation.

2. Loosen tube nut (Figure 2, Item 5) and remove return hose (Figure 2, Item 2) from fitting (Figure 2, Item 3). 3. Remove O-ring (Figure 2, Item 4) from fitting (Figure 2, Item 3). Discard O-ring. 4. Position hose (Figure 2, Item 1) and fitting (Figure 2, Item 3) aside.

Figure 2. Fuel Tank Return Hose.

0171

0171-3

TM 5-2410-241-23-2

0171

REMOVAL CONTINUED

NOTE
Tag and mark all connections to aid installation. Fuel tank removed in art below for clarity.

5. Disconnect backup alarm harness (Figure 3, Item 2) from fuel tank harness (Figure 3, Item 1). 6. Remove tiedown strap (Figure 3, Item 3) from backup alarm harness (Figure 3, Item 2). Set harness aside. Discard tiedown strap. 7. Disconnect three fuel tank harness connectors (Figure 3, Item 5) from chassis connector (Figure 3, Item 4).

Figure 3. Connectors.

0171

0171-4

TM 5-2410-241-23-2

0171

REMOVAL CONTINUED 8. Remove four bolts (Figure 4, Item 1) and washers (Figure 4, Item 2) and set manifold aside (Figure 4, Item 3).

Figure 4. Manifold. 9. Remove six bolts (Figure 5, Item 1), washers (Figure 5, Item 2), and two covers (Figure 5, Item 3) from machine.

0171

Figure 5. Cover.

0171

0171-5

TM 5-2410-241-23-2

0171

REMOVAL CONTINUED

WARNING

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

NOTE
Fuel tank weighs approximately 600 lb (270 kg). 10. Attach lifting device on fuel tank (Figure 6, Item 1). Support fuel tank. 11. Remove four bolts (Figure 6, Item 4), washers (Figure 6, Item 3), and washers (Figure 6, Item 2) from machine. 12. Using lifting device, remove fuel tank (Figure 6, Item 1) from machine. Place fuel tank on suitable supports. 13. Remove lifting device from fuel tank (Figure 6, Item 1).

Figure 6. Fuel Tank. END OF TASK

0171

0171-6

TM 5-2410-241-23-2

0171

SENDING UNIT DISASSEMBLY Remove six bolts (Figure 7, Item 3), washers (Figure 7, Item 4), sending unit (Figure 7, Item 5) and gasket (Figure 7, Item 2) from fuel tank (Figure 7, Item 1). Discard gasket.

000171

Figure 7. Sending Unit. END OF TASK

0171

0171-7

TM 5-2410-241-23-2

0171

STRAINER DISASSEMBLY 1. Open cap (Figure 8, Item 3) on fuel tank (Figure 8, Item 2). 2. Remove two clips (Figure 8, Item 6) and chain (Figure 8, Item 5) from fuel tank (Figure 8, Item 2) and cap (Figure 8, Item 3). 3. Remove strainer (Figure 8, Item 1) from fuel tank (Figure 8, Item 2). 4. Remove O-ring (Figure 8, Item 4) from cap (Figure 8, Item 3). Discard O-ring.

000171

Figure 8. Strainer. END OF TASK

0171

0171-8

TM 5-2410-241-23-2

0171

SUPPLY VALVE DISASSEMBLY

000171

NOTE
Note position and orientation of fittings and valves to aid in assembly. 1. Remove supply valve (Figure 9, Item 8) from fuel tank (Figure 9, Item 7). 2. Remove O-ring (Figure 9, Item 6) from fitting (Figure 9, Item 5). Discard O-ring. 3. Remove fitting (Figure 9, Item 1) from supply valve (Figure 9, Item 3). 4. Remove O-ring (Figure 9, Item 2) from fitting (Figure 9, Item 1). Discard O-ring. 5. Remove fitting (Figure 9, Item 5) from supply valve (Figure 9, Item 3). 6. Remove O-ring (Figure 9, Item 4) from supply valve (Figure 9, Item 3). Discard O-ring.

Figure 9. Supply Valve. END OF TASK

0171

0171-9

TM 5-2410-241-23-2

0171

DRAIN VALVE DISASSEMBLY

000171

NOTE
Note position and orientation of fitting and valve to aid in assembly. 1. Remove drain valve (Figure 10, Item 12) from fuel tank (Figure 10, Item 11). 2. Remove clamp (Figure 10, Item 9) and hose (Figure 10, Item 10) from fitting (Figure 10, Item 8). 3. Remove O-ring (Figure 10, Item 2) from elbow (Figure 10, Item 1). Discard O-ring. 4. Remove elbow (Figure 10, Item 1) from drain valve (Figure 10, Item 4). 5. Remove O-ring (Figure 10, Item 3) from drain valve (Figure 10, Item 4). Discard O-ring. 6. Remove fitting (Figure 10, Item 8) from fitting (Figure 10, Item 6). 7. Remove O-ring (Figure 10, Item 7) from fitting (Figure 10, Item 8). Discard O-ring. 8. Remove fitting (Figure 10, Item 6) from drain valve (Figure 10, Item 4). 9. Remove O-ring (Figure 10, Item 5) from fitting (Figure 10, Item 6). Discard O-ring.

Figure 10. Drain Valve. END OF TASK

0171

0171-10

TM 5-2410-241-23-2

0171

FUEL TANK HARNESS DISASSEMBLY

000171

NOTE
Tag wiring harness to aid installation. 1. Disconnect fuel tank harness connector (Figure 11, Item 1) from fuel sending unit (Figure 11, Item 2). 2. Remove two connectors (Figure 11, Item 9) from clips (Figure 11, Item 6). 3. Remove bolt (Figure 11, Item 8), washer (Figure 11, Item 7), and two clips (Figure 11, Item 6) from fuel tank (Figure 11, Item 5).

NOTE
Note location and quantity of tiedown straps to aid installation. 4. Remove and discard tiedown straps (Figure 11, Item 3) and fuel tank harness (Figure 11, Item 4) from fuel tank (Figure 11, Item 5).

Figure 11. Fuel Tank Harness. END OF TASK

0171

0171-11

TM 5-2410-241-23-2

0171

FUEL TANK RETURN HOSE DISASSEMBLY 1. Remove two bolts (Figure 12, Item 5), washers (Figure 12, Item 6), and clamps (Figure 12, Item 7) from fuel tank (Figure 12, Item 4). 2. Remove two clamps (Figure 12, Item 7) from return hose (Figure 12, Item 3). 3. Disconnect return hose (Figure 12, Item 3) from elbow (Figure 12, Item 1). 4. Loosen jam nut (Figure 12, Item 2) and remove elbow (Figure 12, Item 1) from fuel tank (Figure 12, Item 4). 5. Remove two O-rings (Figure 12, Item 8) from elbow (Figure 12, Item 1). Discard O-rings.

000171

Figure 12. Fuel Tank Return Hose. END OF TASK

0171

0171-12

TM 5-2410-241-23-2

0171

PLATES DISASSEMBLY Remove six bolts (Figure 13, Item 1), washers (Figure 13, Item 2), upper plate (Figure 13, Item 3), and O-ring (Figure 13, Item 4) from fuel tank (Figure 13, Item 5). Discard O-ring. Repeat this step for lower plate.

000171

Figure 13. Plates. END OF TASK

0171

0171-13

TM 5-2410-241-23-2

0171

MOUNTS DISASSEMBLY Remove eight mounts (Figure 14, Item 1) from machine.

000171

Figure 14. Mounts. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK MOUNTS ASSEMBLY Install eight mounts (Figure 14, Item 1) on machine. END OF TASK

0171

000171

000171

0171-14

TM 5-2410-241-23-2

0171

PLATES ASSEMBLY Install new O-ring (Figure 15, Item 4), upper plate (Figure 15, Item 3), six washers (Figure 15, Item 2), and bolts (Figure 15, Item 1) on fuel tank (Figure 15, Item 5). Repeat this step for lower plate.

000171

Figure 15. Plates. END OF TASK

0171

0171-15

TM 5-2410-241-23-2

0171

FUEL TANK RETURN HOSE ASSEMBLY 1. Install two new O-rings (Figure 16, Item 8) on elbow (Figure 16, Item 1). 2. Install elbow (Figure 16, Item 1) on fuel tank (Figure 16, Item 4) and tighten jam nut (Figure 16, Item 2). 3. Connect return hose (Figure 16, Item 3) on elbow (Figure 16, Item 1). 4. Install two clamps (Figure 16, Item 7) on return hose (Figure 16, Item 3). 5. Install two clamps (Figure 16, Item 7), washers (Figure 16, Item 6), and bolts (Figure 16, Item 5) on fuel tank (Figure 16, Item 4).

000171

Figure 16. Fuel Tank Return Hose. END OF TASK

0171

0171-16

TM 5-2410-241-23-2

0171

FUEL TANK HARNESS ASSEMBLY

000171

NOTE
Install wiring harness as tagged during removal. Install tiedown straps as noted in removal.

1. Install fuel tank harness (Figure 17, Item 4) and new tiedown straps (Figure 17, Item 3) on fuel tank (Figure 17, Item 5). 2. Install two clips (Figure 17, Item 6), washer (Figure 17, Item 7), and bolt (Figure 17, Item 8) on fuel tank (Figure 17, Item 5). 3. Install two connectors (Figure 17, Item 9) on clips (Figure 17, Item 6). 4. Connect connector (Figure 17, Item 1) to fuel sending unit (Figure 17, Item 2).

Figure 17. Fuel Tank Harness. END OF TASK

0171

0171-17

TM 5-2410-241-23-2

0171

DRAIN VALVE ASSEMBLY

000171

NOTE
Install fittings and valve as noted during disassembly. 1. Install new O-ring (Figure 18, Item 5) on fitting (Figure 18, Item 6). 2. Install fitting (Figure 18, Item 6) on drain valve (Figure 18, Item 4). 3. Install new O-ring (Figure 18, Item 7) on fitting (Figure 18, Item 8). 4. Install fitting (Figure 18, Item 8) on fitting (Figure 18, Item 6). 5. Install new O-ring (Figure 18, Item 3) on drain valve (Figure 18, Item 4). 6. Install elbow (Figure 18, Item 1) on drain valve (Figure 18, Item 4). 7. Install new O-ring (Figure 18, Item 2) on elbow (Figure 18, Item 1). 8. Install hose (Figure 18, Item 10) and clamp (Figure 18, Item 9) on fitting (Figure 18, Item 8). 9. Install drain valve (Figure 18, Item 12) on fuel tank (Figure 18, Item 11).

Figure 18. Drain Valve. END OF TASK

0171

0171-18

TM 5-2410-241-23-2

0171

SUPPLY VALVE ASSEMBLY

000171

NOTE
Install fittings and valve as noted during disassembly. 1. Install new O-ring (Figure 19, Item 4) on supply valve (Figure 19, Item 3). 2. Install fitting (Figure 19, Item 5) on supply valve (Figure 19, Item 3). 3. Install new O-ring (Figure 19, Item 2) on fitting (Figure 19, Item 1). 4. Install fitting (Figure 19, Item 1) on supply valve (Figure 19, Item 3). 5. Install new O-ring (Figure 19, Item 6) on fitting (Figure 19, Item 5). 6. Install supply valve (Figure 19, Item 8) on fuel tank (Figure 19, Item 7).

Figure 19. Supply Valve. END OF TASK

0171

0171-19

TM 5-2410-241-23-2

0171

STRAINER ASSEMBLY 1. Install new O-ring (Figure 20, Item 4) on cap (Figure 20, Item 3). 2. Install strainer (Figure 20, Item 1) In fuel tank (Figure 20, Item 2). 3. Install chain (Figure 20, Item 5) and two clips (Figure 20, Item 6) on fuel tank (Figure 20, Item 2) and cap (Figure 20, Item 3). 4. Install cap (Figure 20, Item 3) on fuel tank (Figure 20, Item 2).

000171

Figure 20. Strainer. END OF TASK

0171

0171-20

TM 5-2410-241-23-2

0171

SENDING UNIT ASSEMBLY

000171

Install new gasket (Figure 21, Item 2), sending unit (Figure 21, Item 5), six washers (Figure 21, Item 4), and bolts (Figure 21, Item 3) on fuel tank (Figure 21, Item 1).

Figure 21. Sending Unit. END OF TASK

0171

0171-21

TM 5-2410-241-23-2

0171

INSTALLATION

000171

WARNING

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

NOTE
Fuel tank weighs approximately 600 lb (270 kg). 1. Install lifting device on fuel tank (Figure 22, Item 1). 2. Using lifting device, position fuel tank (Figure 22, Item 1) on machine. 3. Install four washers (Figure 22, Item 2), washers (Figure 22, Item 3), and bolts (Figure 22, Item 4) on machine. 4. Remove lifting device from fuel tank (Figure 22, Item 1).

Figure 22. Fuel Tank.

0171

0171-22

TM 5-2410-241-23-2

0171

INSTALLATION CONTINUED 5. Install two covers (Figure 23, Item 3), six washers (Figure 23, Item 2), and bolts (Figure 23, Item 1) on machine.

Figure 23. Cover.

0171

6. Install manifold (Figure 24, Item 3), four washers (Figure 24, Item 2), and bolts (Figure 24, Item 1) on machine.

Figure 24. Manifold.

0171

0171-23

TM 5-2410-241-23-2

0171

INSTALLATION CONTINUED 7. Connect three fuel tank harness connectors (Figure 25, Item 5) on chassis connector. (Figure 25, Item 4).

NOTE
Fuel tank removed in art below for clarity. Install connections as noted in removal. Install tiedown straps as noted in removal.

8. Connect backup alarm harness (Figure 25, Item 2) to fuel tank harness (Figure 25, Item 1). 9. Install new tiedown strap (Figure 25, Item 3) on backup alarm harness (Figure 25, Item 2).

Figure 25. Connectors.

0171

0171-24

TM 5-2410-241-23-2

0171

INSTALLATION CONTINUED 10. Install new O-ring (Figure 26, Item 4) on fitting (Figure 26, Item 3).

NOTE
Install fittings as noted during removal. 11. Position hose (Figure 26, Item 1) and fitting (Figure 26, Item 3) toward return hose (Figure 26, Item 2). 12. Install return hose (Figure 26, Item 2) on fitting (Figure 26, Item 3) and tighten tube nut (Figure 26, Item 5).

Figure 26. Fuel Tank Return Hose.

0171

0171-25

TM 5-2410-241-23-2

0171

INSTALLATION CONTINUED

WARNING

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to equipment and injury or death to personnel. Allow engine to cool off before performing maintenance on fuel system. Hot metal parts can cause severe burns. Wear eye, hand, and skin protection when working with heated parts. Wear fuel resistant gloves and eye protection when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow these warnings may result in injury or death to personnel, or damage to equipment.

NOTE
Install fittings and connections as noted in removal. 13. Install new O-ring (Figure 27, Item 3) on drain valve (Figure 27, Item 4). 14. Install supply hose (Figure 27, Item 1) on drain valve (Figure 27, Item 4), and tighten tube nut (Figure 27, Item 2).

Figure 27. Fuel Tank Supply Hose. END OF TASK FOLLOW-ON TASKS 1. Fill fuel (TM 5-2410-241-10). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0171

000171

0171-26

8 TM 5-2410-241-23-2 0172

FIELD MAINTENANCE
0 1 7 2

CHASSIS HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 96
0

Estimated Time to Complete 0.5 Hr REMOVAL 1. Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 4), and plate (Figure 1, Item 1) from machine. 2. Open door (Figure 1, Item 3) on machine.

000172

Figure 1. Door.

0172

0172-1

TM 5-2410-241-23-2

0172

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

3. Remove tiedown straps (Figure 2, Item 2) from harness (Figure 2, Item 5). Discard tiedown straps. 4. Disconnect connector (Figure 2, Item 1) from connector (Figure 2, Item 6). 5. Disconnect connector (Figure 2, Item 3) from connector (Figure 2, Item 4). 6. Position harness (Figure 2, Item 5) aside.

Figure 2. Chassis Harness.

0172

0172-2

TM 5-2410-241-23-2

0172

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

7. Remove tiedown strap (Figure 3, Item 2) from connector (Figure 3, Item 3). Discard tiedown strap. 8. Disconnect connector (Figure 3, Item 1) from connector (Figure 3, Item 3).

Figure 3. Harness to Harness.

0172

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

9. Remove tiedown straps (Figure 4, Item 1) from harness (Figure 4, Item 2). Discard tiedown straps. 10. Disconnect connector (Figure 4, Item 3) from connector (Figure 4, Item 4). 11. Remove harness (Figure 4, Item 2) from machine.

Figure 4. Temp Sensor Connector. END OF TASK

0172

0172-3

TM 5-2410-241-23-2

0172

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

000172

000172

NOTE
Install electrical connections and route harness as noted during removal. 1. Position harness (Figure 5, Item 2) on machine. 2. Connect connector (Figure 5, Item 3) to connector (Figure 5, Item 4). 3. Install new tiedown straps (Figure 5, Item 1) on harness (Figure 5, Item 2).

Figure 5. Temp Sensor Connector.

0172

0172-4

TM 5-2410-241-23-2

0172

INSTALLATION CONTINUED

NOTE
Install electrical connections and route harness as noted during removal. 4. Connect connector (Figure 6, Item 1) to connector (Figure 6, Item 3). 5. Install new tiedown strap (Figure 6, Item 2) on connector (Figure 6, Item 3).

Figure 6. Harness To Harness.

0172

0172-5

TM 5-2410-241-23-2

0172

INSTALLATION CONTINUED

NOTE
Install electrical connections and route harness as noted during removal. 6. Position harness (Figure 7, Item 5) on machine. 7. Connect connector (Figure 7, Item 3) to connector (Figure 7, Item 4). 8. Connect connector (Figure 7, Item 1) to connector (Figure 7, Item 6). 9. Install tiedown straps (Figure 7, Item 2) on harness (Figure 7, Item 5).

Figure 7. Chassis Harness.

0172

0172-6

TM 5-2410-241-23-2

0172

INSTALLATION CONTINUED 10. Close door (Figure 8, Item 3) on machine. 11. Install plate (Figure 8, Item 1), two washers (Figure 8, Item 4), and bolts (Figure 8, Item 2) on machine.

Figure 8. Door. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0172

000172

0172-7/(8 blank)

14 TM 5-2410-241-23-2 0173

FIELD MAINTENANCE
0 1 7 3

TRANSMISSION SENSOR HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) Bolt 5/8 - 11 x 2 in. Lifting Device (1,000 lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (1)
0

Personnel Required Two

References
0

WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Transmission removed (WP 0142) Drawing Required TM 5-2410-241-24P, Figure 71 Estimated Time to Complete 8.0 Hr

0173-1

TM 5-2410-241-23-2

0173

REMOVAL

000173

WARNING

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

NOTE
Transmission weighs approximately 825 lb (375 kg). 1. Remove bolt (Figure 1, Item 1) and washer (Figure 1, Item 6) from transmission (Figure 1, Item 5). 2. Attach three bracket links (Figure 1, Item 2), washers (Figure 1, Item 3), and bolts (Figure 1, Item 4), on transmission (Figure 1, Item 5). 3. Attach lifting device to bracket links (Figure 1, Item 2). 4. Use lifting device to position transmission (Figure 1, Item 5) as shown on flat level surface.

Figure 1. Transmission.

0173

0173-2

TM 5-2410-241-23-2

0173

REMOVAL CONTINUED

WARNING

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

NOTE
Transmission case weighs approximately 400 lb (180 kg). 5. Remove four bolts (Figure 2, Item 2) from transmission (Figure 2, Item 3). 6. Use lifting device to remove transmission case (Figure 2, Item 3) from transmission (Figure 2, Item 1). 7. Place transmission case (Figure 2, Item 3) on flat level surface.

Figure 2. Transmission Case.

0173

0173-3

TM 5-2410-241-23-2

0173

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

8. Disconnect connector (Figure 3, Item 2) from speed sensor (Figure 3, Item 1). 9. Disconnect connector (Figure 3, Item 3) from speed sensor (Figure 3, Item 4). 10. Remove tiedown straps (Figure 3, Item 6) from harness (Figure 3, Item 5). Discard tiedown straps. 11. Position harness (Figure 3, Item 5) aside.

