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TM 5-2410-241-23-3

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

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WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. 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 III IS 58 AND TOTAL NUMBER OF WORK PACKAGES IN THIS VOLUME IS 108, CONSISTING OF THE FOLLOWING: Page/WP No.

Volume III

Change No.

Page/WP No. Change No. WP 0227 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0228 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0229 (20 pgs) . . . . . . . . . . . . . . . . . 0 WP 0230 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0231 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0232 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0233 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0234 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0235 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0236 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0237 (30 pgs) . . . . . . . . . . . . . . . . . 0 WP 0238 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0239 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0240 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0241 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0242 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0243 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0244 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0245 (18 pgs) . . . . . . . . . . . . . . . . . 0 WP 0246 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0247 (24 pgs) . . . . . . . . . . . . . . . . . 0 WP 0248 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0249 (22 pgs) . . . . . . . . . . . . . . . . . 0 WP 0250 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0251 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0252 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0253 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0254 (22 pgs) . . . . . . . . . . . . . . . . . 0 WP 0255 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0256 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0257 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0258 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0259 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0260 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0261 (4 pgs) . . . . . . . . . . . . . . . . . . 0 A

Front Cover (2 pgs) . . . . . . . . . . . . . . . . 0 Warning Summary (8 pgs) . . . . . . . . . . . 0 TOC (30 pgs) . . . . . . . . . . . . . . . . . . . . 0 WP 0197 (22 pgs) . . . . . . . . . . . . . . . . . 0 WP 0198 (18 pgs) . . . . . . . . . . . . . . . . . 0 WP 0199 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0200 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0201 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0202 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0203 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0204 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0205 (18 pgs) . . . . . . . . . . . . . . . . . 0 WP 0206 (36 pgs) . . . . . . . . . . . . . . . . . 0 WP 0207 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0208 (16 pgs) . . . . . . . . . . . . . . . . . 0 WP 0209 (26 pgs) . . . . . . . . . . . . . . . . . 0 WP 0210 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0211 (28 pgs) . . . . . . . . . . . . . . . . . 0 WP 0212 (26 pgs) . . . . . . . . . . . . . . . . . 0 WP 0213 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0214 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0215 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0216 (32 pgs) . . . . . . . . . . . . . . . . . 0 WP 0217 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0218 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0219 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0220 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0221 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0222 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0223 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0224 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0225 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0226 (8 pgs) . . . . . . . . . . . . . . . . . . 0

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Page/WP No.

Change No.

Page/WP No.

Change No.

WP 0262 (22 pgs) . . . . . . . . . . . . . . . . . 0 WP 0263 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0264 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0265 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0266 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0267 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0268 (26 pgs) . . . . . . . . . . . . . . . . . 0 WP 0269 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0270 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0271 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0272 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0273 (14 pgs) . . . . . . . . . . . . . . . . . 0 WP 0274 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0275 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0276 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0277 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0278 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0279 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0280 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0281 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0282 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0283 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0284 (2 pgs) . . . . . . . . . . . . . . . . . . 0

WP 0285 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0286 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0287 (20 pgs) . . . . . . . . . . . . . . . . . 0 WP 0288 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0289 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0290 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0291 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0292 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0293 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0294 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0295 (8 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0296 (12 pgs) . . . . . . . . . . . . . . . . . 0 WP 0297 (44 pgs) . . . . . . . . . . . . . . . . . 0 WP 0298 (10 pgs) . . . . . . . . . . . . . . . . . 0 WP 0299 (2 pgs) . . . . . . . . . . . . . . . . . . 0 Chapter 5 title page (2 pgs) . . . . . . . . . . 0 WP 0300 (2 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0301 (4 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0302 (18 pgs) . . . . . . . . . . . . . . . . . 0 WP 0303 (6 pgs) . . . . . . . . . . . . . . . . . . 0 WP 0304 (2 pgs) . . . . . . . . . . . . . . . . . . 0 Index (4 pgs) . . . . . . . . . . . . . . . . . . . . . 0 Foldouts (68 pgs) ................ 0 Back Cover (2 pgs)..................................0

TM 5-2410-241-23-3 TECHNICAL MANUAL TM 5-2410-241-23-3 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) Website. The Internet address is https://tulsa.tacom.army.mil. Acc ess to all applications requires CAC authentication, an d yo u 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 Website will enable us to respond more qui ckly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL- MPP/TECH PUBS, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxx Lift Cylinder Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0197 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 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. Tube to Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-2 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-3 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-3 Tube Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-4 Quick Drop Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-5 Front Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-6 Upper Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-7 Lower Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-8 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-9 Right Cover Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-10 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-11 Implement Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-12 Right Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-13 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-14 Lower Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-15 Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-16 Front Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-17 Quick Drop Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-18 Tube Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-19 Hose Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-20 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-20 Tube to Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197-21 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-2 Tilt Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-2 Radiator Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-3 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-4 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-5 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-6 Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-7 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-8 Right Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-9 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-10 Right Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-11 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-12 Rear Hose Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-13 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-14 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-15 Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-16 Radiator Hose Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-17 Tilt Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-17 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198-18

Tilt Cylinder Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0198

Bottom Guards Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0199 ii

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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 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 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.
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Front Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-3 Middle Bottom Guard Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-4 Middle Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-5 Rear Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-6 Rear Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-7 Middle Bottom Guard Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-8 Middle Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-9 Front Bottom Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0199-10 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-1 Fresh Air Intake Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-2 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-2 Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-3 Pre-Cleaner Body Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-4 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-4 Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-5 Hood Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-6 Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-6 Grommets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-7 Slides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-8 Hood Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-8 Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-9 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-10 Pre-Cleaner Body Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-10 Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-11 Muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-12 Fresh Air Intake Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-12 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0200-13 Left Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-2 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-3 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-4 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-5 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-6 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-7 Door Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-8 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-9 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-9 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-10 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-11 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-12 Left Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0201-13 Left Engine Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-1 Left Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0202-2 iii

Hood Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0200

Engine Enclosure Left Door Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0201

Engine Enclosure Left Door Guard Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0202

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WP Sequence No. Page No. 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 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. Figure 19.
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Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202-3 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202-4 Arctic Heater Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202-5 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202-6 Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202-7 Left Engine Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202-7 Left Engine Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202-8 Right Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-2 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-3 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-4 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-5 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-6 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-7 Door Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-8 Door Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-9 Latch Pawl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-9 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-10 Striker Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-11 Hinge Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-12 Right Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203-13 Right Engine Plate and Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204-1 Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204-2 Right Engine Plate and Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204-3 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-2 Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-3 Cylinder Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-4 Radiator Drain Hose and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-5 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-5 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-6 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-6 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-7 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-7 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-8 Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-9 Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-10 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-11 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-11 Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-12 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-13 Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-13 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-14 Radiator Drain Hose and Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . 0205-14 iv

Engine Enclosure Right Door Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0203

Engine Enclosure Right Door Guard Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0204

Radiator Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0205

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WP Sequence No. Page No.
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Figure 20. Cylinder Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0205-15 Figure 21. Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0205-16 Figure 22. Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0205-17 Platform Enclosure Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0206 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 1. Figure 2. Figure 3. Figure 4. Figure 5. Steering Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-2 Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-3 Heater Core Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-4 Heater and A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-5 A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-6 Light Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-7 Fuse Box Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-8 Fuse Box Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-9 Brake Solenoid Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-10 Brake Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-11 Transmission Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . .0206-12 Chassis Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-13 Arctic Heater Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . .0206-14 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-15 Rear Cab Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-16 Front Cab Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-17 Lower Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-18 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-19 Lower Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-20 Front Cab Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-21 Rear Cab Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-22 Bracket Links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-22 Arctic Heater Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . .0206-23 Chassis Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-24 Transmission Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . .0206-25 Brake Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-26 Brake Solenoid Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-27 Fuse Box Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-28 Fuse Box Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-29 Light Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-30 A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-31 Heater and A/C Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-32 Heater Core Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-33 Engine Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-34 Steering Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0206-35 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-1 Lower Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-2 Upper Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-3 Upper Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-4 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0207-5 v

Left Platform Access Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0207

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No.
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Right Platform Access Panels Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0208 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 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-2 Right Armrest Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-3 Lower Right Access Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . 0208-4 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-5 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-6 Switch Pod Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-7 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-8 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-9 Switch Panel Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-10 Pod Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-11 Switch Pod Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-12 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-12 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-13 Lower Right Access Panels Installation. . . . . . . . . . . . . . . . . . . . . 0208-14 Right Armrest Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-15 Cab Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208-16 Right Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-2 Right Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-3 Harness Connector, Plate, and Clip. . . . . . . . . . . . . . . . . . . . . . . . . 0209-4 Right Front Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-5 Platform Harness to Instrument Panel Harness Connector. . . . . . . 0209-6 Platform Harness to Platform Floor. . . . . . . . . . . . . . . . . . . . . . . . . 0209-7 Fuse Panel Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-7 Platform Rear Harness Connections. . . . . . . . . . . . . . . . . . . . . . . . 0209-8 Platform Rear Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . . 0209-9 Platform Rear Harness Connector Plate. . . . . . . . . . . . . . . . . . . . 0209-10 Power Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-10 Platform Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-11 Machine ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-12 Harness Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-13 Left Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-14 Left Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-15 Harness Ground Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-16 Machine ECM Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-17 Platform Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-17 Power Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-18 Platform Rear Harness Connector Plate. . . . . . . . . . . . . . . . . . . . 0209-18 Platform Rear Harness Connectors. . . . . . . . . . . . . . . . . . . . . . . . 0209-19 Platform Rear Harness Connections. . . . . . . . . . . . . . . . . . . . . . . 0209-20 Fuse Panel Access Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-21 Platform Harness to Platform Floor. . . . . . . . . . . . . . . . . . . . . . . . 0209-21 Platform Harness to Instrument Panel Harness Connector. . . . . . 0209-22 Right Front Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209-23 vi

Platform Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0209

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No.
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Figure 28. Harness Connector, Plate, and Clip. . . . . . . . . . . . . . . . . . . . . . . .0209-24 Figure 29. Right Side Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0209-25 Figure 30. Right Rear Harness Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0209-26 Cylinder Flood Lamp and Bracket Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0210 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. 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 1. Figure 2. Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-1 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-2 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-3 Flood Lamp Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-4 Disconnecting Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . .0210-5 Bulb Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-6 Connecting Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-7 Flood Lamp Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-8 Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-9 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-10 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0210-11 Top Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-2 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-3 Hoses and Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-4 Control Lever Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-5 Front Side Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-6 Control Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-7 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-8 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-9 Steering Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . .0211-10 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0211-11 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0211-12 Ripper Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . .0211-13 Ripper Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . .0211-14 Valve Cap Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-14 Ripper Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . .0211-16 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0211-17 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . .0211-18 Steering Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . .0211-19 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-20 Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-21 Control Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-22 Front Side Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-23 Control Lever Linkage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-24 Hoses and Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-25 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-26 Top Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0211-27 Hose Removal from Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . .0212-2 Hose Connections at Front of Valve Bank. . . . . . . . . . . . . . . . . . . .0212-3 vii

Valve Bank GP - Test 5 Service with Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0211

Valve Bank GP - Test 4 Service With Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0212

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. 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 7.
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Hose Connections at Rear of Valve Bank. . . . . . . . . . . . . . . . . . . . 0212-3 Disconnecting Steering Control Link. . . . . . . . . . . . . . . . . . . . . . . . . 0212-4 Valve Bank Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-5 Hose Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-6 Valve Bank Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-7 Valve Bank Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-8 Cover O-ring Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-9 Winch Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-10 O-ring Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-11 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . 0212-12 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . 0212-13 Steering Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-14 Valve Cap Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-14 O-ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-16 Steering Control Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . 0212-17 Bulldozer Lift Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . 0212-17 Bulldozer Tilt Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . 0212-18 Winch Control Valve Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-19 O-ring Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-20 Valve Bank Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-21 Bracket Link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-22 Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-23 Control Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-24 Connecting Steering Control Link. . . . . . . . . . . . . . . . . . . . . . . . . . 0212-24 Hose Connections at Rear of Valve Bank. . . . . . . . . . . . . . . . . . . 0212-25 Hose Connections at Front of Valve Bank. . . . . . . . . . . . . . . . . . . 0212-25 Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212-26 Ripper Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0213-2 Winch Manifold Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-2 Winch Manifold Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-3 Winch Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-4 Winch Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-5 Winch Manifold Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-6 Winch Manifold Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214-7 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-2 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-3 Upper Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-4 Quick Drop Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-5 Upper Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-7 Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-7 Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215-8

Ripper Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0213 Winch Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0214

Quick Drop Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0215

viii

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Control Manifold Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0216 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 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-2 Control Valve Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-3 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-4 Control Manifold Assembly Sampling Valve and Fitting. . . . . . . . . .0216-5 Sampling Valve and Fittings Disassembly. . . . . . . . . . . . . . . . . . . .0216-6 Control Manifold Assembly Diagnostic Port Fitting. . . . . . . . . . . . . .0216-7 Diagnostic Port Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . . .0216-8 Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-9 Front Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-9 Control Manifold Assembly Elbow Fitting. . . . . . . . . . . . . . . . . . . .0216-10 Elbow Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-10 Control Manifold Assembly T Fitting. . . . . . . . . . . . . . . . . . . . . . . .0216-11 Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-12 Rear Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-13 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-14 Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-14 Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-15 Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-16 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-17 Rear Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-18 Fitting Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-19 Control Manifold Assembly T Fitting. . . . . . . . . . . . . . . . . . . . . . . .0216-20 Elbow Fitting Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-21 Control Manifold Assembly Elbow Fitting. . . . . . . . . . . . . . . . . . . .0216-21 Front Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-22 Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-22 Diagnostic Port Fitting Disassembly. . . . . . . . . . . . . . . . . . . . . . . .0216-23 Control Manifold Assembly Diagnostic Port Fitting. . . . . . . . . . . . .0216-24 Sampling Valve and Fittings Assembly. . . . . . . . . . . . . . . . . . . . . .0216-25 Control Manifold Assembly Sampling Valve and Fitting. . . . . . . . .0216-26 Control Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-27 Control Valve Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-28 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-29 Test Equipment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-30 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0216-31 Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-2 Counterbalance Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-3 Counterbalance Valve Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-4 Counterbalance Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0217-5 Fire Extinguisher and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-1 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-2 Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0218-3 ix

Counterbalance Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0217

Lowering Equipment with Engine Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0218

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WP Sequence No. Page No. 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 15. 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 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9.
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Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218-4 Fire Extinguisher and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218-5 Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-1 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-2 Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-3 Blower Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-4 Resistor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-5 Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-5 Blower Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-6 Gasket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-7 Blower Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-8 Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-9 Resistor Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-9 Blower Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-10 Temperature Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-11 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-12 Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0219-12 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-2 Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-3 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-3 Hose Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-4 AC Evaporator Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-5 Temperature Switch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-6 Cab Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-6 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220-7 Heater Hose Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-1 Heater Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-2 Heater Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-3 Heater Coil Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-4 Heater Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-5 Heater Hose Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221-6 Cab Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-1 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-2 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-2 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . . 0222-3 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-4 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-4 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-5 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . . 0222-6 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222-7

Blower Fan Case Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0219

Air Conditioner Evaporator Coil Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0220

Heater Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0221

Front Wiper Motor, Wiper Arm and Wiper Blade Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0222

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WP Sequence No. Page No.
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Figure 10. Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0222-7 Figure 11. Cab Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0222-8 Rear Wiper Motor, Wiper Arm, and Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0223 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 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 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 1. Figure 2. Figure 3. Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-1 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . .0223-2 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-3 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-3 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-4 Bolt and Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-4 Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-5 Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-5 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-6 Spray Nozzle, Hose, and Wiper Arm. . . . . . . . . . . . . . . . . . . . . . . .0223-7 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0223-8 Washer Bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0224-2 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0225-2 ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0225-3 ROPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0225-4 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0225-5 Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-1 Front Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-2 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0226-3 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-4 Left Column Access Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-4 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0226-5 Front Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-6 Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0226-7 Rear Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-1 Rear Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-2 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0227-3 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-4 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-5 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-6 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0227-7 Rear Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-8 Rear Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0227-9 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-2 Door Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-3 Door Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0228-4 xi

Washer Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0224 ROPS Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0225

Front Washer Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0226

Rear Washer Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0227

Door Washer Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0228

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WP Sequence No. Page No. 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 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 1. Figure 2. Figure 3.
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Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . . 0228-5 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228-6 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228-7 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228-8 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228-9 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . 0228-10 Door Washer Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228-11 Door Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228-12 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228-13 Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-1 Front Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-2 Headliner and Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-2 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-3 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-4 Rear Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-4 Rear Headliner Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-5 Headliner Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-6 Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-7 Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-7 Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-8 Cab Lamp Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-8 Right-hand Pillar Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-9 Left-hand Pillar Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-10 Right-hand Pillar Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-11 Cab Lamp Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-11 Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-12 Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-12 Speaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-13 Headliner Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-14 Rear Headliner Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-15 Rear Wiper Motor Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-16 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-16 Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-17 Headliner and Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-18 Front Wiper Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-18 Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229-19 Floor Mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230-1 Front Floor Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230-2 Floor Mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230-3 Floor Mat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231-1 Rear Floor Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231-2 Rear Floor Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231-3 xii

Headliner and Interior Trim Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0229

Front Floor Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0230

Rear Floor Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0231

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WP Sequence No. Page No.
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Headliner Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0232 Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. 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. Headliner Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0232-2 Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0233-1 Cab Lamp Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0233-2 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0233-2 Cab Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0233-3 Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0234-1 Wiper Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0234-2 Wiper Control Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0234-3 Wiper Control Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0234-4 Wiper Control Plate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0234-5 Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0235-1 Rearview Mirror Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0235-2 Rearview Mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0235-3 Messenger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0236-2 Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-2 Steering Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-3 Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-4 Shaft and Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-5 Main Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-6 Parking Brake Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-7 Parking Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-7 Parking Brake Switch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-8 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-8 Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-9 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-10 Backup Alarm Switch Connections. . . . . . . . . . . . . . . . . . . . . . . . .0237-11 Backup Alarm Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-12 Sensor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-12 Forward/Neutral/Reverse Sensor. . . . . . . . . . . . . . . . . . . . . . . . . .0237-13 Detent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-13 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-14 Main Control Housing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-14 Lock Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-15 Lock Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-16 Main Control Housing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-17 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-17 Detent Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0237-18 Forward/Neutral/Reverse Sensor. . . . . . . . . . . . . . . . . . . . . . . . . .0237-18 xiii Cab Overhead Interior Lamp Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0233

Wiper Control Plate and Switches Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0234

Rearview Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0235

Messenger Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0236 Steering, Transmission Control and Parking Brake Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . WP 0237

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WP Sequence No. Page No. 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 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 1. 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 7. Figure 8. Figure 1. Figure 2. Figure 3.
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Sensor Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-19 Backup Alarm Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-19 Backup Alarm Switch Connections. . . . . . . . . . . . . . . . . . . . . . . . . 0237-20 Handle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-21 Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-22 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-23 Parking Brake Switch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-23 Parking Brake Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-24 Parking Brake Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-24 Main Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-25 Shaft and Collar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-26 Control Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-27 Steering Control Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-28 Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237-29 Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0238-1 Bracket. (Hydraulic lines removed for clarity). . . . . . . . . . . . . . . . . . 0238-2 Steering Control Rod Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 0238-3 Bracket. (Hydraulic lines removed for clarity). . . . . . . . . . . . . . . . . . 0238-4 Steering Control Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0238-5 Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0239-2 Receiver Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0240-2 Compressor Hose to Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . 0241-2 Receiver Dryer Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . 0241-3 Receiver Dryer Hose to Condenser Coil. . . . . . . . . . . . . . . . . . . . . . 0241-4 Receiver Dryer Hose to Condenser Coil. . . . . . . . . . . . . . . . . . . . . . 0241-5 Receiver Dryer Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . 0241-6 Compressor Hose to Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . 0241-7 Compressor Hose to Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . 0242-2 Accumulator Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . 0242-3 Accumulator Hose Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-4 Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-5 Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-6 Accumulator Hose to Evaporator Coil. . . . . . . . . . . . . . . . . . . . . . . . 0242-7 Accumulator Hose Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0242-8 Compressor Hose to Accumulator. . . . . . . . . . . . . . . . . . . . . . . . . . 0242-9 Heater Hose Shutoff Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-2 Right Side Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-3 Transmission Cooler Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0243-3 xiv

Steering Control Rod Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0238

Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0239 Receiver Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0240 Air Conditioning High Pressure Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0241

Air Conditioning Low Pressure Hoses Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0242

Heater Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0243

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No. 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 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 1. Figure 2. Figure 3.
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Rear Engine Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0243-4 Heater Coil and Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0243-5 Heater Coil and Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0243-6 Rear Engine Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0243-7 Transmission Cooler Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0243-8 Right Side Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0243-8 Heater Hose Shutoff Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0243-9 Water Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-1 Water Valve Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-2 Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-3 Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-4 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-5 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-6 Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-7 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-8 Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-8 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-9 Water Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-10 Water Valve Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-11 Water Valve Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0244-12 Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . .0245-2 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-3 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-4 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-5 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-6 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-7 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-8 Harness Connector and Angle Bracket. . . . . . . . . . . . . . . . . . . . . . .0245-8 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-9 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-10 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-11 Harness Connector and Angle Bracket. . . . . . . . . . . . . . . . . . . . . .0245-12 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-12 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-13 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-13 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-14 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-15 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0245-16 Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . .0245-17 Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-2 Rear Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-3 Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0246-4 xv

Water Valve and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0244

Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0245

Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0246

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No. 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. 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 1.
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Left Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0246-5 Left Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0246-6 Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0246-7 Rear Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0246-8 Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0246-9 Headrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-1 Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-2 Seat Belt Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-3 Seat Belt Buckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-3 Seat Back Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-4 Seat Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-4 Seat Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-6 Mark Latch and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-6 Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-7 Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-7 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-8 Seat Recliner Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-8 Recliner Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-9 Lumbar Support Adjustment Knob. . . . . . . . . . . . . . . . . . . . . . . . . 0247-10 Seat Adjuster Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-10 Seat Adjuster Release Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-11 Lumbar Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-11 Seat Back Bag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-12 Lumbar Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-13 Seat Adjuster Release Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-13 Seat Adjuster Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-14 Lumbar Support Adjustment Knob. . . . . . . . . . . . . . . . . . . . . . . . . 0247-14 Recliner Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-15 Seat Recliner Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-16 Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-16 Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-17 Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-17 Mark Latch and Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-18 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-18 Seat Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-19 Seat Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-19 Seat Back Cushion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-20 Seat Belt Buckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-20 Seat Belt Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-21 Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-22 Headrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0247-23 Seat Suspension Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0248-2 xvi

Seat Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0247

Seat Suspension Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0248

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No. 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. Figure 29. 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.
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Seat Suspension Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0248-3 Door Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-1 Interior Door Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-2 Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-2 Cap and Grip Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-3 Grip Handle Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-3 Interior Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-4 Door Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-5 Hose and Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-6 Exterior Door Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-7 Door and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-8 Window and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-9 Retaining Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-10 Exterior Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-11 Linkage Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-11 Door Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-12 Linkage Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-13 Exterior Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-13 Retaining Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-14 Window and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-15 Door and Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-16 Exterior Door Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-17 Hose and Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-18 Door Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-19 Interior Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-20 Grip Handle Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-20 Cap and Grip Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-21 Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-21 Interior Door Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-22 Door Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0249-22 Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-1 Spray Nozzle and Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-2 Washer Hose Nut and Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-2 Wiper Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-3 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-4 Spray Nozzle and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-5 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-5 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-6 Spray Nozzle and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-7 Wiper Motor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-8 Wiper Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-9 Washer Hose Nut and Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-9 Spray Nozzle and Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0250-10 xvii

Door Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0249

Door Wiper Motor, Wiper Arm and Wiper Blade Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0250

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No.
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Figure 14. Wiper Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0250-11 Outside Cab Door Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0251 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. 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. Door Latch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0251-1 Door Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0251-2 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0251-3 Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0251-3 Latch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0251-4 Latch Striker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0251-5 Door Latch Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0251-6 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-3 Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-4 Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-5 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-6 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-7 Lamp Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-8 Flood Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-9 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0252-10 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-1 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-2 Flood Lamp and Adjusting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . 0253-3 Adjusting Bracket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-4 Flood Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-5 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-5 Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-6 Flood Lamp Screws and Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-6 Flood Lamp Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-7 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-7 Bulb Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-8 Flood Lamp Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-9 Flood Lamp Screws and Trim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-9 Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-10 Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-10 Flood Lamp Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-11 Adjusting Bracket Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-12 Flood Lamp and Adjusting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . 0253-13 Flood Lamp Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-14 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0253-14 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-2 Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . . 0254-3 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-4 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0254-5

Cab Flood Lamp and Bracket Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0252

Engine Flood Lamp and Bracket Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0253

Cab Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0254

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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 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. 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 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10.
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Instrument Panel Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-6 Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-7 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . . .0254-8 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-9 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-10 Ground Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-10 Cab Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-11 Cab Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-12 Ground Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-13 Left Column Access Hole. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-13 Hose and Harness Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-14 Washer Electrical Harness and Hoses. . . . . . . . . . . . . . . . . . . . . .0254-15 Front Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-16 Instrument Panel Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-17 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-18 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-19 Electrical Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . .0254-20 Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0254-21 Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0255-1 Fire Extinguisher Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0255-2 Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0255-3 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0256-1 Pilot Valve and Hand Control Assembly. . . . . . . . . . . . . . . . . . . . . .0256-2 Knob, Base Plate and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0256-3 Knob, Base Plate and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0256-4 Pilot Valve and Hand Control Assembly. . . . . . . . . . . . . . . . . . . . . .0256-5 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0256-5 Winch Pilot Valve Hoses and Connectors. . . . . . . . . . . . . . . . . . . .0257-1 Winch Pilot Valve and Plate Assembly. . . . . . . . . . . . . . . . . . . . . . .0257-2 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0257-3 Dash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-2 Tiedown Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-2 Instrument Panel Electrical Connectors. . . . . . . . . . . . . . . . . . . . . .0258-3 Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-3 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-4 Wiring Harnesses and Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-5 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . . .0258-6 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . . .0258-7 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-7 Decelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0258-8

Fire Extinguisher and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0255

Pilot Valve Service (With Ripper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0256

Pilot Valve Service (With Winch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0257

Governor and Brake Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0258

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WP Sequence No. Page No. 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 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 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5.
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Decelerator Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-9 Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-9 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . . 0258-10 Brake Pedal, Foot Pad, and Sensor. . . . . . . . . . . . . . . . . . . . . . . . 0258-10 Wiring Harnesses and Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-11 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-12 Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-12 Dash Electrical Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-13 Tiedown Strap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-13 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0258-14 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-2 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-3 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-3 Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-4 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-5 Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-6 Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-6 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-7 Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-8 Electrical Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-9 Hoses and Pilot Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-9 Retainer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0259-10 Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0260-2 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0260-3 Platform Harness to Instrument Panel Harness Connector. . . . . . . 0260-4 Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-5 Platform Harness to Harness Connector. . . . . . . . . . . . . . . . . . . . . 0260-5 Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-6 Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-7 Platform Harness to Instrument Panel Harness Connector. . . . . . . 0260-7 Instrument Panel Main Harness Connector. . . . . . . . . . . . . . . . . . . 0260-8 Platform Harness to Instrument Panel Harness Connector. . . . . . . 0260-8 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0260-9 Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0260-10 Air Conditioning Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 0261-2 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-2 Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-3 Heater Control Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-4 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-4 Support Cable and Gauge Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . 0262-5

Pilot Valve Bulldozer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0259

Instrument Panel Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0260

Air Conditioning Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0261 Instrument Panel Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0262

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WP Sequence No. Page No. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 1. Figure 2. Figure 3. Figure 4. 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 1. Figure 2. Figure 3.
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Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-6 Connector Clamps and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . .0262-7 Indicator Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-8 Upper Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-9 Lower Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-10 Light Socket Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-11 Level and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-11 Level and Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-12 Light Socket Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-13 Lower Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-14 Upper Half of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-15 Indicator Bulb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-16 Connector Clamps and Brackets. . . . . . . . . . . . . . . . . . . . . . . . . .0262-17 Heater Control Knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-18 Support Cable and Gauge Lights. . . . . . . . . . . . . . . . . . . . . . . . . .0262-19 Instrument Panel Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-20 Heater Control Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-20 Back of Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-21 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0262-22 Recovery Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0263-3 Evacuation Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0263-5 Low Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0263-6 Charging Hook-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0263-8 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-2 Pin and Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-3 Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-3 Bearing and Bearing Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-4 Pin and Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-5 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0264-6 Lower Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-2 Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-3 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-4 Lower Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-5 Lower Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-6 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-7 Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-8 Lower Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0265-8 Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-3 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-4 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0266-5

Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0263

Yoke Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0264

Lift Cylinder Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0265

Lift Cylinder (Bulldozer) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0266

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WP Sequence No. Page No. 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 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.
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Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0266-6 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0266-7 Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0266-9 Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0266-9 Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0266-10 Upper Hose Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0266-11 Upper Hose Connection Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0266-12 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-2 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-3 Sling and Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-4 Retainer and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-4 Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-5 Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-6 Sling and Lifting Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-7 Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-8 Retainer and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-8 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-9 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0267-10 Hoses and Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-2 Manifold Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-3 Lift Cylinder Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-4 Retaining Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-5 Push Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-6 Push Arm Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-7 Support Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-8 Blade Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-9 Left Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-11 Pin and Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-12 Knuckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-13 Stabilizer Bar Yoke on Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-14 Stabilizer Bar Yoke on Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-15 Knuckle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-16 Pin and Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-17 Left Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-18 Blade Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-19 Push Arm Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-20 Push Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-20 Retaining Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-21 Lift Cylinder Yoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-22 Support Stabilizer Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-23 Manifold Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-24 Hoses and Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0268-25

Tilt Cylinder (Bulldozer) Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0267

Blade Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0268

Blade Cutting Edge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0269 xxii

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WP Sequence No. Page No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. 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 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 1. Figure 2. Figure 3.
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Blade Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0269-2 Blade Cutting Edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0269-3 Blade Cutting Edge Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0269-4 Blade Cutting Edges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0269-5 Blade Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0269-6 Cutting Edge Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0269-7 Tilt Cylinder and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0270-3 Left Hand Stabilizer Bar and Pin. . . . . . . . . . . . . . . . . . . . . . . . . . . .0271-2 Winch Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-3 Winch Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-4 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-5 Lifting Device Attached to Winch. . . . . . . . . . . . . . . . . . . . . . . . . . .0272-6 Winch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-7 Winch Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-8 Winch Adapter Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-9 Installing Winch on Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-10 Winch Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-11 Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-11 Winch Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-12 Winch Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0272-13 Winch Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-3 Hose Connections at Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-4 Retainer Clip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-5 Hose Retainer Clip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-5 Hose Retainer Clip Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-6 Hose Connections at Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . .0273-6 Pump Hose and Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-7 Pump Hose and Retainer Clips. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-8 Hose Connections at Valve Bank. . . . . . . . . . . . . . . . . . . . . . . . . . .0273-9 Hose Retainer Clip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-9 Hose Retainer Clip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-10 Retainer Clip Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-10 Hose Connections at Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-11 Winch Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0273-12 Winch Plug Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0274-2 Winch Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0275-2 Removing Cable from Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0275-3 Installing Cable on Winch Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . .0275-4 xxiii

Blade Tilt Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0270 Blade Pitch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0271 Winch Assembly Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0272

Winch Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0273

Winch Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0274 Winch Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0275

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Cylinder Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0276 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. Figure 7. Figure 8. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 1. Figure 1. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Ripper Cylinder Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0276-3 Ripper Cylinder Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0276-4 Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-3 Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-3 Ripper Lift Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-4 Ripper Lift Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-4 Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-5 Ripper Lift Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-6 Ripper Lift Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-6 Ripper Lift Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0277-7 Ripper Tilt Cylinder Hose Assemblies. . . . . . . . . . . . . . . . . . . . . . . 0278-2 Ripper Tilt Cylinder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278-3 Ripper Tilt Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278-4 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278-4 Ripper Tilt Cylinder Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278-5 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278-6 Ripper Tilt Cylinder Head End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278-6 Ripper Tilt Cylinder Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0278-7 Ripper Frame Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-2 Ripper Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-3 Tiedown Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-4 Tiedown Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-5 Ripper Frame Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-6 Ripper Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0279-7 Ripper Tooth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0280-2 Shank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0281-2 Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-2 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-2 Ripper Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-3 Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-5 Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-7 Ripper Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-8 Ripper Tilt Cylinder Rod End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-9 Ripper Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0282-10

Cylinder, Ripper Lift Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0277

Cylinder, Ripper Tilt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0278

Ripper Frame Assembly Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0279

Ripper Tooth Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0280 Ripper Shank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0281 Ripper Carriage Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0282

Arctic Kit Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0283 Arctic Kit Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0284

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Arctic Kit Heater Fuel Flow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0285 Figure 1. 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 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. Measuring Fuel Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0285-3 Intake and Exhaust Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0286-1 Intake and Exhaust Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0286-2 Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0287-2 Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0287-3 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0287-4 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . . .0287-5 Positive Battery Cables at Terminal. . . . . . . . . . . . . . . . . . . . . . . . .0287-6 Negative Battery Cables at Disconnect Switch. . . . . . . . . . . . . . . . .0287-7 Negative Battery Cable and Grommets. . . . . . . . . . . . . . . . . . . . . .0287-8 Arctic Kit Positive Battery Cable at Terminal. . . . . . . . . . . . . . . . . .0287-9 Arctic Kit Positive Battery Cables at Junction Block. . . . . . . . . . . .0287-10 Arctic Kit Positive Battery Cables at Junction Block. . . . . . . . . . . .0287-11 Arctic Kit Positive Battery Cable at Terminal. . . . . . . . . . . . . . . . .0287-12 Negative Battery Cable and Grommets. . . . . . . . . . . . . . . . . . . . .0287-13 Negative Battery Cables at Disconnect Switch. . . . . . . . . . . . . . . .0287-14 Positive Battery Cables at Terminal. . . . . . . . . . . . . . . . . . . . . . . .0287-15 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . .0287-16 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0287-17 Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0287-18 Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0287-19 Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-2 Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-3 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-4 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . . .0288-5 Arctic Kit Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-6 Positive and Negative Arctic Kit Battery Cables. . . . . . . . . . . . . . . .0288-8 Cable Clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-9 Crossover Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-10 Arctic Kit Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0288-11 Battery Box Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-1 Arctic Kit Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-2 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-2 Mounting Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-3 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-3 Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-4 Mounting Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-4 Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-5 Arctic Kit Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0289-5 Arctic Kit Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0286

Arctic Kit Battery Cables and Junction Block Power Cable Replacement. . . . . . . . . . . . . . . . . . . . . . . WP 0287

Arctic Kit Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0288

Arctic Kit Battery Box Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0289

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WP Sequence No. Page No.
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Figure 10. Battery Box Latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0289-6 Arctic Kit Heater Switch and Heater Harness Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0290 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. Figure 6. Figure 7. Figure 8. Figure 9. Figure 1. Figure 2. Figure 3. Figure 4. Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-1 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-2 Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-2 Arctic Kit Heater Switch Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-3 Engine Compartment Arctic Kit Heater Harness at Heater. . . . . . . . 0290-3 Engine Compartment Arctic Kit Heater Harness. . . . . . . . . . . . . . . 0290-4 Platform Arctic Kit Heater Harness. . . . . . . . . . . . . . . . . . . . . . . . . . 0290-5 Platform Arctic Kit Heater Harness. . . . . . . . . . . . . . . . . . . . . . . . . . 0290-6 Engine Compartment Arctic Kit Heater Harness. . . . . . . . . . . . . . . 0290-7 Engine Compartment Arctic Kit Heater Harness at Heater. . . . . . . . 0290-8 Arctic Kit Heater Switch Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-8 Arctic Kit Heater Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-9 Switch Pod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-9 Upper Right Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0290-10 Arctic Kit Heater Fuel Shutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-1 Arctic Kit Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-2 Arctic Bracket from Below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-3 Arctic Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-3 Coolant Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-4 Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-5 Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-6 Coolant Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-7 Arctic Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-8 Arctic Bracket from Below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-8 Arctic Kit Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-9 Arctic Kit Heater Fuel Shutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0291-10 Arctic Kit Heater Lower Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . 0292-2 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0292-3 Arctic Kit Heater Upper Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . 0292-4 Arctic Kit Heater Upper Coolant Routing. . . . . . . . . . . . . . . . . . . . . 0292-5 Arctic Kit Heater Upper Coolant Fitting. . . . . . . . . . . . . . . . . . . . . . . 0292-6 Arctic Kit Heater Upper Coolant Routing. . . . . . . . . . . . . . . . . . . . . 0292-7 Arctic Heater Upper Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . 0292-7 Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0292-8 Arctic Kit Heater Lower Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . 0292-9 Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0293-3 Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . 0293-4 Arctic Kit Heater Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . 0293-5 Arctic Kit Heater Fuel Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0293-6

Arctic Kit Heater and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0291

Arctic Kit Heater Hoses and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0292

Arctic Kit Fuel Metering Pump, Hose, and Fitting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0293

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TABLE OF CONTENTS - CONTINUED


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

Arctic Kit Heater Fuel Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0293-7 Arctic Kit Heater Fuel Metering Pump. . . . . . . . . . . . . . . . . . . . . . . .0293-8 Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . .0293-9 Arctic Kit Heater Fuel Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . .0293-10 Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0294-2 Front Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0294-3 Rear Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0294-4 Front Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0294-5

Using Jack Stands to Support Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0294

Mechanical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0295 Electrical General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0296 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 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Connector Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-2 Splicing Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-3 Ring Terminal Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-4 Military Connector Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-5 Weatherproof Connector - Female. . . . . . . . . . . . . . . . . . . . . . . . . .0296-6 Female Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-7 Weatherproof Connector - Female. . . . . . . . . . . . . . . . . . . . . . . . . .0296-7 Weatherproof Connector - Male. . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-8 Male Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-8 Weatherproof Connector - Male. . . . . . . . . . . . . . . . . . . . . . . . . . . .0296-9 Tiedown Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-3 Floodlamp Wiring Harness and Connector. . . . . . . . . . . . . . . . . . . .0297-6 Footlight Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-7 Quick Drop Valve Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-8 Lift Cylinder Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-9 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-9 Lift Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-10 Exhaust Pipe Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-11 Exhaust Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-11 Battery Cable Connections at Junction Block and Stud. . . . . . . . .0297-13 Arctic Kit Heater Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . .0297-14 Arctic Kit Heater Battery Connections. . . . . . . . . . . . . . . . . . . . . . .0297-15 Arctic Kit Heater Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-16 Wiring Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . . .0297-17 Headrest Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-17 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-18 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-18 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-19 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-19 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-20 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0297-20 Wiring Harness Connector and Angle Bracket. . . . . . . . . . . . . . . .0297-21

Preparation for Transport and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0297

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TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No. 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 1. Figure 2. Figure 3. Figure 4. Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Table 8.
-

Cab Lift Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-22 Cab Lift Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-24 Wiring Harness Connector and Angle Bracket. . . . . . . . . . . . . . . . 0297-25 Surround. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-25 Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-26 Cab Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-27 Cab Bolts at Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-27 Rifle Rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-28 Messenger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-28 Headrest Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-29 Wiring Harness and Washer Hoses. . . . . . . . . . . . . . . . . . . . . . . . 0297-29 Arctic Kit Heater Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-31 Arctic Kit Heater Battery Connections. . . . . . . . . . . . . . . . . . . . . . 0297-32 Battery Cable Connections at Junction Block and Stud. . . . . . . . . 0297-33 Arctic Kit Heater Battery Box Cover. . . . . . . . . . . . . . . . . . . . . . . . 0297-34 Exhaust Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-35 Exhaust Pipe Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-36 Lift Cylinder Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-37 Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-38 Lift Cylinder Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-38 Quick Drop Valve Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-39 Floodlamp Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-39 Floodlamp Wiring Harness Connector. . . . . . . . . . . . . . . . . . . . . . 0297-40 Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-41 Thrust Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-42 Outer Axle Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-43 Axle Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0297-43 Front Towing Eye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000297-44 Rear Towing Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 000297-44 Extension Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-2 Torque Wrench Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-2 Torque Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-2 Measuring a Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-3 Torque Limits - SAE Standard Fasteners. . . . . . . . . . . . . . . . . . . . . 0298-4 Torque Limits - Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-5 37 Degree Flare Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-6 Straight Thread with O-ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-7 Split Flange Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-7 O-ring Face Seal End. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-8 O-ring Boss End Fitting or Locknut. . . . . . . . . . . . . . . . . . . . . . . . . . 0298-8 Pipe Fitting.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0298-9

Torque Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0298

Schematics Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0299 Chapter 5 - Supporting Information References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0300 xxviii

TM 5-2410-241-23-3

TABLE OF CONTENTS - CONTINUED


WP Sequence No. Page No.
-

Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0301 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0302 Table 1. Table 2. Table 3. Maintenance Allocation Chart (MAC) for D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper.. . .0302-1 Tools and Test Equipment for the D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper.. .0302-15 Remarks for the D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper. . . . . . . . . . . . . . . . . . . . .0302-18 Expendable and Durable Items for the D7R Series II Dozer, Type I with Winch and D7R Series II Dozer, Type II with Ripper . . .0303-2 Pressure Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0304-1

Expendable and Durable Items List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0303 Table 1.

Special Fabricated Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0304 Figure 1.

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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.

xxx

22 TM 5-2410-241-23-3 0197

FIELD MAINTENANCE LIFT CYLINDER LINES REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 9 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) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (4) Seal (2) References WP 0295 Personnel Required Two
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Engine enclosure right door guard removed (WP 0204) Front floor plate removed (WP 0230) Cab seat removed (WP 0247) Fire extinguisher and bracket removed (WP 0255) Front bottom guards removed (WP 0199) Drawing Required TM 5-2410-241-24P, Figure 80

Estimated Time to Complete 10.0 Hr

0197-1

TM 5-2410-241-23-3

0197

REMOVAL

000197

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.

1. Remove eight bolts (Figure 1, Item 6), washers (Figure 1, Item 5), and two flanges (Figure 1, Item 3) from tubes (Figure 1, Item 2). 2. Disconnect two tubes (Figure 1, Item 2) from hoses (Figure 1, Item 1), and remove and discard two O-rings (Figure 1, Item 4).

Figure 1. Tube to Hose Connection.

0197

0197-2

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED 3. 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. 4. Remove bolt (Figure 3, Item 2), washer (Figure 3, Item 3), and retaining strap (Figure 3, Item 1) from hoses (Figure 3, Item 4). Position hoses aside.

0197

5. Remove two bolts (Figure 3, Item 7), washers (Figure 3, Item 6), and bracket (Figure 3, Item 5) from machine.

Figure 3. Hose Bracket.

0197

0197-3

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED 6. Remove bolt (Figure 4, Item 7), washer (Figure 4, Item 6), two retaining straps (Figure 4, Item 5), and clips (Figure 4, Item 4) from tubes (Figure 4, Items 8 and 9). 7. Remove bolt (Figure 4, Item 1), washer (Figure 4, Item 2), and bracket (Figure 4, Item 3) from machine. 8. Remove nut (Figure 4, Item 10), two retaining straps (Figure 4, Items 11 and 12), washer (Figure 4, Item 14), and bolt (Figure 4, Item 15) from bracket (Figure 4, Item 13). 9. Remove nut (Figure 4, Item 23), two retaining straps (Figure 4, Items 20 and 22), spacer (Figure 4, Item 21), washer (Figure 4, Item 19), and bolt (Figure 4, Item 18) from bracket (Figure 4, Item 13). 10. Remove two bolts (Figure 4, Item 17), washers (Figure 4, Item 16), and bracket (Figure 4, Item 13) from machine.

Figure 4. Tube Clamps.

0197

0197-4

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED 11. Remove four bolts (Figure 5, Item 5), washers (Figure 5, Item 6), and two brackets (Figure 5, Item 2) from radiator guard (Figure 5, Item 1).

NOTE
Tubes will not be easy to remove from radiator guard. With assistance guide each tube individually from guard. Tag hoses and tubes to aid installation.

12. With assistance remove eight bolts (Figure 5, Item 3), washers (Figure 5, Item 4), and two tubes (Figure 5, Item 8) from machine. 13. Remove two seals (Figure 5, Item 7) from two tubes (Figure 5, Item 8). Discard seals.

Figure 5. Quick Drop Valve.

0197

0197-5

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED 14. Remove four bolts (Figure 6, Item 3), washers (Figure 6, Item 4), four clamps (Figure 6, Item 2), and grommets (Figure 6, Item 5) from two hoses (Figure 6, Item 1).

Figure 6. Front Hose Clamps.

0197

0197-6

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED 15. Remove four bolts (Figure 7, Item 3), washers (Figure 7, Item 4), four clamps (Figure 7, Item 2), and grommets (Figure 7, Item 5) from two hoses (Figure 7, Item 1). Position hoses aside.

Figure 7. Upper Rear Hose Clamps.

0197

0197-7

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED

NOTE
Tag all hoses to aid installation. 16. Remove four bolts (Figure 8, Item 3), washers (Figure 8, Item 4), four clamps (Figure 8, Item 2), and grommets (Figure 8, Item 1) from two hoses (Figure 8, Item 5).

Figure 8. Lower Rear Hose Clamps.

0197

0197-8

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0197

REMOVAL CONTINUED 17. Disconnect cable (Figure 9, Item 1) from console (Figure 9, Item 2). 18. Remove two arm rest adjustment knobs (Figure 9, Item 4) from armrest (Figure 9, Item 7). 19. Remove two bolts (Figure 9, Item 5), washers (Figure 9, Item 6), and armrest (Figure 9, Item 7) from console (Figure 9, Item 2). 20. Remove felt cover (Figure 9, Item 3) from console (Figure 9, Item 2).

Figure 9. Cab Interior.

0197

0197-9

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED 21. Remove 10 bolts (Figure 10, Item 3), washers (Figure 10, Item 4), and right cover plate (Figure 10, Item 2) from console (Figure 10, Item 1).

Figure 10. Right Cover Plate.

0197

0197-10

TM 5-2410-241-23-3

0197

REMOVAL CONTINUED

NOTE
It may be necessary to remove or loosen other hoses to gain access to bolts. Note position and orientation of each hose to aid installation. Hoses will be removed from engine compartment.

22. Remove eight bolts (Figure 11, Item 5), washers (Figure 11, Item 6), and two flanges (Figure 11, Item 1) from two hoses (Figure 11, Item 4). 23. Disconnect two hoses (Figure 11, Item 4) from control valve (Figure 11, Item 2), and remove and discard two O-rings (Figure 11, Item 3).

Figure 11. Implement Valve. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0197

000197

0197-11

TM 5-2410-241-23-3

0197

INSTALLATION

000197

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. It may be necessary to remove or loosen other hoses to gain access to bolts. Install hoses through engine compartment into cab.

1. Remove caps and install two new O-rings (Figure 12, Item 3) on hoses (Figure 12, Item 4). 2. Connect two hoses (Figure 12, Item 4) to control valve (Figure 12, Item 2). 3. Install two flanges (Figure 12, Item 1), eight bolts (Figure 12, Item 5), and washers (Figure 12, Item 6) on two hoses (Figure 12, Item 4).

Figure 12. Implement Valve.

0197

0197-12

TM 5-2410-241-23-3

0197

INSTALLATION CONTINUED 4. Install right cover plate (Figure 13, Item 2), 10 washers (Figure 13, Item 4), and bolts (Figure 13, Item 3) on console (Figure 13, Item 1).

Figure 13. Right Panel.

0197

0197-13

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0197

INSTALLATION CONTINUED 5. Install felt cover (Figure 14, Item 3) on console (Figure 14, Item 2). 6. Install armrest (Figure 14, Item 7), two washers (Figure 14, Item 6), and bolts (Figure 14, Item 5) on console (Figure 14, Item 2). 7. Install two arm rest adjustment knobs (Figure 14, Item 4) on armrest (Figure 14, Item 7). 8. Connect cable (Figure 14, Item 1) to console (Figure 14, Item 2).

Figure 14. Cab Interior.

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0197-14

TM 5-2410-241-23-3

0197

INSTALLATION CONTINUED 9. Install two grommets (Figure 15, Item 1), four clamps (Figure 15, Item 2), four washers (Figure 15, Item 4), and bolts (Figure 15, Item 3) on two hoses (Figure 15, Item 5).

Figure 15. Lower Rear Hose Clamps.

0197

0197-15

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0197

INSTALLATION CONTINUED 10. Install two grommets (Figure 16, Item 5), four clamps (Figure 16, Item 2), four washers (Figure 16, Item 4) and bolts (Figure 16, Item 3) on two hoses (Figure 16, Item 1).

Figure 16. Rear Hose Clamps.

0197

0197-16

TM 5-2410-241-23-3

0197

INSTALLATION CONTINUED 11. Install two grommets (Figure 17, Item 5), four clamps (Figure 17, Item 2), four washers (Figure 17, Item 4), and bolts (Figure 17, Item 3) on two hoses (Figure 17, Item 1).

Figure 17. Front Hose Clamps.

0197

0197-17

TM 5-2410-241-23-3

0197

INSTALLATION CONTINUED

NOTE
Tubes will not be easy to install behind radiator guard. With assistance guide each tube individually through guard. 12. Install two new seals (Figure 18, Item 7) on two tubes (Figure 18, Item 8). 13. With assistance install two tubes (Figure 18, Item 8), eight washers (Figure 18, Item 4), and bolts (Figure 18, Item 3) on machine. 14. Install two brackets (Figure 18, Item 2), four washers (Figure 18, Item 6), and bolts (Figure 18, Item 5) on radiator guard (Figure 18, Item 1).

Figure 18. Quick Drop Valve.

0197

0197-18

TM 5-2410-241-23-3

0197

INSTALLATION CONTINUED 15. Install bracket (Figure 19, Item 13), two washers (Figure 19, Item 16), and bolts (Figure 19, Item 17) on machine. 16. Install bolt (Figure 19, Item 18), washer (Figure 19, Item 19), spacer (Figure 19, Item 21), two retaining straps (Figure 19, Items 20 and 22), and nut (Figure 19, Item 23) on bracket (Figure 19, Item 13). 17. Install bolt (Figure 19, Item 15), washer (Figure 19, Item 14), two retaining straps (Figure 19, Items 11 and 12), and nut (Figure 19, Item 10) on bracket (Figure 19, Item 13). 18. Install bracket (Figure 19, Item 3), washer (Figure 19, Item 2) and bolt (Figure 19, Item 1) on machine. 19. Install two clips (Figure 19, Item 4), two retaining straps (Figure 19, Item 5), washer (Figure 19, Item 6), and bolt (Figure 19, Item 7) on tubes (Figure 19, Items 8 and 9).

Figure 19. Tube Clamps.

0197

0197-19

TM 5-2410-241-23-3

0197

INSTALLATION CONTINUED 20. Install bracket (Figure 20, Item 5), two washers (Figure 20, Item 6), and bolts (Figure 20, Item 7), on machine. 21. Install retaining strap (Figure 20, Item 1), washer (Figure 20, Item 3), and bolt (Figure 20, Item 2) on hoses (Figure 20, Item 4).

Figure 20. Hose Bracket. 22. With assistance close two doors (Figure 21, Item 1) on hinges (Figure 21, Item 4) and install eight washers (Figure 21, Item 3) and bolts (Figure 21, Item 2).

0197

Figure 21. Doors.

0197

0197-20

TM 5-2410-241-23-3

0197

INSTALLATION CONTINUED

NOTE
Install tubes and hoses as tagged during removal. 23. Install two new O-rings (Figure 22, Item 4) and connect two tubes (Figure 22, Item 2) on hoses (Figure 22, Item 1). 24. Install two flanges (Figure 22, Item 3), eight washers (Figure 22, Item 5), and bolts (Figure 22, Item 6) on tubes (Figure 22, Item 2).

Figure 22. Tube to Hose Connection. END OF TASK FOLLOW-ON TASKS 1. Fill with hydraulic fluid (WP 0155). 2. Install front bottom guards (WP 0199). 3. Install fire extinguisher and bracket (WP 0255). 4. Install cab seat (WP 0247). 5. Install front floor plate (WP 0230). 6. Install engine enclosure right door guard (WP 0204). 7. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0197

000197

0197-21/(22 blank)

18 TM 5-2410-241-23-3 0198

FIELD MAINTENANCE TILT CYLINDER LINES REPLACEMENT Removal, Cleaning and Inspection, Installation
0 1 9 8

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 0295 Equipment Condition Machine parked (TM 5-2410-241-10) REMOVAL
0

Equipment Condition - Continued

Hydraulic system pressure released (WP 0186) Engine enclosure right door guard removed (WP 0204) Front floor plate removed (WP 0230) Cab seat removed (WP 0247) Fire extinguisher and bracket removed (WP 0255) Hydraulic system drained (WP 0184) Front bottom guards removed (WP 0199) Drawing Required TM 5-2410-241-24P, Figure 83

Estimated Time to Complete 8.5 Hr

000198

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.

0198-1

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 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.

0198

NOTE
Tag all hoses, tubes, and fittings to aid installation. Note routing of hoses and lines to aid installation.

2. Remove eight bolts (Figure 2, Item 5), washers (Figure 2, Item 4), two flanges (Figure 2, Item 2), and two hoses (Figure 2, Item 1) from machine. 3. Remove two O-rings (Figure 2, Item 3) from two hoses (Figure 2, Item 1). Discard O-rings.

Figure 2. Tilt Hose Connection.

0198

0198-2

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 4. Remove bolt (Figure 3, Item 7), washer (Figure 3, Item 6), and retaining strap (Figure 3, Item 5) from two hoses (Figure 3, Item 1). 5. Remove two bolts (Figure 3, Item 4), washers (Figure 3, Item 3), and bracket (Figure 3, Item 2) from machine.

Figure 3. Radiator Hose Clamp.

0198

0198-3

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 6. Remove two bolts (Figure 4, Item 2), washers (Figure 4, Item 3), clamp (Figure 4, Item 4), and grommet (Figure 4, Item 5) from two hoses (Figure 4, Item 1).

Figure 4. Hose Clamp.

0198

0198-4

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 7. Remove two bolts (Figure 5, Item 2), washers (Figure 5, Item 3), clamp (Figure 5, Item 4), and grommet (Figure 5, Item 5) from two hoses (Figure 5, Item 1).

Figure 5. Hose Clamp.

0198

0198-5

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 8. Remove two bolts (Figure 6, Item 2), washers (Figure 6, Item 3), clamp (Figure 6, Item 4), and grommet (Figure 6, Item 5) from two hoses (Figure 6, Item 1).

Figure 6. Hose Clamp.

0198

0198-6

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 9. Remove four bolts (Figure 7, Item 2), washers (Figure 7, Item 1), two clamps (Figure 7, Item 4), and grommets (Figure 7, Item 5) from two hoses (Figure 7, Item 3).

Figure 7. Rear Hose Clamps.

0198

0198-7

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 10. Disconnect cable (Figure 8, Item 1) from console (Figure 8, Item 2). 11. Remove two arm rest adjustment knobs (Figure 8, Item 4) from armrest (Figure 8, Item 7). 12. Remove two bolts (Figure 8, Item 5), washers (Figure 8, Item 6), and armrest (Figure 8, Item 7) from console (Figure 8, Item 2). 13. Remove felt cover (Figure 8, Item 3) from console (Figure 8, Item 2).

Figure 8. Cab Interior.

0198

0198-8

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 14. Remove 10 bolts (Figure 9, Item 3), washers (Figure 9, Item 4), and right cover plate (Figure 9, Item 2) from console (Figure 9, Item 1).

Figure 9. Right Panel.

0198

0198-9

TM 5-2410-241-23-3

0198

REMOVAL CONTINUED 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
It may be necessary to remove or loosen other hoses to gain access to bolts. Note position and orientation of each hose to aid installation. Hoses will be removed from engine compartment.

15. Remove eight bolts (Figure 10, Item 5), washers (Figure 10, Item 6), and two flanges (Figure 10, Item 1) from two hoses (Figure 10, Item 4). 16. Disconnect two hoses (Figure 10, Item 4) from control valve (Figure 10, Item 2), and remove and discard two O-rings (Figure 10, Item 3).

Figure 10. Control Valve. END OF TASK

0198

0198-10

TM 5-2410-241-23-3

0198

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

000198

000198

NOTE
Install tubes and fittings as noted during removal. It may be necessary to remove or loosen other hoses to gain access to bolts. Install hoses through engine compartment into cab.

1. Remove caps and install two new O-rings (Figure 10, Item 3) on hoses (Figure 10, Item 4). 2. Connect two hoses (Figure 10, Item 4) to control valve (Figure 10, Item 2). 3. Install two flanges (Figure 10, Item 1), eight bolts (Figure 10, Item 5), and washers (Figure 10, Item 6) on two hoses (Figure 10, Item 4). 4. Install right cover plate (Figure 11, Item 2), 10 washers (Figure 11, Item 4), and bolts (Figure 11, Item 3) on console (Figure 11, Item 1).

Figure 11. Right Panel.

0198

0198-11

TM 5-2410-241-23-3

0198

INSTALLATION CONTINUED 5. Install felt cover (Figure 12, Item 3) on console (Figure 12, Item 2). 6. Install armrest (Figure 12, Item 7), two washers (Figure 12, Item 6), and bolts (Figure 12, Item 5) on console (Figure 12, Item 2). 7. Install two arm rest adjustment knobs (Figure 12, Item 4) on armrest (Figure 12, Item 7). 8. Connect cable (Figure 12, Item 1) on console (Figure 12, Item 2).

Figure 12. Cab Interior.

0198

0198-12

TM 5-2410-241-23-3

0198

INSTALLATION CONTINUED 9. Install two grommets (Figure 13, Item 5), clamps (Figure 13, Item 4), four washers (Figure 13, Item 1), and bolts (Figure 13, Item 2) on two hoses (Figure 13, Item 3).

Figure 13. Rear Hose Clamps.

0198

0198-13

TM 5-2410-241-23-3

0198

INSTALLATION CONTINUED 10. Install grommet (Figure 14, Item 5), clamp (Figure 14, Item 4), two washers (Figure 14, Item 3), and bolts (Figure 14, Item 2) on two hoses (Figure 14, Item 1).

Figure 14. Hose Clamp.

0198

0198-14

TM 5-2410-241-23-3

0198

INSTALLATION CONTINUED 11. Install grommet (Figure 15, Item 5), clamp (Figure 15, Item 4), two washers (Figure 15, Item 3), and bolts (Figure 15, Item 2) on two hoses (Figure 15, Item 1).

Figure 15. Hose Clamp.

0198

0198-15

TM 5-2410-241-23-3

0198

INSTALLATION CONTINUED 12. Install grommet (Figure 16, Item 5), clamp (Figure 16, Item 4), two washers (Figure 16, Item 3), and bolts (Figure 16, Item 2) on two hoses (Figure 16, Item 1).

Figure 16. Hose Clamp.

0198

0198-16

TM 5-2410-241-23-3

0198

INSTALLATION CONTINUED 13. Install bracket (Figure 17, Item 2), two washers (Figure 17, Item 3), and bolts (Figure 17, Item 4) on machine. 14. Install retaining strap (Figure 17, Item 5), washer (Figure 17, Item 6), and bolt (Figure 17, Item 7) on two hoses (Figure 17, Item 1).

Figure 17. Radiator Hose Clamp. 15. Install two new O-rings (Figure 18, Item 3) on two hoses (Figure 18, Item 1). 16. Install two hoses (Figure 18, Item 1), flanges (Figure 18, Item 2), eight washers (Figure 18, Item 4), and bolts (Figure 18, Item 5) on machine.

0198

Figure 18. Tilt Hose Connection.

0198

0198-17

TM 5-2410-241-23-3

0198

INSTALLATION CONTINUED 17. Close two doors (Figure 19, Item 1) on hinges (Figure 19, Item 4), and install eight washers (Figure 19, Item 3) and bolts (Figure 19, Item 2).

Figure 19. Doors. END OF TASK FOLLOW-ON TASKS 1. Install front bottom guards (WP 0199). 2. Install fire extinguisher and bracket (WP 0255). 3. Install cab seat (WP 0247). 4. Install front floor plate (WP 0230). 5. Install engine enclosure right door guard (WP 0204). 6. Fill with hydraulic fluid (WP 0155). 7. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0198

000198

0198-18

10 TM 5-2410-241-23-3 0199

FIELD MAINTENANCE INSTRUCTIONS BOTTOM GUARDS REPLACEMENT Front Bottom Guard Removal, Middle Bottom Guards Removal, Rear Bottom Guard Removal, Cleaning and Inspection, Rear Bottom Guard Installation, Middle Bottom Guards Installation, Front Bottom Guard Installation
0 1 9 9

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Handle, Ratchet, 1/2 Drive, 10 Long (S0563)(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, 1/2 Drive, 6 Point, 1-1/8 (S0582) (WP 0302, Item 68) Socket, Impact, 3/4 Drive, 6 Point, 30 mm (S0688) (WP 0302, Item 68) Socket, Impact, 3/4 Drive, 6 Point, 1 1/8 (S0972) (WP 0302, Item 68) Wrench, Box, 12 Point, 30 mm and 32 mm (S0772) (WP 0302, Item 68)
0

Tools and Special Tools - Continued Wrench, Electric Impact, 3/4 Square Drive, 1,200 lb-ft (S0730) (WP 0302, Item 68) Lifting Device (200-lb capacity) Wood Blocks Materials/Parts

Rag, Wiping (WP 0303, Item 24) Cotter pin (3) Personnel Required Two

References
0

WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10)

Drawing Required
0

TM 5-2410-241-24P, Figure 92 Estimated Time to Complete

1.5 Hr

0199-1

TM 5-2410-241-23-3

0199

FRONT BOTTOM GUARD REMOVAL

000199

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. Bottom guards will fall when bolts are removed. Debris may accumulate inside bottom guards and add significantly to weight and balance of bottom guards. Use extreme caution during removal of bottom guards. Failure to follow these warnings may cause injury or death to personnel.

NOTE
Front bottom guard weighs approximately 108 lb (49 kg). Mid-forward bottom guard must be removed before front bottom guard can be removed. Use jack stands to support blade off ground when removing bottom guard from under front of machine.

0199-2

TM 5-2410-241-23-3

0199

FRONT BOTTOM GUARD REMOVAL CONTINUED 1. Remove mid-forward bottom guard as described in Middle Bottom Guards Removal in this work package. 2. Install suitable support device under front bottom guard (Figure 1, Item 3).

000199

3. Remove two nuts (Figure 1, Item 1) and washers (Figure 1, Item 2) from front bottom guard (Figure 1, Item 3). 4. Remove six bolts (Figure 1, Item 4), washers (Figure 1, Item 5), and front bottom guard (Figure 1, Item 3) from machine. 5. Remove support device from front bottom guard (Figure 1, Item 3).

Figure 1. Front Bottom Guard. END OF TASK MIDDLE BOTTOM GUARDS REMOVAL

0199

000199

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. Bottom guards will fall when bolts are removed. Debris may accumulate inside bottom guards and add significantly to weight and balance of bottom guards. Use extreme caution during removal of bottom guards. Failure to follow these warnings may cause injury or death to personnel.

0199-3

TM 5-2410-241-23-3

0199

MIDDLE BOTTOM GUARDS REMOVAL CONTINUED

NOTE
There are three middle bottom guards: mid-forward, mid-center, and mid-rearward. Each middle bottom guard weighs approximately 94 lb (43 kg). Use the same removal procedure for all middle bottom guards.

1. Install suitable support device under middle bottom guard (Figure 2, Item 1).

Figure 2. Middle Bottom Guard Support.

0199

0199-4

TM 5-2410-241-23-3

0199

MIDDLE BOTTOM GUARDS REMOVAL CONTINUED 2. Remove four nuts (Figure 3, Item 1) and washers (Figure 3, Item 2) from machine. 3. Remove cotter pin (Figure 3, Item 5) from pin (Figure 3, Item 3). Discard cotter pin. 4. Remove pin (Figure 3, Item 3) and two washers (Figure 3, Item 4) from middle bottom guard (Figure 3, Item 6) and machine. 5. Remove middle bottom guard (Figure 3, Item 6) from machine. 6. Remove support device from middle bottom guard (Figure 3, Item 6).

Figure 3. Middle Bottom Guard. END OF TASK

0199

0199-5

TM 5-2410-241-23-3

0199

REAR BOTTOM GUARDS REMOVAL

000199

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. Bottom guards will fall when bolts are removed. Debris may accumulate inside bottom guards and add significantly to weight and balance of bottom guards. Use extreme caution during removal of bottom guards. Failure to follow these warnings may cause injury or death to personnel.

NOTE
Rear bottom guard weighs approximately 69 lb (31 kg). Mid-rearward middle bottom guard must be removed before rear bottom guard.

1. Remove mid-rearward middle bottom guard as described in Middle Bottom Guards Removal in this work package. 1. Install suitable support device under rear bottom guard (Figure 4, Item 4). 2. Remove two bolts (Figure 4, Item 6) and washers (Figure 4, Item 5) from rear bottom guard (Figure 4, Item 4). 3. Remove two nuts (Figure 4, Item 2) and washers (Figure 4, Item 3) from rear bottom guard (Figure 4, Item 4). 4. With assistance, using suitable support device, remove two bolts (Figure 4, Item 1) and washers (Figure 4, Item 7) and rear bottom guard (Figure 4, Item 4) from machine. 5. Remove support device from rear bottom guard (Figure 4, Item 4).

Figure 4. Rear Bottom Guard. END OF TASK

0199

0199-6

TM 5-2410-241-23-3

0199

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

000199

000199

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. Bottom guards will fall when bolts are removed. Debris may accumulate inside bottom guards and add significantly to weight and balance of bottom guards. Use extreme caution during removal of bottom guards. Front bottom guard must be installed before mid-forward bottom guard. Failure to follow these warnings may cause injury or death to personnel.

NOTE
Rear bottom guard weighs approximately 69 lb (31 kg). 1. Install suitable support device under rear bottom guard (Figure 5, Item 4). 2. With assistance, using suitable support device, install bottom guard (Figure 5, Item 4), two washers (Figure 5, Item 7) and bolts (Figure 5, Item 1) on machine. 3. Install two washers (Figure 5, Item 3) and nuts (Figure 5, Item 2) on bottom guard (Figure 5, Item 4). 4. Install two washers (Figure 5, Item 5) and bolts (Figure 5, Item 6) on bottom guard (Figure 5, Item 4). 5. Remove support device from rear bottom guard (Figure 5, Item 4).

Figure 5. Rear Bottom Guard. END OF TASK

0199

0199-7

TM 5-2410-241-23-3

0199

MIDDLE BOTTOM GUARDS INSTALLATION

000199

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. Failure to follow this warning may cause injury or death to personnel.

NOTE
There are three middle bottom guards: mid-forward, mid-center, and mid-rearward. Each middle bottom guard weighs approximately 94 lb (43 kg). Use the same installation procedure for all middle bottom guards. Ensure that coolant drain hose is properly stowed prior to installation of bottom guards. Rear bottom guard must be installed before mid-rearward middle bottom guard.

1. Install suitable support device under middle bottom guard (Figure 6, Item 1).

Figure 6. Middle Bottom Guard Support.

0199

0199-8

TM 5-2410-241-23-3

0199

MIDDLE BOTTOM GUARDS INSTALLATION CONTINUED 2. Install middle bottom guard (Figure 7, Item 6), four washers (Figure 7, Item 2) and nuts (Figure 7, Item 1) on machine. 3. Install two washers (Figure 7, Item 4) and pin (Figure 7, Item 3) on middle bottom guard (Figure 7, Item 6) and machine. 4. Install new cotter pin (Figure 7, Item 5) on pin (Figure 7, Item 3). 5. Remove support device from middle bottom guard (Figure 7, Item 6).

Figure 7. Middle Bottom Guard. END OF TASK

0199

0199-9

TM 5-2410-241-23-3

0199

FRONT BOTTOM GUARD INSTALLATION

000199

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. Failure to follow this warning may cause injury or death to personnel.

NOTE
Front bottom guard weighs approximately 108 lb (49 kg). Ensure that coolant drain hose is properly stowed prior to installation of bottom guard.

1. Install suitable support device under front bottom guard (Figure 8, Item 3). 2. Install front bottom guard (Figure 8, Item 3), six washers (Figure 8, Item 5), and bolts (Figure 8, Item 4) on machine. 3. Install two washers (Figure 8, Item 2) and nuts (Figure 8, Item 1) on front bottom guard (Figure 8, Item 3). 4. Remove support device from front bottom guard (Figure 8, Item 3).

Figure 8. Front Bottom Guard. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0199

000199

0199-10

14 TM 5-2410-241-23-3 0200

FIELD MAINTENANCE INSTRUCTIONS HOOD REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 0 0

INITIAL SETUP Tools and Special Tools


0

References WP 0295 Equipment Condition

Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) Lifting Device (1,000-lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Locknut (2) Personnel Required Two REMOVAL

Machine parked (TM 5-2410-241-10) Engine access doors removed (WP 0201, WP 0203)
0 0

Drawing Required
0

TM 5-2410-241-24P, Figure 88
0

Estimated Time to Complete


0 0

2.5 Hr

000200

1. Remove two locknuts (Figure 1, Item 1), bolts (Figure 1, Item 4), washers (Figure 1, Item 3), spacer (Figure 1, Item 2), and plates (Figure 1, Item 5) from hood (Figure 1, Item 6). Discard locknuts.

Figure 1. Plate.

0200

0200-1

TM 5-2410-241-23-3

0200

REMOVAL CONTINUED 2. Remove two knobs (Figure 2, Item 2) and fresh air intake cover (Figure 2, Item 1) from hood (Figure 2, Item 3).

Figure 2. Fresh Air Intake Cover. 3. Remove nut (Figure 3, Item 5) and clamp (Figure 3, Item 4) from muffler (Figure 3, Item 6). 4. Remove clamp (Figure 3, Item 2) and hose (Figure 3, Item 1) from exhaust pipe (Figure 3, Item 3). 5. Remove exhaust pipe (Figure 3, Item 3) from muffler (Figure 3, Item 6).

0200

Figure 3. Muffler.

0200

0200-2

TM 5-2410-241-23-3

0200

REMOVAL CONTINUED 6. Remove clamp (Figure 4, Item 3) and hose (Figure 4, Item 1) from air cleaner (Figure 4, Item 2).

Figure 4. Air Cleaner.

0200

0200-3

TM 5-2410-241-23-3

0200

REMOVAL CONTINUED 7. Remove four bolts (Figure 5, Item 2), washers (Figure 5, Item 3) and pre-cleaner body assembly (Figure 5, Item 1) from hood (Figure 5, Item 4).

Figure 5. Pre-Cleaner Body Assembly. 8. Remove two bolts (Figure 6, Item 1), washers (Figure 6, Item 2), left plate (Figure 6, Item 4), and spacer (Figure 6, Item 3) from hood (Figure 6, Item 5). 9. Remove two bolts (Figure 6, Item 6), washers (Figure 6, Item 7), right plate (Figure 6, Item 9), and spacer (Figure 6, Item 8) from hood (Figure 6, Item 5).

0200

Figure 6. Plates.

0200

0200-4

TM 5-2410-241-23-3

0200

REMOVAL CONTINUED

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury or death to personnel.

CAUTION
Cover muffler to avoid foreign object damage.

NOTE
Hood weighs approximately 150 lb (68 kg). 10. Attach suitable lifting device to hood (Figure 7, Item 5). 11. Remove bolt (Figure 7, Item 1), washer (Figure 7, Item 2), and washer (Figure 7, Item 3) from mount (Figure 7, Item 4) on hood (Figure 7, Item 5).

NOTE
Hood may bind or get caught on bolts when lifting. Lift hood from rear. 12. Using lifting device, remove hood (Figure 7, Item 5) from machine and place on flat surface. 13. Remove lifting device from hood (Figure 7, Item 5).

Figure 7. Mount. END OF TASK

0200

0200-5

TM 5-2410-241-23-3

0200

DISASSEMBLY 1. Remove seal (Figure 8, Item 1) from hood (Figure 8, Item 2).

000200

Figure 8. Hood Seal. 2. Remove two slides (Figure 9, Item 1) from machine.

0200

Figure 9. Slides.

0200

0200-6

TM 5-2410-241-23-3

0200

DISASSEMBLY CONTINUED 3. Remove two supports (Figure 10, Item 1) and grommets (Figure 10, Item 2) from machine. 4. Remove two mountings (Figure 10, Item 3) from machine.

Figure 10. Grommets. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY 1. Install two mountings (Figure 10, Item 3) on machine. 2. Install two grommets (Figure 10, Item 2) and supports (Figure 10, Item 1) on machine.

0200

000200

000200

0200-7

TM 5-2410-241-23-3

0200

ASSEMBLY CONTINUED 3. Install two slides (Figure 11, Item 1) on machine.

Figure 11. Slides. 4. Install seal (Figure 12, Item 1) on hood (Figure 12, Item 2).

0200

Figure 12. Hood Seal. END OF TASK

0200

0200-8

TM 5-2410-241-23-3

0200

INSTALLATION

000200

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may cause injury or death to personnel

NOTE
Hood weighs approximately 150 lb (68 kg). Remove cover from muffler before installing hood.

1. Attach suitable lifting device to hood (Figure 13, Item 5). 2. Using lifting device, install hood (Figure 13, Item 5) on machine. 3. Install washer (Figure 13, Item 2), bolt (Figure 13, Item 1), and washer (Figure 13, Item 3) on mount (Figure 13, Item 4) and hood (Figure 13, Item 5). 4. Remove lifting device from hood (Figure 13, Item 5).

Figure 13. Mount.

0200

0200-9

TM 5-2410-241-23-3

0200

INSTALLATION CONTINUED 5. Install left plate (Figure 14, Item 4), spacer (Figure 14, Item 3), two washers (Figure 14, Item 2), and bolts (Figure 14, Item 1) on hood (Figure 14, Item 5). 6. Install right plate (Figure 14, Item 9), spacer (Figure 14, Item 8), two washers (Figure 14, Item 7), and bolts (Figure 14, Item 6) on hood (Figure 14, Item 5).

Figure 14. Plates. 7. Install pre-cleaner body assembly (Figure 15, Item 1), four washers (Figure 15, Item 3) and bolts (Figure 15, Item 2) on hood (Figure 15, Item 4).

0200

Figure 15. Pre-Cleaner Body Assembly.

0200

0200-10

TM 5-2410-241-23-3

0200

INSTALLATION CONTINUED 8. Install hose (Figure 16, Item 1) and clamp (Figure 16, Item 3) on air cleaner (Figure 16, Item 2).

Figure 16. Air Cleaner.

0200

0200-11

TM 5-2410-241-23-3

0200

INSTALLATION CONTINUED 9. Install exhaust pipe (Figure 17, Item 3) on muffler (Figure 17, Item 6). 10. Install hose (Figure 17, Item 1) and clamp (Figure 17, Item 2) on exhaust pipe (Figure 17, Item 3). 11. Install clamp (Figure 17, Item 4) and nut (Figure 17, Item 5) on muffler (Figure 17, Item 6).

Figure 17. Muffler.

0200

12. Install fresh air intake cover (Figure 18, Item 1) and two knobs (Figure 18, Item 2) on hood (Figure 18, Item 3).

Figure 18. Fresh Air Intake Cover.

0200

0200-12

TM 5-2410-241-23-3

0200

INSTALLATION CONTINUED 13. Install two plates (Figure 19, Item 5), spacers (Figure 19, Item 2), washers (Figure 19, Item 3), bolts (Figure 19, Item 4), and new locknuts (Figure 19, Item 1) on hood (Figure 19, Item 6).

Figure 19. Plate. END OF TASK FOLLOW-ON TASKS 1. Install engine access doors (WP 0201 and WP 0203). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0200

000200

0200-13/(14 blank)

14 TM 5-2410-241-23-3 0201

FIELD MAINTENANCE INSTRUCTIONS ENGINE ENCLOSURE LEFT DOOR SERVICE Removal, Door Latch Disassembly, Door Rod Disassembly, Door Assembly Disassembly, Cleaning and Inspection, Door Assembly, Door Rod Assembly, Door Latch Assembly, Installation
0 2 0 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Cotter pin Locknut (3) Personnel Required Two
0

References WP 0295

Equipment Condition
0

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

TM 5-2410-241-24P, Figure 88
0

Estimated Time to Complete


0

2.5 Hr
0

0201-1

TM 5-2410-241-23-3

0201

REMOVAL

000201

WARNING

Support door assembly before removing bolts from machine. Failure to follow this warning may cause injury to personnel. 1. With assistance open door assembly (Figure 1, Item 1), remove two bolts (Figure 1, Item 3), and washers (Figure 1, Item 5), and upper hinge assembly (Figure 1, Item 2) from machine. 2. With assistance remove two bolts (Figure 1, Item 6), washers (Figure 1, Item 7), plate (Figure 1, Item 9), and left door assembly (Figure 1, Item 1) from machine. 3. Remove nut plate (Figure 1, Item 4) from machine. 4. Remove lower hinge assembly (Figure 1, Item 8) and washer (Figure 1, Item 10) from left door assembly (Figure 1, Item 1). 5. Remove upper hinge assembly (Figure 1, Item 2) from left door assembly (Figure 1, Item 1).

Figure 1. Left Door Assembly.

0201

0201-2

TM 5-2410-241-23-3

0201

REMOVAL CONTINUED 6. Remove four bolts (Figure 2, Item 1), washers (Figure 2, Item 2), and hinge plate (Figure 2, Item 3) from machine.

Figure 2. Hinge Plate.

0201

0201-3

TM 5-2410-241-23-3

0201

REMOVAL CONTINUED 7. Remove three bolts (Figure 3, Item 1), washers (Figure 3, Item 2), and striker plate (Figure 3, Item 3) from machine.

Figure 3. Striker Plate. END OF TASK

0201

0201-4

TM 5-2410-241-23-3

0201

DOOR LATCH DISASSEMBLY

000201

NOTE
Note location of latch and pawl on door assembly to aid installation. 1. Remove six bolts (Figure 4, Item 1) and latch assembly (Figure 4, Item 2) from door assembly (Figure 4, Item 3).

Figure 4. Latch Assembly.

0201

0201-5

TM 5-2410-241-23-3

0201

DOOR LATCH DISASSEMBLY CONTINUED 2. Remove locknut (Figure 5, Item 2) and pawl (Figure 5, Item 1) from latch (Figure 5, Item 3). Discard locknut. 3. Remove two bolts (Figure 5, Item 6), locknuts (Figure 5, Item 4), washers (Figure 5, Item 5) and latch handle (Figure 5, Item 3) from latch assembly (Figure 5, Item 7). Discard locknuts.

Figure 5. Latch Pawl. END OF TASK

0201

0201-6

TM 5-2410-241-23-3

0201

DOOR ROD DISASSEMBLY

000201

1. Remove cotter pin (Figure 6, Item 5), washer (Figure 6, Item 4), and rod (Figure 6, Item 1) from door assembly (Figure 6, Item 2). Discard cotter pin. 2. Remove grommet (Figure 6, Item 3) from rod (Figure 6, Item 1). 3. Remove grommet (Figure 6, Item 6) from door assembly (Figure 6, Item 2).

Figure 6. Door Rod. END OF TASK

0201

0201-7

TM 5-2410-241-23-3

0201

DOOR ASSEMBLY DISASSEMBLY 1. Remove seal (Figure 7, Item 1) from door assembly (Figure 7, Item 2). 2. Remove seal (Figure 7, Item 3) from hinge plate (Figure 7, Item 4).

000201

Figure 7. Door Seals. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK DOOR ASSEMBLY ASSEMBLY 1. Install seal (Figure 7, Item 3) on hinge plate (Figure 7, Item 4). 2. Install seal (Figure 7, Item 1) on door assembly (Figure 7, Item 2). END OF TASK

0201

000201

000201

0201-8

TM 5-2410-241-23-3

0201

DOOR ROD ASSEMBLY 1. Install grommet (Figure 8, Item 6) on door assembly (Figure 8, Item 2). 2. Install grommet (Figure 8, Item 3) on rod (Figure 8, Item 1).

000201

3. Install rod (Figure 8, Item 1), washer (Figure 8, Item 4), and new cotter pin (Figure 8, Item 5) on door assembly (Figure 8, Item 2).

