TM 5-2420-224-34

TECHNICAL MANUAL
TABLE OF CONTENTS i
DIRECT AND GENERAL SUPPORT
MAINTENANCE MANUAL HOW TO USE THIS x
FOR MANUAL

TRACTOR, WHEELED, 4 X 4 DED 2-2

SMALL EMPLACEMENT EXCAVATOR (SEE)
(NSN 2420-01-160-2754) (EIC:EDL) 3-1

ELECTRICAL SYSTEM 4-1

MAINTENANCE

BRAKE AND STEERING

SYSTEMS MAINTENANCE 7-1

HYDRAULIC SYSTEM 11-1

MAINTENANCE

ENGINE, FUEL, AND

13-1
TRACTOR, WHEELED, 4 X 4 DED COOLING REPAIR
INSTRUCTIONS
HIGH MOBILITY MATERIAL HANDLER (HMMH)
(NSN 2420-01-205-8636) TRANSMISSION REPAIR 15-1
INSTRUCTIONS

HYDRAULIC SYSTEM
REPAIR INSTRUCTIONS 20-1

MACHINE TOOLS REPAIR 21-1

INSTRUCTIONS

INDEX Index-1

HEADQUARTERS, DEPARTMENT OF THE ARMY 28 JULY 1993

This manual along with TM5-2420-224-20-1 and TM5-2420-224-20-2 supersedes
TM5-2420-224-24 dated December 1989
Approved for public release; distribution unlimited.
TM 5-2420-224-34

WARNING

CARBON MONOXIDE POISONING CAN BE DEADLY

CARBON MONOXIDE IS A COLORLESS, ODORLESS, DEADLY POISONOUS

GAS, WHICH, WHEN BREATHED, DEPRIVES THE BODY OF OXYGEN AND
CAUSES SUFFOCATION. EXPOSURE TO AIR CONTAMINATED WITH CARBON
MONOXIDE PRODUCES SYMPTOMS OF HEADACHE, DIZZINESS, LOSS OF
MUSCULAR CONTROL, APPARENT DROWSINESS, OR COMA. PERMANENT
BRAIN DAMAGE OR DEATH CAN RESULT FROM SEVERE EXPOSURE.

CARBON MONOXIDE OCCURS IN THE EXHAUST FUMES OF FUEL-BURNING

HEATERS AND INTERNAL-COMBUSTION ENGINES AND BECOMES
DANGEROUSLY CONCENTRATED UNDER CONDITIONS OF INADEQUATE
VENTILATION. THE FOLLOWING PRECAUTIONS MUST BE OBSERVED TO
ENSURE THE SAFETY OF PERSONNEL WHENEVER THE PERSONNEL
HEATER, MAIN, OR AUXILIARY ENGINE OF ANY VEHICLE IS OPERATED FOR
MAINTENANCE PURPOSES OR TACTICAL USE:

1. DO NOT operate engine of vehicle in an enclosed area unless it is

ADEQUATELY VENTILATED.

2. DO NOT idle engine for long periods without maintaining ADEQUATE

VENTILATION in the personnel compartments.

3. DO NOT drive any vehicle with inspection plates, cover plates, or engine
compartment doors removed unless necessary for maintenance purposes.

4. BE ALERT at all times during vehicle operation for exhaust odors and
exposure symptoms, If either is present, IMMEDIATELY VENTILATE
personnel compartments. If symptoms persist, remove affected personnel
from vehicle and treat as follows: expose to fresh air; keep warm, DO
NOT PERMIT EXERCISE; if necessary, administer artificial respiration
(see FM 21-11).

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS

ADEQUATE VENTILATION.

a
 TM 5-2420-224-34

WARNING

COMPRESSED AIR

To prevent injury, compressed air used for cleaning and drying purposes will not
exceed 30 psi (207 kPa). Use only with effective chip guarding and personal
protective equipment (goggles/shield, gloves, etc.).

WARNING

Drycleaning solvent P-D-680 is toxic and flammable. Wear protective goggles and
gloves and use only in well-ventilated area. Avoid contact with skin, eyes, and
clothes and do not breathe vapors. Do not use near open flame or excessive
heat. Flash point is 100°-138° F (38°-50°C). If you become dizzy while using
drycleaning solvent, get fresh air immediately and get medical aid. If contact with
eyes is made, wash your eyes with water and get medical aid immediately.

WARNING

Remove rings, bracelets, wristwatches, and neck chains before working on

vehicle. Jewelry can catch on equipment and cause injury, or may short across
an electrical circuit and cause severe burns or electrical shock.

WARNING

Fuel and oil are slippery and can cause falls. To avoid injury, wipe up spilled fuel
or oil with rags.

WARNING

Gear will be hot enough to burn you on contact. Wear heat-resistant gloves when
handling hot gear.

WARNING

Allow engine to cool before performing maintenance on the muffler, exhaust pipe,
exhaust manifold, or turbocharger. If necessary, use insulated pads and gloves.

b
 TM 5-2420-224-34

WARNING

When testing fuel injector nozzles, wear safety goggles and keep hands and
fingers away from the spray of fluid being ejected. The spray is under extreme
pressure and could penetrate deeply into - the body tissues, causing injury and
illness.

WARNING

Remove or disconnect batteries and turn vehicle MASTER disconnect switch OFF
prior to performing maintenance in immediate battery area or working on
electrical system. Such disconnections prevent electrical shock to personnel or
equipment.

WARNING

Support weight of transmission before separating from engine. Failure to do so

could result in serious personal injury.

WARNING

Axle thrust tube weighs 55 pounds (25 kilograms). To avoid personal injury, use
a hoist or suitable lifting device when lifting axle thrust tube.

WARNING

Wheel assembly weighs 170 pounds (77 kilograms). To avoid personal injury, use
a hoist or suitable lifting device when lifting wheel assembly.

WARNING

Support drag link during disconnect of ball joint from pitman arm. Failure
so could result in injury to personnel.

WARNING

Control arm weighs more than 50 pounds (23 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting control arm.

c
 TM 5-2420-224-34

WARNING

Left platform weighs 150 pounds (68 kilograms). To avoid personal injury, use a
hoist or suitable lifting device when lifting left platform.

WARNING

Right platform weighs 136 pounds (62 kilograms). To avoid personal injury, use
a hoist or suitable lifting device when lifting right platform.

WARNING

High pressure hydraulics [oil under 2450 psi (16,893 kPa)] operate this
equipment. Never disconnect any hydraulic line or fitting without first dropping
pressure to zero. A high pressure oil stream can pierce body and cause severe
injury to personnel.

WARNING

Crane inner boom weighs 219 pounds (99 kilograms). To avoid personal injury,
use a hoist or suitable lifting device when lifting crane inner boom.

WARNING

Crane outer boom weighs 119 pounds (89 kilograms). To avoid personal injury,
use a hoist or suitable lifting device when lifting crane outer boom.

WARNING

Crane extension boom weighs 172 pounds (78 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting crane extension boom.

WARNING

Forklift mounting bracket weighs 199 pounds (90 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting forklift mounting bracket.

d
TM 5-2420-224-34

WARNING

Crane assembly weighs 1,625 pounds (738 kilograms). To avoid personal injury,
use a hoist or suitable lifting device when lifting crane assembly.

WARNING

Backhoe assembly without main frame weighs 1,767 pounds (803 kilograms). To
avoid personal injury, use a hoist or suitable lifting device when lifting backhoe
assembly without main frame.

WARNING

Backhoe frame section weighs 489 pounds (223 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting frame section.

WARNING

Do not disconnect any air system lines or fittings unless vehicle engine is shut
off and air system pressure is relieved. To do so could result in injury to
personnel.

WARNING

Engine assembly weighs 1,320 pounds (599 kilograms), To avoid personal injury,
use a hoist or suitable lifting device when lifting engine assembly.

WARNING

Diesel fuel is flammable. Do not perform this procedure near fire, flame, or
sparks. injury or death to personnel could result.

WARNING

Transmission assembly weighs 638 pounds (290 kilograms). To avoid personal

injury, use a hoist or suitable lifting device when lifting transmission assembly.

e
 TM 5-2420-224-34

WARNING

Rear frame section and subframe weigh 598 pounds (272 kilograms). To avoid
personal injury, use a hoist or suitable lifting device when lifting rear frame
section and subframe.

WARNING

Make sure both front or rear wheels are blocked front and rear to prevent roll off.
Failure to do so could result in serious personnel injury.

WARNING

Cab weighs 618 pounds (281 kilograms). To avoid personal injury, use a hoist or
suitable lifting device when lifting cab.

WARNING

Do not connect or disconnect any electrical connector unless vehicle MASTER

disconnect switch is OFF. To do so could result in injury to personnel.

WARNING

Forklift mast assembly weighs 587 pounds (267 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting forklift mast assembly.

WARNING

Forklift carriage assembly weighs 356 pounds (162 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting forklift carriage assembly.

WARNING

Forklift lift cylinder weighs 101 pounds (46 kilograms). To avoid personal injury,
use a hoist or suitable lifting device when lifting forklift lift cylinder.

f
TM 5-2420-224-34

WARNING

Do not work on forklift lift cylinder with load on forks or while anyone is near
forklift controls. To do so could result in injury to personnel.

WARNING

Forklift rail upright weighs 172 pounds (78 kilograms). To avoid personal injury,
use a hoist or suitable lifting device when lifting forklift rail upright.

WARNING

Forklift upright weighs 196 pounds (89 kilograms). To avoid personal injury, use
a hoist or suitable lifting device when lifting forklift upright.

WARNING

Forklift rotator assembly weighs 356 pounds (162 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting forklift rotator assembly.

WARNING

Crane mast weldment weighs 492 pounds (223 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting crane mast weldment.

WARNING

Crane base weldment weighs 205 pounds (93 kilograms). To avoid personal
injury, use a hoist or suitable lifting device when lifting crane base weldment.

WARNING

Fuel is very flammable and can explode easily. To avoid serious injury or death,
clean fuel tank to purge any flammable liquid or vapors before welding, grinding,
or using any heat producing device near the fuel tank.

g
 TM 5-2420-224-34

WARNING

Fuel vapors are toxic. Avoid prolonged exposure or breathing of fumes. Work in
well-ventilated area. Failure to do so could result in injury to personnel.

WARNING

Keep all personnel clear when using lifting device during removal and installation
of transmission assembly. Failure to do so could result in injury to personnel.

WARNING

Support rear axle during removal. Failure to do so could result in injury to

personnel.

WARNING

If NBC exposure is suspected, all air filter media should be handled by personnel
wearing protective equipment. Consult you unit NBC Officer or NBC NCO for
appropriate handling or “disposal instructions.

WARNING

SEE/HMMH should not be operated with front loader (SEE) or forklift (HMMH) or
backhoe (SEE) or crane (HMMH) removed, except in a maintenance facility.
When maintenance is required and front loader or forklift or backhoe or crane is
removed, never operate SEE/HMMH at speeds greater than 5 mph. Tractor
stability and handling characteristics are greatly affected with either front loader
or forklift or backhoe or crane removed. This could cause loss of control and
injury to personnel or damage to vehicle.

WARNING

Edges of glass may be sharp. To avoid personal injury, wear protective gloves
when handling glass.

h
 TM 5-2420-224-34

WARNING

Cascade box housing weighs 78 pounds (36 kilograms). To avoid personal injury,
use a hoist or suitable lifting device when lifting cascade box housing.

WARNING

Wear safety goggles when performing leakage tests on valves. Failure to do may
result in serious eye injury due to high pressure oil.

WARNING

Never use gasoline to clean parts. Gasoline is highly flammable. Serious personal
injury could result if fuel ignites during cleaning.

WARNING

Steam cleaning creates hazardous noise levels and severe burn potential. Eye,
skin, and ear protection are required.

WARNING

Drilling and grinding operations are hazardous to the eyes. Eye protection is
required.

WARNING

On direct contact, uncured silicone sealant irritates eyes. In case of contact, flush
eyes with water and seek medical attention. Avoid prolonged contact with skin.

WARNING

Solvents used with spray gun must be used in spray booth with filter. Face shield
must be used by personnel operating spray gun. Failure to do so could result in
serious injury to personnel.

i
 TM 5-2420-224-34

Technical Manual HEADQUARTERS

No. 5-2420-224-34 DEPARTMENT OF THE ARMY
Washington D. C., 28 July 1993

DIRECT AND GENERAL SUPPORT

MAINTENANCE MANUAL
FOR
TRACTOR, WHEELED, 4 X 4 DED
SMALL EMPLACEMENT EXCAVATOR (SEE)
(NSN 2420-01-160-2754) (EIC:EDL)

AND

TRACTOR, WHEELED, 4 X 4 DED

HIGH MOBILITY MATERIAL HANDLER (HMMH)
(NSN 2420-01-205-8636)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve the manual. If you find any mistakes or if you know
of a way to improve the procedures, please let us know. Mail your letter,
DA Form 2028 (Recommended Changes to Publications and Blank Forms)
or DA Form 2028-2 located in the back of this manual, direct to: Commander,
U.S. Army Tank Automotive Command, Attn: AMSTA-MB, Warren, Ml
48397-5000. A reply will be furnished to you.

TABLE OF CONTENTS

Page

LIST OF TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
I HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . x
CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section I General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section II Equipment Description and Data.. . . . . . . . . . . . . . . . . . . . . . 1-2
Section Ill Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CHAPTER 2 DIRECT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS . . 2-1
Section I Repair Parts, Special Tools; Test, Measurement, and
Diagnostic Equipment (TMDE); and Support Equipment . . . . . . . . . . 2-1
Section II Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Section Ill General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . 2-32
Section IV General Hydraulic System Repair Methods . . . . . . . . . . . . . . . . . 2-39

This manual along with TM5-2420-224-20-1 and TM5-2420-224-20-2 supersedes

TM5-2420-224-24 dated December 1989
Approved for public release; distribution unlimited
i
 TM 5-2420-224-34

TABLE OF CONTENTS (CONT)

Page

CHAPTER 3 POWER PACKAGE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 3-1

Section I Engine Assembly and Related Parts . . . . . . . . . . . . . . . . . . . . . 3-1
Section II Clutch and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Section Ill Transmission and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Section IV Propeller Shafts and Related Parts . . . . . . . . . . . . . . . . . . . . . . 3-102
CHAPTER 4 ELECTRICAL SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . 4-1
CHAPTER 5 FRONT AXLE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . 5-1
CHAPTER 6 REAR AXLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHAPTER 7 BRAKE AND STEERING SYSTEMS MAINTENANCE . . . . . . . . . . . . 7-1
CHAPTER 8 FRAME AND TOWING ATTACHMENTS MAINTENANCE . . . . . . . . . 8-1
CHAPTER 9 SPRINGS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CHAPTER 10 BODY AND CAB MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 10-1
CHAPTER 11 HYDRAULIC SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . . 11-1
CHAPTER 12 CRANES, SHOVELS, AND EARTHMOVING EQUIPMENT
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
CHAPTER 13 ENGINE, FUEL, AND COOLING REPAIR INSTRUCTIONS . . . . . . 13-1
Section I Engine Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Section II Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65
Section Ill Cooling System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71
CHAPTER 14 ELECTRICAL SYSTEM REPAIR INSTRUCTIONS . . . . . . . . . . . . . . 14-1
Section I Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Section II Starter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
Section Ill Battery Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
CHAPTER 15 TRANSMISSION REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . 15-1
Section I Transmission Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Section II Transmission Top Cover Repair. . . . . . . . . . . . . . . . . . . . . . . . 15-54
Section III Transmission Access Cover Repair . . . . . . . . . . . . . . . . . . . . . . 15-65
Section IV Power Take-Off (PTO) Repair... . . . . . . . . . . . . . . . . . . . . . . 15-70
CHAPTER 16 FRONT AND REAR AXLES REPAIR INSTRUCTIONS . . . . . . . . . . . 16-1
Section I Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Section II Steering Knuckle and Front Axle Final Drive Repair . . . . . . . . . . . . 16-25
CHAPTER 17 BRAKE SYSTEM AND TIRES REPAIR INSTRUCTIONS . . . . . . . . . . 17-1
Section I Brake Disc Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Section II Front and Rear Brake Calipers Repair . . . . . . . . . . . . . . . . . . . . 17-3
Section Ill Brake Master Cylinder Repair... . . . . . . . . . . . . . . . . . . . . . . 17-17
Section IV Brake Pressure Regulator (ALB Valve) Repair . . . . . . . . . . . . . . . 17-22
Section V Air Brake Booster Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-24

i i
 TM 5-2420-224-34

TABLE OF CONTENTS (CONT)

Page

Section VI Fluid Regulating Valve Repair.. . . . . . . . . . . . . . . . . . . . . . . 17-28

Section Vll Antifreeze Device Repair . . . . . . . . . . . . . . . . . . . . . . . . . ...17-39
Section Vlll Tandem Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44
Section IX Tire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-48
CHAPTER 18 CAB REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
CHAPTER 19 ACCESSORY ITEMS REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . 19-1
CHAPTER 20 HYDRAULIC SYSTEM REPAIR INSTRUCTIONS . . . . . . . . . . . . . . 20-1
Section I Front Hydraulic Pump Repair.. . . . . . . . . . . . . . . . . . . . . . . . 20-3
Section II Rear Hydraulic Pump Repair... . . . . . . . . . . . . . . . . . . . . . . . 20-6
Section Ill Hydraulic Suspension Lockout Motor and Pump Repair . . . . . . . . . 20-9
Section IV Front Loader/Forklift Control Valve Repair . . . . . . . . . . . . . . . . . 20-14
Section V Tilt and Latch Control Valve Repair . . . . . . . . . . . . . . . . . . . . . 20-33
Section VI Backhoe Control Valve Repair.. . . . . . . . . . . . . . . . . . . . . . . . 20-41
Section Vll Backhoe Swing Cylinder Relief Valve Repair . . . . . . . . . . . . . . . 20-80
Section Vlll Backhoe Stabilizer Control Valve Repair . . . . . . . . . . . . . . 20-82
Section IX Loader Boom Cylinder Repair.. . . . . . . . . . . . . . . . . . . . . . . . 20-88
Section X Loader Bucket Rollback Cylinder Repair . . . . . . . . . . . . . . . . 20-94
Section Xl Backhoe Boom Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . 20-100
Section XII Backhoe Swing Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . 20-105
Section XIII Backhoe Bucket Cylinder Repair . . . . . . . . . . . . . . . . . . . 20-112
Section XIV Backhoe Dipper Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Section XV Backhoe Stabilizer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . 20-125
Section XVI Backhoe/Crane Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . 20-131
Section XVII Backhoe/Crane Latch Cylinder Repair. . . . . . . . . . . . . . . . . . . . . 20-142
Section XVIII Hydraulic Oil Cooler Repair... . . . . . . . . . . . . . . . . . . . . . . . 20-148
Section XIX Crane Valve Bank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
Section XX Forklift Mast Assembly Repair.. . . . . . . . . . . . . . . . . . . . . . . . 20-155
Section XXI Forklift Carriage Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . 20-171
Section XXII Forklift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
Section XXIII Forklift Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180
Section XXIV Forklift Rotator Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . 20-187
Section XXV Forklift Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-192
Section XXVI Crane External End Extension Cylinder Repair . . . . . . . . . . . . . . . 20-206
Section XXVII Crane Inner Boom Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . 20-212
Section XXVIII Crane Mast Locking Cylinder Repair . . . . . . . . . . . . . . . . . . . . 20-219
Section XXIX Crane Outer Boom Cylinder Repair . . . . . . . . . . . . . . . . . . . . . 20-225
Section XXX Crane Horizontal Outrigger Cylinder Repair . . . . . . . . . . . . . . . . 20-232

iii
TM 5-2420-224-34

TABLE OF CONTENTS (CONT)

Page

Section XXXI Crane Vertical Outrigger Cylinder Repair . . . . . . . . . . . . . . . . . . . 20-237

Section XXXII Crane Hydraulic Motor Repair... . . . . . . . . . . . . . . . . . . . . . . 20-243
CHAPTER 21 MACHINE TOOLS REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . 21-1
Section I Hammer Drill Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
Section II Impact Wrench Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-15
Section Ill Pavement Breaker Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
Section IV Chain Saw Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B EXPENDABLE SUPPLIES AND MATERIALS LIST . . . . . . . . . . . . . B-1
APPENDIX C ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . C-1
APPENDIX D TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . Index-1

iv
 TM 5-2420-224-34

LIST OF TASKS

A list of the maintenance procedures included in this manual is shown below, and on the
following pages. If more information is needed, refer to the Table of Contents or the Alphabetical
Index.

POWER PACKAGE MAINTENANCE (Chapter 3)

Page

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Engine Oil Filter Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Push Rod Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Oil Cooler and Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Air Compressor Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Fuel injector Nozzle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Fuel Injection Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Fuel injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Timing Gear Cover, Gears, and Case Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Clutch Release Lever and Shaft Replacement and Adjustment . . . . . . . . . . . . . . . 3-66
Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Power Take-Off (PTO) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Power Take-Off (PTO) Control Linkage Replacement and Adjustment . . . . . . . . . 3-81
Transmission Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Transmission Top Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Air Shift Solenoid Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Air Shift Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Transmission Shift Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Transmission Shift Controls Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Transmission Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Propeller Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
U-Joint Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
Axle Thrust Tube Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

ELECTRICAL SYSTEM MAINTENANCE (Chapter 4)

Alternator Bearings Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starter Brushes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Main Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Alternator Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Crane Mast Floodlight Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-30
Trailer Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Dome Light Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Hazard Warning Light Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Auxiliary Headlight, Front Composite Light, and Blackout Driving Light Wiring
Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
STE/lCE-R Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Forklift Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Forklift Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Forklift Power Cable Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Forklift Connector to Fuse Holder Wiring Harness Replacement . . . . . . . . . . . . . . . 4-48
Cab Floor Separation Point to Hydraulic Suspension Lockout Wiring Harness
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

v
TM 5-2420-224-34

LIST OF TASKS (CONT)

ELECTRICAL SYSTEM MAINTENANCE (Chapter 4) - (CONT)

Page

Cab Floor Separation Point to Rear Wall Wiring Harness Replacement . . . . . . . . . . . 4-52
Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring Harness
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring Harness
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Frame Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Suppressor Filter Electrical Lead Replacement , . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Cap Plug Connector to Heater Panel Switch and Master Light Switch Wiring
Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Throttle Solenoid Electrical Leads Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-74

FRONT AXLE MAINTENANCE (Chapter 5)

Front Axle Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Front AxIe Thrust Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Steering Knuckle and Front Axle Final Drive Replacement . . . . . . . . . . . . . . . . 5-16

REAR AXLE MAINTENANCE (Chapter 6)

Rear Axle Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Rear Axle Thrust Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Rear Axle Final Drive Hub Gears and Axle Shaft Replacement. . . . . . . . . . . . . . . . . . . . 6-15

BRAKE AND STEERING SYSTEMS MAINTENACE (Chapter 7)

Brake Pressure Regulator (ALB Valve) Replacement. . . . . . . . . . . . . . . . . . . 7-1

Brake PressureRegulator (ALB Valve) Adjustment. . . . . . . . . . . . . . . . . . . 7-5
Power Steering Gear Replacement . . . . . . . . . . . . . . . . 7-11
Power Steering Pump and Bracket Replacement . . . . . . . . . . . . 7-14
Pitman Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

FRAME AND TOWING ATTACHMENTS MAINTENANCE

Rear Frame Section and Subframe Replacement . .

. . . . . . . . . . . . 8-1
Forklift Mounting Bracket Replacement . . . . . .. . . . . . . . . . . . 8-7
Left Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Right Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

SPRINGS MAINTENANCE (Chapter 9)

Front Spring Replacement . . . . . . . . . . . . . . . . . . . . 9-1

Rear Spring Replacement . . . . . . . . . . . . . . . . . . . . . 9-4

BODY AND CAB MAINTENANCE (Chapter 10)

Roll-Over Protection (ROPS) Replacement . . . . . . . . . . . 10-1

Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . 10-18
Rear Windows Replacement . . . . . . . . . . . . . . . . . . . 10-20

vi
 TM 5-2420-224-34

LIST OF TASKS (CONT)

HYDRAULIC SYSTEM MAINTENANCE (Chapter 11)

Page

Hydraulic Oil Cooler Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Tilt and Latch Control Valve Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . 11-5
Backhoe Swing Cylinder Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . 11-10
Backhoe Stabilizer Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Backhoe Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Crane Flow Regulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
Crane Valve Bank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
Crane Valve Bank Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
Front Loader/Forklift Control Valve and Bracket Replacement and Adjustment . . . . . . . . 11-28
Forklift Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37
Forklift Mast Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Forklift Carriage Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
Forklift Lift Cylinder Replacement, Bleeding, and Sequencing . . . . . . . . . . . . . . . . . . 11-51
Forklift Bootstrap Chain Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 11-57
Forklift Carriage Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 11-67

CRANES, SHOVELS, AND EARTHMOVING EQUIPMENT MAINTENANCE (Chapter 12)

Backhoe Main Frame Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Crane Mast Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Crane inner Boom Replacement.. . . . . . . . . . . . . . . . . . . . . 12-13
CraneOuterBoomReplacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Crane Extension Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Crane Gear Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Crane intermediate Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25
Crane Drive Gear and Bushings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
Crane Pinion Gear Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . 12-31
Crane Pinion Gear Bushings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

ENGINE, FUEL, AND COOLING REPAIR INSTRUCTIONS (Chapter 13)

Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Crankshaft, Main Bearings, and Rear Seals Replacement . . . . . . . . . . . . . . . . . . . . . 13-15
Crankshaft Pulley Replacement.. . . . . . . . . . . . . . . . . . . . . . . . 13-24
Flywheel Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
Flywheel End Bell Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
Flywheel Ring Gear Replacement. . . . . . . . . . . . . . . . . . . . . . . . 13-29
Pistons, Rings, Connecting Rods, and Bearings Replacement . . . . . . . . . . . . . . . . . . 13-31
Rocker Arms, Push Rods, and Tappets Replacement . . . . . . . . . . . . . . . . . . . . . . . 13-37
Camshaft and Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-43
Cylinder Block Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-48
Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
Oil Pump Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60
Fuel injector Nozzle Test and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65
Fuel Tank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
Radiator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73

vii
TM 5-2420-224-34

LIST OF TASKS (CONT)

ELECTRICAL SYSTEM REPAIR INSTRUCTIONS (Chapter 14)

Page

Alternator Repair. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Starter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 14-8
Battery Repair . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. 14-17

TRANSMISSION REPAIR INSTRUCTIONS (Chapter 15)

Transmission Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Transmission Top Cover Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-54
Transmission Access Cover Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-65
Power Take-Off (PTO) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-70

FRONT AND REAR AXLES REPAIR INSTRUCTIONS (Chapter 16)

Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Steering Knuckle and Front Axle Final Drive Repair . . . . . . . . . . . . . . . . . . . . . . . . 16-25

BRAKE SYSTEM AND TIRES REPAIR INSTRUCTIONS (Chapter 17)

Brake Disc Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Front Brake Caliper Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Rear Brake Caliper Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7
Brake Master Cylinder Repair... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-17
Brake Pressure Regulator (ALB Valve) Repair . . . . . . . . . . . . . . . . . . . . . . . . . 17-22
Air Brake Booster Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-24
Fluid Regulating Valve (P/N 0 481 039 202) Repair. . . . . . . . . . . . . . . . . . . . . . . . 17-28
Fluid Regulating Valve (P/N 975 303 447 0) Repair. . . . . . . . . . . . . . . . . . . . . . . . 17-35
Antifreeze Device (P/N 000 431 57 15 BI.1) Repair . . . . . . . . . . . . . . . . . . . . . . . . 17-39
Antifreeze Device (P/N 932 002 000 0) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-42
Tandem Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44
Tire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17-48

CAB REPAIR INSTRUCTIONS (Chapter 18)

Cab Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

ACCESSORY ITEMS REPAIR INSTRUCTIONS (Chapter 19)

Cab Heater Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1

HYDRAULIC SYSTEM REPAIR INSTRUCTIONS (Chapter 20)

Front Hydraulic Pump Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

Rear Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Hydraulic Suspension Lockout Motor and Pump Repair . . . . . . . . . . . . . . . . . . . . . . 20-9
Front Loader/Forklift Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
Tilt and Latch Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Backhoe Control Valve Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
Backhoe Control Valve, Intake Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
Backhoe Control Valve, Outlet Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
Backhoe Control Valve, Swing Section Valve Repair . . . . . . . . . . . . . . . . . . . . . . . 20-51
Backhoe Control Valve, Boom Section Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . 20-59
Backhoe Control Valve, Dipper and Bucket Section Valves Repair . . . . . . . . . . . . . . . 20-69

viii
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LIST OF TASKS (CONT)

HYDRAULIC SYSTEM REPAIR INSTRUCTIONS (Chapter 20)-(CONT)

Page

Backhoe Swing Cylinder Relief Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80

Backhoe Stabilizer Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
Loader Boom Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-88
Loader Bucket Rollback Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-94
Backhoe Boom Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100
Backhoe Swing Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Backhoe Bucket Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Backhoe Dipper Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Backhoe Stabilizer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
Backhoe/Crane Tilt Cylinder (J.I. Case) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
Backhoe/Crane Tilt Cylinder (Aeroquip) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
Backhoe/Crane Latch Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-142
Hydraulic Oil Cooler Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-148
Crane Valve Bank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
Forklift Mast Assembly Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-155
Forklift Carriage Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171
Forklift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
Forklift Tilt Cylinder Repair... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180
Forklift Rotator Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-187
Forklift Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-192
Crane External End Extension Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
Crane Inner Boom Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Crane Mast Locking Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
Crane Outer Boom Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-225
Crane Horizontal Outrigger Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
Crane Vertical Outrigger Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-237
Crane Hydraulic Motor Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-243

MACHINE TOOLS REPAIR INSTRUCTIONS (Chapter 21)

Hammer Drill Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1

Impact Wrench Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-15
Pavement Breaker Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
Chain Saw Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37

ix
 TM 5-2420-224-34

HOW TO USE THIS MANUAL

This manual has an edge index that will help you find specific information in a hurry. Simply
spread the pages in the right edge of the manual until the printed blocks can be seen. Open the
manual where the block on the edge of the page lines up with your selected topic printed in the
front cover block.