Figure 3. Speed Sensor Harness.

0173

0173-4

TM 5-2410-241-23-2

0173

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

12. Remove tiedown straps (Figure 4, Item 3) from harness (Figure 4, Item 4). Discard tiedown straps. 13. Disconnect five connectors (Figure 4, Item 2) from transmission control manifold solenoids (Figure 4, Item 1).

Figure 4. Control Solenoids Harness.

0173

0173-5

TM 5-2410-241-23-2

0173

REMOVAL CONTINUED 14. Remove nut (Figure 5, Item 6) from main connector (Figure 5, Item 4). 15. Remove connector (Figure 5, Item 4) from plate (Figure 5, Item 5). 16. Remove O-ring (Figure 5, Item 2) from main connector (Figure 5, Item 4). Discard O-ring. 17. Remove harness (Figure 5, Item 3) from transmission (Figure 5, Item 8). 18. Remove two bolts (Figure 5, Item 7), plate (Figure 5, Item 5), and gasket (Figure 5, Item 1) from transmission (Figure 5, Item 8). Discard gasket.

Figure 5. Transmission Harness Main Connector.

0173

0173-6

TM 5-2410-241-23-2

0173

REMOVAL CONTINUED 19. Remove lifting device from bracket links (Figure 6, Item 2). 20. Remove three bolts (Figure 6, Item 4), washers (Figure 6, Item 3), and bracket links (Figure 6, Item 2) from transmission (Figure 6, Item 5). 21. Install washer (Figure 6, Item 6) and bolt (Figure 6, Item 1) on transmission (Figure 6, Item 5).

Figure 6. Transmission Case. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0173

000173

0173-7

TM 5-2410-241-23-2

0173

INSTALLATION

000173

WARNING

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

NOTE
Transmission case weighs approximately 400 lb (180 kg). 1. Remove one bolt (Figure 7, Item 1) and washer (Figure 7, Item 6) from transmission (Figure 7, Item 5). 2. Attach three bracket links (Figure 7, Item 2), washers (Figure 7, Item 3), and bolts (Figure 7, Item 4), on transmission (Figure 7, Item 5). 3. Attach lifting device on bracket links (Figure 7, Item 2).

Figure 7. Transmission Case.

0173

0173-8

TM 5-2410-241-23-2

0173

INSTALLATION CONTINUED

NOTE
Install electrical connections and route harness as noted during removal. 4. Install new gasket (Figure 8, Item 1), plate (Figure 8, Item 5), and two bolts (Figure 8, Item 7) on transmission (Figure 8, Item 8). 5. Position harness (Figure 8, Item 3) in transmission (Figure 8, Item 8). 6. Install new O-ring (Figure 8, Item 2) on main connector (Figure 8, Item 4). 7. Install connector (Figure 8, Item 4) on plate (Figure 8, Item 5). 8. Install nut (Figure 8, Item 6) on main connector (Figure 8, Item 4).

Figure 8. Transmission Harness Main Connector.

0173

0173-9

TM 5-2410-241-23-2

0173

INSTALLATION CONTINUED

NOTE
Install electrical connections and route harness as noted during removal. 9. Connect five connectors (Figure 9, Item 2) on transmission control manifold solenoids (Figure 9, Item 1). 10. Install new tiedown straps (Figure 9, Item 3) on harness (Figure 9, Item 4).

Figure 9. Control Solenoids Harness.

0173

0173-10

TM 5-2410-241-23-2

0173

INSTALLATION CONTINUED

NOTE
Install electrical connections and route harness as noted during removal. 11. Position harness (Figure 10, Item 5) on speed sensor (Figure 10, Item 1). 12. Install new tiedown straps (Figure 10, Item 6) on harness (Figure 10, Item 5). 13. Connect connector (Figure 10, Item 3) to speed sensor (Figure 10, Item 4). 14. Connect connector (Figure 10, Item 2) to speed sensor (Figure 10, Item 1).

Figure 10. Speed Sensor Harness.

0173

0173-11

TM 5-2410-241-23-2

0173

INSTALLATION CONTINUED

WARNING

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

NOTE
Transmission case weighs approximately 400 lb (180 kg). 15. Use lifting device to install transmission case (Figure 11, Item 3) on transmission (Figure 11, Item 1). 16. Install four bolts (Figure 11, Item 2) on transmission (Figure 11, Item 3).

Figure 11. Transmission Case.

0173

0173-12

TM 5-2410-241-23-2

0173

INSTALLATION CONTINUED

WARNING

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

NOTE
Transmission weighs approximately 825 lb (375 kg). 17. Use lifting device to position transmission (Figure 12, Item 5) as shown on flat level surface. 18. Remove lifting device from bracket links (Figure 12, Item 2). 19. Remove three bolts (Figure 12, Item 4), washers (Figure 12, Item 3), and bracket links (Figure 12, Item 2) from transmission (Figure 12, Item 5). 20. Install washer (Figure 12, Item 6) and bolt (Figure 12, Item 1) on transmission (Figure 12, Item 5).

Figure 12. Transmission. END OF TASK

0173

0173-13

TM 5-2410-241-23-2

0173

FOLLOW-ON TASKS 1. Install transmission (WP 0142). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000173

0173-14

14 TM 5-2410-241-23-2 0174

FIELD MAINTENANCE
0 1 7 4

SWITCH AND HARNESS ASSEMBLY (SERVICE BRAKE) REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 110, 119

0

Estimated Time to Complete 1.5 Hr REMOVAL 1. Remove six bolts (Figure 1, Item 1) and plate (Figure 1, Item 3) from brake pedal housing (Figure 1, Item 2).

000174

Figure 1. Plate.

0174

0174-1

TM 5-2410-241-23-2

0174

REMOVAL CONTINUED 2. Remove gasket (Figure 2, Item 4) from brake pedal housing (Figure 2, Item 5). 3. Remove two bolts (Figure 2, Item 1), washers (Figure 2, Item 3), and brake switch assembly (Figure 2, Item 2) from brake pedal housing (Figure 2, Item 5). Position brake switch assembly out of brake pedal housing.

Figure 2. Brake Switch Assembly.

0174

0174-2

TM 5-2410-241-23-2

0174

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

4. Remove two screws (Figure 3, Item 1), washers (Figure 3, Item 2), and wires (Figure 3, Item 3) from brake switch assembly (Figure 3, Item 6). Position wires aside. 5. Remove two screws (Figure 3, Item 4), washers (Figure 3, Item 5), and brake switch assembly (Figure 3, Item 6) from bracket (Figure 3, Item 7).

Figure 3. Brake Switch Wires.

0174

0174-3

TM 5-2410-241-23-2

0174

REMOVAL CONTINUED 6. Remove bolt (Figure 4, Item 2) and washer (Figure 4, Item 1) from instrument panel (Figure 4, Item 3). 7. Remove bolt (Figure 4, Item 4) and washer (Figure 4, Item 5) from instrument panel (Figure 4, Item 3).

Figure 4. Instrument Panel Lower Bolts.

0174

0174-4

TM 5-2410-241-23-2

0174

REMOVAL CONTINUED 8. Remove bolt (Figure 5, Item 1) from instrument panel (Figure 5, Item 3). 9. Remove bolt (Figure 5, Item 2) from instrument panel (Figure 5, Item 3). 10. Remove bolt (Figure 5, Item 4) from instrument panel (Figure 5, Item 3). 11. Remove bolt (Figure 5, Item 5) from instrument panel (Figure 5, Item 3). 12. Allow instrument panel (Figure 5, Item 3) to tilt back.

Figure 5. Instrument Panel Upper Bolts.

0174

0174-5

TM 5-2410-241-23-2

0174

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

13. Remove tiedown strap (Figure 6, Item 2) from connector (Figure 6, Item 3). Discard tiedown strap. 14. Disconnect connector (Figure 6, Item 1) from connector (Figure 6, Item 3). 15. Remove grommet (Figure 6, Item 6) from instrument panel (Figure 6, Item 4). 16. Position harness (Figure 6, Item 5) and connector (Figure 6, Item 3) out from instrument panel (Figure 6, Item 4).

Figure 6. Harness Connector.

0174

0174-6

TM 5-2410-241-23-2

0174

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. 17. Position instrument panel (Figure 7, Item 1) from instrument panel hinge (Figure 7, Item 4). 18. Remove bolt (Figure 7, Item 5) from grommet (Figure 7, Item 3). 19. Remove grommet (Figure 7, Item 3) and harness (Figure 7, Item 6) from brake pedal housing (Figure 7, Item 2). 20. Remove harness (Figure 7, Item 6) from machine. 21. Position instrument panel (Figure 7, Item 1) on instrument panel hinge (Figure 7, Item 4).

Figure 7. Brake Switch Harness Grommet. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0174

000174

0174-7

TM 5-2410-241-23-2

0174

INSTALLATION

000174

NOTE
Route harness as noted during removal. 1. Position instrument panel (Figure 8, Item 1) off instrument panel hinge (Figure 8, Item 4). 2. Install harness (Figure 8, Item 6) on machine. 3. Install harness (Figure 8, Item 6) and grommet (Figure 8, Item 3) on brake pedal housing (Figure 8, Item 2). 4. Install bolt (Figure 8, Item 5) on grommet (Figure 8, Item 3). 5. Position instrument panel (Figure 8, Item 1) on instrument panel hinge (Figure 8, Item 4).

Figure 8. Brake Switch Harness Grommet.

0174

0174-8

TM 5-2410-241-23-2

0174

INSTALLATION CONTINUED

NOTE
Install electrical connectors and route harness as noted during removal. 6. Position connector (Figure 9, Item 3) and harness (Figure 9, Item 5) in instrument panel (Figure 9, Item 4). 7. Connect connector (Figure 9, Item 1) to connector (Figure 9, Item 3). 8. Install grommet (Figure 9, Item 6) on instrument panel (Figure 9, Item 4). 9. Install new tiedown strap (Figure 9, Item 2) on connector (Figure 9, Item 3).

Figure 9. Harness Connector.

0174

0174-9

TM 5-2410-241-23-2

0174

INSTALLATION CONTINUED 10. Lift instrument panel (Figure 10, Item 3) into mounting position. 11. Install bolt (Figure 10, Item 5) on instrument panel (Figure 10, Item 3). 12. Install bolt (Figure 10, Item 4) on instrument panel (Figure 10, Item 3). 13. Install bolt (Figure 10, Item 2) on instrument panel (Figure 10, Item 3). 14. Install bolt (Figure 10, Item 1) on instrument panel (Figure 10, Item 3).

Figure 10. Instrument Panel Upper Bolts.

0174

0174-10

TM 5-2410-241-23-2

0174

INSTALLATION CONTINUED 15. Install washer (Figure 11, Item 5) and bolt (Figure 11, Item 4) on instrument panel (Figure 11, Item 3). 16. Install washer (Figure 11, Item 1) and bolt (Figure 11, Item 2) on instrument panel (Figure 11, Item 3).

Figure 11. Instrument Panel Lower Bolts.

0174

0174-11

TM 5-2410-241-23-2

0174

INSTALLATION CONTINUED 17. Install brake switch (Figure 12, Item 6), two washers (Figure 12, Item 5), and screws (Figure 12, Item 4) on bracket (Figure 12, Item 7).

NOTE
Install electrical connections and route harness as noted during removal. 18. Install two wires (Figure 12, Item 3), washers (Figure 12, Item 2), and screws (Figure 12, Item 1) on brake switch assembly (Figure 12, Item 6).

Figure 12. Brake Switch Wires.

0174

0174-12

TM 5-2410-241-23-2

0174

INSTALLATION CONTINUED 19. Install brake switch assembly (Figure 13, Item 2), two washers (Figure 13, Item 3), and bolts (Figure 13, Item 1) on brake pedal housing (Figure 13, Item 5). 20. Install new gasket (Figure 13, Item 4) on brake pedal housing (Figure 13, Item 5).

Figure 13. Brake Switch Assembly.

0174

0174-13

TM 5-2410-241-23-2

0174

INSTALLATION CONTINUED 21. Install plate (Figure 14, Item 3) and six bolts (Figure 14, Item 1) on brake pedal housing (Figure 14, Item 2).

Figure 14. Plate. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0174

000174

0174-14

6 TM 5-2410-241-23-2 0175

FIELD MAINTENANCE INSTRUCTIONS ECM (POWERTRAIN) REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 7 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) References WP 0017 WP 0295 REMOVAL 1. Record all diagnostic codes and save ECM configuration data (WP 0017). 2. Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and armrest (Figure 1, Item 1) from console (Figure 1, Item 4). 3. Remove felt cover (Figure 1, Item 5) from console (Figure 1, Item 4).
0

Equipment Condition Machine parked (TM 5-2410-241-10) Cab seat removed (WP 0247) Drawing Required TM 5-2410-241-24P, Figure 123 Estimated Time to Complete 2.0 Hr

000175

Figure 1. Cab Interior.

0175

0175-1

TM 5-2410-241-23-2

0175

REMOVAL CONTINUED 4. Remove 10 bolts (Figure 2, Item 3), washers (Figure 2, Item 4), and left cover plate (Figure 2, Item 2) from console (Figure 2, Item 1).

Figure 2. Left Cover Plate.

0175

0175-2

TM 5-2410-241-23-2

0175

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note location of bracket to aid installation.

5. Loosen bolt (Figure 3, Item 2) until connector (Figure 3, Item 3) is removed from powertrain ECM (Figure 3, Item 1). 6. Loosen bolt (Figure 3, Item 4) until connector (Figure 3, Item 5) is removed from powertrain ECM (Figure 3, Item 1). 7. Remove two front mounting bolts (Figure 3, Item 7), washers (Figure 3, Item 8), and position bracket (Figure 3, Item 6) aside from powertrain ECM (Figure 3, Item 1). 8. Remove two rear mounting bolts (Figure 3, Item 7), washers (Figure 3, Item 8), and powertrain ECM (Figure 3, Item 1) from machine. 9. Remove eight isolators (Figure 3, Item 9) and four spacers (Figure 3, Item 10) from powertrain ECM (Figure 3, Item 1).

Figure 3. ECM (Powertrain). END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0175

000175

0175-3

TM 5-2410-241-23-2

0175

INSTALLATION

000175

NOTE
Install electrical connectors as noted during removal. Install bracket as noted during removal.

1. Install eight isolators (Figure 4, Item 9) and four spacers (Figure 4, Item 10) on powertrain ECM (Figure 4, Item 1). 2. Install powertrain ECM (Figure 4, Item 1), two washers (Figure 4, Item 8), and rear mounting bolts (Figure 4, Item 7), on machine. 3. Install bracket (Figure 4, Item 6), two washers (Figure 4, Item 8), and front mounting bolts (Figure 4, Item 7) on powertrain ECM (Figure 4, Item 1). 4. Plug in connector (Figure 4, Item 5) and tighten bolt (Figure 4, Item 4) until connector is installed on powertrain ECM (Figure 4, Item 1). 5. Plug in connector (Figure 4, Item 3) and tighten bolt (Figure 4, Item 2) until connector is installed on powertrain ECM (Figure 4, Item 1).

Figure 4. ECM (Powertrain).

0175

0175-4

TM 5-2410-241-23-2

0175

INSTALLATION CONTINUED 6. Install left cover plate (Figure 5, Item 2), 10 washers (Figure 5, Item 4), and bolts (Figure 5, Item 3) on console (Figure 5, Item 1).

Figure 5. Left Cover Plate. 7. Install felt cover (Figure 6, Item 5) on console (Figure 6, Item 4). 8. Install armrest (Figure 6, Item 1), two washers (Figure 6, Item 3), and bolts (Figure 6, Item 2) on console (Figure 6, Item 4).

0175

Figure 6. Cab Interior. END OF TASK

0175

0175-5

TM 5-2410-241-23-2

0175

FOLLOW-ON TASKS 1. Install cab seat (WP 0247). 2. Program ECM (WP 0017). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000175

0175-6

18 TM 5-2410-241-23-2 0176

FIELD MAINTENANCE INSTRUCTIONS FUSE BOX REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 1 7 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Decal Locknut (2)
0

References WP 0295

Equipment Condition
0 0

Machine parked (TM 5-2410-241-10) Batteries removed (WP 0155) Drawing Required

TM 5-2410-241-24P, Figure 87
0 0

Estimated Time to Complete 3.5 Hr

0176-1

TM 5-2410-241-23-2

0176

REMOVAL

000176

NOTE
Tag and mark connectors to aid installation. 1. Remove two locknuts (Figure 1, Item 18), washers (Figure 1, Item 16), clips (Figure 1, Item 17), and cables (Figure 1, Item 11) from bracket (Figure 1, Item 14). Discard locknuts. 2. Loosen bolt (Figure 1, Item 5) and remove connector (Figure 1, Item 4) from fuse box (Figure 1, Item 1). 3. Remove two bolts (Figure 1, Item 6), washers (Figure 1, Item 7), and cover (Figure 1, Item 15) from machine. 4. Remove two bolts (Figure 1, Item 9), washers (Figure 1, Item 8), and cables (Figure 1, Item 11) from fuse box (Figure 1, Item 1). 5. Remove two lower bolts (Figure 1, Item 13), washers (Figure 1, Item 12), and bracket (Figure 1, Item 14) from fuse box (Figure 1, Item 1). 6. Remove two upper bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and fuse box (Figure 1, Item 1) from machine. 7. Remove isolator (Figure 1, Item 10) from machine.

Figure 1. Fuse Box Connections. END OF TASK

0176

0176-2

TM 5-2410-241-23-2

0176

DISASSEMBLY

000176

NOTE
Tag and mark connectors to aid installation. Note location of straps to aid installation.

1. Remove nut (Figure 2, Item 4) and washer (Figure 2, Item 5) from starter relay (Figure 2, Item 3). 2. Remove nut (Figure 2, Item 7) from main relay (Figure 2, Item 8). 3. Remove nut (Figure 2, Item 1), washer (Figure 2, Item 2), and strap (Figure 2, Item 6) from fuse block assembly (Figure 2, Item 12). 4. Remove nut (Figure 2, Item 13) and washer (Figure 2, Item 14) from strap (Figure 2, Item 11). 5. Remove nut (Figure 2, Item 9), wire (Figure 2, Item 10), and strap (Figure 2, Item 11) from main relay (Figure 2, Item 8)

Figure 2. Starter and Main Relay Straps.

0176

0176-3

TM 5-2410-241-23-2

0176

DISASSEMBLY CONTINUED

NOTE
Tag and mark connector to aid assembly. 6. Disconnect main relay connector (Figure 3, Item 2) from harness (Figure 3, Item 1). 7. Remove two nuts (Figure 3, Item 3) and main relay (Figure 3, Item 4) from fuse box (Figure 3, Item 5).

Figure 3. Main Relay.

0176

0176-4

TM 5-2410-241-23-2

0176

DISASSEMBLY CONTINUED

NOTE
Tag and mark connector to aid assembly. Note location of strap to aid assembly.

8. Remove nut (Figure 4, Item 5), wire (Figure 4, Item 4), and washer (Figure 4, Item 6) from starter relay (Figure 4, Item 7). 9. Remove tiedown strap (Figure 4, Item 2) and disconnect starter relay connector (Figure 4, Item 3) from harness (Figure 4, Item 1). Discard tiedown strap. 10. Remove two nuts (Figure 4, Item 8), washers (Figure 4, Item 9), and starter relay (Figure 4, Item 7) from fuse box (Figure 4, Item 10). 11. Remove bolt (Figure 4, Item 15), washer (Figure 4, Item 14), and strap (Figure 4, Item 11) from alternator fuse (Figure 4, Item 16). 12. Remove bolt (Figure 4, Item 13) and washer (Figure 4, Item 12) from alternator fuse (Figure 4, Item 16).

Figure 4. Starter Relay.

0176

0176-5

TM 5-2410-241-23-2

0176

DISASSEMBLY CONTINUED

NOTE
Note location of strap to aid in assembly. 13. Remove bolt (Figure 5, Item 3), washer (Figure 5, Item 4), and strap (Figure 5, Item 2) from junction block (Figure 5, Item 1).

Figure 5. Junction Block Strap.