Figure 8. Door Rod. END OF TASK DOOR LATCH ASSEMBLY 1. Install latch handle (Figure 9, Item 3), two washers (Figure 9, Item 5), bolts (Figure 9, Item 6), and new locknuts (Figure 9, Item 4) on latch assembly (Figure 9, Item 7). 2. Install pawl (Figure 9, Item 1) and new locknut (Figure 9, Item 2) on latch (Figure 9, Item 3).

0201

000201

Figure 9. Latch Pawl.

0201

0201-9

TM 5-2410-241-23-3

0201

DOOR LATCH ASSEMBLY CONTINUED

NOTE
Install latch and pawl on door assembly as noted in removal. 3. Install latch assembly (Figure 10, Item 2) and six bolts (Figure 10, Item 1) on door assembly (Figure 10, Item 3).

Figure 10. Latch Assembly. END OF TASK

0201

0201-10

TM 5-2410-241-23-3

0201

INSTALLATION 1. Install striker plate (Figure 11, Item 3), three washers (Figure 11, Item 2), and bolts (Figure 11, Item 1) on machine.

000201

Figure 11. Striker Plate.

0201

0201-11

TM 5-2410-241-23-3

0201

INSTALLATION CONTINUED 2. Install hinge plate (Figure 12, Item 3), four washers (Figure 12, Item 2), and bolts (Figure 12, Item 1) on machine.

Figure 12. Hinge Plate.

0201

0201-12

TM 5-2410-241-23-3

0201

INSTALLATION CONTINUED 3. Install upper hinge assembly (Figure 13, Item 2) on left door assembly (Figure 13, Item 1). 4. Install lower hinge assembly (Figure 13, Item 8) and washer (Figure 13, Item 10) on left door assembly (Figure 13, Item 1).

WARNING

Support door assembly when installing bolts on machine. Failure to follow this warning may cause injury to personnel. 5. With assistance install left door assembly (Figure 13, Item 1), plate (Figure 13, Item 9), two washers (Figure 13, Item 7), and bolts (Figure 13, Item 6) on machine. 6. Install nut plate (Figure 13, Item 4) on machine. 7. Install two washers (Figure 13, Item 5) and bolts (Figure 13, Item 3) on machine.

Figure 13. Left Door Assembly. END OF TASK

0201

0201-13

TM 5-2410-241-23-3

0201

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

000201

0201-14

8 TM 5-2410-241-23-3 0202

FIELD MAINTENANCE INSTRUCTIONS ENGINE ENCLOSURE LEFT DOOR GUARD SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 0 2

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
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure left door removed (WP 0201) Drawing Required TM 5-2410-241-24P, Figure 88

Estimated Time to Complete 3.5 Hr

REMOVAL 1. Remove three bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and plate (Figure 1, Item 3) from engine guard (Figure 1, Item 4). 2. Remove clamp (Figure 1, Item 6) and tube (Figure 1, Item 5) from arctic heater port (Figure 1, Item 7).

000202

Figure 1. Left Engine Plate.

0202

0202-1

TM 5-2410-241-23-3

0202

REMOVAL CONTINUED 3. Remove nut (Figure 2, Item 2), washer (Figure 2, Item 3), clamp (Figure 2, Item 4), and hose (Figure 2, Item 5) from engine guard (Figure 2, Item 1). 4. Remove three bolts (Figure 2, Item 6), washers (Figure 2, Item 7), and engine guard (Figure 2, Item 1) from machine.

Figure 2. Left Engine Guard.

0202

0202-2

TM 5-2410-241-23-3

0202

REMOVAL CONTINUED 5. Remove three bolts (Figure 3, Item 1), washers (Figure 3, Item 2), and plate (Figure 3, Item 3) from chassis (Figure 3, Item 4).

Figure 3. Mounting Plate.

0202

0202-3

TM 5-2410-241-23-3

0202

DISASSEMBLY 1. Remove two bolts (Figure 4, Item 6), washers (Figure 4, Item 7), and bracket (Figure 4, Item 5) from top of engine guard (Figure 4, Item 4).

000202

2. Remove five bolts (Figure 4, Item 2), washers (Figure 4, Item 3), and plate (Figure 4, Item 1) from top of engine guard (Figure 4, Item 4).

NOTE
Note position of brackets to aid installation. 3. Remove four nuts (Figure 4, Item 8), washers (Figure 4, Item 9), and two brackets (Figure 4, Item 10) from bottom of engine guard (Figure 4, Item 4).

Figure 4. Plates.

0202

0202-4

TM 5-2410-241-23-3

0202

DISASSEMBLY CONTINUED 4. Remove four bolts (Figure 5, Item 2), washers (Figure 5, Item 1), and arctic heater port (Figure 5, Item 3) from engine guard (Figure 5, Item 4).

Figure 5. Arctic Heater Port. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY 1. Install arctic heater port (Figure 5, Item 3), four washers (Figure 5, Item 1), and bolts (Figure 5, Item 2) on engine guard (Figure 5, Item 4).

0202

000202

000202

0202-5

TM 5-2410-241-23-3

0202

ASSEMBLY CONTINUED 2. Install two brackets (Figure 6, Item 10), four washers (Figure 6, Item 9), and nuts (Figure 6, Item 8) on bottom of engine guard (Figure 6, Item 4). 3. Install plate (Figure 6, Item 1), five washers (Figure 6, Item 3), and bolts (Figure 6, Item 2) on top of engine guard (Figure 6, Item 4). 4. Install bracket (Figure 6, Item 5), two washers (Figure 6, Item 7), and bolts (Figure 6, Item 6) on top of engine guard (Figure 6, Item 4).

Figure 6. Plates. END OF TASK

0202

0202-6

TM 5-2410-241-23-3

0202

INSTALLATION 1. Install plate (Figure 7, Item 3), three washers (Figure 7, Item 2), and bolts (Figure 7, Item 1) on chassis (Figure 7, Item 4).

000202

Figure 7. Mounting Plate. 2. Install engine guard (Figure 8, Item 1), three washers (Figure 8, Item 7), and bolts (Figure 8, Item 6) on machine.

0202

3. Install clamp (Figure 8, Item 4), hose (Figure 8, Item 5), washer (Figure 8, Item 3) and nut (Figure 8, Item 2) on engine guard (Figure 8, Item 1).

Figure 8. Left Engine Guard.

0202

0202-7

TM 5-2410-241-23-3

0202

INSTALLATION CONTINUED 4. Install tube (Figure 9, Item 5) and clamp (Figure 9, Item 6) on arctic heater port (Figure 9, Item 7). 5. Install plate (Figure 9, Item 3), three washers (Figure 9, Item 2), and nuts (Figure 9, Item 1) on engine guard (Figure 9, Item 4).

Figure 9. Left Engine Plate. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure left door (WP 0201). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0202

000202

0202-8

14 TM 5-2410-241-23-3 0203

FIELD MAINTENANCE INSTRUCTIONS ENGINE ENCLOSURE RIGHT DOOR SERVICE Removal, Door Latch Disassembly, Door Rod Disassembly, Door Assembly Disassembly, Cleaning and Inspection, Door Assembly, Door Rod Assembly, Door Latch Assembly, Installation
0 2 0 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Rag, Wiping (WP 0303, Item 24) Cotter pin Locknut (3) References WP 0295
0

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

Drawing Required
0

TM 5-2410-241-24P, Figure 88 Estimated Time to Complete

2.5 Hr
0 0

0203-1

TM 5-2410-241-23-3

0203

REMOVAL

000203

WARNING

Support door assembly before removing bolts from machine. Failure to follow this warning may cause injury to personnel. 1. Open door assembly, remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and upper hinge assembly (Figure 1, Item 3) from machine. 2. Remove two bolts (Figure 1, Item 9), washers (Figure 1, Item 8), plate (Figure 1, Item 7), and right door assembly (Figure 1, Item 4) from machine. 3. Remove lower hinge assembly (Figure 1, Item 6) and washer (Figure 1, Item 5) from right door assembly (Figure 1, Item 4). 4. Remove upper hinge assembly (Figure 1, Item 3) from right door assembly (Figure 1, Item 4).

Figure 1. Right Door Assembly.

0203

0203-2

TM 5-2410-241-23-3

0203

REMOVAL CONTINUED 5. Remove four bolts (Figure 2, Item 1), washers (Figure 2, Item 2), and hinge plate (Figure 2, Item 3) from machine.

Figure 2. Hinge Plate.

0203

0203-3

TM 5-2410-241-23-3

0203

REMOVAL CONTINUED 6. Remove three bolts (Figure 3, Item 2), washers (Figure 3, Item 3), and striker plate (Figure 3, Item 1) from machine.

Figure 3. Striker Plate. END OF TASK

0203

0203-4

TM 5-2410-241-23-3

0203

DOOR LATCH DISASSEMBLY

000203

NOTE
Note location of latch and pawl on door assembly to aid installation. 1. Remove six bolts (Figure 4, Item 1) and latch assembly (Figure 4, Item 2) from door assembly (Figure 4, Item 3).

Figure 4. Latch Assembly.

0203

0203-5

TM 5-2410-241-23-3

0203

DOOR LATCH DISASSEMBLY CONTINUED 2. Remove locknut (Figure 5, Item 2) and pawl (Figure 5, Item 1) from latch (Figure 5, Item 3). discard locknut. 3. Remove two bolts (Figure 5, Item 6), locknuts (Figure 5, Item 4), washers (Figure 5, Item 5) and latch handle (Figure 5, Item 3) from latch assembly (Figure 5, Item 7). Discard locknuts.

000203

Figure 5. Latch Pawl. END OF TASK

0203

0203-6

TM 5-2410-241-23-3

0203

DOOR ROD DISASSEMBLY

000203

1. Remove cotter pin (Figure 6, Item 5), washer (Figure 6, Item 4), and rod (Figure 6, Item 1) from door assembly (Figure 6, Item 2). Discard cotter pin. 2. Remove grommet (Figure 6, Item 3) from rod (Figure 6, Item 1). 3. Remove grommet (Figure 6, Item 6) from door assembly (Figure 6, Item 2).

Figure 6. Door Rod. END OF TASK

0203

0203-7

TM 5-2410-241-23-3

0203

DOOR ASSEMBLY DISASSEMBLY 1. Remove seal (Figure 7, Item 1) from door assembly (Figure 7, Item 2). 2. Remove seal (Figure 7, Item 3) from hinge plate (Figure 7, Item 4).

000203

Figure 7. Door Seals. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK DOOR ASSEMBLY ASSEMBLY 1. Install seal (Figure 7, Item 3) on hinge plate (Figure 7, Item 4). 2. Install seal (Figure 7, Item 1) on door assembly (Figure 7, Item 2). END OF TASK

0203

000203

000203

0203-8

TM 5-2410-241-23-3

0203

DOOR ROD ASSEMBLY 1. Install grommet (Figure 8, Item 6) on door assembly (Figure 8, Item 2). 2. Install grommet (Figure 8, Item 3) on rod (Figure 8, Item 1).

000203

3. Install rod (Figure 8, Item 1), washer (Figure 8, Item 4), and new cotter pin (Figure 8, Item 5) on door assembly (Figure 8, Item 2).

Figure 8. Door Rod. END OF TASK DOOR LATCH ASSEMBLY 1. Install latch handle (Figure 9, Item 3), two washers (Figure 9, Item 5), bolts (Figure 9, Item 6), and new locknuts (Figure 9, Item 4) on latch assembly (Figure 9, Item 7). 2. Install pawl (Figure 9, Item 1) and new locknut (Figure 9, Item 2) on latch (Figure 9, Item 3).

0203

000203

Figure 9. Latch Pawl.

0203

0203-9

TM 5-2410-241-23-3

0203

DOOR LATCH ASSEMBLY CONTINUED

NOTE
Install latch and pawl on door assembly as noted in removal. 3. Install latch assembly (Figure 10, Item 2) and six bolts (Figure 10, Item 1) on door assembly (Figure 10, Item 3).

Figure 10. Latch Assembly. END OF TASK

0203

0203-10

TM 5-2410-241-23-3

0203

INSTALLATION 1. Install striker plate (Figure 11, Item 1), three washers (Figure 11, Item 3), and bolts (Figure 11, Item 2) on machine.

000203

Figure 11. Striker Plate.

0203

0203-11

TM 5-2410-241-23-3

0203

INSTALLATION CONTINUED 2. Install hinge plate (Figure 12, Item 3), four washers (Figure 12, Item 2), and bolts (Figure 12, Item 1) on machine.

Figure 12. Hinge Plate.

0203

0203-12

TM 5-2410-241-23-3

0203

INSTALLATION CONTINUED 3. Install upper hinge assembly (Figure 13, Item 3) on right door assembly (Figure 13, Item 4). 4. Install lower hinge assembly (Figure 13, Item 6) and washer (Figure 13, Item 5) on right door assembly (Figure 13, Item 4).

WARNING

Support door assembly when installing bolts on machine. Failure to follow this warning may cause injury to personnel. 5. Install right door assembly (Figure 13, Item 4), plate (Figure 13, Item 7), two washers (Figure 13, Item 8), and bolts (Figure 13, Item 9) on machine. 6. Install two washers (Figure 13, Item 2) and bolts (Figure 13, Item 1) on machine.

Figure 13. Right Door Assembly. END OF TASK

0203

0203-13

TM 5-2410-241-23-3

0203

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

000203

0203-14

4 TM 5-2410-241-23-3 0204

FIELD MAINTENANCE INSTRUCTIONS ENGINE ENCLOSURE RIGHT DOOR GUARD SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 0 4

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
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Engine enclosure right door removed (WP 0203)
0 0

Drawing Required TM 5-2410-241-24P, Figure 88

Estimated Time to Complete 3.5 Hr

REMOVAL 1. Remove three bolts (Figure 1, Item 4), washers (Figure 1, Item 5), and plate (Figure 1, Item 6) from engine guard (Figure 1, Item 3). 2. Remove three bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and engine guard (Figure 1, Item 3) from machine.

000204

Figure 1. Right Engine Plate and Guard. END OF TASK

0204

0204-1

TM 5-2410-241-23-3

0204

DISASSEMBLY 1. Remove two bolts (Figure 2, Item 1), washers (Figure 2, Item 2), and bracket (Figure 2, Item 3) from top of engine guard (Figure 2, Item 6).

000204

2. Remove five bolts (Figure 2, Item 4), washers (Figure 2, Item 5), and plate (Figure 2, Item 7) from top of engine guard (Figure 2, Item 6). 3. Remove four bolts (Figure 2, Item 8), washers (Figure 2, Item 9), and two brackets (Figure 2, Item 10) from bottom of engine guard (Figure 2, Item 6).

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

0204

000204

0204-2

TM 5-2410-241-23-3

0204

ASSEMBLY

000204

1. Install two brackets (Figure 2, Item 10), four washers (Figure 2, Item 9), and bolts (Figure 2, Item 8) on bottom of engine guard (Figure 2, Item 6). 2. Install plate (Figure 2, Item 7), five washers (Figure 2, Item 4), and bolts (Figure 2, Item 5) on top of engine guard (Figure 2, Item 6). 3. Install bracket (Figure 2, Item 3), two washers (Figure 2, Item 2), and bolts (Figure 2, Item 1) on top of engine guard (Figure 2, Item 6). END OF TASK INSTALLATION 1. Install engine guard (Figure 3, Item 3), three washers (Figure 3, Item 2), and bolts (Figure 3, Item 1) on machine. 2. Install plate (Figure 3, Item 6), three washers (Figure 3, Item 5), and bolts (Figure 3, Item 4) on engine guard (Figure 3, Item 3).
000204

Figure 3. Right Engine Plate and Guard. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure right door (WP 0203). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0204

000204

0204-3/(4 blank)

18 TM 5-2410-241-23-3 0205

FIELD MAINTENANCE INSTRUCTIONS RADIATOR GUARD REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 0 5

INITIAL SETUP Tools and Special Tools


0

Personnel Required Two References WP 0050 WP 0051 WP 0184 WP 0218 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Hood removed (WP 0200) Drawing Required TM 5-2410-241-24P, Figure 80, 86 Estimated Time to Complete 6.0 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (3/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 11) Handle, Ratchet, 3/4 Drive, 17" Long (S0374) (WP 0302, Item 68) Socket, 3/4 Drive, 1-1/8, 12 Point. (S0385) (WP 0302, Item 68) Clamp (2) (BII Item) TM 5-2410-241-10 Clamp (2) (BII Item) TM 5-2410-241-10 Lift Bracket 138-7574 (2) (BII Item) TM 5-2410-241-10 Strap (2) (BII Item) TM 5-2410-241-10 Lifting Device (4,000-lb capacity) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) O-ring (2)

0205-1

TM 5-2410-241-23-3

0205

REMOVAL

000205

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 these warnings may cause injury or death to personnel.

NOTE
Door weighs approximately 120 lb (54 kg.) 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). 2. Attach suitable lifting device to one door (Figure 1, Item 1). 3. Using lifting device, remove one door (Figure 1, Item 1) from hinges (Figure 1, Item 4) and place on flat surface. 4. Remove lifting device from door (Figure 1, Item 1). 5. Repeat steps for other door (Figure 1, Item 1).

Figure 1. Doors.

0205

0205-2

TM 5-2410-241-23-3

0205

REMOVAL CONTINUED

NOTE
Note location and quantity of shims to aid installation. 6. Remove four bolts (Figure 2, Item 2), nuts (Figure 2, Item 3), cap (Figure 2, Item 5), and shims (Figure 2, Item 4) from cylinder (Figure 2, Item 1).

Figure 2. Cylinder Caps. 7. Repeat step 1 for other cylinder.

0205

0205-3

TM 5-2410-241-23-3

0205

REMOVAL CONTINUED 8. Retract lift cylinders, refer to TM 5-2410-241-10. If engine is not operable refer to WP 0218.

WARNING

Install cylinder brackets to secure lift cylinders to radiator guard. Without brackets, uncontrolled cylinder movement may occur during removal and installation of radiator guard. 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 these warnings may cause injury or death to personnel.

NOTE
Steps 9 - 13 describe one lift cylinder. Repeat steps to secure other lift cylinder. 9. Install spacer (Figure 3, Item 3), bracket (Figure 3, Item 4), washer (Figure 3, Item 2), and bolt (Figure 3, Item 1) on radiator guard (Figure 3, Item 12). Do not tighten bolt. 10. Position two clamps (Figure 3, Item 9) on lift cylinder (Figure 3, Item 8) and align with bracket (Figure 3, Item 4) on radiator guard (Figure 3, Item 12). 11. Install washer (Figure 3, Item 6), bolt (Figure 3, Item 5), and nut (Figure 3, Item 7) on bracket (Figure 3, Item 4) and clamps (Figure 3, Item 9). 12. Tighten bolt (Figure 3, Item 1). 13. Install large tiedown strap (Figure 3, Item 11) on lift cylinder (Figure 3, Item 8) and cylinder end (Figure 3, Item 10).

Figure 3. Cylinder Bracket.

0205

0205-4

TM 5-2410-241-23-3

0205

REMOVAL CONTINUED 14. Drain hydraulic tank (WP 0184). 15. Remove cooling fan (WP 0050). 16. Remove after cooler pump inlet hoses and pipe (WP 0051). 17. Remove water temperature regulator outlet hose (WP 0051). 18. Remove water pump inlet hose (WP 0051). 19. Remove vent line (WP 0051). 20. Remove water tank outlet hose (WP 0051). 21. Loosen clamp (Figure 4, Item 2) from hose (Figure 4, Item 3). 22. Remove hose (Figure 4, Item 3) from fitting (Figure 4, Item 1). 23. Remove clamp (Figure 4, Item 2) from hose (Figure 4, Item 3).

Figure 4. Radiator Drain Hose and Fitting.

0205

24. Remove two bolts (Figure 5, Item 4), washers (Figure 5, Item 3), spacers (Figure 5, Item 5) and plate (Figure 5, Item 2) from radiator guard (Figure 5, Item 1).

Figure 5. Plate.

0205

0205-5

TM 5-2410-241-23-3

0205

REMOVAL CONTINUED 25. Remove two bolts (Figure 6, Item 3), washers (Figure 6, Item 4), and manifold (Figure 6, Item 1) from radiator guard (Figure 6, Item 2). Set manifold aside.

Figure 6. Manifold.

0205

NOTE
Tag and mark connectors to aid installation. 26. Disconnect harness connector (Figure 7, Item 2) from front light connector (Figure 7, Item 3). 27. Remove tiedown straps (Figure 7, Item 1) and harness connector (Figure 7, Item 2) from frame (Figure 7, Item 4). Discard tiedown straps.

Figure 7. Harness.

0205

0205-6

TM 5-2410-241-23-3

0205

REMOVAL CONTINUED

NOTE
Install caps and plugs on lines to prevent leaks and contamination. 28. Remove four bolts (Figure 8, Item 2), washers (Figure 8, Item 3), and flange (Figure 8, Item 4) from line (Figure 8, Item 1). 29. Remove O-ring (Figure 8, Item 5) from line (Figure 8, Item 1). Discard O-ring. 30. Repeat step 28 and 29 for second line.

Figure 8. Lines. 31. Remove three bolts (Figure 9, Item 2), washers (Figure 9, Item 1), and cover (Figure 9, Item 3) from radiator guard (Figure 9, Item 4).

0205

Figure 9. Cover.

0205

0205-7

TM 5-2410-241-23-3

0205

REMOVAL CONTINUED 32. Install bracket links (Figure 10, Item 1) on radiator guard (Figure 10, Item 2).

Figure 10. Bracket Links. 33. Remove two bolts (Figure 11, Item 1), washers (Figure 11, Item 2), and plate (Figure 11, Item 3) from radiator guard (Figure 11, Item 4). 34. Repeat step 28 for other side of machine. 35. Remove bolt (Figure 11, Item 6), nut (Figure 11, Item 7), and washer (Figure 11, Item 8) from radiator guard (Figure 11, Item 4). 36. Repeat step 35 for other side of machine.

0205

0205-8

TM 5-2410-241-23-3

0205

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
Radiator guard weighs approximately 3,000 lb (1,361 kg). 37. Attach suitable lifting device to radiator guard. 38. Remove two pins (Figure 11, Item 6) from radiator guard (Figure 11, Item 4). 39. Remove two pins (Figure 11, Item 5) and radiator guard (Figure 11, Item 6) from machine and place on flat surface. 40. Support radiator guard and remove lifting device.

Figure 11. Pins. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0205

000205

0205-9

TM 5-2410-241-23-3

0205

INSTALLATION

000205

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
Radiator guard weighs approximately 3,000 lb (1,361 kg). 1. Attach suitable lifting device to radiator guard (Figure 12, Item 4). 2. Using lifting device, install radiator guard (Figure 12, Item 4) and two pins (Figure 12, Items 5 and 9) on machine. 3. Install plate (Figure 12, Item 3), two washers (Figure 12, Item 2), and bolts (Figure 12, Item 1) on radiator guard (Figure 12, Item 4). 4. Repeat step 3 for other side of machine. 5. Install washer (Figure 12, Item 8), bolt (Figure 12, Item 6), and nut (Figure 12, Item 7) on radiator guard (Figure 12, Item 4). 6. Repeat step 5 for other side of machine.

Figure 12. Pins.

0205

0205-10

TM 5-2410-241-23-3

0205

INSTALLATION CONTINUED 7. Remove lifting device from radiator guard (Figure 13, Item 2). 8. Remove two bracket links (Figure 13, Item 1) from radiator guard (Figure 13, Item 2).

Figure 13. Bracket Links. 9. Install cover (Figure 14, Item 3), three washers (Figure 14, Item 1), and bolts (Figure 14, Item 2) on radiator guard (Figure 14, Item 4).

0205

Figure 14. Cover.

0205

0205-11

TM 5-2410-241-23-3

0205

INSTALLATION CONTINUED 10. Install new O-ring (Figure 15, Item 5) on line (Figure 15, Item 1). 11. Install flange (Figure 15, Item 4), four washers (Figure 15, Item 3), and bolts (Figure 15, Item 2) on line (Figure 15, Item 1). 12. Repeat steps 10 and 11 for other line.

Figure 15. Lines.

0205

0205-12

TM 5-2410-241-23-3

0205

INSTALLATION CONTINUED

NOTE
Route harness and install connectors as noted during removal. 13. Install harness connector (Figure 16, Item 2) and new tiedown straps (Figure 16, Item 1) on frame (Figure 16, Item 4). 14. Connect harness connector (Figure 16, Item 2) to front light connector (Figure 16, Item 3).

Figure 16. Harness. 15. Install manifold (Figure 17, Item 1), two washers (Figure 17, Item 4), and bolts (Figure 17, Item 3) on radiator guard (Figure 17, Item 2).

0205

Figure 17. Manifold.

0205

0205-13

TM 5-2410-241-23-3

0205

INSTALLATION CONTINUED 16. Install plate (Figure 18, Item 2), two spacers (Figure 18, Item 5), washers (Figure 18, Item 3), and bolts (Figure 18, Item 4) on radiator guard (Figure 18, Item 1).

Figure 18. Plate. 17. Install clamp (Figure 19, Item 2) on hose (Figure 19, Item 3). 18. Install hose (Figure 19, Item 3) on fitting (Figure 19, Item 1). 19. Tighten clamp (Figure 19, Item 2) on hose (Figure 19, Item 3).

0205

Figure 19. Radiator Drain Hose and Fitting. 20. Fill hydraulic tank (WP 0184). 21. Install cooling fan (WP 0050). 22. Install vent line (WP 0051). 23. Install water tank outlet hose (WP 0051). 24. Install water pump inlet hose (WP 0051). 25. Install water temperature regulator outlet hose (WP 0051). 26. Install after cooler inlet hoses and pipe (WP 0051).

0205

0205-14

TM 5-2410-241-23-3

0205

INSTALLATION CONTINUED

WARNING

Without brackets, uncontrolled cylinder movement may occur during removal and installation of radiator guard. 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 these warnings may cause injury or death to personnel.

NOTE
Steps 27 - 32 describe one lift cylinder. Repeat steps to release other lift cylinder. 27. Remove large tiedown strap (Figure 20, Item 11) from lift cylinder (Figure 20, Item 8) and cylinder end (Figure 20, Item 10). Discard tiedown strap. 28. Remove bolt (Figure 20, Item 5), nut (Figure 20, Item 7), washer (Figure 20, Item 6) and bracket (Figure 20, Item 4) from clamps (Figure 20, Item 9). 29. Remove two clamps (Figure 20, Item 9) from lift cylinder (Figure 20, Item 8). 30. Remove bolt (Figure 20, Item 1) and bracket (Figure 20, Item 4) from radiator guard (Figure 20, Item 12). 31. Remove bolt (Figure 20, Item 1), washer (Figure 20, Item 2), spacer (Figure 20, Item 3), and bracket (Figure 20, Item 4) from radiator guard (Figure 20, Item 12). 32. Extend lift cylinders, refer to TM 5-2410-241-10. If engine is not operable perform WP 0218.

Figure 20. Cylinder Bracket.

0205

0205-15

TM 5-2410-241-23-3

0205

INSTALLATION CONTINUED

NOTE
Install shims as noted in removal. 33. Install shims (Figure 21, Item 4), cap (Figure 21, Item 5), four bolts (Figure 21, Item 2), and nuts (Figure 21, Item 3) and on cylinder (Figure 21, Item 1). 34. Repeat steps 27- 32 for other cylinder.

Figure 21. Cylinder Caps.

0205

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 these warnings may cause injury or death to personnel.

NOTE
Door weighs approximately 120 lb (54 kg).

0205-16

TM 5-2410-241-23-3

0205

INSTALLATION CONTINUED 35. Attach suitable lifting device to one door (Figure 22, Item 1). 36. Using lifting device, install one door (Figure 22, Item 1) on hinges (Figure 22, Item 4). 37. Remove lifting device from door (Figure 22, Item 1). 38. Repeat steps 35 - 36 for other door (Figure 22, Item 1). 39. Close two doors (Figure 22, Item 1) on hinges (Figure 22, Item 4). 40. Install eight washers (Figure 22, Item 3) and bolts (Figure 22, Item 2) on doors (Figure 22, Item 1).

Figure 22. Doors. END OF TASK FOLLOW-ON TASKS 1. Install hood (WP 0200). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0205

000205

0205-17/(18 blank)

36 TM 5-2410-241-23-3 0206

FIELD MAINTENANCE INSTRUCTIONS PLATFORM ENCLOSURE REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 0 6

INITIAL SETUP Tools and Special Tools


0

Equipment Condition - Continued

Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (1-1/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 12) Socket, 1/2 Drive 6 Point 1 7/16 (S0587) (WP 0302, Item 68) Wrench, Open End, 1 1/16 and 1 1/8 (S0850) (WP 0302, Item 68) Lifting Device (1,000-lb capacity) Materials/Parts 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) Gasket References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Refrigerant recovered from A/C system (WP 0263) Hydraulic system pressure released (WP 0186)

Hydraulic system drained (WP 0184) Cab seat removed (WP 0247) Front floor plates removed (WP 0230) Rear floor plates removed (WP 0231) Left platform access panels removed (WP 0207) Right platform access panels removed (WP 0208) Hood removed (WP 0200) Engine enclosure left door guard removed (WP 0202) Engine enclosure right door guard removed (WP 0204) Cab removed (WP 0245) Fuel tank removed (WP 0171) Ripper pilot valve removed (WP 0256) Bulldozer pilot valve removed (WP 0259) Batteries removed (WP 0155)
0 0 0 0 0 0 0 0 0 0 0 0 0 0

Drawing Required TM 5-2410-241-24P, Figure 126 Estimated Time to Complete 26.0 Hr

0206-1

TM 5-2410-241-23-3

0206

REMOVAL 1. Position clip (Figure 1, Item 4) aside from rod (Figure 1, Item 1). 2. Remove pin (Figure 1, Item 2) from rod (Figure 1, Item 1). 3. Remove rod (Figure 1, Item 1) from steering control (Figure 1, Item 3).

000206

Figure 1. Steering Control.

0206

0206-2

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note wiring harness routing to aid installation. Mark location of tiedown straps before removal.

4. Disconnect plug (Figure 2, Item 8) from relay (Figure 2, Item 7). 5. Remove tiedown strap (Figure 2, Item 3) from harness clamp (Figure 2, Item 4). Discard tiedown strap. 6. Disconnect connector (Figure 2, Item 1) from connector (Figure 2, Item 6). 7. Remove connectors (Figure 2, Items 2 and 5) from harness clamp (Figure 2, Item 4). 8. Disconnect connector (Figure 2, Item 2) from connector (Figure 2, Item 5).

Figure 2. Engine Harness.

0206

0206-3

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED 9. Remove four bolts (Figure 3, Item 2), washers (Figure 3, Item 1), and cover plate (Figure 3, Item 3) from platform (Figure 3, Item 4). 10. Remove gasket (Figure 3, Items 5) from platform (Figure 3, Item 4). Discard gasket.

Figure 3. Heater Core Cover.

0206

0206-4

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Tag hoses and note routing to aid installation. 11. Loosen clamp (Figure 4, Item 2) and disconnect hose (Figure 4, Item 3) from heater core (Figure 4, Item 1). 12. Loosen clamp (Figure 4, Item 5) and disconnect hose (Figure 4, Item 6) from heater valve (Figure 4, Item 4).

Figure 4. Heater and A/C Hoses.

0206

0206-5

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Tag hoses and note routing to aid installation. 13. Loosen tube nut (Figure 5, Item1) and disconnect A/C hose (Figure 5, Item 3) from evaporator core (Figure 5, Item 2). 14. Loosen tube nut (Figure 5, Item 5) and disconnect A/C hose (Figure 5, Item 4) from evaporator core (Figure 5, Item 2).

Figure 5. A/C Hoses.

0206

0206-6

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED 15. Remove two bolts (Figure 6, Item 3), washers (Figure 6, Item 2), and under hood light (Figure 6, Item 1) from platform (Figure 6, Item 4). Set under hood light (Figure 6, Item 1) aside.

NOTE
Note routing and position of harness and cable to aid installation. 16. Remove bolt (Figure 6, Item 9), washer (Figure 6, Item 8), P clip (Figure 6, Item 10), and ladder clip (Figure 6, Item 7) from platform (Figure 6, Item 4). Set hose (Figure 6, Item 5) and harness (Figure 6, Item 6) aside.

Figure 6. Light Harness.

0206

0206-7

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED 17. Remove two nuts (Figure 7, Item 4), washers (Figure 7, Item 5), and clamps (Figure 7, Item 3) from cables (Figure 7, Items 1 and 2). 18. Remove two bolts (Figure 7, Item 7), washers (Figure 7, Item 8), and cover (Figure 7, Item 6) from cables (Figure 7, Items 1 and 2).

Figure 7. Fuse Box Cables.

0206

0206-8

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Tag and mark cables to aid installation. 19. Remove two bolts (Figure 8, Item 3), washers (Figure 8, Item 2), and disconnect two cables (Figure 8, Items 1 and 4) from fuse box (Figure 8, Item 5).

Figure 8. Fuse Box Connection.

0206

0206-9

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Tag and mark wires to aid installation. 20. Remove bolt (Figure 9, Item 7), washer (Figure 9, Item 8), and disconnect two ground wires (Figure 9, Items 5 and 6) from chassis (Figure 9, Item 9). 21. Remove and discard tiedown strap (Figure 9, Item 1) from bracket (Figure 9, Item 10). 22. Remove bolt (Figure 9, Item 2), washer (Figure 9, Item 3), clamp (Figure 9, Item 4), and bracket (Figure 9, Item 10) from chassis (Figure 9, Item 9).

Figure 9. Brake Solenoid Wiring.

0206

0206-10

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Tag and mark connectors to aid installation. 23. Remove and discard tiedown straps (Figure 10, Item 2) from brake solenoid (Figure 10, Item 1). 24. Disconnect two connectors (Figure 10, Items 3 and 4) from brake solenoid (Figure 10, Item 1).

Figure 10. Brake Solenoid.

0206

0206-11

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

25. Disconnect two connectors (Figure 11, Item 2) from connectors (Figure 11, Item 3). 26. Remove tiedown strap (Figure 11, Item 1) from harness (Figure 11, Item 4). Discard tiedown strap and position harness aside.

Figure 11. Transmission Harness Connectors.

0206

0206-12

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

27. Remove tiedown strap (Figure 12, Item 4) from harness (Figure 12, Item 3). Discard tiedown strap and position harness aside. 28. Disconnect connector (Figure 12, Item 1) from connector (Figure 12, Item 2).

Figure 12. Chassis Harness Connectors.

0206

0206-13

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

29. Disconnect connector (Figure 13, Item 1) from connector (Figure 13, Item 2). 30. Position harness (Figure 13, Item 3) aside from platform (Figure 13, Item 4).

Figure 13. Arctic Heater Harness Connectors.

0206

0206-14

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED 31. Install two bracket links (Figure 14, Item 3) on platform rear frame (Figure 14, Item 4). 32. Install two bracket links (Figure 14, Item 2) on platform front cowl (Figure 14, Item 1).

Figure 14. Bracket Links.

0206

0206-15

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED 33. Remove two bolts (Figure 15, Item 2), washers (Figure 15, Item 3), large washers (Figure 15, Item 4), upper mounts (Figure 15, Item 5), and sleeves (Figure 15, Item 6) from platform (Figure 15, Item 1).

Figure 15. Rear Cab Mount.

0206

0206-16

TM 5-2410-241-23-3

0206

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
Platform weighs approximately 680 lb (308.44 kg). 34. Remove two bolts (Figure 16, Item 2), washers (Figure 16, Item 3), large washers (Figure 16, Item 4), sleeves (Figure 16, Item 6) and mounts (Figure 16, Item 5) from platform (Figure 16, Item 1). 35. Attach lifting device to platform (Figure 16, Item 1) and remove platform from machine. 36. Place platform (Figure 16, Item 1) on flat surface. 37. Remove lifting device from platform (Figure 16, Item 1).

Figure 16. Front Cab Mounts.

0206

0206-17

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED

NOTE
Note position and orientation of mounts to aid installation. 38. Remove two mounts (Figure 17, Item 2) from rear of chassis (Figure 17, Item 1). 39. Remove two mounts (Figure 17, Item 3) from front of chassis (Figure 17, Item 1).

Figure 17. Lower Mounts.

0206

0206-18

TM 5-2410-241-23-3

0206

REMOVAL CONTINUED 40. Remove two bracket links (Figure 18, Item 2) from platform front cowl (Figure 18, Item 1). 41. Remove two bracket links (Figure 18, Item 3) from platform rear frame (Figure 18, Item 4).

Figure 18. Bracket Links. 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 bracket links (Figure 18, Item 3) on platform rear frame (Figure 18, Item 4). 2. Install two bracket links (Figure 18, Item 2) on platform front cowl (Figure 18, Item 1).

0206

000206

000206

0206-19

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Install mounts as noted during removal. 3. Install two mounts (Figure 19, Item 3) on front of chassis (Figure 19, Item 1). 4. Install two mounts (Figure 19, Item 2) on rear of chassis (Figure 19, Item 1).

Figure 19. Lower Mounts.

0206

0206-20

TM 5-2410-241-23-3

0206

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
Platform weighs approximately 680 lb (308.44 kg). 5. Attach lifting device to platform (Figure 20, Item 1). 6. Using lifting device, install platform (Figure 20, Item 1) on machine. 7. Install two sleeves (Figure 20, Item 6), mounts (Figure 20, Item 5), large washers (Figure 20, Item 4), washers (Figure 20, Item 3), and bolts (Figure 20, Item 2) on platform (Figure 20, Item 1). 8. Remove lifting device from platform (Figure 20, Item 1).

Figure 20. Front Cab Mounts.

0206

0206-21

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED 9. Install two sleeves (Figure 21, Item 6), upper mounts (Figure 21, Item 5), large washers (Figure 21, Item 4), washers (Figure 21, Item 3), and bolts (Figure 21, Item 2) on platform (Figure 21, Item 1).

Figure 21. Rear Cab Mount. 10. Remove two bracket links (Figure 22, Item 3) from platform rear frame (Figure 22, Item 4). 11. Remove two bracket links (Figure 22, Item 2) from platform front cowl (Figure 22, Item 1).

0206

Figure 22. Bracket Links.

0206

0206-22

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Route harness as noted during removal. Install all electrical connectors as noted during removal.

12. Position harness (Figure 23, Item 3) on platform (Figure 23, Item 4). 13. Connect connector (Figure 23, Item 1) to connector (Figure 23, Item 2).

Figure 23. Arctic Heater Harness Connectors.

0206

0206-23

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Route harness as noted during removal. Install all electrical connectors as tagged during removal. Install tiedown straps as noted during removal.

14. Connect connector (Figure 24, Item 1) on connector (Figure 24, Item 2). 15. Install new tiedown strap (Figure 24, Item 4) on harness (Figure 24, Item 3).

Figure 24. Chassis Harness Connectors.

0206

0206-24

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Route harness as noted during removal. Install all electrical connections as tagged during removal. Install tiedown straps as noted during removal.

16. Connect two connectors (Figure 25, Item 2) to connectors (Figure 25, Item 3). 17. Install new tiedown strap (Figure 25, Item 1) on harness (Figure 25, Item 4).

Figure 25. Transmission Harness Connectors.

0206

0206-25

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Install all electrical connectors as tagged during removal. 18. Connect two connectors (Figure 26, Items 3 and 4) to brake solenoid (Figure 26, Item 1). 19. Install two new tiedown straps (Figure 26, Item 2) on brake solenoid (Figure 26, Item 1).

Figure 26. Brake Solenoid.

0206

0206-26

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED 20. Install bracket (Figure 27, Item 10), clamp (Figure 27, Item 4), washer (Figure 27, Item 3), and bolt (Figure 27, Item 2) on chassis (Figure 27, Item 9).

NOTE
Install wires as tagged during removal. 21. Connect two ground wires (Figure 27, Items 5 and 6) on chassis (Figure 27, Item 9) and install washer (Figure 27, Item 8) and bolt (Figure 27, Item 7). 22. Install new tiedown strap (Figure 27, Item 1) on bracket (Figure 27, Item 10).

Figure 27. Brake Solenoid Wiring.

0206

0206-27

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Install cables as tagged during removal. 23. Connect two cables (Figure 28, Items 1 and 4) to fuse box (Figure 28, Item 5) and install two washers (Figure 28, Item 2) and bolts (Figure 28, Item 3).

Figure 28. Fuse Box Connection.

0206

0206-28

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED 24. Install cover (Figure 29, Item 6), two washers (Figure 29, Item 8), and bolts (Figure 29, Item 7) over cables (Figure 29, Items 1 and 2). 25. Install two clamps (Figure 29, Item 3), washers (Figure 29, Item 5) and nuts (Figure 29, Item 4) on cables (Figure 29, Items 1 and 2).

Figure 29. Fuse Box Cables.

0206

0206-29

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED 26. Position harness (Figure 30, Item 6) and hose (Figure 30, Item 5) on platform (Figure 30, Item 4) as noted during removal. 27. Install ladder clip (Figure 30, Item 7), P clip (Figure 30, Item 10), washer (Figure 30, Item 8), and bolt (Figure 30, Item 9) on platform (Figure 30, Item 4). 28. Install under hood light (Figure 30, Item 1), two washers (Figure 30, Item 2), and bolts (Figure 30, Item 3) on platform (Figure 30, Item 4).

Figure 30. Light Harness.

0206

0206-30

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Route and connect hoses as noted during removal. 29. Connect A/C hose (Figure 31, Item 4) and tighten tube nut (Figure 31, Item 5) on evaporator core (Figure 31, Item 2). 30. Connect A/C hose (Figure 31, Item 3) and tighten tube nut (Figure 31, Item 1) on evaporator core (Figure 31, Item 2).

Figure 31. A/C Hoses.

0206

0206-31

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Route and install hoses as tagged during removal. 31. Install hose (Figure 32, Item 6) and tighten clamp (Figure 32, Item 5) on heater valve (Figure 32, Item 4). 32. Install hoses (Figure 32, Item 3) and tighten clamp (Figure 32, Item 2) on heater core (Figure 32, Item 1).

Figure 32. Heater and A/C Hoses.

0206

0206-32

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED 33. Install new gasket (Figure 33, Item 5) on platform (Figure 33, Item 4). 34. Install cover plate (Figure 33, Item 3), four washers (Figure 33, Item 1), and bolts (Figure 33, Item 2) on platform (Figure 33, Item 4).

Figure 33. Heater Core Cover.

0206

0206-33

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED

NOTE
Install all electrical connectors as tagged during removal. Route harness as noted during removal.

35. Connect connector (Figure 34, Item 2) to connector (Figure 34, Item 5). 36. Install connectors (Figure 34, Items 2 and 5) on harness clamp (Figure 34, Item 4). 37. Connect connector (Figure 34, Item 1) to connector (Figure 34, Item 6). 38. Install new tiedown strap (Figure 34, Item 3) on harness clamp (Figure 34, Item 4). 39. Connect plug (Figure 34, Item 8) to relay (Figure 34, Item 7).

Figure 34. Engine Harness.

0206

0206-34

TM 5-2410-241-23-3

0206

INSTALLATION CONTINUED 40. Install rod (Figure 35, Item 1) on steering control (Figure 35, Item 3). 41. Install pin (Figure 35, Item 2) in rod (Figure 35, Item 1). 42. Position clip (Figure 35, Item 4) on rod (Figure 35, Item 1).

Figure 35. Steering Control. END OF TASK

0206

0206-35

TM 5-2410-241-23-3

0206

FOLLOW-ON TASKS 1. Install batteries (WP 0155). 2. Install bulldozer pilot valve (WP 0259). 3. Install ripper pilot valve (WP 0256). 4. Install fuel tank (WP 0170). 5. Install cab (WP 0245). 6. Install engine enclosure right door guard (WP 0204). 7. Install engine enclosure left door guard (WP 0202). 8. Install hood (WP 0200). 9. Install right platform access panels (WP 0208). 10. Install left platform access panels (WP 0207). 11. Install front and rear floor plates (WP 0230). 12. Install cab seat (WP 0247). 13. Fill hydraulic system (WP 0151). 14. Purge and charge refrigerant in A/C system (WP 0113). 15. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000206

0206-36

6 TM 5-2410-241-23-3 0207

FIELD MAINTENANCE INSTRUCTIONS LEFT PLATFORM ACCESS PANELS Removal, Cleaning and Inspection, Installation
0 2 0 7

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 REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10) Cab seat removed (WP 0247) Drawing Required TM 5-2410-241-24P, Figure 87, 117 Estimated Time to Complete 2.0 Hr

000207

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.

0207

0207-1

TM 5-2410-241-23-3

0207

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. Lower Left Panel.

0207

0207-2

TM 5-2410-241-23-3

0207

REMOVAL CONTINUED 4. Remove two bolts (Figure 3, Item 3), washers (Figure 3, Item 4), and cover plate (Figure 3, Item 5) from upper left panel (Figure 3, Item 6). 5. Remove four bolts (Figure 3, Item 1) and washers (Figure 3, Item 2) from upper left panel (Figure 3, 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. 6. Remove four bolts (Figure 3, Item 9), washers (Figure 3, Item 8), and upper left panel (Figure 3, Item 6) from console (Figure 3, Item 10). 7. If damaged, remove foam (Figure 3, Item 7) from upper left panel (Figure 3, Item 6).

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

0207

000207

0207-3

TM 5-2410-241-23-3

0207

INSTALLATION 1. If removed, install foam (Figure 4, Item 7) on upper left panel (Figure 4, Item 6).

000207

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. 2. Install upper left panel (Figure 4, Item 6), four washers (Figure 4, Item 8), and bolts (Figure 4, Item 9) on console (Figure 4, Item 10). 3. Install four washers (Figure 4, Item 2) and bolts (Figure 4, Item 1) on upper left panel (Figure 4, Item 6). 4. Install cover plate (Figure 4, Item 5), two washers (Figure 4, Item 4), and bolts (Figure 4, Item 3) on upper left panel (Figure 4, Item 6).

Figure 4. Upper Left Panel.

0207

0207-4

TM 5-2410-241-23-3

0207

INSTALLATION CONTINUED

000207

5. 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). 6. Install felt cover (Figure 5, Item 5) on console (Figure 5, Item 4). 7. Install armrest (Figure 5, Item 1), two washers (Figure 5, Item 3), and bolts (Figure 5, Item 2) on console (Figure 5, Item 4).

Figure 5. 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

0207

000207

0207-5/(6 blank)

16 TM 5-2410-241-23-3 0208

FIELD MAINTENANCE INSTRUCTIONS RIGHT PLATFORM ACCESS PANELS SERVICE Lower Right Access Panels Removal, Upper Right Access Panel Removal, Cleaning and Inspection, Upper Right Access Panel Installation, Lower Right Access Panels Installation
0 2 0 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) Personnel Required Two References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Seat suspension removed (WP 0248) Fire extinguisher and bracket removed (WP 0255) Drawing Required TM 5-2410-241-24P, Figure 87, 126 Estimated Time to Complete 3.5 Hr

0208-1

TM 5-2410-241-23-3

0208

LOWER RIGHT ACCESS PANELS REMOVAL 1. Disconnect messenger connector (Figure 1, Item 1) from connector at front of console (Figure 1, Item 2). 2. Remove two arm rest adjustment knobs (Figure 1, Item 3) and right armrest (Figure 1, Item 6) from machine. 3. Remove two bolts (Figure 1, Item 4), washers (Figure 1, Item 5), and armrest (Figure 1, Item 6) from plate (Figure 1, Item 7).

000208

Figure 1. Cab Interior.

0208

0208-2

TM 5-2410-241-23-3

0208

LOWER RIGHT ACCESS PANELS REMOVAL CONTINUED 4. Remove two bolts (Figure 2, Item 3), washers (Figure 2, Item 1), bracket (Figure 2, Item 2) and insulation (Figure 2, Item 4) from machine.

Figure 2. Right Armrest Bracket.

0208

0208-3

TM 5-2410-241-23-3

0208

LOWER RIGHT ACCESS PANELS 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
Lower right access panel weighs approximately 50 lb (23 kg). 5. Remove 10 bolts (Figure 3, Item 4) and washers (Figure 3, Item 5) from lower right access panel (Figure 3, Item 6). 6. With assistance, remove lower right access panel (Figure 3, Item 6) from machine. 7. Remove four bolts (Figure 3, Item 1), washers (Figure 3, Item 2), and front lower right access panel (Figure 3, Item 3) from machine.

Figure 3. Lower Right Access Panel Removal. END OF TASK

0208

0208-4

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL REMOVAL

000208

NOTE
Note position of washers to aid installation. 1. Remove 14 bolts (Figure 4, Item 2), washers (Figure 4, Item 3), and harness clip (Figure 4, Item 4) from upper right access panel (Figure 4, Item 1).

Figure 4. Upper Right Access Panel.

0208

0208-5

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL REMOVAL CONTINUED 2. Remove bolt (Figure 5, Item 2) from upper right access panel (Figure 5, Item 1). 3. From inside right compartment, remove two bolts (Figure 5, Item 4) and washers (Figure 5, Item 5) from switch pod (Figure 5, Item 3). 4. Position switch pod (Figure 5, Item 3) aside.

Figure 5. Switch Pod.

0208

0208-6

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL REMOVAL CONTINUED

NOTE
Mark all connectors and note harness routing to aid installation. 5. Disconnect three connectors (Figure 6, Item 3) from three switches (Figure 6, Item 2). 6. Remove switch pod (Figure 6, Item 1) from machine.

Figure 6. Switch Pod Connectors.

0208

0208-7

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL REMOVAL CONTINUED 7. Remove screw (Figure 7, Item 3), horn button (Figure 7, Item 4), and nut (Figure 7, Item 5) from horn switch (Figure 7, Item 6). 8. Remove grommet (Figure 7, Item 2) and push switch panel harness (Figure 7, Item 1) down through upper right access panel (Figure 7, Item 7).

Figure 7. Pod Harness.

0208

0208-8

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL REMOVAL CONTINUED

NOTE
Note wiring harness routing to aid installation. Tag and mark all electrical connections to aid installation.

9. Remove five tiedown straps (Figure 8, Item 3) from harness (Figure 8, Item 2) and upper right access panel (Figure 8, Item 4). Discard tiedown straps. 10. Disconnect horn switch (Figure 8, Item 1) connector from switch panel harness (Figure 8, Item 2). 11. Disconnect indicator lamp (Figure 8, Item 7) connector from switch panel harness (Figure 8, Item 2). 12. Remove nut (Figure 8, Item 6), washer (Figure 8, Item 5), and indicator lamp (Figure 8, Item 7) from upper right access panel (Figure 8, Item 4). 13. Remove upper right access panel (Figure 8, Item 4) from machine.

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

0208

000208

0208-9

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL INSTALLATION

000208

NOTE
Route wiring harness as noted during removal. Install electrical connections as tagged during removal.

1. Position upper right access panel (Figure 9, Item 4) inside cab of machine. 2. Install indicator lamp (Figure 9, Item 7), washer (Figure 9, Item 5), and nut (Figure 9, Item 6) on upper right access panel (Figure 9, Item 4). 3. Connect indicator lamp (Figure 9, Item 7) connector to switch panel harness (Figure 9, Item 2). 4. Connect horn switch (Figure 9, Item 1) connector to switch panel harness (Figure 9, Item 2). 5. Install five new tiedown straps (Figure 9, Item 3) on switch panel harness (Figure 9, Item 2).

Figure 9. Switch Panel Harness.

0208

0208-10

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL INSTALLATION CONTINUED 6. Push switch panel harness (Figure 10, Item 1) through upper right access panel (Figure 10, Item 7) and install grommet (Figure 10, Item 2).

NOTE
Ensure harness is not trapped between panels. 7. Position upper right access panel (Figure 10, Item 7) to installed location. 8. Install washer (Figure 10, Item 6), nut (Figure 10, Item 5), horn button (Figure 10, Item 4), and screw (Figure 10, Item 3) on horn switch.

Figure 10. Pod Harness.

0208

0208-11

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL INSTALLATION CONTINUED 9. Position switch pod (Figure 11, Item 1) to access switch connectors.

NOTE
Install connectors and harnesses as marked during removal. 10. Connect three connectors (Figure 11, Item 3) to three switches (Figure 11, Item 2).

Figure 11. Switch Pod Connectors. 11. Position switch pod (Figure 12, Item 3) on upper right access panel (Figure 12, Item 1). 12. Install two washers (Figure 12, Item 5) and bolts (Figure 12, Item 4) on switch pod (Figure 12, Item 3). 13. Install bolt (Figure 12, Item 2) on upper right access panel (Figure 12, Item 1).

0208

Figure 12. Switch Pod.

0208

0208-12

TM 5-2410-241-23-3

0208

UPPER RIGHT ACCESS PANEL INSTALLATION CONTINUED

NOTE
Install washers as noted during removal. 14. Install harness clip (Figure 13, Item 4), 14 washers (Figure 13, Item 3), and bolts (Figure 13, Item 2) on upper right access panel (Figure 13, Item 1).

Figure 13. Upper Right Access Panel. END OF TASK

0208

0208-13

TM 5-2410-241-23-3

0208

LOWER RIGHT ACCESS PANELS INSTALLATION

000208

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
Lower right access panel weighs approximately 50 lb (23 kg). 1. Install front lower right access panel (Figure 14, Item 3), four washers (Figure 14, Item 2), and bolts (Figure 14, Item 1). 2. With assistance, install lower right access panel (Figure 14, Item 6), 10 washers (Figure 14, Item 5), and bolts (Figure 14, Item 4) on machine.

Figure 14.

Lower Right Access Panels Installation.

0208

0208-14

TM 5-2410-241-23-3

0208

LOWER RIGHT ACCESS PANELS INSTALLATION CONTINUED 3. Install insulation (Figure 15, Item 4), bracket (Figure 15, Item 2), two washers (Figure 15, Item 1) and bolts (Figure 15, Item 3) on machine.

Figure 15. Right Armrest Bracket.

0208

0208-15

TM 5-2410-241-23-3

0208

LOWER RIGHT ACCESS PANELS INSTALLATION CONTINUED 4. Install armrest (Figure 16, Item 6), two washers (Figure 16, Item 5), and bolts (Figure 16, Item 4) on plate (Figure 16, Item 7).

5. Install armrest (Figure 16, Item 6) and two armrest adjustment knobs (Figure 16, Item 3) on machine. 6. Connect messenger connector (Figure 16, Item 1) to connector at front of console (Figure 16, Item 2).

Figure 16. Cab Interior. END OF TASK FOLLOW-ON TASKS 1. Install fire extinguisher and bracket (WP 0255). 2. Install seat suspension (WP 0248). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0208

000208

0208-16

26 TM 5-2410-241-23-3 0209

FIELD MAINTENANCE
0 2 0 9

PLATFORM WIRING 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
0

Equipment Condition Machine parked (TM 5-2410-241-10) Platform removed (WP 0206) Drawing Required TM 5-2410-241-24P, Figure 87 Estimated Time to Complete 29.0 Hr

0209-1

TM 5-2410-241-23-3

0209

REMOVAL

000209

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

1. Remove six bolts (Figure 1, Item 4), washers (Figure 1, Item 3), and three connectors (Figure 1, Item 5) from platform (Figure 1, Item 1). 2. Remove tiedown straps (Figure 1, Item 2) from harness (Figure 1, Item 6) and platform (Figure 1, Item 1). Position harness aside and discard tiedown straps.

Figure 1. Right Rear Harness Routing.

0209

0209-2

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

3. Remove two connectors (Figure 2, Item 5) from bracket (Figure 2, Item 4). 4. Remove tiedown straps (Figure 2, Item 1) from harness (Figure 2, Item 2) and platform (Figure 2, Item 3). Position harness aside and discard tiedown straps.

Figure 2. Right Side Harness Routing.

0209

0209-3

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

5. Remove four bolts (Figure 3, Item 7), washers (Figure 3, Item 8), and connector (Figure 3, Item 3) from plate (Figure 3, Item 4). Position connector aside. 6. Remove four nuts (Figure 3, Item 10), washers (Figure 3, Item 9), bolts (Figure 3, Item 5), washers (Figure 3, Item 6), and plate (Figure 3, Item 4) from platform (Figure 3, Item 11). 7. Remove bolt (Figure 3, Item 2) and two connector brackets (Figure 3, Item 1) from platform (Figure 3, Item 11).

Figure 3. Harness Connector, Plate, and Clip.

0209

0209-4

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Note number and location of tiedown straps to aid installation.

8. Remove tiedown straps (Figure 4, Item 2) from harness (Figure 4, Item 3) and platform (Figure 4, Item 1). Position harness aside and discard tiedown straps.

Figure 4. Right Front Harness Routing.

0209

0209-5

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections and cables to aid installation. Note number and location of tiedown straps to aid installation.

9. Loosen bolt (Figure 5, Item 8) and disconnect connector (Figure 5, Item 7) from platform (Figure 5, Item 9). Set harness (Figure 5, Item 1) aside. 10. Remove two bolts (Figure 5, Item 2), washers (Figure 5, Item 3), and five ground cables (Figure 5, Item 4) from platform (Figure 5, Item 9). 11. Remove tiedown straps (Figure 5, Item 6) from harness (Figure 5, Item 5) and platform (Figure 5, Item 9). Position harness aside and discard tiedown straps.

Figure 5. Platform Harness to Instrument Panel Harness Connector.

0209

0209-6

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Note number and location of tiedown straps to aid installation.

12. Remove tiedown straps (Figure 6, Item 1) from harness (Figure 6, Item 2) and platform (Figure 6, Item 3). Position harness aside and discard tiedown straps.

Figure 6. Platform Harness to Platform Floor. 13. Open latch (Figure 7, Item 1) and door (Figure 7, Item 2) on platform (Figure 7, Item 6). 14. Remove five bolts (Figure 7, Item 4), washers (Figure 7, Item 5), panel (Figure 7, Item 3), and door (Figure 7, Item 2) from platform (Figure 7, Item 6).

0209

Figure 7. Fuse Panel Access Door.

0209

0209-7

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

15. Disconnect plug (Figure 8, Item 2) from connector (Figure 8, Item 1). Position plug aside. 16. Disconnect cover (Figure 8, Item 3) from connector (Figure 8, Item 6). Position cover aside. 17. Disconnect two connectors (Figure 8, Item 5) from power outlets (Figure 8, Item 4).

Figure 8. Platform Rear Harness Connections.

0209

0209-8

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

18. Remove four nuts (Figure 9, Item 2), washers (Figure 9, Item 3), bolts (Figure 9, Item 4), and connector (Figure 9, Item 1) from plate (Figure 9, Item 7). Position connector aside. 19. Remove four bolts (Figure 9, Item 5), two nut plates (Figure 9, Item 8), and connector (Figure 9, Item 6) from plate (Figure 9, Item 7). Position connector aside.

Figure 9. Platform Rear Harness Connectors.

0209

0209-9

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED 20. Remove four bolts (Figure 10, Item 1), plug (Figure 10, Item 6), cap (Figure 10, Item 5), two tethers (Figure 10, Item 4), and plate (Figure 10, Item 2) from platform (Figure 10, Item 3).

Figure 10. Platform Rear Harness Connector Plate.

0209

NOTE
Steps 21 - 22 remove one power outlet, repeat steps for second power outlet removal. 21. Remove cap (Figure 11, Item 3) from power outlet (Figure 11, Item 1). 22. Remove power outlet (Figure 11, Item 1) from plate (Figure 11, Item 2).

Figure 11. Power Outlets.

0209

0209-10

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Note number and location of tiedown straps to aid installation.

23. Remove tiedown straps (Figure 12, Item 1) from harness (Figure 12, Item 3) and platform (Figure 12, Item 2). Position harness aside and discard tiedown straps.

Figure 12. Platform Rear Harness Routing.

0209

0209-11

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

24. Loosen bolt (Figure 13, Item 5) and disconnect connector (Figure 13, Item 6) from connector (Figure 13, Item 2). 25. Remove four bolts (Figure 13, Item 3), washers (Figure 13, Item 4), and connector (Figure 13, Item 2) from platform (Figure 13, Item 1).

Figure 13. Machine ECM Connector.

0209

0209-12

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all cables to aid installation.

26. Remove bolt (Figure 14, Item 4), washer (Figure 14, Item 3), and four ground cables (Figure 14, Item 2) from platform (Figure 14, Item 1).

Figure 14. Harness Ground Cables.

0209

0209-13

TM 5-2410-241-23-3

0209

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

27. Loosen bolt (Figure 15, Item 3) and disconnect connector (Figure 15, Item 2) from fuse box (Figure 15, Item 1). Set connector aside. 28. Disconnect connector (Figure 15, Item 5) from power converter box (Figure 15, Item 4). Set connector aside. 29. Remove tiedown straps (Figure 15, Item 7) from harness (Figure 15, Item 8) and platform (Figure 15, Item 6). Discard tiedown straps. 30. Remove harness (Figure 15, Item 8) from platform (Figure 15, Item 6).

Figure 15. Left Side Harness Routing. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0209

000209

0209-14

TM 5-2410-241-23-3

0209

INSTALLATION

000209

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

1. Position harness (Figure 16, Item 8) on platform (Figure 16, Item 6). 2. Install new tiedown straps (Figure 16, Item 7) on harness (Figure 16, Item 8) and platform (Figure 16, Item 6). 3. Connect connector (Figure 16, Item 5) to power converter box (Figure 16, Item 4). 4. Connect connector (Figure 16, Item 2) and install bolt (Figure 16, Item 3) on fuse box (Figure 16, Item 1).

Figure 16. Left Side Harness Routing.

0209

0209-15

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

NOTE
Install harness as noted during removal. Install cables as tagged and marked during removal.

5. Install four ground cables (Figure 17, Item 2), one washer (Figure 17, Item 3), and bolt (Figure 17, Item 4) on platform (Figure 17, Item 1).

Figure 17. Harness Ground Cables.

0209

NOTE
Install harness as noted during removal. Install connectors as tagged and marked during removal.

6. Install connector (Figure 18, Item 2), four washers (Figure 18, Item 4), and bolts (Figure 18, Item 3) on platform (Figure 18, Item 1). 7. Connect connector (Figure 18, Item 6) and tighten bolt (Figure 18, Item 5) on connector (Figure 18, Item 2).

0209-16

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

Figure 18. Machine ECM Connector.

0209

NOTE
Install harness as noted during removal. Install tiedown straps as noted during removal.

8. Install new tiedown straps (Figure 19, Item 1) on harness (Figure 19, Item 3) and platform (Figure 19, Item 2).

Figure 19. Platform Rear Harness Routing.

0209

0209-17

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

NOTE
Steps 9 - 10 install one power outlet, repeat steps for second power outlet installation. 9. Install power outlet (Figure 20, Item 1) on plate (Figure 20, Item 2). 10. Install cap (Figure 20, Item 3) on power outlet (Figure 20, Item 1).

Figure 20. Power Outlets. 11. Install plate (Figure 21, Item 2), two tethers (Figure 21, Item 4), cap (Figure 21, Item 5), plug (Figure 21, Item 6), and four bolts (Figure 21, Item 1) on platform (Figure 21, Item 3).

0209

Figure 21. Platform Rear Harness Connector Plate.

0209

0209-18

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

NOTE
Install harness as noted during removal. Install connectors as tagged and marked during removal.

12. Install connector (Figure 22, Item 6), two nut plates (Figure 22, Item 8), and four bolts (Figure 22, Item 5) on plate (Figure 22, Item 7). 13. Install connector (Figure 22, Item 1), four bolts (Figure 22, Item 4), nuts (Figure 22, Item 2), and washers (Figure 22, Item 3) on plate (Figure 22, Item 7).

Figure 22. Platform Rear Harness Connectors.

0209

0209-19

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

NOTE
Install harness as noted during removal. Install connectors as tagged and marked during removal.

14. Connect two connectors (Figure 23, Item 5) to power outlets (Figure 23, Item 4). 15. Connect cover (Figure 23, Item 3) to connector (Figure 23, Item 6). 16. Connect plug (Figure 23, Item 2) to connector (Figure 23, Item 1).

Figure 23. Platform Rear Harness Connections.

0209

0209-20

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED 17. Install door (Figure 24, Item 2), panel (Figure 24, Item 3), five washers (Figure 24, Item 5), and bolts (Figure 24, Item 4) on platform (Figure 24, Item 6). 18. Close door (Figure 24, Item 2) and close latch (Figure 24, Item 1) on platform (Figure 24, Item 6).

Figure 24. Fuse Panel Access Door.

0209

NOTE
Install harness as noted during removal. Install tiedown straps as noted during removal.

19. Install new tiedown straps (Figure 25, Item 1) on harness (Figure 25, Item 2) and platform (Figure 25, Item 3).

Figure 25. Platform Harness to Platform Floor.

0209

0209-21

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

NOTE
Install harness as noted during removal. Install connectors and cables as tagged and marked during removal. Install tiedown straps as noted during removal.

20. Install new tiedown straps (Figure 26, Item 6) on harness (Figure 26, Item 5) and platform (Figure 26, Item 9). 21. Install five ground cables (Figure 26, Item 4), two washers (Figure 26, Item 3), and bolts (Figure 26, Item 2) on platform (Figure 26, Item 9). 22. Connect connector (Figure 26, Item 7) and tighten bolt (Figure 26, Item 8) on platform (Figure 26, Item 9).

Figure 26. Platform Harness to Instrument Panel Harness Connector.

0209

0209-22

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

NOTE
Install harness as noted during removal. Install tiedown straps as noted during removal.

23. Install new tiedown straps (Figure 27, Item 2) on harness (Figure 27, Item 3) and platform. (Figure 27, Item 1).

Figure 27. Right Front Harness Routing.

0209

0209-23

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

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

24. Install two connector brackets (Figure 28, Item 1) and bolt (Figure 28, Item 2) on platform (Figure 28, Item 11). 25. Install plate (Figure 28, Item 4), four washers (Figure 28, Item 6), bolts (Figure 28, Item 5), washers (Figure 28, Item 9), and nuts (Figure 28, Item 10) on platform (Figure 28, Item 11). 26. Install connector (Figure 28, Item 3), four washers (Figure 28, Item 8), and bolts (Figure 28, Item 7) on plate (Figure 28, Item 4).

Figure 28. Harness Connector, Plate, and Clip.

0209

0209-24

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

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

27. Install new tiedown straps (Figure 29, Item 1) on harness (Figure 29, Item 2) and platform (Figure 29, Item 3). 28. Install two connectors (Figure 29, Item 5) on bracket (Figure 29, Item 4).

Figure 29. Right Side Harness Routing.

0209

0209-25

TM 5-2410-241-23-3

0209

INSTALLATION CONTINUED

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

29. Install new tiedown straps (Figure 30, Item 2) on harness (Figure 30, Item 6) and platform (Figure 30, Item 1). 30. Install three connectors (Figure 30, Item 5), six washers (Figure 30, Item 3), and bolts (Figure 30, Item 4) on platform (Figure 30, Item 1).

Figure 30. Right Rear Harness Routing. END OF TASK FOLLOW-ON TASKS 1. Install platform (WP 0207). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0209

000209

0209-26

12 TM 5-2410-241-23-3 0210

FIELD MAINTENANCE CYLINDER FLOOD LAMP AND BRACKET SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 1 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Isopropyl Alcohol (WP 0303, Item 15) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Bulb REMOVAL
0

References WP 0295

Equipment Condition
0

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

TM 5-2410-241-24P, Figure 121


0 0

Estimated Time to Complete 1.0 Hr

000210

NOTE
The following procedure is for right side flood lamp. Follow the same procedure for left side flood lamp. Tag electrical connector to aid installation.

1. Disconnect electrical connector (Figure 1, Item 4). 2. Remove bolt (Figure 1, Item 1), washer (Figure 1, Item 2), and flood lamp (Figure 1, Item 3) from guard (Figure 1, Item 5).

Figure 1. Flood Lamp Assembly.

0210

0210-1

TM 5-2410-241-23-3

0210

REMOVAL CONTINUED 3. Remove nut (Figure 2, Item 1), two washers (Figure 2, Item 4), bolt (Figure 2, Item 3), and bracket (Figure 2, Item 2) from flood lamp (Figure 2, Item 5).

Figure 2. Bracket.

0210

0210-2

TM 5-2410-241-23-3

0210

REMOVAL CONTINUED

NOTE
Steps 4 and 5 are needed only if guard needs to be removed from machine. Note harness routing to aid installation.

4. Cut and discard tiedown straps (Figure 3, Item 6) and position wiring harness (Figure 3, Item 9) aside. 5. Remove four nuts (Figure 3, Item 8), washers (Figure 3, Item 7), and guard (Figure 3, Item 1) from cylinder brackets (Figure 3, Item 2). 6. Remove four nuts (Figure 3, Item 3), washers (Figure 3, Item 4), and mounts (Figure 3, Item 5) from cylinder brackets (Figure 3, Item 2).

Figure 3. Guard. END OF TASK

0210

0210-3

TM 5-2410-241-23-3

0210

DISASSEMBLY

000210

NOTE
Flood lamp can be disassembled without removing guard from machine. 1. Remove bolt (Figure 4, Item 1) and washer (Figure 4, Item 2). Open grille (Figure 4, Item 3). 2. Disengage and remove outer band clamp (Figure 4, Item 5) and pull lamp (Figure 4, Item 4) from grommet (Figure 4, Item 6).

Figure 4. Flood Lamp Removal.

0210

0210-4

TM 5-2410-241-23-3

0210

DISASSEMBLY CONTINUED

NOTE
Tag electrical connectors to aid assembly. 3. Disconnect black connector (Figure 5, Item 1) from lamp assembly (Figure 5, Item 4). 4. Disconnect white wire (Figure 5, Item 2) from bulb (Figure 5, Item 3). Place lamp assembly on suitable work surface.

Figure 5. Disconnecting Lamp Connectors.

0210

0210-5

TM 5-2410-241-23-3

0210

DISASSEMBLY CONTINUED 5. Disengage bale wires (Figure 6, Item 4) from plastic retainer (Figure 6, Item 3) and lugs (Figure 6, Item 5). 6. Remove bulb (Figure 6, Item 2) from lamp assembly (Figure 6, Item 1). Discard bulb.

Figure 6. Bulb Assembly Removal. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY

0210

000210

000210

CAUTION
Do not touch the glass surface of a halogen bulb with bare fingers, as the surface will be exposed to the salts and oils in the hand. If glass is touched, it must be cleaned immediately with a gentle solvent such as alcohol. Failure to follow this caution will result in early bulb failure. 1. Install bulb (Figure 6, Item 2) into lamp assembly (Figure 6, Item 1), feeding the white wire under the plastic retainer (Figure 6, Item 3). 2. Engage bale wires (Figure 6, Item 4) under lugs (Figure 6, Item 5) to secure bulb (Figure 6, Item 2).

0210-6

TM 5-2410-241-23-3

0210

ASSEMBLY CONTINUED

NOTE
Install electrical connectors as tagged during disassembly. 3. Connect black connector (Figure 7, Item 1) on lamp assembly (Figure 7, Item 4). 4. Connect white wire (Figure 7, Item 2) to bulb (Figure 7, Item 3).

Figure 7. Connecting Lamp Connectors.

0210

0210-7

TM 5-2410-241-23-3

0210

ASSEMBLY CONTINUED 5. Install lamp assembly (Figure 8, Item 4) into grommet (Figure 8, Item 6). 6. Position and engage band clamp (Figure 8, Item 5) around grommet (Figure 8, Item 6). 7. Close grille (Figure 8, Item 3) and install washer (Figure 8, Item 2) and bolt (Figure 8, Item 1).

Figure 8. Flood Lamp Installation. END OF TASK

0210

0210-8

TM 5-2410-241-23-3

0210

INSTALLATION 1. Install four mounts (Figure 9, Item 5), washers (Figure 9, Item 4), and nuts (Figure 9, Item 3) on cylinder brackets (Figure 9, Item 2). 2. If removed, install guard (Figure 9, Item 1), four washers (Figure 9, Item 7), and nuts (Figure 9, Item 8) on cylinder brackets (Figure 9, Item 2).

000210

NOTE
Route harness as noted during removal. 3. Route wiring harness (Figure 9, Item 9) and install two new tiedown straps (Figure 9, Item 6) on cylinder brackets (Figure 9, Item 2).

Figure 9. Guard.

0210

0210-9

TM 5-2410-241-23-3

0210

INSTALLATION CONTINUED 4. Position bracket (Figure 10, Item 2) on flood lamp (Figure 10, Item 5) and install bolt (Figure 10, Item 3), two washers (Figure 10, Item 4), and nut (Figure 10, Item 1).

Figure 10. Bracket.

0210

0210-10

TM 5-2410-241-23-3

0210

INSTALLATION CONTINUED 5. Install flood lamp (Figure 11, Item 3), washer (Figure 11, Item 2), and bolt (Figure 11, Item 1) on guard (Figure 11, Item 5).

NOTE
Install electrical connector as tagged during removal. 6. Connect electrical connector (Figure 11, Item 4).

Figure 11. Flood Lamp Assembly. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0210

000210

0210-11/(12 blank)

28 TM 5-2410-241-23-3 0211

FIELD MAINTENANCE VALVE BANK GP - TEST 5 SERVICE WITH RIPPER EFFECTIVITY NOTICE (WITH RIPPER) Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 1 1

INITIAL SETUP Tools and Special Tools


0

Personnel Required Two References WP 0245 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Pilot valve removed (WP 0256) Front floor plate removed (WP 0230) Rear floor plate removed (WP 0231) Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 74, 75 Estimated Time to Complete 12.5 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (3/8 in.; 2,250 lb [1,000 kg]) (WP 0302, Item 10) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Wrench, Combination, 1-1/8 (S0788) (WP 0302, Item 68) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) Wrench, Torque, Dial, 3/8 Drive, 300 lb-in. (WP 0302, Item 74) Lifting Device (500-lb capacity)
0 0 0 0 0 0 0 0

Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Cotter Pin (2) O-ring (79)

0211-1

TM 5-2410-241-23-3

0211

REMOVAL

000211

WARNING

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. Perform disassembly on a clean surface. Clean exterior of component to prevent contamination. Plug all lines, hoses and tubes to prevent contamination and leaks. Tag and mark all hoses and lines to aid installation.

1. Remove eight bolts (Figure 1, Item 4), washers (Figure 1, Item 5), two flanges (Figure 1, Item 1), and hose (Figure 1, Item 2) from control valve (Figure 1, Item 7) and hydraulic tank (Figure 1, Item 3). 2. Remove two O-rings (Figure 1, Item 6) from hose (Figure 1, Item 2). Discard O-rings.

Figure 1. Top Hose.

0211

0211-2

TM 5-2410-241-23-3

0211

REMOVAL CONTINUED

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. Plug all lines, hoses and tubes to prevent contamination and leaks. Tag and mark all hoses and lines to aid installation.

3. Remove 40 bolts (Figure 2, Item 6), washers (Figure 2, Item 5), 10 flanges (Figure 2, Item 1), and 10 hoses (Figure 2, Item 3) from control valve (Figure 2, Item 2). 4. Remove 10 O-rings (Figure 2, Item 4) from hoses (Figure 2, Item 3). Discard O-rings.

Figure 2. Control Valve Hoses.

0211

0211-3

TM 5-2410-241-23-3

0211

REMOVAL CONTINUED

NOTE
Tag and mark all hoses and lines to aid installation. 5. Loosen five tube nuts (Figure 3, Item 1) and remove five hoses (Figure 3, Item 2) and O-rings (Figure 3, Item 3) from front side of control valve (Figure 3, Item 7). Discard O-rings and set hoses aside. 6. Loosen six tube nuts (Figure 3, Item 5) and remove six hoses (Figure 3, Item 4) and O-rings (Figure 3, Item 6) from rear side of control valve (Figure 3, Item 7). Discard O-rings and set hoses aside.

Figure 3. Hoses and Lines.

0211

0211-4

TM 5-2410-241-23-3

0211

REMOVAL CONTINUED

NOTE
Note orientation and location of steering control to aid installation. 7. Remove two cotter pins (Figure 4, Item 5) and washers (Figure 4, Item 4) from linkage (Figure 4, Item 1). Discard cotter pins. 8. Remove linkage (Figure 4, Item 1) from control valve (Figure 4, Item 2) and lever (Figure 4, Item 3).

Figure 4. Control Lever Linkage.

0211

0211-5

TM 5-2410-241-23-3

0211

REMOVAL CONTINUED

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. Plug all lines, hoses and tubes to prevent contamination and leaks. Tag and mark all hoses and lines to aid installation.

9. Remove four bolts (Figure 5, Item 4), washers (Figure 5, Item 3), flange (Figure 5, Item 1), and hose (Figure 5, Item 6) from control valve (Figure 5, Item 2). 10. Remove O-ring (Figure 5, Item 5) from hose (Figure 5, Item 6). Discard O-ring.

Figure 5. Front Side Hose.

0211

0211-6

TM 5-2410-241-23-3

0211

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
Control valve weighs approximately 100 lb (45 kg). 11. Remove cab (WP 0245). 12. Attach bracket link (Figure 6, Item 4), bolt (Figure 6, Item 5), and lifting device on control valve assembly (Figure 6, Item 1). 13. Using lifting device, remove three bolts (Figure 6, Item 3), washers (Figure 6, Item 2), and control valve assembly (Figure 6, Item 1) from machine. 14. Place control valve assembly (Figure 6, Item 1) on flat level surface. 15. Remove lifting device and bracket link (Figure 6, Item 4) from control valve assembly (Figure 6, Item 1).

Figure 6. Control Valve Mounting. END OF TASK

0211

0211-7

TM 5-2410-241-23-3

0211

DISASSEMBLY

000211

NOTE
Note orientation and position of fittings and valves to aid assembly. Tag and mark all fittings and valves to aid installation. Clean exterior of component to prevent contamination. Plug all fitting ports to prevent contamination and leaks.

1. Loosen 10 nuts (Figure 7, Item 2) and remove 10 elbow fittings (Figure 7, Item 1) and O-rings (Figure 7, Item 6) from control valve assembly (Figure 7, Item 5). Discard O-rings. 2. Remove fitting (Figure 7, Item 3) and O-ring (Figure 7, Item 4) from control valve assembly (Figure 7, Item 5). Discard O-ring.

Figure 7. Control Valve Assembly.

0211

0211-8

TM 5-2410-241-23-3

0211

DISASSEMBLY CONTINUED 3. Remove three nuts (Figure 8, Item 1), washers (Figure 8, Item 2), and cover (Figure 8, Item 3) from control valve assembly.

NOTE
Note orientation and position of O-rings to aid assembly. 4. Remove seven O-rings (Figure 8, Item 4) and plug (Figure 8, Item 5) from cover (Figure 8, Item 3). Discard O-rings.

Figure 8. Control Valve Assembly.