This manual is organized by chapters, sectoins, and appendices. A summary of the organization
of this manual, by major divisions, follows:

Front cover index gives you a quick reference to chapters, sections, and appendices that you
will use often.

WARNINGS—AII warnings you should observe while working on or around the SEE/HMMH are
shown in this part of the manual. These are repeated in the parts of hte manual where they apply.

Table of Contents—The contents of the chapters and appendices are listed here.

Chapter 1—This chapter contains general information about the SEE/HMMH.

Chapter 2—This chapter outlines troubleshooting of the SEE/HMMH and their systems. It
includes a troubleshooting index, by symptom and system, for troubleshooting. Other sections
include information on tools, repair parts, general maintenance instructions, and general hydraulic
system repair methods.

Chapters 3 thru 21—These chapters contain step-by-step instructions for doing the maintenance
tasks. Each system of the SEE/HMMH has its own chapter, and any special tools, equipment, or
supplies you may need for a task are listed,

Appendix A—This appendix lists the technical manuals and other publications you may have to
refer to while working on the SEE/HMMH.

Appendix B—This appendix lists the expendable supplies and materials you will need while
performing maintenance on the SEE/HMMH.

Appendix C—This appendix describes any manufactured items you will need for performing
maintenance on the SEE/HMMH.

Appendix D—This appendix describes the proper method of tightening fasteners.

Index—The index is an alphabetical listing of the contents of this manual.

Back Cover—The inside back cover contains a metric conversion table.

USING THE MANUAL ON THE JOB

Find the task or component that needs repair by using the Index (page Index-1), then turn to
the page listed for that task or component.

Read the INITIAL SETUP procedures, and gather the necessary items and personnel. Pay
attention to the warnings. The INITIAL SETUP sheet is described on page xi.

x
 TM 5-2420-224-34

page 11-51

Appendix B

Appendix B

Appendix B

1. TITLE—This is the name of the task.

2. TASK COVERS—This lists all the tasks included in the module.

3. APPLICABLE CONFIGURATION—lf the task is applicable to only one of the vehicles, SEE or
HMMH (as appropriate) will be listed here.

4. TOOLS AND SPECIAL EQUIPMENT—These are the tools and equipment you will need to do
the task.

5. MATERIALS/PARTS—These are the supplies you will need to do the task. If parts or materials
are required, they are listed here or referenced to Appendix B.

6. PERSONNEL REQUIRED—PersonneI required to perform a task will be identified if the task

requires more than one.

7. REFERENCES—These are the other technical publications you will need to do the task.

8. EQUIPMENT CONDITION—This is the condition(s) the vehicle must be in before you start the
task. Other tasks that must be done first are listed by page number or by technical manual
number if another manual is required.

9. GENERAL SAFETY lNSTRUCTIONS—These are the safety precautions that must be observed
while you are doing the task.

10. FOLLOW-ON MAINTENANCE—These are the tasks listed at the end of the procedure that
must be completed to return the vehicle to an operational condition.

xi
 TM 5-2420-224-34

Small Emplacement Excavator (SEE)

xii
 TM 5-2420-224-34

High Mobility Material Handler (HMMH)

xiii/(xiv Blank)
 TM 5-2420-224-34

CHAPTER 1
INTRODUCTION

SCOPE
A list of sections contained in this chapter is shown below,

Page

Section I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section Il. Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section ill. Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section I. GENERAL INFORMATION

OVERVIEW
Type of Manual: Direct and General Support Maintenance.

Model Number and Equipment Name:

Model No. FLU101 44 Tractor, Wheeled, 4X4 DED Small Emplacement Excavator (SEE)
with Attachments, NSN 2420-01-160-2754 (EIC:EDL).

Model No. FLU10344 Tractor, Wheeled, 4X4 DED High Mobility Material Handler (HMMH)
with Attachments, NSN 2420-01-205-8636.

Purpose of Equipment:

The SEE is used for excavation, loading, lifting, and grading on various types of terrain.
The vehicle is equipped with a front loader, backhoe, chain saw, pavement breaker, and
hammer drill and is capable of rapid deployment for constructing protective positions.

The HMMH is used for material handling with forklift and crane attachments. The vehicle
is equipped with an impact wrench to assist in maintenance of other equipment and is
capable of rapid deployment.

MAINTENANCE FORMS. RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those
prescribed by DA Pam 738-750, The Army Maintenance Management System (TAMMS).

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

When the tactical situation requires that Army materiel be abandoned, refer to TM 750-244-6,
Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use, for procedures
on destruction of the vehicle(s).

PREPARATION FOR STORAGE OR SHIPMENT

Instructions for storage and shipment, including administrative storage, are found in
TM 740-90-1, MIL-V-62038D, and TM 5-2420-224-20.

1-1
TM 5-2420-224-34

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRs)

If your vehicle needs improvement, let us know. Send us a Quality Deficiency Report. You, the
user, are the only one who can tell us what you don’t like about your equipment. Let us know
why you don’t like the design or performance. Put it on an SF Form 368 (QDR) and mail it to:

Commander
U.S. Army Tank-Automotive Command
Attn: AMSTA-QRT
Warren, Ml 48397-5000

WARRANTY INFORMATION

The vehicles are warranted by Freightliner Corporation in accordance with TB 5-2420-224-15.

Warranty starts on the date found in block 23, DA Form 2408-9 in the logbook. Report all defects
in material or workmanship to your supervisor, who will take appropriate action through your direct
and general support maintenance shop.

METRIC SYSTEM

The equipment described herein contains metric components and requires metric common and
special tools; therefore, metric units in addition to English units will be used throughout the manual. An
English-to-metric conversion table is included as the last page of this manual inside the back cover.

Section II. EQUIPMENT DESCRIPTION AND DATA

OVERVIEW
This section contains information that can be useful when perfoming direct and general support
maintenance tasks on the SEE/HMMH. For equipment operating data, refer to TM 5-2420-224-10.

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

Refer to TM 5-2420-224-10 and TM 5-2420-224-20 for equipment characteristics, capabilities,

and features.

LOCATION AND DESCRIPTION OF COMPONENTS

Refer to TM 5-2420-224-10 and TM 5-2420-224-20 for location and description of components.

EQUIPMENT DIFFERENCES

Refer to TM 5-2420-224-10 and TM 5-2420-224-20 for equipment differences.

Section Ill. PRINCIPLES OF OPERATION

PRINCIPLES OF OPERATION

Refer to TM 5-2420-224-10 and TM 5-2420-224-20 for principles of operation.

1-2
 TM 5-2420-224-34

CHAPTER 2
DIRECT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS

SCOPE
This chapter contains information for troubleshooting the SEE/HMMH, as well as general
maintenance instructions. The following sections are included in this chapter:

Page

Section I. Repair Parts, Special Tools; Test, Measurement, and . . . . . . . . . . 2-1

Diagnostic Equipment (TMDE); and Support Equipment

Section Il. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Section Ill. General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . 2-32

Section IV. General Hydraulic System Repair Methods . . . . . . . . . . . . . . . . 2-39

Section I. REPAIR PARTS, SPECIAL TOOLS;

TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);
AND SUPPORT EQUIPMENT

OVERVIEW

This section includes information on tools and equipment you need to support the SEE and
HMMH tractors.

COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment, refer to the Modified Table of Organization and
Equipment (MTOE) applicable to your unit. Tool kits required for each task in this manual are
listed on the INITIAL SETUP page of each task.

SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

Special tools required to maintain the SEE/HMMH are listed in the Maintenance Allocation Chart
(TM 5-2420-224-20) and on the INITIAL SETUP page of each task. Special tools are also listed in
the Repair Parts and Special Tools List (TM5-2420-224-24P). Tools that are to be fabricated are
described and listed in Appendix C of this manual.

REPAIR PARTS

Repair parts are listed and illustrated in the Repair Parts and Special Tools List (TM5-2420-224-24P).

2-1
TM 5-2420-224-34

Section Il. TROUBLESHOOTING

OVERVIEW

This section contains troubleshooting, testing, and repair information for the SEE/HMMH. Make
sure the problem is real. Be sure the electrical or hydraulic power is on when needed. Refer to
the preliminary troubleshooting procedures before you start troubleshooting, and during
troubleshooting when referenced.

Page

Preliminary Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Troubleshooting Symptom Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

PRELIMINARY TROULESHOOTING PROCEDURES

NOTE
Fluid leaks are classified as Class I Class II, or Class Ill:

Class I: Seepage of fluid (as indicated by wetness or discoloration) not great enough to
form drops.

Class II: Leakage of fluid great enough to form drops, but not enough to cause drops to
drip from the item being checked or observed.

Class Ill: Leakage of fluid great enough to form drops that fall from the item being
checked or observed.

Before starting any specific troubleshooting procedures, perform the following:

1. Visually check for ruptured oil hoses or tubes, and for Class II or Class Ill leaks.

2. Check for mechanical jamming or binding caused by rocks or other foreign matter,

3. Check fluid levels in subject area and service as required (LO 5-2420-224-12).

4. Relieve hydraulic pressure (TM 5-2420-224-20) and air pressure (TM 5-2420-224-20) before
opening any hydraulic or air lines.

2-2
 TM 5-2420-224-34

Troubleshooting Symptom Index

Troubleshooting
Malfunction Procedure
Number Malfunction Page

ENGINE

1. ENGINE CRANKS BUT WILL NOT START OR HARD TO START 2-5

2. ENGINE RUNS ROUGH OR LACKS POWER... . . . . . . . . . . . . . 2-6
3. FUEL CONSUMPTION EXCESSIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
4. ENGINE OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . 2-6
5. ENGINE OIL CONSUMPTION Excessive. . . . . . . . . . . . . . . . . 2-7
6. ENGINE OIL DILUTED WITH FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
7. ENGINE OIL DILUTED WITH ENGINE COOLANT . . . . . . . . . . . . . . . . . 2-7
8. ENGINE VIBRATES EXCESSIVELY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

TRANSMISSION

9. TRANSMISSION WILL NOT OPERATE IN ANY FORWARD OR REVERSE

GEAR . . . . . . . 2-8
10. TRANSMISSION -
LOCKS UP IN GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
11. TRANSMISSION SLIPS IN ALL RANGES . . . . . . . . . . . . . . . . . . . . . . . 2-9
12. CLUTCH SLIPS OR DRAGS 2-9
13. PTO WILL NOT ENGAGE OR EXCESSIVELY NOISY. . . . . . . . . . . . . . . . . . . . . . . . 2-10
14. FRONT AXLE PROPELLER SHAFT WILL NOT TURN . . . . . . . . . . . . . . . . . 2-10
15. TRANSMISSION GEARS NOISY DURING SHIFTING . . . . . . . . . . . . . . . . . 2-10

BRAKES AND AIR SYSTEM

16. DUAL BRAKE GAGE IN CAB WILL NOT INDICATE CORRECT PRESSURE . . . 2-10
17. INTERMEDIATE SPEED SHIFT VALVE WILL NOT OPERATE . . . . . . . . . . . . 2-13
18. TRAILER BRAKES WILL NOT DISENGAGE . . . . . . . . . . . . . . . . . . . . . . . 2-13

STEERING SYSTEM

19. STEERING HARD TO MOVE FULL RIGHT AND LEFT . . . . . . . . . . . . . . . . 2-14

HYDRAULIC SYSTEM

20. FRONT OR REAR HYDRAULIC PUMP NOISY . . . . . . . . . . . . . . . . . . . . . 2-15

21. HYDRAULIC SYSTEM OIL OVERHEATS . . . . . . . . . . . . . . . . . . . . . . . 2-22
22. BACKHOE/CRANE WILL NOT TILT INTO OR OUT OF TRANSPORT
POSITION . . . 2-22
23. HYDRAULIC FUNCTION SLUGGISH. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

FORKLIFT

24. ERRATIC UP AND DOWN MOVEMENT OF FORKLIFT . . . . . . . . . . . . . . . . 2-23

HD45 HAMMER DRILL

25. HAMMER DRILL WILL NOT OPERATE OR OPERATES SLOWLY . . . . . . . . . 2-23

2-3
TM 5-2420-224-34

Troubleshooting Symptom Index (Cont)

Troubleshooting
Malfunction Procedure
Number Malfunction Page

IMPACT WRENCH

26. IMPACT WRENCH PERFORMS POORLY OR HAS LOW IMPACT . . . . . . . . . 2-23

27. IMPACT WRENCH OPERATES TOO FAST. . . . . . . . . . . . . . . . . . . . . . 2-23
28. IMPACT WRENCH WILL NOT OPERATE . . . . . . . . . . . . . . . . . . 2-24

BR67 PAVEMENT BREAKER

29. PAVEMENT BREAKER WILL NOT OPERATE OR OPERATES SLOWLY . . . . . . 2-24

CHAIN SAW

30. CHAINSAW WILL NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

BACKHOE

31. ALL BACKHOE FUNCTIONS SLUGGISH. . . . . . . . . . . . . . . . . . . 2-24

32. BACKHOE STOPS ABRUPTLY WHEN SWUNG FULL LEFT OR RIGHT. . . . . . . . . . . . . . . . . . . 2-26
33. BACKHOE SWINGS CORRECTLY BUT WILL NOT STOP WHEN SWING
CONTROL RETURNED TO NEUTRAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
34. BACKHOE BOOM DRIFTS WHEN LOADED AND CONTROLS lN NEUTRAL. . . . . . . . 2-26
35. STABILIZER(S) WILL NOT HOLD BACKHOE IN PLACE. . . . . . . . . . . . . . . . . . . 2-26
36. LOAD FALLS WHEN CONTROL VALVE ACTUATED. . . . . . . . . . . . . . . . . . . 2-26

CRANE

37. CRANE CONTROLS WILL NOT RESPOND . . . . . . . . . . . . . . . . . . . . . . 2-26

38 CRANE OPERATION SLOWS DOWN. . . . . . . . . . . . . . . . . . . . . . . . . 2-28
39. CRANE OPERATION UNUSUALLY NOISY, YIELDS OR DRIFTS. . . . . . . . . . . . . . . . . . . . . . 2-28

FRONT LOADER

40. CONTROL VALVE WILL NOT HOLD IN FLOAT POSITION. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

41. CONTROL VALVE STICKS OR WORKS HARD. . . . . . . . . . . . . . . . . . . . . . 2-31

2-4
 TM 5-2420-224-34

Table 2-1. Troubleshooting

Malfunction
Test or Inspection
Corrective Action

ENGINE

1. ENGINE CRANKS BUT WILL NOT START OR HARD TO START.

Step 1. Remove fuel injector nozzles. Check for blocked fuel injector spray holes by
performing fuel injector spray pattern test (page 13-65).
• Repair fuel injector nozzle(s) (page 13-65).

Step 2. Perform compression test as follows:

a. Run engine until it reaches normal operating temperature of 140°-185°F

(60°-85° C). Shut off engine.

b. Remove six fuel injector nozzles (page 3-41).

c. Crank engine several times to remove carbon flakes and dirt.

d. Clean fuel injector nozzle seat base (1) in cylinder head (2).

e. Place compression tester adapter (P/N 352 589 00 21 00) into protective
sleeve. Install nozzle holder nut. Tighten nozzle holder nut to 50 Ib-ft
(68 N·m).

f. Connect compression recorder to compression tester adapter. Crank

engine several times until highest reading is obtained. Record highest
reading. Minimum acceptable compression reading is 284 psi (20 bar).

2-5
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

ENGINE (CONT)

g. Repeat steps d thru f for remaining cylinders. If minimum compression

reading is not 284 psi (20 bar), squirt approximately 1 oz engine oil into
cylinder. Crank engine several times and repeat steps d thru f for each
cylinder.
• If compression reading is higher after second test, on any
cylinder, excessive bypass of air between piston and cylinder
bore is indicated. Replace piston rings (page 13-31).
• If compression reading remains approximately the same after
second test, replace valves and valve guides (page 13-2).
• If variation between cylinders exceeds 21.3 psi (1.47 bar),
replace piston rings (page 13-31).

Step 3. Check fuel injection pump timing (page 3-50).

• If timing is correct and problem persists, replace fuel injection
pump (page 3-43).
• If timing is not correct, time fuel injection pump (page 3-50).

2. ENGINE RUNS ROUGH OR LACKS POWER.

Step 1. Check fuel injection pump timing (page 3-50).

• if timing is correct and problem persists, replace fuel injection
pump (page 3-43).
• If timing is not correct, time fuel injection pump (page 3-50).

Step 2. Remove fuel injector nozzles. Check for blocked fuel injector spray holes by
performing fuel injector spray pattern test (page 13-65).
• Repair fuel injector nozzle(s) (page 13-65).

Step 3. Perform Malfunction 1, step 2.

3. FUEL CONSUMPTION EXCESSIVE.

Check fuel injection pump timing (page 3-50).

• If timing is correct and problem persists, replace fuel injection
pump (page 3-43).
• If timing is not correct, time fuel injection pump (page 3-50).

4. ENGINE OIL PRESSURE LOW.

Step 1. Check for blocked oil suction tube on engine oil pump (page 13-60).
• Clean oil suction tube, or replace if required (page 13-60).

2-6
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

ENGINE (CONT)

Step 2. Check for worn or damaged engine oil pump (page 13-60).
• Repair engine oil pump, or replace if required (page 13-60).

Step 3. Check for worn or damaged piston rod bearings, main bearings, and
camshaft bearings (pages 13-15, 13-31, 13-43).
• Replace bearing(s) (pages 13-15, 13-31, 13-43).

5. ENGINE OIL CONSUMPTION EXCESSIVE.

Perform Malfunction 1, step 2.

6. ENGINE OIL DILUTED WITH FUEL.

Remove fuel injection pump (page 3-43). Inspect shaft seal for evidence of fuel
leakage.
• Replace fuel injection pump (page 3-43).

7. ENGINE OIL DILUTED WITH ENGINE COOLANT.

Step 1. Check for leaks in engine oil cooler element.

• Replace defective part(s) (page 3-30).

Step 2. Check for damaged cylinder head gasket.

• Replace cylinder head gasket (page 3-25).

Step 3. Check for cracked cylinder head.

• Replace cylinder head (page 3-25).

8. ENGINE VIBRATES EXCESSIVELY.

Step 1. Check for damaged vibration damper.

• Replace vibration damper (page 3-56).

Step 2. Check for loose or out-of-balance flywheel (page 13-25).

• Tighten flywheel (page 13-25).

Step 3. Measure alinement of flywheel to flywheel housing (page 13-25).

• If flywheel alinement is outside limits, adjust alinement
(page 13-25).

2-7
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

TRANSMISSION

9. TRANSMISSION WILL NOT OPERATE IN ANY FORWARD OR REVERSE GEAR

Step 1. Check air shift solenoid valve as follows:

a. Disconnect fitting (1) from air shift solenoid valve (2).

b. Have assistant turn on vehicle MASTER disconnect switch and ignition

switch and depress clutch completely.

c. Check for air flow from air shift solenoid valve (2).
• If there is air flow, reconnect fitting (1) and go to step 2.
• If there is no air flow, replace air shift solenoid valve
(page 3-88).

Step 2. Check air shift valve as follows:

2-8
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

TRANSMISSION (CONT)

a. Disconnect two fittings (1 and 2) from air shift valve (3).

b. Have assistant turn on vehicle MASTER disconnect switch and ignition

switch and depress clutch completely.

c. Check for air flow from either port (4 and 5) of air shift valve (3).
• If there is air flow, note from which port air flows and perform
steps d and e.
• If there is no air flow from either port, replace air shift valve
(page 3-90).

d. Have assistant turn on vehicle MASTER disconnect switch and ignition

switch and depress clutch completely.

e. Move shift collar on shift control either up or down and check for air
flow from port opposite port noted in step c.
• If there is air flow, replace clutch (page 3-63).
• If there is no air flow, replace air shift valve (page 3-90).

10. TRANSMISSION LOCKS UP IN GEAR.

Step 1. Check for damaged shift controls.

• Replace shift control(s) (page 3-96).

Step 2. Remove top cover (page 3-86) and inspect for damaged shift forks.
• Repair top cover (page 15-54).

11. TRANSMISSION SLIPS IN ALL RANGES.

Check for worn or damaged clutch.

• Replace clutch (page 3-63).

12. CLUTCH SLIPS OR DRAGS.

Step 1. Check for warped clutch disc or pressure plate.

• Replace clutch (page 3-63).

Step 2. Check for grease or oil on clutch disc facings and for worn clutch facings.
• Replace clutch (page 3-63).

2-9
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or inspection
Corrective Action

TRANSMISSION (CONT)

13. PTO WILL NOT ENGAGE OR EXCESSIVELY NOISY.

Step 1. Check PTO control linkage adjustment.

• Adjust PTO control linkage (page 3-81).

Step 2. Check for PTO and transmission gear damage.

• Repair PTO (page 15-70) and/or transmission (page 15-1).

14. FRONT AXLE PROPELLER SHAFT WILL NOT TURN.

Step 1. Check for loose or sheared propeller shaft mounting bolts.

• Tighten, or replace propeller shaft mounting bolt(s) (page 3-102).

Step 2. Check for broken or damaged U-joints.

• Replace U-joint(s) (page 3-103).

15. TRANSMISSION GEARS NOISY DURING SHIFTING.

Step 1. Remove top cover (page 3-86) and inspect for damaged shift forks.
• Repair top cover (page 15-54).

Step 2. Disassemble transmission (page 15-1) and check for damaged transmission
gear synchronizers.
• Repair transmission (page 15-1).

BRAKES AND AIR SYSTEM

16. DUAL BRAKE GAGE IN CAB WILL NOT lNDICATE CORRECT PRESSURE.

NOTE
Perform the following steps after verifying air compressor is operating.

Step 1. Check for correct fluid regulating valve operation as follows:

2-10
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

BRAKES AND AIR SYSTEM (CONT)

a. Relieve air pressure (TM 5-2420-224-20) completely from air tanks

(1 and 2).

b. Attach 0-200 psi (0-14 bar) pressure gage to test connection (3).

NOTE
When fluid regulating valve reaches cut-out pressure, there will be an audible “pop.”

c. Start and run engine at idle until fluid regulating valve reaches cut-out
pressure.

d. Compare pressure readings between 0-200 psi (0-14 bar) pressure gage
and dual brake gage. Both readings must be the same.
• If pressure on both gages is zero, go to step e.
• If pressure on both gages is the same, but less than 106 psi
(7.3 bar), go to step 2.
• If pressure on dual brake gage is different than pressure on
0-200 psi (0-14 bar) pressure gage, replace dual brake gage
(TM 5-2420-224-20).

e. Remove 0-200 psi (0-14 bar) pressure gage from test connection (3).

f. Relieve air pressure (TM 5-2420-224-20) completely from air tanks

(1 and 2).

g. Attach 0-200 psi (0-14 bar) pressure gage to test connection (4).

h. Repeat steps c and d.

• If pressure on both gages is zero, replace fluid regulating valve
(TM 5-2420-224-20).
• If pressure on both gages is the same, replace large air
pressure tank overflow valve (5) (TM 5-2420-224-20).

2-11
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

BRAKES AND AIR SYSTEM (CONT)

Step 2. Check fluid regulating valve adjustment as follows:

a. Relieve air pressure (TM 5-2420-224-20) completely from air tanks

(1 and 2).

b. Attach 0-200 psi (0-14 bar) pressure gage to test connection (3).

NOTE
When fluid regulating valve reaches cut-out pressure, there will be an audible “pop.”

c. Start and run engine at idle until fluid regulating valve reaches cut-out
pressure.

d. Compare pressure readings between 0-200 psi (0-14 bar) pressure gage
and dual brake gage. Both readings must be approximately 106 psi
(7.3 bar).
• If both readings are not approximately 106 psi (7.3 bar), turn
fluid regulating valve adjusting screw (4) 1/4-turn to right to
increase pressure, or 1/4-turn to left to decrease pressure.
Relieve air pressure (TM 5-2420-224-20) from air tanks (1 and
2) to approximately 80 psi (5.5 bar) and repeat steps c and d
until cut-out pressure is approximately 106 psi (7.3 bar).
• If correct cut-out pressure cannot be attained, replace fluid
regulating valve (TM 5-2420-224-20).

2-12
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

BRAKES AND AIR SYSTEM (CONT)

17. INTERMEDIATE SPEED SHIFT VALVE WILL NOT OPERATE.

Step 1. Check dual brake gage in cab for indication of 106 psi.
• If 106 psi is not indicated, perform Malfunction 16, step 2.

Step 2. Check operation of four-wheel drive/differential lock and crane/backhoe engine

RPM switches.
• If four-wheel drive/differential lock and crane/backhoe engine
RPM switches do not operate properly, replace accessory air
supply overflow valve (TM 5-2420-224-20).
. If four-wheel drive/differential lock and crane/backhoe engine
RPM switches operate properly, perform Malfunction 9, step 1.

18. TRAILER BRAKES WILL NOT DISENGAGE.

Check trailer brake system as follows:

a. Check dual brake gage in cab for indication of 106 psi.

• If 106 psi is not indicated, perform Malfunction 16, step 2.

b. Check that trailer air supply valve is in ON position and trailer hand
brake valve is in OFF position.

c. Attach 0-200 psi (0-14 bar) pressure gage to test connection (1). Check
0-200 psi (0-14 bar) pressure gage for indication of approximately 106 psi
(7.3 bar).
• If 106 psi is not indicated, replace small air pressure tank
overflow valve (2) (TM 5-2420-224-20).

2-13
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or inspection
Corrective Action

STEERING SYSTEM

NOTE
Before troubleshooting steering system, check oil level with engine running. Oil that foams
easily is not recommended due to its tendency to retain air.

19. STEERING HARD TO MOVE FULL RIGHT AND LEFT.

NOTE
Perfom the following steps on both steering knuckles.

Step 1. Check for proper steering knuckle lubrication as follows:

a. Remove two capscrews (1), two washers (2), clamp (3), cap (4), and
lubrication fitting (5). Discard lubrication fitting.

b. Remove and discard washer(s) (6) and seal ring (7).

c. Visually check for proper lubrication of steering knuckle (8).

If steering knuckle is properly lubricated, reassemble parts and
go to step 2.
If steering knuckle is not properly lubricated, replace parts in
Bearing Parts Kit, P/N 419-330-0012 (page 16-25).

2-14
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

STEERING SYSTEM (CONT)

Step 2. Check steering knuckle for binding or excessive tightness as follows:

a. Remove tie rod and drag link (TM 5-2420-224-20).

b. Raise vehicle enough to clear wheel from ground.

c. Move wheel fully left and right and check for free and smooth movement
with no binding.
• If wheel binds or does not move freely, replace steering
knuckle (page 5-16).
• If wheel does not bind and moves freely, replace power
steering gear (page 7-11).

HYDRAULIC SYSTEM

20. FRONT OR REAR HYDRAULIC PUMP NOISY.

NOTE
Perform step 1 for front hydraulic pump. Perform step 2 for rear hydraulic pump.

Step 1. Check front loader/forkIift relief valve pressure as follows:

a. Park vehicle on level surface and set parking brake.

b. Open front loader/forklift travel lock valves.

c. Leave front loader/forklift in transport position.

d. Remove cap (1) from fitting in inlet (2) of front loader/forklift control
valve (3) located behind cab.

2-15
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

HYDRAULIC SYSTEM (CONT)

NOTE
The 0-5000 psi (0-345 bar) pressure gage must be calibrated. If not, performance of front
loader/forklift circuits and tool circuits will not be correct.

e. Connect 0-5000 psi (0-345 bar) pressure gage to fitting in inlet (2) of
control valve (3).

f. Start and run engine at idle speed of 2000 rpm.

g. Move bucket control lever into rollback position and hold for 15 seconds;
then place lever in neutral for 30 seconds.

h. Repeat steps f and g until oil is at operating temperature of 120°F (49°C)

i. Keep engine running at 2000 rpm.

j. Move bucket control tilt lever into rollback/tilt back position and read
0-5000 psi (0-345 bar) pressure gage. Pressure reading must be 2450 psi
(169 bar).
• If pressure reading is not 2450 psi (169 bar), repeat steps i and
j while holding bucket control lever in dump/forward tilt position.
• If pressure reading is still not 2450 psi (169 bar), hold
adjusting screw (4) and loosen lock nut (5) on relief valve (6).
Turn adjusting screw (4) to right to increase pressure, or left to
decrease pressure. Hold adjusting screw (4), tighten lock nut
(5), and check 0-5000 psi (0-345 bar) pressure gage for
reading of 2450 psi (169 bar). Repeat as necessary.
• If 2450 psi (169 bar) cannot be attained, go to step 3.

2-16
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or inspection
Corrective Action

HYDRAULIC SYSTEM (CONT)

k. Disconnect 0-5000 psi (0-345 bar) pressure gage from fitting in inlet (2)
of control valve (3).

i. install cap (1) on fitting in inlet (2) of control valve (3).