0176

0176-6

TM 5-2410-241-23-2

0176

DISASSEMBLY CONTINUED

NOTE
Tag and mark connectors to aid installation. 14. Remove two bolts (Figure 6, Item 2) and position blower motor circuit breaker (Figure 6, Item 1) from fuse box (Figure 6, Item 7). 15. Remove tiedown strap (Figure 6, Item 9) and wire (Figure 6, Item 8) from fuse box (Figure 6, Item 7). Discard tiedown strap. 16. Remove two bolts (Figure 6, Item 5), wires (Figure 6, Item 8), and washers (Figure 6, Item 6) from blower motor circuit breaker (Figure 6, Item 1). 17. Remove four bolts (Figure 6, Item 3) and position harness connector (Figure 6, Item 4) from fuse box (Figure 6, Item 7).

Figure 6. Blower Motor Circuit Breaker.

0176

0176-7

TM 5-2410-241-23-2

0176

DISASSEMBLY CONTINUED 18. Remove bolt (Figure 7, Item 4), washer (Figure 7, Item 5), and fuse block cover (Figure 7, Item 3) from fuse block assembly (Figure 7, Item 2).

NOTE
Note orientation of fuse block assembly in fuse box to aid installation. Note fuse location in fuse block assembly to aid installation.

19. Remove three bolts (Figure 7, Item 4) and fuse block assembly (Figure 7, Item 2) from fuse box (Figure 7, Item 6). 20. Remove all fuses (Figure 7, Item 1) from fuse block assembly (Figure 7, Item 2).

Figure 7. Fuse Block Assembly.

0176

0176-8

TM 5-2410-241-23-2

0176

DISASSEMBLY CONTINUED

NOTE
Note location of strap to aid assembly. 21. Remove bolt (Figure 8, Item 2), washer (Figure 8, Item 3), and strap (Figure 8, Item 1) from junction block (Figure 8, Item 5). 22. Remove three bolts (Figure 8, Item 6) and junction block (Figure 8, Item 5) from fuse box (Figure 8, Item 4).

Figure 8. Junction Block.

0176

0176-9

TM 5-2410-241-23-2

0176

DISASSEMBLY CONTINUED 23. Remove two bolts (Figure 9, Item 1) and alternator fuse cover (Figure 9, Item 2) from alternator fuse holder (Figure 9, Item 3). 24. Remove two bolts (Figure 9, Item 5), washers (Figure 9, Item 4), and alternator fuse (Figure 9, Item 6) from alternator fuse holder (Figure 9, Item 3). 25. Remove bolt (Figure 9, Item 10) and alternator fuse cover (Figure 9, Item 2). 26. Remove three bolts (Figure 9, Item 7) and alternator fuse holder (Figure 9, Item 3) from fuse box (Figure 9, Item 8). 27. Remove decal (Figure 9, Item 9) from fuse box (Figure 9, Item 8). Discard decal.

Figure 9. Alternator Fuse. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0176

000176

0176-10

TM 5-2410-241-23-2

0176

ASSEMBLY 1. Install new decal (Figure 9, Item 9) on fuse box (Figure 9, Item 8). 2. Install alternator fuse holder (Figure 9, Item 3) and three bolts (Figure 9, Item 7) on fuse box (Figure 9, Item 8). 3. Install alternator fuse cover (Figure 9, Item 2) and bolt (Figure 9, Item 10). 4. Install alternator fuse (Figure 9, Item 6), two washers (Figure 9, Item 4), and bolts (Figure 9, Item 5) on alternator fuse holder (Figure 9, Item 3). 5. Install alternator fuse cover (Figure 9, Item 2) and two bolts (Figure 9, Item 1) on alternator fuse holder (Figure 9, Item 3). 6. Install junction block (Figure 10, Item 5) and three bolts (Figure 10, Item 6) on fuse box (Figure 10, Item 4). 7. Install strap (Figure 10, Item 1), washer (Figure 10, Item 3), and bolt (Figure 10, Item 2) on junction block (Figure 10, Item 5).

000176

Figure 10. Junction Block.

0176

0176-11

TM 5-2410-241-23-2

0176

ASSEMBLY CONTINUED

NOTE
Install fuse block assembly in fuse box as noted in removal. Install fuses in fuse block assembly as noted in removal.

8. Install all fuses (Figure 11, Item 1) on fuse block assembly (Figure 11, Item 2). 9. Install fuse block assembly (Figure 11, Item 2) and three bolts (Figure 11, Item 4) on fuse box (Figure 11, Item 6). 10. Install fuse block cover (Figure 11, Item 3), washer (Figure 11, Item 5), and bolt (Figure 11, Item 4) on fuse block assembly (Figure 11, Item 2).

Figure 11. Fuse Block Assembly.

0176

0176-12

TM 5-2410-241-23-2

0176

ASSEMBLY CONTINUED

NOTE
Install connectors as tagged during removal. 11. Install harness connector (Figure 12, Item 4) and four bolts (Figure 12, Item 3) on fuse box (Figure 12, Item 7). 12. Install two washers (Figure 12, Item 6), wires (Figure 12, Item 8), and bolts (Figure 12, Item 5) on blower motor circuit breaker (Figure 12, Item 1). 13. Install wire (Figure 12, Item 8) and new tiedown strap (Figure 12, Item 9) on fuse box (Figure 12, Item 7). 14. Install blower motor circuit breaker (Figure 12, Item 1) and two bolts (Figure 12, Item 2) on fuse box (Figure 12, Item 7).

Figure 12. Blower Motor Circuit Breaker.

0176

0176-13

TM 5-2410-241-23-2

0176

ASSEMBLY CONTINUED

NOTE
Install connectors as tagged in removal. Install straps as noted in disassembly.

15. Install strap (Figure 13, Item 2), washer (Figure 13, Item 4), and bolt (Figure 13, Item 3) on junction block (Figure 13, Item 1).

Figure 13. Junction Block Strap.

0176

0176-14

TM 5-2410-241-23-2

0176

ASSEMBLY CONTINUED

NOTE
Install straps and connectors as noted during disassembly. 16. Install strap (Figure 14, Item 11), washer (Figure 14, Item 14), and bolt (Figure 14, Item 15) on alternator fuse (Figure 14, Item 16). 17. Install washer (Figure 14, Item 12) and bolt (Figure 14, Item 13) on alternator fuse (Figure 14, Item 16). 18. Install starter relay (Figure 14, Item 7), two washers (Figure 14, Item 9), and nuts (Figure 14, Item 8) on fuse box (Figure 14, Item 10). 19. Install wire (Figure 14, Item 4), washer (Figure 14, Item 6), and nut (Figure 14, Item 5) on starter relay (Figure 14, Item 7). 20. Connect starter relay connector (Figure 14, Item 3) on harness (Figure 14, Item 1), install new tiedown strap (Figure 14, Item 2).

Figure 14. Starter Relay.

0176

0176-15

TM 5-2410-241-23-2

0176

ASSEMBLY CONTINUED

NOTE
Install connectors as noted during disassembly. 21. Install main relay (Figure 15, Item 4) and two nuts (Figure 15, Item 3) on fuse box (Figure 15, Item 5). 22. Connect main relay connector (Figure 15, Item 2) to harness (Figure 15, Item 1).

Figure 15. Main Relay.

0176

0176-16

TM 5-2410-241-23-2

0176

ASSEMBLY CONTINUED

NOTE
Install straps as noted during disassembly. 23. Install strap (Figure 16, Item 11), wire (Figure 16, Item 10) and nut (Figure 16, Item 9), on main relay (Figure 16, Item 8) 24. Install washer (Figure 16, Item 14) and nut (Figure 16, Item 13) on strap (Figure 16, Item 11). 25. Install strap (Figure 16, Item 6), washer (Figure 16, Item 2) and nut (Figure 16, Item 1) on fuse block assembly (Figure 16, Item 12). 26. Install nut (Figure 16, Item 7) on main relay (Figure 16, Item 8). 27. Install washer (Figure 16, Item 5) and nut (Figure 16, Item 4) on starter relay (Figure 16, Item 3).

Figure 16. Starter and Main Relay Straps. END OF TASK

0176

0176-17

TM 5-2410-241-23-2

0176

INSTALLATION 1. Install isolator (Figure 17, Item 10) on machine. 2. Install fuse box (Figure 17, Item 1), two washers (Figure 17, Item 3), and upper bolts (Figure 17, Item 2) on machine.

000176

3. Install bracket (Figure 17, Item 14), two washers (Figure 17, Item 12), and lower bolts (Figure 17, Item 13) on fuse box (Figure 17, Item 1).

NOTE
Install connectors as tagged in removal. 4. Install two cables (Figure 17, Item 11), washers (Figure 17, Item 8), and bolts (Figure 17, Item 9) on fuse box. (Figure 17, Item 1) 5. Install cover (Figure 17, Item 15), two washers (Figure 17, Item 7), and bolts (Figure 17, Item 6) on machine. 6. Install connector (Figure 17, Item 4) on fuse box (Figure 17, Item 1) and tighten bolt (Figure 17, Item 5). 7. Install two clips (Figure 17, Item 17), cables (Figure 17, Item 11), washers (Figure 17, Item 16), and new locknuts (Figure 17, Item 18) on bracket (Figure 17, Item 14).

Figure 17. Fuse Box Connections. END OF TASK FOLLOW-ON TASKS 1. Install batteries (WP 0155). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0176

000176

0176-18

2 TM 5-2410-241-23-2 0177

FIELD MAINTENANCE INSTRUCTIONS POWER CONVERTER REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 7 7

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295 REMOVAL 1. Disconnect connector (Figure 1, Item 4) from power converter (Figure 1, Item 1). 2. Remove six bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and power converter (Figure 1, Item 1) from machine.
0

Equipment Condition Machine parked (TM 5-2410-241-10) Batteries removed (WP 0155) Drawing Required TM 5-2410-241-24P, Figure 87 Estimated Time to Complete 2.5 Hr

000177

Figure 1. Power Converter. END OF TASK

0177

0177-1

TM 5-2410-241-23-2

0177

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install power converter (Figure 2, Item 1), six washers (Figure 2, Item 3), and bolts (Figure 2, Item 2) on machine. 2. Connect connector (Figure 2, Item 4) on power converter (Figure 2, Item 1).

000177

000177

Figure 2. Power Converter. END OF TASK FOLLOW-ON TASKS 1. Install batteries (WP 0155). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0177

000177

0177-2

6 TM 5-2410-241-23-2 0178

FIELD MAINTENANCE INSTRUCTIONS

0 1 7 8

WIRING HARNESS ASSEMBLY (STEERING CONTROL) REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10) Cab seat removed (WP 0247) Drawing Required TM 5-2410-241-24P, Figure 123 Estimated Time to Complete 2.0 Hr

000178

1. Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and armrest (Figure 1, Item 1) from console (Figure 1, Item 4). 2. Remove felt cover (Figure 1, Item 5) from console (Figure 1, Item 4).

Figure 1. Cab Interior.

0178

0178-1

TM 5-2410-241-23-2

0178

REMOVAL CONTINUED 3. Remove 10 bolts (Figure 2, Item 3), washers (Figure 2, Item 4), and left cover plate (Figure 2, Item 2) from console (Figure 2, Item 1).

Figure 2. Left Cover Plate.

0178

NOTE
Tag and mark electrical connectors to aid installation. Note wiring harness routing to aid installation. Mark location and number of tiedown straps before removal.

4. Remove tiedown straps (Figure 3, Item 9) from wiring harness (Figure 3, Item 13). Discard tiedown straps. 5. Disconnect connectors (Figure 3, Items 6, 7, 8, and 10) from wiring harness (Figure 3, Item 13). 6. Loosen bolt (Figure 3, Item 4) until connector (Figure 3, Item 5) is removed from powertrain control module (Figure 3, Item 1). 7. Loosen bolt (Figure 3, Item 2) until connector (Figure 3, Item 3) is removed from powertrain control module (Figure 3, Item 1). 8. Loosen bolt (Figure 3, Item 15) until connector (Figure 3, Item 16) is removed from bulkhead (Figure 3, Item 21). 9. Remove two screws (Figure 3, Item 17) and washers (Figure 3, Item 18), and disconnect connector (Figure 3, Item 19) from bulkhead (Figure 3, Item 21). 10. Remove wiring harness (Figure 3, Item 13) from machine cab. 11. Disconnect resistor (Figure 3, Item 14) from wiring harness (Figure 3, Item 13). 12. Remove harness (Figure 3, Item 11) from connector (Figure 3, Item 12). 13. Remove cap (Figure 3, Item 20) from connector (Figure 3, Item 19).

0178-2

TM 5-2410-241-23-2

0178

REMOVAL CONTINUED

Figure 3. Powertrain Control Wiring Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0178

000178

0178-3

TM 5-2410-241-23-2

0178

INSTALLATION

000178

NOTE
Install electrical connectors as noted during removal. Install wiring harness as noted during removal. Install tiedown straps as noted during removal.

1. Install cap (Figure 4, Item 20) on connector (Figure 4, Item 19). 2. Install harness (Figure 4, Item 11) on connector (Figure 4, Item 12). 3. Install resistor (Figure 4, Item 14) on wiring harness (Figure 4, Item 13). 4. Position wiring harness (Figure 4, Item 13) inside bulkhead (Figure 4, Item 21). 5. Connect connector (Figure 4, Item 19) to bulkhead (Figure 4, Item 21) and install two washers (Figure 4, Item 18) and screws (Figure 4, Item 17). 6. Plug in connector (Figure 4, Item 16) and tighten bolt (Figure 4, Item 15) until connector is installed on bulkhead (Figure 4, Item 21). 7. Plug in connector (Figure 4, Item 3) and tighten bolt (Figure 4, Item 2) until connector is installed on powertrain control module (Figure 4, Item 1). 8. Plug in connector (Figure 4, Item 5) and tighten bolt (Figure 4, Item 4) until connector is installed on powertrain control module (Figure 4, Item 1). 9. Connect connectors (Figure 4, Items 6, 7, 8, and 10) to wiring harness (Figure 4, Item 11).

Figure 4. Powertrain Control Wiring Harness.

0178

0178-4

TM 5-2410-241-23-2

0178

INSTALLATION CONTINUED

NOTE
Install tiedown straps as noted during removal. 10. Install new tiedown straps (Figure 4, Item 9) on wiring harness (Figure 4, Item 13). 11. Install left cover plate (Figure 5, Item 2), 10 washers (Figure 5, Item 4), and bolts (Figure 5, Item 3) on console (Figure 5, Item 1).

Figure 5. Left Cover Plate.

0178

0178-5

TM 5-2410-241-23-2

0178

INSTALLATION CONTINUED 12. Install felt cover (Figure 6, Item 5) on console (Figure 6, Item 4). 13. Install armrest (Figure 6, Item 1), two washers (Figure 6, Item 3), and bolts (Figure 6, Item 2) on console (Figure 6, Item 4).

Figure 6. Cab Interior. END OF TASK FOLLOW-ON TASKS 1. Install cab seat (WP 0247). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0178

000178

0178-6

12 TM 5-2410-241-23-2 0179

FIELD MAINTENANCE
0 1 7 9

RIGHT CAB SWITCH PANEL HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295 REMOVAL
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Lower right platform access panels removed (WP 0208) Drawing Required TM 5-2410-241-24P, Figure 87, 125, 126 Estimated Time to Complete 5.5 Hr

000179

NOTE
Note position and location of washers to aid installation. 1. Remove 14 bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and harness clip (Figure 1, Item 4) from upper right access panel (Figure 1, Item 3).

Figure 1. Upper Right Access Panel.

0179

0179-1

TM 5-2410-241-23-2

0179

REMOVAL CONTINUED 2. Remove two bolts (Figure 2, Item 4) and washers (Figure 2, Item 5) from switch pod (Figure 2, Item 3). 3. Position switch pod (Figure 2, Item 3) aside. 4. Remove bolt (Figure 2, Item 2) from upper right access panel (Figure 2, Item 1).

Figure 2. Switch Pod.

0179

NOTE
Note harness routing to aid installation. Tag and mark all electrical connectors to aid installation.

5. Disconnect three connectors (Figure 3, Item 3) from three switches (Figure 3, Item 2). 6. Remove switch pod (Figure 3, Item 1) from machine.

Figure 3. Switch Pod Connectors.

0179

0179-2

TM 5-2410-241-23-2

0179

REMOVAL CONTINUED 7. Remove grommet (Figure 4, Item 3) and switch panel harness (Figure 4, Item 1) from upper right access panel (Figure 4, Item 2). 8. Position harness (Figure 4, Item 1) through upper right access panel (Figure 4, Item 2). Position upper right access panel (Figure 4, Item 2) aside.

Figure 4. Pod Harness.

0179

0179-3

TM 5-2410-241-23-2

0179

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connectors to aid installation. Mark location and note number of tiedown straps before removal.

9. Remove tiedown straps (Figure 5, Item 4) from harness (Figure 5, Item 3) and upper right access panel (Figure 5, Item 1). Discard tiedown straps. 10. Disconnect horn switch (Figure 5, Item 2) connector from harness (Figure 5, Item 3). 11. Disconnect indicator lamp (Figure 5, Item 7) connector from harness (Figure 5, Item 3). 12. Remove nut (Figure 5, Item 6), washer (Figure 5, Item 5), and indicator lamp (Figure 5, Item 7) from upper right access panel (Figure 5, Item 1). 13. Remove upper right access panel (Figure 5, Item 1) from machine.

Figure 5. Switch Panel Harness.

0179

0179-4

TM 5-2410-241-23-2

0179

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Mark location and note number of tiedown straps before removal.

14. Remove tiedown straps (Figure 6, Item 2) from harness (Figure 6, Item 1). Discard tiedown straps. 15. Disconnect connector (Figure 6, Item 3) from connector (Figure 6, Item 4). 16. Disconnect three connectors (Figure 6, Item 5) from three connectors (Figure 6, Item 6). 17. Remove harness (Figure 6, Item 1) from machine.

Figure 6. Harness Connectors. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0179

000179

0179-5

TM 5-2410-241-23-2

0179

INSTALLATION

000179

NOTE
Install electrical connectors and route harnesses as noted during removal. Install tiedown straps as noted during removal.

1. Position harness (Figure 7, Item 1) on machine. 2. Connect three connectors (Figure 7, Item 5) on three connectors (Figure 7, Item 6). 3. Connect connector (Figure 7, Item 3) on connector (Figure 7, Item 4). 4. Install new tiedown straps (Figure 7, Item 2) on harness (Figure 7, Item 1).

Figure 7. Harness Connectors.

0179

0179-6

TM 5-2410-241-23-2

0179

INSTALLATION CONTINUED

NOTE
Install electrical connectors and route harnesses as noted during removal. Install tiedown straps as noted during removal.

5. Position harness (Figure 8, Item 3) on machine. 6. Position upper right access panel (Figure 8, Item 1) on machine. 7. Connect horn switch (Figure 8, Item 2) connector on harness (Figure 8, Item 3). 8. Connect indicator lamp (Figure 8, Item 7) connector on harness (Figure 8, Item 3). 9. Install indicator lamp (Figure 8, Item 7), washer (Figure 8, Item 5), and nut (Figure 8, Item 6) on upper right access panel (Figure 8, Item 1). 10. Install harness (Figure 8, Item 3) and new tiedown straps (Figure 8, Item 4) on upper right access panel (Figure 8, Item 1).

Figure 8. Switch Panel Harness.

0179

0179-7

TM 5-2410-241-23-2

0179

INSTALLATION CONTINUED

NOTE
Install electrical connectors and route harnesses as noted during removal. 11. Position harness (Figure 9, Item 1) through upper right access panel (Figure 9, Item 2). Install grommet (Figure 9, Item 3) on harness (Figure 9, Item 1) and upper right access panel (Figure 9, Item 2).

Figure 9. Pod Harness.

0179

0179-8

TM 5-2410-241-23-2

0179

INSTALLATION CONTINUED

NOTE
Install electrical connectors and route harnesses as noted during removal. 12. Position switch pod (Figure 10, Item 1) on machine. 13. Connect three connectors (Figure 10, Item 3) on three switches (Figure 10, Item 2).

Figure 10. Switch Pod Connector.