0211

0211-9

TM 5-2410-241-23-3

0211

DISASSEMBLY CONTINUED 5. Remove valve (Figure 9, Item 1) from control valve assembly (Figure 9, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 6. Remove seven O-rings (Figure 9, Item 2) from valve (Figure 9, Item 1). Discard O-rings.

Figure 9. Steering Control Valve Manifold.

0211

0211-10

TM 5-2410-241-23-3

0211

DISASSEMBLY CONTINUED 7. Remove valve (Figure 10, Item 1) from control valve assembly (Figure 10, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 8. Remove seven O-rings (Figure 10, Item 2) from valve (Figure 10, Item 1). Discard O-rings.

Figure 10. Bulldozer Lift Control Valve Manifold.

0211

0211-11

TM 5-2410-241-23-3

0211

DISASSEMBLY CONTINUED 9. Remove valve (Figure 11, Item 1) from control valve assembly (Figure 11, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 10. Remove seven O-rings (Figure 11, Item 2) from valve (Figure 11, Item 1). Discard O-rings.

Figure 11. Bulldozer Tilt Control Valve Manifold.

0211

0211-12

TM 5-2410-241-23-3

0211

DISASSEMBLY CONTINUED 11. Remove valve (Figure 12, Item 1) from control valve assembly (Figure 12, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 12. Remove seven O-rings (Figure 12, Item 2) from valve (Figure 12, Item 1). Discard O-rings.

Figure 12. Ripper Tilt Control Valve Manifold.

0211

0211-13

TM 5-2410-241-23-3

0211

DISASSEMBLY CONTINUED 13. Remove valve (Figure 13, Item 1) from control valve assembly (Figure 13, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 14. Remove seven O-rings (Figure 13, Item 2) from valve (Figure 13, Item 1). Discard O-rings.

Figure 13. Ripper Lift Control Valve Manifold. 15. Remove three rods (Figure 14, Item 1) from valve cap (Figure 14, Item 2). 16. Remove relief valve (Figure 14, Item 3) from valve cap (Figure 14, Item 2). 17. Remove two O-rings (Figure 14, Item 4) from relief valve (Figure 14, Item 3). Discard O-rings.

0211

Figure 14. Valve Cap Rods. END OF TASK

0211

0211-14

TM 5-2410-241-23-3

0211

CLEANING AND INSPECTION

000211

NOTE
After cleaning, allow parts to air dry. Do not use rags, as rags may cause lint to be deposited on parts. Perform cleaning, inspection, and assembly on a clean surface. Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY
000211

NOTE
Install valve as noted during removal. Install O-rings as noted during disassembly.

1. Install two new O-rings (Figure 14, Item 4) on relief valve (Figure 14, Item 3). 2. Install relief valve (Figure 14, Item 3) on valve cap (Figure 14, Item 2). 3. Install three rods (Figure 14, Item 1) on valve cap (Figure 14, Item 2). 4. Install seven new O-rings (Figure 13, Item 2) on valve (Figure 13, Item 1). 5. Install valve (Figure 13, Item 1) on valve cap (Figure 13, Item 3).

0211-15

TM 5-2410-241-23-3

0211

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 6. Install seven new O-rings (Figure 15, Item 2) on valve (Figure 15, Item 1). 7. Install valve (Figure 15, Item 1) on control valve assembly (Figure 15, Item 3).

Figure 15. Ripper Tilt Control Valve Manifold.

0211

0211-16

TM 5-2410-241-23-3

0211

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 8. Install seven new O-rings (Figure 16, Item 2) on valve (Figure 16, Item 1). 9. Install valve (Figure 16, Item 1) on control valve assembly (Figure 16, Item 3).

Figure 16. Bulldozer Tilt Control Valve Manifold.

0211

0211-17

TM 5-2410-241-23-3

0211

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 10. Install seven new O-rings (Figure 17, Item 2) on valve (Figure 17, Item 1). 11. Install valve (Figure 17, Item 1) on control valve assembly (Figure 17, Item 3).

Figure 17. Bulldozer Lift Control Valve Manifold.

0211

0211-18

TM 5-2410-241-23-3

0211

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 12. Install seven new O-rings (Figure 18, Item 2) on valve (Figure 18, Item 1). 13. Install valve (Figure 18, Item 1) on control valve assembly (Figure 18, Item 3).

Figure 18. Steering Control Valve Manifold.

0211

0211-19

TM 5-2410-241-23-3

0211

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 14. Install seven new O-rings (Figure 19, Item 4) on cover (Figure 19, Item 3). 15. Install cover (Figure 19, Item 3), three washers (Figure 19, Item 2), and nuts (Figure 19, Item 1) on control valve assembly.

Figure 19. Control Valve Assembly.

0211

0211-20

TM 5-2410-241-23-3

0211

ASSEMBLY CONTINUED

NOTE
Remove plugs from fitting ports. Install fittings as noted during removal.

16. Install new O-ring (Figure 20, Item 4) and fitting (Figure 20, Item 3) on control valve assembly (Figure 20, Item 5). 17. Install 10 new O-rings (Figure 20, Item 6), elbow fittings (Figure 20, Item 1), and nuts (Figure 20, Item 2) on control valve assembly (Figure 20, Item 5).

Figure 20. Control Valve Assembly. END OF TASK

0211

0211-21

TM 5-2410-241-23-3

0211

INSTALLATION

000211

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
Control valve assembly weighs approximately 100 lb (45 kg). 1. Attach bracket link (Figure 21, Item 4) and lifting device on control valve assembly (Figure 21, Item 1). 2. Using lifting device, install control valve assembly (Figure 21, Item 1), three washers (Figure 21, Item 2), and bolts (Figure 21, Item 3) on machine. 3. Remove lifting device bolt (Figure 21, Item 5) and bracket link (Figure 21, Item 4) from control valve assembly (Figure 21, Item 1). 4. Install cab (WP 0245).

Figure 21. Control Valve Mounting.

0211

0211-22

TM 5-2410-241-23-3

0211

INSTALLATION CONTINUED

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

5. Install new O-ring (Figure 22, Item 5) on hose (Figure 22, Item 6). 6. Install hose (Figure 22, Item 6), flange (Figure 22, Item 1), four washers (Figure 22, Item 3), and bolts (Figure 22, Item 4) on control valve (Figure 22, Item 2)

Figure 22. Front Side Hose.

0211

0211-23

TM 5-2410-241-23-3

0211

INSTALLATION CONTINUED

NOTE
Install steering control linkage as noted during removal. 7. Install linkage (Figure 23, Item 1) on control valve (Figure 23, Item 2) and lever (Figure 23, Item 3). 8. Install two washers (Figure 23, Item 4) and new cotter pins (Figure 23, Item 5) on linkage (Figure 23, Item 1).

Figure 23. Control Lever Linkage.

0211

0211-24

TM 5-2410-241-23-3

0211

INSTALLATION CONTINUED

NOTE
Install hoses and lines as noted during removal. 9. Install six new O-rings (Figure 24, Item 6), hoses (Figure 24, Item 4), and tighten tube nuts (Figure 24, Item 5) on rear side of control valve (Figure 24, Item 7). 10. Install five new O-rings (Figure 24, Item 3), hoses (Figure 24, Item 2), and tighten tube nuts (Figure 24, Item 1) on front side of control valve (Figure 24, Item 7).

Figure 24. Hoses and Lines.

0211

0211-25

TM 5-2410-241-23-3

0211

INSTALLATION CONTINUED 11. Install 10 new O-rings (Figure 25, Item 4) on 10 hoses (Figure 25, Item 3).

NOTE
Install hoses as noted during removal. 12. Install 10 hoses (Figure 25, Item 3), 10 flanges (Figure 25, Item 1), 40 washers (Figure 25, Item 5), and bolts (Figure 25, Item 6) on control valve (Figure 25, Item 2).

Figure 25. Control Valve Hoses.

0211

0211-26

TM 5-2410-241-23-3

0211

INSTALLATION CONTINUED 13. Install two new O-rings (Figure 26, Item 6) on hoses (Figure 26, Item 2). 14. Install two hoses (Figure 26, Item 2), flanges (Figure 26, Item 1), eight washers (Figure 26, Item 5), and bolts (Figure 26, Item 4) on control valve (Figure 26, Item 7) and hydraulic tank (Figure 26, Item 3).

Figure 26. Top Hose. END OF TASK FOLLOW-ON TASKS 1. Install pilot valve (WP 0256). 2. Fill hydraulic system (WP 0184). 3. Install front floor plate (WP 0230). 4. Install rear floor plate (WP 0231). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0211

000211

0211-27/(28 blank)

26 TM 5-2410-241-23-3 0212

FIELD MAINTENANCE VALVE BANK GP - TEST 4 SERVICE WITH WINCH EFFECTIVITY NOTICE (WITH WINCH) Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 1 2

INITIAL SETUP Tools and Special Tools


0

Personnel Required Two References WP 0245 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Winch pilot valve removed (WP 0257) Hydraulic system drained (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 93, 94 Estimated Time to Complete 8.0 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (3/8 in.; 2,250 lb [1,000 kg]) (WP 0302, Item 10) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Wrench, Torque, Click, Ratcheting, 3/8 Drive, 75 lb-ft (WP 0302, Item 73) Wrench, Torque, Dial, 3/8 Drive, 300 lb-in. (WP 0302, Item 74) Lifting Device (1,000-lb capacity)
0 0 0 0 0 0 0

Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Cotter pin O-ring (50)

0212-1

TM 5-2410-241-23-3

0212

REMOVAL

000212

WARNING

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. Perform disassembly on a clean surface. Clean exterior of component to prevent contamination. Plug all lines, hoses and tubes to prevent contamination and leaks. Tag and mark all electrical connectors, hoses, and lines to aid installation.

1. Remove 32 bolts (Figure 1, Item 6), washers (Figure 1, Item 5), 16 flanges (Figure 1, Item 1), and eight hoses (Figure 1, Item 3) from valve bank (Figure 1, Item 2). 2. Remove eight O-rings (Figure 1, Item 4) from hoses (Figure 1, Item 3). Discard O-rings.

Figure 1. Hose Removal from Valve Bank.

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0212-2

TM 5-2410-241-23-3

0212

REMOVAL CONTINUED 3. Remove two hoses (Figure 2, Item 1) and O-rings (Figure 2, Item 2) from fittings (Figure 2, Item 3) on valve bank (Figure 2, Item 4). Discard O-rings.

Figure 2. Hose Connections at Front of Valve Bank. 4. Remove two hoses (Figure 3, Item 1) and O-rings (Figure 3, Item 2) from fittings (Figure 3, Item 3) on valve bank (Figure 3, Item 4). Discard O-rings.

0212

Figure 3. Hose Connections at Rear of Valve Bank.

0212

0212-3

TM 5-2410-241-23-3

0212

REMOVAL CONTINUED

NOTE
Note orientation and location of steering control link to aid installation. 5. Remove two cotter pins (Figure 4, Item 4) and washers (Figure 4, Item 3) from steering control link (Figure 4, Item 1). Discard cotter pin. 6. Remove steering control valve link (Figure 4, Item 1) from steering control pivot (Figure 4, Item 2).

Figure 4. Disconnecting Steering Control Link.

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0212-4

TM 5-2410-241-23-3

0212

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
Valve bank weighs approximately 100 lb (45 kg). 7. Remove cab (WP 0245). 8. Attach bracket link (Figure 5, Item 4) and lifting device on valve bank (Figure 5, Item 3). 9. Loosen tube nut (Figure 5, Item 1) and disconnect hose (Figure 5, Item 7) and O-ring (Figure 5, Item 2) from valve bank (Figure 5, Item 3). Discard O-ring. 10. Remove four bolts (Figure 5, Item 5), and washers (Figure 5, Item 6) from valve bank bracket (Figure 5, Item 8).

Figure 5.

Valve Bank Mounting.

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0212-5

TM 5-2410-241-23-3

0212

REMOVAL CONTINUED

NOTE
Valve bank will need to be lifted approximately 1 in. (25 mm) to access and remove one remaining hose at front of valve bank. 11. Using lifting device, raise valve bank (Figure 6, Item 1) to access hose (Figure 6, Item 6) at front of valve bank. 12. Remove four bolts (Figure 6, Item 4), washers (Figure 6, Item 5), two flanges (Figure 6, Item 2), and hose (Figure 6, Item 6) from valve bank (Figure 6, Item 1). Remove O-ring (Figure 6, Item 3) from hose. Discard O-ring.

Figure 6. Hose Removal.

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TM 5-2410-241-23-3

0212

REMOVAL CONTINUED 13. With assistance, remove valve bank (Figure 7, Item 2) from machine and place on clean work surface. 14. Remove lifting device and bracket link (Figure 7, Item 1) from valve bank (Figure 7, Item 2).

Figure 7. END OF TASK

Valve Bank Mounting.

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0212-7

TM 5-2410-241-23-3

0212

DISASSEMBLY

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NOTE
Note position and orientation of hoses and fittings to aid assembly. 1. Disconnect three hoses (Figure 8, Item 1) from fittings (Figure 8, Item 10). Remove O-rings (Figure 8, Item 11) from fittings. Discard O-rings. 2. Remove two fittings (Figure 8, Item 2), and O-rings (Figure 8, Item 3) from cover (Figure 8, Item 4). Discard O-rings. 3. Remove seven fittings (Figure 8, Item 8), and O-rings (Figure 8, Item 9). Discard O-rings. 4. Remove three nuts (Figure 8, Item 7), washers (Figure 8, Item 6), and cover (Figure 8, Item 4) from valve bank (Figure 8, Item 5).

Figure 8. Valve Bank Cover Removal.

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DISASSEMBLY CONTINUED

NOTE
Note orientation and position of O-rings to aid assembly. 5. Remove seven O-rings (Figure 9, Item 1) from cover (Figure 9, Item 2). Discard O-rings.
.

Figure 9. Cover O-ring Removal.

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0212-9

TM 5-2410-241-23-3

0212

DISASSEMBLY CONTINUED

NOTE
Valve bank is comprised of four valves, a cover, and a manifold. The top component is the cover, followed by the winch valve, the bulldozer tilt valve, bulldozer lift valve, and the steering valve. The manifold is the base of the assembly. 6. Remove valve (Figure 10, Item 1) from valve bank assembly (Figure 10, Item 2).

Figure 10.

Winch Valve Removal.

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0212-10

TM 5-2410-241-23-3

0212

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of O-rings to aid assembly. 7. Remove seven O-rings (Figure 11, Item 2) from cover (Figure 11, Item 1). Discard O-rings.

Figure 11. O-ring Removal.

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0212-11

TM 5-2410-241-23-3

0212

DISASSEMBLY CONTINUED 8. Remove valve (Figure 12, Item 1) from control valve assembly (Figure 12, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 9. Remove seven O-rings (Figure 12, Item 2) from valve (Figure 12, Item 1). Discard O-rings.

Figure 12.

Bulldozer Tilt Control Valve Manifold.

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TM 5-2410-241-23-3

0212

DISASSEMBLY CONTINUED 10. Remove valve (Figure 13, Item 1) from control valve assembly (Figure 13, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 11. Remove seven O-rings (Figure 13, Item 2) from valve (Figure 13, Item 1). Discard O-rings.

Figure 13.

Bulldozer Lift Control Valve Manifold.

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TM 5-2410-241-23-3

0212

DISASSEMBLY CONTINUED 12. Remove valve (Figure 14, Item 1) from control valve assembly (Figure 14, Item 3).

NOTE
Note orientation and position of O-rings to aid assembly. 13. Remove seven O-rings (Figure 14, Item 2) from valve (Figure 14, Item 1). Discard O-rings.

Figure 14. Steering Control Valve Manifold. 14. Remove three rods (Figure 15, Item 1) from valve cap (Figure 15, Item 2). 15. Remove relief valve (Figure 15, Item 3) from valve cap (Figure 15, Item 2). 16. Remove two O-rings (Figure 15, Item 4) from relief valve (Figure 15, Item 3). Discard O-rings.

0212

Figure 15. Valve Cap Rods. END OF TASK

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TM 5-2410-241-23-3

0212

CLEANING AND INSPECTION

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NOTE
After cleaning, allow parts to air dry. Do not use rags, as rags may cause lint to be deposited on parts. Perform cleaning, inspection, and assembly on a clean surface. Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY
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NOTE
Install valve as noted during removal. 1. Install two new O-rings (Figure 15, Item 4) on relief valve (Figure 15, Item 3). 2. Install relief valve (Figure 15, Item 3) on valve cap (Figure 15, Item 2). 3. Install three rods (Figure 15, Item 1) on valve cap (Figure 15, Item 2).

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TM 5-2410-241-23-3

0212

ASSEMBLY CONTINUED

NOTE
Valve bank is comprised of four valves, a cover, and a manifold. The bottom component is the manifold, followed by the steering valve, the bulldozer lift valve, bulldozer tilt valve, and the winch valve. The cover is the cap of the assembly. Install O-rings as noted during disassembly.

4. Install seven new O-rings (Figure 16, Item 2) on valve (Figure 16, Item 1).

Figure 16. O-ring Installation.

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0212

ASSEMBLY CONTINUED 5. Install valve (Figure 17, Item 1) on manifold (Figure 17, Item 2).

Figure 17. Steering Control Valve Installation.

0212

NOTE
Install O-rings as noted during disassembly. 6. Install seven new O-rings (Figure 18, Item 2) on valve (Figure 18, Item 1). 7. Install valve (Figure 18, Item 1) on valve cap (Figure 18, Item 3).

Figure 18. Bulldozer Lift Control Valve Manifold.

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0212-17

TM 5-2410-241-23-3

0212

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 8. Install seven new O-rings (Figure 19, Item 2) on valve (Figure 19, Item 1). 9. Install valve (Figure 19, Item 1) on control valve assembly (Figure 19, Item 3).

Figure 19. Bulldozer Tilt Control Valve Manifold.

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0212-18

TM 5-2410-241-23-3

0212

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 10. Install seven new O-rings (Figure 20, Item 2) on valve (Figure 20, Item 1). 11. Install valve (Figure 20, Item 1) on control valve assembly (Figure 20, Item 3).

Figure 20. Winch Control Valve Manifold.

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0212-19

TM 5-2410-241-23-3

0212

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 12. Install seven new O-rings (Figure 21, Item 1) on valve bank cover (Figure 21, Item 2).

Figure 21. O-ring Installation.

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0212-20

TM 5-2410-241-23-3

0212

ASSEMBLY CONTINUED 13. Install cover (Figure 22, Item 4) three washers (Figure 22, Item 6), and nuts (Figure 22, Item 7) on valve bank assembly (Figure 22, Item 5). 14. Install seven new O-rings (Figure 22, Item 9) and fittings (Figure 22, Item 8) on valve bank (Figure 22, Item 5). 15. Install two new O-rings (Figure 22, Item 3) and fittings (Figure 22, Item 2) on cover (Figure 22, Item 4). 16. Install three new O-rings (Figure 22, Item 11) on fittings (Figure 22, Item 10), and connect three hoses (Figure 22, Item 1) to fittings.

Figure 22. Valve Bank Cover Installation. END OF TASK

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0212-21

TM 5-2410-241-23-3

0212

INSTALLATION

000212

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
Valve bank weighs approximately 100 lb (45 kg). 1. Attach bracket link (Figure 23, Item 1) and lifting device to valve bank (Figure 23, Item 2). 2. Using lifting device, position valve bank (Figure 23, Item 2) on machine.

Figure 23. Bracket Link.

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0212-22

TM 5-2410-241-23-3

0212

INSTALLATION CONTINUED

NOTE
Valve bank will need to be positioned approximately 1 in. (25 mm) above the mounting bracket to access and install one hose at front of valve bank. 3. Install new O-ring (Figure 24, Item 3) hose (Figure 25, Item 6), flanges (Figure 24, Item 2), four washers (Figure 24, Item 5), and bolts (Figure 24, Item 4) on valve bank (Figure 24, Item 1).

Figure 24. Hose Installation.

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0212-23

TM 5-2410-241-23-3

0212

INSTALLATION CONTINUED 4. Install valve bank (Figure 25, Item 3), four washers (Figure 25, Item 6), and bolts (Figure 25, Item 5) to valve bank bracket (Figure 25, Item 8). 5. Install new O-ring (Figure 25, Item 2), hose (Figure 25, Item 7), and tighten tube nut (Figure 25, Item 1) on valve bank (Figure 25, Item 3). 6. Remove lifting device and bracket link (Figure 25, Item 4) from valve bank (Figure 25, Item 3). 7. Install cab (WP 0245).

Figure 25. Control Valve Mounting.

0212

8. Install steering control link (Figure 26, Item 1) two washers (Figure 26, Item 3) and new cotter pins (Figure 26, Item 4) on steering control pivot (Figure 26, Item 2) and valve bank.

Figure 26. Connecting Steering Control Link.

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0212-24

TM 5-2410-241-23-3

0212

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 9. Install two new O-rings (Figure 27, Item 2) and two hoses (Figure 27, Item 1), on fittings (Figure 27, Item 3) at valve bank (Figure 27, Item 4)

Figure 27. Hose Connections at Rear of Valve Bank. 10. Install three new O-rings (Figure 28, Item 2) on fittings (Figure 28, Item 3) and connect hoses (Figure 28, Item 1).

0212

Figure 28. Hose Connections at Front of Valve Bank.

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0212-25

TM 5-2410-241-23-3

0212

INSTALLATION CONTINUED 11. Install eight new O-rings (Figure 29, Item 4) on hoses (Figure 29, Item 3).

NOTE
Install hoses as noted during removal. 12. Install eight hoses (Figure 29, Item 3), 16 flanges (Figure 29, Item 1), 32 washers (Figure 29, Item 5), and bolts (Figure 29, Item 6) on valve bank (Figure 29, Item 2).

Figure 29. Hose Installation. END OF TASK FOLLOW-ON TASKS 1. Install winch pilot valve (WP 0257). 2. Fill hydraulic system (WP 0184). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

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000212

0212-26

4 TM 5-2410-241-23-3 0213

FIELD MAINTENANCE RIPPER MANIFOLD REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 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) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (12)
0

References WP 0295

Personnel Required
0

Two Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic system drained (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 75 Estimated Time to Complete 3.0 Hr

REMOVAL

000213

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. 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. Tag and identify all hoses to aid installation.

0213-1

TM 5-2410-241-23-3

0213

REMOVAL CONTINUED

NOTE
Tag and mark hoses to aid installation. Cap and plug all hoses and line to prevent contamination and leaks.

1. Remove 48 bolts (Figure 1, Item 7), washers (Figure 1, Item 6), 12 flanges (Figure 1, Item 5), and hoses (Figure 1, Item 9) from ripper manifold (Figure 1, Item 3). 2. Remove 12 O-rings (Figure 1, Item 4) from hoses (Figure 1, Item 9). 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.

NOTE
Ripper manifold weighs 75 lb (34 kg). 3. With assistance, remove four bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and ripper manifold (Figure 1, Item 3) from fuel tank (Figure 1, Item 8).

Figure 1. Ripper Manifold. END OF TASK

0213

0213-2

TM 5-2410-241-23-3

0213

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

000213

000213

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
Ripper manifold weighs 75 lb (34 kg). 1. With assistance, install ripper manifold (Figure 1, Item 3), four washers (Figure 1, Item 2), and bolts (Figure 1, Item 1) on fuel tank (Figure 1, Item 8). 2. Install 12 new O-rings (Figure 1, Item 4) on hoses (Figure 1, Item 9).

NOTE
Install hoses as tagged in removal. 3. Install 12 flanges (Figure 1, Item 5), hoses (Figure 1, Item 9), 48 washers (Figure 1, Item 6) and bolts (Figure 1, Item 7) on ripper manifold (Figure 1, Item 3). END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0151). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000213

0213-3/(4 blank)

8 TM 5-2410-241-23-3 0214

FIELD MAINTENANCE INSTRUCTIONS WINCH MANIFOLD REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 1 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) Tiedown Strap (WP 0303, Item 36) O-ring (16)
0

References WP 0184 WP 0295 Equipment Condition

Machine parked (TM 5-2410-241-10) Hydraulic system drained (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 95 Estimated Time to Complete 3.0 Hr

0214-1

TM 5-2410-241-23-3

0214

REMOVAL

000214

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. 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. Tag and identify all hoses to aid installation.

1. Disconnect winch manifold harness (Figure 1, Item 1) from machine harness (Figure 1, Item 2).

Figure 1. Winch Manifold Harness.

0214

0214-2

TM 5-2410-241-23-3

0214

REMOVAL CONTINUED

NOTE
Tag and mark hoses to aid installation. 2. Remove 16 bolts (Figure 2, Item 7), washers (Figure 2, Item 8), four flanges (Figure 2, Item 9), hoses (Figure 2, Item 4), and O-rings (Figure 2, Item 10) from winch manifold (Figure 2, Item 1). Discard O-rings. 3. Remove six hoses (Figure 2, Item 5) from fittings(Figure 2, Item 6). 4. Remove four bolts (Figure 2, Item 3), washers (Figure 2, Item 2) and winch manifold (Figure 2, Item 1) from machine (Figure 2, Item 11).

Figure 2. Winch Manifold Removal. END OF TASK

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0214-3

TM 5-2410-241-23-3

0214

DISASSEMBLY 1. Remove tiedown straps (Figure 3, Item 2) from manifold (Figure 3, Item 9). Discard tiedown straps.

000214

Figure 3. Winch Manifold. 2. Remove solenoid (Figure 3, Item 1), and O-ring (Figure 3, Item 13) from manifold (Figure 3, Item 9). 3. Remove bolt (Figure 3, Item 4), washer (Figure 3, Item 5), and bracket (Figure 3, Item 3) from manifold (Figure 3, Item 9). 4. Remove six O-rings (Figure 3, Item 11) from fittings (Figure 3, Item 10). Discard O-rings.

0214

NOTE
Note the location and orientation of the fittings to aid in installation. 5. Remove two bolts (Figure 3, Item 7), washers (Figure 3, Item 8) and mounting bracket (Figure 3, Item 6) from manifold (Figure 3, Item 9). 6. Remove six fittings (Figure 3, Item 10) and O-rings (Figure 3, Item 12) from manifold (Figure 3, Item 9). END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK
000214

0214-4

TM 5-2410-241-23-3

0214

ASSEMBLY

000214

1. Install mounting bracket (Figure 4, Item 6), two washers (Figure 4, Item 8), bolts (Figure 4, Item 7) on manifold (Figure 4, Item 9).

Figure 4. Winch Manifold.

0214

NOTE
Install fittings as noted during disassembly. 2. Install six new O-rings (Figure 4, Item 12) and fittings (Figure 4, Item 10) on manifold (Figure 4, Item 9). 3. Install six new O-rings (Figure 4, Item 11) on fittings (Figure 4, Item 10). 4. Install bracket (Figure 4, Item 3), washer (Figure 4, Item 5), and bolt (Figure 4, Item 4) on manifold. 5. Install new O-ring (Figure 4, Item 13) and solenoid (Figure 4, Item 1) on manifold (Figure 4, Item 9). 6. Install new tiedown strap (Figure 4, Item 2).

0214-5

TM 5-2410-241-23-3

0214

INSTALLATION 1. Position winch manifold (Figure 5, Item 1) on machine (Figure 5 Item 11), install four washers (Figure 5, Item 2), and bolts (Figure 5, Item 3).

000214

NOTE
Install hoses as noted during removal. 2. Install six hoses (Figure 5, Item 5) to fittings (Figure 5, Item 6). 3. Install four new O-rings (Figure 5, Item 10), hoses (Figure 5, Item 4), flanges (Figure 5, Item 9), 16 washers (Figure 5, Item 8), and bolts (Figure 5, Item 7) on manifold (Figure 5, Item 11).

Figure 5. Winch Manifold Installation.

0214

0214-6

TM 5-2410-241-23-3

0214

INSTALLATION CONTINUED 4. Connect winch manifold harness (Figure 6, Item 1) to vehicle harness (Figure 6, Item 2).

000214

Figure 6. Winch Manifold Harness. FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0214

000214

0214-7/(8 blank)

8 TM 5-2410-241-23-3 0215

FIELD MAINTENANCE INSTRUCTIONS QUICK DROP VALVE SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 1 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Lifting device (500-lb) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (6) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0151) Drawing Required

TM 5-2410-241-24P, Figure 79 Estimated Time to Complete 3.5 Hr

0215-1

TM 5-2410-241-23-3

0215

REMOVAL

000215

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 these warnings may cause injury or death to personnel.

NOTE
Door weighs approximately 120 lb (54 kg). 1. Remove eight bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and two doors (Figure 1, Item 1) from hinges (Figure 1, Item 4).

Figure 1. Doors.

0215

0215-2

TM 5-2410-241-23-3

0215

REMOVAL CONTINUED 2. Remove three bolts (Figure 2, Item 2), washers (Figure 2, Item 1), and cover (Figure 2, Item 3) from quick drop valve (Figure 2, Item 4).

Figure 2. Valve Cover.

0215

WARNING

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. Perform disassembly on a clean surface. Clean exterior of component to prevent contamination. Plug all lines, hoses and tubes to prevent contamination and leaks. Tag and mark all hoses and lines to aid installation

0215-3

TM 5-2410-241-23-3

0215

REMOVAL CONTINUED 3. Remove 16 bolts (Figure 3, Item 5), washers (Figure 3, Item 4), four flanges (Figure 3, Item 1), and hoses (Figure 3, Item 2) from quick drop valve (Figure 3, Item 8). 4. Remove four O-rings (Figure 3, Item 3) from hoses (Figure 3, Item 2). Discard O-rings. 5. Remove three bolts (Figure 3, Item 6) and washers (Figure 3, Item 7) from hood (Figure 3, Item 9) and quick drop valve (Figure 3, Item 8).

Figure 3. Upper Hoses.

0215

0215-4

TM 5-2410-241-23-3

0215

REMOVAL CONTINUED 6. Remove four bolts (Figure 4, Item 5), washers (Figure 4, Item 6), and two brackets (Figure 4, Item 2) from radiator guard (Figure 4, Item 1).

NOTE
O-rings will remove from tubes after quick drop valve is removed. 7. Remove eight bolts (Figure 4, Item 3), washers (Figure 4, Item 4), and quick drop valve (Figure 4, Item 7) from machine. 8. Remove two O-rings (Figure 4, Item 8) from two tubes (Figure 4, Item 9). Discard O-rings.

Figure 4. Quick Drop Valve. END OF TASK CLEANING AND INSPECTION

0215

000215

NOTE
After cleaning, allow parts to air dry. Do not use rags, as rags may cause lint to be deposited on parts. Perform cleaning, inspection, and assembly on a clean surface. Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0215-5

TM 5-2410-241-23-3

0215

INSTALLATION

000215

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 4, Item 8) on two tubes (Figure 4, Item 9). 2. Install quick drop valve (Figure 4, Item 7), eight washers (Figure 4, Item 4), and bolts (Figure 4, Item 3) on two tubes (Figure 4, Item 9). 3. Install two brackets (Figure 4, Item 2), four washers (Figure 4, Item 6), and bolts (Figure 4, Item 5) on radiator guard (Figure 4, Item 1).

0215-6

TM 5-2410-241-23-3

0215

INSTALLATION CONTINUED 4. Install three washers (Figure 5, Item 7) and bolts (Figure 5, Item 6) on quick drop valve (Figure 5, Item 8) and hood (Figure 5, Item 9). 5. Install four new O-rings (Figure 5, Item 3) on hoses (Figure 5, Item 2). 6. Install 4 hoses (Figure 5, Item 2), flanges (Figure 5, Item 1), 16 washers (Figure 5, Item 4), and bolts (Figure 5, Item 5) on quick drop valve (Figure 5, Item 8).

Figure 5. Upper Hoses. 7. Install cover (Figure 6, Item 3), three washers (Figure 6, Item 1), and bolts (Figure 6, Item 2) on quick drop valve (Figure 6, Item 4).

0215

Figure 6. Valve Cover.

0215

0215-7

TM 5-2410-241-23-3

0215

INSTALLATION CONTINUED

000215

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. Install two doors (Figure 7, Item 1), eight washers (Figure 7, Item 3), and bolts (Figure 7, Item 2) on hinges (Figure 7, Item 4).

Figure 7. Doors. END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0215

000215

0215-8

32 TM 5-2410-241-23-3 0216

FIELD MAINTENANCE INSTRUCTIONS CONTROL MANIFOLD SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation, Control Manifold Accumulator Charge Pressure Test, Accumulator Charging
0 2 1 6

INITIAL SETUP Tools and Special Tools


0

Personnel Two References WP 0295 WP 0304 Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 81 Estimated Time to Complete

Tool Kit, General Mechanics (WP 0302, Item 65) Charging Kit, Pressuring (Nitrogen) (WP 0302, Item 16) Coupling, Hose (1/4 NPT, Internal Thread) (WP 0302, Item 17) Fitting (WP 0302, Item 24) Gauge, Pressure (Pilot), Dial Indicating (WP 0302, Item 31) Hose Assembly; 6,000 psi (41, 500 kPa), 1/827-NPTF, 18 ft (549 cm) long (WP 0302, Item 34) Wrench, Combination, 1 5/8 (S0794) (WP 0302, Item 68)
0 0 0 0 0 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 (22)

4.5 Hr
0 0

0216-1

TM 5-2410-241-23-3

0216

REMOVAL

000216

NOTE
Tag and mark all electrical connections to aid installation. 1. Remove tiedown strap (Figure 1, Item 2) from connector (Figure 1, Item 3) and bracket (Figure 1, Item 4). Discard tiedown strap. 2. Disconnect connector (Figure 1, Item 3) and position harness (Figure 1, Item 1) aside.

Figure 1. Electrical Connector.

0216

0216-2

TM 5-2410-241-23-3

0216

REMOVAL CONTINUED

WARNING

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. 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. Clean exterior of component to prevent contamination. Plug all lines, hoses and tubes to prevent contamination. Tag and mark lines to aid installation.

3. Loosen two tube nuts (Figure 2, Item 3) and remove line (Figure 2, Item 2) and two O-rings (Figure 2, Item 4) from control manifold (Figure 2, Item 1). Discard O-rings.

Figure 2. Control Valve Line.

0216

0216-3

TM 5-2410-241-23-3

0216

REMOVAL CONTINUED

NOTE
Plug all lines, hoses and tubes to prevent contamination. Tag and mark lines to aid installation.

4. Loosen tube nut (Figure 3, Item 9) and remove hose (Figure 3, Item 1) and O-rings (Figure 3, Item 8) from control manifold (Figure 3, Item 7). Discard O-rings. 5. Loosen tube nut (Figure 3, Item 5) and remove hose (Figure 3, Item 2) and O-rings (Figure 3, Item 6) from control manifold (Figure 3, Item 7). Discard O-rings. 6. Remove two bolts (Figure 3, Item 3), washers (Figure 3, Item 4), and control manifold (Figure 3, Item 7) from machine.

Figure 3. Control Valve Hoses. END OF TASK

0216

0216-4

TM 5-2410-241-23-3

0216

DISASSEMBLY

000216

NOTE
Note orientation and position of fittings to aid assembly. 1. Loosen tube nut (Figure 4, Item 3) and position T fitting (Figure 4, Item 4) out from under control manifold (Figure 4, Item 5). 2. Loosen tube nut (Figure 4, Item 1) and remove fitting assembly (Figure 4, Item 2) from control manifold (Figure 4, Item 5).

Figure 4. Control Manifold Assembly Sampling Valve and Fitting.

0216

0216-5

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of fittings to aid installation. 3. Remove elbow (Figure 5, Item 1) from T fitting (Figure 5, Item 6). 4. Remove two O-rings (Figure 5, Item 5) from elbow (Figure 5, Item 1). Discard O-rings 5. Loosen nut (Figure 5, Item 3) and remove sampling valve (Figure 5, Item 4) from fitting (Figure 5, Item 2). 6. Remove O-ring (Figure 5, Item 8) from sampling valve (Figure 5, Item 4). Discard O-ring. 7. Remove fitting (Figure 5, Item 2) from T fitting (Figure 5, Item 6). 8. Remove O-ring (Figure 5, Item 7) from fitting (Figure 5, Item 2). Discard O-ring. 9. Loosen nut (Figure 5, Item 14) and remove elbow (Figure 5, Item 12) from T fitting (Figure 5, Item 6). 10. Remove O-ring (Figure 5, Item 13) from fitting (Figure 5, Item 12). Discard O-ring. 11. Remove cover and strap (Figure 5, Item 9) from diagnostic port fitting (Figure 5, Item 11). 12. Remove diagnostic port fitting (Figure 5, Item 11) from elbow (Figure 5, Item 12). 13. Remove O-ring (Figure 5, Item 10) from diagnostic port fitting (Figure 5, Item 11) Discard O-ring.

Figure 5. Sampling Valve and Fittings Disassembly.

0216

0216-6

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of fittings to aid assembly. 14. Loosen tube nut (Figure 6, Item 3) and remove fitting assembly (Figure 6, Item 4) from fitting (Figure 6, Item 2). 15. Remove fitting (Figure 6, Item 2) from control manifold (Figure 6, Item 1).

Figure 6. Control Manifold Assembly Diagnostic Port Fitting.

0216

0216-7

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of fittings to aid installation. 16. Remove two O-rings (Figure 7, Item 2) from fitting (Figure 7, Item 1). Discard O-rings. 17. Remove fitting (Figure 7, Item 5) from T fitting (Figure 7, Item 3). 18. Remove O-ring (Figure 7, Item 4) from fitting (Figure 7, Item 5). Discard O-ring. 19. Remove cover and strap (Figure 7, Item 8) from diagnostic port fitting (Figure 7, Item 7). 20. Remove diagnostic port fitting (Figure 7, Item 7) from T fitting (Figure 7, Item 3). 21. Remove O-ring (Figure 7, Item 6) from diagnostic port fitting (Figure 7, Item 7). Discard O-ring.

Figure 7. Diagnostic Port Fitting Disassembly.

0216

0216-8

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of O-rings to aid assembly. 22. Remove pressure reducing valve (Figure 8, Item 2) from control manifold (Figure 8, Item 3). 23. Remove three O-rings (Figure 8, Item 1) from pressure reducing valve (Figure 8, Item 2). Discard O-rings.

Figure 8. Pressure Reducing Valve.

0216

NOTE
Note orientation and position of O-rings to aid assembly. 24. Remove check valve (Figure 9, Item 1) from control manifold (Figure 9, Item 3). 25. Remove two O-rings (Figure 9, Item 2) from check valve (Figure 9, Item 1). Discard O-rings.

Figure 9. Front Check Valve.

0216

0216-9

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of fittings to aid assembly. 26. Remove fitting (Figure 10, Item 2) and elbow (Figure 10, Item 3) from control manifold (Figure 10, Item 1).

Figure 10. Control Manifold Assembly Elbow Fitting. 27. Loosen tube nut (Figure 11, Item 2) and remove elbow assembly (Figure 11, Item 1) from fitting (Figure 11, Item 3). 28. Remove two O-rings (Figure 11, Item 4) from fitting (Figure 11, Item 3). Discard O-rings. 29. Remove O-ring (Figure 11, Item 5) from elbow assembly (Figure 11, Item 1). Discard O-ring.

0216

Figure 11. Elbow Fitting Disassembly.

0216

0216-10

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of fittings to aid assembly. 30. Loosen tube nut (Figure 12, Item 5) and position elbow (Figure 12, Item 4) out from under control manifold (Figure 12, Item 3). 31. Loosen tube nut (Figure 12, Item 1) and remove T fitting (Figure 12, Item 6) from fitting (Figure 12, Item 2). 32. Remove fitting (Figure 12, Item 2) from control manifold (Figure 12, Item 3).

Figure 12. Control Manifold Assembly T Fitting.

0216

0216-11

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of fittings to aid assembly. 33. Remove two O-rings (Figure 13, Item 1) from fitting (Figure 13, Item 2). Discard O-rings. 34. Remove nut (Figure 13, Item 10) and elbow (Figure 13, Item 6) from T fitting (Figure 13, Item 8). 35. Remove O-ring (Figure 13, Item 7) from T fitting (Figure 13, Item 8). Discard O-ring. 36. Remove cover and strap (Figure 13, Item 3) from diagnostic port fitting (Figure 13, Item 4). 37. Loosen nut (Figure 13, Item 9) and remove diagnostic port fitting (Figure 13, Item 4) from elbow (Figure 13, Item 6). 38. Remove O-ring (Figure 13, Item 5) from elbow (Figure 13, Item 6). Discard O-ring.

Figure 13. Fitting Disassembly.

0216

0216-12

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of O-rings to aid assembly. 39. Remove check valve (Figure 14, Item 1) from control manifold (Figure 14, Item 3). 40. Remove two O-rings (Figure 14, Item 2) from check valve (Figure 14, Item 1). Discard O-rings.

Figure 14. Rear Check Valve.

0216

0216-13

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED 41. Remove accumulator (Figure 15, Item 1) from control manifold (Figure 15, Item 4). 42. Remove O-ring (Figure 15, Item 2) from accumulator (Figure 15, Item 1). Discard O-ring. 43. Remove screen (Figure 15, Item 3) from control manifold (Figure 15, Item 4).

Figure 15. Accumulator. 44. Remove nut (Figure 16, Item 4), washer (Figure 16, Item 3), and coil (Figure 16, Item 2) from solenoid (Figure 16, Item 1).

0216

Figure 16. Coil.

0216

0216-14

TM 5-2410-241-23-3

0216

DISASSEMBLY CONTINUED

NOTE
Note orientation and position of O-rings to aid assembly. 45. Remove solenoid (Figure 17, Item 1) from control manifold (Figure 17, Item 3). 46. Remove three O-rings (Figure 17, Item 2) from solenoid (Figure 17, Item 1). Discard O-rings.

Figure 17. Solenoid. END OF TASK CLEANING AND INSPECTION

0216

000216

NOTE
After cleaning, allow parts to air dry. Do not use rags, as rags may cause lint to be deposited on parts. Perform cleaning, inspection and assembly on a clean surface. Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY
000216

NOTE
Install O-rings as noted during disassembly. 1. Install three new O-rings (Figure 17, Item 2) on solenoid (Figure 17, Item 1). 2. Install solenoid (Figure 17, Item 1) on control manifold (Figure 17, Item 3).

0216-15

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED 3. Install coil (Figure 18, Item 2), washer (Figure 18, Item 3), and nut (Figure 18, Item 4) on solenoid (Figure 18, Item 1).

Figure 18. Coil.

0216

0216-16

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED 4. Install screen (Figure 19, Item 3) on control manifold (Figure 19, Item 4). 5. Install new O-ring (Figure 19, Item 2) on accumulator (Figure 19, Item 1).

NOTE
If installing new accumulator, refer to Accumulator Charging in this work package. 6. Install accumulator (Figure 19, Item 1) on control manifold (Figure 19, Item 4).

Figure 19. Accumulator.

0216

0216-17

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 7. Install two new O-rings (Figure 20, Item 2) on check valve (Figure 20, Item 1). 8. Install check valve (Figure 20, Item 1) on control manifold (Figure 20, Item 3).

Figure 20. Rear Check Valve.

0216

0216-18

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install O-rings and fittings as noted during disassembly. 9. Install new O-ring (Figure 21, Item 5) on elbow (Figure 21, Item 6). 10. Install diagnostic port fitting (Figure 21, Item 4) and nut (Figure 21, Item 9) on elbow (Figure 21, Item 6). 11. Install strap and cover (Figure 21, Item 3) on diagnostic port fitting (Figure 21, Item 4). 12. Install new O-ring (Figure 21, Item 7) on T fitting (Figure 21, Item 8). 13. Install elbow (Figure 21, Item 6) and nut (Figure 21, Item 10) on T fitting (Figure 21, Item 8). 14. Install two new O-rings (Figure 21, Item 1) on fitting (Figure 21, Item 2).

Figure 21. Fitting Assembly.

0216

0216-19

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install fittings as noted during disassembly. 15. Install fitting (Figure 22, Item 2) on control manifold (Figure 22, Item 3). 16. Install T fitting (Figure 22, Item 6) and tighten tube nut (Figure 22, Item 1) on fitting (Figure 22, Item 2). 17. Position elbow (Figure 22, Item 4) back under control manifold (Figure 22, Item 3) and tighten tube nut (Figure 22, Item 5).

Figure 22. Control Manifold Assembly T Fitting.

0216

0216-20

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install fittings and O-rings as noted during disassembly. 18. Install new O-ring (Figure 23, Item 5) on elbow assembly (Figure 23, Item 1). 19. Install two new O-rings (Figure 23, Item 4) on fitting (Figure 23, Item 3). 20. Install elbow assembly (Figure 23, Item 1) on fitting (Figure 23, Item 3) and tighten tube nut (Figure 23, Item 2).

Figure 23. Elbow Fitting Assembly.

0216

NOTE
Install fittings as noted during disassembly. 21. Install elbow (Figure 24, Item 3) and fitting (Figure 24, Item 2) on control manifold (Figure 24, Item 1).

Figure 24. Control Manifold Assembly Elbow Fitting.

0216

0216-21

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install O-rings as noted during disassembly. 22. Install two new O-rings (Figure 25, Item 2) on check valve (Figure 25, Item 1). 23. Install check valve (Figure 25, Item 1) on control manifold (Figure 25, Item 3).

Figure 25. Front Check Valve.

0216

NOTE
Install fittings and O-rings as noted during disassembly. 24. Install three new O-rings (Figure 26, Item 1) on pressure reducing valve (Figure 26, Item 2). 25. Install pressure reducing valve (Figure 26, Item 2) on control manifold (Figure 26, Item 3).

Figure 26. Pressure Reducing Valve.

0216

0216-22

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install fittings as noted during disassembly. 26. Install new O-ring (Figure 27, Item 6) on diagnostic port fitting (Figure 27, Item 7). 27. Install diagnostic port fitting (Figure 27, Item 7) on T fitting (Figure 27, Item 3). 28. Install cover and strap (Figure 27, Item 8) on diagnostic port fitting (Figure 27, Item 7). 29. Install new O-ring (Figure 27, Item 4) on fitting (Figure 27, Item 5). 30. Install two new O-rings (Figure 27, Item 2) on fitting (Figure 27, Item 1). 31. Install fitting (Figure 27, Item 5) on T fitting (Figure 27, Item 3).

Figure 27. Diagnostic Port Fitting Disassembly.

0216

0216-23

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install fittings as noted during disassembly. 32. Install fitting (Figure 28, Item 2) on control manifold (Figure 28, Item 1). 33. Install fitting assembly (Figure 28, Item 4) on fitting (Figure 28, Item 2) and tighten tube nut (Figure 28, Item 3).

Figure 28. Control Manifold Assembly Diagnostic Port Fitting.

0216

0216-24

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install fittings as noted during disassembly. 34. Install new O-ring (Figure 29, Item 10) on diagnostic port fitting (Figure 29, Item 11). 35. Install diagnostic port fitting (Figure 29, Item 11) on elbow (Figure 29, Item 12). 36. Install cover and strap (Figure 29, Item 9) on diagnostic port fitting (Figure 29, Item 11). 37. Install new O-ring (Figure 29, Item 13) on fitting (Figure 29, Item 12). 38. Install elbow (Figure 29, Item 12) on T fitting (Figure 29, Item 6) and tighten nut (Figure 29, Item 14). 39. Install new O-ring (Figure 29, Item 7) on fitting (Figure 29, Item 2). 40. Install fitting (Figure 29, Item 2) on T fitting (Figure 29, Item 6). 41. Install new O-ring (Figure 29, Item 8) on sampling valve (Figure 29, Item 4). 42. Install sampling valve (Figure 29, Item 4) on fitting (Figure 29, Item 2) and tighten nut (Figure 29, Item 3). 43. Install two new O-rings (Figure 29, Item 5) on elbow (Figure 29, Item 1). 44. Install elbow (Figure 29, Item 1) on T fitting (Figure 29, Item 6).

Figure 29. Sampling Valve and Fittings Assembly.

0216

0216-25

TM 5-2410-241-23-3

0216

ASSEMBLY CONTINUED

NOTE
Install fittings as noted during disassembly. 45. Install fitting assembly (Figure 30, Item 2) on control manifold (Figure 30, Item 5) and tighten tube nut (Figure 30, Item 1). 46. Position T fitting (Figure 30, Item 4) under control manifold (Figure 30, Item 5) and tighten tube nut (Figure 30, Item 3).

Figure 30. Control Manifold Assembly Sampling Valve and Fitting. END OF TASK

0216

0216-26

TM 5-2410-241-23-3

0216

INSTALLATION

000216

NOTE
Remove plugs from all lines, hoses, and tubes. Install hoses, fittings, and O-rings as noted during removal.

1. Install control manifold (Figure 31, Item 7), two washers (Figure 31, Item 4), and bolts (Figure 31, Item 3) on machine. 2. Install new O-ring (Figure 31, Item 6), hose (Figure 31, Item 2), and tighten tube nut (Figure 31, Item 5) on control manifold (Figure 31, Item 7). 3. Install new O-ring (Figure 31, Item 8), hose (Figure 31, Item 1), and tighten tube nut (Figure 31, Item 9) on control manifold (Figure 31, Item 7).

Figure 31. Control Valve Hoses.

0216

0216-27

TM 5-2410-241-23-3

0216

INSTALLATION CONTINUED

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

4. Install two new O-rings (Figure 32, Item 4), one line (Figure 32, Item 2), and tighten two tube nuts (Figure 32, Item 3) on control manifold (Figure 32, Item 1).

Figure 32. Control Valve Line.

0216

0216-28

TM 5-2410-241-23-3

0216

INSTALLATION CONTINUED

NOTE
Install electrical connections as tagged during removal. 5. Position harness (Figure 33, Item 1) and connect connector (Figure 33, Item 3). 6. Install new tiedown strap (Figure 33, Item 2) on bracket (Figure 33, Item 4) and connector (Figure 33, Item 3).

Figure 33. Electrical Connector. END OF TASK

0216

0216-29

TM 5-2410-241-23-3

0216

CONTROL MANIFOLD ACCUMULATOR CHARGE PRESSURE TEST 1. Assemble Pilot Pressure Gauge (WP 0304). 2. Open access door (Figure 34, Item 1) on machine. 3. Remove rubber cap (Figure 34, Item 3) from Accumulator Charge Pressure port (Figure 34, Item 2). 4. Install Pilot Pressure Gauge on Accumulator Charge Pressure port (Figure 34, Item 2). 5. Start machine and allow it to run for 15 minutes to reach normal operation temperature. 6. Ensure parking brake is engaged and Implement Lockout switch OFF (TM 5-2410-241-10). 7. Set machine to HIGH IDLE (RABBIT MODE) on the throttle switch (TM 5-2410-241-10). 8. With assistance, record pressure readings on gauge. Pilot Pressure Gauge should read 450-500 psi (3,100-3,450 kPa). 9. Set machine to LOW IDLE (TURTLE MODE) on the throttle switch (TM 5-2410-241-10). 10. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10). 11. Turn ignition switch and battery disconnect switch to ON position (TM 5-2410-241-10). 12. Pilot Pressure Gauge should read 450-500 psi (3,100-3,450 kPa). Record pressure readings on gauge. 13. Fully engage and HOLD blade lift control in the blade lift position (TM 5-2410-241-10).

000216

14. Pilot Pressure Gauge should not fall under 150 psi (1,035 kPa) in less than 1 minute. If accumulator pressure falls below 150 psi (1,035 kPa) in less than 1 minute, replace Control Manifold Accumulator (WP 0224). 15. Turn ignition switch and battery disconnect switch to OFF position (TM 5-2410-241-10).

Figure 34. Test Equipment Installation. END OF TASK

0216

0216-30

TM 5-2410-241-23-3

0216

ACCUMULATOR CHARGING

CAUTION
Dry nitrogen is the only gas approved for use in accumulator. Any other gas may cause the accumulator to fail.

NOTE
Accumulator charge pressure should be 150 psi (1035 kPa) when temperature is 70F (20C). New accumulators ship discharged and must be charged. Once unit is properly charged, it is considered a sealed unit and should never be recharged. If unit looses charge it should be replaced. Accumulator should only be charged on the bench.

1. Remove protective cap (Figure 35, Item 2) from valve (Figure 35, Item 1). 2. Attach nitrogen charging group to valve (Figure 35, Item 1). 3. Using nitrogen charging group, charge Accumulator to 150 psi (1,035 kPa) when temperature is 70F (20C). 4. Install protective cap (Figure 35, Item 2) on valve (Figure 35, Item 1). 5. Install accumulator (Figure 35, Item 3) on machine (WP 0217).

Figure 35. Accumulator. END OF TASK

0216

0216-31

TM 5-2410-241-23-3

0216

FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000216

0216-32

6 TM 5-2410-241-23-3 0217

FIELD MAINTENANCE INSTRUCTIONS COUNTERBALANCE VALVE SERVICE Removal, Cleaning and Inspection, Installation
0 2 1 7

INITIAL SETUP Tools and Special Tools


0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Front floor plate removed (WP 0230) Rear floor plate removed (WP 0231) Hydraulic system pressure released (WP 0186) Hydraulic system drained (WP 0184) Drawing Required

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) Lifting Device (500-lb capacity) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (2) Personnel Required Two

TM 5-2410-241-24P, Figure 78 Estimated Time to Complete 5.0 Hr

0217-1

TM 5-2410-241-23-3

0217

REMOVAL

000217

WARNING

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. 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. 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.
000217

REMOVAL

1. Remove eight bolts (Figure 1, Item 5), washers (Figure 1, Item 4), two flanges (Figure 1, Item 2) and hoses (Figure 1, Item 1) from counterbalance valve (Figure 1, Item 6). 2. Remove two O-rings (Figure 1, Item 3) from hoses (Figure 1, Item 1). Discard O-rings.

Figure 1. Counterbalance Valve.

0217

0217-2

TM 5-2410-241-23-3

0217

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
Counterbalance valve weighs approximately 75 lb (35 kg). 3. Attach bracket link (Figure 2, Item 3) and lifting device on counterbalance valve (Figure 2, Item 2). 4. Using lifting device, remove six bolts (Figure 2, Item 1), counterbalance valve (Figure 2, Item 2), and two Orings (Figure 2, Item 5) from motor (Figure 2, Item 4). Discard O-rings 5. Place counterbalance valve (Figure 2, Item 2) on clean work surface. 6. Remove lifting device and bracket link (Figure 2, Item 3) from counterbalance valve (Figure 2, Item 2).

Figure 2. Counterbalance Valve Mounting. END OF TASK

0217

0217-3

TM 5-2410-241-23-3

0217

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

000217

000217

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
Counterbalance valve weighs approximately 75 lb (35 kg). 1. Attach bracket link (Figure 3, Item 3) and lifting device on counterbalance valve (Figure 3, Item 2). 2. Using lifting device, install two O-rings (Figure 3, Item 5), counterbalance valve (Figure 3, Item 2), and six bolts (Figure 3, Item 1) on motor (Figure 3, Item 4). 3. Remove lifting device and bracket link (Figure 3, Item 3) from counterbalance valve (Figure 3, Item 2).

Figure 3. Counterbalance Valve Mounting.

0217

0217-4

TM 5-2410-241-23-3

0217

INSTALLATION CONTINUED

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 from lines, hoses, and tubes. Install hoses and lines as noted during removal.

4. Install two new O-rings (Figure 4, Item 3) on hoses (Figure 4, Item 1). 5. Install two hoses (Figure 4, Item 1), two flanges (Figure 4, Item 2), eight washers (Figure 4, Item 4), and bolts (Figure 4, Item 5) on counterbalance valve (Figure 4, Item 6).

Figure 4. Counterbalance Valve. END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic system (WP 0184). 2. Install front floor plate (WP 0230) 3. Install rear floor plate (WP 0231) 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0217

000217

0217-5/(6 blank)

6 TM 5-2410-241-23-3 0218

FIELD MAINTENANCE LOWERING EQUIPMENT WITH ENGINE STOPPED Access Cover Removal, Lowering Equipment Procedure, Access Cover Installation
0 2 1 8

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

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

Drawing Required
0

TM 5-2410-241-24P, Figure 74 Estimated Time to Complete

1.0 Hr ACCESS COVER REMOVAL

000218

1. Release clasp (Figure 1, Item 7) and remove fire extinguisher (Figure 1, Item 8) from fire extinguisher bracket (Figure 1, Item 3). 2. Remove four screws (Figure 1, Item 4) and fire extinguisher bracket (Figure 1, Item 3) from mounting bracket (Figure 1, Item 6). 3. Remove four bolts (Figure 1, Item 5), and mounting bracket (Figure 1, Item 6) from machine. 4. Disconnect messenger module harness connector (Figure 1, Item 1) from machine and position harness aside. 5. Position trim panel (Figure 1, Item 2) aside.

Figure 1. Fire Extinguisher and Bracket.

0218

0218-1

TM 5-2410-241-23-3

0218

ACCESS COVER REMOVAL CONTINUED 6. Remove four bolts (Figure 2, Item 1), washers (Figure 2, Item 2), and cover (Figure 2, Item 3) from machine.

Figure 2. Cover. END OF TASK LOWERING EQUIPMENT PROCEDURE

0218

000218

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 this warning may result in injury to personnel. Machine equipment will move during this procedure, to prevent injury to personnel ensure adequate clearance is maintained. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
Cap and plug 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.

0218-2

TM 5-2410-241-23-3

0218

LOWERING EQUIPMENT PROCEDURE CONTINUED 1. Remove line (Figure 3, Item 2) and O-ring (Figure 3, Item 3) from elbow (Figure 3, Item 4). Discard O-ring. 2. Remove elbow (Figure 3, Item 4) and O-ring (Figure 3, Item 5) from ripper valve (Figure 3, Item 1). Discard Oring. 3. Remove bolt (Figure 3, Item 6) from cover (Figure 3, Item 7). 4. Insert bolt (Figure 3, Item 6) into ripper valve (Figure 3, Item 1) and slowly tighten bolt to lower ripper attachment. 5. When ripper attachment is completely down, remove bolt (Figure 3, Item 6) from ripper valve (Figure 3, Item 1). 6. Install new O-ring (Figure 3, Item 5) and elbow (Figure 3, Item 4) on ripper valve (Figure 3, Item 1). 7. Install new O-ring (Figure 3, Item 3) and line (Figure 3, Item 2) on elbow (Figure 3, Item 4) on blade valve (Figure 3, Item 9). Discard O-ring. 8. Remove line (Figure 3, Item 2) and O-ring (Figure 3, Item 3) from elbow (Figure 3, Item 4) on blade valve (Figure 3, Item 9). Discard O-ring. 9. Loosen jam nut (Figure 3, Item 6) and remove elbow (Figure 3, Item 4) and O-ring (Figure 3, Item 5) from blade valve (Figure 3, Item 9). Discard O-ring. 10. Insert bolt (Figure 3, Item 7) into blade valve (Figure 3, Item 9) and slowly tighten bolt to lower blade. 11. When blade is completely down, remove bolt (Figure 3, Item 7) and return to cover (Figure 3, Item 8). 12. Install new O-ring (Figure 3, Item 5) and elbow (Figure 3, Item 4) on blade valve (Figure 3, Item 9). 13. Install new O-ring (Figure 3, Item 3) and tube nut (Figure 3, Item 2) on elbow (Figure 3, Item 4).

Figure 3. Valve Bank. END OF TASK

0218

0218-3

TM 5-2410-241-23-3

0218

ACCESS COVER INSTALLATION 1. Install cover (Figure 4, Item 3), four washers (Figure 4, Item 2), and bolts (Figure 4, Item 1) on machine.

000218

Figure 4. Cover.

0218

0218-4

TM 5-2410-241-23-3

0218

ACCESS COVER INSTALLATION CONTINUED 2. Position trim panel (Figure 5, Item 2), and connect messenger module harness connector (Figure 5, Item 1) on machine. 3. Install mounting bracket (Figure 5, Item 6), and four bolts (Figure 5, Item 5) on machine. 4. Install fire extinguisher bracket (Figure 5, Item 3) and four screws (Figure 5, Item 4) on mounting bracket (Figure 5, Item 6). 5. Install fire extinguisher (Figure 5, Item 8) on fire extinguisher bracket (Figure 5, Item 3), and install clasp (Figure 5, Item 7).

Figure 5. Fire Extinguisher and Bracket. END OF TASK END OF WORK PACKAGE

0218

0218-5/(6 blank)

14 TM 5-2410-241-23-3 0219

FIELD MAINTENANCE INSTRUCTIONS BLOWER FAN CASE REPLACEMENT Temperature Switch Removal, Resistor Removal, Blower Motor Removal, Cleaning and Inspection, Blower Motor Installation, Resistor Installation, Temperature Switch Installation
0 2 1 9

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 References WP 0295 TEMPERATURE SWITCH REMOVAL 0 0 0 0 0 0 0 0 0
000219

Equipment Condition Machine parked (TM 5-2410-241-10) Instrument panel opened (WP 0262) Drawing Required TM 5-2410-241-24P, Figure 104 Estimated Time to Complete 3.5 Hr

0 0 0 0 0 0 0

WARNING

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 result in injury or death to personnel. 1. Remove two knobs (Figure 1, Item 2), cover (Figure 1, Item 1), plate (Figure 1, Item 3) and cab filter (Figure 1, Item 4) from platform (Figure 1, Item 5).

Figure 1. Cab Filter. 0219-1

0219

TM 5-2410-241-23-3

0219

TEMPERATURE SWITCH REMOVAL CONTINUED

CAUTION
Use caution when handling temperature switch tube. The tube is made of a soft metal and is over two feet long. Do not kink or bend tube. Damage to equipment will result. 2. Remove temperature switch tube (Figure 2, Item 1) from evaporator coil (Figure 2, Item 3) and grommet (Figure 2, Item 2).

Figure 2. Temperature Switch Tube.

0219

NOTE
Tag connectors to aid installation. 3. Disconnect two blower harness connectors (Figure 3, Item 5) from temperature switch (Figure 3, Item 3). 4. Remove two bolts (Figure 3, Item 1) and temperature switch (Figure 3, Item 3) from bracket (Figure 3, Item 2). Set temperature switch (Figure 3, Item 3) aside.

CAUTION
Use caution when handling temperature switch tube. The tube is made of a soft metal and is over 2 feet long. Do not kink or bend tube. Damage to equipment will result. 5. Remove temperature switch tube (Figure 3, Item 4) from frame. 6. Remove temperature switch (Figure 3, Item 3) and temperature switch tube (Figure 3, Item 4) from machine. 7. Remove grommet (Figure 3, Item 6) from machine.

0219-2

TM 5-2410-241-23-3

0219

TEMPERATURE SWITCH REMOVAL CONTINUED

Figure 3. Temperature Switch. END OF TASK

0219

0219-3

TM 5-2410-241-23-3

0219

RESISTOR REMOVAL 1. Remove four bolts (Figure 4, Item 7), washers (Figure 4, Item 8), and instrument panel enclosure (Figure 4, Item 9) from machine. 2. Remove two screws (Figure 4, Item 4) and temperature switch (Figure 4, Item 5) from bracket (Figure 4, Item 6). Set temperature switch (Figure 4, Item 5) aside.

000219

NOTE
Tag connectors to aid installation. 3. Disconnect harness connector (Figure 4, Item 12) from blower harness (Figure 4, Item 10). 4. Remove tiedown strap (Figure 4, Item 11) from blower harness (Figure 4, Item 10). Discard tiedown strap. 5. Remove four bolts (Figure 4, Item 14) and left foot support (Figure 4, Item 13) from machine. 6. Remove six bolts (Figure 4, Item 1), washers (Figure 4, Item 2), and blower motor and cover (Figure 4, Item 3) from machine.

Figure 4. Blower Motor.

0219

0219-4

TM 5-2410-241-23-3

0219

RESISTOR REMOVAL CONTINUED 7. Remove two bolts (Figure 5, Item 2), washers (Figure 5, Item 3), plate (Figure 5, Item 4), and guard (Figure 5, Item 1) from cover (Figure 5, Item 5).

NOTE
Tag connectors to aid installation. 8. Disconnect blower harness connector (Figure 5, Item 6) from resistor (Figure 5, Item 7). Remove resistor and plate (Figure 5, Item 4) from cover (Figure 5, Item 5).

Figure 5. Resistor Connection. 9. Remove two bolts (Figure 6, Item 4) and resistor (Figure 6, Item 3) from plate (Figure 6, Item 2). Separate guard (Figure 6, Item 1) from plate.

0219

Figure 6. Resistor. END OF TASK

0219

0219-5

TM 5-2410-241-23-3

0219

BLOWER MOTOR REMOVAL 1. Remove temperature switch. Refer to Temperature Switch Removal in this work package. 2. Remove resistor. Refer to Resistor Removal in this work package. 3. Remove six bolts (Figure 7, Item 3), three plates (Figure 7, Item 4), and blower motor (Figure 7, Item 5) from cover (Figure 7, Item 2). 4. Remove blower harness connector (Figure 7, Item 6) from grommet (Figure 7, Item 1) in cover (Figure 7, Item 2). 5. Remove grommet (Figure 7, Item 1) from cover (Figure 7, Item 2).

000219

NOTE
Tag connectors to aid installation. 6. Disconnect blower motor connector (Figure 7, Item 7) from blower harness connector (Figure 7, Item 6) and remove harness.

Figure 7. Blower Motor Cover.

0219

0219-6

TM 5-2410-241-23-3

0219

BLOWER MOTOR REMOVAL CONTINUED 7. Remove two bolts (Figure 8, Item 1), washers (Figure 8, Item 2), and bracket (Figure 8, Item 3) from cover (Figure 8, Item 4). 8. Remove gasket (Figure 8, Item 5) from cover (Figure 8, Item 4). Discard gasket.

Figure 8. Gasket. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK BLOWER MOTOR INSTALLATION 1. Install new gasket (Figure 8, Item 5) on cover (Figure 8, Item 4). 2. Install bracket (Figure 8, Item 3), two washers (Figure 8, Item 2), and bolts (Figure 8, Item 1) on cover (Figure 8, Item 4).

0219

000219

000219

0219-7

TM 5-2410-241-23-3

0219

BLOWER MOTOR INSTALLATION CONTINUED

NOTE
Install connectors as tagged in removal. 3. Install harness and connect blower motor connector (Figure 9, Item 7) to blower harness connector (Figure 9, Item 6). 4. Install grommet (Figure 9, Item 1) in cover (Figure 9, Item 2). 5. Install blower harness connector (Figure 9, Item 6) through grommet (Figure 9, Item 1) in cover (Figure 9, Item 2). 6. Install blower motor (Figure 9, Item 5), three plates (Figure 9, Item 4), and six bolts (Figure 9, Item 3) on cover (Figure 9, Item 2). 7. Install resistor. Refer to Resistor Installation in this work package. 8. Install temperature switch. Refer to Temperature Switch Installation in this work package.

Figure 9. Blower Motor Cover. END OF TASK

0219

0219-8

TM 5-2410-241-23-3

0219

RESISTOR INSTALLATION 1. Install resistor (Figure 10, Item 3) and two bolts (Figure 10, Item 4) on plate (Figure 10, Item 2) and guard (Figure 10, Item 1).

000219

Figure 10. Resistor.

0219

NOTE
Install connectors as tagged in removal. 2. Connect blower harness connector (Figure 11, Item 6) on resistor (Figure 11, Item 7). 3. Install plate (Figure 11, Item 4), guard (Figure 11, Item 1), two washers (Figure 11, Item 3), and bolts (Figure 11, Item 2) on cover (Figure 11, Item 5).

Figure 11. Resistor Connection.

0219

0219-9

TM 5-2410-241-23-3

0219

RESISTOR INSTALLATION CONTINUED 4. Install blower motor and cover (Figure 12, Item 3), six washers (Figure 12, Item 2), and bolts (Figure 12, Item 1) on machine. 5. Install left foot support (Figure 12, Item 13) and four bolts (Figure 12, Item 14) on machine. 6. Install blower harness (Figure 12, Item 10) and new tiedown strap (Figure 12, Item 11) on cover.

NOTE
Install connectors as tagged in removal. 7. Connect harness connector (Figure 12, Item 12) on blower harness (Figure 12, Item 10). 8. Install temperature switch (Figure 12, Item 5) and two screws (Figure 12, Item 4) on bracket (Figure 12, Item 6). 9. Install instrument panel enclosure (Figure 12, Item 9), four washers (Figure 12, Item 8), and bolts (Figure 12, Item 7) on machine.

Figure 12. Blower Motor. END OF TASK

0219

0219-10

TM 5-2410-241-23-3

0219

TEMPERATURE SWITCH INSTALLATION 1. Install grommet (Figure 13, Item 6) on machine.

000219

CAUTION
Use caution when handling temperature switch tube. The tube is made of a soft metal and is over 2 feet long. Do not kink or bend tube. Damage to equipment will result. 2. Position temperature switch tube (Figure 13, Item 4) and temperature switch (Figure 13, Item 3) on machine. 3. Install temperature switch tube (Figure 13, Item 4) through frame. 4. Install temperature switch (Figure 13, Item 3) and two bolts (Figure 13, Item 1) on bracket (Figure 13, Item 2).

NOTE
Install connectors as tagged in removal. 5. Connect two blower harness connectors (Figure 13, Item 5) on temperature switch (Figure 13, Item 3).

Figure 13. Temperature Switch.

0219

0219-11

TM 5-2410-241-23-3

0219

TEMPERATURE SWITCH INSTALLATION CONTINUED

CAUTION
Use caution when handling temperature switch tube. The tube is made of a soft metal and is over 2 feet long. Do not kink or bend tube. Damage to equipment will result. 6. Install temperature switch tube (Figure 14, Item 1) through grommet (Figure 14, Item 2) and evaporator coil (Figure 14, Item 3).

Figure 14. Temperature Switch Tube. 7. Install cab filter (Figure 15, Item 4), plate (Figure 15, Item 3) cover (Figure 15, Item 1), and two knobs (Figure 15, Item 2) on platform (Figure 15, Item 5).

0219

Figure 15. Cab Filter. END OF TASK

0219

0219-12

TM 5-2410-241-23-3

0219

FOLLOW-ON TASKS 1. Close instrument panel (WP 0262). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000219

0219-13/(14 blank)

8 TM 5-2410-241-23-3 0220

FIELD MAINTENANCE INSTRUCTIONS


0 2 2 0

AIR CONDITIONER EVAPORATOR COIL 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) Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) Tool Set, SATS, Base (WP 0302, Item 68) Wrench, Combination 1-1/16 (S0787) (WP 0302, Item 68) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Oil, Lubricating, Refrigerant Compressor (WP 0303, Item 22) Rag, Wiping (WP 0303, Item 24) 0 0
0

Materials/Parts - Continued Refrigerant, R-134a (WP 0303, Item 25) Tag, Marker (WP 0303, Item 34) Gasket O-ring (2) References

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0

WP 0263 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Hood removed (WP 0200) Drawing Required TM 5-2410-241-24P, Figure 100, 105, 124 Estimated Time to Complete 5.5 Hr

0220-1

TM 5-2410-241-23-3

0220

REMOVAL

000220

WARNING

Contact with refrigerant can cause frostbite. Keep hands and face away to prevent personal injury. Protective face shield and gloves must always be worn when refrigerant lines are opened, even if gauges indicate A/C system is empty. Always use caution when disconnecting fittings. Slowly loosen fitting in well-ventilated area. Do not smoke when servicing A/C or wherever refrigerant gas may be present. Failure to follow these warnings may result in injury or death to personnel.

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Recover the air conditioning system. Refer to Air Conditioning System Service (WP 0263). 2. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 1), cover (Figure 1, Item 3) and gasket (Figure 1, Item 4) from platform (Figure 1, Item 5). Discard gasket.

Figure 1. Cover.

0220

0220-2

TM 5-2410-241-23-3

0220

INSTALLATION CONTINUED 3. Remove cab filter (Figure 2, Item 1) from platform (Figure 2, Item 2).

Figure 2. Cab Filter.

0220

CAUTION
Use caution when handling temperature switch tube. The tube is made of a soft metal and is approximately 2 ft long. Do not kink or bend tube. Damage to equipment will result. 4. Remove temperature switch tube (Figure 3, Item 3) from evaporator coil (Figure 3, Item 6) and grommet (Figure 3, Item 4). 5. Remove four bolts (Figure 3, Item 1), washers (Figure 3, Item 2) and two plates (Figure 3, Item 7) from heater coil (Figure 3, Item 5) and evaporator coil (Figure 3, Item 6).

Figure 3. Temperature Switch Tube.

0220

0220-3

TM 5-2410-241-23-3

0220

INSTALLATION CONTINUED 6. Remove two bolts (Figure 4, Item 6), washers (Figure 4, Item 5) on evaporator coil (Figure 4, Item 8).

NOTE
Tag hoses to aid in installation. 7. Disconnect hose assembly (Figure 4, Item 1) from evaporator coil (Figure 4, Item 8). 8. Remove O-ring (Figure 4, Item 2) from hose assembly (Figure 4, Item 1). Discard O-ring. 9. Disconnect hose assembly (Figure 4, Item 3) from evaporator coil (Figure 4, Item 8). 10. Remove O-ring (Figure 4, Item 4) from hose assembly (Figure 4, Item 3). Discard O-ring. 11. Remove evaporator coil (Figure 4, Item 8) from platform (Figure 4, Item 7).

Figure 4. Hose Assembly. END OF TASK

0220

0220-4

TM 5-2410-241-23-3

0220

CLEANING AND INSPECTION 1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect evaporator coil (Figure 5, Item 1) for cracks, damage, or coolant leakage. Replace evaporator coil.

000220

3. Inspect evaporator coil (Figure 5, Item 1) for bent fins (Figure 5, Item 2). Bent fins may be gently straightened by use of a small screwdriver. 4. Inspect pipe (Figure 5, Item 3) and outlet pipe (Figure 5, Item 4) for cracks, breaks, broken welds, coolant leakage or deformity. Replace evaporator coil.

Figure 5. A/C Evaporator Inspection. END OF TASK INSTALLATION 1. Install evaporator coil (Figure 4, Item 8) on platform (Figure 4, Item 7).

0220

000220

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

2. Install new O-ring (Figure 4, Item 4) on hose assembly (Figure 4, Item 3). 3. Connect hose assembly (Figure 4, Item 3) on evaporator coil (Figure 4, Item 8). 4. Install new O-ring (Figure 4, Item 2) to hose assembly (Figure 4, Item 1). 5. Connect hose assembly (Figure 4, Item 1) on evaporator coil (Figure 4, Item 8). 6. Install two washers (Figure 4, Item 5) and bolts (Figure 4, Item 6) on evaporator coil (Figure 4, Item 8).

0220-5

TM 5-2410-241-23-3

0220

INSTALLATION CONTINUED 7. Install two plates (Figure 6, Item 7), four washers (Figure 6, Item 2) and bolts (Figure 6, Item 1) on heater coil (Figure 6, Item 5) and evaporator coil (Figure 6, Item 6).

CAUTION
Use caution when handling temperature switch tube. The tube is made of a soft metal and is approximately 2 ft long. Do not kink or bend tube. Damage to equipment will result. 8. Install temperature switch tube (Figure 6, Item 3) through grommet (Figure 6, Item 4) and into evaporator coil (Figure 6, Item 6).

Figure 6. Temperature Switch Tube. 9. Install cab filter (Figure 7, Item 1) on platform (Figure 7, Item 2).

0220

Figure 7. Cab Filter.

0220

0220-6

TM 5-2410-241-23-3

0220

INSTALLATION CONTINUED 10. Install new gasket (Figure 8, Item 4), cover (Figure 8, Item 3), four washers (Figure 8, Item 1), and bolts (Figure 8, Item 2) on platform (Figure 8, Item 5).

Figure 8. Cover. 11. Evacuate, charge, and leak test the air conditioning system. Refer to A/C System Service (WP 0263). END OF TASK FOLLOW-ON TASK 1. Install hood (WP 0200). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0220

000220

0220-7/(8 blank)

000220

6 TM 5-2410-241-23-3 0221

FIELD MAINTENANCE INSTRUCTIONS HEATER COIL REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 2 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Pan, Drain (S0255) (WP 0302, Item 68) Materials/Parts 0 0
0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Air conditioner evaporator coil removed (WP 0220) Drawing Required TM 5-2410-241-24P, Figure 105 Estimated Time to Complete 6.5 Hr

0 0 0 0 0 0 0 0 0
000221

Antifreeze, Permanent, Ethylene Glycol, Inhibited (WP 0303, Item 1) 0 Cap Set, Protective (WP 0303, Item 4) 0 Rag, Wiping (WP 0303, Item 24) 0 Tag, Marker (WP 0303, Item 34) 0

REMOVAL 1. Close two heater hose valves (Figure 1, Item 2) on heater hoses (Figure 1, Item 1).

Figure 1. Heater Hose Valves.

0221

0221-1

TM 5-2410-241-23-3

0221

REMOVAL CONTINUED

NOTE
Tag hoses to aid installation. Cap and plug all hoses and lines to prevent contamination and leaks. It may be necessary to move A/C hoses out of way to gain access to heater hoses.

2. Lift grommet (Figure 2, Item 4) to gain access to heater hoses (Figure 2, Item 2). 3. Loosen two clamps (Figure 2, Item 1) and disconnect two hoses (Figure 2, Item 2) from heater coil (Figure 2, Item 3). 4. Remove two clamps (Figure 2, Item 1) from two hoses (Figure 2, Item 2).

Figure 2. Heater Hoses.

0221

0221-2

TM 5-2410-241-23-3

0221

REMOVAL CONTINUED 5. Remove heater coil (Figure 3, Item 1) and grommet (Figure 3, Item 3) from platform (Figure 3, Item 2).

Figure 3. Heater Coil. END OF TASK

0221

0221-3

TM 5-2410-241-23-3

0221

CLEANING AND INSPECTION 1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect heater coil (Figure 4, Item 2) for cracks, damage, or coolant leakage. Replace heater coil. 3. Inspect heater coil (Figure 4, Item 2) for bent fins (Figure 4, Item 1). Bent fins may be gently straightened by use of a small screwdriver.

000221

4. Inspect inlet pipe (Figure 4, Item 4) and outlet pipe (Figure 4, Item 3) for cracks, breaks, broken welds, coolant leakage of deformity. Replace heater coil.

Figure 4. Heater Coil Inspection. INSTALLATION 1. Install grommet (Figure 3, Item 3) and heater coil (Figure 3, Item 1) on platform (Figure 3, Item 2).

0221

000221

0221-4

TM 5-2410-241-23-3

0221

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 2. Install two clamps (Figure 5, Item 1) on two hoses (Figure 5, Item 2). 3. Connect two hoses (Figure 5, Item 2) on heater coil (Figure 5, Item 3), tighten clamps (Figure 5, Item 1). 4. Secure grommet (Figure 5, Item 4) on machine.

Figure 5. Heater Hoses.

0221

0221-5

TM 5-2410-241-23-3

0221

INSTALLATION CONTINUED 5. Open two heater hose valves (Figure 6, Item 2) on heater hoses (Figure 6, Item 1).