Step 2. Check backhoe/crane relief valve pressure as follows:

NOTE
Make sure front loader/forklift is resting on flat surface and backhoe/crane is in
three-point stace.

b. Remove seven screws (1) and seven washers (2) from cover (3).

NOTE
Step c is for SEE only.

c. Disconnect wire (4) and set cover (3) aside.

NOTE
Step d is for HMMH only.

d. Disconnect two wires (4) and set cover (3) aside.

2-17
TM 5-2420-244-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or inspection
Corrective Action

HYDRAULIC SYSTEM (CONT)

NOTE
The 0-5000 psi (0-345 bar) pressure gage must be calibrated. If not, performance of
backhoe/crane circuits and tool circuits will not be correct.

e. Connect 0-5000 psi (0-345 bar) pressure gage to test port (5) on inlet
section (6) of control valve (7).

f. Start and run engine at idle speed of 2000 rpm.

g. Place lock control lever (8) in up position and hold for 15 seconds; then
place lever in neutral for 30 seconds.

h. Repeat steps f and g until oil is at operating temperature of 120°F (49°C).

i. Keep engine running at 2000 rpm.

j. Place lock control lever (8) in up position and read 0-5000 psi
(0-345 bar) pressure gage. Reading must be 2450 psi (169 bar).
• If pressure reading is not 2450 psi (169 bar), hold adjusting
screw (9) and loosen lock nut (10) on relief valve (11). Turn
adjusting screw (9) to right to increase pressure, or left to
decrease pressure. Hold adjusting screw (9), tighten lock nut
(10), and check 0-5000 psi (0-345 bar) pressure gage for
reading of 2450 psi (169 bar). Repeat as necessary.
• If 2450 psi (169 bar) cannot be attained, go to step 3.

2-18
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

HYDRAULIC SYSTEM (CONT)

k. Disconnect 0-5000 psi (0-345 bar) pressure gage from test port (5) on
inlet section (6) of control valve (7).

NOTE
Step I is for HMMH only.

1. Install cover (3) and connect two wires (4).

NOTE
Step m is for SEE only.

m. Install cover (3) and connect wire (4).

n. Install seven washers (2) and seven screws (1) in cover (3).

2-19
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

HYDRAULIC SYSTEM (CONT)

Step 3. Check front or rear hydraulic pump flow rate as follows:

NOTE
Procedure is the same for both front and rear hydraulic pumps. Front hydraulic pump is
shown for step a.

a. Disconnect hydraulic hose (1) from inlet side of control valve (2). Install
threaded cap” on control valve (2) inlet.

CAUTION
Make sure flow meter gpm gage will record in excess of 75 gpm. Failure to
do so may result in damage to flow meter or hydraulic pump.

2-20
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

HYDRAULIC SYSTEM (CONT)

b. Connect hydraulic hose (1) to input side of flow meter.

c. Connect hose (3) to outlet side of flow meter. Place other end of hose
(3) into hydraulic tank (4).

NOTE
• Make sure load valve on flow meter is completely open.
• Make sure engine idle speed is maintained at 2000 rpm during entire test. Failure
to do so may result in incorrect readings and improper evaluation of hydraulic pump
flow rate.

d. Start and run engine at idle speed of 2000 rpm.

NOTE
Monitor oil temperature during entire test. Do not allow oil temperature to exceed 140° F
(60 ‘C). Failure to do so may result in incorrect readings and improper evaluation of
hydraulic pump flow rate.

e. Cycle oil until oil is at operating temperature of 120° F (49°C).

f. Record flow rate.

g. Close load valve until 1000 psi (69 bar) is noted on flow meter. Record
flow rate.

h. Open load valve until 0 psi (0 bar) is noted on flow meter.

i. Close load valve until 1500 psi (103.4 bar) is noted on flow meter.
Record flow rate.

j. Open load valve until 0 psi (0 bar) is noted on flow meter.

k. Close load valve until 2000 psi (138 bar) is noted on flow meter.
Record flow rate.

l. Open load valve until 0 psi (0 bar) is noted on flow meter.

m. Close load valve until 2450 psi (169 bar) is noted on flow meter.
Record flow rate.

n. Shut off engine.

o. Divide flow rate recorded in step m by flow rate recorded in step f.

This is the percentage of hydraulic pump efficiency.
• If hydraulic pump efficiency is less than 75 percent, replace
front or rear hydraulic pump (TM 5-2420-224-20).

2-21
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

HYDRAULIC SYSTEM (CONT)

• If hydraulic pump efficiency is more than 75 percent, replace

front loader/forklift relief valve (5) or backhoe/crane relief valve
(6) (TM 5-2420-224-20).

21. HYDRAULIC SYSTEM OIL OVERHEATS.

NOTE
• Perform step 1 for front hydraulic system.
• Perform step 2 for rear hydraulic system.

Step 1. Check front loader/forklift relief valve pressure.

• Perform Malfunction 20, step 1.

Step 2. Check backhoe/crane relief valve pressure.

• Perform Malfunction 20, step 2.

22. BACKHOE/CRANE WILL NOT TILT INTO OR OUT OF TRANSPORT POSITION.

Perform Malfunction 20, step 2.

23. HYDRAULIC FUNCTION SLUGGISH.

Perform Malfunction 20, step 3.

2-22
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

FORKLIFT

24. ERRATIC UP AND DOWN MOVEMENT OF FORKLIFT.

Step 1. Check for air in lift cylinder.

• Bleed air from lift cylinder (page 11-51).

Step 2. Check lift cylinder sequencing.

• Sequence lift cylinder (page 11-51).

Step 3. Check load rollers adjustment.

• Adjust load roller(s) (page 20-155).

Step 4. Check for bent or damaged lift cylinder plungers.

• Replace lift cylinder (page 11-51).

Step 5. Check for leaks or binding of front loader/forklift control valve.

• Replace front loader/forklift control valve (page 11-28).

HD45 HAMMER DRILL

25. HAMMER DRILL WILL NOT OPERATE OR OPERATES SLOWLY.

Step 1. Check for low accumulator charge (pressure hose will pulse more than normal).
• Charge accumulator (page 21-1).

Step 2. Perform Malfunction 20.

IMPACT WRENCH

26. IMPACT WRENCH PERFORMS POORLY OR HAS LOW IMPACT.

Step 1. Perform Malfunction 20.

Step 2. Check for broken hammer pins.

• Replace hammer pin(s) (page 21-15).

27. IMPACT WRENCH OPERATES TOO FAST.

Step 1. Check engine rpm setting.

• Set engine rpm to 2000 rpm.

Step 2. Check for damaged relief spring or valve sleeve.

• Repair impact wrench (page 21-15).

2-23
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or inspection
Corrective Action

IMPACT WRENCH (CONT)

28. IMPACT WRENCH WILL NOT OPERATE.

Step 1. Check for sticking or broken trigger controls.

• Repair impact wrench (page 21-15).

Step 2. Perform Malfunction 20.

BR67 PAVEMENT BREAKER

29. PAVEMENT BREAKER WILL NOT OPERATE OR OPERATES SLOWLY.

Step 1. Check for low accumulator charge (pressure hose will pulse more than normal).
• Charge accumulator (page 21-24).
• If charge loss continues, repair pavement breaker (page 21-24).

Step 2. Perform Malfunction 20.

CHAIN SAW

30. CHAIN SAW WILL NOT OPERATE.

Perform Malfunction 20.

BACKHOE

31. ALL BACKHOE FUNCTIONS SLUGGISH.

Step 1. Perform Malfunction 20.

Step 2. Check for incorrect pressure setting for safety relief valves as follows:

a. Cycle circuit(s) to be tested until oil is at operating temperature of 120°F (49°C).

b. Place backhoe in three-point stance.

c. Shut off engine.

d. Relieve hydraulic pressure by moving controls back and forth.

e. Disconnect hydraulic hose from port to be tested.

f. Connect hand pump to port to be tested.

g. Stroke hand pump until sufficient pressure is built up in circuit to open

safety relief valve.

h. Continue to stroke hand pump until ail airhas been pumped out of lines.

2-24
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

BACKHOE (CONT)

i. Record highest pressure and compare with acceptable ranges shown

below:

Swing Section Valve

A and B ports. . . . . . . . . . . . . 1700-1900 psi (115.6-129.2 bar)

Boom Section Valve

A port (upper) . . . . . . . . . . . . . 925-1075 psi (62.9-73.1 bar)
B port (lower) . . . . . . . . . . . . . 2400-2650 psi (163.2-180.2 bar)

Dipper Section Valve

A and B ports. . . . . . . . . . . . 2400-2650 psi (163.2-180.2 bar)

Bucket Section Valve

A and B ports. . . . . . . . . . . . . 2400-2650 psi (163.2-180.2 bar)

NOTE
Adjustment is the same for both ports. A port is shown.

l If safety relief valve pressure is not correct, loosen lock nut (1).
Turn adjusting screw (2) to right to increase pressure, or left to
decrease pressure. Repeat until correct pressure is attained.

2-25
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

BACKHOE (CONT)

j. When safety relief valve pressure is correct, perform leak test on all
safety relief valves (page 20-69).

32. BACKHOE STOPS ABRUPTLY WHEN SWUNG FULL LEFT OR RIGHT.

Step 1. Check for damage to relief valve in end of swing cylinder.

. Replace relief valve (page 11-10).

Step 2. Disassemble swing cylinder and check for damage to pin inside swing cylinder.
l Replace damaged part(s) (page 20-105).

33. BACKHOE SWINGS CORRECTLY BUT WILL NOT STOP WHEN SWING CONTROL
RETURNED TO NEUTRAL.

Check for damaged springs or valve disc in swing section valve.

l Repair swing section valve (page 20-51).

34. BACKHOE BOOM DRIFTS WHEN LOADED AND CONTROLS IN NEUTRAL.

Check for dirty or defective cylinder load check valves in boom section valve.
. Clean, or repair boom section valve (page 20-59).

35. STABILIZER(S) WILL NOT HOLD BACKHOE IN PLACE.

Check for clogged or defective check valves in stabilizer control valves as follows:

a. With engine stopped, backhoe in operating position, and stabilizers in

down position, pull left stabilizer control lever inward. If cylinder starts to
retract, immediately release lever.

b. Repeat step a using right stabilizer control lever. Vehicle movement

indicates defective check valve(s) in stabilizer control valve on side of
vehicle that moved.
. Replace stabilizer control valve (page 11-12).

36. LOAD FALLS WHEN CONTROL VALVE ACTUATED.

Check for damaged load check valves in backhoe control valve.

l Repair backhoe control valve (page 20-41),

CRANE

37. CRANE CONTROLS WILL NOT RESPOND.

Step 1. Check PTO control linkage adjustment.

. Adjust PTO control linkage (page 3-81).

2-26
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

CRANE (CONT)

Step 2. Perform Malfunction 20.

Step 3. Check flow rate of oil coming from flow regulating valve as follows:

a. Disconnect input hose (1) from elbow fitting (2) at valve (3).

b. Connect flow meter input hose (4) to elbow fitting (2).

c. Disconnect output hose (5) from valve (3).

d. Connect flow meter output hose (6) to tee fitting (7).

e. Start engine and increase engine rpm to 1100 rpm by engaging RPM
switch on control tower.

2-27
TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

CRANE (CONT)

NOTE
Monitor oil temperature during entire test. Do not allow oil temperature to exceed 140°F
(60°C). Failure to do so may result in incorrect readings of flow rate.

f. Cycle oil until oil is at operating temperature of 120°F (49°C).

g. Close load valve until 1000 psi (69 bar) is noted on flow meter.

h. Open load valve until 0 psi (0 bar) is noted on flow meter.

i. Close load valve until 1500 psi (103.4 bar) is noted on flow meter.

j. Open load valve until 0 psi (0 bar) is noted on flow meter.

k. Close load valve until 2000 psi (137.9 bar) is noted on flow meter. Flow
rate at this time should be 9 gpm (34 Ipm).
. If flow rate is not 9 gpm (34 Ipm), replace flow regulating
valve (page 1 1-22).

38. CRANE OPERATION SLOWS DOWN.

Perform Malfunction 37, step 3.

39. CRANE OPERATION UNUSUALLY NOISY, YIELDS OR DRIFTS.

Check holding valve on noisy cylinder as follows:

a. Lift maximum load for crane approximately 6-8 in. off ground.

b. Extend outer boom to its maximum.

c. Shut off engine.

d. Monitor down drift of load for approximately 10 minutes.

. If there is any down drift of load, replace holding valve on
cylinder that drifts down.

FRONT LOADER

40. CONTROL VALVE WILL NOT HOLD IN FLOAT POSITION.

Check for worn or damaged parts in mechanical detent. If parts are worn or
damaged, adjust float detent as follows:

2-28
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or Inspection
Corrective Action

FRONT LOADER (CONT)

a. Loosen jam nut (1) and remove socket head screw (2), spring (3), and
ball (4) from bottom of housing (5).

b. Loosen jam nut (6) and remove socket head screw (7), spring (8), and
ball (9) from top of housing (5).

c. Remove two socket head capscrews (10) and housing (5) from control
valve (11).

d. Inspect spool end (12) for damage.

NOTE
If spool end is damaged, perform steps e and f. If spool end is not damaged, go to
step g.

e. Remove spool end (12), spring retainer (13), spring (14), spring retainer
(15), and packing (16) from housing (5). Discard packing.

2-29
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or inspection
Corrective Action

FRONT LOADER (CONT)

NOTE
Make sure spool end bottoms out completely.

f. install new packing (16), spring retainer (15), spring (14), spring retainer
(13), and spool end (12) in housing (5).

g. Coat bore of housing (5) with GAA and install housing (5) on control
valve (11).

h. install two socket head capscrews (10) in housing (5).

i. Fill two detent holes (17) with GAA.

NOTE
During steps j and k, install socket head screws only three turns.

j. install ball (9), spring (8), and socket head screw (7) in top of housing
(5).

k. install ball (4), spring (3), and socket head screw (2) in bottom of
housing (5).

l. Tighten two socket head screws (7 and 2) until slight resistance is felt.

m. Engage loader lift lever in cab in float position and make sure float lock
is achieved.

2-30
 TM 5-2420-224-34

Table 2-1. Troubleshooting (Cont)

Malfunction
Test or inspection
Corrective Action

FRONT LOADER (CONT)

n. Operate loader lift lever to check for smooth movement in all directions.

o. if movement is not smooth or float lock is not achieved, turn two socket
head screws (7 and 2) either in or out to accomplish smooth movement
and proper float lock.

p. Hold two socket head screws (7 and 2) in place and tighten two jam
nuts (6 and 1).
l if problem continues, replace control valve (page 11-28).

41. CONTROL VALVE STICKS OR WORKS HARD.

Step 1. Check if control valve tie rod nuts (1) are too tight.
l Tighten tie rod nut(s) to 16 ±2 lb-ft (32.5 ±2.7 N.m).

Step 2. Check for incorrectly adjusted detent.

. Perform Malfunction 40.

2-31
TM 5-2420-224-34

Section III. GENERAL MAINTENANCE INSTRUCTIONS

OVERVIEW
This section describes general maintenance instructions that apply to all parts of this manual.
To avoid repetition, these procedures will not be described in specific maintenance sections.

GENERAL REMOVAL INSTRUCTIONS

1. Work Required. Remove only those parts needing repair or replacement. Do not disassemble a
component any further than needed.

2. Preparation. Before removing any part of the electrical, hydraulic, or air systems, make certain
system is not energized or pressurized. Disconnect battery cables. Relieve all pressure from air
system. Make sure brakes are locked and that all controls are in OFF position before starting
any removal procedure.

3. Removal. Make sure there is enough clearance to remove part. Disassemble adjacent parts as
needed to provide working clearance.

4. Lifting. Always use chain hoist, jack, or other aid when lifting heavy parts. Make certain load
limit of lifting device exceeds weight being lifted. Position and rig lifting device before
disconnecting part for removal.

5. Identification. Tag or mark all similar parts, such as electrical leads, before disconnecting and
removing such parts. This will make proper assembly easier. Be sure to identify mating ends of
electric lines, hydraulic lines, and air tubes as they are disconnected.

6. Position of Valves. Before removing valve handles, mark or diagram their positions when open
and closed. This will help during assembly.

GENERAL DISASSEMBLY INSTRUCTIONS

1. Cleanliness. Work area must be kept as clean as possible. This will prevent injury or
contamination of internal parts. This is especially true for valves, cylinders, and other hydraulic
or air system parts.

2. Expendable Parts. As indicated in this manual, all gaskets, packings, and seals removed during
repair must be discarded and replaced with new parts. These items are usually damaged during
removal. In the same way, all lockwire, cotter pins, and like items must be replaced at time of
assembly.

3. Removing Seals. When removing gaskets, packings, or seals, do not use any metal tool that
will scratch the surfaces next to these items.

4. Disassembly. Before disassembly of any item, study the illustration carefully. Note relationship
of internal parts. Knowing details of a component will speed up disassembly and assembly and
will help avoid mistakes.

5. Parts Protection. To prevent moisture and dirt from entering open housings, lines, and other
openings, apply protective caps and plugs as soon as possible after disassembly. Wrap all
removed parts in clean paper or coat parts with solid lubricant preservative.

2-32
 TM 5-2420-224-34

GENERAL CLEANING INSTRUCTIONS

WARNING
. Drycleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in well-ventilated area. Avoid contact with
skin, eyes, and clothes and do not breath vapors. Do not use near open
flame or excessive heat. Flash point is 100° -138°F (38°-50°C). If you
become dizzy while using drycleaning solvent, get fresh air immediately and
get medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.

. Never use gasoline to clean parts. Gasoline is highly flammable. Serious

personal injury could result if fuel ignites during cleaning.

CAUTION
. Petroleum solvents may damage parts that are in contact with hydraulic
fluids.

. To prevent damage to equipment, do not clean tires, lubricant seals, rubber

hoses, or electrical components with solvent mixture.

1. Cleaning Solvents. Use only approved cleaning solvents to clean parts. Drycleaning solvent,
SD-2 (P-D-680) is commonly used. Always work in a well-ventilated area.

WARNING
To prevent injury, compressed air used for cleaning and drying purposes will
not exceed 30 psi (207 kPa). Use only with effective chip guarding and
personal protective equipment (goggles/shield, gloves, etc.).

2. Removing Deposits. After soaking parts in solvent, wash away deposits by flushing or spraying.
Where necessary, brush with a soft-bristle brush moistened in solvent. Use compressed air to
dry all parts, except bearings. Bearings must be allowed to air dry.

3. Tools. Do not use abrasive wheels or compounds when cleaning parts, unless called for in
detailed instructions. These procedures may weaken a highly stressed part.

4. Ball and Roller Bearings. When cleaning ball or roller bearings, place them in a basket and
suspend them in a container of drycleaning solvent. If needed, use a brush to remove bearing
before solid particles are removed to prevent damaging races and balls. When bearings have
been cleaned, coat them lightly with lubricating oil to remove solvent. Refer to TM 9-214 for
additional instructions on cleaning bearings.

5. Rubber Parts. Do not clean rubber parts in drycleaning solvent. Clean by washing with a mild
solution of soap and water. Wipe with a clean, dry, lint-free cloth.

2-33
TM 5-2420-224-34

GENERAL CLEANING INSTRUCTIONS (CONT)

WARNING
Steam cleaning creates hazardous noise levels and severe burn potential.
Eye, skin, and ear protection are required.

6. Exterior Parts. Steam clean all exterior parts thoroughly before removing. This will make
inspection and disassembly easier.

WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in well-ventilated area. Avoid contact with
skin, eyes, and clothes and do not breath vapors. Do not use near open
flame or excessive heat. Flash point is 1000-138°F (38” -50” C). If you
become dizzy while using drycleaning solvent, get fresh air immediately and
get medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.

Solvents used with spray gun must be used in spray booth with filter. Face
shield must be used by personnel operating spray gun. Failure to do so
could result in serious injury to personnel.

7. Engine. Cab. and Body. Use a spray gun and solvent mixture for cleaning exterior of engine,
cab, and body. Allow mixture to remain on item surface for about 10 minutes before rinsing.
Rinse with hot water under 80-120 pounds of pressure, if available. An ordinary garden hose
with nozzle may be used if other equipment is not available. Rinse thoroughly.

8. Decreasing Machine. A decreasing machine may be used to remove heavy grease and oil
accumulations from metal parts.

9. Passages. After removing parts from decreasing machine, and before coating with rust
preventive, check all oil passages and cavities for dirt or blockage. A thin, flexible wire should
be run through oil passages to make certain they are not clogged. Individual passages that are
dirty may be cleaned using a pressure spray gun and drycleaning solvent.

CAUTION
To prevent corrosion, parts should be dipped in rust preventive compound
within 2 hours after decreasing.

10. Electrical Parts. Electrical parts, such as coils, junction blocks, switches, and igniters, which
use insulating materials, should not be soaked or sprayed with cleaning solutions. Clean
these parts with a clean, lint-free cloth moistened with drycleaning solvent.

11. Electrical Grounds. Clean electrical ground contacts with emery cloth.

12. Oil and Fuel Tank. Pay special attention to all warnings and cautions when working on fuel
tank. Oil and fuel tanks should be flushed, using a spray gun and drycleaning solvent.

2-34
 TM 5-2420-224-34

13. Battery. Exterior surfaces of the electrical system and battery should be cleaned with a weak
solution of baking soda and water. Apply solution with a bristle brush to remove corrosion.

WARNING
Drycleaning solvent P-D-680 is toxic and flammable. Wear protective goggles
and gloves and use only in well-ventilated area. Avoid contact with skin, eyes,
and clothes and do not breath vapors. Do not use near open flame or
excessive heat. Flash point is 100° -138° F (38° -50°C). If you become dizzy
while using drycleaning solvent, get fresh air immediately and get medical aid.
If contact with eyes is made, wash your eyes with water and get medical aid
immediately.

CAUTION
To prevent damage to equipment, never use gasoline or other petroleum-base
products to clean or preserve hydraulic system parts.

14. Hydraulic System. When cleaning hydraulic system parts, use drycleaning solvent SD-2
(P-D-680). Clean and dry parts thoroughly to make sure no residue remains. If a coating of
preservative is required before assembly, apply a light film of solid lubricant preservative. If
petroleum-free solvents are not available, use the same hydraulic fluid as used in the
hydraulic system.

GENERAL INSPECTION INSTRUCTIONS

1. Sealing Surfaces. Inspect all surfaces in contact with gaskets, packings, or seals. Make sure
there are no nicks, burrs, or scratches. If any defect is found, remove or repair it as outlined
under General Repair Instructions in this manual.

2. Bearings. Check bearings for rusted or pitted balls, races, or separators. Check balls and races
for brinnelling, abrasion, and serious discoloration. Refer to TM 9-214 for additional instructions
for bearings. Following are causes for bearing rejection:
l Cuts or grooves parallel to ball or roller rotation
l Fatigue pits (not minor machine marks or scratches)
l Cracks

3. Inspection. Inspection consists of checking for defects such as distortion, wear, cracks, and
pitting. Parts under heavy load or pressure must be inspected more thoroughly. Clean all parts
before inspection.

4. Drain Plugs. When removing drain plugs from transmission, engine, or hydraulic system
components, inspect sediment adhering to plug, A buildup of grit and/or fine metal particles
may indicate part failure. A few fine particles are normal. This inspection is effective in
determining defective parts prior to internal inspection of parts.

5. Gears. Gear inspection cannot be described in detail here; there are too many differences in
size and shape of gears. The following steps can be used to make a general visual inspection
of all gears. Follow all steps listed in General Repair Instructions for final inspection.
. Normal Wear. Loss of metal from the surface of gear teeth. Wear must not prevent gears
from meshing or performing properly.
l Initial Pitting. This may occur when a pair of gears is first started in service. It may
continue until most high spots have been reduced, as long as contact surfaces are not
affected. This pitting is not necessarily serious.

2-35
TM 5-2420-224-34

GENERAL INSPECTION INSRTUCTIONS (CONT)

Destructive Pitting. This type of pitting occurs after initial pitting, often at an increasing
rate. This will destroy contact area and reduce the gear’s ability to carry a load. Rapid
destruction will occur with use.
Abrasive Wear. This damage is caused by the fine particles that may come from many
sources: metal detached from gear teeth or bearings, abrasives not completely removed
before assembly, sand or scale from castings, or other impurities in oil or air.
Scoring. Slight scoring, scuffing, galling, or other surface damage is identified by tears or
scratches in the direction of sliding. It starts in areas having the highest stress and
speed. This is usually at the tip of the teeth.
Burning. Burning is indicated by discoloration and loss of hardness due to excessive
temperature. This is caused by too much friction resulting from overload, overspeed, lack
of backlash, or faulty lubrication. If discoloring can be wiped off with clean cloth, such
discoloring usually can be traced to oilburn-trains, which are not serious.
Rolling. This damage occurs mainly on plastic gears. Rolling is when material is pushed out
of shape without breaking off. This is caused by heavy, even loads; sliding; or overheating.
Brinelling. This can be identified by tiny indentations or ridges on the shoulder or race of
a bearing.

6. Splines. Inspect shaft splines for wear, pitting, rolling, peening, and fatigue cracks. In many
cases, the same inspection procedure will apply to gears. However, the problem will often be
much less pronounced. Have a magnetic particle inspection performed on splines, if needed.

7. Tubes, Hoses, Fittings, and Connections. Check all hose surfaces for broken or frayed fabric.
Check for breaks caused by sharp kinks or rubbing against other parts of the truck. Inspect air
tubes for kinks. Inspect the fitting threads for damage. Replace any part found defective.
Following assembly and during initial operation, check for leaks. No leakage is permissible.

8. Electrical Parts. Inspect all wiring harnesses for chafed or burned insulation. Inspect all terminal
connectors for loose connections and broken parts.

9. Metal Parts. Visually inspect all castings and weldments for cracks. Parts that carry a great
load should receive magnetic particle inspection. Critical nonferrous parts may be inspected with
fluorescent penetrant.

GENERAL REPAIR INSTRUCTIONS

WARNING
Drilling and grinding operations are hazardous to the eyes. Eye protection is
required.

1. Burrs. Remove burrs from gear teeth with a fine-cut file or hand grinder. Remove burrs on
closely fitted mating surfaces by lapping the surfaces with emery cloth.

2. Exterior Parts. Chassis and exterior painted parts may be resurfaced where paint is damaged,
or where parts have been repaired, by using an abrasive disc driven by a flexible shaft. Paint
metal surfaces as required per TM 5-2420-224-20.

3. Bearings. Remove residue and oil stain from bearing races with emery cloth.

2-36
 TM 5-2420-224-34

NOTE
The following procedure is used with polished and machined steel parts not protected by
cadmium, tin, copper, or other plating or surface treatment. Bare metal surfaces must be
free of moisture when protective coating is applied.

4. Protective Parts. During repair operations, protect bare steel surfaces from rusting when not
actually undergoing repair work. Dip parts in, or spray them with, corrosion preventive compound.
The same protective coating may be applied to other metals to prevent rust. Aluminum parts may
require protection in atmospheres having a high salt content. Steel parts must always be protected.

5. Welding. Welding and brazing may be used to repair cracks in external steel parts, such as
brackets, panels, and light framework. These repairs should be made only when replacement
parts are not available. Do not weld or braze castings, running parts, or parts under great
stress, except in emergencies. When welding is required, refer to TM 9-237.

6. Stud Installation. When installing studs in engine block and axle housings, use a driver
designed for the stud to be installed. A worn stud driver may damage the end thread. This
makes it necessary to use a chasing die before a nut can be screwed on. This procedure will
remove cadmium plating and allow corrosion, which will make future disassembly difficult and
cause stud to be backed out with nut. Before driving a stud, inspect hole for chips and liquid.
Blow out any foreign matter. Start stud by hand. If it will not start into hole, it is too large or
has defective end thread. Before final insertion, coat thread with antiseize compound; turn stud
in slowly to prevent overheating and galling of casting metal.

7. Electrical Parts. Replace all broken, worn, or burned electrical wiring. Wires with several broken
strands must be replaced. Broken strands will increase the resistance of the wire and impair
efficiency of electrical components, especially the ignition system.

8. Hoses. Replace all broken, frayed, crimped, or soft flexible lines and hoses, Replace stripped
or damaged fittings. Replace entire flexible hose if fittings are damaged. Make sure hose
clamps do not crimp hoses.

9. Fasteners. Replace any bolt, screw, nut, or fitting with damaged threads. Inspect tapped holes
for thread damage. If cross-threading or galling is evident, retap the holes for the next oversize
screw or stud. When retapping will weaken the part, or when the cost of the part makes
retapping impractical, replace the damaged part. Chasing threads with the proper size tap or
die may often be enough.

10. Dents. Straighten minor body dents by bumping with a soft-faced hammer while using a
wooden block backing.

11. Sheet Metal Repair. Repair minor skin cracks by installing patches.

12. Mounting Holes. Reshape oval mounting holes to round. Drill to receive bushing with required
inner diameter. Stake bushing in place with center punch.

GENERAL ASSEMBLY INSTRUCTIONS

1. Preparation. Remove grease from new parts before installation.

2. Packing Installation. Lubricate all packings with a thin coating of light lubricating oil before
installation. Slightly stretch packing and place into position. Rotate component on flat surface or
uniformly press the packing into position.