0179

0179-9

TM 5-2410-241-23-2

0179

INSTALLATION CONTINUED 14. Install bolt (Figure 11, Item 2) on upper right access panel (Figure 11, Item 1). 15. Position switch pod (Figure 11, Item 3) on machine. 16. Install two washers (Figure 11, Item 5) and bolts (Figure 11, Item 4) on switch pod (Figure 11, Item 3).

Figure 11. Switch Pod.

0179

0179-10

TM 5-2410-241-23-2

0179

INSTALLATION CONTINUED

NOTE
Install washers as noted during removal. 17. Install harness clip (Figure 12, Item 4), 14 washers (Figure 12, Item 2), and bolts (Figure 12, Item 1) on upper right access panel (Figure 12, Item 3).

Figure 12. Upper Right Access Panel. END OF TASK FOLLOW-ON TASKS 1. Install lower right platform access panel (WP 0208). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0179

000179

0179-11/(12 blank)

4 TM 5-2410-241-23-2 0180

FIELD MAINTENANCE INSTRUCTIONS

0 1 8 0

WINCH SOLENOID HARNESS ASSEMBLY REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10)

Drawing Required
0

TM 5-2410-241-24P, Figure 95 Estimated Time to Complete

0.5 Hr
0 0

0180-1

TM 5-2410-241-23-2

0180

REMOVAL

000180

NOTE
Tag and mark electrical connectors to aid installation. Note wiring harness routing to aid installation.

1. Cut off tiedown strap (Figure 1, Item 4) from winch solenoid harness assembly (Figure 1, Item 1). Discard tiedown strap. 2. Disconnect winch solenoid harness (Figure 1, Item 1) from chassis harness assembly connector (Figure 1, Item 2). 3. Disconnect winch solenoid harness (Figure 1, Item 1) from winch solenoid connector (Figure 1, Item 3), and remove harness from machine.

Figure 1. Winch Solenoid Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0180

000180

0180-2

TM 5-2410-241-23-2

0180

INSTALLATION

000180

NOTE
Install electrical connectors as noted during removal. Install wiring harness as noted during removal. Install tiedown strap as noted during removal.

1. Connect winch solenoid harness (Figure 2, Item 1) to winch solenoid connector (Figure 2, Item 3). 2. Connect winch solenoid harness (Figure 2, Item 1) to chassis harness assembly connector (Figure 2, Item 2). 3. Install new tiedown strap (Figure 2, Item 4) on winch solenoid harness (Figure 2, Item 1).

Figure 2. Winch Solenoid Harness. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0180

000180

0180-3/(4 blank)

4 TM 5-2410-241-23-2 0181

FIELD MAINTENANCE
0 1 8 1

HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring References WP 0295 REMOVAL 1. Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and plate (Figure 1, Item 1) from machine. 2. Open door (Figure 1, Item 4) on machine.
0

Equipment Condition Machine parked (TM 5-2410-241-10) Transmission filter removed (WP 0152) Hydraulic tank drained (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 96 Estimated Time to Complete 2.6 Hr

000181

Figure 1. Door.

0181

0181-1

TM 5-2410-241-23-2

0181

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connectors to aid installation.

3. Remove tiedown strap (Figure 2, Item 2) from connector (Figure 2, Item 1). Discard tiedown strap. 4. Disconnect connector (Figure 2, Item 1) from connector (Figure 2, Item 3).

Figure 2. Harness. 5. Remove sensor (Figure 3, Item 2) from hydraulic tank (Figure 3, Item 1). 6. Remove O-ring (Figure 3, Item 3) from sensor (Figure 3, Item 2). Discard O-ring.

0181

Figure 3. Sensor. END OF TASK

0181

0181-2

TM 5-2410-241-23-2

0181

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install new O-ring (Figure 3, Item 3) on sensor (Figure 3, Item 2). 2. Install sensor (Figure 3, Item 2) on hydraulic tank (Figure 3, Item 1).

000181

000181

NOTE
Install electrical connectors and route harnesses as noted during removal. 3. Connect connector (Figure 2, Item 1) to connector (Figure 2, Item 3). 4. Install new tiedown strap (Figure 2, Item 2) on connector (Figure 2, Item 1). 5. Close door (Figure 4, Item 4) on machine. 6. Install plate (Figure 4, Item 1), two washers (Figure 4, Item 3), and bolts (Figure 4, Item 2) on machine.

Figure 4. Door. END OF TASK FOLLOW-ON TASKS 1. Install transmission filter (WP 0152). 2. Fill hydraulic tank (WP 0184). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE 0181-3/(4 blank)

0181

000181

6 TM 5-2410-241-23-2 0182

FIELD MAINTENANCE INSTRUCTIONS HORN REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 8 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) References WP 0295 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10)

Drawing Required
0

TM 5-2410-241-24P, Figure 86, 96 Estimated Time to Complete

1.0 Hr
0 0

000182

1. Remove four bolts (Figure 1, Item 1) and washers (Figure 1, Item 2) from left hand door (Figure 1, Item 3) and open door.

Figure 1. Left Hand Door.

0182

0182-1

TM 5-2410-241-23-2

0182

REMOVAL CONTINUED

NOTE
Steps 2 - 4 will remove one horn. Follow same steps for additional horn. Tag electrical connectors to aid installation.

2. Disconnect electrical connector (Figure 2, Item 1) from horn assembly (Figure 2, Item 2). 3. Remove bolt (Figure 2, Item 3) and washer (Figure 2, Item 4) from horn assembly (Figure 2, Item 2) and remove horn assembly from machine.

Figure 2. Horn Assembly.

0182

0182-2

TM 5-2410-241-23-2

0182

REMOVAL CONTINUED 4. Remove nut (Figure 3, Item 1), washer (Figure 3, Item 2), and bracket (Figure 3, Item 4) from horn (Figure 3, Item 3).

Figure 3. Horn and Bracket. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0182

000182

0182-3

TM 5-2410-241-23-2

0182

INSTALLATION

000182

NOTE
Steps 1 - 3 will install one horn. Follow same steps for additional horn. 1. Install bracket (Figure 4, Item 4), washer (Figure 4, Item 2), and nut (Figure 4, Item 1) on horn (Figure 4, Item 3).

Figure 4. Horn and Bracket.

0182

0182-4

TM 5-2410-241-23-2

0182

INSTALLATION CONTINUED 2. Position horn assembly (Figure 5, Item 2) on machine and install washer (Figure 5, Item 4) and bolt (Figure 5, Item 3).

NOTE
Install electrical connectors as tagged during removal. 3. Connect electrical connector (Figure 5, Item 1) to horn assembly.

Figure 5. Horn Assembly.

0182

0182-5

TM 5-2410-241-23-2

0182

INSTALLATION CONTINUED 4. Close left hand door (Figure 6, Item 3) and install four washers (Figure 6, Item 2) and bolts (Figure 6, Item 1).

Figure 6. Left Hand Door. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0182

000182

0182-6

4 TM 5-2410-241-23-2 0183

FIELD MAINTENANCE INSTRUCTIONS BACKUP ALARM REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 8 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 96
0

Estimated Time to Complete 0.5 Hr REMOVAL

000183

1. Remove three bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and cover (Figure 1, Item 3) from machine.

Figure 1. Cover.

0183

0183-1

TM 5-2410-241-23-2

0183

REMOVAL CONTINUED 2. Cut and discard tiedown strap (Figure 2, Item 3) from electrical connector (Figure 2, Item 2).

NOTE
Tag connector to aid installation. 3. Disconnect electrical connector (Figure 2, Item 2) from backup alarm (Figure 2, Item 5). 4. Remove two nuts (Figure 2, Item 7), washers (Figure 2, Item 8), bolts (Figure 2, Item 1), washers (Figure 2, Item 6), bracket (Figure 2, Item 4), and backup alarm (Figure 2, Item 5) from machine.

Figure 2. Backup Alarm. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0183

000183

000183

1. Position backup alarm (Figure 2, Item 5) on machine and install bracket (Figure 2, Item 4), two washers (Figure 2, Item 6), bolts (Figure 2, Item 1), washers (Figure 2, Item 8), and nuts (Figure 2, Item 7) on machine.

NOTE
Install connector as tagged during removal. 2. Connect electrical connector (Figure 2, Item 2) to backup alarm (Figure 2, Item 5). 3. Install new tiedown strap (Figure 2, Item 3) on electrical connector (Figure 2, Item 2).

0183-2

TM 5-2410-241-23-2

0183

INSTALLATION CONTINUED 4. Position cover (Figure 3, Item 3) and install three washers (Figure 3, Item 2) and bolts (Figure 3, Item 1) on machine.

Figure 3. Cover. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0183

000183

0183-3/(4 blank)

4 TM 5-2410-241-23-2 0184

FIELD MAINTENANCE INSTRUCTIONS

0 1 8 4

HYDRAULIC OIL SERVICE Hydraulic System Oil Change

INITIAL SETUP Tools and Special Tools

0

Materials/Parts-Continued Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) Container (25 gallon capacity) Hose 1 ID x 6 Length References

Tool Kit, General Mechanics (WP 0302, Item 65) Swivel, Hydraulic Tank Drain (WP 0302, Item 60) Wrench, Torque, Click, Ratcheting, 1/2 Drive, 250 lb-ft (WP 0302, Item 71)
0 0 0

Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) HYDRAULIC SYSTEM OIL CHANGE

LO 5-2410-241-13 TM 5-2410-241-10 Estimated Time to Complete

1.5 Hr

000184

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns, when draining oil. Failure to follow this warning may cause injury. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Failure to follow this warning may cause injury to personnel. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap slowly only when the engine is stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Failure to follow these warnings may cause injury or death to personnel.

NOTE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

0184-1

TM 5-2410-241-23-2

0184

HYDRAULIC SYSTEM OIL CHANGE CONTINUED 1. Operate machine 30 minutes in order to warm oil. 2. Park machine on level ground. Lower bulldozer blade to ground and apply slight downward pressure. Engage parking brake and stop engine. 3. Remove hydraulic tank filler cap (Figure 1, Item 1) slowly to relieve pressure. 4. Remove retainer ring (Figure 1, Item 4) from oil filler tube (Figure 1, Item 3). 5. Remove strainer (Figure 1, Item 5) from oil filler tube (Figure 1, Item 3). Wash strainer in a clean nonflammable solvent. 6. Inspect the seal (Figure 1, Item 2) on filler cap (Figure 1, Item 1). Replace seal if damaged.

Figure 1. Hydraulic System Oil Fill.

0184

0184-2

TM 5-2410-241-23-2

0184

HYDRAULIC SYSTEM OIL CHANGE CONTINUED 7. Remove bolt (Figure 2, Item 1), washer (Figure 2, Item 2) and plate (Figure 2, Item 3) from hull (Figure 2, Item 4). 8. Remove drain plug (Figure 2, Item 5) and attach hose to a 126-7914 swivel. Install swivel and hose into drain plug opening. A pipe nipple 4 inch (10 cm) and a hose can also be used. Use a 1 inch (25.4 mm) pipe with 1/2 inch NPTF threads. Do not tighten pipe. 9. Rotate swivel clockwise to open internal drain valve. Allow oil to drain into suitable container. 10. Remove swivel from drain plug opening. Internal drain valve will close. 11. Clean drain plug and install drain plug (Figure 2, Item 5). Tighten drain plug to a torque of 50 5 lb-ft (68 7 Nm). 12. Install plate (Figure 2, Item 3), washer (Figure 2, Item 2) and bolt (Figure 2, Item 1) on hull (Figure 2, Item 4).

Figure 2. Hydraulic System Oil Drain. 13. Install filler strainer (Figure 1, Item 5) in oil filler tube (Figure 1, Item 3).

0184

14. Refer to LO 5-2410-241-13 to determine correct amount and type of hydraulic oil to fill hydraulic oil tank. Fill hydraulic oil tank. Maintain oil level to FULL mark in sight gauge. Check with attachments on ground and with cold oil. 15. Start engine. Run engine (TM 5-2410-241-10). 16. Maintain oil level to FULL mark in sight gauge. 17. Install hydraulic tank filler cap (Figure 1, Item 1). 18. Stop engine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0184-3/(4 blank)

6 TM 5-2410-241-23-2 0185

FIELD MAINTENANCE INSTRUCTIONS

0 1 8 5

HYDRAULIC OIL FILTER REPLACEMENT Hydraulic Oil Filter Change

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Pliers Set, Retaining Ring KTC (S0259) (WP 0302, Item 68) Materials/Parts Oil, Lubricating OEA, Arctic (WP 0303, Item 17) Oil, Lubricating OE/HDO-10 (WP 0303, Item 18) Oil, Lubricating OE/HDO-30 (WP 0303, Item 19) Rag, Wiping (WP 0303, Item 24) Filter
0

Materials/Parts - Continued Gasket O-ring Personnel Required

Two
0

References
0

LO 5-2410-241-13 Equipment Condition

Machine parked (TM 5-2410-241-10)

0

Drawing Required TM 5-2410-241-24P, Figure 77 Estimated Time to Complete 1.5 Hr

0185-1

TM 5-2410-241-23-2

0185

HYDRAULIC SYSTEM OIL FILTER CHANGE

000185

WARNING

Oil should be warm to ensure it drains completely. Use caution to protect against burns, when draining oil. Contact with oil can damage skin. Wear gloves when handling oil. If oil contacts skin, wash it off immediately. Lubricating oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may cause injury. At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap slowly only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Failure to follow these warnings may cause injury or death to personnel.

NOTE
This procedure will replace one hydraulic system oil filter. Follow same procedure for other hydraulic system oil filter. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

0185-2

TM 5-2410-241-23-2

0185

HYDRAULIC SYSTEM OIL FILTER CHANGE CONTINUED 1. Lower the implements to the ground. 2. The hydraulic tank is on the right side of machine. Slowly remove hydraulic tank filler cap (Figure 1, Item 4) to relieve system pressure. 3. Remove bolt (Figure 1, Item 1), cap (Figure 1, Item 2), and filter assembly (Figure 1, Item 5) from hydraulic tank (Figure 1, Item 3).

Figure 1. Hydraulic System Oil Filter.

0185

0185-3

TM 5-2410-241-23-2

0185

HYDRAULIC SYSTEM OIL FILTER CHANGE CONTINUED 4. Remove nut (Figure 2, Item 3) from bolt (Figure 2, Item 1). 5. Remove bolt (Figure 2, Item 1), cover (Figure 2, Item 12) and filter (Figure 2, Item 10) from screen (Figure 2, Item 5). Discard filter. 6. Remove O-ring (Figure 2, Item 2) from bolt (Figure 2, Item 1). Discard O-ring. 7. Remove gasket (Figure 2, Item 11) from cover (Figure 2, Item 12). Inspect gasket for damage, replace if damaged.

WARNING

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Fire extinguishers should be placed nearby when using solvent cleaning compound. Cloths or rags saturated with solvent cleaning compound must be disposed of IAW authorized facilities procedure. Eye shields must be worn when cleaning with a wire brush. Flying rust and metal particles may cause injury. Particles blown by compressed air are hazardous. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. Spacer is under spring tension. Secure spacer and spring before removing retainer ring. Failure to follow these warnings may result in injury to personnel.

8. With assistance, remove retaining ring (Figure 2, Item 9) from tube assembly (Figure 2, Item 4). 9. Remove spacer (Figure 2, Item 8), spring (Figure 2, Item 7), and screen (Figure 2, Item 5) from valve (Figure 2, Item 6). 10. Remove valve (Figure 2, Item 6) from tube assembly (Figure 2, Item 4). 11. Wash the screen (Figure 2, Item 5) in a clean nonflammable solvent. 12. Install valve (Figure 2, Item 6) on tube assembly (Figure 2, Item 4). 13. Install screen (Figure 2, Item 5), spring (Figure 2, Item 7), and spacer (Figure 2, Item 8) on valve (Figure 2, Item 4). 14. With assistance, install retainer ring (Figure 2, Item 9) on tube assembly (Figure 2, Item 4). 15. Install new gasket (Figure 2, Item 11) on cover (Figure 2, Item 12). 16. Install new O-ring (Figure 2, Item 2) on bolt (Figure 2, Item 1).

0185-4

TM 5-2410-241-23-2

0185

HYDRAULIC SYSTEM OIL FILTER CHANGE CONTINUED 17. Install new filter (Figure 2, Item 10), cover (Figure 2, Item 12), and bolt (Figure 2, Item 1) on screen (Figure 2, Item 5). 18. Install nut (Figure 2, Item 3) on bolt (Figure 2, Item 1).

Figure 2. Hydraulic Filter Components.

0185

0185-5

TM 5-2410-241-23-2

0185

HYDRAULIC SYSTEM OIL FILTER CHANGE CONTINUED 19. Install filter assembly (Figure 3, Item 5), cap (Figure 3, Item 2), and bolt (Figure 3, Item 1), on hydraulic tank (Figure 3, Item 3). Tighten bolt. 20. Refer to LO 5-2410-241-13 for correct amount and type of hydraulic oil to add to hydraulic tank. Maintain the hydraulic oil to FULL mark in sight gauge. 21. Install hydraulic tank filler cap (Figure 3, Item 4) on hydraulic tank (Figure 3, Item 3).

Figure 3. Hydraulic System Oil Filter. END OF TASK END OF WORK PACKAGE

0185

0185-6

2 TM 5-2410-241-23-2 0186

FIELD MAINTENANCE
0 1 8 6

HYDRAULIC SYSTEM PRESSURE RELEASE

INITIAL SETUP Equipment Condition Machine parked (TM 5-2410-241-10) HYDRAULIC SYSTEM PRESSURE RELEASE 1. Turn engine start switch (Figure 1, Item 2) to ON position, but do not start engine. 2. Verify hydraulic lockout switch (Figure 1, Item 4) is not activated (TM 5-2410-241-10). 3. Relieve hydraulic system pressure by moving steering control lever (Figure 1, Item 1), bulldozer control lever (Figure 1, Item 3), and ripper/winch control lever through full range of travel several times. 4. Turn engine start switch (Figure 1, Item 2) to OFF position.
0

Estimated Time to Complete 0.1 Hr

000186

Figure 1. Cab Controls.

0186

0186-1

TM 5-2410-241-23-2

0186

HYDRAULIC SYSTEM PRESSURE RELEASE CONTINUED

WARNING

At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Lubricating/hydraulic oils used in performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow these warnings may result in injury or death to personnel.

5. Loosen fill cap (Figure 2, Item 1) to relieve pressure from hydraulic tank (Figure 2, Item 2). 6. If hydraulic fluid is to be drained, remove cap. If fluid drain is not required, tighten fill cap (Figure 2, Item 1) 7. Reinstall fill cap after fluid drain is complete.

Figure 2. Hydraulic System Fill Cap. END OF TASK END OF WORK PACKAGE

0186

0186-2

38 TM 5-2410-241-23-2 0187

FIELD MAINTENANCE HYDRAULIC TANK REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 1 8 7

INITIAL SETUP Tools and Special Tools

0

Personnel Required Two References WP 0295 Equipment Condition

Tool Kit, General Mechanics (WP 0302, Item 65) Bar, Extension, 1/2 Drive, 10" Long KTC (S0955) (WP 0302, Item 68) Crowfoot Attachment, Socket Wrench, 1-3/8 (1/2 drive) (WP 0302, Item 19) Extension, 1/2 Drive, 10" Long KTC (S0567) (WP 0302, Item 68) Extension, 1/2 Drive, 6" Long KTC (S0566) (WP 0302, Item 68) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Lifting Device (1,000 lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Gasket (4) Locknut (6) O-ring (35) Seal

Machine parked (TM 5-2410-241-10) Chassis harness removed (WP 0172) Control manifold removed (WP 0216) Transmission system oil filter base removed (WP 0153) Drawing Required TM 5-2410-241-24P, Figure 77, 85, 96 Estimated Time to Complete 4.5 Hr

0187-1

TM 5-2410-241-23-2

0187

REMOVAL 1. Remove two bolts (Figure 1, Item 2) and washers (Figure 1, Item 3) from enclosure (Figure 1, Item 10) and hydraulic tank (Figure 1, Item 1).