Figure 6. Heater Hose Valves. END OF TASK FOLLOW-ON TASK 1. Install air conditioner evaporator coil (WP 0220). 2. Fill cooling system with coolant (WP 0113). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0221

000221

0221-6

8 TM 5-2410-241-23-3 0222

FIELD MAINTENANCE INSTRUCTIONS FRONT WIPER MOTOR, WIPER ARM AND WIPER BLADE REPLACEMENT Wiper Motor Cover Removal, Wiper Blade Removal, Wiper Arm Removal, Wiper Motor Removal, Cleaning and Inspection, Wiper Motor Installation, Wiper Arm Installation, Wiper Blade Installation, Wiper Motor Cover Installation
0 2 2 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Screwdriver Attachment, Torx Bit, T-30 (S0288) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Silicone Sealant (WP 0303, Item 31) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) WIPER MOTOR COVER REMOVAL 1. Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and mirror (Figure 1, Item 3) from machine. 0 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 106, 108, 109 Estimated Time to Complete 1.0 Hr 0 0 0 0 0 0 0 0

000222

Figure 1. Cab Mirror.

0222

0222-1

TM 5-2410-241-23-3

0222

WIPER MOTOR COVER REMOVAL CONTINUED 2. Remove two bolts (Figure 2, Item 1) and cover (Figure 2, Item 2) from machine.

Figure 2. Wiper Motor Cover. END OF TASK WIPER BLADE REMOVAL 1. Position wiper arm (Figure 3, Item 3) back. 2. Squeeze release tab (Figure 3, Item 2) toward wiper arm (Figure 3, Item 3) to release wiper blade (Figure 3, Item 1). 3. Remove wiper blade (Figure 3, Item 1) from wiper arm (Figure 3, Item 3).

0222

000222

Figure 3. Wiper Blade. END OF TASK

0222

0222-2

TM 5-2410-241-23-3

0222

WIPER ARM REMOVAL 1. Disconnect hose (Figure 4, Item 1) from spray nozzle (Figure 4, Item 6). 2. Open two covers (Figure 4, Item 3) and remove two nuts (Figure 4, Item 2) from machine.

000222

NOTE
Note position and orientation of wiper arms. 3. Remove wiper arm (Figure 4, Item 4) from machine. 4. Remove two caps (Figure 4, Item 5) from machine.

Figure 4. Spray Nozzle, Hose, and Wiper Arm. END OF TASK

0222

0222-3

TM 5-2410-241-23-3

0222

WIPER MOTOR REMOVAL

000222

1. Position headliner (Figure 5, Item 1) aside and remove tiedown strap (Figure 5, Item 2) from harness (Figure 5, Item 3). Discard tiedown strap.

NOTE
Tag electrical connector to aid installation. 2. Disconnect wiper motor connector (Figure 5, Item 4) from harness (Figure 5, Item 3).

Figure 5. Wiper Motor Assembly. 3. Remove nut (Figure 6, Item 2) and washer (Figure 6, Item 3) from wiper motor (Figure 6, Item 1).

0222

4. Remove bolt (Figure 6, Item 6), washer (Figure 6, Item 7), plate (Figure 6, Item 4), and wiper motor (Figure 6, Item 1) from machine. 5. Remove gasket (Figure 6, Item 5) from plate (Figure 6, Item 4). Discard gasket.

Figure 6. Plate. END OF TASK

0222

0222-4

TM 5-2410-241-23-3

0222

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

000222

000222

NOTE
Apply silicone sealant to gasket and mating surfaces of motor and machine. 1. Install new gasket (Figure 6, Item 5) on plate (Figure 6, Item 4). 2. Position wiper motor (Figure 6, Item 1) on machine. 3. Install plate (Figure 6, Item 4), washer (Figure 6, Item 3), and nut (Figure 6, Item 2) on wiper motor (Figure 6, Item 1). 4. Install washer (Figure 6, Item 7) and bolt (Figure 6, Item 6) on machine.

NOTE
Install electrical connector as tagged during removal. 5. Connect wiper motor connector (Figure 7, Item 4) to harness (Figure 7, Item 3). 6. Install new tiedown strap (Figure 7, Item 2) on harness (Figure 7, Item 3) and position headliner (Figure 7, Item 1).

Figure 7. Wiper Motor Assembly. END OF TASK

0222

0222-5

TM 5-2410-241-23-3

0222

WIPER ARM INSTALLATION 1. Install two caps (Figure 8, Item 5) on machine.

000222

NOTE
Install wiper arms as noted during removal. 2. Install wiper arm (Figure 8, Item 4) on machine. 3. Install two nuts (Figure 8, Item 2) on machine and close two covers (Figure 8, Item 3). 4. Connect hose (Figure 8, Item 1) on spray nozzle (Figure 8, Item 6).

Figure 8. Spray Nozzle, Hose, and Wiper Arm. END OF TASK

0222

0222-6

TM 5-2410-241-23-3

0222

WIPER BLADE INSTALLATION 1. Install wiper blade (Figure 9, Item 1) on wiper arm (Figure 9, Item 3). 2. Align tab (Figure 9, Item 2) of wiper blade (Figure 9, Item 1) to hole in wiper arm (Figure 9, Item 3) and snap into position. 3. Position wiper arm (Figure 9, Item 3) to operating position.

000222

Figure 9. Wiper Blade. END OF TASK WIPER MOTOR COVER INSTALLATION 1. Position cover (Figure 10, Item 2) on machine and install two bolts (Figure 10, Item 1).

0222

000222

Figure 10. Wiper Motor Cover.

0222

0222-7

TM 5-2410-241-23-3

0222

WIPER MOTOR COVER INSTALLATION CONTINUED 2. Position mirror (Figure 11, Item 3) on machine and install two washers (Figure 11, Item 1) and bolts (Figure 11, Item 2).

Figure 11. Cab Mirror. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0222

000222

0222-8

8 TM 5-2410-241-23-3 0223

FIELD MAINTENANCE INSTRUCTIONS REAR WIPER MOTOR, WIPER ARM, AND WIPER BLADE REPLACEMENT Wiper Blade Removal, Wiper Arm Removal, Rear Wiper Motor, Removal, Cleaning and Inspection, Rear Wiper Motor Installation, Wiper Arm Installation, Wiper Blade Installation
0 2 2 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Screwdriver Attachment, Torx, 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Silicone Sealant (WP 0303, Item 31) Tag, Marker (WP 0303, Item 34) Lockwasher WIPER BLADE REMOVAL 1. Position wiper arm (Figure 1, Item 3) back. 2. Squeeze release tab (Figure 1, Item 2) toward wiper arm (Figure 1, Item 3) to release wiper blade (Figure 1, Item 1). 3. Remove wiper blade (Figure 1, Item 1) from wiper arm (Figure 1, Item 3). 0 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 108, 109 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0 0

000223

Figure 1. Wiper Blade. END OF TASK

0223

0223-1

TM 5-2410-241-23-3

0223

WIPER ARM REMOVAL 1. Remove wiper blade as described in this work package. 2. Disconnect hose (Figure 2, Item 1) from spray nozzle (Figure 2, Item 6). 3. Open cover (Figure 2, Item 3) and remove nut (Figure 2, Item 4) from machine. 4. Remove wiper arm (Figure 2, Item 2) from machine. 5. Remove cap (Figure 2, Item 5) from machine.

000223

Figure 2. Spray Nozzle, Hose, and Wiper Arm. END OF TASK REAR WIPER MOTOR REMOVAL

0223

000223

NOTE
Two of four bolts are hidden under headliner. 1. Remove wiper arm as described in this work package. 2. Remove four bolts (Figure 3, Item 1) and cover (Figure 3, Item 2) from machine.

0223-2

TM 5-2410-241-23-3

0223

REAR WIPER MOTOR REMOVAL CONTINUED

Figure 3. Wiper Motor Cover.

0223

NOTE
Tag electrical connector to aid installation. 3. Position headliner (Figure 4, Item 2) aside and disconnect electrical connector (Figure 4, Item 1).

Figure 4. Connector.

0223

0223-3

TM 5-2410-241-23-3

0223

REAR WIPER MOTOR REMOVAL CONTINUED 4. Remove nut (Figure 5, Item 1), washer (Figure 5, Item 2), and lockwasher (Figure 5, Item 3) from machine. Discard lockwasher.

Figure 5. Nut. 5. Remove bolt (Figure 6, Item 4), washer (Figure 6, Item 3), sleeve (Figure 6, Item 1), and motor (Figure 6, Item 2) from machine.

0223

Figure 6. Bolt and Sleeve. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0223

000223

0223-4

TM 5-2410-241-23-3

0223

REAR WIPER MOTOR INSTALLATION

000223

NOTE
Apply silicone sealant to sleeve and mating surfaces of motor and machine. 1. Position wiper motor (Figure 6, Item 2) on machine and install washer (Figure 6, Item 3), bolt (Figure 6, Item 4), and sleeve (Figure 6, Item 1). 2. Install new lockwasher (Figure 7, Item 3), washer (Figure 7, Item 2), and nut (Figure 7, Item 1) on machine.

Figure 7. Nut.

0223

NOTE
Install electrical connector as tagged during removal. 3. Connect electrical connector (Figure 8, Item 1) and position headliner (Figure 8, Item 2).

Figure 8. Connector.

0223

0223-5

TM 5-2410-241-23-3

0223

REAR WIPER MOTOR INSTALLATION CONTINUED 4. Position cover (Figure 9, Item 2) on machine and install four bolts (Figure 9, Item 1). 5. Install wiper arm as described in this work package.

Figure 9. Wiper Motor Cover. END OF TASK

0223

0223-6

TM 5-2410-241-23-3

0223

WIPER ARM INSTALLATION 1. Install cap (Figure 10, Item 5) on machine. 2. Install wiper arm (Figure 10, Item 2) on machine. 3. Install nut (Figure 10, Item 4) on machine and close cover (Figure 10, Item 3). 4. Connect hose (Figure 10, Item 1) on spray nozzle (Figure 10, Item 6). 5. Install wiper blade as described in this work package.

000223

Figure 10. Spray Nozzle, Hose, and Wiper Arm. END OF TASK

0223

0223-7

TM 5-2410-241-23-3

0223

WIPER BLADE INSTALLATION 1. Install wiper blade (Figure 11, Item 1) on wiper arm (Figure 11, Item 3).

000223

2. Align tab (Figure 11, Item 2) of wiper blade (Figure 11, Item 1) to hole in wiper arm (Figure 11, Item 3) and snap into position. 3. Position wiper arm (Figure 11, Item 3) to operating position.

Figure 11. Wiper Blade. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0223

000223

0223-8

4 TM 5-2410-241-23-3 0224

FIELD MAINTENANCE INSTRUCTIONS WASHER BOTTLE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 2 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) Tiedown Strap (WP 0303, Item 36) Locknut (2) 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 103 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0 0

0224-1

TM 5-2410-241-23-3

0224

REMOVAL

000224

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

1. Remove tiedown strap (Figure 1, Item 6) from machine harness (Figure 1, Item 7) and pivot shaft oil reservoir compartment (Figure 1, Item 5). Discard tiedown strap. 2. Disconnect electrical connector (Figure 1, Item 2) from machine harness (Figure 1, Item 7). 3. Disconnect four hoses (Figure 1, Item 4) from check valves (Figure 1, Item 3). 4. Loosen two bolts (Figure 1, Item 13) and washers (Figure 1, Item 14) from pivot shaft oil reservoir compartment (Figure 1, Item 5). 5. Remove two bolts (Figure 1, Item 9), washers (Figure 1, Item 10), and locknuts (Figure 1, Item 8) from pivot shaft oil reservoir compartment (Figure 1, Item 5). Discard locknuts. 6. Remove two bolts (Figure 1, Item 11), washers (Figure 1, Item 12), and washer bottle (Figure 1, Item 1) from pivot shaft oil reservoir compartment (Figure 1, Item 5).

Figure 1. Washer Bottle. END OF TASK

0224

0224-2

TM 5-2410-241-23-3

0224

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

000224

000224

1. Install washer bottle (Figure 1, Item 1), two washers (Figure 1, Item 12), and bolts (Figure 1, Item 11) on pivot shaft oil reservoir compartment (Figure 1, Item 5). 2. Install two washers (Figure 1, Item 10), bolts (Figure 1, Item 9), and new locknuts (Figure 1, Item 8) on pivot shaft oil reservoir compartment (Figure 1, Item 5). 3. Tighten two washers (Figure 1, Item 14) and bolts (Figure 1, Item 13) on pivot shaft oil reservoir compartment (Figure 1, Item 5).

NOTE
Install tiedown straps as noted during removal. Install connectors as noted during removal. Install hoses as noted during removal.

4. Connect four hoses (Figure 1, Item 4) on check valves (Figure 1, Item 3). 5. Connect electrical connector (Figure 1, Item 2) on machine harness (Figure 1, Item 7). 6. Install machine harness (Figure 1, Item 7) and new tiedown strap (Figure 1, Item 6) on pivot shaft oil reservoir compartment (Figure 1, Item 5). END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000224

0224-3/(4 blank)

6 TM 5-2410-241-23-3 0225

FIELD MAINTENANCE INSTRUCTIONS ROPS REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 2 5

INITIAL SETUP Tools and Special Tools 0 Materials/Parts - Continued Tiedown Strap (WP 0303, Item 36) Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 122 Estimated Time to Complete 1.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Extension 3/4 Dr, 15 Long (S0378) (WP 0302, Item 68) 0 Multiplier, Torque 0 to 2000 lb-ft (S0253) (WP 0302, Item 68) 0 Sling, Multiple Leg (WP 0302, Item 54) 0 Socket, 3/4 Drive, 12 point, 1 5/8 (S0392) (WP 0302, Item 68) 0 Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) 0 Lifting Device (1,500-lb capacity) 0 Link bracket (2) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) 0 0 0

0225-1

TM 5-2410-241-23-3

0225

REMOVAL

000225

NOTE
Tag all electrical harness connectors to aid installation. 1. Disconnect harness connector (Figure 1, Item 1) from light harness connector (Figure 1, Item 2).

Figure 1. Connectors.

0225

2. Loosen top bolt (Figure 2, Item 6), remove bottom bolt (Figure 2, Item 8), and move bracket (Figure 2, Item 7) aside to access bolts (Figure 2, Item 2). 3. Repeat steps 1 and 2 for other side of machine. 4. Attach suitable lifting device to ROPS (Figure 2, Item 5).

0225-2

TM 5-2410-241-23-3

0225

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
ROPS weighs approximately 1000 lb (454 kg). 5. Remove six bolts (Figure 2, Item 2), washers (Figure 2, Item 3), bracket (Figure 2, Item 1) and ROPS (Figure 2, Item 5) from mounting (Figure 2, Item 4). 6. Repeat step 5 for other side of machine. 7. Remove ROPS (Figure 2, Item 5) from machine. Place ROPS on flat surface. 8. Remove lifting device from ROPS (Figure 2, Item 5).

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

0225

000225

0225-3

TM 5-2410-241-23-3

0225

INSTALLATION

000225

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
ROPS weighs approximately 1000 lb (454 kg). 1. Attach suitable lifting device to ROPS (Figure 3, Item 5). 2. Install ROPS (Figure 3, Item 5) on mountings (Figure 3, Item 4). 3. Install bracket (Figure 3, Item 1), six washers (Figure 3, Item 3), and bolts (Figure 3, Item 2) on ROPS (Figure 3, Item 5). Tighten bolts to 600 90 lb-ft (900 100 Nm). 4. Position bracket (Figure 3, Item 7), install lower bolt (Figure 3, Item 8) and tighten upper bolt (Figure 3, Item 6). 5. Repeat step 3 and 4 for other side of machine (Figure 3, Item 5).

Figure 3. ROPS.

0225

0225-4

TM 5-2410-241-23-3

0225

INSTALLATION CONTINUED

NOTE
Install harness connectors as noted during removal. 6. Connect harness connector (Figure 4, Item 1) to light harness connector (Figure 4, Item 2). 7. Repeat step 6 for other side of machine. 8. Remove lifting device from ROPS (Figure 3, Item 5).

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

0225

000225

0225-5/(6 blank)

8 TM 5-2410-241-23-3 0226

FIELD MAINTENANCE INSTRUCTIONS FRONT WASHER HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 2 6

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Drill-driver, Battery Rechargeable, 1/2 (S0188) (WP 0302, Item 68) Drill Set, Twist 1/16 to 1/2 (S0194) (WP 0302, Item 68) Tool Kit, Blind Fastener, Installation (S0700) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Rivet (4) REMOVAL 0 0 0 0 0 0 0 0 0 0 References WP 0295 Equipment Condition 0 0 0

Machine parked (TM 5-2410-241-10) 0 Headliner, and interior trim panels removed (WP 0229) 0 Upper ROPS removed (WP 0225) 0 Drawing Required TM 5-2410-241-24P, Figure 107 Estimated Time to Complete 3.5 Hr 0 0 0 0

000226

NOTE
Tag and mark hose connections to aid installation. Note hose routing to aid installation.

1. Disconnect front washer hose (Figure 1, Item 1) from nipple (Figure 1, Item 2).

Figure 1. Front Wiper.

0226

0226-1

TM 5-2410-241-23-3

0226

REMOVAL CONTINUED

NOTE
Note hose routing to aid installation. Note location of tiedown straps to aid installation.

2. Remove and discard tiedown straps (Figure 2, Item 1) from front washer hose (Figure 2, Item 2) and access hole (Figure 2, Item 3) above left rear column.

Figure 2. Front Washer Hose.

0226

0226-2

TM 5-2410-241-23-3

0226

REMOVAL CONTINUED

NOTE
Tag and mark hose connections to aid installation. Note hose routing to aid installation. Note location of tiedown straps to aid installation.

3. Disconnect cab wiring harness connector (Figure 3, Item 6) and four washer hoses (Figure 3, Item 5) from washer bottle (Figure 3, Item 1). 4. Remove and discard tiedown straps (Figure 3, Item 4) from hose and harness conduit (Figure 3, Item 3). 5. Remove hose and harness conduit (Figure 3, Item 3) from pivot shaft oil reservoir compartment (Figure 3, Item 2).

Figure 3. Washer Electrical Harness and Hoses.

0226

0226-3

TM 5-2410-241-23-3

0226

REMOVAL CONTINUED 6. Remove four rivets (Figure 4, Item 4) from cab harness access panel (Figure 4, Item 3). Discard rivets. 7. Position cab harness access panel (Figure 4, Item 3) away from cab. 8. Remove conduit (Figure 4, Item 1) from cab harness access panel (Figure 4, Item 3) and washer hoses (Figure 4, Item 2). 9. Position washer hoses (Figure 4, Item 2) away from cab harness access panel (Figure 4, Item 3).

Figure 4. Hose and Harness Conduit. 10. Carefully pull front washer hose (Figure 5, Item 2) from column through access hole (Figure 5, Item 1).

0226

Figure 5. Left Column Access Hole END OF TASK

0226

0226-4

TM 5-2410-241-23-3

0226

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Position front washer hose (Figure 5, Item 2) down column through access hole (Figure 5, Item 1). 2. Install washer hoses (Figure 4, Item 2) through cab harness access panel (Figure 4, Item 3).

000226

000226

3. Install conduit (Figure 4, Item 1) on washer hoses (Figure 4, Item 2) and cab harness access panel (Figure 4, Item 3). 4. Position cab harness access panel (Figure 4, Item 3) on cab. 5. Install four new rivets (Figure 4, Item 1) on cab harness access panel (Figure 4, Item 3).

NOTE
Connect hoses as noted during removal. Install hoses as noted during removal. Install tiedown straps as noted during removal.

6. Route hose and harness conduit (Figure 6, Item 3) to pivot shaft oil reservoir compartment (Figure 6, Item 2). 7. Install new tiedown straps (Figure 6, Item 4) on hose and harness conduit (Figure 6, Item 3). 8. Connect cab wiring harness connector (Figure 6, Item 6) and four washer hoses (Figure 6, Item 5) to washer bottle (Figure 6, Item 1).

Figure 6. Washer Electrical Harness and Hoses.

0226

0226-5

TM 5-2410-241-23-3

0226

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. Install tiedown straps as noted during removal.

9. Install new tiedown straps (Figure 7, Item 1) on front washer hose (Figure 7, Item 2) and access hole (Figure 7, Item 3) above left rear column.

Figure 7. Front Washer Hose.

0226

0226-6

TM 5-2410-241-23-3

0226

INSTALLATION CONTINUED

NOTE
Connect hoses as noted during removal. Install hoses as noted during removal.

10. Connect front washer hose (Figure 8, item 1) to nipple (Figure 8, item 2).

Figure 8. Front Wiper. END OF TASK FOLLOW-ON TASKS 1. Install headliner, panels, and rear view mirror (WP 0229). 2. Install upper ROPS (WP 0225). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0226

000226

0226-7/(8 blank)

10 TM 5-2410-241-23-3 0227

FIELD MAINTENANCE INSTRUCTIONS REAR WASHER HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 2 7

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Drill-driver, Battery Rechargeable, 1/2 (S0188) (WP 0302, Item 68) Drill Set, Twist 1/16 to 1/2 (S0194) (WP 0302, Item 68) Tool Kit, Blind Fastener, Installation (S0700) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) Rivet (4) REMOVAL 0 0 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Headliner, interior trim panels removed (WP 0229) ROPS removed (WP 0225) Drawing Required TM 5-2410-241-24P, Figure 107 Estimated Time to Complete 3.5 Hr 0 0 0 0 0 0 0 0 0 0

000227

NOTE
Tag and mark hose connections to aid installation. Note hose routing to aid installation.

1. Disconnect rear washer hose (Figure 1, Item 1) from nipple (Figure 1, Item 2).

Figure 1. Rear Wiper.

0227

0227-1

TM 5-2410-241-23-3

0227

REMOVAL CONTINUED

NOTE
Note hose routing to aid installation. Note location of tiedown straps to aid installation.

2. Remove and discard tiedown straps (Figure 2, Item 1) from rear washer hose (Figure 2, Item 3) and access hole (Figure 2, Item 2) above left rear column.

Figure 2. Rear Washer Hose.

0227

0227-2

TM 5-2410-241-23-3

0227

REMOVAL CONTINUED

NOTE
Tag and mark hose connections to aid installation. Note hose routing to aid installation. Note location of tiedown straps to aid installation.

3. Disconnect cab wiring harness connector (Figure 3, Item 6) and four washer hoses (Figure 3, Item 5) from washer bottle (Figure 3, Item 1). 4. Remove and discard tiedown straps (Figure 3, Item 4) from hose and harness conduit (Figure 3, Item 3). 5. Remove hose and harness conduit (Figure 3, Item 3) from pivot shaft oil reservoir compartment (Figure 3, Item 2).

Figure 3. Washer Electrical Harness and Hoses.

0227

0227-3

TM 5-2410-241-23-3

0227

REMOVAL CONTINUED 6. Remove four rivets (Figure 4, Item 4) from cab harness access panel (Figure 4, Item 3). Discard rivets. 7. Position cab harness access panel (Figure 4, Item 3) away from cab. 8. Remove conduit (Figure 4, Item 1) from cab harness access panel (Figure 4, Item 3) and washer hoses (Figure 4, Item 2). 9. Position washer hoses (Figure 4, Item 2) away from cab harness access panel (Figure 4, Item 3).

Figure 4. Hose and Harness Conduit.

0227

0227-4

TM 5-2410-241-23-3

0227

REMOVAL CONTINUED 10. Carefully pull rear washer hose (Figure 5, Item 1) from column through access hole (Figure 5, Item 2).

Figure 5. Left Column Access Hole. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Position rear washer hose (Figure 5, Item 1) down column through access hole (Figure 5, Item 2).

0227

000227

000227

0227-5

TM 5-2410-241-23-3

0227

INSTALLATION CONTINUED 2. Install washer hoses (Figure 6, Item 2) through cab harness access panel (Figure 6, Item 3). 3. Install conduit (Figure 6, Item 1) on washer hoses (Figure 6, Item 2) and cab harness access panel (Figure 6, Item 3). 4. Position cab harness access panel (Figure 6, Item 3) on cab. 5. Install four new rivets (Figure 6, Item 4) on cab harness access panel (Figure 6, Item 3).

Figure 6. Hose and Harness Conduit.

0227

0227-6

TM 5-2410-241-23-3

0227

INSTALLATION CONTINUED

NOTE
Connect hoses as noted during removal. Install hoses as noted during removal. Install tiedown straps as noted during removal.

6. Route hose and harness conduit (Figure 7, Item 3) to pivot shaft oil reservoir compartment (Figure 7, Item 2). 7. Install new tiedown straps (Figure 7, Item 4) on hose and harness conduit (Figure 7, Item 3). 8. Connect cab wiring harness connector (Figure 7, Item 6) and four washer hoses (Figure 7, Item 5) to washer bottle (Figure 7, Item 1).

Figure 7. Washer Electrical Harness and Hoses.

0227

0227-7

TM 5-2410-241-23-3

0227

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. Install tiedown straps as noted during removal.

9. Install new tiedown straps (Figure 8, Item 1) on rear washer hose (Figure 8, Item 3) to access hole (Figure 8, Item 2) above left rear column.

Figure 8. Rear Washer Hose.

0227

0227-8

TM 5-2410-241-23-3

0227

INSTALLATION CONTINUED

NOTE
Connect hoses as noted during removal. Install hoses as noted during removal.

10. Connect rear washer hose (Figure 9, Item 1) to nipple (Figure 9, Item 2).

Figure 9. Rear Wiper. END OF TASK FOLLOW-ON TASKS 1. Install headliner, panels, and rear view mirror (WP 0229) 2. Install ROPS (WP 0225). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0227

000227

0227-9/(10 blank)

14 TM 5-2410-241-23-3 0228

FIELD MAINTENANCE INSTRUCTIONS DOOR WASHER HOSES REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 2 8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Drill-driver, Battery Rechargeable, 1/2 (S0188) (WP 0302, Item 68) Drill Set, Twist 1/16 to 1/2 (S0194) (WP 0302, Item 68) Tool Kit, Blind Fastener, Installation (S0700) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) Tag, Marker (WP 0303, Item 34) Rivet (4) 0 0 0 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Headliner, interior trim panels removed (WP 0229) ROPS removed (WP 0225) Drawing Required TM 5-2410-241-24P, Figure 107, 113, 114 Estimated Time to Complete 3.5 Hr 0 0 0 0 0 0 0 0 0 0

0228-1

TM 5-2410-241-23-3

0228

REMOVAL

000228

NOTE
The following procedure removes washer hose from right door. Use the same procedure to remove washer hose from left door. 1. Loosen two setscrews (Figure 1, Item 6) and remove door lock handle (Figure 1, Item 5) from door assembly (Figure 1, Item 10). 2. Remove two bolts (Figure 1, Item 7) and interior door handle (Figure 1, Item 8) from door assembly (Figure 1, Item 10). 3. Remove two caps (Figure 1, Item 2) from grip handle (Figure 1, Item 3). 4. Remove two bolts (Figure 1, Item 1) and grip handle (Figure 1, Item 3) from door assembly (Figure 1, Item 10). 5. Remove six bolts (Figure 1, Item 9) and interior cover (Figure 1, Item 4) from door assembly (Figure 1, Item 10).

Figure 1. Door.

0228

0228-2

TM 5-2410-241-23-3

0228

REMOVAL CONTINUED

NOTE
Tag and mark hose connections to aid installation. Note hose routing to aid installation.

6. Disconnect hose (Figure 2, Item 1) from nipple (Figure 2, Item 2).

Figure 2. Door Wiper.

0228

0228-3

TM 5-2410-241-23-3

0228

REMOVAL CONTINUED

NOTE
Note hose routing to aid installation. Note location of tiedown straps to aid installation.

7. Remove and discard tiedown straps (Figure 3, Item 2) from door washer hose (Figure 3, Item 1) and access hole (Figure 3, Item 3) above left rear column. 8. Remove conduit (Figure 3, Item 4) from door washer hose (Figure 3, Item 1).

Figure 3. Door Washer Hose.

0228

0228-4

TM 5-2410-241-23-3

0228

REMOVAL CONTINUED

NOTE
Tag and mark hose connections to aid installation. Note hose routing to aid installation. Note location of tiedown straps to aid installation.

9. Disconnect cab wiring harness connector (Figure 4, Item 6) and four washer hoses (Figure 4, Item 5) from washer bottle (Figure 4, Item 1). 10. Remove and discard tiedown straps (Figure 4, Item 4) from hose and harness conduit (Figure 4, Item 3). 11. Remove hose and harness conduit (Figure 4, Item 3) from pivot shaft oil reservoir compartment (Figure 4, Item 2).

Figure 4. Washer Electrical Harness and Hoses.

0228

0228-5

TM 5-2410-241-23-3

0228

REMOVAL CONTINUED 12. Remove four rivets (Figure 5, Item 4) from cab harness access panel (Figure 5, Item 3). Discard rivets. 13. Position cab harness access panel (Figure 5, Item 3) away from cab. 14. Remove conduit (Figure 5, Item 1) from cab harness access panel (Figure 5, Item 3) and washer hoses (Figure 5, Item 2). 15. Position washer hoses (Figure 5, Item 2) away from cab harness access panel (Figure 5, Item 3).

Figure 5. Hose and Harness Conduit.

0228

0228-6

TM 5-2410-241-23-3

0228

REMOVAL CONTINUED 16. Carefully pull door washer hose (Figure 6, Item 2) from column through access hole (Figure 6, Item 1).

Figure 6. Left Column Access Hole. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0228

000228

0228-7

TM 5-2410-241-23-3

0228

INSTALLATION

000228

NOTE
The following procedure installs washer hose on right door. Use the same procedure to install the washer hose on left door. 1. Position door washer hose (Figure 7, Item 2) down column through access hole (Figure 7, Item 1).

Figure 7. Left Column Access Hole.

0228

0228-8

TM 5-2410-241-23-3

0228

INSTALLATION CONTINUED 2. Install washer hoses (Figure 8, Item 2) through cab harness access panel (Figure 8, Item 3). 3. Install conduit (Figure 8, Item 1) on washer hoses (Figure 8, Item 2) and cab harness access panel (Figure 8, Item 3). 4. Position cab harness access panel (Figure 8, Item 3) on cab. 5. Install four new rivets (Figure 8, Item 4) on cab harness access panel (Figure 8, Item 3).

Figure 8. Hose and Harness Conduit.

0228

0228-9

TM 5-2410-241-23-3

0228

INSTALLATION CONTINUED

NOTE
Connect hoses as noted during removal. Install hoses as noted during removal. Install tiedown straps as noted during removal.

6. Route hose and harness conduit (Figure 9, Item 3) to pivot shaft oil reservoir compartment (Figure 9, Item 2). 7. Install new tiedown straps (Figure 9, Item 4) on hose and harness conduit (Figure 9, Item 3). 8. Connect cab wire harness connector (Figure 9, Item 6) and four washer hoses (Figure 9, Item 5) to washer bottle (Figure 9, Item 1).

Figure 9. Washer Electrical Harness and Hoses.

0228

0228-10

TM 5-2410-241-23-3

0228

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. Install tiedown straps as noted during removal.

9. Install conduit (Figure 10, Item 4) on door washer hose (Figure 10, Item 1). 10. Install new tiedown straps (Figure 10, Item 2) along door washer hose (Figure 10, Item 1) from door to access hole (Figure 10, Item 3) above left rear column.

Figure 10. Door Washer Hose.

0228

0228-11

TM 5-2410-241-23-3

0228

INSTALLATION CONTINUED

NOTE
Connect hoses as noted during removal. Install hoses as noted during removal.

11. Connect door washer hose (Figure 11, Item 1) to nipple (Figure 11, Item 2).

Figure 11. Door Wiper.

0228

0228-12

TM 5-2410-241-23-3

0228

INSTALLATION CONTINUED 12. Install interior cover (Figure 12, Item 4) and six bolts (Figure 12, Item 9) on door assembly (Figure 12, Item 10). 13. Install grip handle (Figure 12, Item 3) and two bolts (Figure 12, Item 1) on door assembly (Figure 12, Item 10). 14. Install two caps (Figure 12, Item 2) on grip handle (Figure 12, Item 3). 15. Install interior door handle (Figure 12, Item 8) and two bolts (Figure 12, Item 7) on door assembly (Figure 12, Item 10). 16. Install door lock handle (Figure 12, Item 5) on door assembly (Figure 12, Item 10) and tighten two setscrews (Figure 12, Item 6).

Figure 12. Door. END OF TASK FOLLOW-ON TASKS 1. Install headliner, panels, and rear view mirror (WP 0229). 2. Install ROPS (WP 0225). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0228

000228

0228-13/(14 blank)

20 TM 5-2410-241-23-3 0229

FIELD MAINTENANCE INSTRUCTIONS HEADLINER AND INTERIOR TRIM PANELS REPLACEMENT Front Wiper Motor Trim Panel Removal, Front Headliner Removal, Rear Wiper Motor Trim Panel Removal, Rear Headliner Removal, Speaker Removal, Wiper Control Plate Removal, Cab Lamp Removal, Right Rear and Front Pillar Liners Removal, Left-Hand Pillar Liner Removal, Cleaning and Inspection, Left-Hand Pillar Liner Installation, Right-Hand Pillar Liner Installation, Cab Lamp Installation, Wiper Control Plate Installation, Speaker Installation, Rear Headliner Installation, Rear Wiper Motor Trim Panel Installation, Front Headliner Installation, Front Wiper Motor Trim Panel Installation
0 2 2 9

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Extension, 1/4 Drive, 3" Long (S04037) (WP 0302, Item 68) Handle, Ratchet, 1/4 Drive 4 Long (S0436) (WP 0302, Item 68) Screwdriver Attachment Torx 1/4 Drive T-20 (S0285) (WP 0302, Item 68) Screwdriver Attachment, Torx 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) FRONT WIPER MOTOR TRIM PANEL REMOVAL 1. Remove two bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and mirror (Figure 1, Item 3) from machine. 0 0 0 References 0 0 0 0 0 0 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 106, 108 Estimated Time to Complete 1.0 Hr 0 0 0 0 0 0 0 0
000229

Materials/Parts - Continued Tiedown Strap (WP 0303, Item 36) RH pillar liner Lockwasher

0 0 0 0

Figure 1. Rearview Mirror.

0229

0229-1

TM 5-2410-241-23-3

0229

FRONT WIPER MOTOR TRIM PANEL REMOVAL CONTINUED 2. Remove two bolts (Figure 2, Item 1) and cover (Figure 2, Item 2) from machine.

Figure 2. Front Wiper Motor Cover. END OF TASK FRONT HEADLINER REMOVAL 1. Remove front wiper motor trim panel as described in this work package. 2. Remove four bolts (Figure 3, Item 1), plate (Figure 3, Item 2), and front headliner (Figure 3, Item 3) from machine.

0229

000229

Figure 3. Headliner and Plate. END OF TASK

0229

0229-2

TM 5-2410-241-23-3

0229

REAR WIPER MOTOR TRIM PANEL REMOVAL

000229

NOTE
Two of four bolts are hidden under headliner. Remove four bolts (Figure 4, Item 1) and cover (Figure 4, Item 2) from machine.

Figure 4. Wiper Motor Cover. END OF TASK

0229

0229-3

TM 5-2410-241-23-3

0229

REAR HEADLINER REMOVAL 1. Remove rear wiper motor trim panel as described in this work package. 2. Remove four bolts (Figure 5, Item 1), and plate (Figure 5, Item 2) from machine.

000229

Figure 5. Plate.

0229

NOTE
Tag electrical connector to aid installation. 3. Position back of headliner (Figure 6, Item 2) aside and disconnect rear wiper motor electrical connector (Figure 6, Item 1).

Figure 6. Rear Wiper Motor Connector.

0229

0229-4

TM 5-2410-241-23-3

0229

REAR HEADLINER REMOVAL CONTINUED

NOTE
Tag electrical connector to aid installation. 4. Disconnect two electrical connectors (Figure 7, Item 1). 5. Remove and discard tiedown strap (Figure 7, Item 3). 6. Remove rear headliner (Figure 7, Item 2) from machine.

Figure 7. Rear Headliner Connectors.

0229

0229-5

TM 5-2410-241-23-3

0229

REAR HEADLINER REMOVAL CONTINUED Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

7. Disconnect 21 electrical connectors (Figure 8, Item 1) from four wiper control switches (Figure 8, Item 2). 8. Remove tiedown straps (Figure 8, Item 3) from wiper control plate assembly (Figure 8, Item 4). Discard tiedown straps. 9. Disconnect two electrical connectors (Figure 8, Item 6) from speaker (Figure 8, Item 5). 10. Disconnect two electrical connectors (Figure 8, Item 9) from speaker (Figure 8, Item 10). 11. Disconnect electrical connectors (Figure 8, Item 13) from light electrical connectors (Figure 8, Item 12). 12. Remove tiedown straps (Figure 8, Item 11) from harness (Figure 8, Item 8) and headliner (Figure 8, Item 7). 13. Remove harness (Figure 8, Item 8) from headliner (Figure 8, Item 7).

Figure 8. Headliner Harness. END OF TASK

0229

0229-6

TM 5-2410-241-23-3

0229

SPEAKER REMOVAL

000229

NOTE
The following step removes one speaker. Repeat step for other speaker. Remove four screws (Figure 9, Item 1) and speaker (Figure 9, Item 2) from headliner (Figure 9, Item 3).

Figure 9. Speaker. END OF TASK WIPER CONTROL PLATE REMOVAL 1. Remove four bolts (Figure 10, Item 1) and wiper control plate (Figure 10, Item 2) from headliner (Figure 10, Item 3). 2. Remove four speed nuts (Figure 10, Item 4) from headliner (Figure 10, Item 3).

0229

000229

Figure 10. Wiper Control Plate Assembly. END OF TASK

0229

0229-7

TM 5-2410-241-23-3

0229

CAP LAMP REMOVAL 1. Remove two covers (Figure 11, Items 1 and 2) from cab lamp assembly.

000229

Figure 11. Cab Lamp Assembly. 2. Remove three screws (Figure 12, Item 1) and cab lamp assembly (Figure 12, Item 2) from headliner (Figure 12, Item 3). 3. Remove three speed nuts (Figure 12, Item 4) from headliner (Figure 12, Item 3).

0229

Figure 12. Cab Lamp Screws. END OF TASK

0229

0229-8

TM 5-2410-241-23-3

0229

RIGHT REAR AND FRONT PILLAR LINERS REMOVAL Right rear and front pillar liners are glued to pillar and cannot be installed once removed. Right rear pillar liner shown. Front pillar liners are similar.

000229

Remove right-hand pillar liner (Figure 13, Item 1) from machine. Discard right-hand pillar liner.

Figure 13. Right-hand Pillar Liner. END OF TASK

0229

0229-9

TM 5-2410-241-23-3

0229

LEFT-HAND PILLAR LINER REMOVAL Remove bolt (Figure 14, Item 1), coat-hook (Figure 14, Item 2), and left-hand pillar liner (Figure 14, Item 3) from machine. Discard left-hand pillar liner.

000229

Figure 14. Left-hand Pillar Liner. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK LEFT-HAND PILLAR LINER INSTALLATION Position left-hand pillar liner (Figure 14, Item 3) on machine and install coat-hook (Figure 14, Item 2) and bolt (Figure 14, Item 1). END OF TASK

0229

000229

000229

0229-10

TM 5-2410-241-23-3

0229

RIGHT-HAND PILLAR LINER INSTALLATION Install new right-hand pillar liner (Figure 15, Item 1) and install on machine.

000229

Figure 15. Right-hand Pillar Liner. END OF TASK CAB LAMP INSTALLATION 1. Install three speed nuts (Figure 16, Item 4) on headliner (Figure 16, Item 3). 2. Install cab lamp assembly (Figure 16, Item 2) and three screws (Figure 16, Item 1) on headliner (Figure 16, Item 3).

0229

000229

Figure 16. Cab Lamp Screws.

0229

0229-11

TM 5-2410-241-23-3

0229

CAB LAMP INSTALLATION 3. Install two covers (Figure 17, Items 1 and 2) on cab lamp assembly.

000229

Figure 17. Cab Lamp Assembly. END OF TASK WIPER CONTROL PLATE INSTALLATION 1. Install four speed nuts (Figure 18, Item 4) on headliner (Figure 18, Item 3). 2. Install four bolts (Figure 18, Item 1) on wiper control plate (Figure 18, Item 2).

0229

000229

Figure 18. Wiper Control Plate Assembly. END OF TASK

0229

0229-12

TM 5-2410-241-23-3

0229

SPEAKER INSTALLATION

000229

NOTE
The following step installs one speaker. Repeat step for other speaker. Install speaker (Figure 19, Item 2) and four screws (Figure 19, Item 1 on headliner (Figure 19, Item 3).

Figure 19. Speaker. END OF TASK

0229

0229-13

TM 5-2410-241-23-3

0229

REAR HEADLINER INSTALLATION Route harness as noted during removal. Install electrical connections as noted during removal. Install tiedown straps as noted during removal.

000229

1. Install harness (Figure 20, Item 8) on headliner (Figure 20, Item 7). 2. Install new tiedown straps (Figure 20, Item 11) on harness (Figure 20, Item 8) and headliner (Figure 20, Item 7). 3. Connect electrical connectors (Figure 20, Item 13) no light electrical connectors (Figure 20, Item 12). 4. Connect two electrical connectors (Figure 20, Item 9) on speaker (Figure 20, Item 10). 5. Connect two electrical connectors (Figure 20, Item 6) on speaker (Figure 20, Item 5). 6. Install three tiedown straps (Figure 20, Item 3) on wiper control plate assembly (Figure 20, Item 4). 7. Connect 21 electrical connectors (Figure 20, Item 1) on four wiper control switches (Figure 20, Item 2).

Figure 20. Headliner Harness.

0229

0229-14

TM 5-2410-241-23-3

0229

REAR HEADLINER INSTALLATION CONTINUED 8. Install rear headliner (Figure 21, Item 2) on machine. 9. Install new tiedown strap (Figure 21, Item 3).

NOTE
Install electrical connector as tagged during removal. 10. Connect two electrical connectors (Figure 21, Item 1).

Figure 21. Rear Headliner Connectors.

0229

0229-15

TM 5-2410-241-23-3

0229

REAR HEADLINER INSTALLATION CONTINUED

NOTE
Install electrical connector as tagged during removal. 11. Position back of headliner (Figure 22, Item 2) aside and connect rear wiper motor electrical connector (Figure 22, Item 1).

Figure 22. Rear Wiper Motor Connector. 12. Position plate (Figure 23, Item 2) and install four bolts (Figure 23, Item 1). 13. Install rear wiper motor trim panel as described in this work package.

0229

Figure 23. Plate. END OF TASK

0229

0229-16

TM 5-2410-241-23-3

0229

REAR WIPER MOTOR TRIM PANEL INSTALLATION

000229

NOTE
Two of four bolts are hidden under headliner. Position cover (Figure 24, Item 2) on machine and install four bolts (Figure 24, Item 1).

Figure 24. Wiper Motor Cover. END OF TASK

0229

0229-17

TM 5-2410-241-23-3

0229

FRONT HEADLINER INSTALLATION 1. Install front headliner (Figure 25, Item 3), plate (Figure 25, Item 2) and four bolts (Figure 25, Item 1) on machine. 2. Install front wiper motor trim panel as described in this work package.

000229

Figure 25. Headliner and Plate. END OF TASK FRONT WIPER MOTOR TRIM PANEL INSTALLATION 1. Install cover (Figure 26, Item 2) and two bolts (Figure 26, Item 1) on machine.

0229

000229

Figure 26. Front Wiper Motor Cover.

0229

0229-18

TM 5-2410-241-23-3

0229

FRONT WIPER MOTOR TRIM PANEL INSTALLATION CONTINUED 2. Position mirror (Figure 27, Item 3) on machine, install two washers (Figure 27, Item 2), and bolts (Figure 27, Item 1).

Figure 27. Rearview Mirror. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0229

000229

0229-19/(20 blank)

4 TM 5-2410-241-23-3 0230

FIELD MAINTENANCE INSTRUCTIONS FRONT FLOOR PLATE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 3 0

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. Remove floor mat (Figure 1, Item 1) from floor plate (Figure 1, Item 2). 0 0 0 0 0 0
000230

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 125 Estimated Time to Complete 1.0 Hr

0 0 0 0 0 0

Figure 1. Floor Mat.

0230

0230-1

TM 5-2410-241-23-3

0230

REMOVAL CONTINUED 2. Remove four bolts (Figure 2, Item 3), washers (Figure 2, Item 4), and two supports (Figure 2, Item 2) from floor plate (Figure 2, Item 1). 3. Remove ten bolts (Figure 2, Item 8), washers (Figure 2, Item 9), and floor plate (Figure 2, Item 1) from platform (Figure 2, Item 10). 4. Remove eight bolts (Figure 2, Item 6), washers (Figure 2, Item 7), and floor plate (Figure 2, Item 5) from platform (Figure 2, Item 10).

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

0230

000230

0230-2

TM 5-2410-241-23-3

0230

INSTALLATION 1. Install floor plate (Figure 2, Item 5), eight washers (Figure 2, Item 7), and bolts (Figure 2, Item 6) on platform (Figure 2, Item 10). 2. Install floor plate (Figure 2, Item 1), ten washers (Figure 2, Item 9), and bolts (Figure 2, Item 8) on platform (Figure 2, Item 10). 3. Install two supports (Figure 2, Item 2), four washers (Figure 2, Item 4), and bolts (Figure 2, Item 3) on floor plate (Figure 2, Item 1). 4. Install floor mat (Figure 3, Item 1) on floor plate (Figure 3, Item 2).

000230

Figure 3. Floor Mat. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0230

000230

0230-3/(4 blank)

4 TM 5-2410-241-23-3 0231

FIELD MAINTENANCE INSTRUCTIONS REAR FLOOR PLATE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 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 1. Release buckle on tiedown strap (Figure 1, Item 1). 2. Remove floor mat (Figure 1, Item 2) from machine. 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Seat suspension removed (WP 0248) Drawing Required TM 5-2410-241-24P, Figure 126 Estimated Time to Complete 2.5 Hr
000231

0 0 0 0 0 0 0

Figure 1. Floor Mat.

0231

0231-1

TM 5-2410-241-23-3

0231

REMOVAL CONTINUED 3. Remove 12 bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and floor plate (Figure 2, Item 1) from platform (Figure 2, Item 4).

Figure 2. Rear Floor Plate. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install floor plate (Figure 2, Item 1), 12 washers (Figure 2, Item 3), and bolts (Figure 2, Item 2) on platform (Figure 2, Item 4).

0231

000231

000231

0231-2

TM 5-2410-241-23-3

0231

INSTALLATION CONTINUED 2. Install floor mat (Figure 3, Item 2). 3. Buckle tiedown strap (Figure 3, Item 1).

Figure 3. Rear Floor Plate. END OF TASK FOLLOW-ON TASKS 1. Install seat suspension (WP 0248). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0231

000231

0231-3/(4 blank)

4 TM 5-2410-241-23-3 0232

FIELD MAINTENANCE INSTRUCTIONS HEADLINER HARNESS REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 3 2

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 0 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Rear headliner removed (WP 0229) Drawing Required TM 5-2410-241-24P, Figure 108 Estimated Time to Complete 1.5 Hr 0 0 0 0 0 0 0

0232-1

TM 5-2410-241-23-3

0232

REMOVAL

000232

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation. Note number and location of tiedown straps to aid installation.

1. Disconnect 21 electrical connectors (Figure 1, Item 1) from four wiper control switches (Figure 1, Item 2). 2. Remove tiedown straps (Figure 1, Item 3) from wiper control plate assembly (Figure 1, Item 4). Discard tiedown straps. 3. Disconnect two electrical connectors (Figure 1, Item 6) from speaker (Figure 1, Item 5). 4. Disconnect two electrical connectors (Figure 1, Item 9) from speaker (Figure 1, Item 10). 5. Disconnect electrical connectors (Figure 1, Item 13) from light electrical connectors (Figure 1, Item 12). 6. Remove tiedown straps (Figure 1, Item 11) from harness (Figure 1, Item 8) and headliner (Figure 1, Item 7). Discard tiedown straps. 7. Remove harness (Figure 1, Item 8) from headliner (Figure 1, Item 7).

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

0232

000232

0232-2

TM 5-2410-241-23-3

0232

INSTALLATION

000232

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

1. Install harness (Figure 1, Item 8) on headliner (Figure 1, Item 7). 2. Install new tiedown straps (Figure 1, Item 11) on harness (Figure 1, Item 8) and headliner (Figure 1, Item 7). 3. Connect electrical connectors (Figure 1, Item 13) on light electrical connectors (Figure 1, Item 12). 4. Connect two electrical connectors (Figure 1, Item 9) on speaker (Figure 1, Item 10). 5. Connect two electrical connectors (Figure 1, Item 6) on speaker (Figure 1, Item 5). 6. Install new tiedown straps (Figure 1, Item 3) on wiper control plate assembly (Figure 1, Item 4). 7. Connect 21 electrical connectors (Figure 1, Item 1) on four wiper control switches (Figure 1, Item 2). END OF TASK FOLLOW-ON TASKS 1. Install rear headliner (WP 0229). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000232

0232-3/(4 blank)

4 TM 5-2410-241-23-3 0233

FIELD MAINTENANCE INSTRUCTIONS


0 2 3 3

CAB OVERHEAD INTERIOR LAMP 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) Light bulb References WP 0295 REMOVAL 1. Remove two covers (Figure 1, Items 1 and 2) from light base (Figure 1, Item 3). 0 0 0 0 0 0 0 0
000233

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 108 Estimated Time to Complete 0.5 Hr

0 0 0 0 0 0

Figure 1. Cab Lamp Assembly.

0233

0233-1

TM 5-2410-241-23-3

0233

REMOVAL CONTINUED 2. Remove light bulb (Figure 2, Item 3) from light base (Figure 2, Item 4). Discard bulb. 3. Remove three screws (Figure 2, Item 1) from cab lamp assembly (Figure 2, Item 2).

Figure 2. Cab Lamp Screws.

0233

NOTE
Tag and mark all electrical connectors to aid installation. 4. Position cab lamp assembly (Figure 3, Item 3) from headliner (Figure 3, Item 5). 5. Disconnect light electrical connector (Figure 3, Item 1) from harness connector (Figure 3, Item 2). 6. Remove three speed nuts (Figure 3, Item 5) from headliner (Figure 3, Item 4).

Figure 3. Electrical Connector. END OF TASK

0233

0233-2

TM 5-2410-241-23-3

0233

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

000233

000233

NOTE
Install electrical connector as tagged during removal. 1. Install three speed nuts (Figure 3, Item 5) on headliner (Figure 3, Item 4). 2. Connect light electrical connector (Figure 3, Item 1) on harness connector (Figure 3, Item 2). 3. Position cab lamp assembly (Figure 3, Item 3) on headliner (Figure 3, Item 5). 4. Install three screws (Figure 2, Item 1) on cab lamp assembly (Figure 2, Item 2). 5. Install new light bulb (Figure 2, Item 3) on light base (Figure 2, Item 4).

Figure 4. Cab Lamp Assembly. 6. Install two covers (Figure 4, Items 1 and 2) on light base (Figure 4, Items 3). END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0233

000233

0233-3/(4 blank)

6 TM 5-2410-241-23-3 0234

FIELD MAINTENANCE INSTRUCTIONS


0 2 3 4

WIPER CONTROL PLATE AND SWITCHES 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) Lockwasher (4) References WP 0295 REMOVAL 1. Remove four screws (Figure 1, Item 1) from wiper control plate (Figure 1, Item 2). 0 0 0 0 0 0 0 0 0
000234

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 108 Estimated Time to Complete 1.0 Hr

0 0 0 0 0 0

Figure 1. Wiper Control Plate Assembly.

0234

0234-1

TM 5-2410-241-23-3

0234

REMOVAL CONTINUED

NOTE
Tag all electrical connectors to aid installation. 2. Position wiper control panel (Figure 2, Item 1) from headliner (Figure 2, Item 3). 3. Disconnect 21 harness connectors (Figure 2, Item 5) from wiper control panel (Figure 2, Item 1). 4. Remove tiedown straps (Figure 2, Item 4) from wiring harness (Figure 2, Item 6) and wiper control panel (Figure 2, Item 1). Discard tiedown straps. 5. Remove wiper control panel (Figure 2, Item 1) from machine. 6. Remove four speed nuts (Figure 2, Item 2) from headliner (Figure 2, Item 3).

Figure 2. Wiper Control Wiring Harness.

0234

0234-2

TM 5-2410-241-23-3

0234

REMOVAL CONTINUED

NOTE
Steps 7 - 8 will remove one wiper switch. Follow same steps for each additional wiper switch. 7. Remove setscrew (Figure 3, Item 2) and knob (Figure 3, Item 3) from wiper control plate (Figure 3, Item 1). 8. Remove nut (Figure 3, Item 5), lockwasher (Figure 3, Item 4), and wiper switch (Figure 3, Item 6) from wiper control plate (Figure 3, Item 1). Discard lockwasher.

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

0234

000234

000234

NOTE
Steps 1 - 2 will install one wiper switch. Follow same steps for each additional wiper switch. 1. Install wiper switch (Figure 3, Item 6), new lockwasher (Figure 3, Item 4), and nut (Figure 3, Item 5) on wiper control plate (Figure 3, Item 1). 2. Install knob (Figure 3, Item 3) and setscrew (Figure 3, Item 2) on wiper control plate (Figure 3, Item 1).

0234-3

TM 5-2410-241-23-3

0234

INSTALLATION CONTINUED 3. Install four speed nuts (Figure 4, Item 2) on headliner (Figure 4, Item 3). 4. Position wiper control panel (Figure 4, Item 1) on wiring harness (Figure 4, Item 6). 5. Install new tiedown straps (Figure 4, Item 4) on wiring harness (Figure 4, Item 6) and wiper control panel (Figure 4, Item 1).

NOTE
Install all electrical connectors as noted during removal. 6. Connect 21 harness connectors (Figure 4, Item 5) on wiper control panel (Figure 4, Item 1) 7. Position wiper control panel (Figure 4, Item 1) on headliner (Figure 4, Item 3).

Figure 4. Wiper Control Wiring Harness.

0234

0234-4

TM 5-2410-241-23-3

0234

INSTALLATION CONTINUED 8. Install four screws (Figure 5, Item 1) on wiper control plate (Figure 5, Item 2).

Figure 5. Wiper Control Plate Assembly. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0234

000234

0234-5/(6 blank)

4 TM 5-2410-241-23-3 0235

FIELD MAINTENANCE INSTRUCTIONS REARVIEW MIRROR REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 3 5

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. Remove two bolts (Figure 1, Item 2), washers (Figure 1, Item 1), and mirror (Figure 1, Item 3) from machine. 0 0 0 0 0 0
000235

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 106 Estimated Time to Complete 0.4 Hr

0 0 0 0 0 0

Figure 1. Rearview Mirror.

0235

0235-1

TM 5-2410-241-23-3

0235

REMOVAL CONTINUED 2. Remove knob (Figure 2, Item 2), bolt (Figure 2, Item 4), and mirror (Figure 2, Item 3) from mount (Figure 2, Item 1).

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

0235

000235

000235

1. Install mirror (Figure 2, Item 3), bolt (Figure 2, Item 4), and knob (Figure 2, Item 2) on mount (Figure 2, Item 1).

0235-2

TM 5-2410-241-23-3

0235

INSTALLATION CONTINUED 2. Install mirror (Figure 3, Item 3), two washers (Figure 3, Item 1), and bolts (Figure 3, Item 2) on machine.

000235

Figure 3. Rearview Mirror. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0235

000235

0235-3/(4 blank)

4 TM 5-2410-241-23-3 0236

FIELD MAINTENANCE INSTRUCTIONS MESSENGER REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 3 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) References WP 0295
0

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

Drawing Required
0

TM 5-2410-241-24P, Figure 128 Estimated Time to Complete

0.5 Hr
0 0

0236-1

TM 5-2410-241-23-3

0236

REMOVAL

000236

NOTE
Tag and mark all electrical connectors to aid installation. 1. Disconnect connector (Figure 1, Item 7) from machine. 2. Remove tiedown straps (Figure 1, Item 9) from harness (Figure 1, Item 8). Discard tiedown straps. 3. Remove four bolts (Figure 1, Item 4), washers (Figure 1, Item 3), and messenger bracket (Figure 1, Item 1) from machine. 4. Disconnect connector (Figure 1, Item 6) from messenger (Figure 1, Item 2). Set harness (Figure 1, Item 8) aside. 5. Remove four screws (Figure 1, Item 5) and messenger (Figure 1, Item 2) from messenger bracket (Figure 1, Item 1).

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

0236

000236

0236-2

TM 5-2410-241-23-3

0236

INSTALLATION

000236

NOTE
Install electrical connectors as noted during removal. 1. Install messenger (Figure 1, Item 2) and four screws (Figure 1, Item 5) on messenger bracket (Figure 1, Item 1). 2. Install harness (Figure 1, Item 8) and connect connector (Figure 1, Item 6) on messenger (Figure 1, Item 2). 3. Install messenger bracket (Figure 1, Item 1), four washers (Figure 1, Item 3), and bolts (Figure 1, Item 4) on machine. 4. Install new tiedown straps (Figure 1, Item 9) on harness (Figure 1, Item 8). 5. Connect connector (Figure 1, Item 7) on machine. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000236

0236-3/(4 blank)

30 TM 5-2410-241-23-3 0237

FIELD MAINTENANCE
0 2 3 7

STEERING, TRANSMISSION CONTROL AND PARKING BRAKE SWITCH REPLACEMENT Removal, Disassembly, Cleaning and Inspection, Assembly, 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) Cotter pin (3) Gasket Lockwasher (3) O-ring Seal (2) 0 0 0 0 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Front floor plate removed (WP 0230) Rear floor plate removed (WP 0231) Left platform access removed (WP 0207) Left upper left panel removed (WP 0207) Left arm rest removed (WP 0207) Drawing Required TM 5-2410-241-24P, Figure 123 Estimated Time to Complete 6.0 Hr 0 0 0 0 0 0 0 0 0 0 0 0 0

0237-1

TM 5-2410-241-23-3

0237

REMOVAL 1. Remove retainer (Figure 1, Item 1) from steering control rod (Figure 1, Item 4). 2. Remove pin (Figure 1, Item 2) and disconnect steering control rod (Figure 1, Item 4) from lever (Figure 1, Item 3).

000237

NOTE
Note lever orientation on shaft to aid installation. 3. Loosen bolt (Figure 1, Item 7) and remove lever (Figure 1, Item 3) and spacer (Figure 1, Item 5) from shaft (Figure 1, Item 6).

Figure 1. Steering Control Rod.

0237

0237-2

TM 5-2410-241-23-3

0237

REMOVAL CONTINUED

NOTE
Note location and quantity of tiedown straps to aid installation. Tag wiring harness to aid installation.

4. Remove tiedown straps (Figure 2, Item 4) from wiring harness (Figure 2, Item 10). Discard tiedown straps. 5. Disconnect four wiring harness connectors (Figure 2, Item 5) from wiring harness (Figure 2, Item 10).

NOTE
Secure grommets to ECM after removing bolts. 6. Remove two bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and bracket (Figure 2, Item 1) from ECM (Figure 2, Item 9). 7. Remove three bolts (Figure 2, Item 8), washers (Figure 2, Item 7), and steering control housing (Figure 2, Item 6) from machine.

Figure 2. Steering Control Housing. END OF TASK

0237

0237-3

TM 5-2410-241-23-3

0237

DISASSEMBLY 1. Remove three bolts (Figure 3, Item 1) and washers (Figure 3, Item 2) from main control housing (Figure 3, Item 3). 2. Loosen setscrew (Figure 3, Item 6) in collar (Figure 3, Item 8). 3. Place a punch or drift in hole (Figure 3, Item 7) of collar (Figure 3, Item 8) and strike with hammer in counterclockwise direction. Position collar away from bearing (Figure 3, Item 10).

000237

4. Remove two bolts (Figure 3, Item 4), washers (Figure 3, Item 5), and retainers (Figure 3, Item 9) from bearing (Figure 3, Item 10) and steering control housing (Figure 3, Item 12). 5. Remove steering control shaft (Figure 3, Item 11) from steering control housing (Figure 3, Item 12).

Figure 3. Control Console.

0237

0237-4

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 6. Remove bearing (Figure 4, Item 7), two retainers (Figure 4, Item 5) and collar (Figure 4, Item 6) from steering control shaft (Figure 4, Item 4). 7. Remove tiedown straps (Figure 4, Item 1) and wire loom (Figure 4, Item 2) from wiring harness (Figure 4, Item 3). Discard tiedown straps.

Figure 4. Shaft and Collar.

0237

0237-5

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 8. Remove four bolts (Figure 5, Item 1) and parking brake control (Figure 5, Item 2) from main control housing (Figure 5, Item 3). 9. Remove two bolts (Figure 5, Item 4), washers (Figure 5, Item 5), and main control housing (Figure 5, Item 3) from shaft (Figure 5, Item 9). 10. Remove bearing housing (Figure 5, Item 6) from bearing (Figure 5, Item 7) and main control housing (Figure 5, Item 3). 11. Remove O-ring (Figure 5, Item 8) from bearing housing (Figure 5, Item 6). Discard O-ring.

Figure 5. Main Control Housing.

0237

0237-6

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 12. Remove gasket (Figure 6, Item 2) from parking brake control (Figure 6, Item 1). Discard gasket.

Figure 6. Parking Brake Control. 13. Remove two bolts (Figure 7, Item 1) and parking brake switch (Figure 7, Item 2) from parking brake control cover (Figure 7, Item 3).

0237

Figure 7. Parking Brake Switch.

0237

0237-7

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 14. Remove two bolts (Figure 8, Item 2) and bracket (Figure 8, Item 6) from parking brake switch (Figure 8, Item 1).

NOTE
Note position of bolt to aid installation. 15. Remove bolt (Figure 8, Item 4) and nut (Figure 8, Item 5) from parking brake control cover (Figure 8, Item 3).

Figure 8. Parking Brake Switch Bracket.

0237

NOTE
Note orientation of shafts on plate to aid assembly. 16. Remove three cotter pins (Figure 9, Item 1), washers (Figure 9, Item 2), and plate (Figure 9, Item 3) from parking brake control cover (Figure 9, Item 4). Discard cotter pins.

Figure 9. Plate.

0237

0237-8

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED

NOTE
Note orientation of shaft and pin. 17. Rotate shaft (Figure 10, Item 2) and remove pin (Figure 10, Item 3) from shaft. Remove shaft from parking brake control cover (Figure 10, Item 1). 18. Rotate shaft (Figure 10, Item 5) and remove pin (Figure 10, Item 4) from shaft. Remove shaft from parking brake control cover (Figure 10, Item 1).

NOTE
Note position of bolts on plate to aid installation. 19. Remove two nuts (Figure 10, Item 6) and bolts (Figure 10, Item 7) from plate (Figure 10, Item 8). 20. Remove two seals (Figure 10, Item 11) from parking brake control cover (Figure 10, Item 1). Discard seals.

NOTE
Note position of knob and jam nut on shaft to aid installation. 21. Loosen jam nut (Figure 10, Item 10) and remove knob (Figure 10, Item 9) and jam nut from shaft (Figure 10, Item 5).

Figure 10. Shafts.

0237

0237-9

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 22. Remove three bolts (Figure 11, Item 2) and pull handle assembly (Figure 11, Item 3) and wiring harnesses (Figure 11, Item 5) from main control housing (Figure 11, Item 1). 23. Remove gasket (Figure 11, Item 4) from handle assembly (Figure 11, Item 3). Discard gasket.

Figure 11. Handle Assembly.

0237

0237-10

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 24. Remove bolt (Figure 12, Item 9), nut (Figure 12, Item 5), washer (Figure 12, Item 6), clip (Figure 12, Item 8), and wires (Figure 12, Item 4) from bracket (Figure 12, Item 7).

NOTE
Tag wires to aid installation. 25. Remove three bolts (Figure 12, Item 1), lockwashers (Figure 12, Item 2), and wires (Figure 12, Item 4) from backup alarm switch (Figure 12, Item 3). Discard lockwashers.

Figure 12. Backup Alarm Switch Connections.

0237

0237-11

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 26. Remove two bolts (Figure 13, Item 1) and backup alarm switch (Figure 13, Item 2) from handle assembly (Figure 13, Item 3).

Figure 13. Backup Alarm Switch.

0237

27. Remove two bolts (Figure 14, Item 2), washers (Figure 14, Item 3), and bracket (Figure 14, Item 1) from handle assembly (Figure 14, Item 4).

Figure 14. Sensor Bracket.

0237

0237-12

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 28. Remove bolt (Figure 15, Item 1), nut (Figure 15, Item 2), washer (Figure 15, Item 3) and forward/neutral/ reverse sensor (Figure 15, Item 4) from bracket (Figure 15, Item 5).

Figure 15. Forward/Neutral/Reverse Sensor. 29. Remove bolt (Figure 16, Item 6) and washer (Figure 16, Item 5) from bracket (Figure 16, Item 4). 30. Remove two bolts (Figure 16, Item 3), springs (Figure 16, Item 2), and detent assemblies (Figure 16, Item 1) from bracket (Figure 16, Item 4).

0237

Figure 16. Detent Assembly.

0237

0237-13

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED 31. If necessary, replace handle assembly (Figure 17, Item1).

Figure 17. Handle Assembly. 32. Remove bearing (Figure 18, Item 1) from main control housing (Figure 18, Item 2).

0237

Figure 18. Main Control Housing Bearing.

0237

0237-14

TM 5-2410-241-23-3

0237

DISASSEMBLY CONTINUED

NOTE
Note orientation of tab on lock assembly to aid installation. 33. Remove nut (Figure 19, Item 1) and tab (Figure 19, Item 2) from lock assembly (Figure 19, Item 6). 34. Open lock tab (Figure 19, Item 4) and remove nut (Figure 19, Item 5) and lock assembly (Figure 19, Item 6). from main control housing (Figure 19, Item 3).

Figure 19. Lock Assembly. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0237

000237

0237-15

TM 5-2410-241-23-3

0237

ASSEMBLY 1. Install lock assembly (Figure 20, Item 6), lock tab (Figure 20, Item 4), and nut (Figure 20, Item 5) on main control housing (Figure 20, Item 3). Secure lock tab.

000237

NOTE
Install tab on lock assembly as noted in removal. 2. Install tab (Figure 20, Item 2) and nut (Figure 20, Item 1) on lock assembly (Figure 20, Item 6).

Figure 20. Lock Assembly.

0237

0237-16

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 3. Install bearing (Figure 21, Item 1) on main control housing (Figure 21, Item 2).

Figure 21. Main Control Housing Bearing. 4. Install handle assembly (Figure 22, Item 1).

0237

Figure 22. Handle Assembly.

0237

0237-17

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 5. Install two detent assemblies (Figure 23, Item 1), springs (Figure 23, Item 2), and bolts (Figure 23, Item 3) on bracket (Figure 23, Item 4). 6. Install washer (Figure 23, Item 5) and bolt (Figure 23, Item 6) on bracket (Figure 23, Item 4).

Figure 23. Detent Assembly. 7. Install forward/neutral/reverse sensor (Figure 24, Item 4), bolt (Figure 24, Item 1), washer (Figure 24, Item 3), and nut (Figure 24, Item 2) on bracket (Figure 24, Item 5).

0237

Figure 24. Forward/Neutral/Reverse Sensor.

0237

0237-18

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 8. Install bracket (Figure 25, Item 1), two washers (Figure 25, Item 3), and bolts (Figure 25, Item 2) on handle assembly (Figure 25, Item 4).

Figure 25. Sensor Bracket. 9. Install backup alarm switch (Figure 26, Item 2) and two bolts (Figure 26, Item 1) on handle assembly (Figure 26, Item 3).

0237

Figure 26. Backup Alarm Switch.

0237

0237-19

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED

NOTE
Install wires as tagged during removal. 10. Install three wires (Figure 27, Item 4), new lockwashers (Figure 27, Item 2), and bolts (Figure 27, Item 1) on backup alarm switch (Figure 27, Item 3). 11. Install wires (Figure 27, Item 3), clip (Figure 27, Item 8), bolt (Figure 27, Item 9), washer (Figure 27, Item 6), and nut (Figure 27, Item 5) on bracket (Figure 27, Item 7).

Figure 27. Backup Alarm Switch Connections.

0237

0237-20

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 12. Install new gasket (Figure 28, Item 4) on handle assembly (Figure 28, Item 3). 13. Install three harnesses (Figure 28, Item 5), handle assembly (Figure 28, Item 3), and three bolts (Figure 28, Item 2) on main control housing (Figure 28, Item 1).

Figure 28. Handle Assembly.

0237

0237-21

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED

NOTE
Position jam nut and knob on shaft as noted in removal. 14. Install jam nut (Figure 29, Item 10) and knob (Figure 29, Item 9) on shaft (Figure 29, Item 5). Tighten jam nut. 15. Install two new seals (Figure 29, Item 11) on parking brake control cover (Figure 29, Item 1).

NOTE
Position bolts on plate as noted in removal. 16. Install two bolts (Figure 29, Item 7) and nuts (Figure 29, Item 6) on plate (Figure 29, Item 8). 17. Install shaft (Figure 29, Item 5) in parking brake control cover (Figure 29, Item 1), rotate shaft, and install pin (Figure 29, Item 4) on shaft. 18. Install shaft (Figure 29, Item 2) in parking brake control cover (Figure 29, Item 1), rotate shaft, and install pin (Figure 29, Item 3) on shaft.

Figure 29. Shafts.

0237

0237-22

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED

NOTE
Orientate shafts on plate as noted in removal. 19. Install plate (Figure 30, Item 3), three washers (Figure 30, Item 2), and new cotter pins (Figure 30, Item 1) on parking brake control cover (Figure 30, Item 4).

Figure 30. Plate.

0237

20. Install parking brake switch (Figure 31, Item 1) and two bolts (Figure 31, Item 2) on bracket (Figure 31, Item 6). 21. Install bolt (Figure 31, Item 4) and nut (Figure 31, Item 5) on parking brake control cover (Figure 31, Item 3).

Figure 31. Parking Brake Switch Bracket.

0237

0237-23

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 22. Install parking brake switch (Figure 32, Item 2) and two bolts (Figure 32, Item 1) on parking brake control cover (Figure 32, Item 3).

Figure 32. Parking Brake Switch. 23. Install new gasket (Figure 33, Item 2) on parking brake control (Figure 33, Item 1).

0237

Figure 33. Parking Brake Control.

0237

0237-24

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 24. Install new O-ring (Figure 34, Item 8) on bearing housing (Figure 34, Item 6). 25. Install bearing housing (Figure 34, Item 6) on bearing (Figure 34, Item 7) on main control housing (Figure 34, Item 3). 26. Install main control housing (Figure 34, Item 3), two washers (Figure 34, Item 5), and bolts (Figure 34, Item 4) on shaft (Figure 34, Item 9). 27. Install parking brake control (Figure 34, Item 2) and four bolts (Figure 34, Item 1) on main control housing (Figure 34, Item 3).

Figure 34. Main Control Housing.

0237

0237-25

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 28. Install wire loom (Figure 35, Item 2) and new tiedown straps (Figure 35, Item 1) on wiring harness (Figure 35, Item 3). 29. Install two retainers (Figure 35, Item 5), collar (Figure 35, Item 6), and bearing (Figure 35, Item 7) on shaft (Figure 35, Item 4).

Figure 35. Shaft and Collar.

0237

0237-26

TM 5-2410-241-23-3

0237

ASSEMBLY CONTINUED 30. Install steering control shaft (Figure 36, Item 11) on steering control housing (Figure 36, Item 12). 31. Install bearing (Figure 36, Item 10), two retainers (Figure 36, Item 9), washers (Figure 36, Item 5), and bolts (Figure 36, Item 4) on steering control housing (Figure 36, Item 12). 32. Place a punch or drift in hole (Figure 36, Item 7) of collar (Figure 36, Item 8) and strike with hammer in clockwise direction. 33. Tighten setscrew (Figure 36, Item 6) in collar (Figure 36, Item 8). 34. Install three washers (Figure 36, Item 2) and bolts (Figure 36, Item 1) on main control housing (Figure 36, Item 3).

Figure 36. Control Console. END OF TASK

0237

0237-27

TM 5-2410-241-23-3

0237

INSTALLATION 1. Install steering control housing (Figure 37, Item 6), three washers (Figure 37, Item 7), and bolts (Figure 37, Item 8), on machine.

000237

NOTE
Ensure grommets are in ECM before installing bolts. Install wiring harness connectors as tagged during removal.

2. Install bracket (Figure 37, Item 1), two washers (Figure 37, Item 3), and bolts (Figure 37, Item 2) on ECM (Figure 37, Item 9). 3. Connect four wiring harness connectors (Figure 37, Item 5) on harness (Figure 37, Item 10).

NOTE
Install tiedown straps as note in removal. 4. Install new tiedown straps (Figure 37, Item 4) on harness (Figure 37, Item 10).

Figure 37. Steering Control Housing.

0237

0237-28

TM 5-2410-241-23-3

0237

INSTALLATION CONTINUED

NOTE
Install lever on shaft as noted in removal. 5. Install spacer (Figure 38, Item 5) and lever (Figure 38, Item 3) on shaft (Figure 38, Item 6) and tighten bolt (Figure 38, Item 7). 6. Connect steering control rod (Figure 38, Item 4) to lever (Figure 38, Item 3) and install pin (Figure 38, Item 2). 7. Install retainer (Figure 38, Item 1) on steering control rod (Figure 38, Item 4).

Figure 38. Steering Control Rod. END OF TASK FOLLOW-ON TASKS 1. Install front floor plate (WP 0230). 2. Install rear floor plate (WP 0231). 3. Install left cover plate (WP 0207). 4. Install left upper left panel (WP 0207). 5. Install left armrest removed (WP 0207). 6. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0237

000237

0237-29/(30 blank)

6 TM 5-2410-241-23-3 0238

FIELD MAINTENANCE
0 2 3 8

STEERING CONTROL ROD REPLACEMENT Removal, Adjustment, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Cotter pin (2) Equipment Condition Machine parked (TM 5-2410-241-10) 0 0 0 0 0 0 Equipment Condition - Continued 0

Front floor plate removed (WP 0230) 0 Right platform access panel removed (WP 0208) 0 Drawing Required TM 5-2410-241-24P, Figure 123 Estimated Time to Complete 5.5 Hr 0 0 0 0
000238

REMOVAL

1. Remove retainer pin (Figure 1, Item 1) from yoke (Figure 1, Item 2) and steering and transmission control lever (Figure 1, Item 3). 2. Remove steering control rod (Figure 1, Item 4) from steering and transmission control lever (Figure 1, Item 3).

NOTE
Note steering control rod orientation to aid installation. 3. Remove retainer pin (Figure 1, Item 7) from yoke (Figure 1, Item 6) and control valve lever (Figure 1, Item 5). 4. Remove steering control rod (Figure 1, Item 4) from control valve lever (Figure 1, Item 5) and machine.

Figure 1. Steering Control Rod.

0238

0238-1

TM 5-2410-241-23-3

0238

REMOVAL CONTINUED 5. Remove two cotter pins (Figure 2, Item 1), washers (Figure 2, Item 2) and link (Figure 2, Item 3) from control valve (Figure 2, Item 4), and lever (Figure 2, Item 5). Discard cotter pins. 6. Remove three bolts (Figure 2, Item 10), washers (Figure 2, Item 9) and bracket (Figure 2, Item 8) from machine.

000238

NOTE
Note orientation of levers for ease of assembly. 7. Loosen bolt (Figure 2, Item 7) and remove lever (Figure 2, Item 5) from shaft (Figure 2, Item 6). 8. Repeat step 7 for other lever.

Figure 2. Bracket. (Hydraulic lines removed for clarity). END OF TASK

0238

0238-2

TM 5-2410-241-23-3

0238

ADJUSTMENT

000238

NOTE
There should be no tension on steering control lever when aligning steering control rod on steering control lever. Position steering control handle in Park position. Steering control rod adjustment procedure is the same on each end of steering control rod. The steering control valve lever side is described.

1. Install steering control rod (Figure 3, Item 5) on steering control valve lever, refer to Installation in this WP. 2. Secure nut (Figure 3, Item 3) and loosen nut (Figure 3, Item 2), adjust yoke (Figure 3, Item 1) until steering control rod (Figure 3, Item 5) aligns with steering control lever (Figure 3, Item 4). 3. Tighten nuts (Figure 3, Item 2 and 3). 4. Refer to installation in this WP to complete install of steering control rod (Figure 3, Item 5).

Figure 3. Steering Control Rod Adjustment. END OF TASK

0238

0238-3

TM 5-2410-241-23-3

0238

INSTALLATION

000238

NOTE
Install levers as noted during removal. 1. Install lever (Figure 4, Item 5) on shaft (Figure 4, Item 6) and tighten bolt (Figure 4, Item 7). 2. Repeat step 1 for other lever. 3. Install bracket (Figure 4, Item 8), three washers (Figure 4, Item 9) and bolts (Figure 4, Item 10) on machine. 4. Install link (Figure 4, Item 3), two washers (Figure 4, Item 2), and new cotter pins (Figure 4, Item 1) on control valve (Figure 4, Item 4) and lever (Figure 4, Item 5).

Figure 4. Bracket. (Hydraulic lines removed for clarity).

0238

0238-4

TM 5-2410-241-23-3

0238

INSTALLATION CONTINUED

NOTE
Install steering control rod as noted during removal. 5. Position steering control rod (Figure 5, Item 4) on control valve lever (Figure 5, Item 5). 6. Install yoke (Figure 5, Item 6) and retainer pin (Figure 5, Item 7) on control valve lever (Figure 5, Item 5). 7. Position steering control rod (Figure 5, Item 4) on steering and transmission control lever (Figure 5, Item 3). 8. Install yoke (Figure 5, Item 2) and retainer pin (Figure 5, Item 1) on steering and transmission control lever (Figure 5, Item 3).

Figure 5. Steering Control Rod. END OF TASK FOLLOW-ON TASKS 1. Install front floor plate (WP 0230). 2. Install right platform access panel (WP 0208). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0238

000238

0238-5/(6 blank)

4 TM 5-2410-241-23-3 0239

FIELD MAINTENANCE INSTRUCTIONS ACCUMULATOR REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 3 9

INITIAL SETUP Tools and Special Tools Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) Wrench, Combination 1 1/16 (S0787) (WP 0302, Item 68) Wrench, Combination 1 1/4 (S0789) (WP 0302, Item 68) 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) O-ring (2) References WP 0295 0 0 0 0 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 Mid forward bottom guard removed (WP 0199) 0 Recover the air conditioning system (WP 0263) 0 Personnel Required 91C Drawing Required TM 5-2410-241-24P, Figure 100 Estimated Time to Complete 8.0 Hr 0 0 0 0 0 0

0239-1

TM 5-2410-241-23-3

0239

REMOVAL

000239

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Disconnect hose assembly (Figure 1, Item 1) from accumulator (Figure 1, Item 3). Remove O-ring (Figure 1, Item 2) from hose assembly. Discard O-ring. 2. Disconnect hose assembly (Figure 1, Item 8) from accumulator (Figure 1, Item 3). Remove O-ring (Figure 1, Item 7) from hose assembly. Discard O-ring. 3. Remove two bolts (Figure 1, Item 5), washers (Figure 1, Item 4), two straps (Figure 1, Item 6), and accumulator (Figure 1, Item 3) from machine.