2-37
TM 5-2420-224-34

GENERAL ASSEMBLY INSTRUCTIONS (CONT)

3. Pipe Joints. Use sealing compound or thread sealing tape when joining piping.

4. Gaskets. To provide added sealing for gasket. coat both sides with sealant. Remove all traces
of previous gasket and sealant before installing new gasket.

5. Silicone Sealant (Sealing Compound).

WARNING
On direct contact, uncured silicone sealant irritates eyes. In case of contact,
flush eyes with water and seek medical attention. Avoid prolonged contact
with skin.

Silicone sealant is often used instead of a gasket to seal mating parts. Mating parts must be
clean, dry, and free of oil or grease for proper adhesion. After silicone sealant has been
applied, mating parts must be assembled within 15 minutes. Silicone sealant starts to set up
in 15 minutes and takes 24 hours to completely cure. Excess silicone sealant should be
wiped off after assembling mating parts.

6. Oil Seals. Install oil seals with seal lip facing toward lubricant, applying an even force to outer
edge of seal. Coat oil seals evenly with grease before installing. If oil seals will be installed
over keyed or splined shafts, use a guide. This will prevent sharp edge of keyway or splines
from cutting the leather or neoprene seal. Construct guides of very thin gage sheet metal and
shape to required diameter. However, make certain guide edges are not sharp. Bend them
sightly inward so they do not cut the seal.

7. Seal Rings. Coat seal rings with oil and carefully install into their bores. If seal rings must be
installed over threaded parts, temporarily wrap the threads with tape to protect the seal ring;
then remove the tape.

8. Bearings and Shafts. During assembly of shafts and bearings in housings, first mount bearing
on shaft, then install the assembly by applying force to shaft. When mounting bearings on
shafts, always apply force to the inner races of the bearing.

9. Bearing Lubrication. Lubricate bearings before reassembly with the type of lubricant normally
used in the related housing or container. This will provide lubrication during the first run-in until
lubricant from the system can reach the bearings.

GENERAL INSTALLATION INSTRUCTIONS

1. Preparation. Before installing any parts, make sure they are clean and that both mounting
surfaces are clean and free of oil and grease (unless otherwise noted).

2. Installation. Make sure there is enough clearance to install part. Disassemble adjacent parts as
needed to provide working clearance.

3. Lifting. Always use chain hoist, jack, or other aid when lifting heavy parts. Make certain load
limit of lifting device exceeds weight being lifted. Position and rig lifting device before
connecting part for installation.

2-38
 TM 5-2420-224-34

GENERAL LUBRICATION INSTRUCTIONS

Keep a light coat of lubricating oil on parts during repair procedures to prevent rusting.
Lubricate parts during repair and assembly as required by LO 5-2420-224-12.

GENERAL TORQUE VALUE INSTRUCTIONS

Use the torque values listed in the maintenance Procedures, if they are given. When no torque
values are given in the maintenance procedures, refer to the torque value guide in Appendix D.

Section IV. GENERAL HYDRAULIC SYSTEM REPAIR METHODS

OVERVIEW

This section contains repair methods for the hydraulic system. If special repair methods or
procedures are required for the hydraulic system or related parts, these methods or procedures are
included in the individual maintenance procedures in Chapters 3 thru 21.

GENERAL REPAIR METHODS

WARNING
High pressure hydraulics [oil under 2450 psi (16,893 kPa)] operate this
equipment. Never disconnect any hydraulic line or fitting without first dropping
pressure to zero. A high pressure oil stream can pierce body and cause
severe injury to personnel.

CAUTION
Always clean around fittings before disconnecting or connecting hose of
fittings. Make sure area is clean before installing hydraulic components.
Failure to do so could result in damage to equipment.

Cover, cap, or plug all openings, ports, and tube or hose ends when
disconnected. Failure to do so could result in damage to equipment.

Mate a fitting only with a fitting designed to mate. Because two fittings will
screw together is no guarantee they will not leak. Never depend on trial
and error. To do so could result in damage to equipment.

Fittings must be installed and hand-tightened. If a fitting cannot be hand-

tightened, it may be cross-threaded or have damaged threads. Use wrench
only for final tightening. Failure to do so could result in damage to equipment.

Do not use pipe dope as sealer on any fitting. Pipe dope can separate from
fittings causing control valves and relief valves to become contaminated and fail.

It is possible to screw a male NPT into a female straiqht thread, but fitting
will leak. NPT has a slight taper.

2-39
TM 5-2420-224-34

GENERAL REPAIR METHODS (CONT)

CAUTION
. Do not attempt to use parts of a 37-degree flare fitting and a flareless
fitting with each other. Fitting will leak.

. W h e n c o n n e c t i n g N P T s , use care not to overtighten. If overtightened,

female pipe thread will split.

. Do not apply sealant to first thread of NPT fitting. If sealant enters

hydraulic system, it may cause components to fail.

. Be careful when installing preformed packings. Sharp threads can nick

packing, causing it to leak.

. Do not overtighten a flareless connection. Overtightening can cause leakage

requiring replacement of entire tube assembly.

. When connecting a hose to fitting, always use two wrenches. Use one
wrench to turn swivel nut onto fitting and other wrench to keep hose or
tube from rotating. Failure to do so could result in damage to equipment.

The following describes the types of fittings used in the vehicles. Refer to this information when
performing hydraulic maintenance tasks.

1. National Pipe Thread (NPT). This thread differs from others in that it is tapered. To obtain a
proper seal with NPT, a sealant must be used. The sealant should be applied to male threads.
Use care not to overtighten.

2. 37-Degree Flare. The 37-degree flare connection has a male straight thread that mates with a
female straight thread. The sealing surface for this connection is the angled nose at the end of
the male fitting. The nose mates with a similar surface in the female 37-degree flare fitting.
These sealing surfaces must be free of nicks and scratches to seal properly.

2-40
 TM 5-2420-224-34

3. O-Ring (Preformed Packing) Boss. The boss connection has a straight thread. The seal for this
connection has a preformed packing that fits on top of the thread. This packing is squeezed
into the extra space at the top of the female thread and seals the connection.

4. Flareless. This fitting has a straight thread. The female fitting contains a ferrule that mates with
a cavity in the male fitting. Use care not to overtighten to avoid damage to the ferrule.

5. Installation of Preformed Packings.

a. Before installing a new packing, inspect threads and packing seat for nicks, cracks, and
distortion.

b. Make sure the packing is correct type and size. If not sure, check Repair Parts and
Special Tools List (TM5-2420-224-24P).

c. Before installing a new packing, apply coat of lubricating oil to packing (Appendix B,
Item 30).

d. When installing a packing, always protect it from cuts or nicks. Do not install packing
directly over threads. If available, install packing over a plastic or rubber thread guard
supplied with new fittings. if no thread guard is available, protect packing by wrapping
fitting threads with heavy, smooth, lint-free paper or tape.

e. If a backup washer is used with the packing, it must be free of cuts, nicks, and
distortion. An unserviceable backup washer can cause packing to distort or rupture when
hydraulic pressure is applied, resulting in a leak.

f. Always make sure packing is not damaged, twisted, or distorted after installation.

6. Installation of Adjustable Fittings.

a. Apply coat of lubricating oil (Appendix B, Item 30) to new packing.

2-41
TM 5-2420-224-34

GENERAL REPAIR METHODS (CONT)

CAUTION
Packing must be located fully in groove and not on threads.

b. Using suitable thread guard, install packing (1) and backup washer (2) in groove.

c. Turn lock nut (3) down until lock nut just contacts backup washer (2).

d. Install fitting (4) in boss (5) until backup washer (2) makes contact with boss.

e. Position fitting (4) in desired position by backing fitting out up to one full turn. Hold fitting
(4) in desired position and tighten lock nut (3).

2-42
 TM 5-2420-224-34

CHAPTER 3
POWER PACKAGE MAINTENANCE

OVERVIEW
This chapter illustrates and describes procedures for maintenance of the power package. A list of
sections contained in this chapter is shown below.

Page

Section I. Engine Assembly and Related Parts. . . . . . . . . . . . . . . . . . . . . . . 3-1

Section Il. Clutch and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Section Ill. Transmission and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Section lV. Propeller Shafts and Related Parts . . . . . . . . . . . . . . . . . . . . . . . . 3-102

Section 1. ENGINE ASSEMBLY AND RELATED PARTS

This section illustrates and describes procedures for maintenance of the engine and related parts. A list
of tasks contained in this section is shown below.

Page

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Engine Oil Fitter Replacement and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Exhaust Manifold Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Push Rod Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Oil Cooler and Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Air Compressor Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Fuel injector Nozzle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Fuel injection Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Fuel injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Timing Gear Cover, Gears, and Case Replacement . . . . . . . . . . . . . . . . . . . . . 3-56

3-1
TM 5-2420-224-34

ENGINE REPLACEMENT
This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

TOOI Kit, SC 5180-90-CL-N26
Shop Equipment, SC 4910-95-CL-A63 LO 5-2420-224-12 Engine Oil Drained

Materiais/Parts: TM 5-2420-224-20 Cooling System Drained

TM 5-2420-224-20 Batteries Disconnected
Gasket
Nut (3) TM 5-2420-224-20 Cab Tilted

Washer, Lock TM 5-2420-224-20 Oil Pressure Sender

Removed
Washer, Lock
TM 5-2420-224-20 Engine Temperature
Washer, Lock Switch Removed

Washer, Lock TM 5-2420-224-20 Alternator Removed

Seal (2) TM 5-2420-224-20 Polarity Breaker

Removed
Washer, Lock
TM 5-2420-224-20 Suppressor Filters
Seal (2) Removed
Seal (2) TM 5-2420-224-20 Water Temperature
Sending Unit Removed
Seal (2)
TM 5-2420-224-20 Heater Hoses and
Strap, Tiedown (5) Clamps Removed
Seal Fan Impeller Removed
TM 5-2420-224-20
Nut, Lock (4) Power Steering Pump
Page 7-14
Washer, Lock (2) and Bracket Removed

Washer, Lock (2)

Washer, Lock (9)

Personnel Required: (2)

References:
LO 5-2420-224-12
TM 5-2420-224-20

3-2
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

General Safety Instructions:

WARNING
l Engine assembly weighs
1,320 pounds (599 kilograms).
To avoid personal injury, use
a hoist or suitable lifting
device when lifting engine
assembly.

. Support weight of transmission

before separating from engine.
Failure to do so could result in
serious personal injury.

REMOVAL

1. DISCONNECT exhaust PIPE (1) from manifold

(2) by removing three screws (3), three nuts
(4), and gasket (5). DISCARD GASKET and
NUTS.

NOTE
Tag all lines, leads, and attaching
hardware prior to removal to aid in
installation.

2. REMOVE nut (6), lock washer (7), and two

WIRES (8 and 9) from starter solenoid (10).
DISCARD lock WASHER.

3. REMOVE screw (11), washer (12), and

CLAMP (13) from starter (14).

3-3
TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

4. REMOVE nut (15), lock washer (16), and

WIRE (17) from starter solenoid (10).
DISCARD lock WASHER.

5. REMOVE screw (18), lock washer (19), and

two WIRES (20 and 21). DISCARD lock
WASHER.

6. REMOVE nut (22), two wires (23 and 24),

and ground STRAP (25).

7. REMOVE NUT (26) and lock washer (27) and

SET CLAMP (28) aside. DISCARD lock
WASHER.

8. LOOSEN NUT (29) and DISCONNECT HOSE

(30).

9. REMOVE SCREW (31) and washer (32) and

SET BRACKET (33) aside.

10. INSTALL washer (32) and SCREW (31).

3-4
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

11. REMOVE screw (34), two seals (35), and

CONNECTOR (36) from power steering oil
tank (37). DISCARD SEALS.

12. REMOVE two nuts (38 and 39) and two

SCREWS (40 and 41) and MOVE power
steering oil TANK (37) out of the way.

13. REMOVE SCREW (42), nut (43), and lock

washer (44) and SEPARATE two CLAMPS
(45 and 46). DISCARD lock WASHER.

14. TEMPORARILY INSTALL SCREW (42), nut

(43), and new lock washer (44). DO NOT
TIGHTEN NUT (43).

15. REMOVE screw (47) and CLAMP (48).

3-5
TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

16. DISCONNECT breather TUBE (49) from hourmeter (50).

17. REMOVE screw (51), UNION (52), and two seals (53 and 54). DISCARD SEALS.

3-6
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

18. REMOVE screw (55), two seals (56 and 57), and UNION (58). DISCARD SEALS.

19. REMOVE screw (59), two seals (60 and 61), and CONNECTOR (62). DISCARD SEALS.

20. DISCONNECT two PLUGS (63 and 64).

21. REMOVE and DISCARD tiedown STRAPS (65).

22. DISCONNECT air compressor outlet TUBE (66) and REMOVE SEAL (67). DISCARD SEAL.

3-7
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

NOTE
Repeat step 23 for both sides of
engine.

23. REMOVE lock nut (66), BOLT (69), lock nut

(70), and BOLT (71). DISCARD lock NUTS.

NOTE
Attach lifting device to engine from
right side of vehicle.

24. ATTACH suitable lifting DEVICE to sling

points and LIFT ENGINE (72) 2.0-2.5 in.
(50-60 mm).

3-8
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

NOTE
Some vehicles may have two nuts
and two studs, instead of two
bolts.

25. REMOVE two BOLTS (73) and two lock

washers (74) from underside of engine and
transmission. DISCARD lock WASHERS.

26. REMOVE two NUTS (75) and two lock

washers (76). DISCARD lock WASHERS.

27. REMOVE nine bolts (77), nine lock washers

(78), and three BRACKETS (79, 80, and 81).
DISCARD lock WASHERS.

3-9
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

28. USING suitable lifting DEVICE, LIFT SLIGHTLY and SUPPORT front of TRANSMISSION (82) from
underneath.

CAUTION
. Make sure engine clears transmission shaft before lifting from vehicle to
prevent damage to equipment.

. Make sure engine has sufficient clearance to avoid contact with cab or
surrounding components to prevent damage to equipment.

NOTE
Always remove and install engine from right side of vehicle.

29. MOVE ENGINE (72) FORWARD to clear studs and transmission (82) and REMOVE ENGINE (72) from
vehicle.

30. REMOVE AIR CYLINDER (TM 5-2420-224-20).

31. REMOVE COOLANT EXPANSION TANK (TM 5-2420-224-20).

32. REMOVE STE/lCE-R FUEL PRESSURE SWITCH (TM 5-2420-224-20).

33. REMOVE CLUTCH (page 3-83).

3-10
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

INSTALLATION

1. INSPECT clutch release BEARING and REPLACE IF REQUIRED. REFER TO CLUTCH RELEASE
LEVER AND SHAFT REPLACEMENT (page 3-66).

2. INSTALL CLUTCH (page 3-63).

3. INSTALL AIR CYLINDER (TM 5-2420-224-20).

4. INSTALL COOLANT EXPANSION TANK (TM 5-2420-224-20).

5. INSTALL STE/iCE-R FUEL PRESSURE SWITCH (TM 5-2420-224-20).

CAUTION
Make sure engine clears transmission shaft during installation to prevent
damage to equipment.

NOTE
Always remove and install engine from right side of vehicle.

6. USING suitable lifting DEVICE, ALINE STUDS on engine (1) to transmission (2) and INSTALL.

3-11
TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

NOTE
Leave engine 2.0-2.5 in. (50-60
mm) off front mounts to allow
clearance for installation of engine
to transmission.

7. INSTALL nine bolts (3), nine new lock

washers (4), and three BRACKETS (5, 6, and
7).

8. INSTALL two NUTS (8) and two new lock

washers (9).

NOTE
Some vehicles may have two nuts
and two studs, instead of two
bolts.

9. INSTALL two BOLTS (10) and two new lock

washers (11) to underside of engine and
transmission. TIGHTEN 11 BOLTS (3 and 10)
and 2 NUTS (8) to 31 Ib-ft (42 N.m).

10. REMOVE SUPPORT from under transmission.

11. LOWER ENGINE onto mounts and INSTALL

two BOLTS (12) and two new lock nuts (13).

12. INSTALL power steering oil TANK (14), two

nuts (15), and two screws (16).

13. REMOVE lifting DEVICE and TIGHTEN four

NUTS (13 and 15) to 104 ±15 Ib-ft (140 ±20
N.m).

3-12
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

14. INSTALL new SEAL (17) and CONNECT air compressor outlet TUBE (18).

15. CONNECT two PLUGS (19 and 20).

16. INSTALL screw (21), two new seals (22 and 23), and CONNECTOR (24).

17. INSTALL screw (25), two new seals (26 and 27), and UNION (28).

18. INSTALL new tiedown STRAPS (29).

19. INSTALL screw (30), UNION (31), and two new seals (32 and 33).

3-13
TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

20. CONNECT breather TUBE (34) to hounmeter

(35).

21. INSTALL CLAMP (36) on breather tube (34).

22. INSTALL CLAMP (36) and screw (37) on

water outlet (38).

23. REMOVE SCREW (39), nut (40), and lock

washer (41).

24. JOIN two CLAMPS (42 and 43) together and

INSTALL SCREW (39), nut (40), and lock
washer (41).

25. INSTALL screw (44), two new seals (45), and

CONNECTOR (46).

26. INSTALL POLARITY BREAKER (TM 5-

2420-224-20).

27. INSTALL two SUPPRESSOR FILTERS (TM 5-

2420-224-20).

28. INSTALL ALTERNATOR (TM 5-2420-224-20).

3-14
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

29. CONNECT HOSE (47) and TIGHTEN NUT

(48).

30. INSTALL CLAMP (49), nut (50), and new lock

washer (51).

31. INSTALL ground STRAP (52), two wires (53

and 54), and nut (55).

32. INSTALL two WIRES (56 and 57), screw (58),

and new lock washer (59).

33. INSTALL WIRE (60) to starter solenoid (61)

and INSTALL NUT (62) and new lock washer
(63).

34. REMOVE SCREW (64) and washer (65).

35. INSTALL BRACKET (66), washer (65), and

screw (64).

3-15
TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

36. INSTALL CLAMP (67) to starter (68) and

INSTALL SCREW (69) and washer (70).

37. INSTALL two WIRES (71 and 72) to starter

solenoid (61) and INSTALL NUT (73) and
new lock washer (74).

NOTE
Long screw is installed on engine
side of exhaust pipe.

38. CONNECT exhaust PIPE (75) to manifold (76)

and INSTALL three SCREWS (77), three new
nuts (78), and new gasket (79). TIGHTEN
NUTS to 34 Ib-ft (45 N.m).

3-16
 TM 5-2420-224-34

ENGINE REPLACEMENT (CONT)

NOTE
Follow-on Maintenance:
Install power steering pump and bracket without follow-on tasks (page 7-14).
Install front rent hydraulic pump belt (TM 5-2420-224-20).
Install fan impeller (TM 5-2420-224-20).
Install heater hoses and clamps without follow-on tasks (TM 5-2420-224-20).
Install water temperature sending unit without follow-on tasks (TM 5-2420-224-20).
Install engine temperature switch (TM 5-2420-224-20).
Install oil pressure sender (TM 5-2420-224-20).
Adjust clutch slave cylinder (TM 5-2420-224-20).
Service cooling system (TM 5-2420-224-20).
Service engine (LO 5-2420-224-12).
Bleed fuel system (TM 5-2420-224-20).
Lower cab (TM 5-2420-224-20).

3-17
TM 5-2420-224-34

ENGINE MOUNT REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Page 7-14 Power Steering Pump
Materials/Parts: Removed

Nut, Lock (4) TM 5-2420-224-20 Front Hydraulic Pump

Removed
Washer, Lock (2)
General Safety Instructions:
Personnel Required: (2)

References: WARNING
TM 5-2420-224-20 Engine assembly weighs 1,320
pounds (599 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting engine assembly.

REMOVAL

1. REMOVE four lock nuts (1) and four

CAPSCREWS (2). DISCARD lock NUTS.

3-18
 TM 5-2420-224-34

ENGINE MOUNT REPLACEMENT (CONT)

2. REMOVE two headed pins (3), two lock

washers (4), and two SPACERS (5).
DISCARD lock WASHERS.

3. RAISE ENGINE assembly (6) 2 in. (50.8 mm)

and REMOVE engine SUPPORT (7).

4. REMOVE MOUNT (8) from engine support

(7).

INSTALLATION

1. INSTALL MOUNT (8) in engine support (7).

2. INSTALL engine SUPPORT (7) and LOWER

ENGINE assembly (6).

3. INSTALL two SPACERS (5), two new lock

washers (4), and two headed pins (3).

4. INSTALL four CAPSCREWS (2) and four new

lock nuts (1).

NOTE
Follow-on Maintenance:
Install front hydraulic pump
(TM 5-2420-224-20).
Install power steering pump (page
7-14).

3-19
TM 5-2420-224-34

ENGINE OIL FILTER REPLACEMENT AND REPAIR

This task covers: a. Removal b. Disassembly c. Inspection d. Assembly e. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Engine Oil Filter Element
Materials/Parts: Removed

Packing (2) Page 3-18 Engine Mount Removed

Gasket General Safety:

Seal
Seal WARNING
Fuel and oil are slippery and
Seal (2) can cause falls. To avoid
Seal (2) injury, wipe up spilled fuel or
oil with rags.
Rags Appendix B, Item 40

References:
TM 5-2420-224-20

REMOVAL

1. REMOVE BOLT (1) and two packings (2).

DISCARD PACKINGS.

NOTE
Have container available to catch
oil that may spill while removing
filter assembly.

2. REMOVE screw (3), two bolts (4 and 5),

COVER (6), and gasket (7). DISCARD
GASKET.

3-20
 TM 5-2420-224-34

ENGINE OIL FILTER REPLACEMENT AND REPAIR (CONT)

DISASSEMBLY

1. REMOVE PLUG (1) and seal (2). DISCARD SEAL.

2. REMOVE plug (3), seal (4), spring (5), and valve DISC (6). DISCARD SEAL.

3. REMOVE two PLUGS (7) and two seals (8). DISCARD SEALS.

4. REMOVE two PLUGS (9) and two seals (10). DISCARD SEALS.

Measure length of spring. Replace spring if length is less than or exceeds 2.6 in. (66 mm).

1. INSTALL two PLUGS (9) and two new seals (10).

2. INSTALL two PLUGS (7) and two new seals (8).

3. INSTALL valve DISC (6), spring (5), new seal (4), and plug (3).

4. INSTALL PLUG (1) and new seal (2).

3-21
TM 5-2420-224-34

ENGINE OIL FILTER REPLACEMENT AND REPAIR (CONT)

CAUTION
Make sure all gasket material
has been removed from mating
surfaces to prevent damage to
equipment.

1. INSTALL new gasket (1), screw (2), two bolts

(3 and 4), and COVER (5). TIGHTEN
SCREW and BOLTS to 44 Ib-ft (60 N.m).

2. INSTALL BOLT (6) and two new packings (7).

NOTE
Follow-on Maintenance:
Install engine oil filter element (TM 5-
2420-224-20).
Install engine mount (page 3-18).

3-22
 TM 5-2420-224-34

EXHAUST MANIFOLD REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TOOI Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Cab Tilted
Materials/Parts:
General Safety Instructions:
Washer, Spring
Tension (2)
Washer, Spring WARNING
Tension BURN HAZARD
Nut (3) Allow engine to cool before
performing maintenance on the
Gasket muffler, exhaust pipe, exhaust
manifold, or turbocharger. If
Gasket (2)
necessary, use insulated pads
References: and gloves.

TM 5-2420-224-20

REMOVAL

1. REMOVE two BOLTS (1) and two spring

tension washers (2) from screening plate (3).
DISCARD spring tension WASHERS.

2. REMOVE screw (4), nut (5), spring tension

washer (6), spacer (7), and screening PLATE
(3). DISCARD spring tension WASHER.

NOTE
Tag screws prior to removal to aid
in installation.

3. REMOVE three SCREWS (8) and three nuts

(9). DISCARD NUTS.

4. REMOVE and DISCARD GASKET (10).

3-23
TM 5-2420-224-34

EXHAUST MANIFOLD REPLACEMENT (CONT)

5. REMOVE two screws (11), three bolts (12),

bolt (13), two BRACKETS (14), clamp (15),
and rear suspension EYE (16).

6. REMOVE two nuts (17), two straps (18), and

exhaust MANIFOLD (19).

REMOVE and DISCARD two GASKETS (20).

INSTALLATION

CAUTION
Make sure all gasket material
has been removed from mating
surfaces to prevent damage to
equipment.

1. INSTALL two new gaskets (1) and exhaust

MANIFOLD (2). INSTALL two STRAPS (3)
and two nuts (4).

2. INSTALL BRACKET (5) and two screws (6).

3. INSTALL BRACKET (7), rear suspension EYE

(8), and two bolts (9 and 10).

4. INSTALL CLAMP (11) and two bolts (12).

5. TIGHTEN two SCREWS (6) and four BOLTS

(9, 10, and 12) to 22 Ib-ft (30 N.m).

6. INSTALL new GASKET (13), three screws

(14), and three new nuts (15).

7. TIGHTEN three NUTS (15) to 34 Ib-ft (45

N.m).

8. INSTALL screening PLATE (16), two screws

(17), and two new spring tension washers
(18).

9. INSTALL screw (19), SPACER (20), new

spring tension washer (21 ), and nut (22).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

3-24
 TM 5-2420-224-34

CYLINDER HEAD REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Socket, P/N FRXM17 TM 5-2420-224-20 Valve Cover and Gasket
Wrench, P/N 000 589 07 03 00 Removed

Materials/Parts: TM 5-2420-224-20 Fuel Filter Assembly

Removed
TM 5-2420-224-20 Water Manifold and
Oil, Lubricating Appendix B, Item 30 Gasket Removed

References: TM 5-2420-224-20 STE/iCE-R Tachometer

Drive and Cable
TM 5-2420-224-20 Removed

Page 3-23 Exhaust Manifold

Removed

REMOVAL

NOTE
Tag lines prior to disconnecting to aid in connecting.

1. USING WRENCH, LOOSEN six CAPNUTS and DISCONNECT six fuel TUBES (1) from fuel pump (2).

3-25
TM 5-2420-224-34

CYLINDER HEAD REPLACEMENT (CONT)

NOTE
Remove rocker arm assemblies one at a time.

2. REMOVE four bolts (3), two bolts (4), two springs (5), two nipples (6), and rocker ARM assemblies (7
and 8).

NOTE
Tag push rods prior to removal to aid in installation.

3. REMOVE 12 push RODS (9).

4. REMOVE 23 BOLTS (10) and 2 BOLTS (11) from cylinder head (12).

5. REMOVE cylinder HEAD (12) and gasket (13). DISCARD GASKET.

3-26
 TM 5-2420-224-34

CYLINDER HEAD REPLACEMENT (CONT)

INSTALLATION

CAUTION
Make sure all gasket material
has been removed from mating
surfaces to prevent damage to
equipment.

1. INSTALL new GASKET (1) with word TOP or

“OBEN” UP.

2. MEASURE length of 23 BOLTS (2). Maximum

allowable length is 4.41 in. (112 mm).
REPLACE any BOLT(S) (2) that exceed
maximum length.

3. APPLY light COAT of LUBRICATING OIL to

THREADS of 23 bolts (2) and 2 BOLTS (3).

4. INSTALL cylinder HEAD (4), 23 bolts (2), and

2 bolts (3).

NOTE
Each tightening sequence must be
completed before performing next
step.

5. USING SEQUENCE shown, TIGHTEN 25

BOLTS (2 and 3) to following values:
Step a: 44 Ib-ft (60 N.m)
Step b: 66 Ib-ft (90 N.m)
Step c: 81 Ib-ft (110 N.m)

6. INSTALL 12 push RODS (5).

7. INSTALL rocker ARM assembly (6), two bolts

(7), and bolt (8).

NOTE
M a k e s u r e l a r g e e n d o f nipple
assembly is facing rear of engine.

8. INSTALL spring (9), two nipples (10),

(11 ), rocker ARM assembly - (12); two bolts
(13), and bolt (14). TIGHTEN BOLTS (7, 8,
13 and 14) to 74 Ib-ft (100 N.m).

3-27
TM 5-2420-224-34

CYLINDER HEAD REPLACEMENT (CONT)

9. USING SOCKET, CONNECT six fuel TUBES

(15) to fuel pump (16). TIGHTEN six
CAPNUTS to 18 Ib-ft (25 N.m).

10. AFTER DRIVING 300-900 miles

(500-1500 km), RETIGHTEN cylinder head
BOLTS.

NOTE
Follow-on Maintenance:
Install exhaust manifold (page
3-23).
Install water manifold and gasket
(TM 5-2420-224-20).
Install fuel filter assembly
(TM 5-2420-224-20).
Install STE/lCE-R tachometer drive
and cable (TM 5-2420-224-20).
Adjust valves (TM 5-2420-224-20).
Install valve cover and gasket (TM 5-
2420-224-20).

3-28
 TM 5-2420-224-34

PUSH ROD COVER REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP
Tools and Special Equipment References:
Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Equipment Condition:
MateriaIs/Parts:
Reference Condition Description
Seal
TM 5-2420-224-20 Cab Tilted

REMOVAL
1. REMOVE screw (1), nut (2), and BRACKET (3).