000187

2. Remove two bolts (Figure 1, Item 11) and washers (Figure 1, Item 12) from enclosure (Figure 1, Item 10) and fender (Figure 1, Item 9). 3. Remove bolt (Figure 1, Item 4), washer (Figure 1, Item 5), and chain (Figure 1, Item 6) from enclosure (Figure 1, Item 10). Position chain aside. 4. Remove bolt (Figure 1, Item 7), washer (Figure 1, Item 8), and enclosure (Figure 1, Item 10), from machine.

Figure 1. Enclosure.

0187

0187-2

TM 5-2410-241-23-2

0187

REMOVAL CONTINUED 5. Remove two bolts (Figure 2, Item 3), washers (Figure 2, Item 4), clip (Figure 2, Item 2), and plate (Figure 2, Item 1) from hydraulic tank (Figure 2, Item 5).

Figure 2. Plate.

0187

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

0187-3

TM 5-2410-241-23-2

0187

REMOVAL CONTINUED

NOTE
Note hose routing to aid installation. Tag and mark all hose connections to aid installation.

6. Loosen tube nut (Figure 3, Item 5) and remove hose (Figure 3, Item 1) from fitting (Figure 3, Item 2). 7. Loosen tube nut (Figure 3, Item 11) and remove hose (Figure 3, Item 3) from fitting (Figure 3, Item 2). Position hose aside. 8. Loosen tube nut (Figure 3, Item 9) and remove hose (Figure 3, Item 8) from fitting (Figure 3, Item 2). Position hose aside. 9. Remove nut (Figure 3, Item 6), washer (Figure 3, Item 7), and fitting (Figure 3, Item 2) from hydraulic tank (Figure 3, Item 16). 10. Remove three O-rings (Figure 3, Item 10) and washer (Figure 3, Item 12) from fitting (Figure 3, Item 2). Discard O-rings. 11. Remove four bolts (Figure 3, Item 13), washers (Figure 3, Item 14), elbow (Figure 3, Item 15), and gasket (Figure 3, Item 4) from hydraulic tank (Figure 3, Item 16). Discard gasket. Position elbow aside.

Figure 3. Elbow.

0187

0187-4

TM 5-2410-241-23-2

0187

REMOVAL CONTINUED

NOTE
Note hose routing to aid installation. Tag and mark all hoses to aid installation.

12. Loosen tube nut (Figure 4, Item 5) and remove hose (Figure 4, Item 4) from fitting (Figure 4, Item 6). 13. Loosen tube nut (Figure 4, Item 7) and remove hose (Figure 4, Item 8) from hydraulic tank (Figure 4, Item 9). Position hose aside. 14. Loosen two tube nuts (Figure 4, Item 2) and remove two hoses (Figure 4, Item 3) from fitting (Figure 4, Item 1). Position hoses aside.

Figure 4. Hydraulic Lines.

0187

0187-5

TM 5-2410-241-23-2

0187

REMOVAL CONTINUED

NOTE
Note hose routing to aid installation. Tag and mark all hose connections to aid installation.

15. Remove eight bolts (Figure 5, Item 5), washers (Figure 5, Item 4), two flanges (Figure 5, Item 3), and two hoses (Figure 5, Items 1 and 6) from hydraulic tank (Figure 5, Item 7). 16. Remove two O-rings (Figure 5, Item 2) from two hoses (Figure 5, Items 1 and 6). Discard O-rings.

Figure 5. Flange.

0187

17. Loosen tube nut (Figure 6, Item 1) and remove hose (Figure 6, Item 2) from elbow (Figure 6, Item 3). Position hose aside.

Figure 6. Hydraulic Line.

0187

0187-6

TM 5-2410-241-23-2

0187

REMOVAL CONTINUED

WARNING

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

NOTE
Hydraulic tank weighs approximately 341 lb (155 kg). 18. Attach lifting device on hydraulic tank (Figure 7, Item 1). 19. With assistance and using lifting device, remove three bolts (Figure 7, Item 2), washers (Figure 7, Item 3), and hydraulic tank (Figure 7, Item 1) from machine. 20. Remove lifting device from hydraulic tank (Figure 7, Item 1).

Figure 7. Hydraulic Tank. END OF TASK

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TM 5-2410-241-23-2

0187

DISASSEMBLY 1. Loosen two bolts (Figure 8, Item 1) and remove two filter assemblies (Figure 8, Item 2) from hydraulic tank (Figure 8, Item 3).

000187

Figure 8. Hydraulic Tank Filters. 2. Lift lever (Figure 9, Item 2) and remove cap (Figure 9, Item 1) from hydraulic tank (Figure 9, Item 8). 3. Remove spring clip (Figure 9, Item 7) from cap (Figure 9, Item 1). 4. Remove seal (Figure 9, Item 6), spacer (Figure 9, Item 5), ball (Figure 9, Item 4), and inner cap (Figure 9, Item 3) from cap (Figure 9, Item 1). Discard seal.

0187

Figure 9. Hydraulic Tank Cap.

0187

0187-8

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED 5. Remove breather cap (Figure 10, Item 1) from hydraulic tank (Figure 10, Item 3). 6. Remove O-ring (Figure 10, Item 2) from breather cap (Figure 10, Item 1). Discard O-ring.

Figure 10. Hydraulic Tank Breather. 7. Remove spring clip (Figure 11, Item 1) and filler screen (Figure 11, Item 2) from hydraulic tank (Figure 11, Item 3).

0187

Figure 11. Hydraulic Tank Filler Screen.

0187

0187-9

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED 8. Remove 20 bolts (Figure 12, Item 4), washers (Figure 12, Item 5), and cover plate (Figure 12, Item 2) from hydraulic tank (Figure 12, Item 1). 9. Remove gasket (Figure 12, Item 3) from cover plate (Figure 12, Item 2). Discard gasket.

Figure 12. Hydraulic Tank Rear Cover Plate.

0187

0187-10

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED 10. Loosen nut (Figure 13, Item 2) on elbow (Figure 13, Item 1).

WARNING

Valve block and spacers are under spring pressure. Note position and orientation of parts as they are removed. 11. Remove two bolts (Figure 13, Item 10), valve block (Figure 13, Item 3), spacer (Figure 13, Item 5), spacer (Figure 13, Item 6), spring (Figure 13, Item 7), and washer (Figure 13, Item 8) from hydraulic tank (Figure 13, Item 11). 12. Remove O-ring (Figure 13, Item 4) from valve block (Figure 13, Item 3). Discard O-ring. 13. Remove elbow (Figure 13, Item 1) from valve block (Figure 13, Item 3). 14. Remove two O-rings (Figure 13, Item 9) from elbow (Figure 13, Item 1). Discard O-rings.

Figure 13. Hydraulic Tank Valve Block.

0187

0187-11

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED 15. Remove tiedown strap (Figure 14, Item 2) from harness (Figure 14, Item 3). Discard tiedown strap. 16. Position harness (Figure 14, Item 3) aside. 17. Remove temperature sensor (Figure 14, Item 6) from fitting (Figure 14, Item 1). 18. Remove O-ring (Figure 14, Item 5) from temperature sensor (Figure 14, Item 6). Discard O-ring. 19. Remove fitting (Figure 14, Item 1) from hydraulic tank (Figure 14, Item 7). 20. Remove O-ring (Figure 14, Item 4) from fitting (Figure 14, Item 1). Discard O-ring. 21. Remove T fitting (Figure 14, Item 8) from hydraulic tank (Figure 14, Item 7). 22. Remove three O-rings (Figure 14, Item 9) from T fitting (Figure 14, Item 8). Discard O-rings. 23. Remove fitting (Figure 14, Item 10) from hydraulic tank (Figure 14, Item 7). 24. Remove two O-rings (Figure 14, Item 11) from fitting (Figure 14, Item 10). Discard O-rings.

Figure 14. Hydraulic Tank Temperature Sensor.

0187

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TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED 25. Remove nut (Figure 15, Item 8), washer (Figure 15, Item 9), and T fitting (Figure 15, Item 1) from hydraulic tank (Figure 15, Item 2). 26. Remove cover and strap (Figure 15, Item 3) from test fitting (Figure 15, Item 7). 27. Loosen tube nut (Figure 15, Item 4) and remove test fitting (Figure 15, Item 7) from T fitting (Figure 15, Item 1). 28. Remove washer (Figure 15, Item 5) and three O-rings (Figure 15, Item 6) from T fitting (Figure 15, Item 1). Discard O-rings.

Figure 15. Hydraulic Tank T Fitting.

0187

0187-13

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED 29. Remove fitting (Figure 16, Item 5) from hydraulic tank (Figure 16, Item 1). 30. Remove two O-rings (Figure 16, Item 6) from fitting (Figure 16, Item 5). Discard O-rings.

NOTE
Note position of harness clips to aid assembly. 31. Remove 20 bolts (Figure 16, Item 8), washers (Figure 16, Item 7), three harness clips (Figure 16, Item 4), and cover plate (Figure 16, Item 2) from hydraulic tank (Figure 16, Item 1). 32. Remove gasket (Figure 16, Item 3) from cover plate (Figure 16, Item 2). Discard gasket.

Figure 16. Hydraulic Tank Front Cover Plate.

0187

0187-14

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED

NOTE
Note orientation of level gauge to aid installation. 33. Remove four locknuts (Figure 17, Item 3), washers (Figure 17, Item 4), and level gauge (Figure 17, Item 2) from hydraulic tank (Figure 17, Item 1). Discard locknuts.

Figure 17. Hydraulic Tank Level Gauge.

0187

NOTE
Note orientation of level gauge components to aid installation. 34. Remove gasket (Figure 18, Item 1) and plate (Figure 18, Item 3) from level gauge housing (Figure 18, Item 4). 35. Remove sight glass (Figure 18, Item 2) from gasket (Figure 18, Item 1). Discard gasket.

Figure 18. Level Gauge.

0187

0187-15

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED 36. Remove drain plug (Figure 19, Item 5) from safety valve housing (Figure 19, Item 1). 37. Remove O-ring (Figure 19, Item 6) from drain plug (Figure 19, Item 5). Discard O-ring. 38. Remove two locknuts (Figure 19, Item 3), washers (Figure 19, Item 2), and safety valve housing (Figure 19, Item 1) from hydraulic tank (Figure 19, Item 10). Discard locknuts. 39. Remove bracket (Figure 19, Item 9), spring (Figure 19, Item 8), and valve (Figure 19, Item 7) from safety valve housing (Figure 19, Item 1). 40. Remove gasket (Figure 19, Item 4) from safety valve housing (Figure 19, Item 1). Discard gasket.

Figure 19. Hydraulic Tank Safety Drain Valve.

0187

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0187

DISASSEMBLY CONTINUED 41. Remove two bolts (Figure 20, Item 3), washers (Figure 20, Item 4), and pick-up tube (Figure 20, Item 2) from hydraulic tank (Figure 20, Item 1) 42. Remove O-ring (Figure 20, Item 5) from pick-up tube (Figure 20, Item 2). Discard O-ring.

Figure 20. Hydraulic Tank Pick-up Tube.

0187

0187-17

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED

NOTE
Steps 43 and 44 will remove one internal pipe assembly from hydraulic tank. Follow same steps for an additional internal pipe assembly. Note orientation and position of internal pipe and block to aid assembly.

43. Remove two bolts (Figure 21, Item 6) and washers (Figure 21, Item 7) from hydraulic tank (Figure 21, Item 4). 44. Remove two bolts (Figure 21, Item 2), washers (Figure 21, Item 3), pipe assembly (Figure 21, Item 1), and block (Figure 21, Item 5) from hydraulic tank (Figure 21, Item 4).

Figure 21. Hydraulic Tank Internal Pipes.

0187

0187-18

TM 5-2410-241-23-2

0187

DISASSEMBLY CONTINUED

NOTE
Steps 45 - 48 will disassemble one internal pipe assembly. Follow same steps for additional internal pipe assembly. Note orientation and position of internal pipe, filter support, and O-rings to aid assembly.

45. Remove two O-rings (Figure 22, Item 4) from block (Figure 22, Item 5). Discard O-rings. 46. Remove two O-rings (Figure 22, Item 6) from filter support (Figure 22, Item 1). Discard O-rings. 47. Remove pipe (Figure 22, Item 3) from filter support (Figure 22, Item 1). 48. Remove two O-rings (Figure 22, Item 2) from pipe (Figure 22, Item 3). Discard O-rings
.

Figure 22. Hydraulic Tank Internal Pipes. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0187

000187

0187-19

TM 5-2410-241-23-2

0187

ASSEMBLY

000187

NOTE
Steps 1 - 4 will assemble one internal pipe assembly. Follow same steps for an additional internal pipe assembly. Install internal pipe, filter support, and O-rings as noted during disassembly.

1. Install two new O-rings (Figure 23, Item 2) on pipe (Figure 23, Item 3). 2. Install pipe (Figure 23, Item 3) on filter support (Figure 23, Item 1). 3. Install two new O-rings (Figure 23, Item 6) on filter support (Figure 23, Item 1). 4. Install two new O-rings (Figure 23, Item 4) on block (Figure 23, Item 5).
.

Figure 23. Hydraulic Tank Internal Pipes.

0187

0187-20

TM 5-2410-241-23-2

0187

ASSEMBLY CONTINUED

NOTE
Steps 5 - 7 will install one internal pipe assembly on hydraulic tank. Follow same steps for an additional internal pipe assembly. Note orientation and position of internal pipe and block to aid assembly.

5. Install block (Figure 24, Item 5), pipe assembly (Figure 24, Item 1), two washers (Figure 24, Item 3), and bolts (Figure 24, Item 2) on hydraulic tank (Figure 24, Item 4). Do not tighten bolts. 6. Install two washers (Figure 24, Item 7) and bolts (Figure 24, Item 6) on hydraulic tank (Figure 24, Item 4). 7. Tighten bolts (Figure 24, Item 2) on hydraulic tank (Figure 24, Item 4).

Figure 24. Hydraulic Tank Internal Pipes.

0187

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0187

ASSEMBLY CONTINUED 8. Install new O-ring (Figure 25, Item 5) on pick-up tube (Figure 25, Item 2). 9. Install pick-up tube (Figure 25, Item 2), two washers (Figure 25, Item 4), and bolts (Figure 25, Item 3) on hydraulic tank (Figure 25, Item 1).

Figure 25. Hydraulic Tank Pick-up Tube.

0187

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0187

ASSEMBLY CONTINUED 10. Install new gasket (Figure 26, Item 4) on safety valve housing (Figure 26, Item 1). 11. Install valve (Figure 26, Item 7), spring (Figure 26, Item 8), and bracket (Figure 26, Item 9) on safety valve housing (Figure 26, Item 1). 12. Install safety valve housing (Figure 26, Item 1), two washers (Figure 26, Item 2), and new locknuts (Figure 26, Item 3) on hydraulic tank (Figure 26, Item 10). 13. Install new O-ring (Figure 26, Item 6) on drain plug (Figure 26, Item 5). 14. Install drain plug (Figure 26, Item 5) on safety valve housing (Figure 26, Item 1).

Figure 26. Hydraulic Tank Safety Drain Valve.

0187

0187-23

TM 5-2410-241-23-2

0187

ASSEMBLY CONTINUED

NOTE
Install level gauge components as noted during disassembly. 15. Install sight glass (Figure 27, Item 2) on new gasket (Figure 27, Item 1). 16. Install plate (Figure 27, Item 3) and gasket (Figure 27, Item 1) on level gauge housing (Figure 27, Item 4).

Figure 27. Level Gauge.

0187

NOTE
Install level gauge as noted during disassembly. 17. Install level gauge (Figure 28, Item 2), four washers (Figure 28, Item 4), and new locknuts (Figure 28, Item 3) on hydraulic tank (Figure 28, Item 1).

Figure 28. Hydraulic Tank Level Gauge.

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0187-24

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0187

ASSEMBLY CONTINUED 18. Install new gasket (Figure 29, Item 3) on cover plate (Figure 29, Item 2).

NOTE
Install harness clips as noted during disassembly. 19. Install cover plate (Figure 29, Item 2), three harness clips (Figure 29, Item 4), 20 washers (Figure 29, Item 7), and bolts (Figure 29, Item 8) on hydraulic tank (Figure 29, Item 1). 20. Install two new O-rings (Figure 29, Item 6) on fitting (Figure 29, Item 5). 21. Install fitting (Figure 29, Item 5) on hydraulic tank (Figure 29, Item 1).

Figure 29. Hydraulic Tank Front Cover Plate.

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0187

ASSEMBLY CONTINUED 22. Install three new O-rings (Figure 30, Item 6) and washer (Figure 30, Item 5) on T fitting (Figure 30, Item 1). 23. Install test fitting (Figure 30, Item 7) and tighten tube nut (Figure 30, Item 4) on T fitting (Figure 30, Item 1). 24. Install cover and strap (Figure 30, Item 3) on test fitting (Figure 30, Item 7). 25. Install T fitting (Figure 30, Item 1), washer (Figure 30, Item 9), and nut (Figure 30, Item 8) on hydraulic tank (Figure 30, Item 2).

Figure 30. Hydraulic Tank T Fitting.

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TM 5-2410-241-23-2

0187

ASSEMBLY CONTINUED 26. Install two new O-rings (Figure 31, Item 11) on fitting (Figure 31, Item 10). 27. Install fitting (Figure 31, Item 10) on hydraulic tank (Figure 31, Item 7). 28. Install three new O-rings (Figure 31, Item 9) on T fitting (Figure 31, Item 8). 29. Install T fitting (Figure 31, Item 8) on hydraulic tank (Figure 31, Item 7). 30. Install new O-ring (Figure 31, Item 4) on fitting (Figure 31, Item 1). 31. Install fitting (Figure 31, Item 1) on hydraulic tank (Figure 31, Item 7). 32. Install new O-ring (Figure 31, Item 5) on temperature sensor (Figure 31, Item 6). 33. Install temperature sensor (Figure 31, Item 6) on fitting (Figure 31, Item 1). 34. Install new tiedown strap (Figure 31, Item 2) on harness (Figure 31, Item 3).

Figure 31. Hydraulic Tank Temperature Sensor.

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TM 5-2410-241-23-2

0187

ASSEMBLY CONTINUED 35. Install two new O-rings (Figure 32, Item 9) on elbow (Figure 32, Item 1). 36. Install elbow (Figure 32, Item 1) on valve block (Figure 32, Item 3). 37. Install new O-ring (Figure 32, Item 4) on valve block (Figure 32, Item 3).

NOTE
Install spacers and valve block as noted during disassembly. 38. Install washer (Figure 32, Item 8), spring (Figure 32, Item 7), spacer (Figure 32, Item 6), spacer (Figure 32, Item 5), valve block (Figure 32, Item 3), and two bolts (Figure 32, Item 10) on hydraulic tank (Figure 32, Item 11). 39. Position elbow (Figure 32, Item 1) and tighten nut (Figure 32, Item 2) on elbow (Figure 32, Item 1).

Figure 32. Hydraulic Tank Valve Block.

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0187

ASSEMBLY CONTINUED 40. Install new gasket (Figure 33, Item 3) on cover plate (Figure 33, Item 2). 41. Install cover plate (Figure 33, Item 2), 20 washers (Figure 33, Item 5), and bolts (Figure 33, Item 4) on hydraulic tank (Figure 33, Item 1).

Figure 33. Hydraulic Tank Rear Cover Plate.

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0187

ASSEMBLY CONTINUED 42. Install filler screen (Figure 34, Item 2) and spring clip (Figure 34, Item 1) on hydraulic tank (Figure 34, Item 3).

Figure 34. Hydraulic Tank Filler Screen. 43. Install new O-ring (Figure 35, Item 2) on breather cap (Figure 35, Item 1). 44. Install breather cap (Figure 35, Item 1) on hydraulic tank (Figure 35, Item 3).

0187

Figure 35. Hydraulic Tank Breather.

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TM 5-2410-241-23-2

0187

ASSEMBLY CONTINUED 45. Install inner cap (Figure 36, Item 3), ball (Figure 36, Item 4), spacer (Figure 36, Item 5), and new seal (Figure 36, Item 6) on cap (Figure 36, Item 1). 46. Install spring clip (Figure 36, Item 7) on cap (Figure 36, Item 1). 47. Install cap (Figure 36, Item 1) on hydraulic tank (Figure 36, Item 8) and lower lever (Figure 36, Item 2).