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

0239

000239

0239-2

TM 5-2410-241-23-3

0239

INSTALLATION

000239

1. Install accumulator (Figure 1, Item 3), two straps (Figure 1, Item 6), two washers (Figure 1, Item 4), and bolts (Figure 1, Item 5) on machine.

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

2. Install new O-ring (Figure 1, Item 7) on hose assembly (Figure 1, Item 8). Connect hose assembly on accumulator (Figure 1, Item 3). 3. Install new O-ring (Figure 1, Item 2) on hose assembly (Figure 1, Item 1). Connect hose assembly on accumulator (Figure 1, Item 3). FOLLOW-ON TASKS 1. Charge and leak test the air conditioning system (WP 0263). 2. Install engine enclosure left door guard (WP 0202). 3. Install mid forward bottom guard (WP 0199). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000239

0239-3/(4 blank)

4 TM 5-2410-241-23-3 0240

FIELD MAINTENANCE INSTRUCTIONS RECEIVER DRYER REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 4 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) References WP 0295 0 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 100 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0

0240-1

TM 5-2410-241-23-3

0240

REMOVAL

000240

WARNING

Contact with refrigerant can cause frostbite. Keep hands and face away to prevent personal injury. Protective face shield and gloves must always be worn when refrigerant lines are opened, even if gauges indicate A/C system is empty. Always use caution when disconnecting fittings. Slowly loosen fitting in well-ventilated area. Do not smoke when servicing A/C or wherever refrigerant gas may be present. Failure to follow these warnings may result in injury or death to personnel.

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination.

1. Disconnect quick disconnect fitting (Figure 1, Item 1) from receiver dryer (Figure 1, Item 2). 2. Disconnect quick disconnect fitting (Figure 1, Item 3) from receiver dryer (Figure 1, Item 2). 3. Remove bolt (Figure 1, Item 5), washer (Figure 1, Item 6), two clamps (Figure 1, Item 4), spacer (Figure 1, Item 7), and receiver dryer (Figure 1, Item 1) from machine.

Figure 1. Receiver Dryer. END OF TASK

0240

0240-2

TM 5-2410-241-23-3

0240

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install receiver dryer (Figure 1, Item 1) in two clamps (Figure 1, Item 4). 2. Install spacer (Figure 1, Item 7), washer (Figure 1, Item 6), and bolt (Figure 1, Item 5) on machine.

000240

000240

WARNING

Contact with refrigerant can cause frostbite. Keep hands and face away to prevent personal injury. Protective face shield and gloves must always be worn when refrigerant lines are opened, even if gauges indicate A/C system is empty. Always use caution when disconnecting fittings. Slowly loosen fitting in well-ventilated area. Do not smoke when servicing A/C or wherever refrigerant gas may be present. Failure to follow these warnings may result in injury or death to personnel.

NOTE
Install hoses as tagged during removal. 3. Connect quick disconnect fitting (Figure 1, Item 3) on receiver dryer (Figure 1, Item 2). 4. Connect quick disconnect fitting (Figure 1, Item 1) on receiver dryer (Figure 1, Item 2). FOLLOW-ON TASKS 1. Leak test the air conditioning system (WP 0263). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000240

0240-3/(4 blank)

8 TM 5-2410-241-23-3 0241

FIELD MAINTENANCE INSTRUCTIONS AIR CONDITIONING HIGH PRESSURE HOSES REPLACEMENT Compressor Hose to Condenser Coil Removal, Receiver Dryer Hose to Evaporator Coil Removal, Receiver Dryer Hose to Condenser Coil Removal, Cleaning and Inspection, Receiver Dryer Hose to Condenser Coil Installation, Receiver Dryer Hose to Evaporator Coil Installation, Compressor Hose to Condenser Coil Installation
0 2 4 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) 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) Gasket O-ring (6) References WP 0295 0 0 0 0 0 0 0 0 0 0 0 0 Equipment Condition 0

Machine parked (TM 5-2410-241-10) 0 Hood removed (WP 0200) 0 Recover the air conditioning system (WP 0263) 0 Engine enclosure left door guard removed (WP 0202) 0 Personnel Required 91C Drawing Required TM 5-2410-241-24P, Figure 100 Estimated Time to Complete 6.5 Hr 0 0 0 0 0 0

0241-1

TM 5-2410-241-23-3

0241

COMPRESSOR HOSE TO CONDENSER COIL REMOVAL

000241

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Loosen nut (Figure 1, Item 2) and disconnect hose (Figure 1, Item 1) from air conditioning compressor (Figure 1, Item 12). 2. Remove O-ring (Figure 1, Item 3) from hose (Figure 1, Item 1). Discard O-ring. 3. Remove bolt (Figure 1, Item 5), washer (Figure 1, Item 4), spacer (Figure 1, Item 7), and clip (Figure 1, Item 6) from hose (Figure 1, Item 1). Set bracket (Figure 1, Item 8) aside. 4. Loosen nut (Figure 1, Item 9) and disconnect hose (Figure 1, Item 1) from condenser (Figure 1, Item 11). 5. Remove O-ring (Figure 1, Item 10) from hose (Figure 1, Item 1). Discard O-ring. 6. Remove hose (Figure 1, Item 1) from machine.

Figure 1. Compressor Hose to Condenser. END OF TASK

0241

0241-2

TM 5-2410-241-23-3

0241

RECEIVER DRYER HOSE TO EVAPORATOR COIL REMOVAL

000241

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Remove four bolts (Figure 2, Item 2), washers (Figure 2, Item 1), cover (Figure 2, Item 3), and gasket (Figure 2, Item 4) from platform. Discard gasket. 2. Loosen nut (Figure 2, Item 5) and disconnect hose (Figure 2, Item 9) from evaporator coil (Figure 2, Item 6). 3. Remove O-ring (Figure 2, Item 7) from hose (Figure 2, Item 9). Discard O-ring. 4. Disconnect quick disconnect fitting (Figure 2, Item 12) from receiver dryer (Figure 2, Item 13). 5. Loosen nut (Figure 2, Item 10) and disconnect hose (Figure 2, Item 9) from quick disconnect fitting (Figure 2, Item 12). 6. Remove O-ring (Figure 2, Item 11) from hose (Figure 2, Item 9). Discard O-ring. 7. Remove hose (Figure 2, Item 9) from machine. 8. Remove grommet (Figure 2, Item 8) from machine.

Figure 2. Receiver Dryer Hose to Evaporator Coil. END OF TASK

0241

0241-3

TM 5-2410-241-23-3

0241

RECEIVER DRYER HOSE TO CONDENSER COIL REMOVAL

000241

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Loosen nut (Figure 3, Item 2) and disconnect hose (Figure 3, Item 1) from condenser coil (Figure 3, Item 4). 2. Remove O-ring (Figure 3, Item 3) from hose (Figure 3, Item 1). Discard O-ring. 3. Disconnect quick disconnect fitting (Figure 3, Item 6) from receiver dryer (Figure 3, Item 5). 4. Loosen nut (Figure 3, Item 7) and disconnect hose (Figure 3, Item 1) from quick disconnect fitting (Figure 3, Item 6). 5. Remove O-ring (Figure 3, Item 8) from hose (Figure 3, Item 1). Discard O-ring. 6. Remove nut (Figure 3, Item 10), washer (Figure 3, Item 11), clip (Figure 3, Item 12), and hose (Figure 3, Item 1) from bracket (Figure 3, Item 9). 7. Remove bolt (Figure 3, Item 16), washer (Figure 3, Item 15), clip (Figure 3, Item 13), and bracket (Figure 3, Item 14) from hose (Figure 3, Item 1). 8. Remove hose (Figure 3, Item 1) from machine.

Figure 3. Receiver Dryer Hose to Condenser Coil. END OF TASK

0241

0241-4

TM 5-2410-241-23-3

0241

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK RECEIVER DRYER HOSE TO CONDENSER COIL INSTALLATION

000241

000241

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

1. Install hose (Figure 4, Item 1) on machine. 2. Install clip (Figure 4, Item 13), hose (Figure 4, Item 1), washer (Figure 4, Item 15), and bolt (Figure 4, Item 16) on bracket (Figure 4, Item 14). 3. Install clip (Figure 4, Item 12), hose (Figure 4, Item 1), washer (Figure 4, Item 11), and nut (Figure 4, Item 10) on bracket (Figure 4, Item 9). 4. Install new O-ring (Figure 4, Item 8) on hose (Figure 4, Item 1). 5. Connect hose (Figure 4, Item 1) on quick disconnect fitting (Figure 4, Item 6) and tighten nut (Figure 4, Item 7). 6. Connect quick disconnect fitting (Figure 4, Item 6) on receiver dryer (Figure 4, Item 5). 7. Install new O-ring (Figure 4, Item 3) to hose (Figure 4, Item 1). 8. Connect hose (Figure 4, Item 1) on condenser coil (Figure 4, Item 4) and tighten nut (Figure 4, Item 2).

Figure 4. Receiver Dryer Hose to Condenser Coil. END OF TASK

0241

0241-5

TM 5-2410-241-23-3

0241

RECEIVER DRYER HOSE TO EVAPORATOR COIL INSTALLATION

000241

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

1. Install hose (Figure 5, Item 9) on machine. 2. Install new O-ring (Figure 5, Item 11) on hose (Figure 5, Item 9). 3. Connect hose (Figure 5, Item 9) on quick disconnect fitting (Figure 5, Item 12) and tighten nut (Figure 5, Item 10). 4. Connect quick disconnect fitting (Figure 5, Item 12) on receiver dryer (Figure 5, Item 13). 5. Install grommet (Figure 5, Item 8) on hose (Figure 5, Item 9). 6. Install new O-ring (Figure 5, Item 7) on hose (Figure 5, Item 9). 7. Connect hose (Figure 5, Item 9) on evaporator coil (Figure 5, Item 6) and tighten nut (Figure 5, Item 5). 8. Install new gasket (Figure 5, Item 4), cover (Figure 5, Item 3), four washers (Figure 5, Item 1), and bolts (Figure 5, Item 2) on platform.

Figure 5. Receiver Dryer Hose to Evaporator Coil. END OF TASK

0241

0241-6

TM 5-2410-241-23-3

0241

COMPRESSOR HOSE TO CONDENSER COIL INSTALLATION

000241

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

1. Install hose (Figure 6, Item 1) on machine. 2. Install new O-ring (Figure 6, Item 10) on hose (Figure 6, Item 1). 3. Connect hose (Figure 6, Item 1) on condenser (Figure 6, Item 11) and tighten nut (Figure 6, Item 9). 4. Install clip (Figure 6, Item 6), spacer (Figure 6, Item 7), bracket (Figure 6, Item 8), washer (Figure 6, Item 4), and bolt (Figure 6, Item 5) on hose (Figure 6, Item 1). 5. Install new O-ring (Figure 6, Item 3) on hose (Figure 6, Item 1). 6. Connect hose (Figure 6, Item 1) on air conditioning compressor (Figure 6, Item 12) and tighten nut (Figure 6, Item 2).

Figure 6. Compressor Hose to Condenser. END OF TASK FOLLOW-ON TASKS 1. Install engine enclosure left door guard (WP 0202). 2. Install hood (WP 0200). 3. Evacuate, charge and leak test the air conditioning system (WP 0263). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0241

000241

0241-7/(8 blank)

10 TM 5-2410-241-23-3 0242

FIELD MAINTENANCE INSTRUCTIONS AIR CONDITIONING LOW PRESSURE HOSES REPLACEMENT Compressor Hose to Accumulator Removal, Accumulator Hose to Evaporator Coil Removal, Cleaning and Inspection, Accumulator Hose to Evaporator Coil Installation, Compressor Hose to Accumulator Installation
0 2 4 2

INITIAL SETUP Tools and Special Tools 0 References WP 0295 Equipment Condition 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) 0 Wrench, combination 1 1/16 (S0787) (WP 0302, Item 68) 0 Wrench, combination 1 1/4 (S0789) (WP 0302, Item 68) 0 Materials/Parts Cap Set, Protective (WP 0303, Item 4) Oil, Lubricating, Refrigerant Compressor (WP 0303, Item 22) Rag, Wiping (WP 0303, Item 24) Refrigerant, R-134a (WP 0303, Item 25) Tag, Marker (WP 0303, Item 34) Gasket O-ring (4) 0 0 0 0 0 0 0 0

Machine parked (TM 5-2410-241-10) 0 Hood removed (WP 0200) 0 Front and mid front bottom guards removed (WP 0199) 0 Recover the air conditioning system (WP 0263) 0 Personnel Required 91C Drawing Required TM 5-2410-241-24P, Figure 105 Estimated Time to Complete 6.5 Hr 0 0 0 0 0 0

0242-1

TM 5-2410-241-23-3

0242

COMPRESSOR HOSE TO ACCUMULATOR REMOVAL

000242

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Loosen nut (Figure 1, Item 2) and disconnect hose (Figure 1, Item 1) from air conditioning compressor (Figure 1, Item 13). 2. Remove O-ring (Figure 1, Item 3) from hose (Figure 1, Item 1). Discard O-ring. 3. Remove bolt (Figure 1, Item 5), washer (Figure 1, Item 4), and clip (Figure 1, Item 6) from machine, and clip from hose (Figure 1, Item 1). 4. Remove bolt (Figure 1, Item 10), washer (Figure 1, Item 12), and clip (Figure 1, Item 11) from machine and clip from hose (Figure 1, Item 1). 5. Loosen nut (Figure 1, Item 9) and disconnect hose (Figure 1, Item 1) from accumulator (Figure 1, Item 7). 6. Remove O-ring (Figure 1, Item 8) from hose (Figure 1, Item 1). Discard O-ring. 7. Remove hose (Figure 1, Item 1) from machine.

Figure 1. Compressor Hose to Accumulator. END OF TASK

0242

0242-2

TM 5-2410-241-23-3

0242

ACCUMULATOR HOSE TO EVAPORATOR COIL REMOVAL

000242

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Loosen nut (Figure 2, Item 2) and disconnect hose (Figure 2, Item 4) from accumulator (Figure 2, Item 1). 2. Remove O-ring (Figure 2, Item 3) from hose (Figure 2, Item 4). Discard O-ring. 3. Remove bolt (Figure 2, Item 5), washer (Figure 2, Item 6), spacer (Figure 2, Item 8), and clip (Figure 2, Item 7) from machine. Remove clip from hose (Figure 2, Item 4). 4. Remove bolt (Figure 2, Item 10), washer (Figure 2, Item 11), and clip (Figure 2, Item 9) from machine. 5. Remove clip from hose (Figure 2, Item 4). Set clip (Figure 2, Item 12) and hoses (Figure 2, Item 13) aside.

Figure 2. Accumulator Hose to Evaporator Coil.

0242

0242-3

TM 5-2410-241-23-3

0242

ACCUMULATOR HOSE TO EVAPORATOR COIL REMOVAL CONTINUED 6. Remove bolt (Figure 3, Item 5), washer (Figure 3, Item 4), ladder clip (Figure 3, Item 3), and clip (Figure 3, Item 2) from hose (Figure 3, Item 1).

Figure 3. Accumulator Hose Clip.

0242

0242-4

TM 5-2410-241-23-3

0242

ACCUMULATOR HOSE TO EVAPORATOR COIL REMOVAL CONTINUED 7. Remove four bolts (Figure 4, Item 2), washers (Figure 4, Item 1), cover (Figure 4, Item 3), and gasket (Figure 4, Item 4) from platform. Discard gasket. 8. Loosen nut (Figure 4, Item 5) and disconnect hose (Figure 4, Item 8) from evaporator coil (Figure 4, Item 6). 9. Remove O-ring (Figure 4, Item 7) from hose (Figure 4, Item 8). Discard O-ring. 10. Remove hose (Figure 4, Item 8) from machine. 11. Remove grommet (Figure 4, Item 9) from machine.

Figure 4. Evaporator Coil. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0242

000242

0242-5

TM 5-2410-241-23-3

0242

ACCUMULATOR HOSE TO EVAPORATOR COIL INSTALLATION

000242

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

1. Install hose (Figure 5, Item 8) on machine. 2. Install grommet (Figure 5, Item 9) on hose (Figure 5, Item 8). 3. Install new O-ring (Figure 5, Item 7) on hose (Figure 5, Item 8). 4. Connect hose (Figure 5, Item 8) on evaporator coil (Figure 5, Item 6) and tighten nut (Figure 5, Item 5). 5. Install new gasket (Figure 5, Item 4), cover (Figure 5, Item 3), four washers (Figure 5, Item 1), and bolts (Figure 5, Item 2) on platform.

Figure 5. Evaporator Coil.

0242

0242-6

TM 5-2410-241-23-3

0242

ACCUMULATOR HOSE TO EVAPORATOR COIL INSTALLATION CONTINUED 6. Position clip (Figure 6, Item 12) and hoses (Figure 6, Item 13). Install clip (Figure 6, Item 9) on hose (Figure 6, Item 4), and clip washer (Figure 6, Item 11) and bolt (Figure 6, Item 10) on machine. 7. Install clip (Figure 6, Item 7) on hose (Figure 6, Item 4), and clip spacer (Figure 6, Item 8), washer (Figure 6, Item 6), and bolt (Figure 6, Item 5) on machine. 8. Install new O-ring (Figure 6, Item 3) on hose (Figure 6, Item 4). 9. Connect hose (Figure 6, Item 4) on accumulator (Figure 6, Item 1) and tighten nut (Figure 6, Item 2).

Figure 6. Accumulator Hose to Evaporator Coil.

0242

0242-7

TM 5-2410-241-23-3

0242

ACCUMULATOR HOSE TO EVAPORATOR COIL INSTALLATION CONTINUED 10. Install clip (Figure 7, Item 2), ladder clip (Figure 7, Item 3), washer (Figure 7, Item 4), and bolt (Figure 7, Item 5) on hose (Figure 7, Item 1).

Figure 7. Accumulator Hose Clip. END OF TASK COMPRESSOR HOSE TO ACCUMULATOR INSTALLATION

0242

000242

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

1. Install hose (Figure 8, Item 1) on machine. 2. Install new O-ring (Figure 8, Item 8) on hose (Figure 8, Item 1). 3. Connect hose (Figure 8, Item 1) on accumulator (Figure 8, Item 7), tighten nut (Figure 8, Item 9). 4. Install clip (Figure 8, Item 11) on hose (Figure 8, Item 1), and clip, washer (Figure 8, Item 12), and bolt (Figure 8, Item 10) on machine. 5. Install clip (Figure 8, Item 6) on hose (Figure 8, Item 1), and clip, washer (Figure 8, Item 4), and bolt (Figure 8, Item 5) on machine. 6. Install new O-ring (Figure 8, Item 3) on hose (Figure 8, Item 1). 7. Connect hose (Figure 8, Item 1) on air conditioning compressor (Figure 8, Item 13), tighten nut (Figure 8, Item 2).

0242-8

TM 5-2410-241-23-3

0242

COMPRESSOR HOSE TO ACCUMULATOR INSTALLATION CONTINUED

Figure 8. Compressor Hose to Accumulator. END OF TASK FOLLOW-ON TASKS 1. Install hood (WP 0200). 2. Evacuate, charge and leak test the air conditioning system (WP 0263). 3. Install front and mid front bottom guards (WP 0199). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0242

000242

0242-9/(10 blank)

10 TM 5-2410-241-23-3 0243

FIELD MAINTENANCE INSTRUCTIONS HEATER LINES REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 4 3

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) References WP 0113 WP 0295 0 0 0 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Hood removed (WP 0200) Drawing Required TM 5-2410-241-24P, Figure 101 Estimated Time to Complete 2.5 Hr 0 0 0 0 0 0 0

0243-1

TM 5-2410-241-23-3

0243

REMOVAL

000243

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

1. Close heater hose valve (Figure 1, Item 3). 2. Loosen clamp (Figure 1, Item 2) and remove hose (Figure 1, Item 1) from heater hose valve (Figure 1, Item 3). 3. Remove clamp (Figure 1, Item 2) from hose (Figure 1, Item 1). 4. Close heater hose valve (Figure 1, Item 6). 5. Loosen clamp (Figure 1, Item 5) and remove hose (Figure 1, Item 4) from heater hose valve (Figure 1, Item 6). 6. Remove clamp (Figure 1, Item 5) from hose (Figure 1, Item 4).

Figure 1. Heater Hose Shutoff Valves.

0243

0243-2

TM 5-2410-241-23-3

0243

REMOVAL CONTINUED 7. Remove nut (Figure 2, Item 9), washer (Figure 2, Item 8), bolt (Figure 2, Item 5), washer (Figure 2, Item 6), and retaining strap (Figure 2, Item 10) from retaining strap (Figure 2, Item 7). 8. Remove retaining strap (Figure 2, Item 10) from hose (Figure 2, Item 11). 9. Remove locknut (Figure 2, Item 4), washer (Figure 2, Item 3), retaining strap (Figure 2, Item 12), and cable (Figure 2, Item 13). Position cable aside. Discard locknut. 10. Remove retaining strap (Figure 2, Item 2) from two hoses (Figure 2, Item 1).

Figure 2. Right Side Connections. 11. Remove bolt (Figure 3, Item 3), washer (Figure 3, Item 4), and retaining strap (Figure 3, Item 2) from bracket (Figure 3, Item 5). 12. Remove retaining strap (Figure 3, Item 2) from hose (Figure 3, Item 1).

0243

Figure 3. Transmission Cooler Strap.

0243

0243-3

TM 5-2410-241-23-3

0243

REMOVAL CONTINUED 13. Remove nut (Figure 4, Item 5), washer (Figure 4, Item 7), bolt (Figure 4, Item 9), washer (Figure 4, Item 8), and retaining strap (Figure 4, Item 4) from two hoses (Figure 4, Item 3). 14. Remove bolt (Figure 4, Item 13), washer (Figure 4, Item 12), retaining strap (Figure 4, Item 1), and hose (Figure 4, Item 2) from support bracket (Figure 4, Item 6). Position hose aside. 15. Remove spacer (Figure 4, Item 11) and retaining strap (Figure 4, Item 10) from two hoses (Figure 4, Item 3).

NOTE
Tag hoses to aid installation. 16. Remove two hoses (Figure 4, Item 3) from machine.

Figure 4. Rear Engine Connections.

0243

0243-4

TM 5-2410-241-23-3

0243

REMOVAL CONTINUED

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

17. Loosen clamp (Figure 5, Item 2) and disconnect hose (Figure 5, Item 1) from heater coil (Figure 5, Item 3). 18. Remove clamp (Figure 5, Item 2) from hose (Figure 5, Item 1). 19. Loosen clamp (Figure 5, Item 6) and disconnect hose (Figure 5, Item 5) from water valve (Figure 5, Item 4). 20. Remove clamp (Figure 5, Item 6) from hose (Figure 5, Item 5). 21. Remove hoses (Figure 5, Items 1 and 5) from machine.

Figure 5. Heater Coil and Water Valve. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0243

000243

0243-5

TM 5-2410-241-23-3

0243

INSTALLATION

000243

NOTE
Install hoses as tagged during removal. 1. Install hoses (Figure 6, Items 1 and 5) on machine. 2. Install clamp (Figure 6, Item 6) on hose (Figure 6, Item 5). 3. Connect hose (Figure 6, Item 5) on water valve (Figure 6, Item 4). Tighten clamp (Figure 6, Item 6). 4. Install clamp (Figure 6, Item 2) on hose (Figure 6, Item 1). 5. Connect hose (Figure 6, Item 1) on heater coil (Figure 6, Item 3). Tighten clamp (Figure 6, Item 2).

Figure 6. Heater Coil and Water Valve.

0243

0243-6

TM 5-2410-241-23-3

0243

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 6. Install two hoses (Figure 7, Item 3) on machine. 7. Install retaining strap (Figure 7, Item 10) and spacer (Figure 7, Item 11) on two hoses (Figure 7, Item 3). 8. Install hose (Figure 7, Item 2), retaining strap (Figure 7, Item 1), spacer (Figure 7, Item 11), retaining strap (Figure 7, Item 10), washer (Figure 7, Item 12), and bolt (Figure 7, Item 13) on support bracket (Figure 7, Item 6). 9. Install retaining strap (Figure 7, Item 4), washer (Figure 7, Item 8), bolt (Figure 7, Item 9), washer (Figure 7, Item 7), and nut (Figure 7, Item 5) on two hoses (Figure 7, Item 3).

Figure 7. Rear Engine Connections.

0243

0243-7

TM 5-2410-241-23-3

0243

INSTALLATION CONTINUED 10. Install retaining strap (Figure 8, Item 2) on hose (Figure 8, Item 1). 11. Install retaining strap (Figure 8, Item 2), washer (Figure 8, Item 4), and bolt (Figure 8, Item 3) on bracket (Figure 8, Item 5).

Figure 8. Transmission Cooler Strap. 12. Install retaining strap (Figure 9, Item 2) on two hoses (Figure 9, Item 1).

0243

13. Install cable (Figure 9, Item 13), retaining strap (Figure 9, Item 12), washer (Figure 9, Item 3), and new locknut (Figure 9, Item 4) on machine. 14. Install retaining strap (Figure 9, Item 10) on hose (Figure 9, Item 11). 15. Install retaining strap (Figure 9, Item 10), washer (Figure 9, Item 6), bolt (Figure 9, Item 5), washer (Figure 9, Item 8), and nut (Figure 9, Item 9) on retaining strap (Figure 9, Item 7).

Figure 9. Right Side Connections.

0243

0243-8

TM 5-2410-241-23-3

0243

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 16. Install clamp (Figure 10, Item 5) on hose (Figure 10, Item 4). 17. Install hose (Figure 10, Item 4) on heater hose valve (Figure 10, Item 6). Tighten clamp (Figure 10, Item 5). 18. Open heater hose valve (Figure 10, Item 6). 19. Install clamp (Figure 10, Item 2) on hose (Figure 10, Item 1). 20. Install hose (Figure 10, Item 1) on heater hose valve (Figure 10, Item 3). Tighten clamp (Figure 10, Item 2). 21. Open heater hose valve (Figure 10, Item 3).

Figure 10. Heater Hose Shutoff Valves. END OF TASK

0243

0243-9

TM 5-2410-241-23-3

0243

FOLLOW-ON TASKS 1. Install hood (WP 0200). 2. Fill cooling system with coolant (WP 0113). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000243

0243-10

12 TM 5-2410-241-23-3 0244

FIELD MAINTENANCE INSTRUCTIONS WATER VALVE AND CABLE REPLACEMENT Water Valve Removal, Cable Removal, Cleaning and Inspection, Cable Installation, Water Valve Installation
0 2 4 4

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) References WP 0295 WATER VALVE REMOVAL
0

Equipment Condition Machine parked (TM 5-2410-241-10) Drain cooling system (WP 0113) Drawing Required TM 5-2410-241-24P, Figure 105, 110 Estimated Time to Complete 3.5 Hr

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NOTE
Cap and plug lines to prevent contamination and leaks. 1. Open left engine enclosure door. 2. Remove clamp (Figure 1, Item 2) and hose (Figure 1, Item 3) from water valve (Figure 1, Item 4). 3. Remove clamp (Figure 1, Item 6) and hose (Figure 1, Item 7) from water valve (Figure 1, Item 4). 4. Remove four bolts (Figure 1, Item 1) and water valve (Figure 1, Item 4) from plate (Figure 1, Item 5).

Figure 1. Water Valve Hoses. 0244-1

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TM 5-2410-241-23-3

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WATER VALVE REMOVAL CONTINUED 5. Remove four bolts (Figure 2, Item 1) and foot plate (Figure 2, Item 2) from machine. 6. Move cable (Figure 2, Item 4) through grommet (Figure 2, Item 3) to provide slack and position water valve.

Figure 2. Water Valve Cable Routing.

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TM 5-2410-241-23-3

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WATER VALVE REMOVAL CONTINUED 7. Remove lever (Figure 3, Item 3), retainer (Figure 3, Item 4), clamp (Figure 3, Item 5), and cable (Figure 3, Item 6) from water valve (Figure 3, Item 7). 8. Remove bolt (Figure 3, Item 1), clamp (Figure 3, Item 2), and cable (Figure 3, Item 6) from water valve (Figure 3, Item 7). 9. Remove water valve (Figure 3, Item 7) from machine.

Figure 3. Water Valve. END OF TASK

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TM 5-2410-241-23-3

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CABLE REMOVAL 1. Loosen setscrew (Figure 4, Item 1) and remove heater control knob (Figure 4, Item 2) from heater control (Figure 4, Item 5).

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2. Remove nut (Figure 4, Item 4), spacer (Figure 4, Item 6), and heater control (Figure 4, Item 5) from instrument panel (Figure 4, Item 3).

Figure 4. Heater Control Knob.

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TM 5-2410-241-23-3

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CABLE REMOVAL CONTINUED 3. Remove four bolts (Figure 5, Item 1) from instrument panel (Figure 5, Item 2). 4. Remove two bolts (Figure 5, Item 3) and washers (Figure 5, Item 4) from instrument panel (Figure 5, Item 2). 5. Tilt instrument panel (Figure 5, Item 2) forward and allow it to rest on support cable.

Figure 5. Instrument Panel.

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TM 5-2410-241-23-3

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CABLE REMOVAL CONTINUED 6. Loosen nut (Figure 6, Item 2) and remove cable (Figure 6, Item 1) from temperature control (Figure 6, Item 3).

Figure 6. Cable. 7. Remove four bolts (Figure 7, Item 1) and foot plate (Figure 7, Item 3) from machine. 8. Remove two bolts (Figure 7, Item 6), washers (Figure 7, Item 5), and plate (Figure 7, Item 8) from machine. 9. Remove plate (Figure 7, Item 8) from grommet (Figure 7, Item 7). 10. Remove grommet (Figure 7, Item 7) from cable (Figure 7, Item 4).

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TM 5-2410-241-23-3

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CABLE REMOVAL CONTINUED

NOTE
Note cable routing to aid installation. 11. Remove cable (Figure 7, Item 4) from machine. 12. Remove grommet (Figure 7, Item 2) from machine.

Figure 7. Cable Routing. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK CABLE INSTALLATION

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NOTE
Route cable as noted during removal. 1. Install grommet (Figure 7, Item 2) on machine. 2. Install cable (Figure 7, Item 4) on machine. 3. Install grommet (Figure 7, Item 7) on cable (Figure 7, Item 4). 4. Install plate (Figure 7, Item 8) on grommet (Figure 7, Item 7). 5. Install plate (Figure 7, Item 8), two washers (Figure 7, Item 5), and bolts (Figure 7, Item 6) on machine. 6. Install foot plate (Figure 7, Item 3) and four bolts (Figure 7, Item 1) on machine.

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TM 5-2410-241-23-3

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CABLE INSTALLATION CONTINUED 7. Install cable (Figure 8, Item 1) on temperature control (Figure 8, Item 3) and tighten nut (Figure 8, Item 2).

Figure 8. Cable. 8. Install spacer (Figure 9, Item 6), heater control (Figure 9, Item 5), and nut (Figure 9, Item 4) on instrument panel (Figure 9, Item 3).

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9. Install heater control knob (Figure 9, Item 2) on heater control (Figure 9, Item 5) and tighten setscrew (Figure 9, Item 1).

Figure 9. Heater Control Knob.

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CABLE INSTALLATION CONTINUED 10. Close instrument panel (Figure 10, Item 2). 11. Install four bolts (Figure 10, Item 1) on instrument panel (Figure 10, Item 2). 12. Install two washers (Figure 10, Item 4) and bolts (Figure 10, Item 3) on instrument panel (Figure 10, Item 2).

Figure 10. Instrument Panel. END OF TASK

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WATER VALVE INSTALLATION 1. Position water valve (Figure 11, Item 7) on machine. 2. Install cable (Figure 11, Item 6), clamp (Figure 11, Item 5), retainer (Figure 11, Item 4), and lever (Figure 11, Item 3) on water valve (Figure 11, Item 7). 3. Install clamp (Figure 11, Item 2), cable (Figure 11, Item 6), and bolt (Figure 11, Item 1) on water valve (Figure 11, Item 7).

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Figure 11. Water Valve.

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TM 5-2410-241-23-3

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WATER VALVE INSTALLATION CONTINUED 4. Move cable (Figure 12, Item 4) through grommet (Figure 12, Item 3) to remove slack and position water valve. 5. Install foot plate (Figure 12, Item 2) and four bolts (Figure 12, Item 1) on machine.

Figure 12. Water Valve Cable Routing.

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TM 5-2410-241-23-3

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WATER VALVE INSTALLATION CONTINUED 6. Install hose (Figure 13, Item 7) and clamp (Figure 13, Item 6) on water valve (Figure 13, Item 4). 7. Install hose (Figure 13, Item 3) and clamp (Figure 13, Item 2) on water valve (Figure 13, Item 4). 8. Install water valve (Figure 13, Item 4) and four bolts (Figure 13, Item 1) on plate (Figure 13, Item 5). 9. Close left engine enclosure door.

Figure 13. Water Valve Hoses. END OF TASK 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

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18 TM 5-2410-241-23-3 0245

FIELD MAINTENANCE INSTRUCTIONS CAB REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 4 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Screwdriver Attachment, Torx, 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) Sling, Nylon (WP 0302, Item 68) Lifting Device (5,000-lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Personnel Required Two 0 0 0 0 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) ROPS removed (WP 0225) Drawing Required TM 5-2410-241-24P, Figure 102, 110 Estimated Time to Complete 4.5 Hr 0 0 0 0 0 0 0 0 0

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TM 5-2410-241-23-3

0245

REMOVAL 1. Open pivot shaft oil reservoir compartment door.

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NOTE
Tag all electrical connectors and hoses to aid installation. 2. Disconnect wiring harness connector (Figure 1, Item 5) and four washer hoses (Figure 1, Item 4) from windshield washer bottle (Figure 1, Item 1). 3. Remove and discard tiedown straps from hose and harness conduit (Figure 1, Item 3). 4. Remove hose and harness conduit (Figure 1, Item 3) from pivot shaft oil reservoir compartment (Figure 1, Item 2). 5. Close pivot shaft oil reservoir compartment door.

Figure 1. Electrical Harness and Washer Hoses.

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TM 5-2410-241-23-3

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REMOVAL CONTINUED

NOTE
Tag all electrical connectors to aid installation. 6. Disconnect messenger connector (Figure 2, Item 7) from console. 7. Remove two bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and ladder clips (Figure 2, Item 4) from cab (Figure 2, Item 5). 8. Position harness (Figure 2, Item 6) inside messenger (Figure 2, Item 1).

Figure 2. Messenger Assembly.

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TM 5-2410-241-23-3

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REMOVAL CONTINUED 9. Remove eight bolts (Figure 3, Item 3) and plate (Figure 3, Item 2) from rifle rack (Figure 3, Item 1).

NOTE
Note position of washers to aid installation. 10. Remove four bolts (Figure 3, Item 4), eight washers (Figure 3, Item 5), and rifle rack (Figure 3, Item 1) from cab (Figure 3, Item 6).

Figure 3. Rifle Rack.

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TM 5-2410-241-23-3

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REMOVAL CONTINUED 11. Remove floor mat (Figure 4, Item 1) from cab floor.

NOTE
Steps 12 and 13 describe removal of hardware at right side cab door opening. Use same method to remove hardware at left side cab door opening. 12. Remove four bolts (Figure 4, Item 2) and washers (Figure 4, Item 3) from cab (Figure 4, Item 6). 13. Remove bolt (Figure 4, Item 4) and washer (Figure 4, Item 5) from cab (Figure 4, Item 6).

Figure 4. Cab Bolts at Door.

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TM 5-2410-241-23-3

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REMOVAL CONTINUED 14. Remove three bolts (Figure 5, Item 4) and washers (Figure 5, Item 5) from left side of cab (Figure 5, Item 1). 15. Remove three bolts (Figure 5, Item 6) and washers (Figure 5, Item 7) from right side of cab (Figure 5, Item 1). 16. Remove six bolts (Figure 5, Item 2) and washers (Figure 5, Item 3) from across back of cab (Figure 5, Item 1).

Figure 5. Cab Bolts.

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TM 5-2410-241-23-3

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REMOVAL CONTINUED 17. Remove four bolts (Figure 6, Item 1) from instrument panel (Figure 6, Item 2). 18. Remove two bolts (Figure 6, Item 4) and washers (Figure 6, Item 3) from instrument panel (Figure 6, Item 2). 19. TIlt instrument panel (Figure 6, Item 2) back and allow it to rest on the support cable.

Figure 6. Instrument Panel.

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TM 5-2410-241-23-3

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REMOVAL CONTINUED 20. Remove four bolts (Figure 7, Item 3), washers (Figure 7, Item 2), and panel (Figure 7, Item 1) from instrument panel (Figure 7, Item 4).

Figure 7. Surround.

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NOTE
Tag all electrical harness connectors to aid installation. 21. Disconnect wire harness connector (Figure 8, Item 5) from instrument panel connector (Figure 8, Item 4) and position connector through hole in flange (Figure 8, Item 6). 22. Remove seven bolts (Figure 8, Item 3), washers (Figure 8, Item 2), and angle bracket (Figure 8, Item 1) from instrument panel.

Figure 8. Harness Connector and Angle Bracket.

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TM 5-2410-241-23-3

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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
Cab weighs approximately 1,000 lb (454 kg). 23. Attach sling and suitable lifting device to cab (Figure 9, Item 1). 24. Remove cab (Figure 9, Item 1) from machine (Figure 9, Item 2).

Figure 9. Cab.

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TM 5-2410-241-23-3

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REMOVAL CONTINUED 25. Place cab (Figure 10, Item 1) on suitable supports. 26. Remove sling and suitable lifting device from cab (Figure 10, Item 1).

Figure 10. Cab. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

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TM 5-2410-241-23-3

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INSTALLATION

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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
Cab weighs approximately 1,000 lb (454 kg). 1. Attach sling and suitable lifting device to cab (Figure 11, Item 1). 2. Install cab (Figure 11, Item 1) on machine (Figure 11, Item 2). Remove sling and suitable lifting device from cab (Figure 11, Item 1).

Figure 11. Cab.

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TM 5-2410-241-23-3

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INSTALLATION CONTINUED 3. Install angle bracket (Figure 12, Item 1), seven washers (Figure 12, Item 2), and bolts (Figure 12, Item 3) on instrument panel.

NOTE
Install all electrical harness connectors as noted during removal. 4. Position harness connector (Figure 12, Item 5) through hole in flange (Figure 12, Item 6) and connect wiring harness connector (Figure 12, Item 5) to instrument panel connector (Figure 12, Item 4).

Figure 12. Harness Connector and Angle Bracket. 5. Install panel (Figure 13, Item 1), four washers (Figure 13, Item 2), and bolts (Figure 13, Item 3) on instrument panel (Figure 13, Item 4).

0245

Figure 13. Surround.

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TM 5-2410-241-23-3

0245

INSTALLATION CONTINUED 6. Raise instrument panel (Figure 14, Item 2) forward and hold up. 7. Install two washers (Figure 14, Item 3) and bolts (Figure 14, Item 4) on instrument panel (Figure 14, Item 2). 8. Install four bolts (Figure 14, Item 1) on instrument panel (Figure 14, Item 2). 9. Release instrument panel (Figure 14, Item 2).

Figure 14. Instrument Panel. 10. Install six washers (Figure 15, Item 3) and bolts (Figure 15, Item 2) across back of cab (Figure 15, Item 1). 11. Install three washers (Figure 15, Item 7) and bolts (Figure 15, Item 6) on right side of cab (Figure 15, Item 1). 12. Install three washers (Figure 15, Item 5) and bolts (Figure 15, Item 4) on left side of cab (Figure 15, Item 1).

0245

Figure 15. Cab Bolts.

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TM 5-2410-241-23-3

0245

INSTALLATION CONTINUED

NOTE
Steps 13 and 14 describe installation of hardware at right side cab door opening. Use same method to install hardware at left side cab door opening. 13. Install washer (Figure 16, Item 5) and bolt (Figure 16, Item 4) on cab (Figure 16, Item 6). 14. Install four washers (Figure 16, Item 3) and bolts (Figure 16, Item 2) on cab (Figure 16, Item 6). 15. Install floor mat (Figure 16, Item 1) on cab floor.

Figure 16. Cab Bolts at Door.

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TM 5-2410-241-23-3

0245

INSTALLATION CONTINUED

NOTE
Note position of washers to aid installation. 16. Install rifle rack (Figure 17, Item 1), eight washers (Figure 17, Item 5), and four bolts (Figure 17, Item 4) on cab (Figure 17, Item 6). 17. Install plate (Figure 17, Item 2) and eight bolts (Figure 17, Item 3) on rifle rack (Figure 17, Item 1).

Figure 17. Rifle Rack.

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TM 5-2410-241-23-3

0245

INSTALLATION CONTINUED

NOTE
Install all electrical connectors as tagged during removal. 18. Position harness (Figure 18, Item 6) from messenger (Figure 18, Item 1). 19. Install two ladder clips (Figure 18, Item 4), washers (Figure 18, Item 3), and bolts (Figure 18, Item 2) on cab (Figure 18, Item 5). 20. Connect messenger connector (Figure 18, Item 7) on console.

Figure 18. Messenger Assembly.

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TM 5-2410-241-23-3

0245

INSTALLATION CONTINUED 21. Open pivot shaft oil reservoir compartment door. 22. Feed hose and harness conduit (Figure 19, Item 3) into pivot shaft oil reservoir compartment (Figure 19, Item 2).

NOTE
Install all electrical connectors and hoses as tagged during removal. 23. Connect wiring harness connector (Figure 19, Item 5) and four washer hoses (Figure 19, Item 4) on windshield washer bottle (Figure 19, Item 1). Install new tiedown straps on wiring harness connector (Figure 19, Item 5) and hoses (Figure 19, Item 4). 24. Close pivot shaft oil reservoir compartment door.

Figure 19. Electrical Harness and Washer Hoses. END OF TASK FOLLOW-ON TASKS 1. Install ROPS (WP 0225). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

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0245-17/(18 blank)

10 TM 5-2410-241-23-3 0246

FIELD MAINTENANCE INSTRUCTIONS WINDOW REPLACEMENT Front Window Removal, Rear Window Removal, Right Side Windows Removal, Left Side Windows Removal, Cleaning and Inspection, Left Side Windows Installation, Right Side Windows Installation, Rear Window Installation, Front Window Installation
0 2 4 6

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 Detergent, General Purpose, Liquid (WP 0303, Item 8) Rag, Wiping (WP 0303, Item 24) Personnel Required Two 0 0
0

References WP 0225 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10)

0 0 0 0 0 0 0 0 0

Drawing Required TM 5-2410-241-24P, Figure 112 Estimated Time to Complete 2.0 Hr

0 0 0 0 0

0246-1

TM 5-2410-241-23-3

0246

FRONT WINDOW REMOVAL

000246

WARNING

To prevent injury to personnel, wear protective eye covering and gloves. 1. Disconnect hose (Figure 1, Item 6) from nipple (Figure 1, Item 5). 2. Open two caps (Figure 1, Item 8) on wiper arms (Figure 1, Item 9). 3. Remove two nuts (Figure 1, Item 7) and wiper arms (Figure 1, Item 9) from machine.

NOTE
Apply liquid detergent to rubber seal to aid removal. 4. Unlock core (Figure 1, Item 2) from rubber seal (Figure 1, Item 3). 5. Remove rubber seal (Figure 1, Item 3) and front window (Figure 1, Item 1) from cab (Figure 1, Item 4).

Figure 1. Front Window. END OF TASK

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TM 5-2410-241-23-3

0246

REAR WINDOW REMOVAL

000246

WARNING

To prevent injury to personnel, wear protective eye covering and gloves. 1. Disconnect hose (Figure 2, Item 6) from nipple (Figure 2, Item 5). 2. Open cap (Figure 2, Item 8) on wiper arm (Figure 2, Item 9). 3. Remove nut (Figure 2, Item 7) and wiper arm (Figure 2, Item 9) from machine.

NOTE
Apply liquid detergent to rubber seal to aid removal. 4. Unlock core (Figure 2, Item 2) from rubber seal (Figure 2, Item 3). 5. Remove rubber seal (Figure 2, Item 3) and rear window (Figure 2, Item 1) from cab (Figure 2, Item 4).

Figure 2. Rear Window. END OF TASK

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0246-3

TM 5-2410-241-23-3

0246

RIGHT SIDE WINDOWS REMOVAL

000246

WARNING

To prevent injury to personnel, wear protective eye covering and gloves.

NOTE
Apply liquid detergent to rubber seal to aid removal. 1. Remove ROPS (WP 0225). 2. Unlock core (Figure 3, Item 2) from rubber seal (Figure 3, Item 3). 3. Remove rubber seal (Figure 3, Item 3) and right rear window (Figure 3, Item 1) from cab (Figure 3, Item 7). 4. Remove core (Figure 3, Item 5) from rubber seal (Figure 3, Item 6). 5. With assistance, remove rubber seal (Figure 3, Item 6) and right front window (Figure 3, Item 4) from cab (Figure 3, Item 7).

Figure 3. Right Side Windows. END OF TASK

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TM 5-2410-241-23-3

0246

LEFT SIDE WINDOWS REMOVAL

000246

WARNING

To prevent injury to personnel, wear protective eye covering and gloves.

NOTE
Apply liquid detergent to rubber seal to aid removal. 1. Remove ROPS (WP 0225). 2. Unlock core (Figure 4, Item 6) from rubber seal (Figure 4, Item 5). 3. Remove rubber seal (Figure 4, Item 5) and left rear window (Figure 4, Item 7) from cab (Figure 4, Item 4). 4. Unlock core (Figure 4, Item 2) from rubber seal (Figure 4, Item 3). 5. With assistance, remove rubber seal (Figure 4, Item 3) and left front window (Figure 4, Item 1) from cab (Figure 4, Item 4).

Figure 4. Left Side Windows. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0246

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0246-5

TM 5-2410-241-23-3

0246

LEFT SIDE WINDOWS INSTALLATION

000246

WARNING

To prevent injury to personnel, wear protective eye covering and gloves.

NOTE
Apply liquid detergent to rubber seal to aid installation. 1. With assistance, install left front window (Figure 5, Item 1) and rubber seal (Figure 5, Item 3) on cab (Figure 5, Item 4). 2. Lock core (Figure 5, Item 2) on rubber seal (Figure 5, Item 3). 3. Install left rear window (Figure 5, Item 7) and rubber seal (Figure 5, Item 5) on cab (Figure 5, Item 4). 4. Lock core (Figure 5, Item 6) on rubber seal (Figure 5, Item 5). 5. Install ROPS (WP 0225).

Figure 5. Left Side Windows. END OF TASK

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TM 5-2410-241-23-3

0246

RIGHT SIDE WINDOWS INSTALLATION

000246

WARNING

To prevent injury to personnel, wear protective eye covering and gloves.

NOTE
Apply liquid detergent to rubber seal to aid installation. 1. With assistance, install right front window (Figure 6, Item 4) and rubber seal (Figure 6, Item 6) on cab (Figure 6, Item 7). 2. Lock core (Figure 6, Item 5) on rubber seal (Figure 6, Item 6). 3. Install right rear window (Figure 6, Item 1) and rubber seal (Figure 6, Item 3) on cab (Figure 6, Item 7). 4. Lock core (Figure 6, Item 2) on rubber seal (Figure 6, Item 3). 5. Install ROPS (WP 0225).

Figure 6. Right Side Windows. END OF TASK

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TM 5-2410-241-23-3

0246

REAR WINDOW INSTALLATION

000246

WARNING

To prevent injury to personnel, wear protective eye covering and gloves.

NOTE
Apply liquid detergent to rubber seal to aid installation. 1. Install rear window (Figure 7, Item 1) and rubber seal (Figure 7, Item 3) on cab (Figure 7, Item 4). 2. Lock core (Figure 7, Item 2) on rubber seal (Figure 7, Item 3). 3. Install wiper arm (Figure 7, Item 9) and nut (Figure 7, Item 7) on machine. 4. Close cap (Figure 7, Item 8) on wiper arm (Figure 7, Item 9). 5. Connect hose (Figure 7, Item 6) to nipple (Figure 7, Item 5).

Figure 7. Rear Window. END OF TASK

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TM 5-2410-241-23-3

0246

FRONT WINDOW INSTALLATION

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WARNING

To prevent injury to personnel, wear protective eye covering and gloves.

NOTE
Apply liquid detergent to rubber seal to aid installation. 1. Install front window (Figure 8, Item 1) and rubber seal (Figure 8, Item 3) on cab (Figure 8, Item 4). 2. Lock core (Figure 8, Item 2) on rubber seal (Figure 8, Item 3). 3. Install two wiper arms (Figure 8, Item 9) and nuts (Figure 8, Item 7) on machine. 4. Close two caps (Figure 8, Item 8) on wiper arms (Figure 8, Item 9). 5. Connect hose (Figure 8, Item 6) to nipple (Figure 8, Item 5).

Figure 8. Front Window. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

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0246-9/(10 blank)

24 TM 5-2410-241-23-3 0247

FIELD MAINTENANCE INSTRUCTIONS SEAT ASSEMBLY SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 4 7

INITIAL SETUP Tools and Special Tools 0 Materials/Parts - Continued Rivet (13) Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 118 Estimated Time to Complete 5.0 Hr 0 0 0 0 0 0 0 0 0 0 0 0
000247

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Tool kit, blind, fastener installation (S0700) (WP 0302, Item 68) 0 Socket, Impact, 3/8 Drive, 6 point 5/8 (S1374) (WP 0302, Item 68) 0 Socket, Impact, 3/8 Drive, 6 point, 9/16 (S1373) (WP 0302, Item 68) 0 Wrench Set, Master, Impact, 3/8 and 1/2 Drive (S0863) (WP 0302, Item 68) 0 Materials/Parts Rag, Wiping (WP 0303, Item 24) Cotter pin (2) Retainer REMOVAL 0 0 0 0

1. Pull straight up on headrest (Figure 1, Item 1) and remove from seat (Figure 1, Item 2).

Figure 1. Headrest.

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0247-1

TM 5-2410-241-23-3

0247

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
The seat weighs approximately 65 lb (30 kg). 2. With assistance, remove bolt (Figure 2, Item 2) and two washers (Figure 2, Item 3), lift lever (Figure 2, Item 4) and slide seat (Figure 2, Item 1) forward off suspension (Figure 2, Item 5) and remove from machine.

Figure 2. Seat. END OF TASK

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0247-2

TM 5-2410-241-23-3

0247

DISASSEMBLY 1. Remove bolt (Figure 3, Item 1), seat belt retractor (Figure 3, Item 2), and spacer (Figure 3, Item 4) from seat recliner bracket (Figure 3, Item 3).

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Figure 3. Seat Belt Retractor.

0247

2. Remove bolt (Figure 4, Item 2) and seat belt buckle (Figure 4, Item 1) from seat belt bracket (Figure 4, Item 3).

Figure 4. Seat Belt Buckle.

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0247-3

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 3. Remove two bolts (Figure 5, Item 2), washers (Figure 5, Item 3), and seat back cushion (Figure 5, Item 1) from seat recliner (Figure 5, Item 4).

Figure 5. Seat Back Cushion. 4. Remove spring (Figure 6, Item 4) from seat pan (Figure 6, Item 3) and seat adjuster (Figure 6, Item 6).

0247

5. Remove retainer (Figure 6, Item 1), adjuster rod (Figure 6, Item 5), and four plastic washers (Figure 6, Item 2) from seat adjuster (Figure 6, Item 6). Discard retainer. 6. Remove seat pan (Figure 6, Item 3) from seat adjuster (Figure 6, Item 6).

Figure 6. Seat Pan.

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0247-4

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 7. Remove five rivets (Figure 7, Item 2) and seat cushion (Figure 7, Item 1) from seat adjuster (Figure 7, Item 3). Discard rivets.

Figure 7. Seat Cushion.

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0247-5

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED

NOTE
Note position of stop on recliner shaft with seat in full upright and full recline position to aid installation. Note position of seat recliner gears on recliner shaft gears to aid installation. Note position of recliner shaft and shaft spring on seat adjuster to aid installation.

8. Remove two bolts (Figure 8, Items 1 and 3), washers (Figure 8, Items 2 and 4), and cover (Figure 8, Item 5) from assembly.

Figure 8. Cover. 9. Mark tooth on gear (Figure 9, Item 2) where latch (Figure 9, Item 1) is engaged.

0247

Figure 9. Mark Latch and Gear.

0247

0247-6

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 10. Remove cotter pin (Figure 10, Item 2), two washers (Figure 10, Item 6), clevis pin (Figure 10, Item 3), bar (Figure 10, Item 1), spring (Figure 10, Item 5), and latch (Figure 10, Item 4) from assembly. Discard cotter pin.

Figure 10. Bar.

0247

11. Remove cotter pin (Figure 11, Item 2), two washers (Figure 11, Item 5), and clevis pin (Figure 11, Item 3) from bar (Figure 11, Item 1) and latch (Figure 11, Item 4). Discard cotter pin.

Figure 11. Latch.

0247

0247-7

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 12. With seat back (Figure 12, Item 1) in full upright position, remove bolt (Figure 12, Item 2), washer (Figure 12, Item 4), and gear (Figure 12, Item 5) from recliner shaft (Figure 12, Item 3).

Figure 12. Gear. 13. Remove six bolts (Figure 13, Item 3) and nuts (Figure 13, Item 2) from two seat recliner brackets (Figure 13, Item 1) and seat adjuster (Figure 13, Item 4).

0247

Figure 13. Seat Recliner Brackets.

0247

0247-8

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 14. Remove two bolts (Figure 14, Item 1), spacers (Figure 14, Item 5), nuts (Figure 14, Item 2), seat recliner brackets (Figure 14, Item 4), and recliner shaft (Figure 14, Item 3) from assembly.

Figure 14. Recliner Shaft.

0247

0247-9

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 15. Remove screw (Figure 15, Item 2) and lumbar support adjustment knob (Figure 15, Item 1) from assembly.

Figure 15. Lumbar Support Adjustment Knob.

0247

NOTE
Mark springs to aid installation. 16. Remove two springs (Figure 16, Item 8) from seat adjuster (Figure 16, Item 6) and seat pan (Figure 16, Item 4). 17. Remove two nuts (Figure 16, Item 3), washers (Figure 16, Item 7), and seat adjuster (Figure 16, Item 6) from seat pan (Figure 16, Item 4). 18. Remove rod (Figure 16, Item 1) from seat adjuster release lever (Figure 16, Item 2). 19. Remove rod (Figure 16, Item 5) from two parts of seat adjuster (Figure 16, Item 6).

Figure 16. Seat Adjuster Springs.

0247

0247-10

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 20. Remove two springs (Figure 17, Item 2) and seat adjuster release levers (Figure 17, Item 1) from seat adjuster plate (Figure 17, Item 3).

Figure 17. Seat Adjuster Release Lever. 21. Remove two rivets (Figure 18, Item 3) and lumbar support (Figure 18, Item 4) from seat back (Figure 18, Item 2). Discard rivets. 22. Remove spring (Figure 18, Item 1) from lumbar support (Figure 18, Item 4).

0247

Figure 18. Lumbar Support.

0247

0247-11

TM 5-2410-241-23-3

0247

DISASSEMBLY CONTINUED 23. Remove six rivets (Figure 19, Item 3), bag (Figure 19, Item 5), plate (Figure 19, Item 4), and lanyard (Figure 19, Item 2) from seat back (Figure 19, Item 1). Discard rivets.

Figure 19. Seat Back Bag. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY 1. Install bag (Figure 19, Item 5), plate (Figure 19, Item 4), lanyard (Figure 19, Item 2), and six new rivets (Figure 19, Item 3) on seat back (Figure 19, Item 1).

0247

000247

000247

0247-12

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 2. Position lumbar support (Figure 20, Item 4) on seat back (Figure 20, Item 2) and install two new rivets (Figure 20, Item 3). 3. Install spring (Figure 20, Item 1) on lumbar support (Figure 20, Item 4).

000247

Figure 20. Lumbar Support. 4. Position seat adjuster release levers (Figure 21, Item 1) on seat adjuster plate (Figure 21, Item 3) and install two springs (Figure 21, Item 2).

0247

Figure 21. Seat Adjuster Release Lever.

0247

0247-13

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 5. Install rod (Figure 22, Item 1) on seat adjuster release lever (Figure 22, Item 2). 6. Install rod (Figure 22, Item 5) on two parts of seat adjuster (Figure 22, Item 6).

000247

7. Position two washers (Figure 22, Item 7) and seat adjuster (Figure 22, Item 6) on seat pan (Figure 22, Item 4) and install two nuts (Figure 22, Item 3). 8. Install two springs (Figure 22, Item 8) on seat pan (Figure 22, Item 4) and seat adjuster (Figure 22, Item 6).

Figure 22. Seat Adjuster Springs.

0247

9. Position lumbar support adjustment knob (Figure 23, Item 1) on assembly and install screw (Figure 23, Item 2).

Figure 23. Lumbar Support Adjustment Knob.

0247

0247-14

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 10. Install recliner shaft (Figure 24, Item 3), seat recliner brackets (Figure 24, Item 4), two spacers (Figure 24, Item 5), bolts (Figure 24, Item 1), and nuts (Figure 24, Item 2) on assembly.

Figure 24. Recliner Shaft.

0247

0247-15

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 11. Position two seat recliner brackets (Figure 25, Item 1) on seat adjuster (Figure 25, Item 4), and install six bolts (Figure 25, Item 3) and nuts (Figure 25, Item 2).

Figure 25. Seat Recliner Brackets. 12. With seat back (Figure 26, Item 1) in full upright position, install gear (Figure 26, Item 5), washer (Figure 26, Item 4), and bolt (Figure 26, Item 2) on recliner shaft (Figure 26, Item 3).

0247

Figure 26. Gear.

0247

0247-16

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 13. Install clevis pin (Figure 27, Item 3), two washers (Figure 27, Item 5), and new cotter pin (Figure 27, Item 2) on bar (Figure 27, Item 1) and latch (Figure 27, Item 4).

Figure 27. Latch. 14. Install latch (Figure 28, Item 4), spring (Figure 28, Item 5), bar (Figure 28, Item 1), clevis pin (Figure 28, Item 3), two washers (Figure 28, Item 6), and new cotter pin (Figure 28, Item 2) on assembly.

0247

Figure 28. Bar.

0247

0247-17

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 15. Engage latch (Figure 29, Item 1) at marked tooth on gear (Figure 29, Item 2).

Figure 29. Mark Latch and Gear.

0247

NOTE
Install components with seat in full upright and full recline position with stop on recliner shaft position as noted during disassembly. Install components with seat recliner gears on recliner shaft gears as noted during disassembly. Install components with recliner shaft and shaft spring positioned on seat adjuster as noted during disassembly.

16. Install cover (Figure 30, Item 5), two washers (Figure 30, Items 2 and 4), and bolts (Figure 30, Items 1 and 3) on assembly.

Figure 30. Cover.

0247

0247-18

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 17. Install seat adjuster (Figure 31, Item 6) on seat pan (Figure 31, Item 3). 18. Install four plastic washers (Figure 31, Item 2), adjuster rod (Figure 31, Item 5), and new retainer (Figure 31, Item 1) on seat adjuster (Figure 31, Item 6). 19. Install spring (Figure 31, Item 4) on seat pan (Figure 31, Item 3) and seat adjuster (Figure 31, Item 6).

Figure 31. Seat Pan. 20. Position seat cushion (Figure 32, Item 1) on seat adjuster (Figure 32, Item 3) and install five new rivets (Figure 32, Item 2).

0247

Figure 32. Seat Cushion.

0247

0247-19

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 21. Install seat back cushion (Figure 33, Item 1), two washers (Figure 33, Item 3), and bolts (Figure 33, Item 2) on seat recliner (Figure 33, Item 4).

Figure 33. Seat Back Cushion.

0247

22. Install seat belt buckle (Figure 34, Item 1) and bolt (Figure 34, Item 2) on seat belt bracket (Figure 34, Item 3).

Figure 34. Seat Belt Buckle.

0247

0247-20

TM 5-2410-241-23-3

0247

ASSEMBLY CONTINUED 23. Install spacer (Figure 35, Item 4), seat belt retractor (Figure 35, Item 2), and bolt (Figure 35, Item 1) on seat recliner bracket (Figure 35, Item 3).

Figure 35. Seat Belt Retractor. END OF TASK

0247

0247-21

TM 5-2410-241-23-3

0247

INSTALLATION

000247

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 seat weighs approximately 65 lb (30 kg). 1. With assistance, lift lever (Figure 36, Item 4), slide seat (Figure 36, Item 1) on suspension (Figure 36, Item 5), and install two washers (Figure 36, Item 3) and bolt (Figure 36, Item 2).

Figure 36. Seat.

0247

0247-22

TM 5-2410-241-23-3

0247

INSTALLATION CONTINUED 2. Install headrest (Figure 37, Item 1) on seat (Figure 37, Item 2).

000247

Figure 37. Headrest. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0247

000247

0247-23/(24 blank)

4 TM 5-2410-241-23-3 0248

FIELD MAINTENANCE SEAT SUSPENSION REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 4 8

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 0 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Seat assembly removed (WP 0247) Drawing Required TM 5-2410-241-24P, Figure 118 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0

0248-1

TM 5-2410-241-23-3

0248

REMOVAL

000248

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 seat suspension weighs approximately 61 lb (30 kg). With assistance, remove four bolts (Figure 1, Item 3), washers (Figure 1, Item 2), and seat suspension assembly (Figure 1, Item 1) from machine.

Figure 1. Seat Suspension Mounting. END OF TASK CLEANING AND INSPECTION Clean and inspect all components IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0248

000248

0248-2

TM 5-2410-241-23-3

0248

INSTALLATION

000248

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 seat suspension weighs approximately 61 lb (30 kg). With assistance, position seat suspension assembly (Figure 2, Item 1) on machine and install four washers (Figure 2, Item 2) and bolts (Figure 2, Item 3).

Figure 2. Seat Suspension Mounting. END OF TASK FOLLOW-ON TASKS 1. Install seat assembly (WP 0247). 2. Verify correct operation of air seat suspension (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0248

000248

0248-3/(4 blank)

22 TM 5-2410-241-23-3 0249

FIELD MAINTENANCE INSTRUCTIONS DOOR ASSEMBLY REPLACEMENT Door Removal, Door Glass Removal, Door Disassembly, Cleaning and Inspection, Door Assembly, Door Glass Installation, Door Installation
0 2 4 9

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Screwdriver Attachment, Torx 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Detergent, General Purpose, Liquid (WP 0303, Item 8) Seal (Foam) Seal (Rubber) 0 0 0 0 0 0 0 0 0 Personnel Required Two References WP 0250 WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 112, 113, 114 Estimated Time to Complete 2.5 Hr 0 0 0 0 0 0 0 0 0 0 0

NOTE
This procedure covers one door. Follow same procedure for other door. DOOR REMOVAL 1. Loosen two setscrews (Figure 1, Item 1) and remove door lock handle (Figure 1, Item 2) from machine.
000249

Figure 1. Door Lock.

0249

0249-1

TM 5-2410-241-23-3

0249

DOOR REMOVAL CONTINUED 2. Remove two bolts (Figure 2, Item 1) and interior door handle (Figure 2, Item 2) from machine.

Figure 2. Interior Door Handle. 3. Remove clip (Figure 3, Item 1) from machine.

0249

Figure 3. Clip.

0249

0249-2

TM 5-2410-241-23-3

0249

DOOR REMOVAL CONTINUED 4. Remove two caps (Figure 4, Item 2) from grip handle (Figure 4, Item 1).

Figure 4. Cap and Grip Handle. 5. Remove two bolts (Figure 5, Item 2) and grip handle (Figure 5, Item 1) from machine.

0249

Figure 5. Grip Handle Mounting Bolts.

0249

0249-3

TM 5-2410-241-23-3

0249

DOOR REMOVAL CONTINUED 6. Remove six bolts (Figure 6, Item 2) and interior cover (Figure 6, Item 1) from door assembly (Figure 6, Item 3).

Figure 6. Interior Cover.

0249

0249-4

TM 5-2410-241-23-3

0249

DOOR REMOVAL CONTINUED

NOTE
Mark and note position of door striker to aid installation. Note position and quantity of shims to aid installation.

7. Remove door striker (Figure 7, Item 2) and shims (Figure 7, Item 5) from cab (Figure 7, Item 1). 8. Remove shims (Figure 7, Item 5), O-ring (Figure 7, Item 4), and washer (Figure 7, Item 3) from door striker (Figure 7, Item 2). Discard O-ring.

Figure 7. Door Striker.

0249

0249-5

TM 5-2410-241-23-3

0249

DOOR REMOVAL CONTINUED

NOTE
Tag electrical connector to aid installation. 9. Disconnect hose (Figure 8, Item 3) from door (Figure 8, Item 6). 10. Disconnect harness electrical connector (Figure 8, Item 4) from wiper motor electrical connector (Figure 8, Item 5). 11. Remove tiedown strap (Figure 8, Item 1) from door (Figure 8, Item 6), hose (Figure 8, Item 3), and wiring harness (Figure 8, Item 2). Discard tiedown strap. 12. Position hose (Figure 8, Item 3) and wiring harness (Figure 8, Item 2) aside.

Figure 8. Hose and Electrical Connector.

0249

0249-6

TM 5-2410-241-23-3

0249

DOOR REMOVAL CONTINUED

NOTE
Mark position of exterior door latch bracket to aid installation. 13. Remove three bolts (Figure 9, Item 3), washers (Figure 9, Item 4), and exterior door latch bracket (Figure 9, Item 2) from door (Figure 9, Item 1).

Figure 9. Exterior Door Latch.

0249

0249-7

TM 5-2410-241-23-3

0249

DOOR REMOVAL CONTINUED 14. Remove seal (Figure 10, Item 1) 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
Door weighs approximately 75 lb (34 kg). 15. With assistance, remove six bolts (Figure 10, Item 2), washers (Figure 10, Item 3), and door (Figure 10, Item 4) from machine.

Figure 10. Door and Seal. END OF TASK

0249

0249-8

TM 5-2410-241-23-3

0249

DOOR GLASS REMOVAL

000249

1. Split seam of window seal (Figure 11, Item 3) as shown, and remove seal and window (Figure 11, Item 4) from door (Figure 11, Item 1). 2. Remove door seal (Figure 11, Item 2) from door (Figure 11, Item 1). Discard seal.

Figure 11. Window and Seal. END OF TASK

0249

0249-9

TM 5-2410-241-23-3

0249

DOOR DISASSEMBLY 1. Remove wiper arm and motor (WP 0250). 2. Remove retaining pin (Figure 12, Item 1) from assembly. 3. Remove four bolts (Figure 12, Item 3) and latch assembly (Figure 12, Item 2) from machine.

000249

Figure 12. Retaining Pin.

0249

0249-10

TM 5-2410-241-23-3

0249

DOOR DISASSEMBLY CONTINUED 4. Remove two bolts (Figure 13, Item 1) and exterior handle (Figure 13, Item 2) from machine.

Figure 13. Exterior Handle. 5. Remove clip (Figure 14, Item 1) and linkage assembly (Figure 14, Item 2) from machine.

0249

Figure 14. Linkage Assembly.

0249

0249-11

TM 5-2410-241-23-3

0249

DOOR DISASSEMBLY CONTINUED

NOTE
Door seals are glued on and are not re-usable if removed. Note location of seals to aid installation. 6. Remove foam seal (Figure 15, Item 3) and rubber seal (Figure 15, Item 2) from door (Figure 15, Item 1). Discard seals.

Figure 15. Door Seals. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0249

000249

0249-12

TM 5-2410-241-23-3

0249

DOOR ASSEMBLY

000249

NOTE
Door seals are glued on and are not re-usable if removed. Install seals as noted during removal. 1. Install new rubber seal (Figure 15, Item 2) and foam seal (Figure 15, Item 3) on door (Figure 15, Item 1). 2. Install linkage assembly (Figure 16, Item 2) and clip (Figure 16, Item 1) on door.

Figure 16. Linkage Assembly. 3. Install exterior handle (Figure 17, Item 2) and two bolts (Figure 17, Item 1) on machine.

0249

Figure 17. Exterior Handle.

0249

0249-13

TM 5-2410-241-23-3

0249

DOOR ASSEMBLY CONTINUED 4. Install latch assembly (Figure 18, Item 2) and four bolts (Figure 18, Item 3) on machine. 5. Install retaining pin (Figure 18, Item 1) on assembly. 6. Install wiper arm and motor (WP 0250).

Figure 18. Retaining Pin. END OF TASK

0249

0249-14

TM 5-2410-241-23-3

0249

DOOR GLASS INSTALLATION 1. Install new door seal (Figure 19, Item 2) on door (Figure 19, Item 1).

000249

NOTE
Lubricate inside of seal to aid window installation. 2. Install window seal (Figure 19, Item 3) in door (Figure 19, Item 1) and install window (Figure 19, Item 4) in seal. Close seam around window.

Figure 19. Window and Seal. END OF TASK

0249

0249-15

TM 5-2410-241-23-3

0249

DOOR INSTALLATION

000249

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
Door weighs approximately 75 lb (34 kg). 1. With assistance, install door (Figure 20, Item 4), six washers (Figure 20, Item 3), and bolts (Figure 20, Item 2) on machine. 2. Install seal (Figure 20, Item 1) on machine.

Figure 20. Door and Seal.

0249

0249-16

TM 5-2410-241-23-3

0249

DOOR INSTALLATION CONTINUED

NOTE
Install exterior door latch bracket as noted during removal. 3. Install exterior door latch bracket (Figure 21, Item 2), three washers (Figure 21, Item 4), and bolts (Figure 21, Item 3) on door (Figure 21, Item 1).

Figure 21. Exterior Door Latch.

0249

0249-17

TM 5-2410-241-23-3

0249

DOOR INSTALLATION CONTINUED

NOTE
Install electrical connector as noted during removal. 4. Position wiring harness (Figure 22, Item 2) and hose (Figure 22, Item 3) on door (Figure 22, Item 6). 5. Install new tiedown strap (Figure 22, Item 1) on wiring harness (Figure 22, Item 2), hose (Figure 22, Item 3), and door (Figure 22, Item 6). 6. Connect harness electrical connector (Figure 22, Item 4) on wiper motor electrical connector (Figure 22, Item 5). 7. Connect hose (Figure 22, Item 3) on door (Figure 22, Item 6).

Figure 22. Hose and Electrical Connector.

0249

0249-18

TM 5-2410-241-23-3

0249

DOOR INSTALLATION CONTINUED

NOTE
Install door striker as noted during removal. Install shims as noted during removal.

8. Install washer (Figure 23, Item 3), new O-ring (Figure 23, Item 4), and shims (Figure 23, Item 5) on door striker (Figure 23, Item 2). 9. Install door striker (Figure 23, Item 2) and shims (Figure 23, Item 5) on cab (Figure 23, Item 1).

Figure 23. Door Striker.

0249

0249-19

TM 5-2410-241-23-3

0249

DOOR INSTALLATION CONTINUED 10. Install interior cover (Figure 24, Item 1) and six bolts (Figure 24, Item 2) on door assembly (Figure 24, Item 3).

Figure 24. Interior Cover. 11. Install grip handle (Figure 25, Item 1) and two bolts (Figure 25, Item 2) on machine.

0249

Figure 25. Grip Handle Mounting Bolts.

0249

0249-20

TM 5-2410-241-23-3

0249

DOOR INSTALLATION CONTINUED 12. Install two caps (Figure 26, Item 2) on grip handle (Figure 26, Item 1).

Figure 26. Cap and Grip Handle. 13. Install clip (Figure 27, Item 1) on machine.

0249

Figure 27. Clip.

0249

0249-21

TM 5-2410-241-23-3

0249

DOOR INSTALLATION CONTINUED 14. Install interior door handle (Figure 28, Item 2) and two bolts (Figure 28, Item 1) on machine.

Figure 28. Interior Door Handle. 15. Install door lock handle (Figure 29, Item 2) on machine and tighten two setscrews (Figure 29, Item 1).

0249

Figure 29. Door Lock. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0249

000249

0249-22

12 TM 5-2410-241-23-3 0250

FIELD MAINTENANCE INSTRUCTIONS DOOR WIPER MOTOR, WIPER ARM AND WIPER BLADE REPLACEMENT Wiper Blade Removal, Wiper Arm Removal, Wiper Motor Removal, Cleaning and Inspection, Wiper Motor Installation, Wiper Arm Installation, Wiper Blade Installation
0 2 5 0

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Screwdriver Attachment, Torx 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Interior cover removed (WP 0249) Drawing Required TM 5-2410-241-24P, Figure 109 Estimated Time to Complete 2.0 Hr WIPER BLADE REMOVAL 1. Fold wiper arm (Figure 1, Item 3) back. 2. Squeeze release tab (Figure 1, Item 2) toward wiper arm (Figure 1, Item 3) to release wiper blade (Figure 1, Item 1). 3. Remove wiper blade (Figure 1, Item 1) from wiper arm (Figure 1, Item 3). 0 0 0 0 0 0 0 0 0
000250

Figure 1. Wiper Blade. END OF TASK

0250

0250-1

TM 5-2410-241-23-3

0250

WIPER ARM REMOVAL 1. Disconnect hose (Figure 2, Item 2) from spray nozzle (Figure 2, Item 1).

000250

Figure 2. Spray Nozzle and Hose. 2. Remove nut (Figure 3, Item 1) and clip (Figure 3, Item 2) from machine.

0250

Figure 3. Washer Hose Nut and Clip.

0250

0250-2

TM 5-2410-241-23-3

0250

WIPER BLADE REMOVAL CONTINUED 3. Lift cap (Figure 4, Item 1) and remove nut (Figure 4, Item 3), washer (Figure 4, Item 5), and wiper arm (Figure 4, Item 2) from wiper motor (Figure 4, Item 4).

Figure 4. Wiper Arm Assembly. END OF TASK

0250

0250-3

TM 5-2410-241-23-3

0250

WIPER MOTOR REMOVAL 1. Cut and discard tiedown straps (Figure 5, Item 2).

000250

NOTE
Tag electrical connector to aid installation. 2. Disconnect electrical connector (Figure 5, Item 1).

Figure 5. Wiper Motor Assembly.

0250

0250-4

TM 5-2410-241-23-3

0250

WIPER MOTOR REMOVAL CONTINUED 3. Disconnect hose (Figure 6, Item 1) from spray nozzle (Figure 6, Item 2). 4. Remove nut (Figure 6, Item 3), washer (Figure 6, Item 4), and spray nozzle (Figure 6, Item 2) from machine.

Figure 6. Spray Nozzle and Hoses. 5. Remove cap (Figure 7, Item 6) and collar (Figure 7, Item 7) from stud (Figure 7, Item 5).

0250

6. Remove cap (Figure 7, Item 3), nut (Figure 7, Item 2), washer (Figure 7, Item 8), sleeve (Figure 7, Item 1), and wiper motor (Figure 7, Item 4) from machine.

Figure 7. Wiper Motor Assembly. END OF TASK

0250

0250-5

TM 5-2410-241-23-3

0250

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK WIPER MOTOR INSTALLATION 1. Install wiper motor (Figure 8, Item 4), sleeve (Figure 8, Item 1), washer (Figure 8, Item 8), nut (Figure 8, Item 2), and cap (Figure 8, Item 3) on machine. 2. Install collar (Figure 8, Item 7) and cap (Figure 8, Item 6) on stud (Figure 8, Item 5).

000250

000250

Figure 8. Wiper Motor Assembly.

0250

0250-6

TM 5-2410-241-23-3

0250

WIPER MOTOR INSTALLATION CONTINUED 3. Install spray nozzle (Figure 9, Item 2), washer (Figure 9, Item 4), and nut (Figure 9, Item 3) on machine. 4. Connect hose (Figure 9, Item 1) on spray nozzle (Figure 9, Item 2).

000250

Figure 9. Spray Nozzle and Hoses.

0250

0250-7

TM 5-2410-241-23-3

0250

WIPER MOTOR INSTALLATION CONTINUED

000250

NOTE
Install electrical connector as tagged during removal. 5. Connect electrical connector (Figure 10, Item 1). 6. Install new tiedown straps (Figure 10, Item 2).

Figure 10. Wiper Motor Assembly. END OF TASK

0250

0250-8

TM 5-2410-241-23-3

0250

WIPER ARM INSTALLATION 1. Lift cap (Figure 11, Item 1) and install nut (Figure 11, Item 3), washer (Figure 11, Item 5), and wiper arm (Figure 11, Item 2) on wiper motor (Figure 11, Item 4).

000250

Figure 11. Wiper Arm Assembly. 2. Install clip (Figure 12, Item 2) and nut (Figure 12, Item 1) on machine.

0250

Figure 12. Washer Hose Nut and Clip.

0250

0250-9

TM 5-2410-241-23-3

0250

WIPER ARM INSTALLATION CONTINUED 3. Connect hose (Figure 13, Item 2) on spray nozzle (Figure 13, Item 1).

Figure 13. Spray Nozzle and Hose. END OF TASK

0250

0250-10

TM 5-2410-241-23-3

0250

WIPER BLADE INSTALLATION 1. Install wiper blade (Figure 14, Item 1) on wiper arm (Figure 14, Item 3). 2. Align tab (Figure 14, Item 2) of wiper blade (Figure 14, Item 1) to hole in wiper arm (Figure 14, Item 3) and snap into position. 3. Fold wiper arm (Figure 14, Item 3) to operating position.

000250

Figure 14. Wiper Blade. END OF TASK FOLLOW-ON TASKS 1. Install interior cover (WP 0249). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0250

000250

0250-11/(12 blank)

6 TM 5-2410-241-23-3 0251

FIELD MAINTENANCE INSTRUCTIONS


0 2 5 1

OUTSIDE CAB DOOR LATCH REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) 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) Rubber Washer Seal REMOVAL
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 113, 114 Estimated Time to Complete 0.5 Hr

000251

NOTE
Procedure will remove left outside cab door latch. Follow same procedure for right outside door latch. 1. Position door latch (Figure 1, Item 1) open on machine. 2. Remove three bolts (Figure 1, Item 3), washers (Figure 1, Item 4), and door latch bracket (Figure 1, Item 2) from machine.