2. REMOVE screw (4) and tachometer DRIVE (5).

3. REMOVE four screws (6), push rod COVER (7), and seal (8). DISCARD SEAL.

1. INSTALL new seal (8), push rod COVER (7), and four screws (6). TIGHTEN SCREWS to 32 Ib-ft
(43 N.m).

2. INSTALL tachometer DRIVE (5) and screw (4).

3. INSTALL BRACKET (3), nut (2), and screw (1).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

3-29
TM 5-2420-224-34

OIL COOLER AND GASKET REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
LO 5-2420-224-12 Oil Drained
Materials/Parts:
TM 5-2420-224-20 Coolant Drained
Washer, Spring
Tension (3) TM 5-2420-224-20 Starter Removed
TM 5-2420-224-20 Oil Pressure Sender
Seal
Removed
Packing
TM 5-2420-224-20 Alternator Removed
Kit, Parts
TM 5-2420-224-20 Power Steering Tank
References: (Reservoir) Removed
TM 5-2420-224-20 Polarity Breaker Removed
LO 5-2420-224-12
TM 5-2420-224-20 TM 5-2420-224-20 Suppressor Filters
Removed

TM 5-2420-224-20 Engine Temperature

Switch Removed

3-30
 TM 5-2420-224-34

OIL COOLER AND GASKET REPLACEMENT (CONT)

REMOVAL

1. REMOVE three screws (1), three spring tension washers (2), and alternator BRACKET (3). DISCARD
spring tension WASHERS.

2. REMOVE remaining 28 outer screws (4), oil cooler COVER (5), and gasket (6). DISCARD GASKET.

3. REMOVE 16 inner screws (7), 16 metal seals (8), and four GASKETS (9). DISCARD SEALS and
GASKETS.

4. REMOVE oil cooler COVER (5) from cooler (10) and REMOVE GASKET (11). DISCARD GASKET.

5. REMOVE plug (12), packing (13), spring (14), and VALVE (15). DISCARD PACKING.

6. REMOVE PLUG (16) and seal (17). DISCARD SEAL.

3-31
TM 5-2420-224-34

OIL COOLER AND GASKET REPLACEMENT (CONT)

INSTALLATION

1. INSTALL PLUG (1) and new seal (2).

2. INSTALL VALVE (3), spring (4), new packing (5), and plug (6).

CAUTION
Make sure all gasket material has been removed from mating surfaces to
prevent damage to equipment.

3. INSTALL oil cooler COVER (7) and new gasket (8) on cooler (9) and INSTALL 12 inner SCREWS (10)
and 12 new metal seals (11). TIGHTEN SCREWS to 24 Ib-ft (35 N.m) using tightening sequence
shown.

3-32
 TM 5-2420-224-34

OIL COOLER AND GASKET REPLACEMENT (CONT)

4. INSTALL alternator BRACKET (12), three

screws (13), and three new spring tension
washers (14).

5. INSTALL ENGINE TEMPERATURE SWITCH

(15) (TM 5-2420-224-20) and screw (16).

6. INSTALL oil cooler COVER (7), new gasket

(17), four new gaskets (18), four new metal
seals (19), and 4 screws (20).

7. INSTALL 27 outer SCREWS (21).

a. TIGHTEN SCREWS (13, 16, 20, and 21) to

24 lb-ft (35 N•m) using tightening sequence
shown.

NOTE
Follow-on Maintenance:
Install suppressor filters (TM 5-2420-
224-20).
Install polarity breaker (TM 5-
2420-224-20).
Install power steering tank
(reservoir) (TM 5-2420-224-20).
Install alternator (TM 5-2420-224-
20).
Install oil pressure sender (TM 5-
2420-224-20).
Install starter (TM 5-2420-224-20).
Fill with coolant (TM 5-2420-224-
20).
Fill with oil (LO 5-2420-224-12).

3-33
TM 5-2420-224-34

AIR COMPRESSOR REPLACEMENT AND REPAIR

This task covers: a. Removal b. Disassembly c. Cleaning d. Inspection e. Assembly
f. Installation

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20

TooI Kit, SC 5180-90-CL-N26
Shop Equipment, SC 4910-95-CL-A63 Equipment Condition:
Wrench, P/N 352 589 03 07 00
Reference Condition Description
Materials/Parts:
TM 5-2420-224-20 Air System Supply Lines
Set, Bearing and Fittings Disconnected

Kit, Paris TM 5-2420-224-20 Right Front Fender and

Splash Guard Removed
Kit, Parts
Compound, Sealing Appendix B, Item 16

1. REMOVE four screws (1), cylinder HEAD (2),

and gasket (3). DISCARD GASKET.

2. REMOVE cylinder LINER (4).

3-34
 TM 5-2420-224-34

AIR COMPRESSOR REPLACEMENT AND REPAIR (CONT)

3. REMOVE two nuts (5) and both parts of

connecting ROD (6).

1. REMOVE nut (1), gasket (2), and pressure

VALVE (3). DISCARD GASKET and pressure
VALVE.

2. USING WRENCH, REMOVE and DISCARD

suction VALVE (4).

3. REMOVE and DISCARD bearing SET (5).

4. REMOVE and DISCARD three RINGS (6).

5. REMOVE two retaining rings (7), pin (8), and

PISTON (9) from connecting rod (10).

6. IF DAMAGED, REMOVE BUSHING (11) from

connecting rod (10).

7. IF DAMAGED, REMOVE two BOLTS (12)

from end cap (13).

During cleaning of piston, make sure all carbon

deposits are removed from ring grooves.

3-35
TM 5-2420-224-34

AIR COMPRESSOR REPLACEMENT AND REPAIR (CONT)

1. Measure diameter of camshaft journal to Camshaft Journal

determine bearing set to be installed. (Refer
to table.) If journal measurement is between Bearing
Camshaft
repair stages, use repair stage closest to
measurement. Repair Journal Set
Stage In. In.
Example: (mm)
repair stage I = 1.256 in. (31.902 mm) (mm)
repair stage II = 1.250 in. (31.750 mm)
Standard 1.259-1.260 1.260
journal
measurement = 1.254 in. (31.851 mm) (31.984-32.000) (32.000)

Use repair stage I Standard I 1.255-1.256 1.256

(31.884-31.900) (31.900)
If journal measurement is less than 1.230 in.
Stage I 1.249-1.250 1.250
(31 .234 mm), replace camshaft.
(31.734-31 .750) (31.750)
2. Inspect cylinder liner for scratches, gouges, Stage II 1.239-1.240 1.240
pitting, and nicks. Replace cylinder liner if any (31.484-31 .500) (31.500)
of these defects are present.
Stage Ill 1.229-1.230 1.230
3. Measure cylinder liner bore twice (in line with (31.234-31 .250) (31.250)
camshaft journal, and at 90 degrees to
camshaft journal) at three different places
along liner. If cylinder bore deviation is more
than 0.0012 in. (0.030 mm), replace cylinder
liner.

4. Measure inside diameter of bushing. If

diameter is more than 0.6312-0.6318 in.
(16.022-1 6.038 mm), replace bushing.

5. Inspect piston for damage. Replace If

damaged.

6. Check end gap of each ring by inserting

squarely into cylinder and measuring with
feeler gage. Gap should be 0.016-0.026 in.
(0.406-0.660 mm).

7. Check piston ring side clearance with new

rings installed. Ring side clearance should be
0.0004-0.0018 in. (0.010-0.045 mm). If side
clearance is not within this measurement,
replace piston.

3-36
 TM 5-2420-224-34

AIR COMPRESSOR REPLACEMENT AND REPAIR (CONT)

1. IF REMOVED, INSTALL new BUSHING (1) in

connecting rod (2).

2. INSTALL PISTON (3), pin (4), and two

retaining rings (5) on connecting rod (2).

3. STARTING from BOTTOM of piston (3),

INSTALL three new RINGS (6) so that
openings are offset and above centerline of
piston, as shown.

NOTE
Bearing half with groove is
installed in end cap.

4. INSTALL new bearing SET (7) in end cap (8)

and connecting rod (2).

NOTE
Make sure flat sides of bolts are
toward center of end cap.

5. IF REMOVED, INSTALL two new BOLTS (9)

in end cap (8).

3-37
TM 5-2420-224-34

AIR COMPRESSOR REPLACEMENT AND REPAIR (CONT)

6. USING WRENCH, INSTALL new suction

VALVE (10) in cylinder head (11). TIGHTEN
VALVE to 133 ±15 Ib-ft (180 ±20 N•m).

7. INSTALL new pressure VALVE (12), new

gasket (13), and nut (14). TIGHTEN NUT to
7 ±1 Ib-ft (10 ±1 N•m).

CAUTION
Flat side of each bolt must be
facing center of bottom portion
of connecting rod to prevent
damage to equipment.

1. INSTALL bottom portion of connecting ROD

(1) on camshaft (2).

2. INSTALL upper portion of connecting ROD (3)

and two nuts (4). TIGHTEN NUTS to
11-15 Ib-ft (15-20 N•m).

3-38
 TM 5-2420-224-34

AIR COMPRESSOR REPLACEMENT AND REPAIR (CONT)

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

3. APPLY light COAT of SEALING COMPOUND

on cylinder BLOCK (5).

4. USING ring COMPRESSOR, INSTALL cylinder

LINER (6).

5. TO DETERMINE gasket THICKNESS,

MEASURE DISTANCE A between cylinder
LINER (6) and cylinder HEAD (7) with piston
(8) at Top Dead Center.

6. SELECT GASKET from measurement

determined in STEP 5:

Piston Protrusion Above Liner . . . . . . . . . . . . . . . . . . . . . 0.010-0.018 in. (0.25-0.45 mm)

Use Head Gasket Size . . . . . . . . . . . . . . . . . . . . . . . . 0.026-0.032 in. (0.65-0.80 mm)

Piston Protrusion Above Liner . . . . . . . . . . . . . . . . . . . . . 0.018-0.028 in. (0.45-0.70 mm)

Use Head Gasket Size . . . . . . . . . . . . . . . . . . . . . 0.034-0.037 in. (0.85-0.95 mm)

3-39
TM 5-2420-224-34

AIR COMPRESSOR REPLACEMENT AND REPAIR (CONT)

NOTE
If air inlet elbow pipe was
removed from head, connect it
before installing head.

7. INSTALL new gasket (9), cylinder HEAD (7),

and four screws (10). ‘TIGHTEN SCREWS to
26 Ib-ft (35 NŽm).

NOTE
Follow-on Maintenance:
Connect air system supply lines
and fittings (TM 5-2420-224-20).
Install right front fender and
splash guard (TM 5-2420-224-20).

3-40
 TM 5-2420-224-34

FUEL INJECTOR NOZZLE REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

Tools and Special Equipment: References:

Puller, P/N 352 589 00 33 00 TM 5-2420-224-20
Socket, P/N 000 589 75 09 00
Equipment Condition:
Materials/Parts:
Reference Condition Description
Seal
TM 5-2420-224-20 Fuel Injector Lines
Removed

NOTE
Procedure is the same for all
nozzles.

1. USING SOCKET, REMOVE nozzle HOLDER

(1).

2. USING PULLER, REMOVE injector NOZZLE

(2).

3. REMOVE copper SEAL (3) and measure

thickness. DISCARD SEAL.

Test nozzles (page 13-65).

3-41
TM 5-2420-224-34

FUEL INJECTOR NOZZLE REPLACEMENT (CONT)

NOTE
Procedure is the same for all
nozzles.

1. INSTALL new copper SEAL (1) the same

thickness as one removed.

2. INSTALL injector NOZZLE (2).

3. USING SOCKET, INSTALL nozzle HOLDER

(3) and TIGHTEN to 43-50 Ib-ft (60-70 N•m).

NOTE
Follow-on Maintenance:
Install fuel injector lines (TM 5-
2420-224-20).

3-42
 TM 5-2420-224-34

FUEL INJECTION PUMP REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20

TooI Kit, SC 5180-90-CL-N26
Socket, P/N FRXM17 Equipment Condition:
Wrench, P/N 000 589 07 03 00
Reference Condition Description
Materials/Parts:
TM 5-2420-224-20 Cab Tilted
Seal (2)
TM 5-2420-224-20 Accelerator Linkage
Seal (4) Disconnected
Packing (2) Page 3-20 Engine Oil Fitter
Removed
Seal (2)
General Safety instructions:
Gasket
Washer, Spring
Tension WARNING
Diesel fuel is flammable. Do
Key
not perform this procedure near
Seal fire, flame, or sparks. Injury or
death to personnel could result.
Compound, Sealing Appendix B, item 15

1. Disconnect timing gear case VENT (1).

3-43
TM 5-2420-224-34

FUEL INJECTION PUMP REPLACEMENT (CONT)

NOTE
Arrow in timing gear case must
point to mark on fuel injection
pump drive gear, and FB mark
(start of delivery) on timing pointer
must be alined with FB mark on
vibration damper.

2. MOVE No. 1 CYLINDER to start of delivery in

impression stroke.

NOTE
Tag all lines prior to disconnecting
to aid in connecting.

3. USING WRENCH, LOOSEN six CAPNUTS

and DISCONNECT six injection TUBES (2)
from fuel injection pump (3).

4. REMOVE fuel return hose bolt (4), fuel return

HOSE (5), and two seals (6). DISCARD
SEALS.

5. REMOVE three fuel hose bolts (7, 8, and 9),

three fuel HOSES (10, 11, and 12), four seals
(13), and two packings (14). DISCARD
SEALS and PACKINGS.

6. REMOVE oil supply hose bolt (15), oil supply

HOSE (16), and two seals (17). DISCARD
SEALS.

3-44
 TM 5-2420-224-34

FUEL INJECTION PUMP REPLACEMENT (CONT)

7. REMOVE five screws (18), fuel injection

PUMP (3), and gasket (19). DISCARD
GASKET.

8. REMOVE nut (20), spring tension washer

(21), key (22), and GEAR (23). DISCARD
spring tension WASHER and KEY.

9. REMOVE four nuts (24), four washers (25),

pump SUPPORT (26), and seal (27) from fuel
injection pump (3). DISCARD SEAL.

10. IF DAMAGED, REMOVE four STUDS (28)

from pump support (26).

3-45
TM 5-2420-224-34

FUEL INJECTION PUMP REPLACEMENT (CONT)

1. IF REMOVED, INSTALL four new STUDS (1) on pump support (2).

2. INSTALL new seal (3), pump SUPPORT (2), four washers (4), and four nuts (5) on fuel injection pump
(6). TIGHTEN NUTS to 37 Ib-ft (50 N•m).

3. INSTALL GEAR (7), new key (8), new spring tension washer (9), and nut (10). TIGHTEN NUT to 221
Ib-ft (300 N•m).

3-46
 TM 5-2420-224-34

FUEL INJECTION PUMP REPLACEMENT (CONT)

WARNING
Adhesive causes immediate bonding on contact with eyes, skin, or clothing and
also gives off harmful vapors, Wear protective goggles and use in
well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush eyes
with water for 15 minutes and get immediate medical attention.

CAUTION
Make sure all gasket material has been removed from mating surfaces to
prevent damage to equipment.

NOTE
Make sure FB mark on timing pointer is alined with FB mark on vibration damper.

Rotate gear on fuel injection pump so that marked tooth will aline with arrow in
timing gear case, when installed.

4. APPLY COAT of SEALING COMPOUND to THREADS of five screws (11).

5. INSTALL new gasket (12), fuel injection PUMP (6), and five screws (11).

3-47
 TM 5-2420-224-34

FUEL INJECTION PUMP REPLACEMENT (CONT)

CAUTION
During steps 6 thru 8, make sure seals and packings are installed on each side
of banjo fittings. Failure to do so could result in fuel and oil leaks.

6. INSTALL two new seals (13), oil supply HOSE (14), and oil supply hose boll (15).

7. INSTALL four new seals (16), two new packings (17), three fuel HOSES (18, 19, and 20), and three
fuel hose bolts (21, 22, and 23).

8. INSTALL two new seals (24), fuel return HOSE (25), and fuel return hose bolt (26).

3-48
 TM 5-2420-224-34

FUEL INJECTION PUMP REPLACEMENT (CONT)

9. USING SOCKET, CONNECT six injection TUBES (27) on fuel injection pump (6). TIGHTEN six
CAPNUTS to 18 Ib-ft (25 N•m).

10. CONNECT timing gear case VENT (28).

NOTE
Follow-on Maintenance:
Install engine oil filter (page 3-20).
Time fuel injection pump (page 3-50).
Connect accelerator linkage (TM 5-2420-224-20).
Lower cab (TM 5-2420-224-20).

3-49
TM 5-2420-224-34

FUEL INJECTION PUMP TIMING

This task covers: Timing

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TooI Kit, SC 5180-90-CL-N26
Socket, P/N FRXM17 TM 5-2420-224-20 Cab Tilted
Tank, P/N 001 589 65 21 00
Tube, P/N 636 589 02 23 00 TM 5-2420-224-20 Accelerator Linkage
Wrench, P/N 000 589 07 03 00 Disconnected

Materials/Parts: General Safety Instructions:

Fuel, Diesel Appendix B, Item 22

Rags Appendix B, Item 40 WARNING
Diesel fuel is flammable. Do
References: not perform this procedure
TM 5-2420-224-20 near fire, flame, or sparks.
Injury or death to personnel
could result.

Fuel and oil are slippery and

can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

1. Disconnect timing gear case vent (1).

3-50
 TM 5-2420-224-34

FUEL INJECTION PUMP TIMING (CONT)

NOTE
Tag all lines prior to disconnecting
to aid in connecting.

2. Using wrench, loosen capnut and disconnect

No. 1 injection tube (2) from fuel injection
pump (3).

3. Loosen screw (4) and remove rim clamp (5)

from No. 1 cylinder (6) of fuel injection pump
(3).

4. Remove pipe union (7), valve cone (8), spring

(9), and breather (10).

5. Install pipe union (7) in No. 1 cylinder (6) of

fuel injection pump (3).

6. Install tube on No. 1 cylinder (6).

7. Disconnect fuel supply hose (11).

3-51
TM 5-2420-224-34

FUEL INJECTION PUMP TIMING (CONT)

8. Install tank and fill with clean fuel.

NOTE
Arrow in timing gear case must
point to mark on fuel injection
pump drive gear, and FB mark
(start of delivery) on timing pointer
must be alined with FB mark on
vibration damper.

9. Turn crankshaft to right until No. 1 cylinder is

at start of delivery in compression stroke.

NOTE
Have suitable container available
to catch fuel that will drip from
tube.

10. Open isolating cock (12) on tank and loosen

cap to avoid vacuum lock.

11. Set throttle lever (13) in forward position.

NOTE
Monitor fuel flow in step 12 for
3-5 minutes.

12. Monitor flow of fuel at tube. If setting is

correct, fuel will flow at a rate of one drop
every 15-20 seconds.

3-52
 TM 5-2420-224-34

FUEL INJECTION PUMP TIMING (CONT)

13. If fuel is flowing too fast or too slow, loosen

five capnuts using wrench. Disconnect
remaining five injection tubes (14).

14. Loosen four nuts (15) and turn fuel injection

pump (3) either toward engine to slow fuel
flow or away from engine to increase fuel
flow. Continue until fuel flow is correct.

15. Tighten four nuts (15) to 37 Ib-ft (50 N•m).

16. Connect five injection tubes (14) to fuel

injection pump (3). Using socket, tighten five
capnuts to 18 Ib-ft (25 N•m).

17. Remove tank.

3-53
TM 5-2420-224-34

FUEL INJECTION PUMP TIMING (CONT)

18. Connect fuel supply hose (11).

19. Remove tube from No. 1 cylinder (6).

20. Remove pipe union (7).

21. install valve cone (8), spring (9), breather

(10), and pipe union (7).

22. Install rim clamp (5) and tighten screw (4).

23. Install No. 1 injection tube (2). Using socket,

tighten capnut to 18 Ib-ft (25 N•m).

3-54
 TM 5-2420-224-34

FUEL INJECTION PUMP TIMING (CONT)

24. Install timing gear case vent (1).

NOTE
Follow-on Maintenance:
Connect accelerator linkage (TM 5-
2420-224-20).
Bleed fuel system (TM 5-2420-224-
20).
Lower cab (TM 5-2420-224-20).

3-55
TM 5-2420-224-34

TIMING GEAR COVER, GEARS, AND CASE REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
TooI Kit, SC 5180-90-CL-N26
Installing Tool, P/N 352 589 07 15 00 Equipment Condition:
Puller, P/N 355 589 00 33 00
Reference Condition Description
Materials/Parts:
TM 5-2420-224-20 Fan Impeller Removed
Gasket
TM 5-2420-224-20 Counter Engine Revolution
Seal (Hourmeter) Removed
Key TM 5-2420-224-20 Fan Belt Removed
Gasket Page 3-43 Fuel injection Pump
Removed

NOTE
Prior to performing step 1, place
transmission shift control lever in
first gear position.

1. REMOVE bolt (1), PULLEY (2), and bearing

(3) from crankshaft (4).

2. USING PULLER, REMOVE vibration DAMPER

(5).

3-56
 TM 5-2420-224-34

TIMING GEAR COVER, GEARS, AND CASE REPLACEMENT (CONT)

3. REMOVE 13 screws (6), timing pointer (7),

timing gear COVER (8), and gasket (9).
DISCARD GASKET.

4. REMOVE SEAL (10) from timing gear cover

(8). DISCARD SEAL.

5. ROTATE GEARS (11 and 12) until single

mark on crankshaft gear (11) is between the
two marks on camshaft gear (12).

6. REMOVE socket head SCREW (13) from

camshaft (14).

3-57
TM 5-2420-224-34

TIMING GEAR COVER, GEARS, AND CASE REPLACEMENT (CONT)

7. USING PULLER, REMOVE camshaft GEAR

(12) and drive GEAR (15) from camshaft (14).

8. REMOVE washer (16) and woodruff KEY (17)

from camshaft (14). DISCARD woodruff KEY.

9. REMOVE two screws (18 and 19), two pins

(20), and lower part of timing gear CASE
(21).

10. REMOVE four screws (22), thrust washer

(23), three screws (24), upper timing gear
CASE (25), and gasket (26). DISCARD
GASKET.

3-58
 TM 5-2420-224-34

TIMING GEAR COVER, GEARS, AND CASE REPLACEMENT (CONT)

11. INSTALL camshaft GEAR (12) in soft-jawed

VISE and PRY two GEARS (12 and 15)
apart.

12. REMOVE two WEIGHTS (27), two pins (28),

and two springs (29).

1. Inspect gears for wear or damage.

2. Inspect cover for cracks.

1. INSTALL two springs (1), two pins (2), and

two WEIGHTS (3) in camshaft gear (4).

3-59
TM 5-2420-224-34

TIMING GEAR COVER, GEARS, AND CASE REPLACEMENT (CONT)

2. INSTALL drive GEAR (5) on camshaft gear

(4).

3. INSTALL new gasket (6), upper timing gear

CASE (7), three screws (8), thrust washer (9),
and four screws (10).

4. INSTALL lower part of timing gear CASE (11),

two pins (12), and two screws (13 and 14).

5. INSTALL drive GEAR (5) and camshaft GEAR

(4) on camshaft (15) making sure that single
mark on crankshaft gear (16) is between the
two marks on camshaft gear (4).

6. INSTALL WASHER (17) on camshaft (15).

7. INSTALL new woodruff KEY (18) in camshaft

(15).

3-60
 TM 5-2420-224-34

TIMING GEAR COVER, GEARS, AND CASE REPLACEMENT (CONT)

8. INSTALL socket head SCREW (19) in

camshaft (15). TIGHTEN to 221 Ib-ft
(300 NŽm).

9. USING INSTALLING TOOL, INSTALL new

SEAL (20) in timing gear cover (21).

10. INSTALL new gasket (22), timing gear

COVER (21), timing pointer (23), and 13
screws (24). TIGHTEN SCREWS to 71 lb-in.
(800 N•cm).

3-61
TM 5-2420-224-34

TIMING GEAR COVER, GEARS, AND CASE REPLACEMENT (CONT)

NOTE
Prior to performing step 11, place
transmission shift control lever in
first gear position.

11. INSTALL vibration DAMPER (25), pulley (26),

bearing (27), and bolt (28). TIGHTEN BOLT
to 360-400 Ib-ft (500-550 NŽm).

NOTE
Follow-on Maintenance:
Install fan impeller (TM 5-2420-
224-20).
Install fan belt (TM 5-2420-
224-20).
Install counter engine revolution
(hourmeter) (TM 5-2420-224-20).
Install fuel injection pump (page
3-43).

3-62
 TM 5-2420-224-34

Section Il. CLUTCH AND RELATED PARTS

This section illustrates and describes procedures for maintenance of the clutch and related parts. A list
of tasks contained in this section is shown below.

Page

Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Clutch Release Lever and Shaft Replacement and Adjustment . . . . . . . . . . . . . . . 3-66

CLUTCH REPLACEMENT
This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Installing Tool, P/N 406 589 00 61 00 Page 3-2 Engine Removed

Materials/Parts:
Washer, Spring
Tension (8)

1. REMOVE eight screws (1), eight spring

tension washers (2), clutch PLATE (3), and
clutch DISC (4). DISCARD spring tension
WASHERS.

3-63
TM 5-2420-224-34

CLUTCH REPLACEMENT (CONT)

2. USING suitable PULLER, REMOVE BEARING

AND COVER ASSEMBLY (5) from crankshaft
(6).

1. INSTALL BEARING AND COVER ASSEMBLY

(1) in crankshaft (2).

CAUTION
• During installation, make
sure collar on clutch disc is
facing flywheel to prevent
damage to equipment.

• Make sure flywheel and

clutch plate are clean and
free of grease and oil or
damage to clutch will result.

NOTE
Always replace the clutch plate
and clutch disc as a set.

2. USING INSTALLING TOOL, INSTALL clutch

DISC (3).

3-64
 TM 5-2420-224-34

CLUTCH REPLACEMENT (CONT)

3. INSTALL clutch PLATE (4), eight screws (5),

and eight new spring tension washers (6).
TIGHTEN SCREWS to 22 lb-ft (29 N•m).

4. REMOVE INSTALLING TOOL.

NOTE
Follow-on Maintenance:
Install engine (page 3-2).

3-65
TM 5-2420-224-34

CLUTCH RELEASE LEVER AND SHAFT REPLACEMENT AND

ADJUSTMENT
This task covers: a. Removal b. Installation c. Adjustment

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Page 3-2 Engine Removed
Materials/Parts:
Washer, Spring
Tension (2)
Bearing
Oil, Lubricating Appendix B, Item 30

1. DISCONNECT SPRING (1) from clutch lever

(2).

NOTE
Prior to performing step 2,
matchmark clutch lever and shaft
to aid in installation.

2. REMOVE bolt (3) and clutch LEVER (2) from

shaft (4).

3. REMOVE two SCREWS (5) and two spring

tension washers (6) from clutch release lever
(7). DISCARD spring tension WASHERS.

4. REMOVE BEARING (8) and washer (9).

DISCARD BEARING.

NOTE
Prior to performing step 5,
matchmark shaft and clutch
release lever to aid in installation.

5. REMOVE bolt (10), shaft (4), and clutch

release LEVER (7).

3-66
 TM 5-2420-224-34

CLUTCH RELEASE LEVER AND SHAFT REPLACEMENT AND

ADJUSTMENT (CONT)

INSTALLATlON

1. INSTALL clutch release LEVER (7), shaft (4),

and bolt (10) as match marked during
Removal.

2. APPLY COAT of LUBRICATING OIL to

WASHER (9) and INSTALL washer (9) and
new BEARING (8).

3. INSTALL two new spring tension washers (6)

and two SCREWS (5) in clutch release lever
(7).

4. INSTALL clutch LEVER (2) and bolt (3) in

shaft (4) as matchmarked during Removal.

5. CONNECT SPRING (1) to clutch lever (2).

6. INSTALL ENGINE (page 3-2).

ADJUSTMENT

1. Remove spring (1) from clutch slave cylinder

(2) and clutch-lever (3).

2. Loosen lock nut (4).

3. Move clutch lever (3) down until it stops.

4. Insert a measuring device between clutch

lever top surface (5) and bottom surface of
spring bracket (6). Raise clutch lever (3).
Movement of clutch lever must be 1/8 in. (3
±0.5 mm).

5. Turn adjusting pin (7) to adjust clearance.

When proper clearance is obtained, tighten
lock nut (4).

6. Attach spring (1) to clutch slave cylinder (2)

and clutch lever (3).