Figure 36. Hydraulic Tank Cap. 48. Install two filter assemblies (Figure 37, Item 2) and tighten two bolts (Figure 37, Item 1) on hydraulic tank (Figure 37, Item 3).

0187

Figure 37. Hydraulic Tank Filters. END OF TASK

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TM 5-2410-241-23-2

0187

INSTALLATION

000187

WARNING

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

NOTE
Hydraulic tank weighs approximately 341 lb (155 kg). 1. Attach lifting device on hydraulic tank (Figure 38, Item 1). 2. Using lifting device install hydraulic tank (Figure 38, Item 1), three washers (Figure 38, Item 3), and bolts (Figure 38, Item 2) on machine. 3. Remove lifting device from hydraulic tank (Figure 38, Item 1).

Figure 38. Hydraulic Tank. 4. Install hose (Figure 39, Item 2) and tighten tube nut (Figure 39, Item 1) on elbow (Figure 39, Item 3).

0187

Figure 39. Hydraulic Line.

0187

0187-32

TM 5-2410-241-23-2

0187

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 5. Install two new O-rings (Figure 40, Item 2) on two hoses (Figure 40, Items 6 and 1). 6. Install two hoses (Figure 40, Items 1 and 6), two flanges (Figure 40, Item 3), eight washers (Figure 40, Item 4), and bolts (Figure 40, Item 5) on hydraulic tank (Figure 40, Item 7).

Figure 40. Flange.

0187

0187-33

TM 5-2410-241-23-2

0187

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 7. Install two hoses (Figure 41, Item 3) and tighten tube nuts (Figure 41, Item 2) on fitting (Figure 41, Item 1). 8. Install hose (Figure 41, Item 8) and tighten tube nut (Figure 41, Item 7) on hydraulic tank (Figure 41, Item 9). 9. Install hose (Figure 41, Item 4) and tighten tube nut (Figure 41, Item 5) on fitting (Figure 41, Item 6).

Figure 41. Hydraulic Lines.

0187

0187-34

TM 5-2410-241-23-2

0187

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 10. Install new gasket (Figure 42, Item 4), elbow (Figure 42, Item 15), four washers (Figure 42, Item 14), and bolts (Figure 42, Item 13) on hydraulic tank (Figure 42, Item 16). 11. Install washer (Figure 42, Item 12) and three new O-rings (Figure 42, Item 10) on fitting (Figure 42, Item 2). 12. Install fitting (Figure 42, Item 2), washer (Figure 42, Item 7), and nut (Figure 42, Item 6) on hydraulic tank (Figure 42, Item 16). 13. Install hose (Figure 42, Item 8) and tighten tube nut (Figure 42, Item 9) on fitting (Figure 42, Item 2). 14. Install hose (Figure 42, Item 3) and tighten tube nut (Figure 42, Item 11) on fitting (Figure 42, Item 2). 15. Install hose (Figure 42, Item 1) and tighten tube nut (Figure 42, Item 5) on fitting (Figure 42, Item 2).

Figure 42. Elbow.

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TM 5-2410-241-23-2

0187

INSTALLATION CONTINUED 16. Install plate (Figure 43, Item 1), clip (Figure 43, Item 2), two washers (Figure 43, Item 4), and bolts (Figure 43, Item 3) on hydraulic tank (Figure 43, Item 5).

Figure 43. Plate.

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TM 5-2410-241-23-2

0187

INSTALLATION CONTINUED 17. Install enclosure (Figure 44, Item 10), washer (Figure 44, Item 8), and bolt (Figure 44, Item 7) on machine. 18. Install chain (Figure 44, Item 6), washer (Figure 44, Item 5), and bolt (Figure 44, Item 4) on enclosure (Figure 44, Item 10). 19. Install two washers (Figure 44, Item 12) and bolts (Figure 44, Item 11) on enclosure (Figure 44, Item 10) and fender (Figure 44, Item 9). 20. Install two washers (Figure 44, Item 3) and bolts (Figure 44, Item 2) on enclosure (Figure 44, Item 10) and hydraulic tank (Figure 44, Item 1).

Figure 44. Enclosure. END OF TASK FOLLOW-ON TASKS 1. Install transmission system oil filter base (WP 0153). 2. Install control manifold (WP 0216). 3. Install chassis harness (WP 0172). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE 0187-37/(38 blank)

0187

000187

6 TM 5-2410-241-23-2 0188

FIELD MAINTENANCE INSTRUCTIONS

0 1 8 8

HYDRAULIC TANK ENCLOSURE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools

0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 85 Estimated Time to Complete 1.0 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Tool Kit, Blind Fastener Installation (S0700) (WP 0302, Item 68) Drill-driver, Battery Rechargeable 1/2 (S0188) (WP 0302, Item 68) Drill Set, Twist 1/16 to 1/2 (S0194) (WP 0302, Item 68)
0 0 0 0

Materials/Parts Rag, Wiping (WP 0303, Item 24) Rivet (6)

0188-1

TM 5-2410-241-23-2

0188

REMOVAL

000188

1. Remove two bolts (Figure 1, Item 5), washers (Figure 1, Item 6), and bracket (Figure 1, Item 4) from enclosure (Figure 1, Item 3). 2. Remove bolt (Figure 1, Item 1), washer (Figure 1, Item 2), and chain (Figure 1, Item 7) from enclosure (Figure 1, Item 3). Position chain aside.

Figure 1. Enclosure Bracket and Chain.

0188

0188-2

TM 5-2410-241-23-2

0188

REMOVAL CONTINUED 3. Remove two bolts (Figure 2, Item 1), washers (Figure 2, Item 2), and cover (Figure 2, Item 3) from machine. 4. Remove two bolts (Figure 2, Item 6), washers (Figure 2, Item 5), and cover (Figure 2, Item 4) from machine. 5. Remove two bolts (Figure 2, Item 19) and washers (Figure 2, Item 18) from hydraulic tank enclosure (Figure 2, Item 7), and fender (Figure 2, Item 20). 6. Remove two bolts (Figure 2, Item 21) and washers (Figure 2, Item 22) from hydraulic tank enclosure (Figure 2, Item 7), and hydraulic tank (Figure 2, Item 23). 7. Remove hydraulic tank enclosure (Figure 2, Item 7) from hydraulic tank (Figure 2, Item 23) and fender (Figure 2, Item 20). 8. Remove pins (Figure 2, Items 9 and 12), nut plate (Figure 2, Item 11), knob (Figure 2, Item 8), and stud (Figure 2, Item 10) from hydraulic tank enclosure (Figure 2, Item 7). 9. Remove pins (Figure 2, Items 15 and 16), nut plate (Figure 2, Item 17), knob (Figure 2, Item 14), and stud (Figure 2, Item 13) from hydraulic tank enclosure (Figure 2, Item 7).

Figure 2. Enclosure.

0188

0188-3

TM 5-2410-241-23-2

0188

REMOVAL CONTINUED 10. Remove four nuts (Figure 3, Item 5), bolts (Figure 3, Item 7), eight washers (Figure 3, Item 6), and number plate (Figure 3, Item 8) from hydraulic tank enclosure (Figure 3, Item 1). 11. Remove six rivets (Figure 3, Item 3) and lube order information plate (Figure 3, Item 4) from door (Figure 3, Item 2). Discard rivets.

Figure 3. Information Plates. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install lube order information plate (Figure 3, Item 4) and six new rivets (Figure 3, Item 3) on door (Figure 3, Item 2).

0188

000188

000188

2. Install number plate (Figure 3, Item 8), eight washers (Figure 3, Item 6), four bolts (Figure 3, Item 7), and nuts (Figure 3, Item 5) on hydraulic tank enclosure (Figure 3, Item 1).

0188-4

TM 5-2410-241-23-2

0188

INSTALLATION CONTINUED 3. Install stud (Figure 4, Item 13), knob (Figure 4, Item 14), nut plate (Figure 4, Item 17), and two pins (Figure 4, Items 15 and 16) on hydraulic tank enclosure (Figure 4, Item 7). 4. Install stud (Figure 4, Item 10), knob (Figure 4, Item 8), nut plate (Figure 4, Item 11), and two pins (Figure 4, Items 9 and 12), on hydraulic tank enclosure (Figure 4, Item 7). 5. Install hydraulic tank enclosure (Figure 4, Item 7) on hydraulic tank (Figure 4, Item 23) and fender (Figure 4, Item 20). 6. Install two washers (Figure 4, Item 22) and bolts (Figure 4, Item 21), on hydraulic tank enclosure (Figure 4, Item 7), and hydraulic tank (Figure 4, Item 23). 7. Install two washers (Figure 4, Item 18) and bolts (Figure 4, Item 19), on hydraulic tank enclosure (Figure 4, Item 7) and fender (Figure 4, Item 20). 8. Install cover (Figure 4, Item 4), two washers (Figure 4, Item 5), and bolts (Figure 4, Item 6) on machine. 9. Install cover (Figure 4, Item 3), two washers (Figure 4, Item 2), and bolts (Figure 4, Item 1) on machine.

Figure 4. Enclosure.

0188

0188-5

TM 5-2410-241-23-2

0188

INSTALLATION CONTINUED 10. Install chain (Figure 5, Item 7), washer (Figure 5, Item 2), and bolt (Figure 5, Item 1) on enclosure (Figure 5, Item 3). 11. Install bracket (Figure 5, Item 4), two washers (Figure 5, Item 6), and bolts (Figure 5, Item 5) on enclosure (Figure 5, Item 3).

Figure 5. Enclosure Bracket and Chain. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0188

000188

0188-6

16 TM 5-2410-241-23-2 0189

FIELD MAINTENANCE HYDRAULIC OIL COOLER LINES REPLACEMENT Upper Hydraulic Oil Cooler Line Removal, Lower Hydraulic Oil Cooler Line Removal, Cleaning and Inspection, Upper Hydraulic Oil Cooler Line Installation, Lower Hydraulic Oil Cooler Line Installation
0 1 8 9

INITIAL SETUP Tools and Special Tools

0

References WP 0295 Equipment Condition

Tool Kit, General Mechanics (WP 0302, Item 65) Crowfoot Attachment, Socket Wrench, 1-3/8 (1/2 drive) (WP 0302, Item 19) Extension, 1/2 Drive 10 Long (S0567) (WP 0302, Item 68) Qty 3 Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Wrench, Combination 1 3/8 (S0791) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Cleaning Compound, Windshield (WP 0303, Item 5) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (8)

Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Engine enclosure left door guard removed (WP 0202) Front and rear floor plates removed (WP 0230 and WP 0231) Right platform access panels removed (WP 0208) Bottom guards removed (WP 0199)
0 0 0 0 0 0 0

Drawing Required
0

TM 5-2410-241-24P, Figure 82 Estimated Time to Complete 13.1 Hr

0189-1

TM 5-2410-241-23-2

0189

UPPER HYDRAULIC OIL COOLER LINE REMOVAL

000189

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag all hoses, tubes, and fittings to aid installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. Note routing of hoses and lines to aid installation.

0189-2

TM 5-2410-241-23-2

0189

UPPER HYDRAULIC OIL COOLER LINE REMOVAL CONTINUED

NOTE
Note orientation of fitting to aid installation. 1. Disconnect front upper line (Figure 1, Item 3) from elbow (Figure 1, Item 2). 2. Remove elbow (Figure 1, Item 2) from hydraulic oil cooler (Figure 1, Item 1). 3. Remove two O-rings (Figure 1, Items 4 and 5) from elbow (Figure 1, Item 2). Discard O-rings.

Figure 1. Upper Hydraulic Oil Cooler Line Elbow.

0189

0189-3

TM 5-2410-241-23-2

0189

UPPER HYDRAULIC OIL COOLER LINE REMOVAL CONTINUED

NOTE
Mark location and number of tiedown straps before removal. 4. Remove tiedown strap (Figure 2, Item 2) and front upper line (Figure 2, Item 3) from swivel (Figure 2, Item 1). Discard tiedown strap. 5. Remove tiedown strap (Figure 2, Item 2) from swivel (Figure 2, Item 1). Discard tiedown strap.

NOTE
Note location of clamps to aid installation. 6. Remove two bolts (Figure 2, Item 8), washers (Figure 2, Item 7), and clamps (Figure 2, Item 6) from front upper and lower lines (Figure 2, Items 3 and 9). 7. Disconnect front upper line (Figure 2, Item 3) and remove from tee (Figure 2, Item 5). 8. Remove O-ring (Figure 2, Item 4) from tee (Figure 2, Item 5). Discard O-ring. 9. Remove front upper line (Figure 2, Item 3) from machine.

Figure 2. Upper Hydraulic Oil Cooler Line.

0189

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TM 5-2410-241-23-2

0189

UPPER HYDRAULIC OIL COOLER LINE REMOVAL CONTINUED 10. Disconnect rear upper line (Figure 3, Item 3) from tee (Figure 3, Item 5). 11. Disconnect rear upper line (Figure 3, Item 3) from elbow (Figure 3, Item 1) on counterbalance valve (Figure 3, Item 4). 12. Remove rear upper line (Figure 3, Item 3) from machine. 13. Remove two O-rings (Figure 3, Items 2 and 4) from elbow (Figure 3, Item 1) and tee (Figure 3, Item 5). Discard O-rings.

Figure 3. Upper Hydraulic Oil Cooler Line at Counterbalance Valve. END OF TASK

0189

0189-5

TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE REMOVAL

000189

NOTE
Mark location and number of tiedown straps before removal. 1. Disconnect lower line (Figure 4, Item 2) from fitting (Figure 4, Item 1). 2. Remove connector (Figure 4, Item 1) from hydraulic oil cooler (Figure 4, Item 11). 3. Remove two O-rings (Figure 4, Items 8 and 9) from fitting (Figure 4, Item 1). Discard O-rings. 4. Remove tiedown strap (Figure 4, Item 3) and lower line (Figure 4, Item 2) from swivel (Figure 4, Item 4). Discard tiedown strap. 5. Remove tiedown strap (Figure 4, Item 3) from swivel (Figure 4, Item 4). Discard tiedown strap.

NOTE
Note location of clamps to aid installation. 6. Remove two bolts (Figure 4, Item 6), washers (Figure 4, Item 7), and clamps (Figure 4, Item 5) from upper (Figure 4, Item 10) and lower (Figure 4, Item 2) lines.

Figure 4. Lower Hydraulic Oil Cooler Line Connector.

0189

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TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE REMOVAL CONTINUED 7. Remove three bolts (Figure 5, Item 3), washers (Figure 5, Item 4), and clamps (Figure 5, Item 2) from lower line (Figure 5, Item 1).

Figure 5. Clamps Under Machine.

0189

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TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE REMOVAL CONTINUED 8. Remove two bolts (Figure 6, Item 3), washers (Figure 6, Item 4), and clamps (Figure 6, Item 2) from lower line (Figure 6, Item 1).

Figure 6. Clamps Under Foot Plate.

0189

0189-8

TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE REMOVAL CONTINUED 9. Remove nut (Figure 7, Item 4), washer (Figure 7, Item 5), clamp (Figure 7, Item 7), and spacer (Figure 7, Item 6) from lower line (Figure 7, Item 3). 10. Disconnect lower line (Figure 7, Item 3) from hydraulic tank (Figure 7, Item 1). 11. Remove lower line (Figure 7, Item 3) from machine. 12. Remove O-ring (Figure 7, Item 2) from hydraulic tank (Figure 7, Item 1). Discard O-ring.

Figure 7. Lower Hydraulic Oil Cooler Line at Hydraulic Tank. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0189

000189

0189-9

TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE INSTALLATION

000189

WARNING

Lubricating/hydraulic oils used in performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

NOTE
Install tubes and fittings as noted during removal. 1. Install new O-ring (Figure 8, Item 2) on hydraulic tank (Figure 8, Item 1). 2. Position lower line (Figure 8, Item 3) on machine. 3. Connect lower line (Figure 8, Item 3) to hydraulic tank (Figure 8, Item 1). 4. Install spacer (Figure 8, Item 6), lower line (Figure 8, Item 3), clamp (Figure 8, Item 7), washer (Figure 8, Item 5), and nut (Figure 8, Item 4) on machine.

Figure 8. Lower Hydraulic Oil Cooler Line at Hydraulic Tank.

0189

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TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE INSTALLATION CONTINUED 5. Install lower line (Figure 9, Item 1), two clamps (Figure 9, Item 2), washers (Figure 9, Item 4), and bolts (Figure 9, Item 3) on machine.

Figure 9. Clamps Under Foot Plate.

0189

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TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE INSTALLATION CONTINUED 6. Install lower line (Figure 10, Item 1), three clamps (Figure 10, Item 2), washers (Figure 10, Item 4), and bolts (Figure 10, Item 3) on machine.

Figure 10. Clamps Under Machine.

0189

0189-12

TM 5-2410-241-23-2

0189

LOWER HYDRAULIC OIL COOLER LINE INSTALLATION CONTINUED 7. Install upper (Figure 11, Item 10) and lower lines (Figure 11, Item 2), two clamps (Figure 11, Item 5), washers (Figure 11, Item 7), and bolts (Figure 11, Item 6) on machine.

NOTE
Note location of clamps to aid installation. 8. Install lower line (Figure 11, Item 2) and new tiedown strap (Figure 11, Item 3) on swivel (Figure 11, Item 4). 9. Install two new O-rings (Figure 11, Items 8 and 9) on fitting (Figure 11, Item 1). 10. Install connector (Figure 11, Item 1) on hydraulic oil cooler (Figure 11, Item 11). 11. Connect lower line (Figure 11, Item 2) to fitting (Figure 11, Item 1).

Figure 11. Lower Hydraulic Oil Cooler Line Connector. END OF TASK

0189

0189-13

TM 5-2410-241-23-2

0189

UPPER HYDRAULIC OIL COOLER LINE INSTALLATION 1. Install two new O-rings (Figure 12, Items 2 and 4) on elbow (Figure 12, Item 1) and tee (Figure 12, Item 5). 2. Position rear upper line (Figure 12, Item 3) on machine. 3. Connect rear upper line (Figure 12, Item 3) to elbow (Figure 12, Item 1) on counterbalance valve (Figure 12, Item 4). 4. Connect rear upper line (Figure 12, Item 3) to tee (Figure 12, Item 5).

000189

Figure 12. Upper Hydraulic Oil Cooler Line at Counterbalance Valve.

0189

0189-14

TM 5-2410-241-23-2

0189

UPPER HYDRAULIC OIL COOLER LINE INSTALLATION CONTINUED 5. Position front upper line (Figure 13, Item 3) on machine. 6. Install new O-ring (Figure 13, Item 4) on tee (Figure 13, Item 5). 7. Connect front upper line (Figure 13, Item 3) to tee (Figure 13, Item 5).

NOTE
Install clamps as noted during removal. Install tiedown straps as noted during removal.

8. Install two clamps (Figure 13, Item 6), washers (Figure 13, Item 7), and bolts (Figure 13, Item 8) on front upper and lower lines (Figure 13, Items 3 and 9). 9. Install two new tiedown straps (Figure 13, Item 2) on front upper line (Figure 13, Items 3) and swivel (Figure 13, Item 1).

Figure 13. Upper Hydraulic Oil Cooler Line.

0189

0189-15

TM 5-2410-241-23-2

0189

UPPER HYDRAULIC OIL COOLER LINE INSTALLATION CONTINUED

NOTE
Install fitting as noted during removal. 10. Install two new O-rings (Figure 14, Items 4 and 5) on elbow (Figure 14, Item 2). 11. Install elbow (Figure 14, Item 2) on hydraulic oil cooler (Figure 14, Item 1). 12. Connect front upper line (Figure 14, Item 3) on elbow (Figure 14, Item 2).