Figure 1. Door Latch Bracket.

0251

0251-1

TM 5-2410-241-23-3

0251

REMOVAL CONTINUED 3. Loosen bolt (Figure 2, Item 5) from door striker (Figure 2, Item 1).

WARNING

Springs may have significant spring tension, depending upon type or position of spring. Use extreme caution when removing springs. Springs under tension can act as projectiles when released and could result in severe injury to personnel. 4. Remove spring (Figure 2, Item 4) from bolt (Figure 2, Item 3) and bracket (Figure 2, Item 7).

NOTE
Note and mark position of nut and bolt to aid installation. 5. Loosen nut (Figure 2, Item 2) and tighten bolt (Figure 2, Item 3) in door striker (Figure 2, Item 1). 6. Remove door striker (Figure 2, Item 1) from shaft (Figure 2, Item 6) and bracket (Figure 2, Item 7).

Figure 2. Door Striker.

0251

0251-2

TM 5-2410-241-23-3

0251

REMOVAL CONTINUED 7. Remove key (Figure 3, Item 5) from shaft (Figure 3, Item 2). 8. Remove shaft (Figure 3, Item 2) from bracket (Figure 3, Item 6) and cab. 9. Remove handle (Figure 3, Item 1) from shaft (Figure 3, Item 2). 10. Remove bumper (Figure 3, Item 7) from bracket (Figure 3, Item 6). 11. Remove four bolts (Figure 3, Item 4), washers (Figure 3, Item 3) and bracket (Figure 3, Item 6) from cab.

Figure 3. Latch Assembly. 12. Remove rubber washer seal (Figure 4, Item 1) from cab. Discard rubber washer seal.

0251

Figure 4. Cab. END OF TASK

0251

0251-3

TM 5-2410-241-23-3

0251

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install new rubber washer seal (Figure 4, Item 1) on cab. 2. Install bracket (Figure 5, Item 6), four washers (Figure 5, Item 3), and bolts (Figure 5, Item 4) on cab. 3. Install bumper (Figure 5, Item 7) on bracket (Figure 5, Item 6). 4. Install handle (Figure 5, Item 1) on shaft (Figure 5, Item 2). 5. Install shaft (Figure 5, Item 2) on bracket (Figure 5, Item 6) and cab. 6. Install key (Figure 5, Item 5) on shaft (Figure 5, Item 2).

000251

000251

Figure 5. Latch Assembly.

0251

0251-4

TM 5-2410-241-23-3

0251

INSTALLATION CONTINUED

NOTE
Position nut and bolt as noted during removal. 7. Install door striker (Figure 6, Item 1) on shaft (Figure 6, Item 6) and bracket (Figure 6, Item 7). 8. Loosen bolt (Figure 6, Item 3) and tighten nut (Figure 6, Item 2) on door striker (Figure 6, Item 1).

WARNING

Springs may have significant spring tension, depending upon type or position of spring. Use extreme caution when installing springs. Springs under tension can act as projectiles when released and could result in severe injury to personnel. 9. Install spring (Figure 6, Item 4) on bolt (Figure 6, Item 3) and bracket (Figure 6, Item 7). 10. Install bolt (Figure 6, Item 5) on door striker (Figure 6, Item 1).

Figure 6. Latch Striker.

0251

0251-5

TM 5-2410-241-23-3

0251

INSTALLATION CONTINUED 11. Install door latch bracket (Figure 7, Item 2), three washers (Figure 7, Item 4), and bolts (Figure 7, Item 3) on machine. 12. Position door latch (Figure 7, Item 1) down on machine.

Figure 7. Door Latch Bracket. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0251

000251

0251-6

12 TM 5-2410-241-23-3 0252

FIELD MAINTENANCE INSTRUCTIONS CAB FLOOD LAMP AND BRACKET SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 5 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Isopropyl Alcohol (WP 0303, Item 15) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Bulb (4) 0 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 121 Estimated Time to Complete 1.0 Hr 0 0 0 0 0 0 0 0

0252-1

TM 5-2410-241-23-3

0252

REMOVAL

000252

NOTE
Tag electrical connector to aid installation. The following procedure is for the right side cab flood lamps. Use the same procedure for the left side cab flood lamps.

1. Disconnect electrical connector (Figure 1, Item 13). 2. Remove bolt (Figure 1, Item 3), washer (Figure 1, Item 2), and flood lamp (Figure 1, Item 7) from guard (Figure 1, Item 8). 3. Remove nut (Figure 1, Item 1), two washers (Figure 1, Item 6), bolt (Figure 1, Item 5), and bracket (Figure 1, Item 4) from flood lamp (Figure 1, Item 7). 4. Repeat Steps 1-3 for other light.

NOTE
Only perform steps 5 through 7 if guard will be removed from machine. Tag wiring harness to aid installation.

5. Remove tiedown straps (Figure 1, Item 11) and position wiring harness (Figure 1, Item 9) aside. Discard tiedown straps.

0252-2

TM 5-2410-241-23-3

0252

REMOVAL CONTINUED

000252

NOTE
Nuts are located on both side of flexible mount. 6. Remove four nuts (Figure 1, Item 14), washers (Figure 1, Item 15), one ladder clip (Figure 1, Item 12), and guard (Figure 1, Item 8) from machine. 7. Remove four nuts (Figure 1, Item 14), washers (Figure 1, Item 15), and flexible mounts (Figure 1, Item 10) from guard (Figure 1, Item 8).

Figure 1. Flood Lamp Assembly. END OF TASK

0252

0252-3

TM 5-2410-241-23-3

0252

DISASSEMBLY

000252

NOTE
Flood lamp can be disassembled without removing guard from machine. 1. Remove bolt (Figure 2, Item 1) and open grille (Figure 2, Item 2). 2. Disengage and remove outer band clamp (Figure 2, Item 4) and pull lamp (Figure 2, Item 3) from grommet (Figure 2, Item 5).

Figure 2. Flood Lamp.

0252

0252-4

TM 5-2410-241-23-3

0252

DISASSEMBLY CONTINUED

NOTE
Tag electrical connectors to aid assembly. 3. Disconnect black connector (Figure 3, Item 1) from lamp assembly (Figure 3, Item 3). 4. Disconnect bulb white wire (Figure 3, Item 2) from lamp assembly (Figure 3, Item 3). Place lamp assembly on suitable bench.

Figure 3. Lamp Connectors.

0252

0252-5

TM 5-2410-241-23-3

0252

DISASSEMBLY CONTINUED 5. Disengage bale wires (Figure 4, Item 4) from lugs (Figure 4, Item 5). 6. Remove bulb (Figure 4, Item 2) from lamp assembly (Figure 4, Item 1) and feed bulb white wire from under the plastic retainer (Figure 4, Item 3). Discard bulb.

Figure 4. Bulb Assembly. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0252

000252

0252-6

TM 5-2410-241-23-3

0252

ASSEMBLY

000252

CAUTION
Do not touch the glass surface of a halogen bulb with bare fingers, as the surface will be exposed to the salts and oils in the hand. If glass is touched, it must be cleaned immediately with a gentle solvent such as alcohol. Failure to follow this caution will result in early bulb failure. 1. Install new bulb (Figure 5, Item 2) into lamp assembly (Figure 5, Item 1), feeding the bulb white wire under the plastic retainer (Figure 5, Item 3). 2. Secure bulb in place by engaging bale wires (Figure 5, Item 4) under lugs (Figure 5, Item 5).

Figure 5. Bulb Assembly.

0252

0252-7

TM 5-2410-241-23-3

0252

ASSEMBLY CONTINUED

NOTE
Install connectors as tagged during disassembly. 3. Connect black connector (Figure 6, Item 1) on lamp assembly (Figure 6, Item 3). 4. Connect white wire (Figure 6, Item 2) on lamp assembly (Figure 6, Item 3).

Figure 6. Lamp Connectors.

0252

0252-8

TM 5-2410-241-23-3

0252

ASSEMBLY CONTINUED 5. Install lamp assembly (Figure 7, Item 3) into grommet (Figure 7, Item 5). 6. Position and engage band clamp (Figure 7, Item 4) around grommet. 7. Close grille (Figure 7, Item 2) and install bolt (Figure 7, Item 1).

Figure 7. Flood Lamp. END OF TASK

0252

0252-9

TM 5-2410-241-23-3

0252

INSTALLATION

000252

NOTE
Nuts are located on both sides of flexible mount. 1. Install four flexible mounts (Figure 8, Item 10), washers (Figure 8, Item 15), and nuts (Figure 8, Item 14) on guard (Figure 8, Item 8). 2. Install guard (Figure 8, Item 8), ladder clip (Figure 8, Item 12), four washers (Figure 8, Item 15), and nuts (Figure 8 Item 14) on machine. 3. Position bracket (Figure 8, Item 4) on flood lamp (Figure 8, Item 7) and install bolt (Figure 8, Item 5), two washers (Figure 8, Item 6), and nut (Figure 8, Item 1). 4. Install flood lamp (Figure 8, Item 7), washer (Figure 8, Item 2), and bolt (Figure 8, Item 3) on guard (Figure 8, Item 8).

NOTE
Install electrical connector as tagged during removal. 5. Connect electrical connector (Figure 8, Item 13). 6. Route wiring harness (Figure 8, Item 9) and install new tiedown straps (Figure 8, Item 11).

Figure 8. Flood Lamp Assembly. END OF TASK

0252

0252-10

TM 5-2410-241-23-3

0252

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

000252

0252-11/(12 blank)

16 TM 5-2410-241-23-3 0253

FIELD MAINTENANCE INSTRUCTIONS ENGINE FLOOD LAMP AND BRACKET SERVICE Flood Lamp Removal, Flood Lamp Switch Removal, Flood Lamp Disassembly, Cleaning and Inspection, Flood Lamp Assembly, Flood Lamp Switch Installation, Flood Lamp Installation
0 2 5 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Materials/Parts Isopropyl Alcohol (WP 0303, Item 15) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Bulb Locknut Lockwasher FLOOD LAMP REMOVAL 0 0 0 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 99 Estimated Time to Complete 1.0 Hr 0 0 0 0 0 0 0 0

000253

NOTE
Tag electrical connectors to aid installation. 1. Disconnect electrical connector (Figure 1, Item 2) from flood lamp (Figure 1, Item 1).

Figure 1. Electrical Connector.

0253

0253-1

TM 5-2410-241-23-3

0253

FLOOD LAMP REMOVAL CONTINUED 2. Remove nut (Figure 2, Item 1) and flood lamp (Figure 2, Item 3) from mounting bracket (Figure 2, Item 2).

Figure 2. Flood Lamp Assembly.

0253

0253-2

TM 5-2410-241-23-3

0253

FLOOD LAMP REMOVAL CONTINUED

NOTE
Remove adjusting bracket from flood lamp carefully to avoid losing clips. 3. Remove locknut (Figure 3, Item 3), washer (Figure 3, Item 1), bolt (Figure 3, Item 7), adjusting bracket (Figure 3, Item 2), clips (Figure 3, Item 4), and sleeve (Figure 3, Item 6) from flood lamp (Figure 3, Item 5). Discard locknut.

Figure 3. Flood Lamp and Adjusting Bracket.

0253

0253-3

TM 5-2410-241-23-3

0253

FLOOD LAMP REMOVAL CONTINUED 4. Remove bolt (Figure 4, Item 1) and two washers (Figure 4, Item 2) from adjusting bracket (Figure 4, Item 3).

Figure 4. Adjusting Bracket Assembly. END OF TASK

0253

0253-4

TM 5-2410-241-23-3

0253

FLOOD LAMP SWITCH REMOVAL

000253

1. Remove nut (Figure 5, Item 2), lockwasher (Figure 5, Item 6), washer (Figure 5, Item 1), key (Figure 5, Item 4), and switch (Figure 5, Item 5) from bracket (Figure 5, Item 3). Discard lockwasher.

Figure 5. Flood Lamp Switch. 2. Cut and discard tiedown strap (Figure 6, Item 1). 3. Disconnect connector (Figure 6, Item 2) from flood lamp switch connector (Figure 6, Item 3) and remove switch.

0253

Figure 6. Connectors.

0253

0253-5

TM 5-2410-241-23-3

0253

FLOOD LAMP SWITCH REMOVAL CONTINUED 4. Remove two bolts (Figure 7, Item 2), washers (Figure 7, Item 1), and mounting bracket (Figure 7, Item 3) from machine.

Figure 7. Mounting Bracket. END OF TASK FLOOD LAMP DISASSEMBLY

0253

000253

NOTE
Flood lamp assembly does not have to be removed for this procedure. 1. Remove two screws (Figure 8, Item 1) and trim (Figure 8, Item 2) from flood lamp (Figure 8, Item 3).

Figure 8. Flood Lamp Screws and Trim.

0253

0253-6

TM 5-2410-241-23-3

0253

FLOOD LAMP DISASSEMBLY CONTINUED

NOTE
Tag electrical connectors to aid assembly. 2. Disconnect black wire (Figure 9, Item 1) from lamp assembly (Figure 9, Item 2). 3. Disengage white wire (Figure 9, Item 4) from plastic retainer (Figure 9, Item 3), and disconnect white wire from lamp assembly (Figure 9, Item 2). Place lamp assembly on suitable bench.

Figure 9. Flood Lamp Connections. 4. Disengage bale wires (Figure 10, Item 4) from lugs (Figure 10, Item 2). 5. Remove bulb (Figure 10, Item 3) from lamp assembly (Figure 10, Item 1). Discard bulb.

0253

Figure 10. Bulb Assembly. END OF TASK

0253

0253-7

TM 5-2410-241-23-3

0253

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK FLOOD LAMP ASSEMBLY
000253

CAUTION
Do not touch the glass surface of a halogen bulb with bare fingers, as the surface will be exposed to the salts and oils in the hand. If glass is touched, it must be cleaned immediately with a gentle solvent such as alcohol. Failure to follow this caution will result in early bulb failure. 1. Install new bulb (Figure 11, Item 3) in lamp assembly (Figure 11, Item 1). 2. Secure bulb in place by engaging bale wires (Figure 11, Item 4) on lugs (Figure 11, Item 2).

Figure 11. Bulb Assembly.

0253

0253-8

TM 5-2410-241-23-3

0253

FLOOD LAMP ASSEMBLY CONTINUED

NOTE
Install electrical connectors as tagged during disassembly. 3. Connect black wire (Figure 12, Item 1) to lamp assembly (Figure 12, Item 2). 4. Connect white wire (Figure 12, Item 4) to plastic retainer (Figure 12, Item 3).

Figure 12. Flood Lamp Connections. 5. Position trim (Figure 13, Item 2) on flood lamp (Figure 13, Item 3). 6. Install two screws (Figure 13, Item 1) on trim (Figure 13, Item 2).

0253

Figure 13. Flood Lamp Screws and Trim. END OF TASK

0253

0253-9

TM 5-2410-241-23-3

0253

FLOOD LAMP SWITCH INSTALLATION

000253

1. Position mounting bracket (Figure 14, Item 3) on machine and install two washers (Figure 14, Item 2) and bolts (Figure 14, Item 1).

Figure 14. Mounting Bracket. 2. Connect connector (Figure 15, Item 2) on flood lamp switch connector (Figure 15, Item 3). 3. Install new tiedown strap (Figure 15, Item 1).

0253

Figure 15. Connectors.

0253

0253-10

TM 5-2410-241-23-3

0253

FLOOD LAMP SWITCH INSTALLATION CONTINUED 4. Install switch (Figure 16, Item 5), key (Figure 16, Item 4), washer (Figure 16, Item 1), new lockwasher (Figure 16, Item 6), and nut (Figure 16, Item 2) on bracket (Figure 16, Item 3).

Figure 16. Flood Lamp Switch. END OF TASK

0253

0253-11

TM 5-2410-241-23-3

0253

FLOOD LAMP INSTALLATION 1. Install two washers (Figure 17, Item 2) and bolt (Figure 17, Item 1) on adjusting bracket (Figure 17, Item 3).

000253

Figure 17. Adjusting Bracket Assembly.

0253

0253-12

TM 5-2410-241-23-3

0253

FLOOD LAMP INSTALLATION CONTINUED 2. Install sleeve (Figure 18, Item 6), clips (Figure 18, Item 4), adjusting bracket (Figure 18, Item 2), bolt (Figure 18, Item 7), washer (Figure 18, Item 1), and new locknut (Figure 18, Item 3) on flood lamp (Figure 18, Item 5).

Figure 18. Flood Lamp and Adjusting Bracket.

0253

0253-13

TM 5-2410-241-23-3

0253

FLOOD LAMP INSTALLATION CONTINUED 3. Install flood lamp assembly (Figure 19, Item 3) and nut (Figure 19, Item 1) on mounting bracket (Figure 19, Item 2).

Figure 19. Flood Lamp Assembly.

0253

NOTE
Install electrical connectors as tagged during removal. 4. Connect electrical connector (Figure 20, Item 2) on flood lamp (Figure 20, Item 1).

Figure 20. Electrical Connector. END OF TASK

0253

0253-14

TM 5-2410-241-23-3

0253

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

000253

0253-15/(16 blank)

22 TM 5-2410-241-23-3 0254

FIELD MAINTENANCE INSTRUCTIONS CAB WIRING HARNESS REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 5 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Drill-driver, Battery Rechargeable (S0188) (WP 0302, Item 68) Drill Set, 1/16 to 1/2 Twist (S0194) (WP 0302, Item 68) Screwdriver Attachment, Torx, 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) Tool Kit, Blind Fastener Installation (S0700) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Rivet (4) 0 0 0 0 0 0 0 0 0 0 0 References WP 0295 Equipment Condition 0 0 0

Machine parked (TM 5-2410-241-10) 0 Headliner, and interior trim panels, removed (WP 0229) 0 ROPS removed (WP 0225) 0 Drawing Required 0

TM 5-2410-241-24P, Figure 107, 108, 113, 114 0 Estimated Time to Complete 4.5 Hr 0 0

0254-1

TM 5-2410-241-23-3

0254

REMOVAL

000254

NOTE
The following procedure removes the cab wiring harness from right door. Use the same procedure to remove the cab wiring harness from the left door. 1. Loosen two setscrews (Figure 1, Item 6) and remove door lock handle (Figure 1, Item 5) from door assembly (Figure 1, Item 10). 2. Remove two bolts (Figure 1, Item 7) and interior door handle (Figure 1, Item 8) from door assembly (Figure 1, Item 10). 3. Remove two caps (Figure 1, Item 2) from grip handle (Figure 1, Item 3). 4. Remove two bolts (Figure 1, Item 1) and grip handle (Figure 1, Item 3) from door assembly (Figure 1, Item 10). 5. Remove six bolts (Figure 1, Item 9) and interior cover (Figure 1, Item 4) from door assembly (Figure 1, Item 10).

Figure 1. Door.

0254

0254-2

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED

NOTE
Tag all electrical harness connectors to aid installation. 6. Disconnect cab wiring harness connector (Figure 2, Item 1) from door wiper motor (Figure 2, Item 2).

Figure 2. Electrical Harness and Washer Hoses.

0254

0254-3

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED

NOTE
Tag all electrical harness connectors to aid installation. 7. Remove four bolts (Figure 3, Item 1) from instrument panel (Figure 3, Item 2). 8. Remove two bolts (Figure 3, Item 4) and washers (Figure 3, Item 3) from instrument panel (Figure 3, Item 2). 9. Tilt instrument panel (Figure 3, Item 2) back and allow it to rest on the support cable.

Figure 3. Instrument Panel.

0254

0254-4

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED 10. Remove four bolts (Figure 4, Item 3), washers (Figure 4, Item 2), and surround (Figure 4, Item 1) from instrument panel (Figure 4, Item 4).

Figure 4. Surround.

0254

0254-5

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED

NOTE
Tag all electrical harness connectors to aid installation. 11. Disconnect cab wiring harness connector (Figure 5, item 2) from instrument panel connector (Figure 5, item 4) and position connector through hole in flange (Figure 5, item 5). 12. Remove felt liner (Figure 5, item 1) from cab (Figure 5, item 3) along left side of front window.

Figure 5. Instrument Panel Connector.

0254

0254-6

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note wiring harness routing to aid installation. Note location of tiedown straps to aid installation.

13. Remove and discard tiedown straps (Figure 6, Item 2) from cab wiring harness (Figure 6, Item 1) and front wiper motor (Figure 6, Item 3) connector. 14. Disconnect front wiper motor (Figure 6, Item 3) from cab wiring harness (Figure 6, Item 1).

Figure 6. Front Wiper.

0254

0254-7

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note wiring harness routing to aid installation. Note location of tiedown straps to aid installation.

15. Disconnect cab wiring harness connector (Figure 7, Item 6) and four washer hoses (Figure 7, Item 5) from windshield washer bottle (Figure 7, Item 1). 16. Remove and discard tiedown straps (Figure 7, Item 4) from hose and harness conduit (Figure 7, Item 3). 17. Remove hose and harness conduit (Figure 7, Item 3) from pivot shaft oil reservoir compartment (Figure 7, Item 2).

Figure 7. Washer Electrical Harness and Hoses.

0254

0254-8

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED 18. Remove four rivets (Figure 8, Item 4) from cab harness access plate (Figure 8, Item 3). Position cab harness access plate from cab. Discard rivets. 19. Remove conduit (Figure 8, Item 1) from cab wiring harness (Figure 8, Item 2) and cab harness access plate (Figure 8, Item 3). 20. Position cab wiring harness (Figure 8, Item 2) from cab harness access plate (Figure 8, Item 3).

Figure 8. Hose and Harness Conduit.

0254

0254-9

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED 21. Carefully pull cab wiring harness (Figure 9, item 1) from column through access hole (Figure 9, item 2).

Figure 9. Left Column Access Hole.

0254

NOTE
Tag and mark electrical connectors to aid installation. 22. Remove nut (Figure 10, Item 2), washer (Figure 10, Item 3), and ground terminal (Figure 10, Item 1) from cross member of cab (Figure 10, Item 4).

Figure 10. Ground Connection.

0254

0254-10

TM 5-2410-241-23-3

0254

REMOVAL CONTINUED

NOTE
Tag and mark electrical connectors to aid installation. Note wiring harness routing to aid installation. Note location of tiedown straps to aid installation.

23. Remove and discard tiedown straps (Figure 11, Item 1) from cab wiring harness (Figure 11, Item 2) and cab. 24. Remove two pieces of conduit (Figure 11, Items 4 and 5) from cab wiring harness (Figure 11, Item 2) at doors. 25. Remove cab wiring harness (Figure 11, Item 2) through access hole (Figure 11, Item 3) in cab cross member.

Figure 11. Cab Wiring Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0254

000254

0254-11

TM 5-2410-241-23-3

0254

INSTALLATION

000254

NOTE
Install electrical connectors as noted during removal. Install wiring harness as noted during removal. Install tiedown straps as noted during removal.

1. Install cab wiring harness (Figure 12, Item 2) through access hole (Figure 12, Item 3) in cab cross member. 2. Install two pieces of conduit (Figure 12, Item 4 and 5) on cab wiring harness (Figure 12, Item 2) at doors. 3. Install new tiedown straps (Figure 12, Item 1) on cab wiring harness (Figure 12, Item 2) and cab.

Figure 12. Cab Wiring Harness.

0254

0254-12

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. 4. Install ground terminal (Figure 13, Item 1), washer (Figure 13, Item 3), and nut (Figure 13, Item 2) on cross member of cab (Figure 13, Item 4).

Figure 13. Ground Connection. 5. Install cab wiring harness (Figure 14, Item 1) into column through access hole (Figure 14, Item 2).

0254

Figure 14. Left Column Access Hole.

0254

0254-13

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED 6. Position cab wiring harness (Figure 15, Item 2) in cab harness access plate (Figure 15, Item 3). 7. Install conduit (Figure 15, Item 1) on cab wiring harness (Figure 15, Item 2) and cab harness access plate (Figure 15, Item 3). 8. Position cab harness access plate (Figure 15, Item 3) on cab. 9. Install four new rivets (Figure 15, Item 4) on cab harness access plate (Figure 15, Item 3).

Figure 15. Hose and Harness Conduit.

0254

0254-14

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. Install wiring harness as noted during removal. Install tiedown straps as noted during removal.

10. Route hose and harness conduit (Figure 16, Item 3) into pivot shaft oil reservoir compartment (Figure 16, Item 2). 11. Install new tiedown straps (Figure 16, Item 4) on hose and harness conduit (Figure 16, Item 3). 12. Connect cab wiring harness connector (Figure 16, Item 6) and four washer hoses (Figure 16, Item 5) to windshield washer bottle (Figure 16, Item 1).

Figure 16. Washer Electrical Harness and Hoses.

0254

0254-15

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. Install wiring harness as noted during removal. Install tiedown straps as noted during removal.

13. Connect front wiper motor (Figure 17, Item 3) to cab wiring harness (Figure 17, Item 1). 14. Install new tiedown straps (Figure 17, Item 2) on cab wiring harness (Figure 17, Item 1) and front wiper motor (Figure 17, Item 3) connector.

Figure 17. Front Wiper.

0254

0254-16

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. 15. Install felt liner (Figure 18, Item 1) on cab (Figure 18, Item 3) along left side of front window. 16. Insert cab wiring harness connector (Figure 18, Item 2) through hole in flange (Figure 18, Item 5) and connect cab wiring harness connector to instrument panel connector (Figure 18, Item 4).

Figure 18. Instrument Panel Connector.

0254

0254-17

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED 17. Install surround (Figure 19, Item 1), four washers (Figure 19, Item 2), and bolts (Figure 19, Item 3) on instrument panel (Figure 19, Item 4).

Figure 19. Surround.

0254

0254-18

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. 18. Lift instrument panel (Figure 20, Item 2) up to mounting position. 19. Install two washers (Figure 20, Item 3) and bolts (Figure 20, Item 4) on instrument panel (Figure 20, Item 2). 20. Install four bolts (Figure 20, Item 1) on instrument panel (Figure 20, Item 2).

Figure 20. Instrument Panel.

0254

0254-19

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED

NOTE
Install electrical connectors as noted during removal. The following procedure installs the cab wiring harness on right door. Use the same procedure to install the cab wiring harness on the left door.

21. Connect cab wiring harness connector (Figure 21, Item 1) to door wiper motor (Figure 21, Item 2).

Figure 21. Electrical Harness and Washer Hoses.

0254

0254-20

TM 5-2410-241-23-3

0254

INSTALLATION CONTINUED 22. Install interior cover (Figure 22, Item 4) and six bolts (Figure 22, Item 9) on door assembly (Figure 22, Item 10). 23. Install grip handle (Figure 22, Item 3) and two bolts (Figure 22, Item 1) on door assembly (Figure 22, Item 10). 24. Install two caps (Figure 22, Item 2) on grip handle (Figure 22, Item 3). 25. Install interior door handle (Figure 22, Item 8) and two bolts (Figure 22, Item 7) on door assembly (Figure 22, Item 10). 26. Install door lock handle (Figure 22, Item 5) on door assembly (Figure 22, Item 10) and tighten two setscrews (Figure 22, Item 6).

Figure 22. Door. END OF TASK FOLLOW-ON TASKS 1. Install headliner, panels, and rear view mirror (WP 0229). 2. Install ROPS (WP 0225) 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0254

000254

0254-21/(22 blank)

4 TM 5-2410-241-23-3 0255

FIELD MAINTENANCE INSTRUCTIONS


0 2 5 5

FIRE EXTINGUISHER AND BRACKET 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) References WP 0295 REMOVAL 1. Open latch (Figure 1, Item 2) and lift and remove fire extinguisher (Figure 1, Item 1) from bracket (Figure 1, Item 3). 0 0 0 0 0 0
000255

Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 126 Estimated Time to Complete 0.5 Hr

0 0 0 0 0 0

Figure 1. Fire Extinguisher.

0255

0255-1

TM 5-2410-241-23-3

0255

REMOVAL CONTINUED 2. Remove four screws (Figure 2, Item 5) and extinguisher bracket (Figure 2, Item 1) from bracket (Figure 2, Item 4). 3. Remove four bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and bracket (Figure 2, Item 4) from console panel (Figure 2, Item 6).

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

0255

000255

0255-2

TM 5-2410-241-23-3

0255

INSTALLATION 1. Install bracket (Figure 2, Item 4), four washers (Figure 2, Item 3), and bolts (Figure 2, Item 2) on console panel (Figure 2, Item 6). 2. Install extinguisher bracket (Figure 2, Item 1) and four screws (Figure 2, Item 5) on bracket (Figure 2, Item 4). 3. Install fire extinguisher (Figure 3, Item 1) on bracket (Figure 3, Item 3) and close latch (Figure 3, Item 2).

Figure 3. Fire Extinguisher. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0255

000255

0255-3/(4 blank)

6 TM 5-2410-241-23-3 0256

FIELD MAINTENANCE INSTRUCTIONS PILOT VALVE SERVICE (WITH RIPPER) Removal, Cleaning and Inspection, Installation Effectivity Notice (With Ripper)
0 2 5 6

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 O-ring (12) REMOVAL 0 0 0 0 0 0 0 0 References WP 0295 Equipment Condition Bulldozer pilot valve removed (WP 0259) Drawing Required TM 5-2410-241-24P, Figure 74, 115 Estimated Time to Complete 7.0 Hr
000256

0 0 0 0 0 0 0 0

NOTE
Tag hoses to aid installation. Cap and plug all hoses to prevent contamination and leaks.

1. Disconnect six hoses (Figure 1, Item 1) from pilot valve (Figure 1, Item 2).

Figure 1. Hoses and Pilot Valve.

0256

0256-1

TM 5-2410-241-23-3

0256

REMOVAL CONTINUED 2. Remove pilot valve and hand control assembly (Figure 2, Item 2) and plate (Figure 2, Item 1) from machine.

Figure 2. Pilot Valve and Hand Control Assembly. 3. Unscrew and remove knob (Figure 3, Item 1) from assembly. 4. Remove four bolts (Figure 3, Item 10), washers (Figure 3, Item 9) and lever assembly (Figure 3, Item 2) from base plate (Figure 3, Item 4).

0256

NOTE
Note orientation of retainer plate. 5. Remove retainer plate (Figure 3, Item 7) from lever assembly (Figure 3, Item 2). 6. Remove boot (Figure 3, Item 3) from lever assembly (Figure 3, Item 2).

0256-2

TM 5-2410-241-23-3

0256

REMOVAL CONTINUED

NOTE
Note position and orientation of fittings and O-rings. 7. Remove 6 fittings (Figure 3, Item 5) and 12 O-rings (Figure 3, Item 6) from valve body (Figure 3, Item 8). Discard O-rings.

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

0256

000256

0256-3

TM 5-2410-241-23-3

0256

INSTALLATION

000256

NOTE
Install fittings and O-rings as noted during removal. 1. Install 12 new O-rings (Figure 4, Item 6) and 6 fittings (Figure 4, Item 5) on valve body (Figure 4, Item 8).

NOTE
Install retainer plate as noted during removal. 2. Install boot (Figure 4, Item 3), and retainer plate (Figure 4, Item 7) on lever assembly (Figure 4, Item 2). 3. Install lever assembly (Figure 4, Item 2), four washers (Figure 4, Item 9) and bolts (Figure 4, Item 10) on base plate (Figure 4, Item 4). 4. Screw knob (Figure 4, Item 1) on assembly.

Figure 4. Knob, Base Plate and Fittings.

0256

0256-4

TM 5-2410-241-23-3

0256

INSTALLATION CONTINUED 5. Position pilot valve and hand control assembly (Figure 5, Item 2) and plate (Figure 5, Item 1) on machine.

000256

Figure 5. Pilot Valve and Hand Control Assembly.

0256

NOTE
Install hoses as tagged during removal. 6. Connect six hoses (Figure 6, Item 1) on pilot valve (Figure 6, Item 2).

Figure 6. Hoses and Pilot Valve. END OF TASK FOLLOW-ON TASKS 1. Install bulldozer pilot valve (WP 0259). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE 0256-5/(6 blank)

0256

000256

4 TM 5-2410-241-23-3 0257

FIELD MAINTENANCE INSTRUCTIONS PILOT VALVE SERVICE (WITH WINCH) Removal, Cleaning and Inspection, Installation Effectivity Notice (With Winch)
0 2 5 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) O-ring (16) References WP 0295 REMOVAL 0 0 0 0 0 0 0 0 Equipment Condition Machine parked (TM 5-2410-241-10) Seat suspension removed (WP 0248) Right access panels removed (WP 0208) Bulldozer pilot valve removed (WP 0259) Drawing Required TM 5-2410-241-24P, Figure 116 Estimated Time to Complete 7.5 Hr 0 0 0 0 0 0 0 0 0
000257

NOTE
Tag hoses to aid installation. Tag electrical connectors to aid installation.

1. Disconnect six hoses (Figure 1, Item 5) from pilot valve (Figure 1, Item 4). 2. Disconnect two pilot valve wire harness connectors (Figure 1, Items 2 and 3) from machine harnesses (Figure 1, Item 1).

Figure 1. Winch Pilot Valve Hoses and Connectors.

0257

0257-1

TM 5-2410-241-23-3

0257

REMOVAL CONTINUED 3. Remove winch pilot valve (Figure 2, Item 1) and plate (Figure 2, Item 3) from machine and place on suitable work bench.

NOTE
Note position and orientation of fittings to aid installation. 4. Remove six O-rings (Figure 2, Item 6) from fittings (Figure 2, Item 4). Discard O-rings. 5. Remove six fittings (Figure 2, Item 4) and O-rings (Figure 2, Item 5) from valve body (Figure 2, Item 7). Discard O-rings. 6. Remove four bolts (Figure 2, Item 11), washers (Figure 2, Item 10) and pilot valve (Figure 2, Item 1) from plate (Figure 2, Item 3). 7. Loosen set screw (Figure 2, Item 9) and remove handle (Figure 2, Item 2) and boot (Figure 2, Item 8) from pilot valve (Figure 2, Item 1).

Figure 2. Winch Pilot Valve and Plate Assembly. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0257

000257

0257-2

TM 5-2410-241-23-3

0257

INSTALLATION

000257

NOTE
Install fittings as noted during disassembly. 1. Install boot (Figure 2, Item 8), handle (Figure 2, Item 2) and tighten set screw (Figure 2, Item 9) on pilot valve (Figure 2, Item 1). 2. Install pilot valve (Figure 2, Item 1), four washers (Figure 2, Item 10) and bolts (Figure 2, Item 11) on plate (Figure 2, Item 3). 3. Install six new O-rings (Figure 2, Item 5) and fittings (Figure 2, Item 1) on valve body (Figure 2, Item 7). 4. Install six O-rings (Figure 2, Item 6) on fittings (Figure 2, Item 4). 5. Position winch pilot valve assembly (Figure 2, Item 1) and plate (Figure 2, Item 3) on machine.

NOTE
Install hoses as tagged during removal. Connect wiring harness connectors as tagged during removal.

6. Connect two pilot valve wire harness connectors (Figure 3, Items 2 and 3) to machine harnesses (Figure 3, Item 1). 7. Connect six hoses (Figure 3, Item 5) to pilot valve (Figure 3, Item 4).

Figure 3. Hoses and Pilot Valve. END OF TASK

0257

0257-3

TM 5-2410-241-23-3

0257

FOLLOW-ON TASKS 1. Install bulldozer pilot valve (WP 0259). 2. Install right access panels (WP 0208). 3. Install seat suspension (WP 0248). 4. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000257

0257-4

14 TM 5-2410-241-23-3 0258

FIELD MAINTENANCE INSTRUCTIONS


0 2 5 8

GOVERNOR AND BRAKE PEDAL REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools 0 Materials/Parts - Continued Rivet (4) Seal (4) References WP 0037 WP 0295 Equipment Condition 0 0 0 0 0 0 Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 119 Estimated Time to Complete 1.5 Hr 0 0 0 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Goggles (S0209) (WP 0302, Item 68) 0 Screwdriver Attachment, Torx, T-10 (S0283) (WP 0302, Item 68) 0 Materials/Parts Grease, Automotive and Artillery (GAA) (WP 0303, Item 12) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Bearing (4) Locknut (2) 0

0258-1

TM 5-2410-241-23-3

0258

REMOVAL

000258

NOTE
Tag all electrical harness connectors to aid installation. 1. Remove four screws (Figure 1, Item 1), two bolts (Figure 1, Item 3), and washers (Figure 1, Item 4) from instrument panel (Figure 1, Item 2) and open dash.

Figure 1. Dash. 2. Cut and discard tiedown strap (Figure 2, Item 1).

0258

Figure 2. Tiedown Strap.

0258

0258-2

TM 5-2410-241-23-3

0258

REMOVAL CONTINUED

NOTE
Tag electrical connector to aid installation. 3. Disconnect two electrical connectors (Figure 3, Item 1).

Figure 3. Instrument Panel Electrical Connectors. 4. Remove grommet (Figure 4, Item 1) from instrument panel housing (Figure 4, Item 2).

0258

Figure 4. Grommet.

0258

0258-3

TM 5-2410-241-23-3

0258

REMOVAL CONTINUED

NOTE
Tag electrical connector to aid installation. 5. Disconnect electrical connector (Figure 5, Item 1).

Figure 5. Electrical Connector.

0258

0258-4

TM 5-2410-241-23-3

0258

REMOVAL CONTINUED

NOTE
Tag wiring harnesses and note routing to aid installation. 6. Remove two wiring harnesses (Figure 6, Item 4) from instrument panel (Figure 6, Item 3). 7. Remove two nuts (Figure 6, Item 1), washers (Figure 6, Item 2), bolts (Figure 6, Item 6), washers (Figure 6, Item 2), and governor housing (Figure 6, Item 5) from machine.

Figure 6. Wiring Harnesses and Mounting.

0258

0258-5

TM 5-2410-241-23-3

0258

REMOVAL CONTINUED

NOTE
Mark shaft and brake pedal to aid installation. 8. Loosen bolt (Figure 7, Item 7) and remove brake pedal (Figure 7, Item 1) from shaft (Figure 7, Item 2). 9. Remove six bolts (Figure 7, Item 6), foot pad (Figure 7, Item 5), and gasket (Figure 7, Item 4) from housing (Figure 7, Item 3).

Figure 7. Brake Pedal, Foot Pad, and Sensor.

0258

0258-6

TM 5-2410-241-23-3

0258

REMOVAL CONTINUED 10. Remove two bolts (Figure 8, Item 1), washers (Figure 8, Item 2), and brake position sensor (Figure 8, Item 3) from brake housing (Figure 8, Item 4).

Figure 8. Brake Pedal, Foot Pad, and Sensor. 11. Remove two bolts (Figure 9, Item 1) and decelerator sensor (Figure 9, Item 2) from governor housing (Figure 9, Item 3).

0258

Figure 9. Sensor.

0258

0258-7

TM 5-2410-241-23-3

0258

REMOVAL CONTINUED 12. Loosen bolt (Figure 10, Item 2) and remove decelerator pedal (Figure 10, Item 3) from shaft (Figure 10, Item 1).

Figure 10. Decelerator Pedal. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0258

000258

0258-8

TM 5-2410-241-23-3

0258

INSTALLATION 1. Install decelerator pedal (Figure 11, Item 3) on shaft (Figure 11, Item 1) and tighten bolt (Figure 11, Item 2).

000258

Figure 11. Decelerator Pedal. 2. Position decelerator sensor (Figure 12, Item 2) on governor housing (Figure 12, Item 3) and install two bolts (Figure 12, Item 1).

0258

Figure 12. Sensor.

0258

0258-9

TM 5-2410-241-23-3

0258

INSTALLATION CONTINUED 3. Install brake position sensor (Figure 13, Item 3), two washers (Figure 13, Item 2), and bolts (Figure 13, Item 1) on brake housing (Figure 13, Item 4).

Figure 13. Brake Pedal, Foot Pad, and Sensor.

0258

NOTE
Align marks made on shaft and brake pedal during disassembly. 4. Install gasket (Figure 14, Item 4), foot pad (Figure 14, Item 5), and six bolts (Figure 14, Item 6), on housing (Figure 14, Item 3). 5. Install brake pedal (Figure 14, Item 1) and bolt (Figure 14, Item 7) on shaft (Figure 14, Item 2).

Figure 14. Brake Pedal, Foot Pad, and Sensor.

0258

0258-10

TM 5-2410-241-23-3

0258

INSTALLATION CONTINUED 6. Position governor housing (Figure 15, Item 5) on machine and install four washers (Figure 15, Item 2), two nuts (Figure 15, Item 1), and bolts (Figure 15, Item 6).

NOTE
Remove screw installed in dash during removal. 7. Install two wiring harnesses (Figure 15, Item 4) on dash (Figure 15, Item 3).

Figure 15. Wiring Harnesses and Mounting.

0258

0258-11

TM 5-2410-241-23-3

0258

INSTALLATION CONTINUED

NOTE
Install electrical connector as tagged during removal. 8. Connect electrical connector (Figure 16, Item 1).

Figure 16. Electrical Connector. 9. Install grommet (Figure 17, Item 1) on instrument panel housing (Figure 17, Item 2).

0258

Figure 17. Grommet.

0258

0258-12

TM 5-2410-241-23-3

0258

INSTALLATION CONTINUED

NOTE
Install electrical connector as tagged during removal. 10. Connect two electrical connectors (Figure 18, Item 1).

Figure 18. Dash Electrical Connectors. 11. Install new tiedown strap (Figure 19, Item 1).

0258

Figure 19. Tiedown Strap.

0258

0258-13

TM 5-2410-241-23-3

0258

INSTALLATION CONTINUED 12. Close dash and install four screws (Figure 20, Item 1), two washers (Figure 20, Item 4), and bolts (Figure 20, Item 3) on instrument panel (Figure 20, Item 2).

Figure 20. Instrument Panel. END OF TASK FOLLOW-ON TASKS 1. Adjust brake pedal (WP 0037). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0258

000258

0258-14

10 TM 5-2410-241-23-3 0259

FIELD MAINTENANCE INSTRUCTIONS PILOT VALVE BULLDOZER SERVICE Removal, Cleaning and Inspection, Installation
0 2 5 9

INITIAL SETUP Tools and Special Tools 0 References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Right access panels removed (WP 0208) Drawing Required TM 5-2410-241-24P, Figure 81, 120 Estimated Time to Complete 5.5 Hr 0 0 0 0 0 0 0 0 0

Tool Kit, General Mechanics (WP 0302, Item 65) 0 Screwdriver Attachment, Torx, 3/8 Drive T-30 (S0288) (WP 0302, Item 68) 0 Tool, Removal, Yellow (WP 0302, Item 67) 0 Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) Gasket O-ring (14) 0 0 0 0 0 0

0259-1

TM 5-2410-241-23-3

0259

REMOVAL

000259

NOTE
Cap and plug all hoses to prevent contamination and leaks. Tag hoses to aid installation.

1. Disconnect seven hoses (Figure 1, Item 2) and O-rings (Figure 1, Item 3) from pilot valve (Figure 1, Item 1). Discard O-rings.

Figure 1. Hoses and Pilot Valve.

0259

0259-2

TM 5-2410-241-23-3

0259

REMOVAL CONTINUED 2. Remove four bolts (Figure 2, Item 2) and washers (Figure 2, Item 3) from base plate (Figure 2, Item 1).

Figure 2. Retainer Plate.

0259

NOTE
Tag electrical connectors to aid installation. 3. Pull pilot valve and hand control assembly (Figure 3, Item 3) away from plate (Figure 3, Item 2) and disconnect electrical connector (Figure 3, Item 1). 4. Remove pilot valve and hand control assembly (Figure 3, Item 3) from machine.

Figure 3. Electrical Connector.

0259

0259-3

TM 5-2410-241-23-3

0259

REMOVAL CONTINUED

NOTE
Note position and orientation of handle. 5. Loosen two setscrews (Figure 4, Item 2) and remove handle (Figure 4, Item 1) from assembly.

Figure 4. Handle.

0259

0259-4

TM 5-2410-241-23-3

0259

REMOVAL CONTINUED

NOTE
Note position and orientation of retainer plate to aid installation. 6. Remove retainer plate (Figure 5, Item 1) from assembly.

NOTE
Note position and orientation of fittings to aid installation. 7. Remove six fittings (Figure 5, Item 2) and 14 O-rings (Figure 5, Item 3) from assembly. Discard O-rings.

Figure 5. Retainer Plate.

0259

0259-5

TM 5-2410-241-23-3

0259

REMOVAL CONTINUED 8. Remove boot (Figure 6, Item 1) from assembly.

Figure 6. Boot. CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Install boot (Figure 7, Item 1) on assembly.

0259

000259

000259

Figure 7. Boot.

0259

0259-6

TM 5-2410-241-23-3

0259

INSTALLATION CONTINUED

NOTE
Install fittings as noted during removal. 2. Install 14 new O-rings (Figure 8, Item 3) and 6 fittings (Figure 8, Item 2) on assembly.

NOTE
Install retainer as noted during removal. 3. Install retainer plate (Figure 8, Item 1) on assembly.

Figure 8. Retainer Plate.

0259

0259-7

TM 5-2410-241-23-3

0259

INSTALLATION CONTINUED

NOTE
Install handle as noted during removal. 4. Install handle (Figure 9, Item 1) on assembly and tighten two setscrews (Figure 9, Item 2).

Figure 9. Handle.

0259

0259-8

TM 5-2410-241-23-3

0259

INSTALLATION CONTINUED

NOTE
Install electrical connector as tagged during removal. 5. Connect electrical connector (Figure 10, Item 1) and position pilot valve and hand control assembly (Figure 10, Item 3) on plate (Figure 10, Item 2).

Figure 10. Electrical Connector.

0259

NOTE
Install hoses as tagged during removal. 6. Install seven O-rings (Figure 11, Item 3) and hoses (Figure 11, Item 2) on pilot valve (Figure 11, Item 1).

Figure 11. Hoses and Pilot Valve.

0259

0259-9

TM 5-2410-241-23-3

0259

INSTALLATION CONTINUED 7. Install four washers (Figure 12, Item 3) and bolts (Figure 12, Item 2) on base plate (Figure 12, Item 1).

Figure 12. Retainer Plate. 8. Tighten seven hoses (Figure 11, Item 2) on pilot valve (Figure 11, Item 1). END OF TASK FOLLOW-ON TASKS 1. Install right access panels (WP 0208). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0259

000259

0259-10

10 TM 5-2410-241-23-3 0260

FIELD MAINTENANCE INSTRUCTIONS


0 2 6 0

INSTRUMENT PANEL 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) Tiedown Strap (WP 0303, Item 36) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Platform removed (WP 0206) Drawing Required TM 5-2410-241-24P, Figure 110 Estimated Time to Complete 27.5 Hr

0260-1

TM 5-2410-241-23-3

0260

REMOVAL 1. Remove and discard all tiedown straps (Figure 1, Item 14) securing wiring harness (Figure 1, Item 1) to instrument panel (Figure 1, Item 11).

000260

NOTE
Tag all electrical harness connectors to aid installation. 2. Disconnect eight electrical connectors (Figure 1, Items 3, 4, 7, 8, 9, 10, 13 and 15) from instrument panel (Figure 1, Item 11). 3. Disconnect four plugs (Figure 1, Items 2, 5, 6 and 12) from instrument panel (Figure 1, Item 11).

Figure 1. Back of Instrument Panel.

0260

0260-2

TM 5-2410-241-23-3

0260

REMOVAL CONTINUED 4. Remove two lights (Figure 2, Items 1 and 2) from instrument panel (Figure 2, Item 4). 5. Position harness (Figure 2, Item 3) aside.

Figure 2. Instrument Panel Lights.

0260

0260-3

TM 5-2410-241-23-3

0260

REMOVAL CONTINUED

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

6. Remove and discard tiedown strap (Figure 3, Item 1) from connector (Figure 3, Item 2). 7. Disconnect connector (Figure 3, Item 3) from connector (Figure 3, Item 2). 8. Disconnect connector (Figure 3, Item 4) from connector (Figure 3, Item 5). 9. Remove and discard tiedown strap (Figure 3, Item 6) from connector (Figure 3, Item 7). 10. Disconnect connector (Figure 3, Item 8) from connector (Figure 3, Item 7).

Figure 3. Platform Harness to Instrument Panel Harness Connector.

0260

0260-4

TM 5-2410-241-23-3

0260

REMOVAL CONTINUED 11. Remove tiedown strap (Figure 4, Item 2) from connector (Figure 4, Item 3). Discard tiedown strap. 12. Disconnect connector (Figure 4, Item 1) from connector (Figure 4, Item 3).

Figure 4. Instrument Panel Main Harness Connector.

0260

NOTE
Note harness routing to aid installation. Tag and mark all electrical connections to aid installation.

13. Loosen bolt (Figure 5, Item 4) and disconnect platform harness connector (Figure 5, Item 3) from instrument panel harness (Figure 5, Item 2). 14. Set harness (Figure 5, Item 1) aside.

Figure 5. Platform Harness to Harness Connector.

0260

0260-5

TM 5-2410-241-23-3

0260

REMOVAL CONTINUED 15. Remove four bolts (Figure 6, Item 3) and washers (Figure 6, Item 4) from connector (Figure 6, Item 2). 16. Remove instrument panel harness (Figure 6, Item 1) from machine.

Figure 6. Instrument Panel Main Harness Connector. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0260

000260

0260-6

TM 5-2410-241-23-3

0260

INSTALLATION 1. Position instrument panel harness (Figure 7, Item 1) on machine. 2. Install four washers (Figure 7, Item 4) and bolts (Figure 7, Item 3) on connector (Figure 7, Item 2).

000260

Figure 7. Instrument Panel Main Harness Connector.

0260

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

3. Position harness (Figure 8, Item 1) on platform. 4. Connect connector (Figure 8, Item 3) and install bolt (Figure 8, Item 4) on instrument panel harness (Figure 8, Item 2).

Figure 8. Platform Harness to Instrument Panel Harness Connector.

0260

0260-7

TM 5-2410-241-23-3

0260

INSTALLATION CONTINUED 5. Connect connector (Figure 9, Item 1) on connector (Figure 9, Item 3). 6. Install new tiedown strap (Figure 9, Item 2) on connector (Figure 9, Item 3).

Figure 9. Instrument Panel Main Harness Connector.

0260

NOTE
Install harness routing as noted during removal. Install electrical connection as noted during removal.

7. Connect connector (Figure 10, Item 8) on connector (Figure 10, Item 7). 8. Install new tiedown strap (Figure 10, Item 6) on connector (Figure 10, Item 7). 9. Connect connector (Figure 10, Item 4) on connector (Figure 10, Item 5). 10. Connect connector (Figure 10, Item 3) on connector (Figure 10, Item 2). 11. Install new tiedown strap (Figure 10, Item 1) to connector (Figure 10, Item 2).

Figure 10. Platform Harness to Instrument Panel Harness Connector.

0260

0260-8

TM 5-2410-241-23-3

0260

INSTALLATION CONTINUED 12. Position harness (Figure 11, Item 3) on instrument panel (Figure 11, Item 4). 13. Install two lights (Figure 11, Items 1 and 2) on instrument panel (Figure 11, Item 4).

Figure 11. Instrument Panel Lights.

0260

0260-9

TM 5-2410-241-23-3

0260

INSTALLATION CONTINUED

NOTE
Install electrical connectors as tagged during removal. 14. Connect four plugs (Figure 12, Items 2, 5, 6 and 12) on instrument panel (Figure 12, Item 11). 15. Connect eight electrical connectors (Figure 12, Items 3, 4, 7, 8, 9, 10, 13 and 15) on instrument panel (Figure 12, Item 11). 16. Install new tiedown straps (Figure 12, Item 14) to secure wiring harness (Figure 12, Item 1) on instrument panel (Figure 12, Item 11).

Figure 12. Back of Instrument Panel. END OF TASK FOLLOW-ON TASKS 1. Verify correct operation of machine (TM 5-2410-241-10). 2. Install platform (WP 0206). END OF TASK END OF WORK PACKAGE

0260

000260

0260-10

4 TM 5-2410-241-23-3 0261

FIELD MAINTENANCE INSTRUCTIONS


0 2 6 1

AIR CONDITIONING PRESSURE SWITCH 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) Oil, Lubricating, Refrigerant Compressor (WP 0303, Item 22) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring 0 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 41, 100 Estimated Time to Complete 0.5 Hr 0 0 0 0 0 0 0 0

0261-1

TM 5-2410-241-23-3

0261

REMOVAL

000261

NOTE
Tag hoses to aid installation. Clean exterior of hoses before removal to prevent contamination. Cap and plug all hoses and lines to prevent contamination and leaks.

1. Disconnect harness connector (Figure 1, Item 3) from air conditioning pressure switch (Figure 1, Item 4). 2. Position harness (Figure 1, Item 2) aside. 3. Remove air conditioning pressure switch (Figure 1, Item 4) from compressor (Figure 1, Item 1). 4. Remove O-ring (Figure 1, Item 5) from compressor (Figure 1, Item 1). Discard O-ring.

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

0261

000261

0261-2

TM 5-2410-241-23-3

0261

INSTALLATION

000261

NOTE
Coat new O-rings with clean refrigerant oil before installation. Install hoses as tagged during removal.

1. Install new O-ring (Figure 1, Item 5) on compressor (Figure 1, Item 1). 2. Install air conditioning pressure switch (Figure 1, Item 4) on compressor (Figure 1, Item 1). 3. Position harness (Figure 1, Item 2) on compressor (Figure 1, Item 1). 4. Connect harness connector (Figure 1, Item 3) on air conditioning pressure switch (Figure 1, Item 4). END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000261

0261-3/(4 blank)

22 TM 5-2410-241-23-3 0262

FIELD MAINTENANCE INSTRUCTIONS INSTRUMENT PANEL SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 6 2

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Screwdriver Attachment, Torx, 3/8 Drive, T-30 (S0288) (WP 0302, Item 68) Screwdriver Attachment, Torx, 1/4 Drive, T-15 (S0284) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Tiedown Strap (WP 0303, Item 36) Decal (2) Lockwasher (4)
0

References WP 0295

Equipment Condition
0

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

TM 5-2410-241-24P, Figure 110


0

Estimated Time to Complete


0

3.5 Hr
0 0

0262-1

TM 5-2410-241-23-3

0262

REMOVAL 1. Remove four bolts (Figure 1, Item 1) from instrument panel (Figure 1, Item 2). 2. Remove two bolts (Figure 1, Item 4) and washers (Figure 1, Item 3) from instrument panel (Figure 1, Item 2). 3. Tilt instrument panel (Figure 1, Item 2) back and allow it to rest on the support cable.

000262

Figure 1. Instrument Panel.

0262

0262-2

TM 5-2410-241-23-3

0262

REMOVAL CONTINUED 4. Remove and discard all tiedown straps (Figure 2, Item 14) securing wiring harness (Figure 2, Item 1) to instrument panel (Figure 2, Item 12).

NOTE
Tag all electrical harness connectors to aid installation. 5. Disconnect eight electrical connectors (Figure 2, Items 3, 4, 7, 8, 9, 10, 13, and 15) from instrument panel (Figure 2, Item 12). 6. Disconnect four plugs (Figure 2, Items 2, 5, 6, and 12) from instrument panel (Figure 2, Item 11).

Figure 2. Back of Instrument Panel.

0262

0262-3

TM 5-2410-241-23-3

0262

REMOVAL CONTINUED 7. Remove clip (Figure 3, Item 2) from cable (Figure 3, Item 1) and bracket (Figure 3, Item 3). 8. Remove cable (Figure 3, Item 1) from heater control valve (Figure 3, Item 4).

Figure 3. Heater Control Cable. 9. Remove two lights (Figure 4, Items 1 and 2) from instrument panel (Figure 4, Item 3).

0262

Figure 4. Instrument Panel Lights.

0262

0262-4

TM 5-2410-241-23-3

0262

REMOVAL CONTINUED 10. Remove two lights (Figure 5, Item 6) from gauge (Figure 5, Item 7). 11. Remove bolt (Figure 5, Item 2), washer (Figure 5, Item 3), and support cable (Figure 5, Item 4) from instrument panel (Figure 5, Item 1). 12. Remove instrument panel (Figure 5, Item 5) from machine.

Figure 5. Support Cable and Gauge Lights. END OF TASK

0262

0262-5

TM 5-2410-241-23-3

0262

DISASSEMBLY 1. Loosen setscrew (Figure 6, Item 6) and remove heater control knob (Figure 6, Item 2) from instrument panel (Figure 6, Item 1).

000262

NOTE
Note position and orientation of spacer to aid installation. 2. Remove nut (Figure 6, Item 3), heater control (Figure 6, Item 5), and spacer (Figure 6, Item 4) from instrument panel (Figure 6, Item 1).

Figure 6. Heater Control Knob.

0262

0262-6

TM 5-2410-241-23-3

0262

DISASSEMBLY CONTINUED 3. Remove and discard tiedown straps (Figure 7, Item 2) from connectors (Figure 7, Item 1). 4. Remove three bolts (Figure 7, Item 5), washers (Figure 7, Item 6), two brackets (Figure 7, Item 4), and clips (Figure 7, Item 7) from gauge (Figure 7, Item 3). 5. Remove two bolts (Figure 7, Item 12), washers (Figure 7, Item 11), bracket (Figure 7, Item 9), and two clamps (Figure 7, Item 10) from gauge (Figure 7, Item 8). 6. Remove four bolts (Figure 7, Item 17), washers (Figure 7, Item 16), two brackets (Figure 7, Item 15), clip (Figure 7, Item 13), and three clamps (Figure 7, Item 18) from gauge (Figure 7, Item 14) and post (Figure 7, Item 19).

Figure 7. Connector Clamps and Brackets.

0262

0262-7

TM 5-2410-241-23-3

0262

DISASSEMBLY CONTINUED 7. Remove indicator bulb (Figure 8, Item 3) from holder (Figure 8, Item 2) and instrument panel (Figure 8, Item 1).

Figure 8. Indicator Bulb.

0262

0262-8

TM 5-2410-241-23-3

0262

DISASSEMBLY CONTINUED 8. Remove four screws (Figure 9, Item 3) and two louvers (Figure 9, Item 2) from instrument panel (Figure 9, Item 1). 9. Remove two nuts (Figure 9, Item 4), lockwashers (Figure 9, Item 14), and two switches (Figure 9, Item 5) from instrument panel (Figure 9, Item 1). Discard lockwashers. 10. Remove screw (Figure 9, Item 8), lockwasher (Figure 9, Item 9), knob (Figure 9, Item 7), nut (Figure 9, Item 6), and ignition switch (Figure 9, Item 10) from instrument panel (Figure 9, Item 1). Discard lockwashers. 11. Remove four screws (Figure 9, Item 11), washers (Figure 9, Item 12), and gauge (Figure 9, Item 13) from instrument panel (Figure 9, Item 1). 12. Remove four screws (Figure 9, Item 15), washers (Figure 9, Item 16), and gauge (Figure 9, Item 17) from instrument panel (Figure 9, Item 1).

Figure 9. Upper Half of Instrument Panel.

0262

0262-9

TM 5-2410-241-23-3

0262

DISASSEMBLY CONTINUED

NOTE
Note position and orientation of spacers to aid installation. 13. Loosen two setscrews (Figure 10, Item 10) and remove two knobs (Figure 10, Item 9), nuts (Figure 10, Item 6) selector switches (Figure 10, Item 4), and spacers (Figure 10, Item 5) from instrument panel (Figure 10, Item 8). 14. Remove two switches (Figure 10, Item 7) from instrument panel (Figure 10, Item 8). 15. Remove six screws (Figure 10, Item 21), washer (Figure 10, Item 20), nuts (Figure 10, Item 1), plate (Figure 10, Item 2), and deflector (Figure 10, Item 3) from instrument panel (Figure 10, Item 8). 16. Remove nut (Figure 10, Item 14), lockwasher (Figure 10, Item 12), and switch (Figure 10, Item 13) from instrument panel (Figure 10, Item 8). Discard lockwasher. 17. Remove four screws (Figure 10, Item 15), washers (Figure 10, Item 16), and gauge (Figure 10, Item 17) from instrument panel (Figure 10, Item 8). 18. Remove six screws (Figure 10, Item 19) and three louvers (Figure 10, Item 18) from instrument panel (Figure 10, Item 8). 19. Remove two display decals (Figure 10, Item 11) from instrument panel (Figure 10, Item 8). Discard decals.

Figure 10. Lower Half of Instrument Panel.

0262

0262-10

TM 5-2410-241-23-3

0262

DISASSEMBLY CONTINUED 20. Remove light socket base (Figure 11, Item 1) from instrument panel (Figure 11, Item 2).

Figure 11. Light Socket Base.

0262

21. Remove two screws (Figure 12, Item 1) and level (Figure 12, Item 2) from instrument panel (Figure 12, Item 3). 22. Remove two screws (Figure 12, Item 4), nuts (Figure 12, Item 6), four washers (Figure 12, Item 5), and level bracket (Figure 12, Item 3) from instrument panel (Figure 12, Item 7).

Figure 12. Level and Bracket. END OF TASK

0262

0262-11

TM 5-2410-241-23-3

0262

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK ASSEMBLY 1. Install level bracket (Figure 13, Item 3), four washers (Figure 13, Item 5), two nuts (Figure 13, Item 6), and screws (Figure 13, Item 4) on instrument panel (Figure 13, Item 7). 2. Install level (Figure 13, Item 2) and two screws (Figure 13, Item 1) on instrument panel (Figure 13, Item 3).

000262

000262

Figure 13. Level and Bracket.

0262

0262-12

TM 5-2410-241-23-3

0262

ASSEMBLY CONTINUED 3. Install light socket base (Figure 14, Item 1) on instrument panel (Figure 14, Item 2).

Figure 14. Light Socket Base.

0262

0262-13

TM 5-2410-241-23-3

0262

ASSEMBLY CONTINUED 4. Install two new display decals (Figure 15, Item 11) on instrument panel (Figure 15, Item 8). 5. Install three louvers (Figure 15, Item 18) and six screws (Figure 15, Item 19) on instrument panel (Figure 15, Item 8). 6. Install gauge (Figure 15, Item 17), four washers (Figure 15, Item 16), and screws (Figure 15, Item 15) on instrument panel (Figure 15, Item 8). 7. Install switch (Figure 15, Item 13), new lockwasher (Figure 15, Item 12), and nut (Figure 15, Item 14) on instrument panel (Figure 15, Item 8). 8. Install plate (Figure 15, Item 2), deflector (Figure 15, Item 3), six washers (Figure 15, Item 20), screws (Figure 15, Item 21) and nuts (Figure 15, Item 1) on instrument panel (Figure 15, Item 8). 9. Install two switches (Figure 15, Item 7) on instrument panel (Figure 15, Item 8).

NOTE
Install spacers as noted during removal. 10. Install two spacers (Figure 15, Item 5), selector switches (Figure 15, Item 4), nuts (Figure 15, Item 6), knobs (Figure 15, Item 9), and setscrews (Figure 15, Item 10) on instrument panel (Figure 15, Item 8).

Figure 15. Lower Half of Instrument Panel.

0262

0262-14

TM 5-2410-241-23-3

0262

ASSEMBLY CONTINUED 11. Install gauge (Figure 16, Item 17), four washers (Figure 16, Item 16), and screws (Figure 16, Item 15) on instrument panel (Figure 16, Item 1). 12. Install gauge (Figure 16, Item 13), four washers (Figure 16, Item 12), and screws (Figure 16, Item 11) on instrument panel (Figure 16, Item 1). 13. Install ignition switch (Figure 16, Item 10), nut (Figure 16, Item 6), knob (Figure 16, Item 7), new lockwasher (Figure 16, Item 9), and screw (Figure 16, Item 8) on instrument panel (Figure 16, Item 1). 14. Install two switches (Figure 16, Item 5), new lockwashers (Figure 16, Item 14), and nuts (Figure 16, Item 4) on instrument panel (Figure 16, Item 1). 15. Install two louvers (Figure 16, Item 2) and four screws (Figure 16, Item 3) on instrument panel (Figure 16, Item 1).

Figure 16. Upper Half of Instrument Panel.

0262

0262-15

TM 5-2410-241-23-3

0262

ASSEMBLY CONTINUED 16. Install indicator bulb (Figure 17, Item 3) on holder (Figure 17, Item 2) and instrument panel (Figure 17, Item 1).

Figure 17. Indicator Bulb.

0262

0262-16

TM 5-2410-241-23-3

0262

ASSEMBLY CONTINUED 17. Install three clamps (Figure 18, Item 18), clip (Figure 18, Item 13), two brackets (Figure 18, Item 15), four washers (Figure 18, Item 16), and bolts (Figure 18, Item 17) on gauge (Figure 18, Item 14) and post (Figure 18, Item 19). 18. Install two clamps (Figure 18, Item 10), bracket (Figure 18, Item 9), two washers (Figure 18, Item 11), and bolts (Figure 18, Item 12) on gauge (Figure 18, Item 8). 19. Install three clips (Figure 18, Item 7), two brackets (Figure 18, Item 4), three washers (Figure 18, Item 6), and bolts (Figure 18, Item 5) on gauge (Figure 18, Item 3). 20. Install two new tiedown straps (Figure 18, Item 2) on connectors (Figure 18, Item 1).

Figure 18. Connector Clamps and Brackets.

0262

0262-17

TM 5-2410-241-23-3

0262

ASSEMBLY CONTINUED

NOTE
Position spacer as noted during removal. 21. Install spacer (Figure 19, Item 4), heater control (Figure 19, Item 5), and nut (Figure 19, Item 3) on instrument panel (Figure 19, Item 1). 22. Install heater control knob (Figure 19, Item 2) and tighten setscrew (Figure 19, Item 6) on instrument panel (Figure 19, Item 1).

Figure 19. Heater Control Knob. END OF TASK

0262

0262-18

TM 5-2410-241-23-3

0262

INSTALLATION 1. Install instrument panel (Figure 20, Item 5) on machine.

000262

2. Install support cable (Figure 20, Item 4), washer (Figure 20, Item 3), and bolt (Figure 20, Item 2) on instrument panel (Figure 20, Item 1). 3. Install two lights (Figure 20, Item 6) on gauge (Figure 20, Item 7).

Figure 20. Support Cable and Gauge Lights.

0262

0262-19

TM 5-2410-241-23-3

0262

INSTALLATION CONTINUED 4. Install two lights (Figure 21, Items 1 and 2) on instrument panel (Figure 21, Item 3).

Figure 21. Instrument Panel Lights. 5. Install cable (Figure 22, Item 1) on heater control valve (Figure 22, Item 4). 6. Install clip (Figure 22, Item 2) on cable (Figure 22, Item 1) and bracket (Figure 22, Item 3).

0262

Figure 22. Heater Control Cable.

0262

0262-20

TM 5-2410-241-23-3

0262

INSTALLATION CONTINUED

NOTE
Install electrical connectors as tagged during removal. 7. Connect four plugs (Figure 23, Items 2, 5, 6, and 12) on instrument panel (Figure 23, Item 11). 8. Connect eight electrical connectors (Figure 23, Items 3, 4, 7, 8, 9, 10, 13, and 15) on instrument panel (Figure 23, Item 11). 9. Install new tiedown straps (Figure 23, Item 14) to secure wiring harness (Figure 23, Item 1) to instrument panel (Figure 23, Item 11).

Figure 23. Back of Instrument Panel.

0262

0262-21

TM 5-2410-241-23-3

0262

INSTALLATION CONTINUED 10. Lift instrument panel (Figure 24, Item 2) into mounting position. 11. Install two washers (Figure 24, Item 3) and bolts (Figure 24, Item 4) on instrument panel (Figure 24, Item 2). 12. Install four bolts (Figure 24, Item 1) on instrument panel (Figure 24, Item 2).

Figure 24. Instrument Panel. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0262

000262

0262-22

8 TM 5-2410-241-23-3 0263

FIELD MAINTENANCE
0 2 6

AIR CONDITIONING SYSTEM SERVICE Leak Test, Recovery, Evacuation, Charging


3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Reclaimer, Refrigerant (WP 0302, Item 46) Tool Kit, Service, Refrigeration, Ordnance (WP 0302, Item 66) Materials/Parts Oil, Lubricating, Refrigerant Compressor (WP 0303, Item 22) Rag, Wiping (WP 0303, Item 24)
0

Materials/Parts - Continued Refrigerant, R-134a (WP 0303, Item 25) Personnel Required 91C

Equipment Conditions
0

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


0

Estimated Time to Complete 2.0 Hr

WARNING

Contact with refrigerant can cause frostbite. Keep hands and face away to prevent personal injury. Protective face shield and gloves must always be worn when refrigerant lines are opened, even if gauges indicate air conditioning (A/C) system is empty. Always use caution when disconnecting fittings. Slowly loosen fitting in well-ventilated area. Do not smoke when servicing A/C or wherever refrigerant gas may be present. Failure to follow these warnings may result in injury or death to personnel.

NOTE
Replace receiver/dryer if one or more following conditions occur before purging A/C system: A/C system has been previously opened for service. Too much air or moisture in A/C system, indicated by low refrigerant. Receiver/dryer has been operated for 2 or more years. A/C system has been opened for longer than 5 minutes. Large A/C system leak (break in hose or line).

0263-1

TM 5-2410-241-23-3

0263

LEAK TEST

000263

NOTE
If service work is required on air conditioning (A/C) system, refrigerant must be recovered first before components are removed. A/C system must contain at least 0.88 lb (0.4 kg) of refrigerant. Manifold gauge set can determine if pressure exists in A/C system. Leaks in high side of A/C system are more easily found if A/C is operated for 5 to 10 minutes. Leak test must be performed immediately after unit is turned off. Leak test for high side needs to be performed before pressure in A/C system equalizes. Leaks in low side of A/C system are more easily found if A/C has been shut off for 5 to 10 minutes. Leak test for low side needs to be performed before pressure in A/C system equalizes.

1. Move leak detector sensor tip along possible leak points at rate of 1 in. (25 mm) per second. 2. Leak detector will indicate if leak is present in A/C system. END OF TASK

0263-2

TM 5-2410-241-23-3

0263

RECOVERY

000263

NOTE
Refrigerant identifier will prevent other refrigerants from contaminating R-134a recovery and charging tools. Refrigerant identifier will also detect percentage of air that may be in A/C system. If service is required on A/C system, refrigerant must be recovered before A/C system components are removed.

1. Use refrigerant identifier to ensure refrigerant in A/C system is R-134a. 2. Install blue low-side hose (Figure 1, Item 4) on suction (low) side (Figure 1, Item 3) of A/C compressor (Figure 1, Item 5). 3. Install red high-side hose (Figure 1, Item 1) on discharge (high) side (Figure 1, Item 2) of A/C compressor (Figure 1, Item 5). 4. Follow recovery station OEM instructions and recover R-134a refrigerant.

Figure 1. Recovery Hook-Up. END OF TASK

0263

0263-3

TM 5-2410-241-23-3

0263

EVACUATION

000263

CAUTION
Moisture will combine with metals in refrigerant system and this will produce highly corrosive by-products. By-products are oxides, iron hydroxide, and aluminum hydroxide and they will damage A/C system. Moisture in A/C system can freeze and damage expansion valve and orifice tube. If there is water in A/C system, it must be removed. Failure to follow these cautions may result in damage to equipment.

NOTE
If replacement or repair of component is necessary, refrigerant must be recovered from A/C system. If A/C system has lost any charge after long period of time, refrigerant in A/C system must be recovered. It is necessary to perform evacuating procedures to remove all air and moisture from A/C system. A complete charge must never be given to A/C system without first performing evacuating procedures. If A/C system has been left open for more than 30 minutes, A/C system has been exposed to air and moisture. New receiver/dryer must be installed. Evacuating A/C system with vacuum pump will boil and remove any water in A/C system. Remove water from A/C system by evacuating A/C system with vacuum pump.

1. Install blue low-side hose (Figure 2, Item 4) on suction (low) side (Figure 2, Item 3) of A/C compressor (Figure 2, Item 5). 2. Install red high-side hose (Figure 2, Item 1) on discharge (high) side (Figure 2, Item 2) of A/C compressor (Figure 2, Item 5). 3. Follow recovery station OEM instructions to evacuate A/C system.

0263-4

TM 5-2410-241-23-3

0263

EVACUATION CONTINUED

Figure 2. Evacuation Hook-Up.

0263

NOTE
At high elevations, less vacuum is required. 28 to 29 inHg (95 to 98 kPa) is required specification at sea level. For every 1,000 ft (305 m) above sea level, decrease required specification by 1 inHg (3 kPa). AMBIENT TEMPERATURE 100F (38C) 90F (32C) 81F (27C) 70F (21C) VACUUM REQUIRED TO BOIL WATER IN A/C SYSTEM 28 in.Hg (95 kPa) 28.5 in.Hg (96.5 kPa) 28.8 in.Hg (97.5 kPa) 29.2 in.Hg (98.8 kPa)

0263-5

TM 5-2410-241-23-3

0263

EVACUATION CONTINUED

NOTE
Evacuation procedure removes air and moisture from A/C system. Do not use evacuation procedure primarily to indicate A/C system leak. 4. Evacuate A/C system until low pressure gauge (Figure 3, Item 1) indicates vacuum between 28 and 29 inHg (95 and 98 kPa). a. If specific vacuum cannot be reached, A/C system may have leak. Repair all leaks and repeat steps 1 through 4. b. If specific vacuum can be reached, continue to evacuate A/C system for minimum of 30 minutes and then proceed to Step 5.

Figure 3. Low Pressure Gauge.

0263

NOTE
Excessive vacuum loss is an indication of possible leak in A/C system. Amount of vacuum loss in 5 minutes must not exceed 2 inHg (7 kPa).

5. If vacuum loss exceeds 2 inHg (7 kPa) in 5 minutes, repair all leaks and repeat steps 1 through 5. If vacuum loss does not exceed 2 inHg (7 kPa) in 5 minutes, A/C system is ready to charge. END OF TASK

0263-6

TM 5-2410-241-23-3

0263

CHARGING

000263

WARNING

Contact with refrigerant can cause frostbite. Keep hands and face away to prevent personal injury. Protective face shield and gloves must always be worn when refrigerant lines are opened, even if gauges indicate A/C system is empty. Always use caution when disconnecting fittings. Slowly loosen fitting in well-ventilated area. Do not smoke when servicing A/C or wherever refrigerant gas may be present. Failure to follow these warnings may result in injury or death to personnel.

CAUTION
DO NOT charge A/C system with liquid refrigerant through compressor suction ports. This could seriously damage compressor.

NOTE
Charging should be performed at air temperature of 70F (21C) and above. Changes in ambient air temperature will affect A/C systems ability to take charge and will vary gauge readings. Do not add partial charge to A/C system. Accurate refrigerant charge can only be determined by weight or by temperature of evaporator core. Always recover refrigerant then evacuate A/C system before charging. Operating A/C system periodically during off-season will lubricate seals and reduce possibility of refrigerant loss. Up to 7 oz (200 g) of refrigerant loss per year is considered normal.

1. Install blue low-side hose (Figure 4, Item 2) on suction (low) side of A/C compressor. 2. Install red high-side hose (Figure 4, Item 1) on discharge (high) side of A/C compressor.

0263-7

TM 5-2410-241-23-3

0263

CHARGING CONTINUED

CAUTION
DO NOT invert R-134a refrigerant tank while charging A/C system. Liquid refrigerant entering low side of A/C system will permanently damage compressor. 3. Follow recovery station OEM instructions and charge A/C system with R-134a refrigerant. Refrigerant capacity is 3.3 lb (1.5 kg). 4. Once charging is complete, disconnect blue low-side hose (Figure 4, Item 4) from suction (low) side (Figure 4, Item 3) of A/C compressor (Figure 4, Item 5) and red high-side hose (Figure 4, Item 1) from discharge (high) side (Figure 4, Item 2) of A/C compressor (Figure 4, Item 5). 5. Operate A/C system to verify correct operation (TM 5-2410-241-10).

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

0263

000263

0263-8

6 TM 5-2410-241-23-3 0264

FIELD MAINTENANCE YOKE REPLACEMENT Removal, Cleaning and Inspection, Installation


0 2 6 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Bolt, Eye (WP 0302, Item 13) Bracket, Link (3/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 11) Lifting Device (500-lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Bolt 1-3/16 (2) Gasket Lip Seal
0

References LO 5-2410-241-13 WP 0205 WP 0295 Equipment Condition

Machine parked (TM 5-2410-241-10) Lift cylinder removed (WP 0266) Drawing Required

TM 5-2410-241-24P, Figure 129 Estimated Time to Complete 3.5 Hr

0264-1

TM 5-2410-241-23-3

0264

REMOVAL

000264

NOTE
This procedure is for the right yoke. Use the same procedure to remove the left yoke. 1. Remove four bolts (Figure 1, Item 1), washers (Figure 1, Item 2), gasket (Figure 1, Item 4), and cover (Figure 1, Item 3) from radiator guard (Figure 1, Item 5). Discard gasket. 2. Install two bracket links (Figure 1, Item 7) and bolts (Figure 1, Item 6) on yoke (Figure 1, Item 8).

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
Yoke weighs approximately 93 lb (42 kg). 3. Attach lifting device to two bracket links (Figure 1, Item 7).

Figure 1. Cover.

0264

0264-2

TM 5-2410-241-23-3

0264

REMOVAL CONTINUED 4. Install eye bolt (Figure 2, Item 1) on pin (Figure 2, Item 2). 5. Remove pin (Figure 2, Item 2) from radiator guard (Figure 2, Item 3). 6. Using a lifting device, remove yoke (Figure 2, Item 6) from radiator guard (Figure 2, Item 3) and place on flat surface. 7. Remove lifting device from yoke (Figure 2, Item 6). 8. Remove two bolts (Figure 2, Item 4) and bracket links (Figure 2, Item 5) from yoke (Figure 2, Item 6).

Figure 2. Pin and Yoke. 9. Remove lip seal (Figure 3, Item 2) from radiator guard (Figure 3, Item 1). Discard lip seal.

0264

Figure 3. Bearing. END OF TASK

0264

0264-3

TM 5-2410-241-23-3

0264

CLEANING AND INSPECTION 1. Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). 2. Inspect inner and outer sleeve bearings. If sleeve bearings are damaged, replace radiator guard (WP 0205). END OF TASK INSTALLATION

000264

000264

NOTE
This procedure is for the right yoke. Use the same procedure to install the left yoke. 1. Install new lip seal (Figure 4, Item 2) with lip on outside of radiator guard (Figure 4, Item 1) hole.

Figure 4. Bearing and Bearing Angle.

0264

0264-4

TM 5-2410-241-23-3

0264

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
Yoke weighs approximately 93 lb (42 kg). 2. Install two bracket links (Figure 5, Item 3) and bolts (Figure 5, Item 4) on yoke (Figure 5, Item 5). 3. Using a lifting device, install yoke (Figure 5, Item 5) on radiator guard (Figure 5, Item 1). 4. Install pin (Figure 5, Item 2) in radiator guard (Figure 5, Item 1).