3-67
TM 5-2420-224-34

Section Ill. TRANSMISSION AND RELATED PARTS

This section illustrates and describes procedures for maintenance of the transmission and related parts.
A list of tasks contained in this section is shown below.
Page

Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68

Power Take-Off (PTO) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79

Power Take-Off (PTO) Control Linkage Replacement and Adjustment . . . . . . . . . . . . 3-81

Transmission Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83

Transmission Top Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

Air Shift Solenoid Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88

Air Shift Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

Transmission Shift Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92

Transmission Shift Controls Replacement . . . . . . . . . . . . . 3-96

Transmission Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

TRANSMISSION REPLACEMENT
This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: Personnel Required: (2)

Shop Equipment, SC 4910-95-CL-A31 References:

Tool Kit, SC 5180-90-CL-N26
Shop Equipment, SC 4910-95-CL-A63 TM 5-2420-224-20
LO 5-2420-224-12
Materials/Parts:
Equipment Condition:
Strap, Tiedown (4)
Reference Condition Description
Packing (3)
TM 5-2420-224-20 Backhoe (SEE) or Crane
Washer, Lock (4) (HMMH) in Three-Point
Seal (2) Stance

Washer, Spring Page 3-2 Engine Removed

Tension (2) TM 5-2420-224-20 Floor Platform Removed
Grease, Molybdenum Appendix B, Item 24
Page 3-96 Transmission Shift
Disulfide
Controls Removed

3-68
 TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

Equipment Condition (Cont): General Safety instructions (Cont):

Reference Condition Description

LO 5-2420-224-12 Transmission Drained WARNING
Ž Do not connect or disconnect
Page 5-1 Front Axle Assembly any electrical connector
Removed (Steps 1 thru unless vehicle MASTER
26 Only) disconnect switch is OFF. To
Page 6-1 Rear Axle Assembly do so could result in injury
Removed (Steps 5, 14, to personnel.
and 18 thru 20 Only)
• Keep all personnel clear
General Safety Instructions: when using lifting device
during removal and
installation of transmission
WARNING assembly. Failure to do so
could result in injury to
• Transmission assembly
personnel.
weighs 638 pounds (290
kilograms). To avoid personal
injury, use a hoist or suitable
lifting device when lifting
transmission assembly.

NOTE
Procedure is the same for both
vehicles.

1. REMOVE and DISCARD tiedown STRAPS (1

and 2).

2. MOVE STE/ICE-R wiring HARNESS (3) aside.

3. REMOVE SCREW (4) and SET BRACKET (5)

aside.

3-69
TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

NOTE
Tag all lines and electrical
connectors prior to disconnecting
to aid in connecting.

4. REMOVE fluid passage BOLT (6) and three

packings (7, 8, and 9) and DISCONNECT two
HOSES (10 and 11). DISCARD PACKINGS.

5. DISCONNECT three electrical CONNECTORS

(12, 13, and 14).

3-70
 TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

6. DISCONNECT electrical CONNECTOR (15)

from Power Take-Off (16).

NOTE
Tag air lines and battery cables
held by clamps prior to removal to
aid in installation.

7. REMOVE nut (17), two CLAMPS (18 and 19),

and screw (20).

8. MOVE two battery CABLES (21 and 22) and

two air HOSES (23 and 24) and SET wiring
HARNESS (25) aside.

9. REMOVE SCREW (26) and SET BRACKET

(27) aside.

10. REMOVE two BOLTS (28) from hydraulic

pump (29) and DISENGAGE PUMP (29) from
PTO (16).

11. REMOVE and DISCARD tiedown STRAPS

(30).

3-71
TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

12. REMOVE four screws (31), four lock washers

(32), four spacers (33), and SPRING (34).
DISCARD lock WASHERS.

13. MOVE clutch slave CYLINDER and MOUNT

(35) aside.

14. REMOVE fluid passage BOLT (36), two seals

(37), and FITTING (38) from intermediate
speed mechanism (39). DISCARD SEALS.

15. REMOVE two nuts (40), two washers (41),

and two SCREWS (42) and LAY pressure
reducing VALVE assembly (43) aside.

3-72
 TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

16. DISCONNECT speedometer CABLE (44) from

transmission (45).

17. ATTACH suitable lifting DEVICE to

transmission (45).

NOTE
Leave four screws (46) in place to
help support transmission during
removal.

18. REMOVE four NUTS (47).

3-73
TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

19. USING suitable lifting DEVICE, REMOVE

TRANSMISSION (45).

20. REMOVE lifting DEVICE.

21. REMOVE screw (48) and BRACKET (49).

INSTALL SCREW (48).

22. REMOVE two capscrews (50), two spring

tension washers (51), and WASHER with
BEARING (52). DISCARD spring tension
WASHERS.

Inspect transmission for damage, missing parts,

and fluid leakage.

NOTE
Procedure is the same for both
vehicles.

1. APPLY COAT of MOLYBDENUM DISULFIDE

GREASE to input SHAFT (1).

2. INSTALL WASHER with BEARING (2), two

new spring tension washers (3), and two
capscrews (4).

3. REMOVE SCREW (5). INSTALL BRACKET

(6) and screw (5).

3-74
 TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

4. ATTACH suitable lifting DEVICE to

transmission (7).

5. USING lifting DEVICE, INSTALL

TRANSMISSION (7) in vehicle and on four
rear mount screws (8).

6. INSTALL four NUTS (9). TIGHTEN NUTS to

192 Ib-ft (260 N•m).

WARNING
Prior to performing step 7,
insert floor jack under front of
transmission. Failure to do so
could result in injury to
personnel and damage to
transmission.

7. REMOVE lifting DEVICE.

8. CONNECT speedometer CABLE (10).

3-75
TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

9. INSTALL pressure reducing VALVE assembly

(11), two screws (12), two washers (13), and
two nuts (14).

10. INSTALL FlTTlNG (15), two new seals (16),

and fluid passage BOLT (17) to intermediate
speed mechanism (18).

11. INSTALL clutch slave CYLINDER and MOUNT

(19), spring (20), four spacers (21), four new
lock washers (22), and four screws (23).

3-76
 TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

12. ALINE SPLINES on hydraulic PUMP (24) and

PTO (25).

13. INSTALL new tiedown STRAPS (26).

14. INSTALL two BOLTS (27).

15. POSITION two battery CABLES (28 and 29),

two air HOSES (30 and 31), and wiring
HARNESS (32) in place.

16. INSTALL screw (33), two CLAMPS (34 and

35), and nut (36).

17. CONNECT electrical CONNECTOR (37).

18. INSTALL BRACKET (38) and screw (39).

19. CONNECT three electrical CONNECTORS

(40, 41, and 42).

3-77
TM 5-2420-224-34

TRANSMISSION REPLACEMENT (CONT)

20. lNSTALL three new packings (43, 44, and 45)

and fluid passage BOLT (46) and CONNECT
two HOSES (47 and 48).

21. POSITION STE/lCE-R wiring HARNESS (49)

in place.

22. INSTALL new tiedown STRAPS (50 and 51).

23. POSITION BRACKET (52) and INSTALL

SCREW (53).

NOTE
Follow-on Maintenance:
Fill transmission with oil (LO 5-2420-
224-12).
Install transmission shift controls
(page 3-96).
Install floor platform (TM 5-2420-
224-20).
Install engine (page 3-2).
Install rear axle (steps 13 thru 20,
page 6-1).
Install front axle (steps 8 thru 35,
page 5-1).
Bleed brake system (TM5-2420-
224-20).

3-78
 TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

TooI Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Cab Tilted
Materials/Parts:
LO 5-2420-224-12 Transmission Fluid
Compound, Sealing Appendix B, Item 16 Drained

References:
TM 5-2420-224-20
LO 5-2420-224-12

1. REMOVE two mounting BOLTS (1) and MOVE rear hydraulic PUMP (2) toward rear of vehicle.

CAUTION
To prevent damage to transmission, do not remove mounting bolt on PTO shaft.

2. REMOVE CLIP (3) from PTO lever arm (4).

3. REMOVE PTO lever ARM (4).
4. REMOVE eight mounting screws (5) and PTO (6).

3-79
TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPLACEMENT (CONT)

WARNING
Adhesive causes immediate bonding on contact with eyes, skin, or clothing
and also gives off harmful vapors. Wear protective goggles and use in
well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush
eyes with water for 15 minutes and get immediate medical attention.

1. APPLY light COAT of SEALING COMPOUND to mounting FLANGE of PTO (1).

2. INSTALL PTO (1) and eight mounting screws (2).

3. INSTALL PTO lever ARM (3) and clip (4).

4. MOVE rear hydraulic PUMP (5) forward and INSTALL two mounting BOLTS (6).

NOTE
Follow-on Maintenance:
Fill transmission fluid (LO 5-2420-224-12).
Lower cab (TM 5-2420-224-20).

3-80
 TM 5-2420-224-34

POWER TAKE-OFF (PTO) CONTROL LINKAGE REPLACEMENT AND

ADJUSTMENT
This task covers: a. Removal b. Installation c. Adjustment

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Packing (2)
TM 5-2420-224-20 Cab Tilted
Packing

1. REMOVE two clips (1), two ball sockets (2),

and control LEVER (3).

2. REMOVE capscrew (4), washer (5), bearing

(6), packing (7), bushing (8), LEVER (9),
packing (10), and washer (11). DISCARD
PACKINGS.

3. REMOVE capscrew (12), control LEVER

assembly (13), and packing (14). DISCARD
PACKINGS.

1. INSTALL new packing (14), control LEVER

assembly (13), and capscrew (12).

2. INSTALL washer (11), new packing (10),

LEVER (9), bushing (8), new packing (7),
bearing (6), washer (5), and capscrew (4).

3. INSTALL control LEVER (3), two ball sockets

(2), and two clips (1).

3-81
TM 5-2420-224-34

POWER TAKE-OFF (PTO) CONTROL LINKAGE REPLACEMENT AND

ADJUSTMENT (CONT)

1. Remove clip from rod end.

2. Lift rod end off ball socket.

3. Loosen lock nut.

4. Turn rod end to increase/decrease length of

rod. Length of rod from ball pivot to center of
ball pivot is 7.5 in. (190 mm).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

3-82
 TM 5-2420-224-34

TRANSMISSION ACCESS COVER REPLACEMENT

This task covers: a. Removal b. Installation

lNlTIAL SETUP

Tools and Special Equipment: General Safety Instructions:

TOOI Kit, SC 5180-90-CL-N26

Materials/Parts: WARNING
Do not disconnect any air
Seal (4)
system lines or fittings
Compound, Sealing Appendix B, Item 16 unless vehicle engine is shut
off and air system pressure
References: is relieved. To do so could
result in injury to personnel.
TM 5-2420-224-20
Do not connect or disconnect
Equipment Condition:
any electrical connector
Reference unless vehicle MASTER
Condition Description
disconnect switch is OFF. To
TM 5-2420-224-20 Floor Platform Removed do so could result in injury
to personnel.
TM 5-2420-224-20 Air Pressure Relieved

1. DISCONNECT electrical CONNECTOR (1)

from switch (2).

NOTE
Tag air lines prior to disconnecting
to aid in connecting.

2. DISCONNECT two air LINES (3 and 4) by

REMOVING two hollow SCREWS (5 and 6)
and four seals (7). DISCARD SEALS.

3. REMOVE SCREW (8) and SET BRACKET (9)

aside.

4. REMOVE SCREW (10) and SET BRACKET

(11) aside.

3-83
TM 5-2420-224-34

TRANSMISSION ACCESS COVER REPLACEMENT (CONT)

5. DISCONNECT SPRING (12) from clutch slave

cylinder (13).

6. REMOVE four SCREWS (14), four washers

(15), and four spacers (16) and SET clutch
slave CYLINDER (13) aside.

7. REMOVE six screws (17) and transmission

access COVER (18).

INSTALLATION

NOTE
Make sure both mating surfaces
are completely clean prior to
applying sealing compound.
While performing step 1, make
sure access cover pin is
engaged with shifting fork in
transmission.

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

1. APPLY COAT of SEALING COMPOUND to

both mating SURFACES and INSTALL
transmission access COVER (1) and six
screws (2).

2. POSITION clutch slave CYLINDER (3) and

INSTALL four spacers (4), four washers (5),
and four SCREWS (6).

3. CONNECT SPRING (7)

. . to clutch slave
cylinder (3).

3-84
 TM 5-2420-224-34

TRANSMISSION ACCESS COVER REPLACEMENT (CONT)

4. POSITION BRACKET (8) and INSTALL

SCREW (9).

5. POSITION BRACKET (10) and INSTALL

SCREW (11).

6. CONNECT two air LINES (12 and 13) by

INSTALLING four new seals (14) and two
hollow SCREWS (15 and 16).

7. CONNECT electrical CONNECTOR (17) to

switch (18).

NOTE
Follow-on Maintenance:
Install floor platform (TM 5-2420-
224-20).

3-85
TM 5-2420-224-34

TRANSMISSION TOP COVER REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Page 3-68 Transmission Removed
Materials/Parts:

Adhesive Appendix B, Item 3

1. REMOVE retaining RING (1) and washer (2) from pin (3).

2. REMOVE clip (4) and CYLINDER (5) from pin (3) and SET CYLINDER (5) aside.

3. REMOVE WASHER (6).

4. REMOVE 12 screws (7) and COVER assembly (8).

3-86
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPLACEMENT (CONT)

lNSTALLATION

WARNING
Adhesive causes immediate bonding on contact with eyes, skin, or clothing
and also gives off harmful vapors. Wear protective goggles and use in
well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush
eyes with water for 15 minutes and get immediate medical attention.

1. APPLY COAT of ADHESIVE to COVER assembly (8) and to THREADS of 12 screws (7) and INSTALL
COVER assembly (8) and 12 screws (7). TIGHTEN SCREWS to 18 Ib-ft (25 N.m).

2. INSTALL washer (6), CYLINDER (5), and clip (4) on pin (3).

3. INSTALL washer (2) and retaining RING (1) on pin (3).

Follow-on Maintenance:
Install transmission (page 3-68).

3-87
TM 5-2420-224-34

AIR SHIFT SOLENOID VALVE REPLACEMENT

This task covers: a. Removal b. Installation

INTIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Tool Kit, SC 5180-90-CL-N26

Materials/Parts: WARNING
Do not disconnect any air
Packing, Preformed (2) system lines or fittings
Washer (2) unless vehicle engine is shut
off and air system pressure
Adapter, Straight Tube is relieved. To do so could
result in injury to personnel.
References:
Do not connect or disconnect
TM 5-2420-224-20
any electrical connector
Equipment Condition: unless vehicle MASTER
disconnect switch is OFF. To
Reference Condition Description do so could result in injury
to personnel.
TM 5-2420-224-20 Cab Tilted
TM 5-2420-224-20 Air Pressure Relieved

1. DISCONNECT electrical CONNECTOR (1) from air shift solenoid valve (2).

NOTE
Tag all air lines prior to disconnecting to aid in connecting.

2. DISCONNECT air LINE (3) from air shift solenoid valve (2).

3. DISCONNECT two air LINES (4 and 5) from air shift solenoid valve (2) by REMOVING two fluid
passage BOLTS (6 and 7), two preformed packings (8), and two washers (9). DISCARD preformed
PACKINGS and WASHERS.

4. REMOVE two screws (10), two washers (11), and air shift solenoid VALVE (2) from mounting bracket
(12).

5. REMOVE straight tube ADAPTER (13) from air shift solenoid valve (2). DISCARD straight tube
ADAPTER.

3-88
 TM 5-2420-224-34

AIR SHIFT SOLENOID VALVE REPLACEMENT (CONT)

1. INSTALL new straight tube ADAPTER (13) in air shift solenoid valve (2).

2. INSTALL air shift solenoid VALVE (2), two washers (11), and two screws (10) on mounting bracket
(12).

3. CONNECT two air LINES (4 and 5) to air shift solenoid valve (2) by INSTALLING two new preformed
packings (8), two new washers (9), and two fluid passage BOLTS (6 and 7).

4. CONNECT air LINE (3) to air shift solenoid valve (2).

5. CONNECT electrical CONNECTOR (1) to air shift solenoid valve (2).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

3-89
TM 5-2420-224-34

AIR SHIFT VALVE REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

TOOI Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts:
Do not disconnect any air
Washer, Lock (2) system lines or fittings unless
vehicle engine is shut off and
Packing, Preformed (7) air system pressure is relieved.
To do so could result in injury
References:
to personnel.
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Cab Tilted
TM 5-2420-224-20 Air Pressure Relieved

1. REMOVE SCREW (1) and lock washer (2) and SET BRACKET (3) aside. DISCARD lock WASHER.

NOTE
Tag all air lines prior to disconnecting to aid in connecting.

2. DISCONNECT three air LINES (4) from air shift valve (5).
3. DISCONNECT air LINE (6) from air shift valve (5) by REMOVING fluid passage BOLT (7) and two
preformed packings (8). DISCARD preformed PACKINGS.
4. DISCONNECT air LINE (9) from air shift valve (5) by REMOVING hollow SCREW (10) and two
preformed packings (11). DISCARD preformed PACKINGS.
5. REMOVE screw (12), lock washer (13), and air shift VALVE (5) from mounting bracket (14). DISCARD
lock WASHER.

6. REMOVE three ADAPTERS (15) and three preformed packings (16) from air shift valve (5). DISCARD
preformed PACKINGS.

3-90
 TM 5-2420-224-34

AIR SHIFT VALVE REPLACEMENT (CONT)

INSTALLATION

1. INSTALL three new preformed packings (16) and three ADAPTERS (15) on air shift valve (5).

2. INSTALL air shift VALVE (5), new lock washer (13), and screw (12) on mounting bracket (14).

3. CONNECT air LINE (9) to air shift valve (5) by INSTALLING two new preformed packings (11) and
hollow SCREW (10).

4. CONNECT air LINE (6) to air shift valve (5) by INSTALLING two new preformed packings (8) and fluid
passage BOLT (7).

5. CONNECT three air LINES (4) to air shift valve (5).

6. POSITION BRACKET (3) and INSTALL new lock washer (2) and SCREW (1).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

3-91
TM 5-2420-224-34

TRANSMISSION SHIFT LINES REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: General Safety InstructIons:

TOOl Kit, SC 5180-90-CL-N26

Materials/Parts: WARNING
Do not disconnect any air
Sleeve, Compression system lines or fittings unless
vehicle engine is shut off and
References: air system pressure is relieved.
TM 5-2420-224-20 To do so could result in injury
to personnel.
Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Cab Tilted
TM 5-2420-224-20 Air Pressure Relieved

NOTE
Procedure is the same for all
three transmission shift lines.
If all three transmission shift
lines are to be disconnected,
tag connectors on bar prior to
disconnecting to aid in
connecting.

1. LOOSEN NUT (1) and DISCONNECT

transmission shift HOSE (2).

2, REMOVE compression SLEEVE (3) and nut

(1). DISCARD compression SLEEVE.

3-92
 TM 5-2420-224-34

TRANSMISSION SHIFT LINES REPLACEMENT (CONT)

3. REMOVE CAP (4), nut (5), and knob (6).

4. REMOVE BELLOWS (7) from floor platform

(8) and SLIDE BELLOWS (7) UP lever (9)
enough to clear hole in lever (9).

5. REMOVE three screws (10) and VALVE (11).

6. REMOVE transmission shift HOSE (2) from

lever (9).

3-93
TM 5-2420-224-34

TRANSMISSION SHIFT LINES REPLACEMENT (CONT)

NOTE
Procedure is the same for all
three transmission shift lines.

1. INSTALL transmission shift HOSE (1)

. . in Iever
(2).

2. INSTALL VALVE (3) and three screws (4).

3. SLIDE BELLOWS (5) DOWN lever (2) and

INSTALL BELLOWS (5) in floor platform (6).

4. INSTALL knob (7), nut (8), and CAP (9).

3-94
 TM 5-2420-224-34

TRANSMISSION SHlFT LINES REPLACEMENT (CONT)

5. INSTALL nut (10) and new compression

SLEEVE (11).

6. CONNECT transmission shift HOSE (1) and

TIGHTEN NUT (11).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

3-95
TM 5-2420-224-34

TRANSMISSION SHIFT CONTROLS REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INTIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TOOl Kit, SC 5180-90-CL-N26
Page 3-92 Transmission Shift Lines
References: Removed
TM 5-2420-224-20 TM 5-2420-224-20 Floor Platform Removed

1. LOOSEN CLAMP (1), PULL UP BELLOWS

(2), and ROTATE COVER (3) to left to
unlock.

2. REMOVE main shift LEVER (4).

3. LOOSEN CLAMP (5), PULL UP BELLOWS

(6), and ROTATE COVER (7) to left to
unlock.

4. REMOVE group selector LEVER (8).

5. REMOVE plate (9) and KNOB (10) from

group selector lever (8).

6. REMOVE COVER (7), spherical piece (11),

and spring (12).

3-96
 TM 5-2420-224-34

TRANSMISSION SHlFT CONTROLS REPLACEMENT (CONT)

7. REMOVE COVER (3), spherical pieoe (14),

and spring (15) from main shift lever (4).

Inspect levers and springs for cracks or damage.

1. INSTALL spring (1), spherical piece (2), and

COVER (3) on main shift lever (4).

3-97
TM 5-2420-224-34

TRANSMISSION SHIFT CONTROLS REPLACEMENT (CONT)

2. INSTALL spring (5), spherioal piece (6), and

COVER (7) on group seleotor lever (8).

3. INSTALL KNOB (9) and plate (10).

4. INSTALL group selector LEVER (8) in

transmission top cover (11) and ROTATE
COVER (7) to right to lock.

5. INSTALL BELLOWS (12) and TIGHTEN

CLAMP (13).

6. INSTALL main shift LEVER (4) and ROTATE

COVER (3) to right to lock.

7. INSTALL BELLOWS (14) and TIGHTEN

CLAMP (15).

NOTE
Follow-on Maintenance:
Install transmission shift lines
(page 3-92).
Install floor platform (TM 5-2420-
224-20).

3-98
 TM 5-2420-224-34

TRANSMISSION MOUNT REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Page 3-68 Transmission Removed
Personnel Required: (2)

1. REMOVE nut (1), washer (2), capscrew (3),

two bushings (4), and SPACER (5).

2. REMOVE four capscrews (6), two bearing

brackets (7), and two bearing COVERS (8).

3-99
 TM 5-2420-224-34

TRANSMISSION MOUNT REPLACEMENT (CONT)

3. REMOVE four GROMMETS (9).

1. INSTALL tour GROMMETS (1).

2. INSTALL two bearing COVERS (2), two

bearing brackets (3), and four capscrews (4).

3-100
 TM 5-2420-224-34

TRANSMISSION MOUNT REPLACEMENT (CONT)

3. INSTALL SPACER (5), two bushings (6),

capscrew (7), washer (8), and nut (9).

NOTE
Follow-on Maintenance:
Install transmission (page 3-68).

3-101
TM 5-2420-224-34

Section IV. PROPELLER SHAFTS AND RELATED PARTS

This section illustrates and describes procedures for maintenance of the propeller shafts and related
parts. A list of tasks contained in this section is shown below.

Page

Propeller Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102

U-Joint Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

Axle Thrust Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

PROPELLER SHAFT REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment:

Shop Equipment, SC 4910-95-CL-A31
TOOI Kit, SC 5180-90-CL-N26

NOTE
If replacing front propeller shaft,
perform Removal steps 1 thru
30 of Front Axle Assembly
Replacement (page 5-1).
If replacing rear propeller shaft,
perform Removal steps 1 thru
21 of Rear Axle Assembly
Replacement (page 6-1).

REMOVE propeller SHAFT (1) from axle thrust

tube (2).

1. INSTALL propeller SHAFT (1) in axle thrust

tube (2).
2. IF FRONT propeller SHAFT was REMOVED,
PERFORM Installation STEPS 11 thru 35 of
FRONT AXLE ASSEMBLY REPLACEMENT
(page 5-1).
3. IF REAR propeller SHAFT was REMOVED,
PERFORM - Installation STEPS 14 thru 33 of
REAR AXLE ASSEMBLY R E P L A C E M E N T
(page 6-1).

3-102
 TM 5-2420-224-34

U-JOINT REPLACEMENT
This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

TOOl Kit, SC 5180-90-CL-N26
Page 3-102 Front or Rear Propeller
Materials/Parts: Shaft Removed

Kit, U-Joint

NOTE
Procedure is the same for both
U-joints.

1. REMOVE and DISCARD four retaining RINGS

(1).

2. USING suitable PRESS, REMOVE two

bearing caps (2) and cross SHAFT (3) from
shaft (4). DISCARD bearing CAPS.

3. USING suitable PRESS, REMOVE two

bearing caps (5) and cross SHAFT (3) from
yoke (6). DISCARD bearing CAPS and cross
SHAFT.

1. Inspect shaft for wear or cracks.

2. Inspect flange for burrs, wear, or cracks.

3. Inspect flange mounting bolt holes for

elongation.

3-103
TM 5-2420-224-34

U-JOINT REPLACEMENT (CONT)

INSTALLATION

NOTE
Procedure is the same for both
U-joints.

1. USING suitable PRESS, INSTALL new cross

SHAFT (1) and two new bearing caps (2) in
yoke (3).

2. USING suitable PRESS, INSTALL new cross

SHAFT (1) and two new bearing caps (4) in
shaft (5).

3. INSTALL four new retaining RINGS (6).

NOTE
Follow-on Maintenance:
Install front or rear propeller shaft
(page 3-102).

3-104
 TM 5-2420-224-34

AXLE THRUST TUBE REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TOOI Kit, SC 5180-90-CL-N26
Guide, P/N 406 589 01 59 00 Page 5-1 or 6-1 Front or Rear Axle
Installer, P/N 435 489 01 35 00 Assembly Removed
Installing Tool, P/N 406 589 03 59 00
Puller, P/N 000 589 34 33 00 Page 5-14 or 6-12 Front or Rear Axle
Puller, P/N 00 589 68 33 00 Thrust Arms Removed
Page 3-102 Front or Rear Propeller
Materials/Parts:
Shaft Removed
Washer, Lock (4)
General Safety Instructions:
Seal
Packing
Compound, Sealing Appendix B, Item 15

Grease, Molybdenum Appendix B, Item 24

Disulfide
Twine, Cotton Appendix B, Item 49
4 Ft Long

REMOVAL

NOTE
Procedure is the same for both
thrust tubes.

1. REMOVE eight bolts (1) and axle thrust TUBE

(2) from pinion shaft assembly (3).

2. REMOVE HOUSING (4).

3. LOOSEN CLAMP (5) and CLAMP (6).

4. REMOVE four nuts (7), four lock washers (8),

HOUSING (9), and HOUSING (10). DISCARD
lock WASHERS.

5. REMOVE BELLOWS (11) and two clamps (5

and 6).

6. REMOVE FlTTING (12) from housing (9).

3-105
TM 5-2420-224-34

AXLE THRUST TUBE REPLACEMENT (CONT)

7. IF WORN or DAMAGED, REMOVE four

STUDS (13) from housing (10).

8. IF WORN or DAMAGED, REMOVE two PINS

(14).

9. USING PULLERS, REMOVE SEAL (15) from

axle thrust tube (2). DISCARD SEAL.

1. inspect bellows for tears or cracks.

2. Inspect axle thrust tube and two housings for

cracks, scoring, or other defects.

NOTE
Procedure is the same for both
thrust tubes.

1. USING INSTALLING TOOL, INSTALL new

SEAL (1) in axle thrust tube (2).

3-106
 TM 5-2420-224-34

AXLE THRUST TUBE REPLACEMENT (CONT)

2. IF REMOVED, INSTALL two new PINS (3).

3. IF REMOVED, INSTALL four new STUDS (4).

4. APPLY COAT of MOLYBDENUM DISULFIDE

GREASE to SEAL (1).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

5. APPLY COAT of SEALING COMPOUND to

mating SURFACES of thrust tube (2) and
pinion shaft assembly (5).

6. USING GUIDE, POSITION thrust TUBE (2) on

pinion shaft assembly (5).

7. APPLY COAT of SEALING COMPOUND to

eight BOLTS (6) and INSTALL eight BOLTS
(6). TIGHTEN BOLTS to 67 Ib-ft (90 N.m).

8. INSTALL BELLOWS (7) and two clamps (8

and 9). DO NOT TIGHTEN CLAMPS.

9. INSTALL two HOUSINGS (10 and 11), four

nuts (12), and four new lock washers (13).

10. TIGHTEN two CLAMPS (8 and 9).

11. INSTALL HOUSING (14).

12. INSTALL FlTTING (15).

3-107
TM 5-2420-224-34

AXLE THRUST TUBE REPLACEMENT (CONT)

13. REMOVE PACKING (16) and SHIM(S) (17)

from transmission housing (18). DISCARD
PACKING.

14. INSTALL INSTALLER on two housings (10

and 11) using suitable bolts and nuts. DO
NOT TIGHTEN.

15. EVENLY TIGHTEN NUTS and BOLTS while

moving installer up and down until a
noticeable change in resistance is felt.

16. USING feeler GAGE, MEASURE GAP

between two housings (10 and 11) and
installer in three different locations.

17. AVERAGE MEASUREMENTS from step 16 to

obtain thiokness of shim(s) to be installed.

18. REMOVE INSTALLER from two housings (10

and 11).

19. INSTALL SHIM(S) (17), equal to thickness

determined in step 17, on transmission (18).

20. INSTALL new PACKING (16) on transmission

housing (18).

3-108
 TM 5-2420-224-34

AXLE THRUST TUBE REPLACEMENT (CONT)

21. REMOVE four nuts (12), four lock washers

(13), HOUSING (10), and HOUSING (11).
DISCARD lock WASHERS.

NOTE
Follow-on Maintenance:
Install front or rear propeller shaft
(page 3-102).
Install front or rear axle thrust
arms (page 5-14 or 6-12).
Install front or rear axle assembly
(page 5-1 or 6-1l).

3-109/(3-110 Blank)
 TM 5-2420-224-34

CHAPTER 4
ELECTRICAL SYSTEM MAINTENANCE

This chapter illustrates and describes procedures for maintenance of the electrical system. A list of tasks
contained in this chapter is shown below.