Figure 14. Upper Hydraulic Oil Cooler Line Elbow. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure left door guard (WP 0202). 2. Install front and rear floor plates (WP 0230 and WP 0231). 3. Install right platform access panels (WP 0208). 4. Install bottom guards (WP 0199). 5. Fill hydraulic system (WP 0184). 6. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0189

000189

0189-16

14 TM 5-2410-241-23-2 0190

FIELD MAINTENANCE
0 1 9 0

HYDRAULIC SUCTION LINE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (4) References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Transmission system oil fIlter base removed (WP 0153) Front and rear floor plates removed (WP 0230 and WP 0231) Right platform access panels removed (WP 0208) Bottom guards removed (WP 0199)
0 0 0 0 0 0 0

Drawing Required
0

TM 5-2410-241-24P, Figure 82
0

Estimated Time to Complete

0

14.6 Hr

0190-1

TM 5-2410-241-23-2

0190

REMOVAL

000190

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag all hoses, tubes, and fittings to aid installation. Note routing of hoses and lines to aid installation.

0190-2

TM 5-2410-241-23-2

0190

REMOVAL CONTINUED 1. Remove and discard tiedown strap (Figure 1, Item 5) from upper hydraulic suction line (Figure 1, Item 1). 2. Remove bolt (Figure 1, Item 2), washer (Figure 1, Item 3), and clamp (Figure 1, Item 4) from upper hydraulic suction line (Figure 1, Item 1). 3. Remove two clamps (Figure 1, Item 6) and hose (Figure 1, Item 7) from upper hydraulic suction line (Figure 1, Item 1).

Figure 1. Upper Hydraulic Suction Line at Right Front Panel.

0190

0190-3

TM 5-2410-241-23-2

0190

REMOVAL CONTINUED 4. Remove four bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and lower hydraulic suction line (Figure 2, Item 4) from implement pump (Figure 2, Item 1). 5. Remove lower hydraulic suction line (Figure 2, Item 4) and hose (Figure 2, Item 5) from machine. 6. Remove O-ring (Figure 2, Item 7) from lower hydraulic suction line (Figure 2, Item 4). Discard O-ring. 7. Remove two clamps (Figure 2, Item 6) and hose (Figure 2, Item 5) from lower hydraulic suction line (Figure 2, Item 4).

Figure 2. Lower Hydraulic Suction Line.

0190

0190-4

TM 5-2410-241-23-2

0190

REMOVAL CONTINUED 8. Remove bolt (Figure 3, Item 7), washer (Figure 3, Item 8), and clamp (Figure 3, Item 9) from filler tube (Figure 3, Item 10). 9. Remove bolt (Figure 3, Item 5), washer (Figure 3, Item 4), and test port bracket (Figure 3, Item 12) from bracket (Figure 3, Item 6). 10. Position test port bracket (Figure 3, Item 12) and test port lines (Figure 3, Item 11) aside. 11. Remove bolt (Figure 3, Item 3), washer (Figure 3, Item 2), and bracket (Figure 3, Item 6) from right fender (Figure 3, Item 1).

Figure 3. Brackets.

0190

0190-5

TM 5-2410-241-23-2

0190

REMOVAL CONTINUED 12. Remove hose (Figure 4, Item 1) from fitting (Figure 4, Item 2). 13. Remove hose (Figure 4, Item 5) from fitting (Figure 4, Item 2). 14. Remove nut (Figure 4, Item 4) from fitting (Figure 4, Item 2), and fitting (Figure 4, Item 2) from hydraulic tank (Figure 4, Item 3). 15. Remove two O-rings (Figure 4, Items 6 and 7) from fitting (Figure 4, Item 2). Discard O-rings.

Figure 4. Lines.

0190

0190-6

TM 5-2410-241-23-2

0190

REMOVAL CONTINUED 16. Remove bolt (Figure 5, Item 3), washer (Figure 5, Item 4), and two clamps (Figure 5, Item 2) from upper hydraulic suction line (Figure 5, Item 1). 17. Remove bolt (Figure 5, Item 6), washer (Figure 5, Item 7), and clamp (Figure 5, Item 5) from upper hydraulic suction line (Figure 5, Item 1) and machine.

Figure 5. Right Front Panel Clamps.

0190

0190-7

TM 5-2410-241-23-2

0190

REMOVAL CONTINUED 18. Remove four bolts (Figure 6, Item 1), washers (Figure 6, Item 2), and upper hydraulic suction line (Figure 6, Item 4) from hydraulic tank (Figure 6, Item 5). 19. Remove upper hydraulic suction line (Figure 6, Item 4) from machine. 20. Remove and discard O-ring (Figure 6, Item 3) from upper hydraulic suction line (Figure 6, Item 4).

Figure 6. Upper Hydraulic Suction Line at Hydraulic Tank. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0190

000190

0190-8

TM 5-2410-241-23-2

0190

INSTALLATION

000190

WARNING

Lubricating/hydraulic oils used in performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

NOTE
Install all hoses, tubes, and fittings as noted in removal. 1. Install new O-ring (Figure 6, Item 3) on upper hydraulic suction line (Figure 6, Item 4). 2. Position upper hydraulic suction line (Figure 6, Item 4) on machine. 3. Install upper hydraulic suction line (Figure 6, Item 4), four washers (Figure 6, Item 2), and bolts (Figure 6, Item 1) on hydraulic tank (Figure 6, Item 5). 4. Install clamp (Figure 7, Item 5) on upper hydraulic suction line (Figure 7, Item 1), and washer (Figure 7, Item 7) and bolt (Figure 7, Item 6) on machine. 5. Install two clamps (Figure 7, Item 2), washer (Figure 7, Item 4), and bolt (Figure 7, Item 3) on upper hydraulic suction line (Figure 7, Item 1).

Figure 7. Right Front Panel Clamps.

0190

0190-9

TM 5-2410-241-23-2

0190

INSTALLATION CONTINUED

NOTE
Install all hoses, tubes, and fittings as noted during removal. 6. Install two new O-rings (Figure 8, Items 6 and 7) on fitting (Figure 8, Item 2). 7. Install fitting (Figure 8, Item 2) on hydraulic tank (Figure 8, Item 3), and nut (Figure 8, Item 4) on fitting (Figure 8, Item 2). 8. Install hose (Figure 8, Item 5) on fitting (Figure 8, Item 2). 9. Install hose (Figure 8, Item 1) on fitting (Figure 8, Item 2.

Figure 8. Lines.

0190

0190-10

TM 5-2410-241-23-2

0190

INSTALLATION CONTINUED

NOTE
Install all hoses, lines, and tubes as noted during removal. 10. Install bracket (Figure 9, Item 6), washer (Figure 9, Item 2), and bolt (Figure 9, Item 3) on right fender (Figure 9, Item 1). 11. Position test port bracket (Figure 9, Item 12) and test port lines (Figure 9, Item 11) on right fender (Figure 9, Item 1). 12. Install test port bracket (Figure 9, Item 12), washer (Figure 9, Item 4), and bolt (Figure 9, Item 5) on bracket (Figure 9, Item 6). 13. Install clamp (Figure 9, Item 9), washer (Figure 9, Item 8), and bolt (Figure 9, Item 7) on filler tube (Figure 9, Item 10).

Figure 9. Brackets.

0190

0190-11

TM 5-2410-241-23-2

0190

INSTALLATION CONTINUED

NOTE
Install all hoses, tubes, and fittings as noted during removal. 14. Install hose (Figure 10, Item 5) and two clamps (Figure 10, Item 6) on lower hydraulic suction line (Figure 10, Item 4). 15. Install new O-ring (Figure 10, Item 7) on lower hydraulic suction line (Figure 10, Item 4). 16. Position lower hydraulic suction line (Figure 10, Item 4) and hose (Figure 10, Item 5) on machine. 17. Install lower hydraulic suction line (Figure 10, Item 4), four washers (Figure 10, Item 3), and bolts (Figure 10, Item 2) on implement pump (Figure 10, Item 1).

Figure 10. Lower Hydraulic Suction Line.

0190

NOTE
Install all hoses, tubes, and fittings as noted during removal. 18. Install hose (Figure 11, Item 7) and two clamps (Figure 11, Item 6) on upper hydraulic suction line (Figure 11, Item 1).

0190-12

TM 5-2410-241-23-2

0190

INSTALLATION CONTINUED 19. Install clamp (Figure 11, Item 4), washer (Figure 11, Item 3), and bolt (Figure 11, Item 2) on upper hydraulic suction line (Figure 11, Item 1). 20. Install new tiedown strap (Figure 11, Item 5) on upper hydraulic suction line (Figure 11, Item 1).

Figure 11. Upper Hydraulic Suction Line at Right Front Panel. END OF TASK FOLLOW-ON TASKS 1. Install transmission system oil fIlter base (WP 0153). 2. Fill hydraulic system (WP 0184). 3. Install front and rear floor plates (WP 0230 and WP 0231). 4. Install right platform access panels (WP 0208). 5. Install bottom guards (WP 0199). 6. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0190

000190

0190-13/(14 blank)

8 TM 5-2410-241-23-2 0191

FIELD MAINTENANCE
0 1 9 1

HYDRAULIC IMPLEMENT PUMP TANK HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (3) References WP 0295
0

Equipment Condition Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Front and rear floor plates removed (WP 0230 and WP 0231) Right platform access panels removed (WP 0208) Drawing Required TM 5-2410-241-24P, Figure 82 Estimated Time to Complete 6.0 Hr

0191-1

TM 5-2410-241-23-2

0191

REMOVAL

000191

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag hose and fittings to aid installation. Note routing of hose to aid installation.

0191-2

TM 5-2410-241-23-2

0191

REMOVAL CONTINUED 1. Disconnect hose (Figure 1, Item 3) from elbow (Figure 1, Item 2) on implement pump (Figure 1, Item 1). 2. Remove elbow (Figure 1, Item 2) from implement pump (Figure 1, Item 1).

Figure 1. Implement Pump to Hydraulic Tank. 3. Remove two O-rings (Figure 2, Items 2 and 3) from elbow (Figure 2, Item 1). Discard O-rings.

0191

Figure 2. Elbow.

0191

0191-3

TM 5-2410-241-23-2

0191

REMOVAL CONTINUED 4. Remove bolt (Figure 3, Item 2), washer (Figure 3, Item 1), clamp (Figure 3, Item 3), and hose (Figure 3, Item 4) from machine.

Figure 3. Clamp. 5. Remove bolt (Figure 4, Item 2), washer (Figure 4, Item 3), two retaining straps (Figure 4, Item 1), and two hoses (Figure 4, Items 4 and 5) from hydraulic suction line (Figure 4, Item 6).

0191

Figure 4. Clamps at Filler Tube.

0191

0191-4

TM 5-2410-241-23-2

0191

REMOVAL CONTINUED 6. Disconnect hose (Figure 5, Item 3) from tee (Figure 5, Item 1) at hydraulic tank (Figure 5, Item 4). Remove hose from machine. 7. Remove O-ring (Figure 5, Item 2) from tee (Figure 5, Item 1). Discard O-ring.

Figure 5. Hydraulic Tank. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0191

000191

000191

NOTE
Install hose and tee as noted during removal. 1. Install new O-ring (Figure 5, Item 2) on tee (Figure 5, Item 1). 2. Position hose (Figure 5, Item 3) on machine. 3. Connect hose (Figure 5, Item 3) on tee (Figure 5, Item 1) at hydraulic tank. (Figure 5, Item 4).

0191-5

TM 5-2410-241-23-2

0191

INSTALLATION CONTINUED 4. Install two retaining straps (Figure 6, Item 1), two hoses (Figure 6, Items 4 and 5), washer (Figure 6, Item 3), and bolt (Figure 6, Item 2) on hydraulic suction line (Figure 6, Item 6).

Figure 6. Clamps at Filler Tube.

0191

0191-6

TM 5-2410-241-23-2

0191

INSTALLATION CONTINUED 5. Install clamp (Figure 7, Item 3), hose (Figure 7, Item 4), washer (Figure 7, Item 1), and bolt (Figure 7, Item 2) on machine.

Figure 7. Clamp. 6. Install two new O-rings (Figure 8, Items 2 and 3) on elbow (Figure 8, Item 1).

0191

Figure 8. Elbow.

0191

0191-7

TM 5-2410-241-23-2

0191

INSTALLATION CONTINUED

NOTE
Install fitting as noted during removal. 7. Install elbow (Figure 9, Item 2) on implement pump (Figure 9, Item 1). 8. Connect hose (Figure 9, Item 3) to elbow (Figure 9, Item 2) on implement pump (Figure 9, Item 1).

Figure 9. Implement Pump to Hydraulic Tank. END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Install front and rear floor plates (WP 0230 and WP 0231). 3. Install right platform access panels (WP 0208). END OF TASK END OF WORK PACKAGE

0191

000191

0191-8

6 TM 5-2410-241-23-2 0192

FIELD MAINTENANCE
0 1 9 2

HYDRAULIC IMPLEMENT PUMP STEERING MOTOR HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (3) References WP 0295
0

Equipment Condition Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Front and rear floor plates removed (WP 0230 and WP 0231) Right platform access panels removed (WP 0208) Drawing Required TM 5-2410-241-24P, Figure 82 Estimated Time to Complete 7.1 Hr

0192-1

TM 5-2410-241-23-2

0192

REMOVAL

000192

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag all hoses and fittings to aid installation. Note routing of hose to aid installation.

0192-2

TM 5-2410-241-23-2

0192

REMOVAL CONTINUED

NOTE
Note position and orientation of elbow and hoses to aid installation. 1. Disconnect hose (Figure 1, Item 3) from elbow (Figure 1, Item 2) on implement pump (Figure 1, Item 1). 2. Remove elbow (Figure 1, Item 2) from implement pump (Figure 1, Item 1). 3. Disconnect hose (Figure 1, Item 3) from steering motor tee (Figure 1, Item 5). Remove hose from machine. 4. Remove O-ring (Figure 1, Item 4) from tee (Figure 1, Item 5). Discard O-ring.

Figure 1. Implement Pump to Steering Motor Tee.

0192

0192-3

TM 5-2410-241-23-2

0192

REMOVAL CONTINUED 5. Remove two O-rings (Figure 2, Items 2 and 3) from elbow (Figure 2, Item 1). Discard O-rings.

Figure 2. Elbow. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0192

000192

000192

NOTE
Install hose and elbow as noted during removal. 1. Install two new O-rings (Figure 2, Items 2 and 3) on elbow (Figure 2, Item 1).

0192-4

TM 5-2410-241-23-2

0192

INSTALLATION CONTINUED 2. Install new O-ring (Figure 3, Item 4) on tee (Figure 3, Item 5). 3. Position hose (Figure 3, Item 3) on machine. 4. Connect hose (Figure 3, Item 3) on steering motor tee (Figure 3, Item 5). 5. Install elbow (Figure 3, Item 2) on implement pump (Figure 3, Item 1). 6. Connect hose (Figure 3, Item 3) to elbow (Figure 3, Item 2) on implement pump (Figure 3, Item 1).

Figure 3. Implement Pump to Steering Motor Tee. END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Install front and rear floor plates (WP 0230 and WP 0231). 3. Install right platform access panels (WP 0208). END OF TASK END OF WORK PACKAGE

0192

000192

0192-5/(6 blank)

6 TM 5-2410-241-23-2 0193

FIELD MAINTENANCE
0 1 9 3

HYDRAULIC IMPLEMENT PUMP MAIN CONTROL VALVE HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (3) Preformed Packing Seal
0

References WP 0295

Equipment Condition
0

Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Front and rear floor plates removed (WP 0230) Right platform access panels removed (WP 0208) Drawing Required

TM 5-2410-241-24P, Figure 82
0 0

Estimated Time to Complete 6.0 Hr

0193-1

TM 5-2410-241-23-2

0193

REMOVAL

000193

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag hoses and fittings to aid installation. Note routing of hose to aid installation.

0193-2

TM 5-2410-241-23-2

0193

REMOVAL CONTINUED 1. Remove four bolts (Figure 1, Item 4) and washers (Figure 1, Item 5) from flange (Figure 1, Item 2). 2. Disconnect hose (Figure 1, Item 3) and flange (Figure 1, Item 2) from spacer (Figure 1, Item 9). 3. Disconnect pilot accumulator hose (Figure 1, Item 6) from elbow (Figure 1, Item 7). 4. Remove spacer (Figure 1, Item 9) and seal (Figure 1, Item 10) from implement pump (Figure 1, Item 1). Discard seal.

NOTE
Note position and orientation of elbow to aid installation. 5. Remove elbow (Figure 1, Item 7) from spacer (Figure 1, Item 9). 6. Remove two O-rings (Figure 1, Item 8) from elbow (Figure 1, Item 7). Discard O-rings.

Figure 1. Implement Pump to Main Hydraulic Control Valve. 7. Remove O-ring (Figure 2, Item 1) from hose (Figure 2, Item 2). Discard O-ring.

0193

Figure 2. Flange.

0193

0193-3

TM 5-2410-241-23-2

0193

REMOVAL CONTINUED 8. Remove nut (Figure 3, Item 1), washer (Figure 3, Item 2), and two spring tension clips (Figure 3, Item 3) from hose (Figure 3, Item 5). 9. Remove two spring tension clips (Figure 3, Item 3) and grommet (Figure 3, Item 4) from hose (Figure 3, Item 5). 10. Remove four bolts (Figure 3, Item 6), washers (Figure 3, Item 7), and hose (Figure 3, Item 5) from main hydraulic control valve (Figure 3, Item 8). Remove hose from machine. 11. Remove preformed packing (Figure 3, Item 9) from hose (Figure 3, Item 5). Discard preformed packing.

Figure 3. Main Hydraulic Control Valve. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0193

000193

0193-4

TM 5-2410-241-23-2

0193

INSTALLATION

000193

NOTE
Install hose as noted in removal. 1. Position hose (Figure 3, Item 5) on machine. 2. Install new preformed packing (Figure 3, Item 9) on hose (Figure 3, Item 5). 3. Install hose (Figure 3, Item 5), four washer (Figure 3, Item 7), and bolts (Figure 3, Item 6) on main hydraulic control valve (Figure 3, Item 8). 4. Install grommet (Figure 3, Item 4) and two spring tension clips (Figure 3, Item 3) on hose (Figure 3, Item 5). 5. Install two spring tension clips (Figure 3, Item 3), washer (Figure 3, Item 2) and nut (Figure 3, Item 1) on hose (Figure 3, Item 5). 6. Install new O-ring (Figure 4, Item 1) on hose (Figure 4, Item 2).

Figure 4. Flange.

0193

0193-5

TM 5-2410-241-23-2

0193

INSTALLATION CONTINUED

NOTE
Install elbow as noted during removal. 7. Install two new O-rings (Figure 5, Item 8) on elbow (Figure 5, Item 7). 8. Install elbow (Figure 5, Item 7) on spacer (Figure 5, Item 9). 9. Install new seal (Figure 5, Item 10) and spacer (Figure 5, Item 9) on implement pump (Figure 5, Item 1). 10. Connect hose (Figure 5, Item 3) and two pipe flange (Figure 5, Item 2) on spacer (Figure 5, Item 9). 11. Install four washers (Figure 5, Item 5) and bolts (Figure 5 Item 4) on flange (Figure 5, Item 2). 12. Install pilot accumulator hose (Figure 5, Item 6) on elbow (Figure 5, Item 7).

Figure 5. Implement Pump to Main Hydraulic Control Valve. END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Install front and rear floor plates (WP 0230). 3. Install right platform access panels (WP 0208). END OF TASK END OF WORK PACKAGE

0193

000193

0193-6

10 TM 5-2410-241-23-2 0194

FIELD MAINTENANCE
0 1 9 4

HYDRAULIC IMPLEMENT PUMP PILOT ACCUMULATOR HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) O-ring (3) References WP 0295
0

Equipment Condition Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Front and rear floor plates removed (WP 0230) Right platform access panels removed (WP 0208) Drawing Required TM 5-2410-241-24P, Figure 81 Estimated Time to Complete 6.0 Hr

0194-1

TM 5-2410-241-23-2

0194

REMOVAL

000194

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag hose and fittings to aid installation. Note routing of hose to aid installation.

0194-2

TM 5-2410-241-23-2

0194

REMOVAL CONTINUED

NOTE
Note position and orientation of hose to aid installation. 1. Disconnect hose (Figure 1, Item 2) from elbow (Figure 1, Item 3) on implement pump (Figure 1, Item 1). 2. Remove elbow (Figure 1, Item 3) from spacer (Figure 1, Item 4).

Figure 1. Implement Pump to Pilot Accumulator. 3. Remove two O-rings (Figure 2, Items 2 and 3) from elbow (Figure 2, Item 1). Discard O-rings.