Figure 5. Pin and Yoke.

0264

0264-5

TM 5-2410-241-23-3

0264

INSTALLATION CONTINUED 5. Remove lifting device from bracket links (Figure 6, Item 7). 6. Remove two bolts (Figure 6, Item 6) and bracket links (Figure 6, Item 7) from yoke (Figure 6, Item 8). 7. Install new gasket (Figure 6, Item 4), cover (Figure 6, Item 3), four washers (Figure 6, Item 2), and bolts (Figure 6, Item 1) on radiator guard (Figure 6, Item 5).

Figure 6. Cover. END OF TASK FOLLOW-ON TASKS 1. Install lift cylinder (WP 0266). 2. Apply grease to yoke at grease fitting (LO 5-2410-241-13). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0264

000264

0264-6

10 TM 5-2410-241-23-3 0265

FIELD MAINTENANCE LIFT CYLINDER HOSES REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 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) Pan, Drain (S0255) (WP 0302, Item 68) Wrench, Combination 1-5/8 (S1334) (WP 0302, Item 68) Wrench, Combination 1-7/8 (S1338) (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 (5) 0 0
0

References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Drawing Required

0 0 0 0 0
0

0 0 0
0

TM 5-2410-241-24P, Figure 130 Estimated Time to Complete 1.1 Hr

0 0

0 0 0 0

0265-1

TM 5-2410-241-23-3

0265

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. Engine/hydraulic oils can be very slippery. Immediately wipe up any spills. 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
REMOVAL 1. Remove three bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and cover (Figure 1, Item 1) from radiator guard (Figure 1, Item 4). 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. These procedures cover right lift cylinder hoses. Follow same procedures for left side.
000265

Figure 1. Lower Hose Connection Cover.

0265

0265-2

TM 5-2410-241-23-3

0265

REMOVAL CONTINUED 2. Remove two bolts (Figure 2, Item 8), nuts (Figure 2, Item 10), four washers (Figure 2, Item 9), two harness clips (Figure 2, Item 11), and four flanges (Figure 2, Item 6) from tube (Figure 2, Item 7). 3. Remove two bolts (Figure 2, Item 4), washers (Figure 2, Item 5), and cover (Figure 2, Item 3) from machine. 4. Remove four bolts (Figure 2, Item 1) and washers (Figure 2, Item 2) from cover (Figure 2, Item 3). Set harness (Figure 2, Item 12), cover (Figure 2, Item 3), and light (Figure 2, Item 13) aside.

Figure 2. Upper Hose Connection Cover.

0265

0265-3

TM 5-2410-241-23-3

0265

REMOVAL CONTINUED

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.

5. Remove four bolts (Figure 3, Item 10), washers (Figure 3, Item 9), bracket (Figure 3, Item 2), and disconnect hose (Figure 3, Item 1) from lift cylinder (Figure 3, Item 11). 6. Remove two flanges (Figure 3, Item 8) and O-ring (Figure 3, Item 7) from hose (Figure 3, Item 1). Discard Oring. 7. Disconnect hose (Figure 3, Item 3) from elbow (Figure 3, Item 4). 8. Remove elbow (Figure 3, Item 4) from lift cylinder (Figure 3, Item 11). 9. Remove and discard two O-rings (Figure 3, Items 5 and 6) from elbow (Figure 3, Item 4).

Figure 3. Upper Hose Connection.

0265

0265-4

TM 5-2410-241-23-3

0265

REMOVAL CONTINUED 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
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. Note routing of hoses and lines to aid installation.

10. Remove eight bolts (Figure 4, Item 7), washers (Figure 4, Item 6), and disconnect two hoses (Figure 4, Items 2 and 3) from manifold (Figure 4, Item 1). 11. Remove four flanges (Figure 4, Item 4) and two O-rings (Figure 4, Item 5) from two hoses (Figure 4, Items 2 and 3). Discard O-rings.

Figure 4. Lower Hose Connection. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0265

000265

000265

NOTE
Install tubes and fittings as noted during removal.

0265-5

TM 5-2410-241-23-3

0265

1. Install two new O-rings (Figure 5, Item 5) and four flanges (Figure 5, Item 4) on two hoses (Figure 5, Items 2 and 3). 2. Connect two hoses (Figure 5, Items 2 and 3) to manifold (Figure 5, Item 1), and install eight washers (Figure 5, Item 6) and bolts (Figure 5, Item 7).

Figure 5. Lower Hose Connection.

0265

0265-6

TM 5-2410-241-23-3

0265

INSTALLATION CONTINUED 3. Install two new O-rings (Figure 6, Items 5 and 6) on elbow (Figure 6, Item 4). 4. Install elbow (Figure 6, Item 4) on lift cylinder (Figure 6, Item 11). 5. Connect hose (Figure 6, Item 3) to elbow (Figure 6, Item 4). 6. Install new O-ring (Figure 6, Item 7) and two flanges (Figure 6, Item 8) on hose (Figure 6, Item 1). 7. Connect hose (Figure 6, Item 1) to lift cylinder (Figure 6, Item 11), and install bracket (Figure 6, Item 2), four washers (Figure 6, Item 9), and bolts (Figure 6, Item 10).

Figure 6. Upper Hose Connection.

0265

0265-7

TM 5-2410-241-23-3

0265

INSTALLATION CONTINUED 8. Install harness (Figure 7, Item 12), cover (Figure 7, Item 3), light (Figure 7, Item 13), four washers (Figure 7, Item 2), and bolts (Figure 7, Item 1) on machine. 9. Install two washers (Figure 7, Item 5) and bolts (Figure 7, Item 4) on cover (Figure 7, Item 3). 10. Install four flanges (Figure 7, Item 6), two harness clips (Figure 7, Item 11), four washers, (Figure 7, Item 9), two nuts (Figure 7, Item 10), and bolts (Figure 7, Item 8) on tube (Figure 7, Item 7).

Figure 7. Upper Hose Connection Cover.

0265

11. Install cover (Figure 8, Item 1), three washers (Figure 8, Item 3) and bolts (Figure 8, Item 2) on radiator guard (Figure 8, Item 4).

Figure 8. Lower Hose Connection Cover. END OF TASK

0265

0265-8

TM 5-2410-241-23-3

0265

FOLLOW-ON TASKS 1. Restore hydraulic system pressure (WP 0186). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000265

0265-9/(10 blank)

12 TM 5-2410-241-23-3 0266

FIELD MAINTENANCE
0 2 6 6

LIFT CYLINDER (BULLDOZER) REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Pan, Drain (WP 0302, Item 68) Sling, Multiple Leg (WP 0302, Item 54) Socket, Impact, 1-3/4 Drive, 6 Point, 30MM, (S0688) (WP 0302, Item 68) Socket, Impact, 3/4 Drive, 6 Point, 1-1/8 (S0972) (WP 0302, Item 68) Wrench, Combination 1-5/8 (S1334) (WP 0302, Item 68) Wrench, Combination 1-7/8 (S1338) (WP 0302, Item 68) Wrench, Combination 1-3/4 (S0096) (WP 0302, Item 68) Wrench, Electric Impact, 3/4 Square Drive, 1200 lb-ft (S0730) (WP 0302, Item 68) Lifting Device (2,000-lb capacity) 0 0 0 0 0 0 0 0 0 Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (5) Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Drawing Required 0 0 TM 5-2410-241-24P, Figure 121, 129, 130 Estimated Time to Complete 1.6 Hr 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

0266-1

TM 5-2410-241-23-3

0266

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. Engine/hydraulic oils can be very slippery. Immediately wipe up any spills. 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. Note routing of hoses and lines to aid installation. This procedure is for the right lift cylinder. Use the same procedure to remove the left lift cylinder.

0266-2

TM 5-2410-241-23-3

0266

REMOVAL 1. Remove two bolts (Figure 1, Item 8), nuts (Figure 1, Item 10), four washers (Figure 1, Item 9), two harness clips (Figure 1, Item 11), and four flanges (Figure 1, Item 6) from tube (Figure 1, Item 7). 2. Remove two bolts (Figure 1, Item 4) and washers (Figure 1, Item 5) from cover (Figure 1, Item 3) from machine.

000266

3. Remove four bolts (Figure 1, Item 1), and washers (Figure 1, Item 2) from cover (Figure 1, Item 3). Set harness (Figure 1, Item 12), cover (Figure 1, Item 3), and light (Figure 1, Item 13) aside.

Figure 1. Upper Hose Connection Cover.

0266

0266-3

TM 5-2410-241-23-3

0266

REMOVAL CONTINUED 4. Remove four bolts (Figure 2, Item 10), washers (Figure 2, Item 9) and bracket (Figure 2, Item 2), and disconnect hose (Figure 2, Item 1) from lift cylinder tube (Figure 2, Item 12). 5. Remove two flanges (Figure 2, Item 7) and O-ring (Figure 2, Item 8) from hose (Figure 2, Item 1). Discard Oring. 6. Disconnect hose (Figure 2, Item 3) from elbow (Figure 2, Item 4). 7. Remove elbow (Figure 2, Item 4) from lift cylinder (Figure 2, Item 11). 8. Remove and discard two O-rings (Figure 2, Items 5 and 6) from elbow (Figure 2, Item 4).

Figure 2. Upper Hose Connection.

0266

0266-4

TM 5-2410-241-23-3

0266

REMOVAL CONTINUED 9. Disconnect tube (Figure 3, Item 1) from cylinder (Figure 3, Item 2). 10. Remove fitting (Figure 3, Item 4) and two O-rings (Figure 3, Item 5) from elbow (Figure 3, Item 3). Discard Orings.

Figure 3. Tube.

0266

0266-5

TM 5-2410-241-23-3

0266

REMOVAL CONTINUED

NOTE
Note the number of shims to assist in installation. 11. Remove four bolts (Figure 4, Item 6), nuts (Figure 4, Item 3), cap (Figure 4, Item 5), shims (Figure 4, Item 4), and rod (Figure 4, Item 2) from blade (Figure 4, Item 1).

Figure 4. Rod.

0266

0266-6

TM 5-2410-241-23-3

0266

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
Lift cylinder weighs approximately 440 lb (200 kg). 12. Attach sling and lifting device to cylinder (Figure 5, Item 3) underneath bracket. 13. Remove slack from sling. 14. Remove four bolts (Figure 5, Item 1) and two caps (Figure 5, Item 2) from cylinder (Figure 5, Item 3) and yoke (Figure 5, Item 4). 15. Using a lifting device, remove cylinder (Figure 5, Item 3) from machine and place on flat surface. 16. Remove lifting device and sling from cylinder (Figure 5, Item 3).

Figure 5. Cylinder. END OF TASK

0266

0266-7

TM 5-2410-241-23-3

0266

CLEANING AND INSPECTION 1. Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295).

000266

NOTE
Replace caps and cylinder bushings as matched pairs. 2. Inspect caps for damage or wear to bushings. 3. Inspect lift cylinder bushings for wear, cracks, breaks or excessive pitting. 4. If either bushings in caps or cylinder bushings need to be replaced, replace both caps and both cylinder bushings. END OF TASK INSTALLATION
000266

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
Lift cylinder weighs approximately 440 lb (200 kg). This procedure is for the right lift cylinder. Use the same procedure to install the left lift cylinder.

1. Attach sling and lifting device to cylinder (Figure 6, Item 3). 2. Place cylinder (Figure 6, Item 3) in yoke (Figure 6, Item 4). 3. Install two caps (Figure 6, Item 2) and four bolts (Figure 6, Item 1) on cylinder (Figure 6, Item 3) and yoke (Figure 6, Item 4). 4. Remove lifting device and sling from cylinder (Figure 6, Item 3).

0266-8

TM 5-2410-241-23-3

0266

INSTALLATION CONTINUED

Figure 6. Cylinder.

0266

NOTE
Install same number of shims as noted during removal. 5. Install rod (Figure 7, Item 2), shims (Figure 7, Item 4), cap (Figure 7, Item 5), four nuts (Figure 7, Item 3), and bolts (Figure 7, Item 6) on blade (Figure 7, Item 1).

Figure 7. Rod.

0266

0266-9

TM 5-2410-241-23-3

0266

INSTALLATION CONTINUED

NOTE
Install tubes and fittings as noted during removal. 6. Install two new O-rings (Figure 8, Item 5) and fitting (Figure 8, Item 4) on elbow (Figure 8, Item 3). 7. Connect tube (Figure 8, Item 1) to cylinder (Figure 8, Item 2).

Figure 8. Tube.

0266

0266-10

TM 5-2410-241-23-3

0266

INSTALLATION CONTINUED

NOTE
Install tubes and fittings as noted during removal. 8. Install two new O-rings (Figure 9, Items 5 and 6) on elbow (Figure 9, Item 4). 9. Install elbow (Figure 9, Item 4) on lift cylinder (Figure 9, Item 11). 10. Connect hose (Figure 9, Item 3) to elbow (Figure 9, Item 4). 11. Install new O-ring (Figure 9, Item 7) and clamp (Figure 9, Item 8) on hose (Figure 9, Item 1). 12. Connect hose (Figure 9, Item 1) to lift cylinder tube (Figure 9, Item 12) and install four washers (Figure 9, Item 9), bracket (Figure 9, Item 2), and bolts (Figure 9, Item 10).

Figure 9. Upper Hose Connection.

0266

0266-11

TM 5-2410-241-23-3

0266

INSTALLATION CONTINUED 13. Position harness (Figure 10, Item 12), cover (Figure 10, Item 3), light (Figure 10, Item 13), two washers (Figure 10, Item 5), and bolts (Figure 10, Item 4) on machine. 14. Install four washers (Figure 10, Item 2) and bolts (Figure 10, Item 1) on cover (Figure 10, Item 3). 15. Install four flanges (Figure 10, Item 6), two harness clips (Figure 10, Item 11), four washers (Figure 10, Item 9), two nuts (Figure 10, Item 10), and bolts (Figure 10, Item 8) on tube (Figure 10, Item 7).

Figure 10. Upper Hose Connection Cover. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0266

000266

0266-12

10 TM 5-2410-241-23-3 0267

FIELD MAINTENANCE INSTRUCTIONS


0 2 6 7

TILT CYLINDER (BULLDOZER) REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools


0

Materials/Parts - Continued 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) Tag, Marker (WP 0303, Item 34) O-ring (3) Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic pressure relieved (WP 0186) Drawings Required

Tool Kit, General Mechanics (WP 0302, Item 65) Pan, Drain (S0255) (WP 0302, Item 68) Sling, Engine and Transmission, 2 Ton (S1051) (WP 0302, Item 68) Socket, Impact Wrench, 3/4 Drive, 6 Point, 1-5/16 (S0974) (WP 0302, Item 68) Wrench, Combination 1-5/16 (S0790) (WP 0302, Item 68) Wrench Kit, Ratchet, Pneumatic (S0985) (WP 0302, Item 68) Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) Lifting device, 500-lb capacity
0 0 0 0 0 0 0 0

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

TM 5-2410-241-24P, Figure 133 Estimated Time to Complete 1.1 Hr

0267-1

TM 5-2410-241-23-3

0267

REMOVAL 1. Remove two bolts (Figure 1, Item 2), front cover (Figure 1, Item 3), four bolts (Figure 1, Item 4), washers (Figure 1, Item 5), and bottom cover (Figure 1, Item 6) from tilt cylinder (Figure 1, Item 1).

000267

Figure 1. Covers.

0267

0267-2

TM 5-2410-241-23-3

0267

REMOVAL CONTINUED

WARNING

Oil is hot at operating temperature. Allow oil to cool before service. 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.

2. Use a drain pan to catch oil.

NOTE
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. Tag hoses to aid installation. Cap and plug all hoses and openings.

3. Remove eight bolts (Figure 2, Item 3), washers (Figure 2, Item 4), four flanges (Figure 2, Item 5), two hoses (Figure 2, Item 2), and O-rings (Figure 2 Item 6) from tilt cylinder (Figure 2, Item 1). Discard O-rings.

Figure 2. Hoses.

0267

0267-3

TM 5-2410-241-23-3

0267

REMOVAL CONTINUED 4. Attach sling (Figure 3, Item 2) and lifting device on tilt cylinder (Figure 3, Item 1).

Figure 3. Sling and Lifting Device. 5. Remove two bolts (Figure 4, Item 1), retainer (Figure 4, Item 2), and pin (Figure 4, Item 3) from machine.

0267

Figure 4. Retainer and Pin.

0267

0267-4

TM 5-2410-241-23-3

0267

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
Tilt cylinder weighs approximately 341 lb (155 kg). Note location and quantity of shims for ease of installation.

6. Remove four nuts (Figure 5, Item 5), bolts (Figure 5, Item 4), half-yoke (Figure 5, Item 1), shim pack (Figure 5, Item 2) and tilt cylinder (Figure 5, Item 3) from machine. 7. Remove sling from tilt cylinder (Figure 5, Item 3).

Figure 5. Yoke.

0267

0267-5

TM 5-2410-241-23-3

0267

REMOVAL CONTINUED 8. Remove four bolts (Figure 6, Item 4), washers (Figure 6, Item 5), fitting (Figure 6, Item 2), and O-ring (Figure 6, Item 3) from tilt cylinder (Figure 6, Item 1). Discard O-ring.

Figure 6. Fitting. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0267

000267

0267-6

TM 5-2410-241-23-3

0267

INSTALLATION

000267

NOTE
Lubricate O-rings prior to installation. 1. Position new O-ring (Figure 6, Item 3) and fitting (Figure 6, Item 2) on tilt cylinder (Figure 6, Item 1), and install four washers (Figure 6, Item 5) and bolts (Figure 6, 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
Tilt cylinder weighs 341 lb (155 kg). 2. Attach sling (Figure 7, Item 2) and lifting device on tilt cylinder (Figure 7, Item 1) and with assistance position tilt cylinder on machine.

Figure 7. Sling and Lifting Device.

0267

0267-7

TM 5-2410-241-23-3

0267

INSTALLATION CONTINUED

NOTE
Install shims as noted in removal. 3. Position four bolts (Figure 8, Item 4), half-yoke (Figure 8, Item 1), and shim pack (Figure 8, Item 2) on machine. 4. Install tilt cylinder (Figure 8, Item 3) and four nuts (Figure 8, Item 5) on machine. Tighten nuts to 460-580 lb-ft (623-786 Nm).

Figure 8. Yoke. 5. Install pin (Figure 9, Item 3), retainer (Figure 9, Item 2), and two bolts (Figure 9, Item 1) on machine. Tighten bolts to 293-362 lb-ft (397-490 Nm).

0267

Figure 9. Retainer and Pin.

0267

0267-8

TM 5-2410-241-23-3

0267

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 6. Install two new O-rings (Figure 10, Item 6), hoses (Figure 10, Item 2), four flanges (Figure 10, Item 5), eight washers (Figure 10, Item 4), and bolts (Figure 10, Item 3) on tilt cylinder (Figure 10, Item 1).

Figure 10. Hoses.

0267

0267-9

TM 5-2410-241-23-3

0267

INSTALLATION CONTINUED 7. Install bottom cover (Figure 11, Item 6), four washers (Figure 11, Item 5), and bolts (Figure 11, Item 4) on tilt cylinder (Figure 11, Item 1). 8. Install front cover (Figure 11, Item 3) and two bolts (Figure 11, Item 2) on tilt cylinder (Figure 11, Item 1).

Figure 11. Covers. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0267

000267

0267-10

26 TM 5-2410-241-23-3 0268

FIELD MAINTENANCE INSTRUCTIONS BLADE ASSEMBLY SERVICE Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
0 2 6 8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Crowbar (S0160) (WP 0302, Item 68) Gloves, Rubber (S0208) (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Pan, Drain (S0255) (WP 0302, Item 68) Sling, Engine and Transmission, 2 Ton (S1051) (WP 0302, Item 68) Socket, Impact Wrench, 3/4 Drive, 6 Point, 1-7/8 (S0430) (WP 0302, Item 68) Wrench, Combination 1-1/8 (S0788) (WP 0302, Item 68) Wrench, Combination 1-5/16 (S0790) (WP 0302, Item 68) Cover 5H4018 (BII Item) (2) Kit, Lift Cylinder Brace 6V-7934 (BII Item) Lifting device, 8,000-lb capacity O-ring 4J5267 (BII Item) (2) Materials/Parts Cap Set, Protective (WP 0303, Item 4) 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)
0

Materials/Parts - Continued 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) Tag, Marker (WP 0303, Item 34) Tiedown Strap (WP 0303, Item 36) Cotter pin Personnel Required

Two
0

References WP 0116 WP 0267 WP 0295 Equipment Condition Cutting edges removed (WP 0269) Hydraulic pressure relieved (WP 0186) Position blade assembly on ground (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 134

Estimated Time to Complete


0

5.0 Hr

0268-1

TM 5-2410-241-23-3

0268

REMOVAL. Engine/hydraulic oils, coolant, and fuel can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

000268

NOTE
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. Tag hoses to aid installation. Cap and plug all hoses and openings.

1. Remove eight bolts (Figure 1, Item 1), and washers (Figure 1, Item 2), and four flanges (Figure 1, Item 3) from two hoses (Figure 1, Item 4) and disconnect hoses from manifold (Figure 1, Item 5).

Figure 1. Hoses and Manifold.

0268

0268-2

TM 5-2410-241-23-3

0268

REMOVAL. CONTINUED

WARNING

If two covers are not installed, fluid will spray from manifold when lift cylinders are retracted. Failure to follow this warning will result in injury to personnel and damage to equipment. 2. Install two O-rings (Figure 2, Item 5) and two covers (Figure 2, Item 4) on manifold (Figure 2, Item 1). 3. Install eight bolts (Figure 2, Item 2), washers (Figure 2, Item 3), and four flanges (Figure 2, Item 6) on manifold (Figure 2, Item 1).

Figure 2. Manifold Plugs.

0268

0268-3

TM 5-2410-241-23-3

0268

REMOVAL. CONTINUED

NOTE
Note location and quantity of shims to aid installation. 4. Remove four bolts (Figure 3, Item 4), nuts (Figure 3, Item 1), half-yoke (Figure 3, Item 3), and shim pack (Figure 3, Item 2) from blade assembly (Figure 3, Item 5). Repeat step 4 for other side. 5. Retract lift cylinders (Figure 3, Item 6) (TM 5-2410-241-10).

Figure 3. Lift Cylinder Yoke.

0268

0268-4

TM 5-2410-241-23-3

0268

REMOVAL. CONTINUED 6. Install retaining clamps on lift cylinders (Figure 4, Item 1). a. Collapse lift cylinder (Figure 4, Item 1) (TM 5-2410-241-10). b. Install two heavy duty tiedown straps (Figure 4, Item 6) to hold lift cylinder in collapsed position. c. Install bar (Figure 4, Item 2), spacer (Figure 4, Item 5), washer (Figure 4, Item 4), and bolt (Figure 4, Item 3) loosely on machine.

d. Install two half-clamps (Figure 4, Item 10), bar (Figure 4, Item 2), bolt (Figure 4, Item 9), two washers (Figure 4, Item 7), and nut (Figure 4, Item 8) on lift cylinder (Figure 4, Item 1). e. Tighten all nuts and bolts. f. Repeat substeps a-e for other lift cylinder (Figure 4, Item 1).

Figure 4. Retaining Clamps.

0268

0268-5

TM 5-2410-241-23-3

0268

REMOVAL. CONTINUED 7. Place suitable blocks (Figure 5, Item 2) under push arm (Figure 5, Item 1). Repeat step 7 for other side.

Figure 5. Push Arm.

0268

NOTE
Note orientation of nut. Nut must be installed with the same orientation. Note location and quantity of shims to aid installation.

0268-6

TM 5-2410-241-23-3

0268

REMOVAL. CONTINUED 8. Remove two bolts (Figure 6, Item 4), washers (Figure 6, Item 3), nuts (Figure 6, Item 1), shim pack (Figure 6, Item 2), and half-yoke (Figure 6, Item 5) from push arm (Figure 6, Item 6). Repeat step 8 for other side.

Figure 6. Push Arm Yoke.

0268

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
Stabilizer bar weighs 207 lb (94 kg).

0268-7

TM 5-2410-241-23-3

0268

REMOVAL. CONTINUED 9. Attach suitable lifting device to secure stabilizer bar (Figure 7, Item 1). 10. Remove four bolts (Figure 7, Item 3), nuts (Figure 7, Item 6), shim pack (Figure 7, Item 2), and half-yoke (Figure 7, Item 4) from stabilizer bar (Figure 7, Item 1). 11. Back machine away from blade assembly (Figure 7, Item 5). 12. If machine is inoperable, remove rear axle (WP 0116) and tow machine away from blade assembly (Figure 7, Item 5). 13. Using lifting device place stabilizer bar (Figure 7, Item 1) on floor. 14. Remove lifting device
.

Figure 7. Support Stabilizer Bar. END OF TASK

0268

0268-8

TM 5-2410-241-23-3

0268

DISASSEMBLY

000268

WARNING

Blade weighs 6,700 lb (3,039 Kg). 1. Support blade assembly (Figure 8, Item 1).

Figure 8. Blade Support.

0268

0268-9

TM 5-2410-241-23-3

0268

DISASSEMBLY CONTINUED 2. Remove tilt cylinder from machine (WP 0267).

NOTE
Left stabilizer bar weighs 175 lb (79 kg). 3. Attach suitable lifting device to left stabilizer bar (Figure 9, Item 6).

NOTE
Note location and quantity of shims to aid installation. 4. Remove four bolts (Figure 9, Item 2), nuts (Figure 9, Item 10), yoke half (Figure 9, Item 1), and shim pack (Figure 9, Item 3) from blade assembly (Figure 9, 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
Note location of pin and stabilizer bar on arm to aid installation. 5. Remove cotter pin (Figure 9, Item 8) from retaining pin (Figure 9, Item 7). Discard cotter pin. 6. Remove retaining pin (Figure 9, Item 7), pin (Figure 9, Item 5), and left stabilizer bar (Figure 9, Item 6) from left push arm (Figure 9, Item 9). 7. Remove lifting device.

0268-10

TM 5-2410-241-23-3

0268

DISASSEMBLY CONTINUED

Figure 9. Left Stabilizer Bar.

0268

0268-11

TM 5-2410-241-23-3

0268

DISASSEMBLY CONTINUED

NOTE
Note orientation of knuckle on push arm and blade to aid installation. The following steps will remove one push arm. Repeat steps for other push arm.

8. Remove two bolts (Figure 10, Item 2), lock (Figure 10, Item 3), pin (Figure 10, Item 1), from push arm (Figure 10, Item 5) and blade assembly (Figure 10, 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
Push arm weighs 880 lb (399 kg). 9. Attach lifting device to push arm (Figure 10, Item 5) and with assistance carefully separate push arm (Figure 10, Item 5) from blade assembly (Figure 10, Item 4). 10. Remove lifting device.

Figure 10. Pin and Lock.

0268

0268-12

TM 5-2410-241-23-3

0268

11. Remove two bolts (Figure 11, Item 5), lock (Figure 11, Item 4), pin (Figure 11, Item 3), and knuckle (Figure 11, Item 2) from each push arm (Figure 11, Item 1).

Figure 11. Knuckle.

0268

0268-13

TM 5-2410-241-23-3

0268

DISASSEMBLY CONTINUED

NOTE
Note location and quantity of shims to aid installation. 12. Attach lifting device to stabilizer bar (Figure 12, Item 1).

CAUTION
Use care when moving or placing stabilizer bar down to prevent damage to hoses. 13. With assistance, remove four bolts (Figure 12, Item 5), nuts (Figure 12, Item 2), half-yoke (Figure 12, Item 4), shim pack (Figure 12, Item 3), and stabilizer bar (Figure 12, Item 1) from blade assembly. Remove sling from stabilizer bar.

Figure 12. Stabilizer Bar Yoke on Blade. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0268

000268

0268-14

TM 5-2410-241-23-3

0268

ASSEMBLY

000268

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
Stabilizer bar weighs 207 lb (94 kg). 1. Install lifting device on stabilizer bar (Figure 13, Item 1). 2. With assistance, install stabilizer bar (Figure 13, Item 1), shim pack (Figure 13, Item 3), half-yoke (Figure 13, Item 4), four bolts (Figure 13, Item 5), and nuts (Figure 13, Item 2) on blade assembly.

Figure 13. Stabilizer Bar Yoke on Blade.

0268

0268-15

TM 5-2410-241-23-3

0268

ASSEMBLY CONTINUED 3. Install knuckle (Figure 14, Item 2), pin (Figure 14, Item 3), lock (Figure 14, Item 4), and two bolts (Figure 14, Item 5) on right push arm (Figure 14, Item 1). Repeat this step for left push arm.

Figure 14. Knuckle.

0268

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
Push arm weighs 880 lb (399 kg). 4. Attach lifting device to push arm (Figure 15, Item 5) and place on suitable blocks. Repeat step 4 for other push arm. 5. With assistance, carefully position two push arms (Figure 15, Item 5) on blade assembly (Figure 15, Item 4). 6. Install pin (Figure 15, Item 1) and push arm (Figure 15, Item 5) on blade assembly (Figure 15, Item 4). 7. Install lock (Figure 15, Item 3) and two bolts (Figure 15, Item 2). Repeat steps 6 and 7 for other side. 8. Remove lifting device.

0268-16

TM 5-2410-241-23-3

0268

ASSEMBLY CONTINUED

Figure 15. Pin and Lock.

0268

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
Left stabilizer bar weighs 175 lb (79 kg).

0268-17

TM 5-2410-241-23-3

0268

ASSEMBLY CONTINUED 9. Use lifting device to position left stabilizer bar (Figure 16, Item 6) on left push arm (Figure 16, Item 9). 10. Install pin (Figure 16, Item 5) and retaining pin (Figure 16, Item 7). 11. Install new cotter pin (Figure 16, Item 8) on retaining pin (Figure 16, Item 7).

NOTE
Install shims as noted during removal. 12. Install left stabilizer bar (Figure 16, Item 6), shim pack (Figure 16, Item 3), yoke half (Figure 16, Item 1), four bolts (Figure 16, Item 2), and nuts (Figure 16, Item 10) on blade assembly (Figure 16, Item 4). 13. Remove lifting device from left stabilizer bar.

Figure 16. Left Stabilizer Bar.

0268

0268-18

TM 5-2410-241-23-3

0268

ASSEMBLY CONTINUED 14. Install tilt cylinder on machine (WP 0267). 15. Ensure supports are still in place on blade assembly (Figure 17, Item 1).

Figure 17. Blade Support. END OF TASK

0268

0268-19

TM 5-2410-241-23-3

0268

INSTALLATION 1. Drive machine into position on blade assembly (TM 5-2410-241-10).

000268

NOTE
Install nut in same orientation noted during removal. 2. Install half-yoke (Figure 18, Item 5), shim pack (Figure 18, Item 2), two washers (Figure 18, Item 3), bolts (Figure 18, Item 4), and nuts (Figure 18, Item 1) on machine. Repeat step 2 for other side.

Figure 18. Push Arm Yoke. 3. Remove all blocks (Figure 19, Item 2) under push arms (Figure 19, Item 1).

0268

Figure 19. Push Arm.

0268

0268-20

TM 5-2410-241-23-3

0268

INSTALLATION CONTINUED 4. Remove retaining clamps from lift cylinders (Figure 20, Item 1). a. Remove bolt (Figure 20, Item 9), two washers (Figure 20, Item 7), nut (Figure 20, Item 8), and two halfclamps (Figure 20, Item 10) from lift cylinder (Figure 20, Item 1). b. Remove bolt (Figure 20, Item 3), washer (Figure 20, Item 4), spacer (Figure 20, Item 5), and bar (Figure 20, Item 2). c. Cut and discard two heavy duty tiedown straps (Figure 20, Item 6) from lift cylinder (Figure 20, Item 1). d. Repeat substeps a through c for other lift cylinder (Figure 20, Item 1).

Figure 20. Retaining Clamps.

0268

0268-21

TM 5-2410-241-23-3

0268

INSTALLATION CONTINUED 5. Fully extend lift cylinders (Figure 21, Item 6). 6. Install half-yoke (Figure 21, Item 3), shim pack (Figure 21, Item 2), four bolts (Figure 21, Item 4), and nuts (Figure 21, Item 1) on blade assembly (Figure 21, Item 5). Repeat for other side.

Figure 21. Lift Cylinder Yoke.

0268

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
Stabilizer bar weighs 207 lb (94 kg).

0268-22

TM 5-2410-241-23-3

0268

INSTALLATION CONTINUED 7. Attach suitable lifting device to stabilizer bar (Figure 22, Item 2).

WARNING

Do not stand between blade and machine when installing stabilizer bar. Machine may move unexpectedly and injury or death may occur.

CAUTION
Use care when moving or placing stabilizer bar to prevent damage to hoses. 8. Install shim pack (Figure 22, Item 2), half-yoke (Figure 22, Item 4), four bolts (Figure 22, Item 3), nuts (Figure 22, Item 6), and stabilizer bar (Figure 22, Item 1) on machine (Figure 22, Item 5).

Figure 22. Support Stabilizer Bar.

0268

0268-23

TM 5-2410-241-23-3

0268

INSTALLATION CONTINUED 9. Remove eight bolts (Figure 23, Item 2), washers (Figure 23, Item 3), two covers (Figure 23, Item 4), O-rings (Figure 23, Item 5), and four flanges (Figure 23, Item 6) from manifold (Figure 23, Item 1).

Figure 23. Manifold Plugs. 10. Remove supports from under blade assembly.

0268

0268-24

TM 5-2410-241-23-3

0268

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 11. Connect two hoses (Figure 24, Item 4) to manifold (Figure 24, Item 5) and install four flanges (Figure 24, Item 3), eight washers (Figure 24, Item 2), and bolts (Figure 24, Item 1) on two hoses.

Figure 24. Hoses and Manifold. END OF TASK FOLLOW-ON TASKS 1. Install cutting edges (WP 0269). 2. Check and fill hydraulic fluid level (TM 5-2410-241-10). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0268

000268

0268-25/(26 blank)

8 TM 5-2410-241-23-3 0269

FIELD MAINTENANCE INSTRUCTIONS BLADE CUTTING EDGE REPLACEMENT Removal, Cleaning and Inspection, Installation, Blade Cutting Edge Rotation
0 2 6 9

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) Drawings Required TM 5-2410-241-24P, Figure 134 Estimated Time to Complete 1.0 Hr

Tool Kit, General Mechanics (WP 0302, Item 65) 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, Impact Wrench 3/4 Drive, 1 5/16 Point (S0387) (WP 0302, Item 68) Lifting device, 200-lb capacity
0 0 0 0 0 0 0 0 0

0269-1

TM 5-2410-241-23-3

0269

REMOVAL 1. Using vehicle support stands (Figure 1, Item 1), support blade assembly (Figure 1, Item 3) under push arms (Figure 1, Item 2). 2. Inspect blade cutting edges. Refer to Cleaning and Inspection in this work package.

000269

Figure 1. Blade Assembly.

0269

0269-2

TM 5-2410-241-23-3

0269

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
Corner blade cutting edges weigh 70 lb (32 kg) each. 3. With assistance, remove seven nuts (Figure 2, Item 3), washers (Figure 2, Item 4), bolts (Figure 2, Item 1), and right corner blade cutting edge (Figure 2, Item 9) from blade assembly (Figure 2, Item 2). 4. With assistance, remove seven nuts (Figure 2, Item 3), washers (Figure 2, Item 4), bolts (Figure 2, Item 1), and left corner blade cutting edge (Figure 2, Item 5) from blade assembly (Figure 2, Item 2).

NOTE
Center blade cutting edges weigh 90 lb (41 kg) each. 5. With assistance, remove six nuts (Figure 2, Item 3), washers (Figure 2, Item 4), bolts (Figure 2, Item 1), and center blade cutting edge (Figure 2, Item 7) from blade assembly (Figure 2, Item 2). 6. With assistance, remove six nuts (Figure 2, Item 3), washers (Figure 2, Item 4), bolts (Figure 2, Item 1), and left center blade cutting edge (Figure 2, Item 6) from blade assembly (Figure 2, Item 2). 7. With assistance, remove six nuts (Figure 2, Item 3), washers (Figure 2, Item 4), bolts (Figure 2, Item 1), and right center blade cutting edge (Figure 2, Item 8) from blade assembly (Figure 2, Item 2).

Figure 2. Blade Cutting Edges. END OF TASK

0269

0269-3

TM 5-2410-241-23-3

0269

CLEANING AND INSPECTION 1. Clean all parts IAW Mechanical General Maintenance Instructions (WP 0295).

000269

2. Inspect three blade cutting edges (Figure 3, Item 2) for wear. If blade cutting edges are worn down to the bottom of the blade assembly (Figure 3, Item 1), rotate or replace blade cutting edges. Refer to Blade Cutting Edge Rotation in this work package. 3. Inspect blade corner cutting edges (Figure 3, Item 3) for wear. If blade corner cutting edges are worn down to the bottom of the blade assembly (Figure 3, Item 1) replace blade corner cutting edges. Refer to Removal and Installation in this work package.

Figure 3. Blade Cutting Edge Inspection. END OF TASK

0269

0269-4

TM 5-2410-241-23-3

0269

INSTALLATION

000269

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
Center blade cutting edges weigh 90 lb (41 kg) each. 1. With assistance, install right center blade cutting edge (Figure 4, Item 8), six bolts (Figure 4, Item 1), washers (Figure 4, Item 4), and nuts (Figure 4, Item 3) on blade assembly (Figure 4, Item 2). 2. With assistance, install left center blade cutting edge (Figure 4, Item 6), six bolts (Figure 4, Item 1), washers (Figure 4, Item 4), and nuts (Figure 4, Item 3) on blade assembly (Figure 4, Item 2). 3. With assistance, install center blade cutting edge (Figure 4, Item 7), six bolts (Figure 4, Item 1), washers (Figure 4, Item 4), and nuts (Figure 4, Item 3) on blade assembly (Figure 4, Item 2).

NOTE
Corner blade cutting edges weigh 70 lb (32 kg) each. 4. With assistance, install left corner blade cutting edge (Figure 4, Item 5), seven bolts (Figure 4, Item 1), washers (Figure 4, Item 4), and nuts (Figure 4, Item 3) on blade assembly (Figure 4, Item 2). 5. With assistance, install right corner blade cutting edge (Figure 4, Item 9), seven bolts (Figure 4, Item 1), washers (Figure 4, Item 4), and nuts (Figure 4, Item 3) on blade assembly (Figure 4, Item 2).

Figure 4. Blade Cutting Edges.

0269

0269-5

TM 5-2410-241-23-3

0269

INSTALLATION CONTINUED 6. Remove vehicle support stands (Figure 5, Item 1) from under push arms (Figure 5, Item 2) and lower blade assembly (Figure 5, Item 3).

Figure 5. Blade Assembly. END OF TASK

0269

0269-6

TM 5-2410-241-23-3

0269

BLADE CUTTING EDGE ROTATION

000269

1. If blade left corner cutting edges (Figure 6, Items 2) and right corner cutting edges (Figure 6, Items 6) are worn down to bottom of blade assembly (Figure 3, Item 1), replace blade corner cutting edges. Refer to Removal and Installation in this work package. 2. Remove three center blade cutting edges (Figure 6, Items 3, 4, and 5) from blade assembly (Figure 6, Item 1). Refer to Removal in this work package. 3. With worn edge facing up, position center blade cutting edge (Figure 6, Item 4) on blade assembly (Figure 6, Item 1). Refer to Installation in this work package. 4. With worn edges facing up, switch positions of left center blade cutting edge (Figure 6, Items 3) and right center blade cutting edge (Figure 6, Items 5) on blade assembly (Figure 6, Item 1). Refer to Installation in this work package.

Figure 6. Cutting Edge Rotation. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0269

000269

0269-7/(8 blank)

4 TM 5-2410-241-23-3 0270

FIELD MAINTENANCE INSTRUCTIONS


0 2 7 0

BLADE TILT ADJUSTMENT Adjustment

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Sling, Multiple Leg (WP 0302, Item 54) Wrench, Combination 1-1/8 (S0788) (WP 0302, Item 68) Lifting Device (500-lb capacity) Personnel Required Two
0

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

Drawing Required
0

TM 5-2410-241-24P, Figure 132 Estimated Time to Complete

0.5 Hr
0 0

0270-1

TM 5-2410-241-23-3

0270

BLADE TILT ADJUSTMENT

000270

NOTE
Blade tilt can lower the left or right side of the blade as viewed from the operator seat. The blade can be adjusted to provide more or less tilt angle based on job requirements. 1. Start engine (TM 5-2410-241-10). 2. Lower blade to ground (TM 5-2410-241-10). 3. Remove two bolts (Figure 1, Item 1), lock (Figure 1, Item 2), and pin (Figure 1, Item 5) from tilt cylinder (Figure 1, Item 3) and push arm (Figure 1, Item 4).

WARNING

Keep fingers clear. Do not place your fingers into pin holes in tilt cylinder or push arm bracket at any time during the adjustment procedure. Failure to follow this warning may result in injury to personnel.

NOTE
Blade tilt can be adjusted in two different positions: To tilt left side of blade down, extend tilt cylinder (pull joystick left). To tilt right side of blade down, retract tilt cylinder (push joystick right).

4. Tilt blade according to job requirement. Align tilt cylinder (Figure 1, Item 3) with applicable hole in push arm (Figure 1, Item 4). 5. Install pin (Figure 1, Item 5), lock (Figure 1, Item 2), and two bolts (Figure 1, Item 1) on tilt cylinder (Figure 1, Item 3) and push arm (Figure 1, Item 4).

0270-2

TM 5-2410-241-23-3

0270

BLADE TILT ADJUSTMENT CONTINUED

Figure 1. Tilt Cylinder and Pin. 6. Stop engine (TM 5-2410-241-10). END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0270

000270

0270-3/(4 blank)

4 TM 5-2410-241-23-3 0271

FIELD MAINTENANCE INSTRUCTIONS


0 2 7 1

BLADE PITCH ADJUSTMENT Adjustment

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Wood block Materials/Parts Cotter pin Personnel Required Two
0

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

Drawing Required
0

TM 5-2410-241-24P, Figure 132


0

Estimated Time to Complete


0

0.5 Hr
0 0

0271-1

TM 5-2410-241-23-3

0271

BLADE PITCH ADJUSTMENT

000271

NOTE
Blade pitch is the fore/aft angle of the blade as viewed from the side of the machine. Blade is factory set to a NEUTRAL pitch angle which, under most circumstances, will provide ample bulldozing capacity. The blade can be adjusted to provide more or less pitch angle based on bulldozing requirements. Pitching blade back causes blade to carry more material. Pitching blade forward causes blade to carry less material. 1. Start engine, refer to (TM 5-2410-241-10). 2. Lower blade to ground, refer to (TM 5-2410-241-10). 3. Place blade control in FLOAT position, refer to (TM 5-2410-241-10).

NOTE
Retainer pin between left hand stabilizer bar and push arm must be loose and able to move freely. 4. Actuate tilt cylinder to remove all force from left hand stabilizer arm (Figure 1, Item 1). 5. Stop engine (TM 5-2410-241-10). 6. Support left hand stabilizer arm (Figure 1, Item 1) with blocks (Figure 1, Item 6). 7. Remove cotter pin (Figure 1, Item 3), pin (Figure 1, Item 4), and retainer pin (Figure 1, Item 2) from left hand stabilizer arm (Figure 1, Item 1). Discard cotter pin.

Figure 1. Left Hand Stabilizer Bar and Pin.

0271

0271-2

TM 5-2410-241-23-3

0271

BLADE PITCH ADJUSTMENT CONTINUED 8. Start engine (TM 5-2410-241-10).

WARNING

Keep fingers clear. Do not place your fingers into pin holes in left hand stabilizer bar or push arm bracket at any time during the adjustment procedure. Failure to follow this warning may result in injury to personnel.

NOTE
To tilt blade to pitch back position, blade must first be in tilt back position. Blade can be tilted in three different pitch positions: pitch forward, pitch neutral, and pitch back: To pitch blade forward, extend tilt cylinder (pull joystick left). To pitch blade back, retract tilt cylinder (push joystick right). To regain pitch neutral, extend or retract tilt cylinder accordingly from current position.

9. Tilt blade according to job requirement. 10. Stop engine (TM 5-2410-241-10). 11. Align left hand stabilizer bar (Figure 1, Item 1) with applicable hole in push arm bracket (Figure 1, Item 5). 12. Install retainer pin (Figure 1, Item 2), pin (Figure 1, Item 4), and new cotter pin (Figure 1, Item 3). 13. Remove blocks. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000271

0271-3/(4 blank)

14 TM 5-2410-241-23-3 0272

FIELD MAINTENANCE WINCH ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation
0 2 7 2

INITIAL SETUP Tools and Special Tools


0

Materials/Parts - Continued O-ring (5) Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Winch cable removed (WP 0275) Hydraulic system pressure released (WP 0186) Drawing Required TM 5-2410-241-24P, Figure 135, 136, 137

Tool Kit, General Mechanics (WP 0302, Item 65) Extension 3/4 Drive, 7 Long (S0377) (WP 0302, Item 68) Lifting Link (1/2 in.; 4,000 lb [1,800 kg]) (WP 0302, Item 36) Multiplier, Torque, 0 to 2,000 lb-ft (S0253) (WP 0302, Item 68) Sling, Multiple Leg (WP 0302, Item 54) Socket, Impact, 3/4 Drive, 6 Point, 1 7/8 (S0430) (WP 0302, Item 68) Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) Lifting Device (5,000-lb capacity)
0 0 0 0 0 0 0 0

Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34)

Estimated Time to Complete 3.6 Hr

0272-1

TM 5-2410-241-23-3

0272

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 fittings, hoses, 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. 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 to aid installation.

0272-2

TM 5-2410-241-23-3

0272

REMOVAL 1. Attach lift link (Figure 1, Item 4), chain or sling (Figure 1, Item 3), and lift device to winch cover (Figure 1, Item 5). 2. Remove 13 bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and cover (Figure 1, Item 5) from winch (Figure 1, Item 6).

000272

Figure 1. Winch Cover Removal.

0272

0272-3

TM 5-2410-241-23-3

0272

REMOVAL CONTINUED 3. Disconnect three hoses (Figure 2, Item 2, 5, 6) and O-rings (Figure 2, Item 3) from fittings (Figure 2, Item 1). Discard O-rings. 4. Remove four bolts (Figure 2, Item 12), washers (Figure 2, Item 13), flanges (Figure 2, Item 10), and disconnect hose (Figure 2, Item 4) from winch motor (Figure 2, Item 9). 5. Remove and discard O-ring (Figure 2, Item 11) from hose (Figure 2, Item 4). 6. Disconnect hose (Figure 2, Item 7) and O-ring (Figure 2, Item 8) from winch motor (Figure 2, Item 9). Discard O-ring.

Figure 2. Winch Hoses.

0272

0272-4

TM 5-2410-241-23-3

0272

REMOVAL CONTINUED

NOTE
Note position and location of washers. 7. Remove four bolts (Figure 3, Item 4), eight washers (Figure 3, Item 3), and bracket (Figure 3, Item 2) from winch (Figure 3, Item 1).

Figure 3. Bracket.

0272

0272-5

TM 5-2410-241-23-3

0272

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
Winch weighs approximately 4,025 lb (1,826 kg). 8. Attach sling and lifting device (Figure 4, Item 1) to winch (Figure 4, Item 2).

Figure 4. Lifting Device Attached to Winch.

0272

0272-6

TM 5-2410-241-23-3

0272

REMOVAL CONTINUED 9. With assistance, remove 10 bolts (Figure 5, Item 2), washers (Figure 5, Item 1), and winch (Figure 5, Item 3) from machine. Place on a suitable, flat surface. 10. Remove lifting device and sling from winch (Figure 5, Item 3).

Figure 5. Winch.

0272

0272-7

TM 5-2410-241-23-3

0272

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
The following steps remove winch adapters. Only remove adapters if needed. Adapter weighs approximately 330 lb (150 kg). Steps 11 through 14 remove one adaptor from machine. Repeat steps 11 through 14 to remove other adaptor.

11. Attach sling and lifting device to winch adapter (Figure 6, Item 4). 12. Remove slack from sling. 13. Remove seven bolts (Figure 6, Item 3), washers (Figure 6, Item 2), and adapter (Figure 6, Item 4) from machine (Figure 6, Item 1). Place adaptor on suitable surface. 14. Remove lifting device and sling from adapter (Figure 6, Item 4).

Figure 6. Winch Adapter. END OF TASK

0272

0272-8

TM 5-2410-241-23-3

0272

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

000272

000272

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
Adapter weighs approximately 330 lb (150 kg). Steps 1 through 5 install one adaptor from machine. Repeat steps 1 through 5 to install other adaptor.

1. Attach sling and lifting device to winch adapter (Figure 7, Item 4). 2. Using a lifting device, place adapter (Figure 7, Item 4) on machine (Figure 7, Item 1). 3. Install one washer (Figure 7, Item 2) and bolt (Figure 7, Item 3) on machine (Figure 7, Item 1). 4. Install six washers (Figure 7, Item 2) and bolts (Figure 7, Item 3) on machine (Figure 7, Item 1). Tighten seven bolts to 640 lb-ft (870 Nm). 5. Remove lifting device and sling from right adapter (Figure 7, Item 4).

Figure 7. Winch Adapter Removal.

0272

0272-9

TM 5-2410-241-23-3

0272

INSTALLATION CONTINUED 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.

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
Winch weighs approximately 4,025 lb (1,826 kg). 6. Attach sling and lifting device (Figure 8, Item 1) to winch (Figure 8, Item 2) 7. Using a lifting device, place winch (Figure 8, Item 2) on machine.

Figure 8. Installing Winch on Machine.

0272

0272-10

TM 5-2410-241-23-3

0272

INSTALLATION CONTINUED 8. Install 10 washers (Figure 9, Item 1) and bolts (Figure 9, Item 2) on winch (Figure 9, Item 3). Tighten bolts to 640 lb-ft (870 Nm). 9. Remove lifting device and sling from winch.

Figure 9. Winch Bolt.

0272

NOTE
Install washers as noted during removal. 10. Install bracket (Figure 10, Item 2), eight washers (Figure 10, Item 3), and four bolts (Figure 10, Item 4) on winch (Figure 10, Item 1).

Figure 10. Bracket.

0272

0272-11

TM 5-2410-241-23-3

0272

INSTALLATION CONTINUED

NOTE
Connect hoses as marked during removal. 11. Install new O-ring (Figure 11, Item 8) and connect hose (Figure 11, Item 7) on winch motor (Figure 11, Item 9). 12. Install new O-ring (Figure 11, Item 11) on hose (Figure 11, Item 4). 13. Connect hose (Figure 11, Item 4) on winch motor (Figure 11, Item 9) and install flanges (Figure 11, Item 10), four washers (Figure 11, Item 13), and bolts (Figure 11, Item 12). 14. Install three new O-rings (Figure 11, Item 3) and hoses (Figure 11, Items 2, 5, and 6) on fittings (Figure 11, Item 1).

Figure 11. Winch Hoses.

0272

0272-12

TM 5-2410-241-23-3

0272

INSTALLATION CONTINUED 15. Install cover (Figure 12, Item 5), 13 washers (Figure 12, Item 2), and bolts (Figure 12, Item 1) on winch (Figure 12, Item 6). 16. Remove lifting device, chain or sling (Figure 12, Item 3) and lift link (Figure 12, Item 4) from cover.

Figure 12. Winch Cover. END OF TASK FOLLOW-ON TASKS 1. Restore hydraulic system pressure (WP 0186). 2. Install winch cable (WP 0275). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0272

000272

0272-13/(14 blank)

14 TM 5-2410-241-23-3 0273

FIELD MAINTENANCE WINCH HOSES REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 7 3

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Tool Set, SATS, Base (WP 0302, Item 68) 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) Sling, Multiple Leg (WP 0302, Item 54) Lifting Device (1,500-lb capacity) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (26) References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Hydraulic system drained (WP 0184) Seat suspension removed (WP 0248) Right cab switch panel removed (WP 0179) Right platform access panels removed (WP 0208) Rear floor plate removed (WP 0231) Drawing Required TM 5-2410-241-24P, Figure 135, 137, 146 Estimated Time to Complete 8.5 Hr

0273-1

TM 5-2410-241-23-3

0273

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 fittings, hoses, 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. 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 to aid installation.

0273-2

TM 5-2410-241-23-3

0273

REMOVAL

000273

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
Winch cover weighs approximately 100 lb (45 kg). 1. Attach lift link (Figure 1, Item 4), chain or sling (Figure 1, Item 3) and lift device to winch cover (Figure 1, Item 5). 2. Using lift device, remove 13 bolts (Figure 1, Item 1), washers (Figure 1, Item 2), and cover (Figure 1, Item 5) from winch (Figure 1, Item 6).

Figure 1. Winch Cover Removal.

0273

0273-3

TM 5-2410-241-23-3

0273

REMOVAL CONTINUED 3. Remove eight bolts (Figure 2, Item 2), washers (Figure 2, Item 3), 2 flanges (Figure 2, Item 4), hoses (Figure 2, Item 1), and O-rings (Figure 2, Item 8) from winch manifold (Figure 2, Item 5). Discard O-rings. 4. Remove three hoses (Figure 2, Item 7) and O-rings (Figure 2, Item 6) from winch manifold (Figure 2, Item 5). Discard O-rings.

Figure 2. Hose Connections at Manifold.

0273

0273-4

TM 5-2410-241-23-3

0273

REMOVAL CONTINUED

NOTE
Note position and routing of hoses to aid installation. 5. Remove nut (Figure 3, Item 3), washer (Figure 3, Item 4), bolt (Figure 3, Item 2), and two retainer clips (Figure 3, Item 1), from three hoses (Figure 3, Item 5).

Figure 3. Retainer Clip Removal. 6. Remove bolt (Figure 4, Item 2), washer (Figure 4, Item 3), and retainer clip (Figure 4, Item 4), from hose (Figure 4, Item 1).

0273

Figure 4. Hose Retainer Clip Removal.

0273

0273-5

TM 5-2410-241-23-3

0273

REMOVAL CONTINUED 7. Remove bolt (Figure 5, Item 4), washer (Figure 5, Item 3), and retainer clip (Figure 5, Item 1), from two hoses (Figure 5, Item 2).

Figure 5. Hose Retainer Clip Removal. 8. Disconnect two hoses (Figure 6, Item 4) and O-rings (Figure 6, Item 3) from pilot valve (Figure 6, Item 2). Remove hoses from machine. Discard O-rings. 9. Remove eight bolts (Figure 6, Item 9), washers (Figure 6, Item 8), four flanges (Figure 6, Item 1), two O-rings (Figure 6, Item 7), and two hoses (Figure 6, Item 6) from valve bank (Figure 6, Item 5). Remove hoses from machine. Discard O-rings.

0273

Figure 6. Hose Connections at Valve Bank.

0273

0273-6

TM 5-2410-241-23-3

0273

REMOVAL CONTINUED 10. Remove bolt (Figure 7, Item 6), washer (Figure 7, Item 7), and two clips (Figure 7, Item 5) from pump hose (Figure 7, Item 4). 11. Disconnect tube nut (Figure 7, Item 3) and remove O-ring (Figure 7, Item 2) from tee (Figure 7, Item 1). Remove pump hose (Figure 7, Item 4) from machine. Discard O-ring.

Figure 7. Pump Hose and Retainer. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 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.

0273

000273

000273

NOTE
Install hoses and fittings as noted during removal.

0273-7

TM 5-2410-241-23-3

0273

1. Install new O-ring (Figure 8, Item 2) and connect tube nut (Figure 8, Item 3) on tee (Figure 8, Item 1). 2. Position two retainer clips (Figure 8, Item 5) around pump hose (Figure 8, Item 4) and install washer (Figure 8, Item 7) and bolt (Figure 8, Item 6).

Figure 8. Pump Hose and Retainer Clips.

0273

0273-8

TM 5-2410-241-23-3

0273

INSTALLATION CONTINUED 3. Install two new O-rings (Figure 9, Item 7) on hoses (Figure 9, Item 6). 4. Connect two hoses (Figure 9, Item 6) on valve bank (Figure 9, Item 5) and install four flanges (Figure 9, Item 1), eight washers (Figure 9, Item 8), and bolts (Figure 9, Item 9). 5. Install two new O-rings (Figure 9, Item 3) and connect two hoses (Figure 9, Item 4) on valve bank (Figure 9, Item 5).

Figure 9. Hose Connections at Valve Bank.

0273

6. Install retainer clip (Figure 10, Item 1), washer (Figure 10, Item 3), bolt (Figure 10, Item 4) on two hoses (Figure 10, Item 2).

Figure 10. Hose Retainer Clip Installation.

0273

0273-9

TM 5-2410-241-23-3

0273

INSTALLATION CONTINUED 7. Position pump hose (Figure 11, Item 1) and install two retainer clips (Figure 11, Item 4), washer (Figure 11, Item 3), and bolt (Figure 11, Item 2).

Figure 11. Hose Retainer Clip Installation. 8. Install retainer clip (Figure 12, Item 1) over two hoses (Figure 12, Item 5), and install bolt (Figure 12, Item 2), washer (Figure 12, Item 4), and nut (Figure 12, Item 3).

0273

Figure 12. Retainer Clip Installation.

0273

0273-10

TM 5-2410-241-23-3

0273

INSTALLATION CONTINUED 9. Install three new O-rings (Figure 13, Item 6) and connect three hoses (Figure 13, Item 7) to winch manifold (Figure 13, Item 5). 10. Install two new O-rings (Figure 13, Item 8) on hoses (Figure 13, Item 1), and install two flanges (Figure 13, Item 4), eight washers (Figure 13, Item 3), and bolts (Figure 13, Item 2) on winch manifold (Figure 13, Item 5).

Figure 13. Hose Connections at Manifold.

0273

0273-11

TM 5-2410-241-23-3

0273

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
Winch cover weighs approximately 100 lb (45 kg). 11. Using lift device, install cover (Figure 14, Item 5), 13 washers (Figure 14, Item 2), bolts (Figure 14, Item 1) on winch (Figure 14, Item 6). 12. Remove lift device and chain or sling (Figure 14, Item 3) and lift link (Figure 14, Item 4) from cover (Figure 14, Item 5).

Figure 14. Winch Cover Installation. END OF TASK

0273

0273-12

TM 5-2410-241-23-3

0273

FOLLOW-ON TASKS 1. Install rear floor plate (WP 0231). 2. Install right access panels (WP 0208). 3. Install right cab switch panel (WP 0179). 4. Install seat suspension (WP 0248). 5. Fill hydraulic system (WP 0184). 6. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000273

0273-13/(14 blank)

4 TM 5-2410-241-23-3 0274

FIELD MAINTENANCE WINCH OIL SERVICE Drain, Cleaning and Inspection, Fill
0 2 7 4

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Pan, Drain (S0255) (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) Oil, Lubricating OE/HDO-40 (WP 0303, Item 20)
0

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

LO 5-2410-241-13 WP 0295 Equipment Condition

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

TM 5-2410-241-24P, Figure 137


0

Estimated Time to Complete 1.0 Hr

WARNING

Oil could be hot. Allow oil to cool before draining. 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.

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.

0274-1

TM 5-2410-241-23-3

0274

DRAIN

000274

1. Remove fill plug (Figure 1, Item 5) and O-ring (Figure 1, Item 6) from winch (Figure 1, Item 9). Discard O-ring. 2. Remove breather (Figure 1, Item 3) and O-ring (Figure 1, Item 4) from winch (Figure 1, Item 9). Discard O-ring. 3. Remove check plug (Figure 1, Item 1) and O-ring (Figure 1, Item 2) from winch (Figure 1, Item 9). Discard O-ring.

NOTE
Gear case oil capacity is 16 qt (15 L). 4. Remove drain plug (Figure 1, Item 7) and O-ring (Figure 1, Item 8) from winch (Figure 1, Item 9). Allow oil to drain into a suitable container. Discard O-ring.

Figure 1. Winch Plug Locations. END OF TASK CLEANING AND INSPECTION Clean vent and plugs IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0274

000274

0274-2

TM 5-2410-241-23-3

0274

FILL 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. 1. Install new O-ring (Figure 1, Item 8) on drain plug (Figure 1, Item 7). 2. Install drain plug (Figure 1, Item 7) on winch (Figure 1, Item 9).

000274

NOTE
Gear case oil capacity is 16 qt (15 L). 3. Fill winch (Figure 1, Item 9) with oil through fill plug (Figure 1, Item 5) opening until oil is sighted at the bottom of check plug (Figure 1, Item 1) opening. Refer to LO 5-2410-241-13 for correct type and amount of lubricant. 4. Install new O-ring (Figure 1, Item 2) on checkplug (Figure 1, Item 1) and install plug on winch (Figure 1, Item 9). 5. Install new O-ring (Figure 1, Item 6) on fill plug (Figure 1, Item 5) and install plug on winch (Figure 1, Item 9). 6. Install new O-ring (Figure 1, Item 4) on breather plug (Figure 1, Item 3) and install breather on winch (Figure 1, Item 9). END OF TASK FOLLOW-ON TASKS Verify correct operation of winch (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000274

0274-3/(4 blank)

4 TM 5-2410-241-23-3 0275

FIELD MAINTENANCE WINCH CABLE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 7 5

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Glove, Leather Work, Mens and Womens (WP 0302, Item 68) Goggles (S0209) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Personnel Required Three
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 136 Estimated Time to Complete 1.5 Hr

0275-1

TM 5-2410-241-23-3

0275

WARNING
Personal Protective Equipment (PPE), such as Gloves-Leather Work, Mens and Womens and goggles, is required for this operation. Failure to follow these warnings may result in injury or death to personnel. REMOVAL 1. Start machine (TM 5-2410-241-10).
000275

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.

CAUTION
Cable must not be allowed to tangle, or birds nest, during removal. Pull cable in straight line from back of machine or feed cable into suitable container for storage. Failure to follow this caution may damage equipment.

NOTE
Based on actual length, cable could weigh up to 400 lb (181 kg). Original cable length is 175 ft (53 m). Ensure adequate space or suitable container is available to perform this operation.

1. With assistance, unreel cable (Figure 1, Item 1) straight off back of winch (Figure 1, Item 2) (TM 5-2410-24110).

Figure 1. Winch Cable.

0275

0275-2

TM 5-2410-241-23-3

0275

REMOVAL CONTINUED 2. When cable is fully reeled out exposing the cable ferrule in the winch drum pocket, shut off machine. Remove cable ferrule (Figure 2, Item 2) from pocket (Figure 2, Item 1).

Figure 2. Removing Cable from Drum. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION

0275

000275

000275

CAUTION
Cable must be under tension when being reeled onto winch drum, and must be packed tightly around drum with no gaps. Failure to follow this caution may cause damage to equipment.

NOTE
To keep tension on cable at all times during installation, connect cable hook to a secondary machine. Operator of secondary machine must apply brakes to maintain tension. Cable must be fully stretched out in a straight line behind D7R dozer. 1. Install cable ferrule (Figure 2, Item 2) in pocket (Figure 2, Item 1) of winch drum.

0275-3

TM 5-2410-241-23-3

0275

INSTALLATION CONTINUED 2. Start machine (TM-5-2410-241-10). 3. Keeping tension on cable at all times, and with assistant guiding cable onto drum, reel cable (Figure 3, Item 2) onto winch drum (Figure 3, Item 1). 4. Disconnect cable hook from secondary machine. Secure hook for stowage on winch and shut off machine.

Figure 3. Installing Cable on Winch Drum. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0275

000275

0275-4

6 TM 5-2410-241-23-3 0276

FIELD MAINTENANCE CYLINDER HOSE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 7 6

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 (2)
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Hydraulic system pressure released (WP 0186) Drawings Required TM 5-2410-241-24P, Figure 149 Estimated Time to Complete 1.1 Hr

0276-1

TM 5-2410-241-23-3

0276

REMOVAL

000276

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 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
Hydraulic hoses and fittings are all removed in generally the same manner. This procedure covers removal of one hydraulic hose and fitting from the machine. Tag all hoses 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 to aid installation. Remove additional components as required.

1. If required, remove two clamps (Figure 1, Item 3) and sleeve (Figure 1, Item 2) from hose (Figure 1, Item 1). 2. Remove four bolts (Figure 1, Item 4), washers (Figure 1, Item 5), guard, if installed (Figure 1, Item 6), and two flanges (Figure 1, Item 7) from hose (Figure 1, Item 1). 3. Remove four bolts (Figure 1, Item 8), washers (Figure 1, Item 9), and two flanges (Figure 1, Item 10), and hose (Figure 1, Item 1) from machine. 4. Remove and discard two O-rings (Figure 1, Item 11) from hose (Figure 1, Item 1).

0276-2

TM 5-2410-241-23-3

0276

REMOVAL CONTINUED

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

0276

000276

0276-3

TM 5-2410-241-23-3

0276

INSTALLATION 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.

000276

NOTE
Install hoses and fittings as noted during removal. Hydraulic hoses and fittings are all installed in generally the same manner. This procedure covers installation of one hydraulic hose, line, and fitting on the machine.

1. Install two new O-rings (Figure 2, Item 11) on hose (Figure 2, Item 1). 2. Install hose (Figure 2, Item 1), two flanges (Figure 2, Item 10), four washers (Figure 2, Item 9), and bolts (Figure 2, Item 8) on machine. 3. Install two flanges (Figure 2, Item 7), guard, if removed, (Figure 2, Item 6), four washers (Figure 2, Item 5), and bolts (Figure 2, Item 4) on hose (Figure 2, Item 1). 4. If removed, install sleeve (Figure 2, Item 2) and two clamps (Figure 2, Item 3) on hose (Figure 2, Item 1).

Figure 2. Ripper Cylinder Hose. END OF TASK

0276

0276-4

TM 5-2410-241-23-3

0276

FOLLOW-ON TASKS 1. Restore hydraulic system pressure (WP 0186). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000276

0276-5/(6 blank)

8 TM 5-2410-241-23-3 0277

FIELD MAINTENANCE INSTRUCTIONS CYLINDER, RIPPER LIFT SERVICE Removal, Cleaning and Inspection, Installation
0 2 7 7

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Sling, Multiple Leg (WP 0302, Item 54) Wrench, Combination, 30 mm (S0824) (WP 0302, Item 68) Lifting Device (500 lb capacity) Materials/Parts Cap Set, Protective (WP 0303, Item 4) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) O-ring (2) Personnel Required Two
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Lower ripper to ground (TM 5-2410-241-10) Drain hydraulic system oil (WP 0184) Drawings Required TM 5-2410-241-24P, Figure 149, 150 Estimated Time to Complete 1.1 Hr

0277-1

TM 5-2410-241-23-3

0277

REMOVAL

000277

WARNING

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.

CAUTION
Cap and plug all hydraulic hose ends to prevent leaks and contamination. Failure to follow this caution may result in damage to equipment.

NOTE
Collect fluid in suitable containers. Dispose of all fluids according to local regulations and mandates. This procedure is for one ripper lift cylinder. Use same procedure for other ripper lift cylinder. Tag and identify hoses to aid installation.

1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 1), plate (Figure 1, Item 4), flange (Figure 1, Item 12), and hose (Figure 1, Item 3) from rod end of ripper lift cylinder (Figure 1, Item 5). Set hose aside. 2. Remove O-ring (Figure 1, Item 11) from hose (Figure 1, Item 3). Discard O-ring. 3. Remove four bolts (Figure 1, Item 7), washers (Figure 1, Item 8), flange (Figure 1, Item 10), and hose (Figure 1, Item 6) from head end of ripper lift cylinder (Figure 1, Item 5). Set hose aside. 4. Remove O-ring (Figure 1, Item 9) from hose (Figure 1, Item 6). Discard O-ring.

0277-2

TM 5-2410-241-23-3

0277

REMOVAL CONTINUED

Figure 1. Ripper Lift Cylinder.

0277

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
Use suitable lifting device to support ripper lift cylinder. The lift cylinder weighs approximately 255 lb (115 kg). 5. Attach a suitable lifting device to ripper lift cylinder (Figure 2, Item 1).

Figure 2. Ripper Lift Cylinder.

0277

0277-3

TM 5-2410-241-23-3

0277

REMOVAL CONTINUED 6. Remove two bolts (Figure 3, Item 1), plate (Figure 3, Item 2), and pin assembly (Figure 3, Item 3) from the rod end of ripper lift cylinder (Figure 3, Item 4).

Figure 3. Ripper Lift Cylinder Rod End. 7. Remove two bolts (Figure 4, Item 1), plate (Figure 4, Item 2), and pin assembly (Figure 4, Item 3) from head end of the ripper lift cylinder (Figure 4, Item 4). 8. Remove ripper lift cylinder (Figure 4, Item 4) from machine and place on flat surface. 9. Remove lifting device from ripper lift cylinder (Figure 4, Item 4).

0277

Figure 4. Ripper Lift Cylinder Head End. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0277

000277

0277-4

TM 5-2410-241-23-3

0277

INSTALLATION

000277

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
Use suitable lifting device to support the ripper lift cylinder. The lift cylinder weighs approximately 255 lb (115 kg). 1. Install lifting device on ripper lift cylinder (Figure 5, Item 1).

Figure 5. Ripper Lift Cylinder.

0277

0277-5

TM 5-2410-241-23-3

0277

INSTALLATION CONTINUED 2. Position ripper lift cylinder (Figure 6, Item 4) on machine. 3. Install pin assembly (Figure 6, Item 3), plate (Figure 6, Item 2), and two bolts (Figure 6, Item 1) on head end of ripper lift cylinder (Figure 6, Item 4).

Figure 6. Ripper Lift Cylinder Head End. 4. Install pin assembly (Figure 7, Item 3), plate (Figure 7, Item 2), and two bolts (Figure 7, Item 1) on rod end of ripper lift cylinder (Figure 7, Item 4).

0277

Figure 7. Ripper Lift Cylinder Rod End.

0277

0277-6

TM 5-2410-241-23-3

0277

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 5. Install new O-ring (Figure 8, Item 9) on hose (Figure 8, Item 6). 6. Install hose (Figure 8, Item 6), flange (Figure 8, Item 10), four washers (Figure 8, Item 8), and bolts (Figure 8, Item 7) on head end of ripper lift cylinder (Figure 8, Item 5). 7. Install new O-ring (Figure 8, Item 11) on hose (Figure 8, Item 3). 8. Install hose (Figure 8, Item 3), flange (Figure 8, Item 12), plate (Figure 8, Item 4), four washers (Figure 8, Item 1) and bolts (Figure 8, Item 2) on rod end of ripper lift cylinder (Figure 8, Item 5).

Figure 8. Ripper Lift Cylinder. END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic oil (WP 0184). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0277

000277

0277-7/(8 blank)

8 TM 5-2410-241-23-3 0278

FIELD MAINTENANCE INSTRUCTIONS CYLINDER, RIPPER TILT SERVICE Removal, Cleaning and Inspection, Installation
0 2 7 8

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Gloves, Rubber (S0208) (WP 0302, Item 68) Sling, Multiple Leg (WP 0302, Item 54) Wrench, Combination, 30 mm (S0824) (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) Tag, Marker (WP 0303, Item 34) Locknut O-ring (2)
0

Personnel Required Two

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Lower ripper to ground (TM 5-2410-241-10) Drain hydraulic system oil (WP 0184) Drawing Required TM 5-2410-241-24P, Figure 149, 151

Estimated Time to Complete


0

1.1 Hr
0 0

0278-1

TM 5-2410-241-23-3

0278

REMOVAL

000278

WARNING

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.

CAUTION
Cap and plug all hydraulic hose ends to prevent leaks and contamination. Failure to follow this caution may result in damage to equipment.

NOTE
Collect fluid in suitable containers. Dispose of all fluids according to local regulations and mandates. This procedure is for one ripper tilt cylinder. Use the same procedure for other ripper tilt cylinder. Tag and identify hoses to aid installation.

1. Remove four bolts (Figure 1, Item 2), washers (Figure 1, Item 1), plate (Figure 1, Item 3), flange (Figure 1, Item 13), and hose (Figure 1, Item 5) from rod end of ripper tilt cylinder (Figure 1, Item 6). Set hose aside. 2. Remove O-ring (Figure 1, Item 4) from hose (Figure 1, Item 5). Discard O-ring. 3. Remove four bolts (Figure 1, Item 8), washers (Figure 1, Item 9), plate (Figure 1, Item 10), flange (Figure 1, Item 12), and hose (Figure 1, Item 7) from head end of ripper tilt cylinder (Figure 1, Item 6). Set hose aside. 4. Remove O-ring (Figure 1, Item 11) from hose (Figure 1, Item 7). Discard O-ring.

Figure 1. Ripper Tilt Cylinder Hose Assemblies.

0278

0278-2

TM 5-2410-241-23-3

0278

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
Use suitable lifting device to support ripper tilt cylinder. The tilt cylinder weighs approximately 250 lb (113 kg). 5. Attach a suitable lifting device to ripper tilt cylinder (Figure 2, Item 1).

Figure 2. Ripper Tilt Cylinder Support.

0278

0278-3

TM 5-2410-241-23-3

0278

REMOVAL CONTINUED 6. Remove bolt (Figure 3, Item 1), locknut (Figure 3, Item 3), and pin (Figure 3, Item 2) from head end of ripper tilt cylinder (Figure 3, Item 4). Discard locknut.

Figure 3. Ripper Tilt Cylinder Head End.

0278

7. Remove two bolts (Figure 4, Item 1), plate (Figure 4, Item 2), and pin assembly (Figure 4, Item 3) from rod end of the ripper tilt cylinder (Figure 4, Item 4). 8. Remove ripper tilt cylinder (Figure 4, Item 4) from machine and place on flat surface. 9. Remove lifting device from ripper tilt cylinder (Figure 4, Item 4).

Figure 4. Ripper Tilt Cylinder Rod End. END OF TASK

0278

0278-4

TM 5-2410-241-23-3

0278

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

000278

000278

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
Use suitable lifting device to support the ripper tilt cylinder. The tilt cylinder weighs approximately 250 lb (113 kg). 1. Install suitable lifting device on ripper tilt cylinder (Figure 5, Item 1). 2. Position ripper tilt cylinder (Figure 5, Item 1) on machine.

Figure 5. Ripper Tilt Cylinder Support.

0278

0278-5

TM 5-2410-241-23-3

0278

INSTALLATION CONTINUED 3. Install pin assembly (Figure 6, Item 3), plate (Figure 6, Item 2), and two bolts (Figure 6, Item 1) on rod end of ripper tilt cylinder (Figure 6, Item 4).

Figure 6. Ripper Tilt Cylinder Rod End.

0278

4. Install pin (Figure 7, Item 2), bolt (Figure 7, Item 1), and new locknut (Figure 7, Item 3) on head end of ripper tilt cylinder (Figure 7, Item 4). 5. Remove lifting device from ripper tilt cylinder (Figure 7, Item 4).

Figure 7. Ripper Tilt Cylinder Head End.

0278

0278-6

TM 5-2410-241-23-3

0278

INSTALLATION CONTINUED

NOTE
Install hoses as tagged during removal. 6. Install new O-ring (Figure 8, Item 11) on hose (Figure 8, Item 7). 7. Install hose (Figure 8, Item 7), flange (Figure 8, Item 12), plate (Figure 8, Item 10), four washers (Figure 8, Item 9), and bolts (Figure 8, Item 8) on head end of ripper tilt cylinder (Figure 8, Item 6). 8. Install new O-ring (Figure 8, Item 4) on hose (Figure 8, Item 5). 9. Install hose (Figure 8, Item 5), flange (Figure 8, Item 13), plate (Figure 8, Item 3), four washers (Figure 8, Item 1), and bolts (Figure 8, Item 2) on rod end of ripper tilt cylinder (Figure 8, Item 6).

Figure 8. Ripper Tilt Cylinder Assemblies. END OF TASK FOLLOW-ON TASKS 1. Fill hydraulic system with oil (WP 0184). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0278

000278

0278-7/(8 blank)

8 TM 5-2410-241-23-3 0279

FIELD MAINTENANCE INSTRUCTIONS RIPPER FRAME ASSEMBLY SERVICE Removal, Cleaning and Inspection, Installation
0 2 7 9

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Handle, Sliding T, 3/4 Drive, 17 Long (S0375) (WP 0302, Item 68) Lifting Link (1/2 in.; 4,000 lb [1,800 kg]) (WP 0302, Item 36) Socket, Impact, 3/4 Drive, 6 pt 46 mm (S0694) (WP 0302, Item 68) Stand Assembly, Jack Stand (WP 0302, Item 56) Universal Drive, 3/4 Drive (WP 0302, Item 70) Wrench, Combination 1-13/16 (S0797) (WP 0302, Item 68) Wrench, Electric Impact, 3/4 Drive, 1200 lb-ft (S0730) (WP 0302, Item 68) Lifting Device (5,000 lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Bolt, 36 mm (2)
0

References WP 0295

Personnel Required
0

Two Equipment Condition

Machine parked (TM 5-2410-241-10) Ripper tilt cylinders removed (WP 0278) Ripper carriage removed ( WP 0282) Ripper lift cylinders removed (WP 0277) Bottom guards removed (WP 0199) Drawings Required TM 5-2410-241-24P, Figure 147

Estimated Time to Complete


0

1.1 Hr

0279-1

TM 5-2410-241-23-3

0279

REMOVAL 1. Install two lifting links (Figure 1, Item 2) and bolts (Figure 1, Item 3) on ripper frame (Figure 1, Item 1). 2. Attach suitable lifting device on ripper frame (Figure 1, Item 1). 3. Support ripper frame (Figure 1, Item 1) with suitable supports.

000279

Figure 1. Ripper Frame Support.

0279

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
Ripper frame weighs approximately 1650 lb (750 kg).

NOTE
Note orientation of plates to aid installation. Note location and quantity of shims to aid installation. Loosen outside bolts prior to inside bolts.

0279-2

TM 5-2410-241-23-3

0279

REMOVAL CONTINUED 4. Remove two bolts (Figure 2, Item 1), two plates (Figure 2, Item 2), lower pivot pin (Figure 2, Item 3), and shims (Figure 2, Item 6) from ripper mounting (Figure 2, Item 7). 5. Repeat step 4 for other side of ripper mounting (Figure 2, Item 7). 6. With assistance, remove ripper frame (Figure 2, Item 5) from ripper mounting (Figure 2, Item 7) and tiedown plate (Figure 2, Item 4), and place on flat surface. 7. Remove lifting device from ripper frame (Figure 2, Item 5). 8. Remove two bolts (Figure 1, Item 3) and lifting links (Figure 1, Item 2) from ripper frame (Figure 1, Item 1).

Figure 2. Ripper Frame.