Page

Altemator Bearings Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starter Brushes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Main Wiring Harness Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1o
Alternator Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Crane Mast Floodlight Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . 4-30
Trailer Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Dome Light Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Hazard Warning Light Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . 4-36
Auxiliary Headlight, Front Composite Light, and Blackout Driving Light
Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
STE/lCE-R Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Forklift Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Forklift Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Forklift Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Forklift Connector to Fuse Holder Wiring Harness Replacement . . . . . . . . . . . . . . . 4-46
Cab Floor separation Point to Hydraulic Suspension Lockout Wiring
Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Cab Floor Separation Point to Rear Wall Wiring Harness Replacement . . . . . . . . . . 4-52
Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring
Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring
Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Frame Wiring Harness Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Suppressor Filter Electrical Lead Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Cap Plug Connector to Heater Panel Switch and Master Light Switch
Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Throttle Solenoid Electrical Leads Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-74

4-1
TM 5-2420-224-34

ALTERNATOR BEARINGS REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
TOOI Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Washer, Spring
Tension (4) TM 5-2420-224-20 Alternator Removed

Packing Page 4-4 Regulator Removed

Kit, Parts

1. REMOVE nut (1), retaining ring (2), washer (3), retainer (4), pulley (5), spacer (6), spacer (7), and
IMPELLER (8).

2. MATCHMARK front HOUSING (9), STATOR (10), and rear HOUSING (11).

3. REMOVE four nuts (12), four spring tension washers (13), four capscrews (14), four washers (15), four
screws (16), and front HOUSING (9). DISCARD spring tension WASHERS.

4. REMOVE ROTOR (17), four screws (18), and cover (19).

5. USING suitable PULLER, REMOVE BEARING (20).

6. REMOVE and DISCARD PACKING (21).

7. USING suitable PULLER, REMOVE BEARING (22).

4-2
 TM 5-2420-224-34

ALTERNATOR BEARINGS REPLACEMENT (CONT)

1. INSTALL BEARING (22) and new packing (21).

2. INSTALL bearing (20), cover (19), four screws (18), and ROTOR (17).

3. ALINE MATCHMARKS on rear HOUSING (11), STATOR (10), and front HOUSING (9).

4. INSTALL front HOUSING (9), four screws (16), four washers (15), four capscrews (14), four new spring
tension washers (13), and four nuts (12).

5. INSTALL IMPELLER (8), spacer (7), spacer (6), pulley (5), retainer (4), washer (3), retaining ring (2),
and nut (1).

NOTE
Follow-on Maintenance:
Install regulator (page 4-4).
Install alternator (TM 5-2420-224-20).

4-3
TM 5-2420-224-34

REGULATOR REPLACEMENT
This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Cab Tilted
Materials/Parts:
General Safety Instructions:
Washer, Spring
Tension (2)
WARNING
References:
Remove or disconnect batteries
TM 5-2420-224-20 and turn vehicle MASTER
disconnect switch OFF prior to
performing maintenance in
immediate battery area or
working on electrical system.
Such disconnections prevent
electrical shock to personnel or
equipment.

REMOVE two screws (1), two spring tension washers (2), and REGULATOR (3). DISCARD spring tension
WASHERS.

INSTALL REGULATOR (3), two new spring tension washers (2), and two screws (1).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

4-4
 TM 5-2420-224-34

REGULATOR REPLACEMENT (CONT)

4-5
 TM 5-2420-224-34

STARTER BRUSHES REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: References:

TOOI Kit, SC 5180-90-CL-N26 TM 5-2420-224-20
Shop Equipment, SC4910-95-CL-A31
Dowel (4), Appendix C, Item 1 Equipment condition:

Materials/Parts: Reference Condition Description

Screw (2) TM 5-2420-224-20 Starter Removed
Gasket
Kit

1. REMOVE two sorews (1), end BELL (2), and gasket (3) from end bell (4), DISCARD SCREWS and
GASKET.

NOTE
Shims and washers may or may not be present. if present, note quanitity of shims and
washers removed to aid in assembly.

2. REMOVE and DISCARD lock washer RING (5), SHIM(S) (6), and WASHER(S) (7) from armature (8).

3. REMOVE two nuts (9), two washers (10), and end BELL (4) from housing (11).

4. IF DAMAGED, REMOVE BUSHING (12) from end bell (4).

4-6
 TM 5-2420-224-34

STARTER BRUSHES REPLACEMENT (CONT)

5. REMOVE HOUSING (11) from housing (13) UNTIL brush set BRACKET (14) is approximately
HALF-WAY off armature (8).

CAUTION
Install dowels carefully to prevent damage to brushes.

6. INSTALL four DOWELS in brush holder (15). HOLD four DOWELS together and REMOVE HOUSING
(11).

CAUTION
Use care to avoid damaging brushes.

7. REMOVE four DOWELS from brush holder (15).

NOTE
Brush set bracket may be attached to brush holder and housing with screws or it may
be soldered. If brush set bracket is soldered, do not perform step 8 until inspection has
been performed and replacement of brush holder is determined to be necessary.

8. IF DAMAGED, REMOVE brush set BRACKET (14) from brush holder (15) and housing (11).

4-7
TM 5-2420-224-34

STARTER BRUSHES REPLACEMENT (CONT)

1. IF REMOVED, INSTALL new brush set BRACKET (1) in brush holder (2) and housing (3).

CAUTION
Use care to avoid damaging brushes.

2. INSTALL BRUSH in its bracket on brush holder (2). INSTALL DOWEL in brush holder (2)
approximately half the width of brush to hold brush in place.

3. REPEAT STEP 2 for remaining three brushes in brush set bracket (1).

4. HOLD four DOWELS together and INSTALL HOUSING (3) and brush holder (2) over armature (4).

5. REMOVE four DOWELS and completely INSTALL HOUSING (3) in housing (5).

6. IF REMOVED, INSTALL new BUSHING (6) in end bell (7).

7. INSTALL end BELL (7), two washers (8), and two nuts (9) on housing (3).

8. INSTALL new washer(s) (10), new shim(s) (11), and new lock washer RING (12) as noted during
Removal.

4-8
 TM 5-2420-224-34

STARTER BRUSHES REPLACEMENT (CONT)

9. USING feeler GAGE. MEASURE GAP between shim(s) (11 ) and end bell (7). Measurement MUST be
0.002-0.016 in. (0.05-0.4 mm). If measurement is NOT corrected, ADD or REMOVE SHIM(S) to achieve
correct measurement.

10. INSTALL new gasket (13), end BELL (14), and two new screws (15) on end bell (7).

NOTE
Follow-on Maintenance:
Install starter (TM 5-2420-224-20).

4-9
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31

Tool Kit; SC 5180-90-CL-N26 WARNING
Remove or disconnect batteries
Materials/Parts:
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
working on electrical system.
TM 5-2420-224-20
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Fuse Holders Removed
TM 5-2420-224-20 Air Cleaner Ducts
Removed
TM 5-2420-224-20 Relays Removed

4-10
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

NOTE
Wiring harnesses and leads are secured to vehicle with tiedown straps and screw
terminals. Discard tiedown strap(s).

Only remove hardware securing wiring harness or lead to be removed.

1. DISCONNECT five 6-pin CONNECTORS (1) from auxiliary headlight, front composite light, and blackout
driving light wiring harness (2) and frame wiring harness (3).

2. Disconnect 8-pin CONNECTOR (4) and 4-pin CONNECTOR (5) from alternator cable assembly (6).

3. Disconnect TERMINAL (7) from mounting bracket (8).

4. Disconnect 2-pin CONNECTOR (9) from diode (10).

5. Disconnect two CONNECTORS (11) from clutch hydraulic reservoir (12).

6. Disconnect two CONNECTORS (13) from brake fluid reservoir (14).

7. Disconnect two CONNECTORS (15) from air cleaner restrictor indicator switch (16).

4-11
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

8. DISCONNECT 6-pin CONNECTOR (17) from warning horn delay relay (18).

9. DISCONNECT 6-pin CONNECTOR (19) from wiper switch (20).

10. DISCONNECT five 5-pin CONNECTORS (21) from mounting bracket (22).

11. DISCONNECT two 2-pin CONNECTORS (23) from cab heater lead (24) and dome light cable
assembly (25).

4-12
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

12. DISCONNECT four 4-pin CONNECTORS (26) from cap plug connector to heater panel switch and
master Iight switch wiring harness (27).

13. DISCONNECT 4-pin CONNECTOR (28) and two 3-pin connectors (29) from hazard warning light wiring
harness (30).

4-13
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

14. DISCONNECT 10-pin CONNECTOR (31) from hazard warning switch (32).

15. DISCONNECT two CONNECTORS (33) from starter switch (34).

16. DISCONNECT six CONNECTORS (35) from windshield wiper/washer switch (36).

17. DISCONNECT five TERMINALS (37) from ignition switch (38).

4-14
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

18. DISCONNECT 4-pin CONNECTOR (39) from speedometer (40).

19. DISCONNECT six CONNECTORS (41) from instrument cluster panel light (42).

20. DISCONNECT four CONNECTORS (43) from tachometer (44).

21. DISCONNECT four TERMINALS (45) from ground stud (46).

4-15
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

22. DISCONNECT 6-pin CONNECTOR (47) and 8-pin connector (48) from liquid indicator (49).

23. DISCONNECT 6-pin CONNECTOR (50) from horn, low beam/high beam switch lead (51).

24. DISCONNECT 6-pin CONNECTOR (52) from windshield wiper motor (53).

4-16
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

25. DISCONNECT three CONNECTORS (54) from (55).

26. DISCONNECT two CONNECTORS (56) from check engine switch (57).

27. DISCONNECT four CONNECTORS (58) from cold start switch (59).

28. DISCONNECT six TERMINALS (60) from turn signal lever switch (61).

4-17
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

29. DISCONNECT three CONNECTORS (62) from three windshield heater connectors (63).

30. DISCONNECT two 2-pin CONNECTORS (64) from low pressure warning buzzer (65) and plug (66).

31. REMOVE main wiring HARNESS (67) from vehicle.

4-18
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

INSTALLATION

NOTE
Make sure main wiring harness is secure and all hardware is tight.

Install new tiedown strap(s).

1. INSTALL main wiring HARNESS (1) in vehicle.

2. CONNECT two 2-pin CONNECTORS (2) to low pressure warning buzzer (3) and plug (4).

3. CONNECT three CONNECTORS (5) to three windshield heater connectors (6).

4-19
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

4. CONNECT six TERMINALS (7) to turn signal lever switch (8).

5. CONNECT four CONNECTORS (9) to cold start switch (10).

6. CONNECT two CONNECTORS (11) to check engine switch (12).

7. CONNECT three CONNECTORS (13) to ammeter (14).

4-20
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

8. CONNECT 6-pin CONNECTOR (15) to windshield wiper motor (16).

9. CONNECT 6-pin CONNECTOR (17) to horn, low beam/high beam switch lead (18).

10. CONNECT 6-pin CONNECTOR (19) and 8-pin connector (20) to liquid indicator (21).

4-21
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

11. CONNECT four TERMINALS (22) to ground stud (23).

12. CONNECT four CONNECTORS (24) to tachometer (25).

13. CONNECT six CONNECTORS (26) to instrument cluster panel Iight (27).

14. CONNECT 4-pin CONNECTOR (28) to speedometer (29).

4-22
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

15. CONNECT five TERMINALS (30) to ignition switch (31).

16. CONNECT six CONNECTORS (32) to windshield wiper/washer switch (33).

17. CONNECT two CONNECTORS (34) to starter switch (35).

18. CONNECT 10-pin CONNECTOR (36) to hazard warning switch (37).

4-23
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

19. CONNECT 4-pin CONNECTOR (38) and two 3-pin connectors (39) to hazard warning light wiring
harness (40).

20. CONNECT four 4-pin CONNECTORS (41) to cap plug connector to heater panel switch and master
Iight switch wiring harness (42).

4-24
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

21. CONNECT two 2-pin CONNECTORS (43) to cab heater lead (44) and dome light cable assembly (45).

22. CONNECT five 5-pin CONNECTORS (46) to mounting bracket (47).

23. CONNECT 6-pin CONNECTOR (46) to wiper switch (49).

24. CONNECT 6-pin CONNECTOR (50) to warning horn delay relay (51).

4-25
TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

25. CONNECT two CONNECTORS (52) to air cleaner restrictor indicator switch (53).

26. CONNECT two CONNECTORS (54) to brake fluid reservoir (55).

27. CONNECT two CONNECTORS (56) to clutch hydraulic reservoir (57).

28. CONNECT 2-pin CONNECTOR (58) to diode (59).

29. CONNECT TERMINAL (60) to mounting bracket (61).

4-26
 TM 5-2420-224-34

MAIN WIRING HARNESS REPLACEMENT (CONT)

30. CONNECT 8-pin CONNECTOR (62) and 4-pin connector (63) to alternator cable assembly (64).

31. CONNECT five 6-pin CONNECTORS (65) to auxiliary headlight, front composite light, and blackout
driving Iight wiring harness (66) and frame wiring harness (67).

NOTE
Follow-on Maintenance:
Install fuse holders (TM 5-2420-224-20).
Install air cleaner ducts (TM 5-2420-224-20).
Install relays (TM 5-2420-224-20).

4-27
TM 5-2420-224-34

ALTERNATOR CABLE ASSEMBLY REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TooI Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Cab Tilted
Materials/Parts:
General Safety Instructions:
Strap, Tiedown Appendix B, Item 44

References:
WARNING
TM 5-2420-224-20 Remove or disconnect batteries
and turn vehicle MASTER
disconnect switch OFF prior to
performing maintenance in
immediate battery area or
working on electrical system.
Such disconnections prevent
electrical shock to personnel or
equipment.

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE alternator CABLE assembly using illustration and legend as a guide.

NOTE
• Make sure alternator cable assembly is secure and all hardware is tight.

• Install new tiedown strap(s).

INSTALL alternator CABLE assembly using illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

4-28
 TM 5-2420-224-34

ALTERNATOR CABLE ASSEMBLY REPLACEMENT (CONT)

4-29
TM 5-2420-224-34

CRANE MAST FLOODLIGHT WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH
WARNING
Tools and Special Equipment:
Remove or disconnect batteries
TooI Kit, SC 5180-90-CL-N26 and turn vehicle MASTER
disconnect switch OFF prior to
Materials/Parts: performing maintenance in
immediate battery area or
Strap, Tiedown Appendix B, Item 44
working on electrical system.
Such disconnections prevent
electrical shock to personnel or
equipment.

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE crane mast floodlight wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure crane mast floodlight wiring harness is secure and all hardware is tight.

Ž Install new tiedown strap(s).

INSTALL crane mast floodlight wiring HARNESS using illustration and legend as a guide.

4-30
 TM 5-2420-224-34

CRANE MAST FLOODLIGHT WIRING HARNESS REPLACEMENT (CONT)

4-31
TM 5-2420-224-34

TRAILER WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: General Safety instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit,- SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
immediate battery area or
working on electrical system.
Such disconnections prevent
electrical shock to personnel or
equipment.

REMOVAL

NOTE
Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

Only remove hardware securing wiring harness or lead to be removed.

REMOVE trailer wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure trailer wiring harness is secure and all hardware is tight.

• install new tiedown strap(s).

INSTALL trailer wiring HARNESS using illustration and legend as a guide.

4-32
TM 5-2420-224-34

4-33
TM 5-2420-224-34

DOME LIGHT CABLE ASSEMBLY REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31

TooI Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
immediate battery area or
working on electrical system.
Such disconnections prevent
electrical shock to personnel or
equipment.

NOTE
Ž Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE dome Iight CABLE assembly using illustration and legend as a guide.

NOTE
• Make sure dome light cable assembly is secure and all hardware is tight.

• Install new tiedown strap(s).

INSTALL dome light CABLE assembly using illustration and legend as a guide.

4-34
 TM 5-2420-224-34

DOME LIGHT CABLE ASSEMBLY REPLACEMENT (CONT)

4-35
TM 5-2420-224-34

HAZARD WARNING LIGHT WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, [tern 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Air Cleaner Ducts
Removed

NOTE
Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

Only remove hardware securing wiring harness or lead to be removed.

REMOVE hazard warning light wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure hazard warning light wiring harness is secure and all hardware is tight.

• Install new tiedown strap(s).

INSTALL hazard warning Iight wiring HARNESS using illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Install air cleaner ducts (TM 5-2420-224-20).

4-36
 TM 5-2420-224-34

HAZARD WARNING LIGHT WIRING HARNESS REPLACEMENT (CONT)

4-37
 TM 5-2420-224-34

AUXILIARY HEADLIGHT, FRONT COMPOSITE LIGHT, AND BLACKOUT

DRIVING LIGHT WIRING HARNESS REPLACEMENT
This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Air Cleaner Ducts
Removed

NOTE
Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

Only remove hardware securing wiring harness or lead to be removed.

REMOVE auxiliary headlight, front composite light, and blackout driving light wiring HARNESS using
illustration and legend as a guide.

NOTE
• Make sure auxiliary headlight, front composite light, and blackout driving light wiring
harness is secure and all hardware is tight.

• Install new tiedown strap(s).

INSTALL auxiliary headlight, front composite Iight, and blackout driving light wiring HARNESS using
illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Install air cleaner ducts (TM 5-2420-224-20).

4-38
 TM 5-2420-224-34

AUXILIARY HEADLIGHT, FRONT COMPOSITE LIGHT, AND BLACKOUT

DRIVING LIGHT WIRING HARNESS REPLACEMENT (CONT)

4-39
TM 5-2420-224-34

STE/lCE-R WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31

Tool Kit; SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Cab Tilted

NOTE
Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

Only remove hardware securing wiring harness or lead to be removed.

REMOVE STE/lCE-R wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure STE/lCE-R wiring harness is secure and all hardware is tight.

• Install new tiedown strap(s).

INSTALL STE/ICE-R wiring HARNESS using illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

4-40
 TM 5-2420-224-34

STE/lCE-R WIRING HARNESS REPLACEMENT (CONT)

4-41
TM 5-2420-224-34

FORKLIFT WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH (Reg. No. UC053E thru UC053K)

Tools and Special Equipment: WARNING

Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
Tool Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
Materials/Parts: immediate battery area or
Strap, Tiedown Appendix B, Item 44 working on electrical system.
Such disconnections prevent
References: electrical shock to personnel or
equipment.
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Fuse Holders Removed

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE forklift wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure forklift wiring harness is secure and all hardware is tight.

• Install new tiedown strap(s).

INSTALL forklift wiring HARNESS using illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Install fuse holders (TM 5-2420-224-20).

4-42
 TM 5-2420-224-34

FORKLIFT WIRING HARNESS REPLACEMENT (CONT)

4-43
TM 5-2420-244-34

This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH (Reg. No. UC053L and On)
WARNING
Tools and Special Equipment:
Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
TooI Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
MateriaIs/Parts: immediate battery area or
Strap, Tiedown Appendix B, Item 44 working on electrical system.
Such disconnections prevent
References: electrical shock to personnel o r
equipment.
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Fuse Holders Removed

NOTE
Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

Only remove hardware securing wiring harness or lead to be removed.

REMOVE forklift wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure forklift wiring harness is secure and all hardware is tight.

• Install new tiedown strap(s).

INSTALL forklift wiring HARNESS using illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Install fuse holders (TM 5-2420-224-20).

4-44
 TM 5-2420-224-34

FORKLIFT WIRING HARNESS REPLACEMENT (CONT)

4-45
TM 5-2420-224-34

FORKLIFT POWER CABLE REPLACEMENT

This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH
WARNING
Tools and Special Equipment:
Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
Tool Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
Materials/Parts: immediate battery area or
working on electrical system.
Strap, Tiedown Appendix B, Item 44
Such disconnections prevent
electrical shock to personnel or
equipment.

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tie down strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE forklift power CABLE using illustration and legend as a guide.

NOTE
Ž Make sure forklift power cable is secure and all hardware is tight.

Ž Install new tiedown strap(s).

INSTALL forklift power CABLE using illustration and legend as a guide.

4-46
 TM 5-2420-224-34

FORKLIFT POWER CABLE REPLACEMENT (CONT)

4-47
 TM 5-2420-224-34

FORKLIFT CONNECTOR TO FUSE HOLDER WIRING HARNESS

REPLACEMENT
This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH (Reg. No. UC053L and on)

WARNING
Tools and Special Equipment:
Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
Tool Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
Materials/Parts: immediate battery area or
Strap, Tiedown Appendix B, item 44 working on electrical system.
Such disconnections prevent
References: electrical shock to personnel or
equipment.
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Fuse Holders Removed

TM 5-2420-224-20 Air Cleaner Ducts

Removed

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE forklift connector to fuse holder wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure forklift connector to fuse holder wiring harness is secure and ail hardware
is tight.

• install new tiedown strap(s).

INSTALL forklift connector to fuse holder wiring HARNESS using illustration and legend as a guide.

4-48
 TM 5-2420-224-34

FORKLIFT CONNECTOR TO FUSE HOLDER WIRING HARNESS

REPLACEMENT (CONT)

NOTE
Follow-on Maintenance:
Install fuse holders (TM 5-2420-224-20).
Install air cleaner ducts (TM 5-2420-224-20).

4-49
TM 5-2420-224-34

CAB FLOOR SEPARATION POINT TO HYDRAULIC SUSPENSION

LOCKOUT WIRING HARNESS REPLACEMENT
This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: General Safety Instructions:

HMMH
WARNING
Tools and Special Equipment:
Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
Tool Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
Materials/Parts: immediate battery area or
Gasket working on electrical system.
Such disconnections prevent
Strap, Tiedown Appendix B, Item 44 electrical shock to personnel or
equipment.

NOTE
Ž Discard gasket.

• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE cab floor separation point to hydraulic suspension lockout wiring HARNESS using illustration and
legend as a guide.

NOTE
Make sure cab floor separation point to hydraulic suspension lockout wiring harness
is secure and all hardware is tight.

Install new tiedown strap(s).

Install new gasket.

INSTALL cab floor serparation point to hydraulic suspension lockout wiring HARNESS using illustration and
legend as a guide.

4-50
 TM 5-2420-224-34

CAB FLOOR SEPARATION POINT TO HYDRAULIC SUSPENSION

LOCKOUT WIRING HARNESS REPLACEMENT (CONT)

4-51
TM 5-2420-224-34

CAB FLOOR SEPARATION POINT TO REAR WALL WIRING HARNESS

REPLACEMENT
This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH
WARNING
TooIs and Special Equipment:
Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
Tool Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
Materials/Parts: immediate battery area or
Strap, Tiedown Appendix B, Item 44 working on electrical system.
Such disconnections prevent
References: electrical shock to personnel or
equipment.
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Passenger Seat and
Framework Removed

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

Ž Only remove hardware securing wiring harness or lead to be removed.

REMOVE cab floor separation point to rear wall wiring HARNESS using illustration and legend as a guide.

NOTE
• Make sure cab floor separation point to rear wall wiring harness is secure and all
hardware is tight.

Ž Install new tiedown strap(s).

INSTALL cab floor separation point to rear wall wiring HARNESS using illustration and legend as a guide.

4-52
 TM 5-2420-224-34

CAB FLOOR SEPARATION POINT TO REAR WALL WIRING HARNESS

REPLACEMENT (CONT)

NOTE
Follow-on Maintenance:
Install passenger seat and framework (TM 5-2420-224-20).

4-53
TM 5-2420-224-34

FUSE HOLDER TO HYDRAULIC SUSPENSION LOCKOUT/REAR WALL

WIRING HARNESS REPLACEMENT
This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH (Reg. No. UC053E thru UC053K)

WARNING
Tools and Special Equipment:
Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
Tiil Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Fuse Holders Removed
TM 5-2420-224-20 Passenger Seat and
Framework Removed

NOTE
• Wiring harnesses and leads are secured to vehicle with loop clamps and screw
terminals.

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE fuse holder to hydraulic suspension Iockout/rear wall wiring HARNESS using illustration and
legend as a guide.

NOTE
Make sure fuse holder to hydraulic suspension lockout/rear wall wiring harness is secure
and all hardware is tight.

INSTALL fuse holder to hydraulic suspension lockout/rear wall wiring HARNESS using illustration and legend
as a guide.

NOTE
Follow-on Maintenance:
Install fuse holders (TM 5-2420-224-20).
Install passenger seat and framework (TM 5-2420-224-20).

4-54
 TM 5-2420-224-34

FUSE HOLDER TO HYDRAULIC SUSPENSION LOCKOUT/REAR WALL

WIRING HARNESS REPLACEMENT (CONT)

4-55
TM 5-2420-224-34

FUSE HOLDER TO HYDRAULIC SUSPENSION LOCKOUT/REAR WALL

WIRING HARNESS REPLACEMENT
This task covers: a. Removal b. Installation

Applicable Configuration: General Safety Instructions:

HMMH (Reg. No. UC053L and On)
WARNING
Tools and Special Equipment:
Remove or disconnect batteries
Shop Equipment, SC 4910-95-CL-A31 and turn vehicle MASTER
Tool Kit, SC 5180-90-CL-N26 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Fuse Holders Removed
TM 5-2420-224-20 Passenger Seat and
Framework Removed

NOTE
Wiring harnesses and leads are secured to vehicle with loop clamps and screw
terminals.

Only remove hardware securing wiring harness or lead to be removed.

REMOVE fuse holder to hydraulic suspension lookout/rear wall wiring HARNESS using illustration and
legend as a guide.

INSTALLATION

NOTE
Make sure fuse holder to hydraulic suspension Iockout/rear wall wiring harness is secure
and all hardware is tight.

INSTALL fuse holder to hydraulic suspension Iockout/rear wall wiring HARNESS using illustration and legend
as a guide.

NOTE
Follow-on Maintenance:
Install fuse holders (TM 5-2420-224-20).
Install passenger seat and framework (TM 5-2420-224-20).

4-56
 TM 5-2420-224-34

FUSE HOLDER TO HYDRAULIC SUSPENSION LOCKOUT/REAR WALL

WIRING HARNESS REPLACEMENT (CONT)

4-57
TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment. SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Cab Tilted

4-58
 TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT (CONT)

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

1. DISCONNECT three 6-pin CONNECTORS (1) from main wiring harness (2).

2. DISCONNECT 4-pin CONNECTOR (3) from front disc brake pad indicator wiring harness (4) on torque
tube (5).

3. DISCONNECT five 2-pin CONNECTORS (6) from transmission assembly (7).

4-59
TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT (CONT)

4. DISCONNECT 4-pin CONNECTOR (8) from chassis wiring harness (9).

5. DISCONNECT two TERMINALS (10) from fuel level gage (11).

6. DISCONNECT three TERMINALS (12) from frame (13).

4-60
 TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT (CONT)

7. DISCONNECT 2-pin CONNECTOR (14) from parking brake switch (15).

8. REMOVE COVER (16) from box (17) and DISCONNECT two 6-pin CONNECTORS (18) from trailer
wiring harness (19).

9. REMOVE frame wiring HARNESS (20) from vehicle.

4-61
 TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT (CONT)

NOTE
• Make sure frame wiring harness is secure and all hardware is tight.

Ž Install new tiedown strap(s).

1. INSTALL frame wiring HARNESS (1) in vehicle.

2. CONNECT two 6-pin CONNECTORS (2) to trailer wiring harness (3) and INSTALL COVER (4) on box
(5).

3. CONNECT 2-pin CONNECTOR (6) to parking brake switch (7).

4-62
 TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT (CONT)

4. CONNECT three TERMINALS (8) to frame (9).

5. CONNECT two TERMINALS (10) to fuel level gage (11).

6. CONNECT 4-pin CONNECTOR (12) to chassis wiring harness (13).

4-63
TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT (CONT)

7. CONNECT five 2-pin CONNECTORS (14) to transmission assembly (15).

8. CONNECT 4-pin CONNECTOR (16) to front disc brake pad indicator wiring harness (17) on torque
tube (18).

4-64
 TM 5-2420-224-34

FRAME WIRING HARNESS REPLACEMENT (CONT)

9. CONNECT three 6-pin CONNECTORS (19) to main wiring harness (20).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).

4-65
TM 5-2420-224-34

SUPPRESSOR FILTER ELECTRICAL LEAD REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment. SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
References: Remove or disconnect batteries
and turn vehicle MASTER
TM 5-2420-224-20 disconnect switch OFF prior to
performing maintenance in
Equipment Condition: immediate battery area or
working on electrical system.
Reference Condition Description
Such disconnections prevent
TM 5-2420-224-20 Suppressor Filter electrical shock to personnel or
Removed equipment.

NOTE
Procedure is the same for both supressor filters.

Wiring harnesses and leads are secured to vehicle with loop clamps and screw
terminals.

Only remove hardware securing wiring harness or lead to be removed.

REMOVE suppressor filter electrical LEAD using illustration and legend as a guide.

NOTE
• Procedure is the same for both supressor filters.

• Make sure suppressor filter electrical lead is secure and all hardware is tight.

INSTALL suppressor filter electrical LEAD using illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Install suppressor filter (TM 5-2420-224-20).

4-66
 TM 5-2420-224-34

SUPPRESSOR FILTER ELECTRICAL LEAD REPLACEMENT (CONT)

4-67
TM 5-2420-224-34

CAP PLUG CONNECTOR TO HEATER PANEL SWITCH AND MASTER

LIGHT SWITCH WIRING HARNESS REPLACEMENT
This task covers. a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Air Cleaner Ducts
Removed

NOTE
• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

REMOVE cap plug connector to heater panel switch and master light switch wiring HARNESS using
illustration and legend as a guide.