0194

Figure 2. Elbow.

0194

0194-3

TM 5-2410-241-23-2

0194

REMOVAL CONTINUED 4. Remove bolt (Figure 3, Item 4), washer (Figure 3, Item 3), two clamps (Figure 3, Item 1), and hoses (Figure 3, Items 2 and 6) from hydraulic suction tube (Figure 3, Item 7). 5. Remove tiedown strap (Figure 3, Item 5) from hose (Figure 3, Item 2) and hydraulic suction tube (Figure 3, Item 7). Discard tiedown strap.

Figure 3. Clamps.

0194

0194-4

TM 5-2410-241-23-2

0194

REMOVAL CONTINUED 6. Open front access on hydraulic tank. 7. Disconnect hose (Figure 4, Item 3) from pilot accumulator (Figure 4, Item 1). 8. Remove O-ring (Figure 4, Item 2) from pilot accumulator (Figure 4, Item 1). Discard O-ring. 9. Remove tiedown strap (Figure 4, Item 8) and hose (Figure 4, Item 3) from hydraulic suction tube (Figure 4, Item 7). Discard tiedown strap. 10. Remove bolt (Figure 4, Item 5), washer (Figure 4, Item 6), clamp (Figure 4, Item 4), and hose (Figure 4, Item 3) from hydraulic suction tube (Figure 4, Item 7). Remove hose from machine.

Figure 4. Pilot Accumulator. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0194

000194

0194-5

TM 5-2410-241-23-2

0194

INSTALLATION

000194

NOTE
Install hose as noted in removal. 1. Position hose (Figure 5, Item 3) on machine. 2. Install clamp (Figure 5, Item 4), hose (Figure 5, Item 3), washer (Figure 5, Item 6), and bolt (Figure 5, Item 5) on hydraulic suction tube (Figure 5, Item 7). 3. Install hose (Figure 5, Item 3) and new tiedown strap (Figure 5, Item 8) on hydraulic suction tube (Figure 5, Item 7). 4. Install new O-ring (Figure 5, Item 2) on pilot accumulator (Figure 5, Item 1). 5. Connect hose (Figure 5, Item 3) on pilot accumulator (Figure 5, Item 1). 6. Close front access on hydraulic tank.

Figure 5. Pilot Accumulator.

0194

0194-6

TM 5-2410-241-23-2

0194

INSTALLATION CONTINUED 7. Install new tiedown strap (Figure 6, Item 5) on hose (Figure 6, Item 2) and hydraulic suction tube (Figure 6, Item 7). 8. Install two clamps (Figure 6, Item 1), hoses (Figure 6, Items 2 and 6), washer (Figure 6, Item 3), and bolt (Figure 6, Item 4) on hydraulic suction tube (Figure 6, Item 7).

Figure 6. Clamps.

0194

0194-7

TM 5-2410-241-23-2

0194

INSTALLATION CONTINUED 9. Install two new O-rings (Figure 7, Items 2 and 3) on elbow (Figure 7, Item 1).

Figure 7. Elbow.

0194

NOTE
Install elbow as noted during removal. 10. Install elbow (Figure 8, Item 3) on spacer (Figure 8, Item 4). 11. Connect hose (Figure 8, Item 2) on elbow (Figure 8, Item 3) on implement pump (Figure 8, Item 1).

Figure 8. Implement Pump to Pilot Accumulator. END OF TASK

0194

0194-8

TM 5-2410-241-23-2

0194

FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Install front and rear floor plates (WP 0230). 3. Install right platform access panels (WP 0208). END OF TASK END OF WORK PACKAGE

000194

0194-9/(10 blank)

10 TM 5-2410-241-23-2 0195

FIELD MAINTENANCE
0 1 9 5

HYDRAULIC STEERING MOTOR/TANK HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (3)
0

References WP 0295

Equipment Condition
0

Hydraulic system drained (WP 0184) Front and rear floor plates removed (WP 0230) Right platform access panels removed (WP 0208) Drawing Required

TM 5-2410-241-24P, Figure 82
0 0

Estimated Time to Complete 7.5 Hr

0195-1

TM 5-2410-241-23-2

0195

REMOVAL

000195

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag all hoses and fittings to aid installation. Note routing of hose to aid installation.

0195-2

TM 5-2410-241-23-2

0195

REMOVAL CONTINUED 1. Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and plate (Figure 1, Item 1) from machine. 2. Open door (Figure 1, Item 4).

Figure 1. Plate.

0195

3. Remove hose (Figure 2, Item 2) from fitting (Figure 2, Item 1) on transmission filter housing (Figure 2, Item 4). 4. Remove O-ring (Figure 2, Item 3) from fitting (Figure 2, Item 1). Discard O-ring.

Figure 2. Hose.

0195

0195-3

TM 5-2410-241-23-2

0195

REMOVAL CONTINUED 5. Remove two bolts (Figure 3, Item 3), washers (Figure 3, Item 2), and bracket (Figure 3, Item 1) from hydraulic tank (Figure 3, Item 4). Set bracket aside.

Figure 3. Bracket.

0195

6. Remove bolt (Figure 4, Item 3), washer (Figure 4, Item 2), and two spring tension clips (Figure 4, Item 4), and set hose (Figure 4, Item 1) aside. 7. Remove four bolts (Figure 4, Item 8), washers (Figure 4, Item 7), flange (Figure 4, Item 9) and hose (Figure 4, Item 1) from hydraulic tank (Figure 4, Item 5). 8. Remove O-ring (Figure 4, Item 6) from hose (Figure 4, Item 1). Discard O-ring.

D7R-3836

Figure 4. Hydraulic Tank.

0195

0195-4

TM 5-2410-241-23-2

0195

REMOVAL CONTINUED 9. Disconnect hose (Figure 5, Item 4) from tee (Figure 5, Item 6). 10. Remove O-ring (Figure 5, Item 5) from tee (Figure 5, Item 6). Discard O-ring. 11. Remove bolt (Figure 5, Item 3), washer (Figure 5, Item 2), two spring tension clips (Figure 5, Item 1), and hose (Figure 5, Item 4) from machine.

Figure 5. Steering Motor. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0195

000195

0195-5

TM 5-2410-241-23-2

0195

INSTALLATION

000195

NOTE
Install hose as noted during removal. 1. Install two spring tension clips (Figure 6, Item 1), hose (Figure 6, Item 4), washer (Figure 6, Item 2), and bolt (Figure 6, Item 3) on machine. 2. Install new O-ring (Figure 6, Item 5) on tee (Figure 6, Item 6). 3. Connect hose (Figure 6, Item 4) to tee (Figure 6, Item 6).

Figure 6. Steering Motor.

0195

0195-6

TM 5-2410-241-23-2

0195

INSTALLATION CONTINUED 4. Install new O-ring (Figure 7, Item 6) on hose (Figure 7, Item 1). 5. Install hose (Figure 7, Item 1), flange (Figure 7, Item 9), four washers (Figure 7, Item 7), and bolts (Figure 7, Item 8) on hydraulic tank (Figure 7, Item 5). 6. Install two spring tension clips (Figure 7, Item 4), hose (Figure 7, Item 1), washer (Figure 7, Item 2), and bolt (Figure 7, Item 3) on machine.

Figure 7. Hydraulic Tank.

0195

7. Install bracket (Figure 8, Item 1), two washers (Figure 8, Item 2), and bolts (Figure 8, Item 3) on hydraulic tank (Figure 8, Item 4).

Figure 8. Bracket.

0195

0195-7

TM 5-2410-241-23-2

0195

INSTALLATION CONTINUED 8. Install new O-ring (Figure 9, Item 3) on fitting (Figure 9, Item 1). 9. Install hose (Figure 9, Item 2) on fitting (Figure 9, Item 1) of transmission filter housing (Figure 9, Item 4).

Figure 9. Hose. 10. Install plate (Figure 10, Item 1), two washers (Figure 10, Item 3), and bolts (Figure 10, Item 2) on machine. 11. Close door (Figure 10, Item 4).

0195

Figure 10. Plate. END OF TASK

0195

0195-8

TM 5-2410-241-23-2

0195

FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Install front and rear floor plates (WP 0230). 3. Install right platform access panels (WP 0208). END OF TASK END OF WORK PACKAGE

000195

0195-9/(10 blank)

8 TM 5-2410-241-23-2 0196

FIELD MAINTENANCE
0 1 9 6

HYDRAULIC COUNTERBALANCE VALVE LINES REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (4) References WP 0189 WP 0191
0

References - Continued WP 0295

Equipment Condition
0

Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Front and rear floor plates removed (WP 0230) Right platform access panels removed (WP 0208) Drawing Required TM 5-2410-241-24P, Figure 82

Estimated Time to Complete

0

7.6 Hr

0196-1

TM 5-2410-241-23-2

0196

REMOVAL

000196

WARNING

DO NOT disconnect or remove any hydraulic system hoses, tubes, or fittings unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before removing any hydraulic fitting. To prevent injury to personnel, wear protective eye covering and gloves. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap all hydraulic hose and tube ends along with component connections during removal to protect against contamination. Failure to follow this caution may cause damage to equipment.

NOTE
Tag all hoses, tubes, and fittings to aid installation. Note routing of hoses and lines to aid installation.

0196-2

TM 5-2410-241-23-2

0196

REMOVAL CONTINUED

NOTE
Removal steps for two upper lines are identical. 1. Remove eight bolts (Figure 1, Item 3), washers (Figure 1, Item 4), and two flanges (Figure 1, Item 2) from counterbalance valve (Figure 1, Item 5). 2. Disconnect two hoses (Figure 1, Item 1) from counterbalance valve (Figure 1, Item 5). 3. Remove two nuts (Figure 1, Item 8), washers (Figure 1, Item 9), clamp (Figure 1, Item 6), and grommet (Figure 1, Item 7) from two hoses (Figure 1, Item 1).

Figure 1. Counterbalance Valve.

0196

0196-3

TM 5-2410-241-23-2

0196

REMOVAL CONTINUED 4. Remove and discard two O-rings (Figure 2, Item 2) from hoses (Figure 2, Item 1).

Figure 2. Flange.

0196

5. Remove eight bolts (Figure 3, Item 3), washers (Figure 3, Item 4), and two flanges (Figure 3, Item 5) from main control valve (Figure 3, Item 1). 6. Disconnect two hoses (Figure 3, Item 2) from main control valve (Figure 3, Item 1). 7. Remove and discard two O-rings (Figure 3, Item 6) from hoses (Figure 3, Item 2).

Figure 3. Implement Valve.

0196

0196-4

TM 5-2410-241-23-2

0196

REMOVAL CONTINUED 8. Refer to hydraulic implement line replacement (WP 0191) and hydraulic oil cooler line replacement (WP 0189) for remaining counterbalance valve line removal. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK
000196

0196-5

TM 5-2410-241-23-2

0196

INSTALLATION

000196

WARNING

Lubricating/hydraulic oils used in performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

NOTE
Install tubes and fittings as noted during removal. Installation steps for two upper lines are identical.

1. Lubricate and install two new O-rings (Figure 4, Item 6) on hoses (Figure 4, Item 2). 2. Connect two hoses (Figure 4, Item 2) to main control valve (Figure 4, Item 1). 3. Install two flanges (Figure 4, Item 5), eight washers (Figure 4, Item 4), and bolts (Figure 4, Item 3) on main control valve (Figure 4, Item 1).

Figure 4. Implement Valve.

0196

0196-6

TM 5-2410-241-23-2

0196

INSTALLATION CONTINUED 4. Lubricate and install two new O-rings (Figure 5, Item 2) on hoses (Figure 5, Item 1).

Figure 5. Flange.

0196

5. Install clamp (Figure 6, Item 6), grommet (Figure 6, Item 7), two washers (Figure 6, Item 9), and nuts (Figure 6, Item 8) on two hoses (Figure 6, Item 1). 6. Connect two hoses (Figure 6, Item 1) to counterbalance valve (Figure 6, Item 5). 7. Install two flanges (Figure 6, Item 2), eight washers (Figure 6, Item 4), and bolts (Figure 6, Item 3) on counterbalance valve (Figure 6, Item 5).

Figure 6. Counterbalance Valve.

0196

0196-7

TM 5-2410-241-23-2

0196

INSTALLATION CONTINUED 8. Refer to hydraulic implement line replacement (WP 0191) and hydraulic oil cooler line replacement (WP 0189) for remaining counterbalance valve line installation. END OF TASK FOLLOW-ON TASKS 1. Install right platform access panels (WP 0208). 2. Install front and rear floor plates (WP 0230). 3. Fill hydraulic system (WP 0184). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000196

0196-8

Index

6 TM 5-2410-241-23-2

Index
Subject WP Sequence No.-Page No.

A
A/C Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Compressor V-Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accumulator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aftercooler Housing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aftercooler Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet Manifold Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Inlet Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator and Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0097-1 WP 0096-1 WP 0126-1 WP 0115-1 WP 0068-1 WP 0078-1 WP 0111-1 WP 0092-1 WP 0063-1 WP 0099-1 WP 0163-1 WP 0090-1 WP 0116-1

B
Backup Alarm Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crossover Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnect Switch, Receptacle and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake and Differential Drive Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake and Planetary Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0168-1 WP 0183-1 WP 0156-1 WP 0161-1 WP 0162-1 WP 0160-1 WP 0159-1 WP 0155-1 WP 0139-1 WP 0138-1

C
Camshaft Timing Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valve (Steering and Brake) Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Rear Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Damper, Pulley and Adapter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0093-1 WP 0172-1 WP 0147-1 WP 0064-1 WP 0075-1 WP 0113-1 WP 0120-1 WP 0102-1 WP 0080-1 WP 0108-1

D
Dipstick Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0087-1

Index-1

TM 5-2410-241-23-2

Index - Continued
Subject WP Sequence No.-Page No. Double Flange Track Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0132-1 Drive Belt and Tensioner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0096-1

E
ECM (Powertrain) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECM Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter, Base and Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Transfer of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equalizer Bar Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ether Bottle, Valve, Bracket, and Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0175-1 WP 0057-1 WP 0094-1 WP 0101-1 WP 0058-1 WP 0084-1 WP 0083-1 WP 0091-1 WP 0114-1 WP 0059-1 WP 0125-1 WP 0060-1 WP 0067-1

F
Fan Hub Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Drive Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final Drive Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flange (Flywheel Housing) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flood Lamp Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flange Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Housing Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Housing Cover Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Lighting Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter, Base and Bracket Replacement, Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter, Base and Hose, Secondary Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0095-1 WP 0136-1 WP 0149-1 WP 0104-1 WP 0154-1 WP 0100-1 WP 0104-1 WP 0103-1 WP 0079-1 WP 0081-1 WP 0167-1 WP 0071-1 WP 0072-1 WP 0069-1 WP 0157-1 WP 0070-1 WP 0170-1 WP 0171-1 WP 0065-1 WP 0073-1 WP 0176-1

G
Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0141-1

H
Harness Assembly (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0105-1 Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0182-1 Hydraulic

Index-2

TM 5-2410-241-23-2

Index - Continued
Subject WP Sequence No.-Page No. WP 0196-1 WP 0189-1 WP 0185-1 WP 0184-1 WP 0181-1 WP 0195-1 WP 0190-1 WP 0186-1 WP 0187-1 WP 0193-1 WP 0194-1 WP 0192-1 WP 0191-1 WP 0188-1 WP 0140-1

Counterbalance Valve Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Motor/Tank Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Pressure Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Implement Pump Main Control Valve Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Pilot Accumulator Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Steering Motor Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Tank Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Tank Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Drive Motor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I
Idler Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0135-1 Implement Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0112-1

J
Junction Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0165-1 Junction Block Replacement (With Arctic Kit Heater) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0166-1

L
Lower Radiator Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0110-1

M
Main Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0117-1

O
Oil Filler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Engine Base Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0086-1 WP 0082-1 WP 0089-1 WP 0088-1

P
Pivot Shaft Lubrication Line Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary Fuel Filter, Base and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0158-1 WP 0177-1 WP 0118-1 WP 0119-1 WP 0071-1

R
Radiator

Index-3

TM 5-2410-241-23-2

Index - Continued
Subject WP Sequence No.-Page No. WP 0109-1 WP 0110-1 WP 0102-1 WP 0085-1 WP 0150-1 WP 0179-1 WP 0107-1 Core Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Crankshaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Gear Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil Spring Compartment Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Cab Switch Panel Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S
Secondary Fuel Filter, Base and Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Camshaft Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Flange Track Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sprocket Segment Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Strip Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch and Harness Assembly (Service Brake) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0072-1 WP 0093-1 WP 0133-1 WP 0137-1 WP 0164-1 WP 0061-1 WP 0131-1 WP 0174-1

T
Temperature Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Relief Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Relief Valve Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Track Adjuster and Recoil Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Speed Sensor One Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Speed Sensor Two Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission System Oil Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Inlet Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0074-1 WP 0122-1 WP 0123-1 WP 0124-1 WP 0148-1 WP 0134-1 WP 0129-1 WP 0127-1 WP 0128-1 WP 0142-1 WP 0145-1 WP 0169-1 WP 0143-1 WP 0144-1 WP 0121-1 WP 0173-1 WP 0153-1 WP 0152-1 WP 0151-1 WP 0146-1 WP 0130-1 WP 0066-1 WP 0062-1

V
Valve Mechanism Cover, Base, and Injector Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0106-1 V-Belt (A/C Compressor) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0096-1

Index-4

TM 5-2410-241-23-2

Index - Continued
Subject WP Sequence No.-Page No.

V-Belt Set (Alternator) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0098-1

W
Water Pump Elbow Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Winch Solenoid Harness Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Assembly (Steering Control) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0076-1 WP 0077-1 WP 0180-1 WP 0178-1

Index-5 /(Index-6 blank)

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE Date you ed out this form .

TO (Forward to proponent of publicatio n or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

Your mailing address

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE

TM 5-2410-241-23-2
ITEM NO. PAGE NO. PARAGRAPH LINE NO. FIGURE NO. TABLE NO.

29 February 2012

Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper

RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)

0017-2

Part number supplied for item 2 is incorrect.

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

Your Name
DA FORM 2028, FEB 74

Your Phone Number

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

Your Signature
APD V4.00

TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

DATE Date you ed out this form

Your Address

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LI STS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE Field Maintenance Manual D7R Series II Dozer TM 5-2410-241-23-2 29 February 2012 Type I with Winch, Type II with Ripper PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE NO. FIGURE NO. ITEM 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, PLUS EXTENSION

SIGNATURE

Your Name

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

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

TO (Forward to proponent of publicat ion or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE

TM 5-2410-241-23-2
ITEM NO. PAGE NO. PARAGRAPH LINE NO. FIGURE NO. TABLE NO.

29 February 2012

Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper

RECOMMENDED CHANGES AND REASON

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

DATE

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LI STS AND SUPPLY CATALOGS/SUPPLY MANUALS Field Maintenance Manual PUBLICATION/FORM NUMBER DATE TITLE D7R Series II Dozer TM 5-2410-241-23-2 29 February 2012 Type I with Winch, Type II with Ripper PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE NO. FIGURE NO. ITEM 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, PLUS EXTENSION

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

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

TO (Forward to proponent of publicat ion or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE

TM 5-2410-241-23-2
ITEM NO. PAGE NO. PARAGRAPH LINE NO. FIGURE NO. TABLE NO.

29 February 2012

Field Maintenance Manual D7R Series II Dozer Type I with Winch, Type II with Ripper

RECOMMENDED CHANGES AND REASON

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

DATE

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LI STS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER DATE TITLE Field Maintenance Manual D7R Series II Dozer TM 5-2410-241-23-2 29 February 2012 Type I with Winch, Type II with Ripper PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER REFERENCE NO. FIGURE NO. ITEM 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 n eeded.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

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

1201202

DISTRIBUTION: To be distributed in accordance with the initial distribution number (IDN) 257898 requirements for TM 5-2410-241-23-2.

Back Cover

THE METRIC SYSTEM AND EQUIVALENTS

Linear Measure 1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles Weights 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 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 Square Measure 1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles Cubic Measure 1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature

APPROXIMATE CONVERSION FACTORS

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

Kilometers per Liter Kilometers per Hour

0.425 1.609

Kilometers per Liter Kilometers per Hour

2.354 0.621

PIN: 086458-000