0279

0279-3

TM 5-2410-241-23-3

0279

REMOVAL CONTINUED

NOTE
Note orientation of tiedown plate to aid installation. 9. Remove two bolts (Figure 3, Item 5), plates (Figure 3, Item 4), spacers (Figure 3, Item 3), tiedown plate (Figure 3, Item 2), upper pivot pin (Figure 3, Item 6), and shims (Figure 3, Item 1) from ripper mounting (Figure 3, Item 7). 10. Repeat step 9 for other side of ripper mounting (Figure 3, Item 7).

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

0279

000279

0279-4

TM 5-2410-241-23-3

0279

INSTALLATION

000279

CAUTION
Tiedown plates are installed with flat side facing toward front of machine. Plates are installed with flat side toward pin, depression toward bolt. Failure to follow this caution may result in damage to equipment.

NOTE
Install shims as noted. Tighten inside bolts first.

1. Install tiedown plate (Figure 4, Item 2), upper pivot pin (Figure 4, Item 6), shims (Figure 4, Item 1), two spacers (Figure 4, Item 3), plates (Figure 4, Item 4), and bolts (Figure 4, Item 5) on ripper mounting (Figure 4, Item 7). 2. Repeat step 1 for other side of ripper mounting (Figure 4, Item 7).

Figure 4. Tiedown Plate.

0279

0279-5

TM 5-2410-241-23-3

0279

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
Ripper frame weighs approximately 1650 lb (750 kg). 3. Install two lifting links (Figure 5, Item 2) and bolts (Figure 5, Item 3) on ripper frame (Figure 5, Item 1). 4. Install suitable lifting device on ripper frame (Figure 5, Item 1).

Figure 5. Ripper Frame Support.

0279

0279-6

TM 5-2410-241-23-3

0279

INSTALLATION CONTINUED 5. With assistance, install ripper frame (Figure 6, Item 5), shims (Figure 6, Item 6), lower pivot pin (Figure 6, Item 3), two plates (Figure 6, Item 2), and two bolts (Figure 6, Item 1) on ripper mounting (Figure 6, Item 7) and tiedown plate (Figure 6, Item 4). 6. Repeat step 5 for other side of ripper frame (Figure 6, Item 5). 7. Remove lifting device from ripper frame (Figure 6, Item 5). 8. Remove two bolts (Figure 5, Item 3) and lifting links (Figure 5, Item 2) from ripper frame (Figure 5, Item 1).

Figure 6. Ripper Frame. END OF TASK FOLLOW-ON TASKS 1. Install ripper lift cylinders (WP 0277). 2. Install ripper tilt cylinders (WP 0278). 3. Install ripper carriage (WP 0282). 4. Install bottom guards (WP 0199). 5. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0279

000279

0279-7/(8 blank)

4 TM 5-2410-241-23-3 0280

FIELD MAINTENANCE INSTRUCTIONS RIPPER TOOTH REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 8 0

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

Equipment Condition Machine parked (TM 5-2410-241-10) Ripper in raised position (TM 5-2410-241-10) Drawing Required TM 5-2410-241-24P, Figure 147 Estimated Time to Complete

0.5 Hr
0 0

0280-1

TM 5-2410-241-23-3

0280

REMOVAL

000280

NOTE
This procedure is for one ripper tooth. Use the same procedure for other ripper teeth. Note orientation of pin to aid installation. Retainer only fits pin one way.

Remove pin (Figure 1, Item 1), retainer (Figure 1, Item 2), and ripper tooth (Figure 1, Item 3) from ripper shank (Figure 1, Item 4). Discard pin and retainer.

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

0280

000280

000280

NOTE
Install pin as noted in removal. Install ripper tooth (Figure 1, Item 3), new retainer (Figure 1, Item 2), and new pin (Figure 1, Item 1) on ripper shank (Figure 1, Item 4). END OF TASK

0280-2

TM 5-2410-241-23-3

0280

FOLLOW-ON TASKS 1. Lower ripper assembly (TM 5-2410-241-10). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

000280

0280-3/(4 blank)

4 TM 5-2410-241-23-3 0281

FIELD MAINTENANCE INSTRUCTIONS RIPPER SHANK REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 8 1

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Bracket, Link (3/4 in.; 9,000 lb [4,000 kg]) (WP 0302, Item 11) Lifting device (500-lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) Cotter pin (2) Personnel Required Two
0

References WP 0295

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Ripper tooth removed (WP 0280) Drawing Required TM 5-2410-241-24P, Figure 147 Estimated Time to Complete 0.5 Hr

0281-1

TM 5-2410-241-23-3

0281

REMOVAL

000281

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
Ripper shank weighs approximately 325 lb (147 kg). This procedure is for one ripper shank. Use the same procedure for other ripper shanks.

1. Attach bracket link and suitable lifting device on ripper shank (Figure 1, Item 1). 2. Remove two cotter pins (Figure 1, Item 5), retainers (Figure 1, Item 4), and pin (Figure 1, Item 3) from ripper shank (Figure 1, Item 1). Discard cotter pins. 3. With assistance, raise ripper shank (Figure 1, Item 1) and remove through top of ripper carriage (Figure 1, Item 2).

Figure 1. Shank. 4. Remove lifting device and bracket link from ripper shank (Figure 1, Item 1). END OF TASK

0281

0281-2

TM 5-2410-241-23-3

0281

CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK INSTALLATION 1. Attach bracket link and suitable lifting device on ripper shank (Figure 1, Item 1).

000281

000281

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
Ripper shank weighs approximately 325 lb (147 kg). 2. With assistance, install ripper shank (Figure 1, Item 1) in ripper carriage (Figure 1, Item 2) from the top. 3. Install pin (Figure 1, Item 3), two retainers (Figure 1, Item 4), and new cotter pins (Figure 1, Item 5) on ripper shank (Figure 1, Item 1). 4. Remove lifting device and bracket link from ripper shank (Figure 1, Item 1). END OF TASK FOLLOW-ON TASKS 1. Install ripper tooth (WP 0280). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE
000281

0281-3/(4 blank)

10 TM 5-2410-241-23-3 0282

FIELD MAINTENANCE INSTRUCTIONS RIPPER CARRIAGE REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 8 2

INITIAL SETUP Tools and Special Tools


0

Personnel Required Two References WP 0295 Equipment Condition Machine parked (TM 5-2410-241-10) Ripper shanks removed (WP 0281) Drawing Required TM 5-2410-241-24P, Figure 147 Estimated Time to Complete

Tool Kit, General Mechanics (WP 0302, Item 65) Hammer, Hand, Soft Face, Dead Blow 52 oz (S0221) (WP 0302, Item 68) Sling, Multiple Leg (WP 0302, Item 54) Stand Assembly, Jack Stand (WP 0302, Item 56) Wrench, Torque, Click, Ratcheting, 3/4 Drive, 600 lb-ft (WP 0302, Item 72) Lifting Device (5,000-lb capacity) Wood block 8x8x12
0 0 0 0 0 0 0

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

2.5 Hr

0282-1

TM 5-2410-241-23-3

0282

REMOVAL 1. Lower ripper carriage (Figure 1, Item 1) on jack stands (TM 5-2410-240-10).

000282

Figure 1. Ripper Carriage.

0282

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
Use suitable lifting device to support ripper tilt cylinder. The ripper tilt cylinder weighs approximately 250 lb (113 kg). 2. Install a suitable lifting device on ripper tilt cylinder (Figure 2, Item 4). 3. Remove two bolts (Figure 2, Item 1), plate (Figure 2, Item 2), and pin assembly (Figure 2, Item 3) from ripper tilt cylinder (Figure 2, Item 4) and ripper carriage (Figure 2, Item 5).

Figure 2. Ripper Tilt Cylinder Rod End.

0282

0282-2

TM 5-2410-241-23-3

0282

REMOVAL CONTINUED 4. With assistance, place wood block in position. Use suitable lifting straps to lower ripper tilt cylinder (Figure 3, Item 1) on wood block. 5. Remove lifting device from ripper tilt cylinder (Figure 3, Item 1). 6. Repeat steps 2 through 5 for other ripper tilt cylinder (Figure 3, Item 1).

Figure 3. Ripper Tilt Cylinder.

0282

0282-3

TM 5-2410-241-23-3

0282

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
Use suitable lifting device to support ripper carriage. The ripper carriage weighs approximately 2,500 lb (1,134 kg). 7. Install pin assembly (Figure 4, Item 3), plate (Figure 4, Item 2), and two bolts (Figure 4, Item 1) on carriage assembly (Figure 4, Item 4) on both sides. 8. Attach lifting device around pins (Figure 4, Item 3) and support carriage (Figure 4, Item 4).

NOTE
Note quantity and position of shims before removal to aid installation. 9. Remove two bolts (Figure 4, Item 5), plate (Figure 4, Item 6), pin assembly (Figure 4, Item 7), and shims (Figure 4, Item 9) from ripper carriage (Figure 4, Item 4) and ripper frame (Figure 4, Item 8). 10. Remove ripper carriage (Figure 4, Item 4) from ripper frame (Figure 4, Item 8). 11. Remove lifting device from ripper carriage (Figure 4, Item 4). 12. Remove two bolts (Figure 4, Item 1), plate (Figure 4, Item 2), and pin (Figure 4, Item 3) from carriage on each side.

0282-4

TM 5-2410-241-23-3

0282

REMOVAL CONTINUED

Figure 4. Ripper Carriage. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0282

000282

0282-5

TM 5-2410-241-23-3

0282

INSTALLATION

000282

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
Use suitable lifting device to support ripper carriage. The ripper carriage weighs approximately 2500 lb (1134 kg). 1. Install pin (Figure 5, Item 3), plate (Figure 5, Item 2), and two bolts (Figure 5, Item 1) on each side of carriage (Figure 5, Item 4). 2. Attach suitable lifting device around pins (Figure 5, Item 3) and support ripper carriage (Figure 5, Item 4). 3. With assistance, install ripper carriage (Figure 5, Item 4) on machine.

NOTE
Install shims as noted during removal. 4. Install shims (Figure 5, Item 9), pin assembly (Figure 5, Item 7), plate (Figure 5, Item 6), and two bolts (Figure 5, Item 5) on ripper carriage (Figure 5, Item 4) and ripper frame (Figure 5, Item 8). Tighten bolts to 340 45 lb-ft (460 60 Nm). 5. Repeat step 4 for other side of ripper carriage (Figure 5, Item 4) and ripper frame (Figure 5, Item 8). 6. Support ripper carriage (Figure 5, Item 4) with jack stands. 7. Remove two bolts (Figure 5, Item 1), plate (Figure 5, Item 2), and pin (Figure 5, Item 3) from each side of carriage (Figure 5, Item 4).

0282-6

TM 5-2410-241-23-3

0282

INSTALLATION CONTINUED

Figure 5. Ripper Carriage.

0282

0282-7

TM 5-2410-241-23-3

0282

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
Use suitable lifting device to support ripper tilt cylinder. The ripper tilt cylinder weighs approximately 250 lb (113 kg). 8. Use suitable lifting straps to raise ripper tilt cylinder (Figure 6, Item 1).

Figure 6. Ripper Tilt Cylinder.

0282

0282-8

TM 5-2410-241-23-3

0282

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
Use suitable lifting device to support ripper tilt cylinder. The ripper tilt cylinder weighs approximately 250 lb (113 kg). 9. Install pin assembly (Figure 7, Item 3), plate (Figure 7, Item 2), and bolts (Figure 7, Item 1) on ripper tilt cylinder (Figure 7, Item 4) and ripper carriage (Figure 7, Item 5). Tighten bolts to 340 45 lb ft (460 60 Nm). 10. Remove lifting straps from ripper tilt cylinder (Figure 7, Item 4). 11. Repeat steps 8 through 10 for other ripper tilt cylinder (Figure 7, Item 4). 12. Remove wood block.

Figure 7. Ripper Tilt Cylinder Rod End.

0282

0282-9

TM 5-2410-241-23-3

0282

INSTALLATION CONTINUED 13. Raise ripper carriage (TM 2410-241-10). 14. Remove jack stands from ripper carriage (Figure 8, Item 1) and ripper tilt cylinder.

Figure 8. Ripper Carriage. END OF TASK FOLLOW-ON TASKS 1. Install ripper shanks (WP 0281). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0282

000282

0282-10

2 TM 5-2410-241-23-3 0283

FIELD MAINTENANCE
0 2 8 3

ARCTIC KIT TROUBLESHOOTING INTRODUCTION

INTRODUCTION

000283

1. This chapter provides information for identifying and correcting malfunctions that may develop during operation of the D7R Dozer Arctic Kit. 2. The Troubleshooting Symptom Index in WP 0284 lists common malfunctions which may occur, and refers to the proper page in Arctic Kit Troubleshooting (WP 0286). 3. If you are unsure of the location of an item mentioned in troubleshooting, refer to Arctic Kit Troubleshooting Introduction (WP 0283). 4. Before performing troubleshooting, read and follow all safety instructions found in the Warning Summary at the front of this manual. 5. The Troubleshooting Symptom Index (WP 0284) cannot list all malfunctions that may occur, nor can troubleshooting list all tests or inspections and corrective actions. If a malfunction is not listed, or is not corrected by the listed corrective actions, notify your supervisor. 6. When troubleshooting a malfunction: a. Locate the symptom or symptoms in Troubleshooting Symptom Index (WP 0284) that best describe the malfunction. b. Turn to the page in Troubleshooting Procedures (WP 0286) where the troubleshooting procedures for the malfunction in question are described. c. Perform the task, answer the question, and perform the corrective action in the order listed until the malfunction is corrected. Do not perform any maintenance task unless the troubleshooting procedure tells you to do so.
000283

EXPLANATION OF COLUMNS The columns in the troubleshooting table are defined as follows: a. MALFUNCTION. A visual or operational indication that something is wrong with the equipment. b. TEST OR INSPECTION. A procedure to isolate the problem in a system or component. c. CORRECTIVE ACTION. A procedure to correct the problem.

END OF WORK PACKAGE

0283-1/(2 blank)

2 TM 5-2410-241-23-3 0284

FIELD MAINTENANCE
0 2 8 4

ARCTIC KIT TROUBLESHOOTING SYMPTOM INDEX

Malfunction/Symptom 1 2 3

Troubleshooting Procedure Page

Arctic Heater Does Not Heat Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0286-1 Arctic Heater Turns ON and Shuts Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0286-2 Arctic Heater Does Not Turn ON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0286-3

END OF WORK PACKAGE

0284-1/(2 blank)

4 TM 5-2410-241-23-3 0285

FIELD MAINTENANCE
0 2 8 5

ARCTIC KIT HEATER FUEL FLOW TEST Prepare For Test, Measuring Fuel Flow

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) 25 mL measuring cylinder
0

Materials/Parts Rag, Wiping (WP 0303, Item 24)

Equipment Condition
0

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


0 0

Estimated Time to Complete 0.5 Hr

0285-1

TM 5-2410-241-23-3

0285

PREPARE FOR TEST

000285

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.

NOTE
Only conduct flow test if battery is sufficiently charged. During measurement, voltage applied to the heater should be at least 23 Volts and not more than 25 Volts. 1. Disconnect fuel pressure line (Figure 1, Item 2) from arctic heater (Figure 1, Item 3). 2. Place end of fuel pressure line (Figure 1, Item 2) in 25 mL measuring cylinder (Figure 1, Item 4). 3. Switch arctic heater (Figure 1, Item 3) ON (TM 5-2410-241-10). When fuel discharges free of bubbles, fuel pipe is full and vented. 4. Switch arctic heater (Figure 1, Item 3) OFF (TM 5-2410-241-10) and empty measuring cylinder (Figure 1,Item 4). END OF TASK

0285-2

TM 5-2410-241-23-3

0285

MEASURING FUEL FLOW

000285

Figure 1. Measuring Fuel Flow. 1. Place fuel pressure line (Figure 1, Item 2) from metering pump (Figure 1, Item 1) into 25 mL measuring cylinder (Figure 1, Item 4).

0285

2. Switch arctic heater (Figure 1, Item 3) ON (TM 5-2410-241-10) and wait until metering pump (Figure 1, Item 1) starts pumping fuel. 3. Hold measuring cylinder (Figure 1, Item 4) at level of arctic heater (Figure 1, Item 3) for duration of test.

NOTE
Metering pump will automatically stop pumping fuel after 68 seconds. 4. Once metering pump (Figure 1, Item 1) stops pumping fuel, switch arctic heater (Figure 1, Item 3) OFF (TM 52410-241-10). 5. Replace fuel metering pump (Figure 1, Item 1) (WP 0293) if fuel level in metering cylinder (Figure 1, Item 4) is: a. above 8.25 mL or, b. below 6.75 mL, 6. Once measurement is completed, reconnect fuel pressure line (Figure 1, Item 2) to arctic heater (Figure 1, Item 3). 7. Return to Arctic Kit Troubleshooting. END OF TASK END OF WORK PACKAGE

0285-3/(4 blank)

8 TM 5-2410-241-23-3 0286

FIELD MAINTENANCE
0 2 8 6

ARCTIC KIT TROUBLESHOOTING PROCEDURES

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer. MALFUNCTION 1. ARCTIC HEATER DOES NOT HEAT UP TEST OR INSPECTION 1. Open left engine bay door (TM 5-2410-241-10) and inspect arctic heater hoses for kinks and damage. CORRECTIVE ACTION Arctic Heater Hoses Kinked Position arctic heater hoses to remove kinks and sharp bends. Arctic Heater Hoses Damaged Replace arctic heater hoses (WP 0292). Arctic Heater Exhaust Tube Kinked, Bent or Damaged Replace arctic heater exhaust tube (WP 0292). Arctic Heater Exhaust Tube Restricted - Clear restriction from arctic heater exhaust tube. 3. Inspect arctic heater fresh air intake tube (Figure 1, Item 1) and port for kinks, bends, damage, and restrictions. Arctic Heater Fresh Air Tube Kinked, Bent, or Damaged Replace arctic heater fresh air intake tube (WP 0292). Arctic Heater Fresh Air Intake Tube Restricted - Clear restriction from arctic heater fresh air intake tube.

2. Inspect arctic heater exhaust tube (Figure 1, Item 2) for kinks, bends, damage, and restrictions.

Figure 1. Intake and Exhaust Tubes.

0286

0286-1

TM 5-2410-241-23-3

0286

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer - Continued. MALFUNCTION 1. ARCTIC HEATER DOES NOT HEAT UP CONTINUED. TEST OR INSPECTION 4. Turn arctic heater switch ON (TM 5-2410-241-10) and verify arctic fuel metering pump is activated. Pump will run when switch is activated and arctic heater determines the temperature is OK for arctic heater operation. CORRECTIVE ACTION Arctic Heater Does Not Turn ON Proceed to Arctic Heater Does Not Turn On (Malfunction 4) in this work package. Arctic Heater Turns ON - Perform Arctic Heater Fuel Flow Test (WP 0285).

Figure 2. Intake and Exhaust Tubes. 2. ARCTIC HEATER TURNS ON AND SHUTS DOWN 1. Open left engine bay door (TM 5-2410-241-10) and inspect arctic heater hoses for kinks and damage. Arctic Heater Hoses Kinked Position arctic heater hoses to remove kinks and sharp bends. Arctic Heater Hoses Damaged Replace arctic heater hoses (WP 0292). Arctic Heater Exhaust Tube Kinked, Bent or Damaged Replace arctic heater exhaust tube (WP 0292). Arctic Heater Exhaust Tube Restricted - Clear restriction from arctic heater exhaust tube.

0286

2. Inspect arctic heater exhaust tube (Figure 2, Item 2) for kinks, bends, damage, and restrictions.

0286-2

TM 5-2410-241-23-3

0286

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer - Continued. MALFUNCTION 2. ARCTIC HEATER TURNS ON AND SHUTS DOWN CONTINUED. TEST OR INSPECTION 3. Inspect arctic heater fresh air intake tube (Figure 2, Item 1) and port for kinks, bends, damage, and restrictions. CORRECTIVE ACTION Arctic Heater Fresh Air Tube Kinked, Bent, or Damaged Replace arctic heater fresh air intake tube (WP 0292). Arctic Heater Fresh Air Intake Tube Restricted - Clear restriction from arctic heater fresh air intake tube. Arctic Heater Turns On and Shuts Down - Replace the arctic heater (WP 0291). Arctic Heater Fuel Metering Pump Turns ON - Perform Arctic Heater Fuel Flow Test (WP 0285).

4. Turn arctic heater switch ON (TM 5-2410-241-10) and verify arctic fuel metering pump is activated. Pump will run when switch is activated and arctic heater determines the temperature is OK for arctic heater operation. 3. ARCTIC HEATER DOES NOT TURN ON Test 1 - Inspect Fuse. 1. Turn battery disconnect switch and ignition switch to the OFF position (TM 52410-241-10). 2. Inspect the Auxiliary PWR Unswitched 15a fuse (TM 5-2410-241-10). Test 2 - Test Arctic Heater Power, Ground, and Signal. 1. Disconnect harness connector B2 (WP 0018, Figure 18) from arctic heater (WP 0018, Figure 18). 2. Turn battery disconnect switch and ignition switch to the ON position (TM 52410-241-10). 3. Turn arctic heater switch to the ON position (TM 52410-241-10). 4. Using digital multimeter, test for voltage between harness connector B2 terminal A3 (WP 0018, Figure 18) and machine ground. Voltage should be between 1826 Volts.

Fuse Open - Proceed to Test 3. Fuse OK - Proceed to Test 2.

Voltage OK - Proceed to next step. Voltage Not OK - Proceed to Test 4.

0286-3

TM 5-2410-241-23-3

0286

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer - Continued. MALFUNCTION 3. ARCTIC HEATER DOES NOT TURN ON CONTINUED. TEST OR INSPECTION 5. Using digital multimeter, test for voltage between harness connector B2 terminal A3 and terminal A2 (WP 0018, Figure 18). Voltage should be between 1826 Volts. 6. Using digital multimeter, test for voltage between harness connector B2 terminal C4 (WP 0018, Figure 18) and machine ground. Voltage should be between 1826 volts. Test 3 - Test Power Circuit For Short. 1. Disconnect harness connector XX-C2 (WP 0018, Figure 120) from arctic heater switch (WP 0018, Figure 119) (WP 0290). 2. Install new Auxiliary PWR Unswitched 15a fuse (TM 5-2410-241-10). 3. Turn battery disconnect switch to the ON position (TM 5-2410-241-10). 4. Inspect the Auxiliary PWR Unswitched 15a fuse. 5. Disconnect harness connector XX-C1 (WP 0018, Figure 129) from harness connector XY-C3 (WP 0018, Figure 130). 6. Install new Auxiliary PWR Unswitched 15a fuse (TM 5-2410-241-10). 7. Inspect the Auxiliary PWR Unswitched 15a fuse. Fuse Open - Proceed to next step. Fuse OK - Replace arctic heater (WP 0291). Fuse Open - Proceed to next step. Fuse OK - Replace arctic heater harness switch (WP 0290). CORRECTIVE ACTION Voltage OK - Proceed to next step. Voltage Not OK - Proceed to Test 5.

Voltage OK - Arctic heater faulty, replace arctic heater (WP 0291). Voltage Not OK - Proceed to Test 6.

0286-4

TM 5-2410-241-23-3

0286

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer - Continued. MALFUNCTION 3. ARCTIC HEATER DOES NOT TURN ON CONTINUED. TEST OR INSPECTION 8. Disconnect harness connector YY-C1 (WP 0018, Figure 127) from harness connector XY-C4 (WP 0018, Figure 128). 9. Install new Auxiliary PWR Unswitched 15a fuse (TM 5-2410-241-10). 10. Inspect the Auxiliary PWR Unswitched 15a fuse. 11. Disconnect harness connector XY-C1 (WP 0018, Figure 131) from harness connector MA-C21 (WP 0018, Figure 132). 12. Install new Auxiliary PWR Unswitched 15a fuse (TM 5-2410-241-10). 13. Inspect the Auxiliary PWR Unswitched 15a fuse. Fuse Open - Replace fuse panel harness (WP 0176). Fuse OK - Replace cab wiring harness (WP 0254). 14. Disconnect harness connector B2 (WP 0018, Figure 18) from arctic heater. 15. Connect harness connector YY-C1 (WP 0018, Figure 127) to harness connector XY-C4 (WP 0018, Figure 128). 16. Install new Auxiliary PWR Unswitched 15a fuse (TM 5-2410-241-10). 17. Inspect the Auxiliary PWR Unswitched 15a fuse. Fuse Open - Replace heater harness (WP 0290). Fuse OK - Replace arctic heater (WP 0291). Fuse Open - Proceed to next step. Fuse OK - Proceed to Step 14. CORRECTIVE ACTION

0286-5

TM 5-2410-241-23-3

0286

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer - Continued. MALFUNCTION 3. ARCTIC HEATER DOES NOT TURN ON CONTINUED. TEST OR INSPECTION Test 4 - Test Power Circuit for Open. 1. Turn ignition switch and battery disconnect switch to the OFF position (TM 52410-241-10). 2. Disconnect harness connector YY-C1 (WP 0018, Figure 127) from harness connector XY-C4 (WP 0018, Figure 128). 3. Using digital multimeter, test for voltage between harness connector XY-C4 terminal A and machine ground. Voltage should be between 1826 Volts. 4. Disconnect harness connector XY-C1 (WP 0018, Figure 131) from harness connector MA-C21 (WP 0018, Figure 132). 5. Using digital multimeter, test for voltage between harness connector MA-C21 (WP 0018, Figure 132) terminal 1 and machine ground. Voltage should be between 1826 Volts. Test 5 - Test Ground Circuit. 1. Turn ignition switch and battery disconnect switch to the OFF position (TM 52410-241-10). 2. Disconnect harness connector YY-C1 (WP 0018, FIgure 127) from harness connector XY-C4 (WP 0018, Figure 128). Voltage OK - Replace platform arctic heater harness (WP 0290). Voltage Not OK - Replace platform wiring harness (WP 0209). Voltage OK - Replace engine compartment arctic heater harness (WP 0290). Voltage Not OK - Proceed to next step. CORRECTIVE ACTION

0286-6

TM 5-2410-241-23-3

0286

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer - Continued. MALFUNCTION 3. ARCTIC HEATER DOES NOT TURN ON CONTINUED. TEST OR INSPECTION 3. Using digital multimeter, test for continuity between harness connector XY-C4 terminal B and machine ground. Resistance should be less than 5 Ohms. Test 6 - Test Arctic Heater Signal Circuit. 1. Turn ignition switch and battery disconnect switch to the OFF position (TM 52410-241-10). 2. Disconnect harness connector YY-C1 (WP 0018, FIgure 127) from harness connector XY-C4 (WP 0018, Figure 128). 3. Disconnect harness connector XX-C1 (WP 0018, Figure 129) from harness connector XY-C3 (WP 0018, Figure 130). 4. Using digital multimeter, test for continuity between harness connector XY-C4 (WP 0018, Figure 128) Terminal C and harness connector XY-C3 (WP 0018, (Figure 130) terminal C. Resistance should be less than 5 Ohms. 5. Disconnect harness connector XX-C2 WP 0018, Figure 120) from arctic heater switch (WP 0018, FIgure 119) (WP 0290). Resistance Less Than Specified Value - Proceed to next step. Resistance More Than Specified Value - Replace platform wiring harness (WP 0209). CORRECTIVE ACTION Resistance Less Than Specified Value - Replace platform wiring harness (WP 0209). Resistance More Than Specified Value - Replace cab wiring harness (WP 0254).

0286-7

TM 5-2410-241-23-3

0286

Table 1. Arctic Kit Troubleshooting Procedures for the D7R Dozer - Continued. MALFUNCTION 3. ARCTIC HEATER DOES NOT TURN ON CONTINUED. TEST OR INSPECTION 6. Using digital multimeter, test for continuity between harness connector XX-C2 (WP 0018, Figure 128) terminal 3 and XX-C1 (WP 0018, Figure 129) terminal C. Resistance should be less than 5 Ohms. 7. With the arctic heater switch in the OFF position (TM 5-2410-241-10) test for continuity between arctic heater switch (WP 0018, FIgure 119) terminal 2 and terminal 3. There should be No continuity with the switch in the OFF position, and 5 Ohms with switch in the ON position. 8. Using digital multimeter, test for continuity between harness connector XX-C2 (WP 0018, Figure 128) terminal 3 and XX-C1 (WP 0018, Figure 129) terminal C. Resistance should be less than 5 Ohms. END OF WORK PACKAGE CORRECTIVE ACTION Resistance Less Than Specified Value - Proceed to next step. Resistance More Than Specified Value - Replace arctic heater switch harness (WP 0290).

Continuity Of Switch Does Not Match In One Or More Positions Replace arctic heater switch (WP 0290). Continuity Of Switch OK in Both Positions - Replace arctic heater (WP 0291).

Resistance Less Than Specified Value - Proceed to next step. Resistance More Than Specified Value - Replace arctic heater switch harness (WP 0290).

0286-8

20 TM 5-2410-241-23-3 0287

FIELD MAINTENANCE ARCTIC KIT BATTERY CABLES AND JUNCTION BLOCK POWER CABLE REPLACEMENT Arctic Kit Battery Cables Removal, Arctic Kit Junction Block Power Cable Removal, Cleaning and Inspection, Arctic Kit Junction Block Power Cable Installation, Arctic Kit Battery Cables Installation
0 2 8 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) Materials/Parts Detergent, General Purpose, Liquid (WP 0303, Item 8) Rag, Wiping (WP 0303, Item 24) Tag, Marker (WP 0303, Item 34) References WP 0230 WP 0295
0

Personnel Required Two

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Battery ground cable disconnected from batteries (WP 0160) Drawing Required TM 5-2410-241-24P, Figure 96, 154

Estimated Time to Complete 1.0 Hr

0287-1

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES REMOVAL

000287

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.

1. Release two latches (Figure 1, Item 2) and with assistance remove arctic kit battery cover (Figure 1, Item 1) from arctic kit battery box (Figure 1, Item 3).

Figure 1. Arctic Kit Battery Box Cover.

0287

0287-2

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES REMOVAL CONTINUED 2. Position two crossover cable covers (Figure 2, Item 1) aside.

NOTE
Tag and mark all cables to aid installation. 3. Loosen two nuts (Figure 2, Item 4) from clamps (Figure 2, Item 3) on crossover cable (Figure 2, Item 2) and remove cable from batteries (Figure 2, Item 5).

Figure 2. Crossover Cable.

0287

0287-3

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES REMOVAL CONTINUED 4. Remove bolt (Figure 3, Item 5), washer (Figure 3, Item 4), and two clamps (Figure 3, Item 3) from battery hold down (Figure 3, Item 9). 5. Remove two clamps (Figure 3, Item 3) from arctic kit battery cables (Figure 3, Items 1 and 2). 6. Remove bolt (Figure 3, Item 8), washer (Figure 3, Item 7), and clamp (Figure 3, Item 6) from battery hold down (Figure 3, Item 9) 7. Remove clamp (Figure 3, Item 6) from negative arctic kit battery cable (Figure 3, Item 1).

Figure 3. Cable Clamps.

0287

0287-4

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES REMOVAL CONTINUED 8. Position positive arctic kit battery cable cover (Figure 4, Item 4) aside.

NOTE
Tag and mark all cables to aid installation. 9. Loosen nut (Figure 4, Item 6), from clamp (Figure 4, Item 5) on positive arctic kit battery cable (Figure 4, Item 7) and remove cable from battery (Figure 4, Item 8). 10. Position negative arctic kit cable cover (Figure 4, Item 1) aside. 11. Loosen nut (Figure 4, Item 3) from clamp (Figure 4, Item 2) on negative arctic kit battery cable (Figure 4, Item 9) and remove cable from battery (Figure 4, Item 8).

Figure 4. Positive and Negative Arctic Kit Battery Cables.

0287

0287-5

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES REMOVAL CONTINUED 12. Position positive cable cover (Figure 5, Item 2) aside.

NOTE
Note cable routing to aid installation. Tag and mark all cables to aid installation.

13. Remove nut (Figure 5, Item 3), positive cable (Figure 5, Item 1), and positive arctic kit battery cable (Figure 5, Item 4) from terminal (Figure 5, Item 8). 14. Remove two grommets (Figure 5, Item 5) from arctic kit battery box (Figure 5, Item 6) and battery box (Figure 5, Item 7). 15. Remove positive arctic kit battery cable (Figure 5, Item 4) from machine.

Figure 5. Positive Battery Cables at Terminal.

0287

0287-6

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES REMOVAL CONTINUED 16. Position negative cable cover (Figure 6, Item 3) aside.

NOTE
Note cable routing to aid installation. Tag and mark all cables to aid installation.

17. Remove nut (Figure 6, Item 1), washer (Figure 6, Item 2), negative battery cable (Figure 6, Item 4) and negative arctic kit battery cable (Figure 6, Item 5) from disconnect switch (Figure 6, Item 6).

Figure 6. Negative Battery Cables at Disconnect Switch.

0287

0287-7

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES REMOVAL CONTINUED

NOTE
Apply soapy water to grommets and cables. 18. Remove negative arctic kit battery cable (Figure 7, Item 1) from machine. 19. Remove two grommets (Figure 7, Item 2) from arctic kit battery box (Figure 7, Item 3) and battery box (Figure 7, Item 4).

Figure 7. Negative Battery Cable and Grommets. END OF TASK

0287

0287-8

TM 5-2410-241-23-3

0287

ARCTIC KIT JUNCTION BLOCK POWER CABLE REMOVAL 1. Position positive cable cover (Figure 8, Item 2) aside.

000287

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections and cables to aid installation.

2. Remove nut (Figure 8, Item 3), arctic kit junction block positive cable (Figure 8, Item 1) and positive arctic kit battery cable (Figure 8, Item 4) from terminal (Figure 8, Item 5). Position cables aside.

Figure 8. Arctic Kit Positive Battery Cable at Terminal.

0287

0287-9

TM 5-2410-241-23-3

0287

ARCTIC KIT JUNCTION BLOCK POWER CABLE REMOVAL CONTINUED 3. Remove front floor plates (WP 0230) 4. Position positive cable cover (Figure 9, Item 3) aside.

NOTE
Note cable routing to aid installation. Tag and mark all electrical connections and cables to aid installation.

5. Remove nut (Figure 9, Item 2), washer (Figure 9, Item 5), positive cable (Figure 9, Item 4), and arctic kit junction block positive cable (Figure 9, Item 1) from junction block (Figure 9, Item 6). 6. Remove arctic kit junction block positive cable (Figure 9, Item 1) from machine.

Figure 9. Arctic Kit Positive Battery Cables at Junction Block. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0287

000287

0287-10

TM 5-2410-241-23-3

0287

ARCTIC KIT JUNCTION BLOCK POWER CABLE INSTALLATION

000287

NOTE
Route cables as noted during removal. Remove tags and install electrical connections and cables as noted during removal.

1. Install arctic kit junction block positive cable (Figure 10, Item 1) on machine. 2. Install arctic kit junction block positive cable (Figure 10, Item 1), positive cable (Figure 10, Item 4), washer (Figure 10, Item 5), and nut (Figure 10, Item 2) on junction block (Figure 10, Item 6). 3. Position positive cable cover (Figure 10, Item 3) over nut (Figure 10, Item 2). 4. Install front floor plates (WP 0230).

Figure 10. Arctic Kit Positive Battery Cables at Junction Block.

0287

0287-11

TM 5-2410-241-23-3

0287

ARCTIC KIT JUNCTION BLOCK POWER CABLE REMOVAL CONTINUED

NOTE
Route cables as noted during removal. Remove tags and install electrical connections and cables as noted during removal.

5. Install positive arctic kit battery cable (Figure 11, Item 4), arctic junction block positive cable (Figure 11, Item 1), and nut (Figure 11, Item 3) on terminal (Figure 11, Item 5). 6. Position positive cable cover (Figure 11, Item 2) aside.

Figure 11. Arctic Kit Positive Battery Cable at Terminal. END OF TASK

0287

0287-12

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES INSTALLATION

000287

NOTE
Apply soapy water to grommets and cables. 1. Install two grommets (Figure 12, Item 2) on arctic kit battery box (Figure 12, Item 3) and battery box (Figure 12, Item 4). 2. Install negative arctic kit battery cable (Figure 12, Item 1) on machine through grommets in battery boxes.

Figure 12. Negative Battery Cable and Grommets.

0287

0287-13

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES INSTALLATION CONTINUED

NOTE
Install cables as noted in removal. 3. Install negative arctic kit battery cable (Figure 13, Item 5), negative battery cable (Figure 13, Item 4), washer (Figure 13, Item 2), and nut (Figure 13, Item 1) on disconnect switch (Figure 13, Item 6). 4. Position negative cable cover (Figure 13, Item 3) over nut.

Figure 13. Negative Battery Cables at Disconnect Switch.

0287

0287-14

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES INSTALLATION CONTINUED 5. Install two grommets (Figure 14, Item 5) on arctic kit battery box (Figure 14, Item 6) and battery box (Figure 14, Item 7).

NOTE
Install cables as noted during removal. 6. Install positive arctic kit battery cable (Figure 14, Item 4) on machine. 7. Install positive arctic kit battery cable (Figure 14, Item 4), positive cable (Figure 14, Item 1), and nut (Figure 14, Item 3) on terminal (Figure 14, Item 8). 8. Position positive cable cover (Figure 14, Item 2) on terminal (Figure 14, Item 8).

Figure 14. Positive Battery Cables at Terminal.

0287

0287-15

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES INSTALLATION CONTINUED

NOTE
Install cable as noted during removal. 9. Install negative arctic kit battery cable (Figure 15, Item 9) on battery (Figure 15, Item 8) and tighten nut (Figure 15, Item 3) on clamp (Figure 15, Item 2). 10. Position negative arctic kit battery cable cover (Figure 15, Item 1) on nut (Figure 15, Item 3). 11. Install positive arctic kit battery cable (Figure 15, Item 7) on battery (Figure 15, Item 8) and tighten nut (Figure 15, Item 6) on clamp (Figure 15, Item 5). 12. Position positive arctic kit battery cable cover (Figure 15, Item 4) on clamps (Figure 15, Items 2 and 5).

Figure 15. Positive and Negative Arctic Kit Battery Cables.

0287

0287-16

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES INSTALLATION CONTINUED 13. Install clamp (Figure 16, Item 6) on negative arctic kit battery cable (Figure 16, Item 1). 14. Install clamp (Figure 16, Item 6), washer (Figure 16, Item 7), and bolt (Figure 16, Item 8) on battery hold down (Figure 16, Item 9) 15. Install two clamps (Figure 16, Item 3) on arctic kit battery cables (Figure 16, Items 1 and 2). 16. Install two clamps (Figure 16, Item 3), washer (Figure 16, Item 4), and bolt (Figure 16, Item 5) on battery hold down (Figure 16, Item 9).

Figure 16. Cable Clamps.

0287

0287-17

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES INSTALLATION CONTINUED 17. Install crossover cable (Figure 17, Item 2) on batteries (Figure 17, Item 5) and tighten two nuts (Figure 17, Item 4) on clamps (Figure 17, Item 3). 18. Position two crossover cable covers (Figure 17, Item 1) on clamps (Figure 17, Item 3).

Figure 17. Crossover Cable.

0287

0287-18

TM 5-2410-241-23-3

0287

ARCTIC KIT BATTERY CABLES INSTALLATION CONTINUED 19. With assistance, install arctic kit battery cover (Figure 18, Item 1) on arctic kit battery box (Figure 18, Item 3) and secure two latches (Figure 18, Item 2).

Figure 18. Arctic Kit Battery Box Cover. END OF TASK FOLLOW-ON TASKS 1. Connect battery ground cable to batteries (WP 0160). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0287

000287

0287-19/(20 blank)

12 TM 5-2410-241-23-3 0288

FIELD MAINTENANCE ARCTIC KIT BATTERIES REPLACEMENT Removal, Cleaning and Inspection, Installation
0 2 8 8

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) Sling, Multiple Leg (WP 0302, Item 54) Lifting Device (200 lb capacity) Materials/Parts Rag, Wiping (WP 0303, Item 24) References WP 0295
0

Personnel Required Two

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Battery ground cable disconnected (WP 0160) Drawing Required TM 5-2410-241-24P, Figure 154 Estimated Time to Complete 1.0 Hr

0288-1

TM 5-2410-241-23-3

0288

REMOVAL

000288

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.

1. Release two latches (Figure 1, Item 2) and with assistance remove arctic kit battery cover (Figure 1, Item 1) from arctic kit battery box (Figure 1, Item 3).

Figure 1. Arctic Kit Battery Box Cover.

0288

0288-2

TM 5-2410-241-23-3

0288

REMOVAL CONTINUED 2. Position two covers (Figure 2, Item 1) aside.

NOTE
Tag and mark all electrical connections and cables to aid installation. 3. Loosen two nuts (Figure 2, Item 4) and clamps (Figure 2, Item 3) from batteries (Figure 2, Item 5). 4. Remove crossover cable (Figure 2, Item 2) from batteries (Figure 2, Item 5).

Figure 2. Crossover Cable.

0288

0288-3

TM 5-2410-241-23-3

0288

REMOVAL CONTINUED 5. Remove bolt (Figure 3, Item 7), washer (Figure 3, Item 6), and two clamps (Figure 3, Items 4 and 5) from battery hold down (Figure 3, Item 3). 6. Position clamps (Figure 3, Items 4 and 5) aside on cables (Figure 3, Items 1 and 2). 7. Remove bolt (Figure 3, Item 10), washer (Figure 3, Item 9), and clamp (Figure 3, Item 8) from battery hold down (Figure 3, Item 3). 8. Position clamps (Figure 3, Item 8) aside on cable (Figure 3, Item 1).

Figure 3. Cable Clamps. 9. Position cable cover (Figure 4, Item 4) aside.

0288

0288-4

TM 5-2410-241-23-3

0288

REMOVAL CONTINUED

NOTE
Tag and mark all electrical connections and cables to aid installation. 10. Loosen nut (Figure 4, Item 6) from clamp (Figure 4, Item 5) on positive arctic kit battery cable (Figure 4, Item 7) and remove cable from battery (Figure 4, Item 8). Position positive arctic kit battery cable aside. 11. Position negative arctic kit battery cable cover (Figure 4, Item 1) aside. 12. Loosen nut (Figure 4, Item 3) from clamp (Figure 4, Item 2) on negative arctic kit battery cable (Figure 4, Item 9) and remove cable from battery (Figure 4, Item 8). Position negative arctic kit battery cable aside.

Figure 4. Positive and Negative Arctic Kit Battery Cables.

0288

0288-5

TM 5-2410-241-23-3

0288

REMOVAL CONTINUED 13. Remove two nuts (Figure 5, Item 3), washers (Figure 5, Item 4), and battery hold down (Figure 5, Item 1) from batteries (Figure 5, Item 2). Use assistance and appropriate lifting device when removing battery. Failure to follow this warning may result in injury or death to personnel.

NOTE
Each battery weighs approximately 121 lb (55 kg). Note position of batteries to aid installation.

14. Install lifting device on arctic kit batteries (Figure 5, Item 2). 15. Using lifting device, remove two arctic kit batteries (Figure 5, Item 2) from arctic kit battery box (Figure 5, Item 5). 16. Remove lifting device from arctic kit batteries (Figure 5, Item 2).

Figure 5. Arctic Kit Batteries. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0288

000288

0288-6

TM 5-2410-241-23-3

0288

INSTALLATION Use assistance and appropriate lifting device when lifting battery. Failure to follow this warning may result in injury to personnel.

000288

NOTE
Each battery weighs approximately 121 lb (55 kg). Install batteries as noted during removal.

1. Install lifting device on arctic kit batteries (Figure 5, Item 2). 2. Install two arctic kit batteries (Figure 5, Item 2) on arctic kit battery box (Figure 5, Item 5). 3. Remove lifting device from arctic kit batteries (Figure 5, Item 2). 4. Install battery hold down (Figure 5, Item 1), two washers (Figure 5, Item 4), and nuts (Figure 5, Item 3) on batteries (Figure 5, Item 2). 5. Position cable cover (Figure 5, Item 4) aside.

0288-7

TM 5-2410-241-23-3

0288

INSTALLATION CONTINUED

NOTE
Install cables as noted during removal. 6. Position negative arctic kit battery cable (Figure 6, Item 9) on battery (Figure 6, Item 8). 7. Install negative arctic kit battery cable (Figure 6, Item 9), clamp (Figure 6, Item 2), and tighten nut (Figure 6, Item 3) on battery (Figure 6, Item 8). 8. Position cable cover (Figure 6, Item 1) over clamp (Figure 6, Item 2). 9. Position positive arctic kit battery cable (Figure 6, Item 7) on battery (Figure 6, Item 8). 10. Install positive arctic kit battery cable (Figure 6, Item 7), clamp (Figure 6, Item 5), and tighten nut (Figure 6, Item 6) on battery (Figure 6, Item 8). 11. Position cable cover (Figure 6, Item 4) over clamp (Figure 6, Item 5).

Figure 6. Positive and Negative Arctic Kit Battery Cables.

0288

0288-8

TM 5-2410-241-23-3

0288

INSTALLATION CONTINUED 12. Position clamp (Figure 7, Item 8) and cable (Figure 7, Item 1) on battery hold down (Figure 7, Item 3). 13. Install clamp (Figure 7, Item 8), washer (Figure 7, Item 9), and bolt (Figure 7, Item 10) on battery hold down (Figure 7, Item 3). 14. Position clamps (Figure 7, Items 4 and 5) and cables (Figure 7, Items 1 and 2) on battery hold down (Figure 7, Item 3). 15. Install two clamps (Figure 7, Items 4 and 5), washer (Figure 7, Item 6), and bolt (Figure 7, Item 7) on battery hold down (Figure 7, Item 3).

Figure 7. Cable Clamps.

0288

0288-9

TM 5-2410-241-23-3

0288

INSTALLATION CONTINUED

NOTE
Install cables as noted in removal. 16. Install crossover cable (Figure 8, Item 2) on batteries (Figure 8, Item 5). 17. Install two clamps (Figure 8, Item 3) and tighten nuts (Figure 8, Item 4) on batteries (Figure 8, Item 5). 18. Position two covers (Figure 8, Item 1) on clamps (Figure 8, Item 3).

Figure 8. Crossover Cable.

0288

0288-10

TM 5-2410-241-23-3

0288

INSTALLATION CONTINUED 19. Install arctic kit battery cover (Figure 9, Item 1) on arctic kit battery box (Figure 9, Item 3) and secure two latches (Figure 9, Item 2).
.

Figure 9. Arctic Kit Battery Box Cover. END OF TASK FOLLOW-ON TASKS 1. Connect battery ground cable (WP 0160). 2. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0288

000288

0288-11/(12 blank)

6 TM 5-2410-241-23-3 0289

FIELD MAINTENANCE
0 2 8 9

ARCTIC KIT BATTERY BOX REPLACEMENT Removal, Cleaning and Inspection, Installation

INITIAL SETUP Tools and Special Tools Tool Kit, General Mechanics (WP 0302, Item 65) Blind Fastener Installation Kit (S0700) (WP 0302, Item 68) Drill-driver, Battery Operated (S0188) (WP 0302, Item 68) Drill Set, Twist (S0194) (WP 0302, Item 68) Materials/Parts Rag, Wiping (WP 0303, Item 24) Rivet (6) References WP 0295 REMOVAL
0

Personnel Required Two

Equipment Condition
0

Machine parked (TM 5-2410-241-10) Arctic kit batteries removed (WP 0288) Arctic kit battery cables removed (WP 0287) Drawing Required TM 5-2410-241-24P, Figure 154 Estimated Time to Complete 1.0 Hr

000289

NOTE
Latches should only be removed from battery box if replacing battery box or if latches are damaged. 1. Remove six rivets (Figure 1, Item 2) and two latches (Figure 1, Item 3) from battery box (Figure 1, Item 1). Discard rivets.

Figure 1. Battery Box Latch.

0289

0289-1

TM 5-2410-241-23-3

0289

REMOVAL CONTINUED 2. Remove eight nuts (Figure 2, Item 11), washers (Figure 2, Item 12), bolts (Figure 2, Item 2), washers (Figure 2, Item 6), and gusset plate (Figure 2, Item 9) from arctic kit battery box (Figure 2, Item 7). 3. Loosen two nuts (Figure 2, Item 5) from studs (Figure 2, Item 1). 4. Remove two studs (Figure 2, Item 1) and washers (Figure 2, Item 10) from arctic kit battery box (Figure 2, Item 7). 5. Remove two nuts (Figure 2, Item 5) from studs (Figure 2, Item 1). 6. Remove four bolts (Figure 2, Item 3), washers (Figure 2, Item 4), and arctic kit battery box (Figure 2, Item 7) from arctic kit battery box mounts (Figure 2, Item 13) and with assistance, battery box enclosure (Figure 2, Item 8).

Figure 2. Arctic Kit Battery Box. 7. Remove four nuts (Figure 3, Item 4), washers (Figure 3, Item 5), bolts (Figure 3, Item 2), washers (Figure 3, Item 3) and two plates (Figure 3, Item 1) from two mounts (Figure 3, Item 6).

0289

Figure 3. Plate.

0289

0289-2

TM 5-2410-241-23-3

0289

REMOVAL CONTINUED 8. Remove six bolts (Figure 4, Item 3), washers (Figure 4, Item 4) and two mounting plates (Figure 4, Item 2) from fender (Figure 4, Item 1).

Figure 4. Mounting Plates. 9. Remove four rivets (Figure 5, Item 5) and warning plate (Figure 5, Item 6) from cover (Figure 5, Item 1). Discard rivets. 10. Remove six bolts (Figure 5, Item 3), washers (Figure 5, Item 2), and cover (Figure 5, Item 1) from cover (Figure 5, Item 4).

0289

Figure 5. Cover. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0289

000289

000289

0289-3

TM 5-2410-241-23-3

0289

INSTALLATION

000289

1. Install cover (Figure 6, Item 1), six washers (Figure 6, Item 2), and bolts (Figure 6, Item 3) on cover (Figure 6, Item 4). 2. Install warning plate (Figure 6, Item 6) and four new rivets (Figure 6, Item 5) on cover (Figure 6, Item 1).

Figure 6. Cover. 3. Install two mounting plates (Figure 7, Item 2), six washers (Figure 7, Item 4), and bolts (Figure 7, Item 3) on fender (Figure 7, Item 1).

0289

Figure 7. Mounting Plates.

0289

0289-4

TM 5-2410-241-23-3

0289

INSTALLATION CONTINUED 4. Install two plates (Figure 8, Item 1), four washers (Figure 8, Item 3), bolts (Figure 8, Item 2), washers (Figure 8, Item 5), and nuts (Figure 8, Item 4) on two mounts (Figure 8, Item 6).

Figure 8. Plate. 5. With assistance, install arctic kit battery box (Figure 9, Item 7), four washers (Figure 9, Item 4), and bolts (Figure 9, Item 3) on arctic kit battery box mounts (Figure 9, Item 13) and battery box enclosure (Figure 9, Item 8). 6. Install two nuts (Figure 9, Item 5) on studs (Figure 9, Item 1).

0289

7. Install two washers (Figure 9, Item 10) and studs (Figure 9, Item 1) on arctic kit battery box (Figure 9, Item 7). 8. Tighten two nuts (Figure 9, Item 5) on studs (Figure 9, Item 1). 9. Install gusset plate (Figure 9, Item 9), eight washers (Figure 9, Item 6), bolts (Figure 9, Item 2), washers (Figure 9, Item 12), and nuts (Figure 9, Item 11) on arctic kit battery box (Figure 9, Item 7).

Figure 9. Arctic Kit Battery Box.

0289

0289-5

TM 5-2410-241-23-3

0289

INSTALLATION CONTINUED

NOTE
If latches were removed to replace battery box or due to damages, complete Step 10. 10. Install two latches (Figure 10, Item 3) and six new rivets (Figure 10, Item 2) on battery box (Figure 10, Item 1).

Figure 10. Battery Box Latch. END OF TASK FOLLOW-ON TASKS 1. Install arctic kit batteries (WP 0288). 2. Install arctic kit battery cables (WP 0287). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0289

000289

0289-6

10 TM 5-2410-241-23-3 0290

FIELD MAINTENANCE ARCTIC KIT HEATER SWITCH AND HEATER HARNESS SWITCH REPLACEMENT Arctic Kit Heater Switch Removal, Arctic Kit Heater Switch Harness Removal, Engine Compartment Arctic Kit Heater Harness Removal, Platform Arctic Kit Heater Harness Removal, Cleaning and Inspection, Platform Arctic Kit Heater Harness Installation, Engine Compartment Arctic Kit Heater Harness Installation, Arctic Kit Heater Switch Harness Installation, Arctic Kit Heater Switch Installation
0 2 9 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) Tiedown Strap (WP 0303, Item 36) References WP 0208 WP 0230 ARCTIC KIT HEATER SWITCH REMOVAL 1. Remove right arm rest (WP 0208).
0

References - Continued WP 0231 WP 0296 Equipment Condition Machine parked (TM 5-2410-241-10) Drawing Required

TM 5-2410-241-24P, Figure 152


0

Estimated Time to Complete


0

1.0 Hr
0

000290

NOTE
Note position and location of washers to aid installation. 2. Remove 14 bolts (Figure 1, Item 2), washers (Figure 1, Item 3), and ladder clip (Figure 1, Item 4) from upper right access panel (Figure 1, Item 1).

Figure 1. Upper Right Access Panel.

0290

0290-1

TM 5-2410-241-23-3

0290

ARCTIC KIT HEATER SWITCH REMOVAL CONTINUED 3. Remove bolt (Figure 2, Item 2) from upper right access panel (Figure 2, Item 1). 4. Remove two bolts (Figure 2, Item 4), and washers (Figure 2, Item 5), located under upper right access panel (Figure 2, Item 1) and switch pod (Figure 2, Item 3). 5. Position switch pod (Figure 2, Item 3) aside.

Figure 2. Switch Pod. 6. Invert switch pod (Figure 3, Item 5) to access wiring.

0290

7. Remove four bolts (Figure 3, Item 1) and switch pod cover (Figure 3, Item 2) from switch pod (Figure 3, Item 5). 8. Disconnect arctic kit heater switch harness connector (Figure 3, Item 4) from arctic kit heater switch (Figure 3, Item 3). 9. Remove arctic kit heater switch (Figure 3, Item 3) and guard (Figure 3, Item 6) from switch pod (Figure 3, Item 5).

Figure 3. Arctic Kit Heater Switch. END OF TASK

0290

0290-2

TM 5-2410-241-23-3

0290

ARCTIC KIT HEATER SWITCH HARNESS REMOVAL 1. Disconnect arctic kit heater switch harness from arctic kit heater switch, refer to this work package. 2. Remove grommet (Figure 4, Item 2) from upper right access panel (Figure 4, Item 3). 3. Remove arctic kit heater switch harness (Figure 4, Item 1) from grommet (Figure 4, Item 2).

000290

4. Disconnect arctic kit heater switch harness (Figure 4, Item 1) from arctic kit heater platform harness (Figure 4, Item 4). Remove arctic kit heater switch harness from machine.

Figure 4. Arctic Kit Heater Switch Harness. END OF TASK ENGINE COMPARTMENT ARCTIC KIT HEATER HARNESS REMOVAL 1. Disconnect engine compartment arctic kit heater harness connector (Figure 5, Item 4) from arctic kit heater (Figure 5, Item 3).

0290

000290

2. Disconnect engine compartment arctic kit heater harness connector (Figure 5, Item 2) from fuel metering valve (Figure 5, Item 1).

Figure 5. Engine Compartment Arctic Kit Heater Harness at Heater.

0290

0290-3

TM 5-2410-241-23-3

0290

ENGINE COMPARTMENT ARCTIC KIT HEATER HARNESS REMOVAL CONTINUED

NOTE
Note location and quantity of tiedown straps to aid installation. Note routing of engine compartment arctic kit heater harness to aid installation.

3. Remove tiedown straps (Figure 6, Item 1) from arctic kit heater bracket (Figure 6, Item 4) and ether bracket (Figure 6, Item 3). Discard tiedown straps. 4. Disconnect engine compartment arctic kit heater harness (Figure 6, Item 2) from arctic kit heater platform harness connector (Figure 6, Item 5) and remove engine compartment arctic kit heater harness from machine.

Figure 6. Engine Compartment Arctic Kit Heater Harness. END OF TASK

0290

0290-4

TM 5-2410-241-23-3

0290

PLATFORM ARCTIC KIT HEATER HARNESS REMOVAL 1. Remove front floor plate (WP 0230) and rear floor plate (WP 0231).

000290

2. Disconnect platform arctic kit heater harness from arctic kit heater switch harness, refer to this work package. 3. Disconnect platform arctic kit heater harness from engine compartment arctic kit heater harness, refer to this work package.

NOTE
Note location and quantity of tiedown straps to aid installation. Note routing of platform arctic kit heater harness to aid installation.

4. Remove tiedown straps (Figure 7, Item 2) and platform arctic kit heater harness (Figure 7, Item 1) from platform (Figure 7, Item 3). 5. Disconnect platform arctic kit heater harness (Figure 7, Item 1) connector from machine harness connector (Figure 7, Item 4) and remove platform arctic kit heater harness from machine.

Figure 7. Platform Arctic Kit Heater Harness. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Electrical General Maintenance Instructions (WP 0296). END OF TASK

0290

000290

0290-5

TM 5-2410-241-23-3

0290

PLATFORM ARCTIC KIT HEATER HARNESS INSTALLATION

000290

NOTE
Install tiedown straps as noted during removal. Position platform arctic kit heater harness as noted during removal.

1. Position platform arctic kit heater harness on machine. Connect platform arctic kit heater harness (Figure 8, Item 1) connector to machine harness connector (Figure 8, Item 4). 2. Install platform arctic kit heater harness (Figure 8, Item 1) and new tiedown straps (Figure 8, Item 2) on platform (Figure 8, Item 3). 3. Connect platform arctic kit heater harness to engine compartment arctic kit heater harness, refer to this work package. 4. Connect platform arctic kit heater harness to arctic kit heater switch harness, refer to this work package. 5. Install front floor plate (WP 0230) and rear floor plate (WP 0231).

Figure 8. Platform Arctic Kit Heater Harness. END OF TASK

0290

0290-6

TM 5-2410-241-23-3

0290

ENGINE COMPARTMENT ARCTIC KIT HEATER HARNESS INSTALLATION

000290

NOTE
Install tiedown straps as noted in removal. Install arctic kit heater harness as noted in removal.

1. Position engine compartment arctic kit heater harness on machine. Connect engine compartment arctic kit heater harness (Figure 9, Item 2) to arctic kit heater platform harness connector (Figure 9, Item 5). 2. Install arctic kit heater harness (Figure 9, Item 2) and new tiedown straps (Figure 9, Item 1) on heater bracket (Figure 9, Item 4) and ether bracket (Figure 9, Item 3).

Figure 9. Engine Compartment Arctic Kit Heater Harness.

0290

0290-7

TM 5-2410-241-23-3

0290

ENGINE COMPARTMENT ARCTIC KIT HEATER HARNESS INSTALLATION CONTINUED 3. Connect engine compartment arctic kit heater harness connector (Figure 10, Item 2) to fuel metering valve (Figure 10, Item 1). 4. Connect engine compartment arctic kit heater harness connector (Figure 10, Item 4) to arctic kit heater (Figure 10, Item 3).

Figure 10. Engine Compartment Arctic Kit Heater Harness at Heater. END OF TASK ARCTIC KIT HEATER SWITCH HARNESS INSTALLATION

0290

000290

1. Install arctic kit heater switch harness on machine. Connect arctic kit heater switch harness (Figure 11, Item 1) to arctic kit heater platform harness (Figure 11, Item 4). 2. Install grommet (Figure 11, Item 2) on arctic kit heater switch harness (Figure 11, Item 1). 3. Install grommet (Figure 11, Item 2) on upper right access panel (Figure 11, Item 3). 4. Connect arctic kit heater switch harness to arctic kit heater switch, refer to this work package.

Figure 11. Arctic Kit Heater Switch Harness. END OF TASK

0290

0290-8

TM 5-2410-241-23-3

0290

ARCTIC KIT HEATER SWITCH INSTALLATION 1. Invert switch pod (Figure 12, Item 5) to access wiring. 2. Install arctic kit heater switch (Figure 12, Item 3) and guard (Figure 12, Item 6) on switch pod (Figure 12, Item 5). 3. Connect arctic kit heater switch harness connector (Figure 12, Item 4) to arctic kit heater switch (Figure 12, Item 3).

000290

4. Install switch pod cover (Figure 12, Item 2) and four bolts (Figure 12, Item 1) on switch pod (Figure 12, Item 5).

Figure 12. Arctic Kit Heater Switch. 5. Position switch pod (Figure 13, Item 3) on upper right access panel (Figure 13, Item 1). 6. Install switch pod (Figure 13, Item 3), two washers (Figure 13, Item 5), and two bolts (Figure 13, Item 4) from under upper right access panel (Figure 13, Item 1). 7. Install bolt (Figure 13, Item 2) on upper right access panel (Figure 13, Item 1).

0290

Figure 13. Switch Pod.

0290

0290-9

TM 5-2410-241-23-3

0290

ARCTIC KIT HEATER SWITCH INSTALLATION CONTINUED

NOTE
Install washers as noted during removal. 8. Install upper right access panel (Figure 14, Item 1), 14 washers (Figure 14, Item 3), bolts (Figure 14, Item 2), and ladder clip (Figure 14, Item 4). 9. Install right arm rest (WP 0208).

Figure 14. Upper Right Access Panel. END OF TASK FOLLOW-ON TASKS Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0290

0290-10

10 TM 5-2410-241-23-3 0291

FIELD MAINTENANCE
0 2 9 1

ARCTIC KIT HEATER AND BRACKET 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) O-ring References WP 0295
0

Equipment Condition Machine parked (TM 5-2410-241-10) Cooling system drained (WP 0113) Ether bottle, valve, and bracket removed (WP 0060) Personnel Required Two Drawing Required TM 5-2410-241-24P, Figure 152 Estimated Time to Complete 4.5 Hr

REMOVAL 1. Turn fuel valve (Figure 1, Item 1) to OFF position.

000291

Figure 1. Arctic Kit Heater Fuel Shutoff.

0291

0291-1

TM 5-2410-241-23-3

0291

REMOVAL CONTINUED

NOTE
Tag and identify connectors to aid installation. 2. Disconnect harness connector (Figure 2, Item 8) from arctic kit heater (Figure 2, Item 3). 3. Disconnect connector (Figure 2, Item 2) from fuel metering pump (Figure 2, Item 1).

CAUTION
Cap and plug hoses to prevent contamination and leaks, or damage to equipment may occur.

NOTE
Tag and identify hoses to aid installation. 4. Remove fitting (Figure 2, Item 14) and fuel hose (Figure 2, Item 13) from fuel metering pump (Figure 2, Item 1). 5. Loosen clamp (Figure 2, Item 7) and remove fuel hose (Figure 2, Item 6) from arctic kit heater (Figure 2, Item 3). 6. Remove clamp (Figure 2, Item 7) from fuel hose (Figure 2, Item 6). 7. Loosen clamp (Figure 2, Item 4) and remove coolant hose (Figure 2, Item 5) from arctic kit heater (Figure 2, Item 3). 8. Remove clamp (Figure 2, Item 4) from coolant hose (Figure 2, Item 5). 9. Loosen clamp (Figure 2, Item 11) and remove coolant hose (Figure 2, Item 12) from arctic kit heater (Figure 2, Item 3). 10. Remove clamp (Figure 2, Item 11) from coolant hose (Figure 2, Item 12). 11. Loosen clamp (Figure 2, Item 9) and remove exhaust tube (Figure 2, Item 10) from arctic kit heater (Figure 2, Item 3). 12. Remove clamp (Figure 2, Item 9) from exhaust tube (Figure 2, Item 10).

Figure 2. Arctic Kit Heater.

0291

0291-2

TM 5-2410-241-23-3

0291

REMOVAL CONTINUED 13. With assistance, remove two bolts (Figure 3, Item 2), washers (Figure 3, Item 3), and arctic kit bracket (Figure 3, Item 4) with heater from air cleaner bracket (Figure 3, Item 1).

Figure 3. Arctic Bracket from Below.

0291

14. Remove two bolts (Figure 4, Item 1), four washers (Figure 4, Item 2), two clips (Figure 4, Item 3) and fuel hose (Figure 4, Item 4) from arctic kit bracket (Figure 4, Item 5).

NOTE
Note quantity and location of tiedown straps to aid installation. 15. Remove two bolts (Figure 4, Item 6), four washers (Figure 4, Item 7), two clips (Figure 4, Item 8) and arctic kit heater (Figure 4, Item 9) from arctic kit bracket (Figure 4, Item 5).

Figure 4. Arctic Bracket.

0291

0291-3

TM 5-2410-241-23-3

0291

REMOVAL CONTINUED 16. Loosen clamp (Figure 5, Item 4) and remove intake tube (Figure 5, Item 5) from arctic kit heater (Figure 5, Item 10). 17. Remove clamp (Figure 5, Item 4) from intake tube (Figure 5, Item 5) 18. Remove bolt (Figure 5, Item 1), washer (Figure 5, Item 2), clip (Figure 5, Item 3), and intake tube (Figure 5, Item 5) from arctic kit heater (Figure 5, Item 10). 19. Remove clip (Figure 5, Item 3) from intake tube (Figure 5, Item 5). 20. Disconnect connector (Figure 5, Item 6) from coolant pump (Figure 5, Item 7). 21. Loosen clamp (Figure 5, Item 8) and remove coolant pump (Figure 5, Item 7) from arctic kit heater (Figure 5, Item 10). Remove clamp from coolant pump. 22. Remove O-ring (Figure 5, Item 9) from coolant pump (Figure 5, Item 7). Discard O-ring.

Figure 5. Coolant Pump.

0291

0291-4

TM 5-2410-241-23-3

0291

REMOVAL CONTINUED 23. Loosen clamp (Figure 6, Item 4) and remove fuel hose (Figure 6, Item 3) from fuel metering pump (Figure 6, Item 5). 24. Remove clamp (Figure 6, Item 4) from fuel hose (Figure 6, Item 3). 25. Remove two clips (Figure 6, Item 2) from fuel hose (Figure 6, Item 3). 26. Remove bolt (Figure 6, Item 6) and fuel metering pump (Figure 6, Item 5) from clamp (Figure 6, Item 7). 27. Remove two bolts (Figure 6, Item 8), nuts (Figure 6, Item 10), washers (Figure 6, Item 9), and clamp (Figure 6, Item 7) from arctic kit bracket (Figure 6, Item 1). 28. Remove two bolts (Figure 6, Item 12), washers (Figure 6, Item 13), and bracket (Figure 6, Item 11) from arctic kit bracket (Figure 6, Item 1).

Figure 6. Fuel Metering Pump. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). END OF TASK

0291

000291

0291-5

TM 5-2410-241-23-3

0291

INSTALLATION 1. Install bracket (Figure 7, Item 11), two washers (Figure 7, Item 13), and bolts (Figure 7, Item 12) on arctic kit bracket (Figure 7, Item 1). 2. Install clamp (Figure 7, Item 7) and bolt (Figure 7, Item 6) on fuel metering pump (Figure 7, Item 5). 3. Install clamp (Figure 7, Item 7), two washers (Figure 7, Item 9), bolts (Figure 7, Item 8), and nuts (Figure 7, Item 10) on arctic kit bracket (Figure 7, Item 1). 4. Install two clips (Figure 7, Item 2) on fuel hose (Figure 7, Item 3). 5. Install clamp (Figure 7, Item 4) on fuel hose (Figure 7, Item 3). 6. Install fuel hose (Figure 7, Item 3) on fuel metering pump (Figure 7, Item 5) and tighten clamp (Figure 7, Item 4).

000291

Figure 7. Fuel Metering Pump.

0291

0291-6

TM 5-2410-241-23-3

0291

INSTALLATION CONTINUED 7. Install new O-ring (Figure 8, Item 9) on coolant pump (Figure 8, Item 7). 8. Install coolant pump (Figure 8, Item 7) and clamp (Figure 8, Item 8) on arctic kit heater (Figure 8, Item 10). 9. Connect connector (Figure 8, Item 6) to coolant pump (Figure 8, Item 7). 10. Install clip (Figure 8, Item 3) on intake tube (Figure 8, Item 5). 11. Install clip (Figure 8, Item 3), intake tube (Figure 8, Item 5), washer (Figure 8, Item 2), and bolt (Figure 8, Item 1) on arctic kit heater (Figure 8, Item 10). 12. Install clamp (Figure 8, Item 4) on intake tube (Figure 8, Item 5). 13. Install intake tube (Figure 8, Item 5) on arctic kit heater (Figure 8, Item 10) and tighten clamp (Figure 8, Item 4).

Figure 8. Coolant Pump.

0291

0291-7

TM 5-2410-241-23-3

0291

INSTALLATION CONTINUED

NOTE
Position harness and install tiedown straps as noted during removal. 14. Install arctic kit heater (Figure 9, Item 9), two clips (Figure 9, Item 8), four washers (Figure 9, Item 7), and two bolts (Figure 9, Item 6) on arctic kit bracket (Figure 9, Item 5). 15. Install two bolts (Figure 9, Item 1), four washers (Figure 9, Item 2), two clips (Figure 9, Item 3,) and fuel hose (Figure 9, Item 4) on arctic kit bracket (Figure 9, Item 5).

Figure 9. Arctic Bracket. 16. With assistance, install arctic kit bracket (Figure 10, Item 4) with heater, two washers (Figure 10, Item 3), and bolts (Figure 10, Item 2) on air cleaner bracket (Figure 10, Item 1).

0291

Figure 10. Arctic Bracket from Below.

0291

0291-8

TM 5-2410-241-23-3

0291

INSTALLATION CONTINUED

NOTE
Install hoses as noted during removal. 17. Install clamp (Figure 11, Item 9) on exhaust tube (Figure 11, Item 10). 18. Install exhaust tube (Figure 11, Item 10) on arctic kit heater (Figure 11, Item 3) and tighten clamp (Figure 11, Item 9). 19. Install clamp (Figure 11, Item 11) on coolant hose (Figure 11, Item 12). 20. Install coolant hose (Figure 11, Item 12) on arctic kit heater (Figure 11, Item 3) and tighten clamp (Figure 11, Item 11). 21. Install clamp (Figure 11, Item 4) on coolant hose (Figure 11, Item 5). 22. Install coolant hose (Figure 11, Item 5) on arctic kit heater (Figure 11, Item 3) and tighten clamp (Figure 11, Item 4). 23. Install clamp (Figure 11, Item 7) on fuel hose (Figure 11, Item 6). 24. Install fuel hose (Figure 11, Item 6) on arctic kit heater (Figure 11, Item 3) and tighten clamp (Figure 11, Item 7). 25. Install fitting (Figure 11, Item 14) and fuel hose (Figure 11, Item 13) on fuel metering pump (Figure 11, Item 1).

NOTE
Install connectors as noted during removal. 26. Connect connector (Figure 11, Item 2) to fuel metering pump (Figure 11, Item 1). 27. Connect harness connector (Figure 11, Item 8) to arctic kit heater (Figure 11, Item 3).

Figure 11. Arctic Kit Heater.

0291

0291-9

TM 5-2410-241-23-3

0291

INSTALLATION CONTINUED 28. Turn fuel valve (Figure 12, Item 1) to ON position.

Figure 12. Arctic Kit Heater Fuel Shutoff. END OF TASK FOLLOW-ON TASKS 1. Fill cooling system (WP 0113). 2. Install ether bottle valve and bracket (WP 0060). 3. Verify correct operation of machine (TM 5-2410-241-10). END OF TASK END OF WORK PACKAGE

0291

0291-10

10 TM 5-2410-241-23-3 0292

FIELD MAINTENANCE
0 2 9 2

ARCTIC KIT HEATER HOSES AND FITTINGS 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) References WP 0295
0

Equipment Condition

Machine parked (TM 5-2410-241-10) Cooling system drained (WP 0113) Engine enclosure right door guard removed (WP 0204) Drawing Required TM 5-2410-241-24P, Figure 49, 153

Estimated Time to Complete 1.0 Hr

0292-1

TM 5-2410-241-23-3

0292

REMOVAL

000292

CAUTION
Cap and plug hoses and fittings to prevent contamination and leaks or damage to equipment may occur. 1. Loosen clamp (Figure 1, Item 2) and remove lower hose (Figure 1, Item 1) from arctic kit heater (Figure 1, Item 3). 2. Remove clamp (Figure 1, Item 2) from lower hose (Figure 1, Item 1). 3. Remove bolt (Figure 1, Item 4), washer (Figure 1, Item 5), clip (Figure 1, Item 7), and lower hose (Figure 1, Item 1) from bracket (Figure 1, Item 6). 4. Remove clip (Figure 1, Item 7) from hose (Figure 1, Item 1). 5. Loosen clamp (Figure 1, Item 8) and remove lower hose (Figure 1, Item 1) from engine. 6. Remove clamp (Figure 1, Item 8) from lower hose (Figure 1, Item 1).

Figure 1. Arctic Kit Heater Lower Coolant Hose.

0292

0292-2

TM 5-2410-241-23-3

0292

REMOVAL CONTINUED 7. Loosen two clamps (Figure 2, Item 3) and remove hose (Figure 2, Item 4) from air cleaner housing (Figure 2, Item 1) and turbo (Figure 2, Item 2). 8. Remove two clamps (Figure 2, Item 3) from hose (Figure 2, Item 4).

Figure 2. Hose.

0292

0292-3

TM 5-2410-241-23-3

0292

REMOVAL CONTINUED 9. Loosen clamp (Figure 3, Item 2) and remove upper hose (Figure 3, Item 1) from arctic heater (Figure 3, Item 3). 10. Remove clamp (Figure 3, Item 2) from upper hose (Figure 3, Item 1). 11. Remove bolt (Figure 3, Item 5), washer (Figure 3, Item 6), clip (Figure 3, Item 4), upper hose (Figure 3, Item 1) and spacer (Figure 3, Item 7) from bracket (Figure 3, Item 8). 12. Remove clip (Figure 3, Item 4) from upper hose (Figure 3, Item 1).

NOTE
Note location and quantity of tiedown straps to aid installation. 13. Remove tiedown strap (Figure 3, Item 9) from upper hose (Figure 3, Item 1). Discard tiedown strap.

Figure 3. Arctic Kit Heater Upper Coolant Hose.

0292

0292-4

TM 5-2410-241-23-3

0292

REMOVAL CONTINUED 14. Remove two bolts (Figure 4, Item 1), washers (Figure 4, Item 2), two half clamps (Figure 4, Item 3), and grommet (Figure 4, Item 4) from hoses (Figure 4, Item 5). Position hoses aside.

Figure 4. Arctic Kit Heater Upper Coolant Routing.

0292

0292-5

TM 5-2410-241-23-3

0292

REMOVAL CONTINUED 15. Loosen clamp (Figure 5, Item 2) and remove upper hose (Figure 5, Item 1) from fitting (Figure 5, Item 3). 16. Remove clamp (Figure 5, Item 2) from upper hose (Figure 5, Item 1). 17. Remove fitting (Figure 5, Item 3) from elbow (Figure 5, Item 4). 18. Remove elbow (Figure 5, Item 4) from housing (Figure 5, Item 5).

Figure 5. Arctic Kit Heater Upper Coolant Fitting. END OF TASK CLEANING AND INSPECTION Clean and inspect all parts IAW Mechanical General Maintenance Instructions (WP 0295). INSTALLATION 1. Install elbow (Figure 5, Item 4) on housing (Figure 5, Item 5). 2. Install fitting (Figure 5, Item 3) on elbow (Figure 5, Item 4). 3. Install clamp (Figure 5, Item 2) on upper hose (Figure 5, Item 1). 4. Install upper hose (Figure 5, Item 1) on fitting (Figure 5, Item 3) and tighten clamp (Figure 5, Item 2).

0292

000292

000292

0292-6

TM 5-2410-241-23-3

0292

INSTALLATION CONTINUED 5. Position hoses (Figure 6, Item 5) and install grommet (Figure 6, Item 4), two half clamps (Figure 6, Item 3), two washers (Figure 6, Item 2), and bolts (Figure 6, Item 1) on hoses.

Figure 6. Arctic Kit Heater Upper Coolant Routing. 6. Install new tiedown strap (Figure 7, Item 9) on upper hose (Figure 7, Item 1.) 7. Install clip (Figure 7, Item 4) on upper hose (Figure 7, Item 1). 8. Install spacer (Figure 7, Item 7), clip (Figure 7, Item 4), upper hose (Figure 7, Item 1), washer (Figure 7, Item 6), and bolt (Figure 7, Item 5) on bracket (Figure 7, Item 8). 9. Install clamp (Figure 7, Item 2) on upper hose (Figure 7, Item 1). 10. Install upper hose (Figure 7, Item 1) on arctic heater (Figure 7, Item 3) and tighten clamp (Figure 7, Item 2).

0292

Figure 7. Arctic Heater Upper Coolant Hose.

0292

0292-7

TM 5-2410-241-23-3

0292

INSTALLATION CONTINUED 11. Install two clamps (Figure 8, Item 3) on hose (Figure 8, Item 4). 12. Install hose (Figure 8, Item 4) on air cleaner housing (Figure 8, Item 1) and turbo (Figure 8, Item 2). Tighten two clamps (Figure 8, Item 3).

Figure 8. Hose.

0292

0292-8

TM 5-2410-241-23-3

0292

INSTALLATION CONTINUED 13. Install clamp (Figure 9, Item 8) on lower hose (Figure 9, Item 1). 14. Install lower hose (Figure 9, Item 1) on engine and tighten clamp (Figure 9, Item 8). 15. Install clip (Figure 9, Item 7) on hose (Figure 9, Item 1). 16. Install clip (Figure 9, Item 7), lower hose (Figure 9, Item 1), washer (Figure 9, Item 5), and bolt (Figure 9, Item 4) on bracket (Figure 9, Item 6). 17. Install clamp (Figure 9, Item 2) on lower hose (Figure 9, Item 1). 18. Install lower hose (Figure 9, Item 1) on arctic heater (Figure 9, Item 3) and tighten clamp (Figure 9, Item 2).

Figure 9. Arctic Kit Heater Lower Coolant Hose. 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

0292

0292-9/(10 blank)

12 TM 5-2410-241-23-3 0293

FIELD MAINTENANCE
0 2 9 3

ARCTIC KIT FUEL METERING PUMP, HOSE, AND FITTING REPLACEMENT Removal, Cleaning and Inspection, Installation

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) Wrench, Combination, 1/8 (S0788) (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 (5)
0

References WP 0295

Equipment Condition
0

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


0

Drawing Required
0

TM 5-2410-241-24P, Figure 153 Estimated Time to Complete 1.0 Hr

0293-1

TM 5-2410-241-23-3

0293

REMOVAL

000293

WARNING

DO NOT perform fuel system checks, ins