NOTE
Make sure cap plug connector to heater panel switch and master light switch wiring
harness is secure and all hardware is tight.
Install new tiedown strap(s).

INSTALL cap plug connector to heater panel switch and master Iight switch wiring HARNESS using
illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Install air cleaner ducts (TM 5-2420-224-20).

4-68
 TM 5-2420-224-34

CAP PLUG CONNECTOR TO HEATER PANEL SWITCH AND MASTER

LIGHT SWITCH WIRING HARNESS REPLACEMENT (CONT)

4-69
TM 5-2420-224-34

CHASSIS WIRING HARNESS REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: General Safety Instructions:

Shop Equipment. SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Item 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Tool and Work Light
Switches Removed
TM 5-2420-224-20 Bucket and Auxiliary
Throttle Switches (SEE)
or Auxiliary Throttle
Switch (HMMH) Removed
TM 5-2420-224-20 Work Lights Removed

NOTE
• Procedure is the same for both vehicles.

• Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

• Only remove hardware securing wiring harness or lead to be removed.

1. DISCONNECT 4-pin CONNECTOR (1) from frame wiring harness (2).

2. DISCONNECT two TERMINALS (3) from hydraulic oil cooler thermal switch (4).

3. DISCONNECT six CONNECTORS (5) from front Ioader/forklift control valve (6).

4. REMOVE chassis wiring HARNESS (7) from vehicle.

4-70
 TM 5-2420-224-34

CHASSIS WIRING HARNESS REPLACEMENT (CONT)

4-71
TM 5-2420-224-34

CHASSIS WIRING HARNESS REPLACEMENT (CONT)

NOTE
• Procedure is the same for both vehicles.

• Make sure chassis wiring harness is secure and all hardware is tight.

• Install new tiedown strap(s).

1. INSTALL chassis wiring HARNESS (1) in vehicle.

2. CONNECT six CONNECTORS (2) to front loader/forklift control valve (3).

3. CONNECT two TERMINALS (4) to hydraulic oil cooler thermal switch (5).

4. CONNECT 4-pin CONNECTOR (6) to frame wiring harness (7).

NOTE
Follow-on Maintenance:
Install tool and work light switches (TM 5-2420-224-20).
Install bucket and auxiliary throttle switches (SEE) or auxiliary throttle switch (HMMH)
(TM 5-2420-224-20).
Install work lights (TM 5-2420-224-20).

4-72
 TM 5-2420-224-34

CHASSIS WIRING HARNESS REPLACEMENT (CONT)

4-73
TM 5-2420-224-34

THROTTLE SOLENOID ELECTRICAL LEADS REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: General Safety instructions:

Shop Equipment. SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Remove or disconnect batteries
and turn vehicle MASTER
Strap, Tiedown Appendix B, Itern 44 disconnect switch OFF prior to
performing maintenance in
References: immediate battery area or
TM 5-2420-224-20 working on electrical system.
Such disconnections prevent
Equipment Condition: electrical shock to personnel or
equipment.
Reference Condition Description
TM 5-2420-224-20 Tool and Work Light
Switches Removed

REMOVAL

NOTE
Wiring harnesses and leads are secured to vehicle with tiedown straps, loop clamps,
and screw terminals. Discard tiedown strap(s).

Only remove hardware securing wiring harness or lead to be removed.

REMOVE throttle solenoid electrical LEADS using illustration and legend as a guide.

INSTALLATION

NOTE
Make sure throttle solenoid electrical leads are secure and all hardware is tight.

Install new tiedown strap(s).

INSTALL throttle solenoid electrical LEADS using illustration and legend as a guide.

NOTE
Follow-on Maintenance:
Install tool and work light switches (TM 5-2420-224-20).

4-74
 TM 5-2420-224-34

THROTTLE SOLENOID ELECTRICAL LEADS REPLACEMENT (CONT)

4-75/(4-76 Blank)
 TM 5-2420-224-34

CHAPTER 5
FRONT AXLE MAINTENANCE
OVERVIEW

This chapter illustrates and describes procedures for maintenance of the front axle. A list of tasks
contained in this chapter is shown below.

Page

Front Axle Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Front Axle Thrust Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Steering Knuckle and Front Axle Final Drive Replacement . . . . . . . . . . . . . . . . . . 5-16

FRONT AXLE ASSEMBLY REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Remover, P/N 406 589 05 33 00 TM 5-2420-224-20 Exhaust Pipe (Front)
Wrench, P/N 000 589 51 03 00 Removed

Materials/Parts: TM 5-2420-224-20 Front Loader (SEE) or

Forklift (HMMH) Removed
Pin, Cotter
TM 5-2420-224-20 Cab Tilted
Nut, Lock
TM 5-2420-224-20 Front Axle Torsion Bar
Washer, Lock Removed
Seal (2) LO 5-2420-224-12 Transmission Drained
Nut, Lock (2) LO 5-2420-224-12 Front Axle Center
Housing Drained
Washer, Lock (6)
LO 5-2420-224-12 Wheel Hub Drive Drained
Compound, Sealing Appendix B, Item 15
Grease, Molybdenum Appendix B, Item 24 General Safety instructions:
Disulfide
Rags Appendix B, Item 40
WARNING
Personnel Required: (2) Wheel assembly weighs 170
pounds (77 kilograms). To
References: avoid personal injury, use a
hoist or suitable lifting device
TM 5-2420-224-20
when lifting wheel assembly.
LO 5-2420-224-12

5-1
TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

General Safety Instructions (Cont): GeneraI Safety Instructions (Cont):

WARNING WARNING
Control arm weighs more SEE/HMMH should not be
than 50 pounds (23 operated with front loader
kilograms). To avoid personal (SEE) or forklift (HMMH)
injury, use a hoist or suitable removed, except in a
lifting device when lifting maintenance facility. When
control arm. maintenance is required and
front loader or forklift is
Support drag link during removed, never operate
disconnect of ball joint from SEE/HMMH at speeds
pitman arm. Failure to do so greater than 5 mph. Tractor
could result in injury to stability and handling
personnel. characteristics are greatly
affected with either front
Fuel and oil are slippery and
loader or forklift removed.
can cause falls. To avoid
This could cause loss of
injury, wipe up spilled fuel or
control and injury to
oil with rags.
personnel or damage to
Adhesive causes immediate vehicle.
bonding on contact with
eyes, skin, or clothing and
also gives off harmful vapors.
Wear protective goggles and
use in well-ventilated area. If
adhesive gets in eyes, try to
keep eyes open; flush eyes
with water for 15 minutes
and get immediate medical
attention.

REMOVAL

NOTE
Procedure is the same for both
vehicles except as noted.

1. REMOVE cotter pin (1) and castellated NUT

(2) from drag link (3). DISCARD cotter PIN.

5-2
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

2. USING REMOVER, DISCONNECT ball JOINT

(4) from pitman arm (5).

3. SWING drag LINK (3) aside.

4. REMOVE lock nut (6), screw (7), screw (8),

lock washer (9), and control ARM (10).
DISCARD lock NUT and lock WASHER.

5. REMOVE nut (11), lock washer (12), and

SCREW (13) and DISCONNECT left front
shock ABSORBER (14) at axle (15).
REINSTALL SCREW (13), lock washer (12),
and nut (11).

6. REPEAT STEP 5 for right front shock

absorber.

7. REMOVE CLAMP (16).

5-3
TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

NOTE
Tag all lines prior to disconnecting
to aid in connecting.

8. USING WRENCH, DISCONNECT two brake

LINES (17 and 18).

NOTE
Step 9 is for HMMH only.

9. DISCONNECT hydraulic suspension lockout

LINE (19)

10. DISCONNECT differential lock air HOSE (20)

from left side of axle (15).

NOTE
Step 11 is for HMMH only.

11. DISCONNECT hydraulic suspension lockout

HOSES (21) from both sides of vehicle.

12. REMOVE fluid passage BOLT (22), union

(23), and two seals (24 and 25) and
DISCONNECT axle vent HOSE (26) from right
side of axle (15). DISCARD SEALS.

5-4
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

13. DISCONNECT brake wear indicator

CONNECTOR (27).

14. REMOVE screw (28), CLAMP (29), and

CLAMP (30) from torque tube (31).

15. REMOVE lock nut (32), screw (33), and

COVER (34) from right front spring mount.
DISCARD lock NUT.

16. REPEAT STEP 15 for left front spring mount.

5-5
TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

17. USING suitable JACK or lifting device, RAISE

VEHICLE off right front spring (35).

18. REMOVE SPRING (35) and LOWER

VEHICLE back onto jack stand.

19. REPEAT STEPS 17 and 18 for left front

spring.

20. INSTALL suitable BAR through two lifting eyes

(36).

21. INSTALL suitable cable PULLER to right front

axle shock absorber mounting screw (13) and
bar.

22. REPEAT STEP 21 for left front axle.

23. REMOVE SCREW (37), washer (38), SCREW

(39), and washer (40).

5-6
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

24. REMOVE two clamps (41) and vent HOSE

(42).

25. SLIDE BELLOWS (43) down torque tube (31).

26. REMOVE four NUTS (44) and four lock

washers (45). DISCARD lock WASHERS.

27. REMOVE four screws (46), four washers (47),

and lower housing HALF (48).

WARNING
Place a suitable support under
torque tube and one wheel.
Failure to do so could result in
injury to personnel.

28. USING suitable cable PULLER, PULL AXLE

forward until torque ball housing (49)
separates from transmission (50).

NOTE
Front wheel can be rotated to gain
access to screws in step 29.

29. REMOVE six SCREWS (51).

30. REMOVE front AXLE assembly (52) and

upper housing HALF (53).

5-7
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

31 PLACE AXLE (52) on suitable STANDS.

32. REMOVE BAR installed in step 20.

33. REMOVE TIE ROD (TM 5-2420-224-20).

34. REMOVE DRAG LINK (TM 5-2420-224-20).

35. REMOVE FRONT BRAKE CALIPERS

HYDRAULIC LINES AND FITTINGS (TM 5-
2420-224-20).

36. REMOVE HYDRAULIC SUSPENSION

LOCKOUT LINES AND FITTINGS (HMMH)
(TM 5-2420-224-20).

37. REMOVE FRONT BRAKE CALIPERS (TM 5-

2420-224-20).

38. REMOVE FRONT PROPELLER SHAFT (page

3-102).

39. REMOVE FRONT AXLE THRUST TUBE

(page 3-105).

INSTALLATION

NOTE
Procedure is the same for both
vehicles except as noted.

1. INSTALL TIE ROD (TM 5-2420-224-20),

2. INSTALL DRAG LINK (TM 5-2420-224-20).

3. INSTALL FRONT BRAKE CALIPERS

HYDRAULIC LINES AND FITTINGS (TM 5-
2420-224-20).

4. INSTALL HYDRAULIC SUSPENSION

LOCKOUT LINES AND FITTINGS (HMMH)
(TM 5-2420-224-20).

5-8
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

5. INSTALL FRONT BRAKE CALIPERS

(TM 5-2420-224-20).

6. INSTALL FRONT AXLE THRUST TUBE (page

3-105).

7. INSTALL FRONT PROPELLER SHAFT (page

3-102).

8. POSITION upper housing HALF (1) on

propeller shaft (2).

9. WITH VEHICLE on suitable jack STANDS,

RAISE VEHICLE and place front axle
assembly (3) in position.

WARNING
Place a suitable support under
torque tube and one wheel.
Failure to do so could result in
injury to personnel.

CAUTION
Make sure slots are alined in
shaft and transmission during
installation to prevent damage
to equipment.

10. APPLY COAT of MOLYBDENUM DISULFIDE

GREASE to propeller shaft FLANGE (4) and
ALINE propeller shaft FLANGE (4) with
transmission output flange (5).

11. APPLY COAT OF SEALING COMPOUND to

six SCREWS (6) and INSTALL. TIGHTEN
SCREWS to 42 Ib-ft (56 N.m).

12. INSTALL lower housing HALF (7), four new

lock washers (8), and four nuts (9). HAND
TIGHTEN.

13. APPLY COAT of SEALING COMPOUND to

four SCREWS (10) and INSTALL four
SCREWS (10) and four washers (11).
TIGHTEN SCREWS to 45 Ib-ft (60 N.m).

14. SLIDE BELLOWS (12) up and INSTALL two

CLAMPS (13). TIGHTEN CLAMPS.

15. INSTALL vent HOSE (14) on bellows (12).

5-9
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

16. APPLY COAT of SEALING COMPOUND to

two SCREWS (15 and 16) and INSTALL
SCREW (15), washer (17), SCREW (16), and
washer (18). TIGHTEN SCREWS to 45 Ib-ft
(60 N.m).

17. USING suitable LIFTING DEVICE, RAISE

VEHICLE off jack stands as required and
place right spring (19) in position.

18. REPEAT STEP 17 for left spring.

19. LOWER VEHICLE onto jack stands.

20. INSTALL screw (20), COVER (21), and new

lock nut (22). TO COMPLETE installation of
right spring (19), TIGHTEN to 103 Ib-ft
(140 N.m).

21. REPEAT STEP 20 for left spring.

5-10
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

22. INSTALL differential lock air HOSE (23), axle

vent HOSE (24), screw (25), clamp (26), and
clamp (27) to torque tube (28).

23. CONNECT brake wear indicator CONNECTOR

(29).

24. INSTALL fluid passage bolt (30), union (31),

two new seals (32 and 33), and axle vent
HOSE (24) to right side of axle assembly (3).

5-11
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

25. CONNECT differential lock air HOSE (23) to

left side of axle assembly (3).

NOTE
Step 26 is for HMMH only.

26. CONNECT hydraulic suspension lockout

HOSES (34) on both sides of vehicle.

27. USING WRENCH, CONNECT two brake

LINES (35 and 36).

NOTE
Step 28 is for HMMH only.

28. CONNECT hydraulic suspension lockout LINE

(37).

29. INSTALL differential lock air HOSE (23), axle

vent HOSE (24), and clamp (38) to torque
tube (28).

5-12
 TM 5-2420-224-34

FRONT AXLE ASSEMBLY REPLACEMENT (CONT)

30. REMOVE SCREW (39), nut (40), and lock

washer (41) from left front shock absorber
mount (42). DISCARD lock WASHER.

31. INSTALL left front shock ABSORBER (43),

screw (39), nut (40), and new lock washer
(41). TIGHTEN to 177 Ib-ft (240 N.m).

32. REPEAT STEPS 30 and 31 for right front

shock absorber.

33. LIFT VEHICLE and REMOVE jack STANDS.

34. INSTALL control ARM (44), screw (45), new

lock washer (46), screw (47), and new lock
nut (46). TIGHTEN to 133 Ib-ft (180 N.m).

35. INSERT drag link ball JOINT (49) into pitman

arm (50) and INSTALL castellated NUT (51)
and new cotter pin (52). TIGHTEN NUT to
111 Ib-ft (150 N.m).

NOTE
Follow-on Maintenance:
Install front loader (SEE) or forklift
(HMMH) (TM 5-2420-224-20).
Install exhaust pipe (front) (TM 5-
2420-224-20).
Install front axle torsion bar
(TM 5-2420-224-20).
Lower cab (TM 5-2420-224-20).
Fill front axle center housing with
oil (LO 5-2420-224-12).
Fill wheel hub drive with oil
(LO 5-2420-224-12).
Fill transmission with fluid (LO 5-
2420-224-12).
Bleed and test brakes (TM 5-
2420-224-20).

5-13
TM 5-2420-224-34

FRONT AXLE THRUST ARMS REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment General Safety instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Adhesive causes immediate
bonding on contact with eyes,
Washer, Lock (8) skin, or clothing and also gives
off harmful vapors. Wear
Washer, Spring
protective goggles and use in
Tension (4)
well-ventilated area. if adhesive
Compound, Sealing Appendix B, Item 15 gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

REMOVAL

NOTE
Procedure is the same for both
front axle thrust arms.

1. REMOVE two SCREWS (1), four lock

washers (2), and two nuts (3). DISCARD lock
WASHERS.

2. REMOVE screw (4), two spring tension

washers (5), nut (6), and front axle thrust
ARM (7). DISCARD spring tension
WASHERS.

5-14
 TM 5-2420-224-34

FRONT AXLE THRUST ARMS REPLACEMENT (CONT)

NOTE
Procedure is the same for both
front axle thrust arms.

1. APPLY COAT of SEALING COMPOUND to

SCREW (1) and INSTALL front axle thrust
ARM (2), screw (1), two new spring tension
washers (3) (with concave side facing away
from nut), and nut (4). TIGHTEN NUT to 184
Ib-ft (250 N.m).

2. APPLY COAT of SEALING COMPOUND to

two SCREWS (5) and INSTALL two SCREWS
(5), four new lock washers (6) (with concave
sides facing each other), and two nuts (7).
TIGHTEN NUTS to 184 Ib-ft (250 N.m).

5-15
TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Materials/Parts (Cont):

Shop Equipment, SC 4910-95-CL-A31 Grease, Molybdenum Appendix B, Item 24

Tool Kit, SC 5180-90-CL-N26 Disulfide
Installation Tool, P/N 387 589 02 15 00
Installing Tool, P/N 387 589 01 15 00 References:
Puller, P/N 406 589 07 33 00
Puller, P/N 000 589 30 33 00 TM 5-2420-224-20
Puller, P/N 000 589 34 33 00 LO 5-2420-224-12

Materials/Parts: Equipment Condition:

Seal (2) Reference Condition Description

Seal (2) TM 5-2420-224-20 Front Brake Calipers

Removed
Washer, Spring
Tension (2) TM 5-2420-224-20 Drag Link Removed

Kit, Parts TM 5-2420-224-20 Tie Rod Removed

Compound, Sealing Appendix B, Item 15

REMOVAL

NOTE
Procedure is the same for both
sides.

1. REMOVE two capscrews (1), two spring

tension washers (2), clamp (3), PLATE (4),
and lubrication fitting (5). DISCARD lubrication
FlTTING.

2. REMOVE and DISCARD WASHER(S) (6).

5-16
 TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

(CONT)

3. REMOVE two expansion capscrews (7),

capscrew (8), steering ARM (9), and LINK
(10).

4. REMOVE bolt (11), two seals (12), and HOSE

(13). DISCARD SEALS.

5. REMOVE SCREW (14) and RELEASE brake

hose CLAMP (15).

6. USING PULLER, REMOVE and DISCARD

BEARING (16).

5-17
TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

(CONT)

7. REMOVE and DISCARD SEAL (17).

8. REMOVE lubrication FITTING (18).

9. REMOVE and DISCARD seal RING (19),

BUSHING (20), seal RING (21), BEARING
(22), RING (23), and seal RING (24).

5-18
 TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

(CONT)

10. REMOVE final DRIVE (25) and propeller

SHAFT assembly (26) from axle (27).

11. USING PULLERS, REMOVE and DISCARD

two SEALS (28).

CAUTION
Be careful not to damage
retaining ring behind bearing.

12. IF DAMAGED, USING PULLERS, REMOVE

BEARING (29).

5-19
TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

(CONT)

INSTALLATION

NOTE
Procedure is the same for both
sides.
Apply coat of molybdenum
disulfide grease to bearings and
seals prior to installation.

1. IF REMOVED, USING INSTALLATION TOOL,

INSTALL new BEARING (1).

2. USING INSTALLING TOOL, INSTALL two

new SEALS (2) with lips facing inward.

3. INSTALL new seal ring (3), new ring (4) with

bevel facing downward, and new BEARING
(5).

5-20
 TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

(CONT)

4. INSTALL final DRIVE (6) and propeller

SHAFT assembly (7) in axle (8).

5. INSTALL new seal ring (9), new BUSHING

(10), and new seal ring (11).

WARNING
Adhesive causes Immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
weil-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

6. APPLY COAT of SEALING COMPOUND to

three CAPSCREWS (12 and 13).

7. INSTALL LINK (14), steering ARM (15),

capscrew (12), and two expansion capscrews
(13). TIGHTEN two CAPSCREWS (13) to
295 Ib-ft (400 N.m). TIGHTEN CAPSCREW
(12) to 133 Ib-ft (180 N.m).

8. INSTALL HOSE (16), two new seals (17), and

bolt (18).

5-21
TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

(CONT)

9. INSTALL lubrication FITTING (19).

10. INSTALL new SEAL (20) with bevel facing

upward.

11. INSTALL new BEARING (21) with recesses

on outer edge facing forward and extractor
groove facing upward.

12. INSTALL new Iubrication fitting (22), PLATE

(23), two spring tension washers (24), and
two capscrews (25). TIGHTEN CAPSCREWS
(25) just enough to make MOVEMENT of final
drive (6) STIFF.

13. BACK OUT two CAPSCREWS (25) just

enough until final drive (6) MOVES
SMOOTHLY.

14. USING feeler GAGE, MEASURE SPACE

between final drive (6) and plate (23).
Measurement is equal to thickness of new
washer(s).

5-22
 TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPLACEMENT

(CONT)

15. REMOVE two capscrews (25), two spring

tension washers (24), and PLATE (23).
INSTALL new WASHER(S) (26). DISCARD
spring tension WASHERS.

16. INSTALL PLATE (23), clamp (27), two new

spring tension washers (24), and two
capscrews (25).

17. INSTALL brake hose CLAMP (28) and screw

(29).

NOTE
Follow-on Maintenance:
Install front brake calipers (TM 5-
2420-224-20).
Install drag link (TM 5-2420-224-
20).
Install tie rod (TM 5-2420-224-20).
Service front axle (LO 5-2420-224-
12).
Service steering knuckle (LO 5-
2420-224-12).

5-23/(5-24 Blank)
 TM 5-2420-224-34

CHAPTER 6
REAR AXLE MAINTENANCE
OVERVIEW

This chapter illustrates and describes procedures for maintenance of the rear axle. A list of tasks
contained in this chapter is shown below.

Page

Rear Axle Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Rear Axle Thrust Arms Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Rear Axle Final Drive Hub Gears and Axle Shaft Replacement . . . . . . . . . . . . . . . 6-15

REAR AXLE ASSEMBLY REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Personnel Required: (2)

Shop Equipment, SC 4910-95-CL-A31 References:

Tool Kit, SC 5180-90-CL-N26
Wrench. P/N 00058951 0300 TM 5-2420-224-20
LO 5-2420-224-12
Materials/Parts:
Equipment Condition:
Nut, Lock
Reference Condition Description
Screw, Lock
TM 5-2420-224-20 Rear Tires Removed
Washer, Lock
TM 5-2420-224-20 Spare Tire and Mount
Nut, Lock (2)
Removed
Nut, Lock
LO 5-2420-224-12 Rear Axle Center Housing
Nut, Lock Drained

Nut, Lock LO 5-2420-224-12 Wheel Hub Drive Drained

Washer, Lock (4) TM 5-2420-224-20 Backhoe (SEE) or Crane

(HMMH) in Three-Point
Washer, Spring Stance
Tension (6)
Packing
Compound, Sealing Appendix B, Item 14

Grease, Molybdenum Appendix B, Item 24

Disulfide
Rags Appendix B, Item 40
Strap, Tiedown Appendix B, Item 43

6-1
TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

General Safety Instructions: General Safety Instructions (Cont):

WARNING WARNING
Control arm weighs more Adhesive causes immediate
than 50 pounds (23 bonding on contact with
kilograms). To avoid personal eyes, skin, or clothing and
injury, use a hoist or suitable also gives off harmful vapors.
lifting device when lifting Wear protective goggles and
control arm. use in well-ventilated area. If
adhesive gets in eyes, try to
Support rear axle during keep eyes open; flush eyes
removal. Failure to do so with water for 15 minutes
could result in injury to and get immediate medical
personnel. attention.
Fuel and oil are slippery and
can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

REMOVAL

NOTE
Procedure is the same for both
vehicles.

1. REMOVE nut (1), washer (2), two spacers (3),

washer (4), and BOLT (5) and Disconnect
ALB valve SPRING (6).

6-2
 TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

2. REMOVE lock nut (7), screw (8), lock screw

(9), lock washer (10), and control ARM (11).
DISCARD lock NUT, lock SCREW, and lock
WASHER.

3. REMOVE lock nut (12), washer (13), and

SCREW (14) and DISCONNECT left rear
shock ABSORBER (15) and torsion bar LINK
(16) at left rear shock absorber mount (17).
DISCARD lock NUT.

4. REPEAT STEP 3 for right rear shock

absorber.

NOTE
Tag all lines prior to disconnecting
to aid in connecting.

5. DISCONNECT two air HOSES (18 and 19).

6. LOOSEN SCREW (20) and RELEASE brake

HOSE (21).

7. USING WRENCH, DISCONNECT brake

HOSE (21).

6-3
TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

8. REMOVE BOLT (22) and look nut (23) and

LIFT left parking brake wire ROPE (24) from
parking brake lever (25). DISCARD lock NUT.

9. REMOVE two screws (26), two nuts (27), two

washers (28), and left parking brake wire
ROPE (24).

10. REMOVE SCREW (29) and nut (30) from left

spring shackle (31).

11. REMOVE bolt (32), lock nut (33), tiedown

straps (34), and right parking brake wire
ROPE (35). DISCARD lock NUT.

12. REMOVE BOLT (36) and lock nut (37) from

right spring cover (38). DISCARD lock NUT.

6-4
 TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

13. POSITION transmission JACK or equivalent

under differential of rear axle.

14. REMOVE screw (39), washer (40), and

BRACKET (41).

15. REMOVE vent HOSE (42) from bellows (43).

16. LOOSEN two SCREWS (44), REMOVE two

CLAMPS (45 and 46), and SLIDE BELLOWS
(43) back toward axle.

17. REMOVE four NUTS (47) and four lock

washers (48). DISCARD lock WASHERS.

18. REMOVE six SCREWS (49) and six spring

tension washers (50). DISCARD spring
tension WASHERS.

19. REMOVE two HOUSINGS (51).

NOTE
To gain access to all screws,
rotate propeller shaft.

20. REMOVE six SCREWS (52) and packing (53).

DISCARD PACKING.

CAUTION
Support axle torque tube prior
to removal to prevent damage
to equipment.

21. REMOVE rear AXLE assembly (54) and

PLACE ON suitable STANDS.

6-5
TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

NOTE
Number of tiedown straps varies
between vehicles.

22. REMOVE tiedown STRAP(S) (55).

23. REMOVE clamp (56), BRACKET (57), and

grommet (58).

24. REMOVE two clamps (59) and four clamp

BLOCKS (60).

25. REMOVE air HOSE (18).

26. REMOVE clamp (61), clamp block (62), bolt

(63), and air HOSE (19).

27. REMOVE REAR BRAKE CALIPERS

HYDRAULIC LINES AND FITTINGS (TM 5-
2420-224-20).

28. REMOVE REAR BRAKE CALIPERS (TM 5-

2420-224-20).

29. REMOVE REAR PROPELLER SHAFT (page

3-102).

30. REMOVE REAR AXLE THRUST TUBE (page

3-105).

6-6
 TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

INSTALLATION

NOTE
Procedure is the same for both
vehicles.

1. INSTALL REAR BRAKE CALIPERS

HYDRAULIC LINES AND FlTTINGS (TM 5-
2420-224-20).

2. INSTALL REAR BRAKE CALIPERS (TM 5-

2420-224-20).

3. INSTALL REAR AXLE THRUST TUBE (page

3-105).

4. INSTALL rear PROPELLER SHAFT (page

3-102).

5. INSTALL air HOSE (1) to rear axle assembly (2).

6. INSTALL air HOSE (3), bolt (4), clamp block

(5), and clamp (6).

7. INSTALL four clamp BLOCKS (7) and two

clamps (8) securing two air hoses (1 and 3)
to rear axle assembly (2).

8. INSTALL clamp (9), BRACKET (10), and

grommet (11).

9. INSTALL tiedown STRAP(S) (12) as required

to secure two air hoses (1 and 3).

6-7
TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

10. PLACE rear AXLE assembly (2) on

transmission JACK or equivalent.
11. INSTALL new PACKING (13).

CAUTION
Support axle torque tube prior
to installing rear axle assembly
to prevent damage to
equipment.

12. WITH VEHICLE on suitable jack STANDS,

RAISE VEHICLE and PLACE rear AXLE
assembly (2) in position.

CAUTION
Make sure slots are alined in
shaft and transmission during
installation to prevent damage to
equipment.

13. APPLY COAT of MOLYBDENUM DISULFIDE

GREASE to propeller shaft FLANGE (14) and
ALINE propeller shaft FLANGE (14) with
transmission output FLANGE (15).
14. APPLY COAT of SEALING COMPOUND to
six SCREWS (16). INSTALL six SCREWS
(16) and TIGHTEN to 42 Ib-ft (56 N.m).

15. INSTALL two HOUSINGS (17), four new lock

washers (18), and four nuts (19). TIGHTEN
NUTS hand-tight.
16. APPLY COAT of SEALING COMPOUND to
six SCREWS (20). INSTALL six SCREWS
(20) and six new spring tension washers (21 )
until SNUG.
17. TIGHTEN four NUTS (19).
18. TIGHTEN six SCREWS (20) to 42 lb-ft
(62 N.m).
19. INSTALL BELLOWS (22) and clamps (23 and
24). TIGHTEN two SCREWS (25).
20. INSTALL vent HOSE (26) in bellows (22).
21. INSTALL BRACKET (27), screw (28), and
washer (29).

6-8
 TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

22. USING WRENCH, CONNECT brake HOSE

(30).

23. INSTALL brake HOSE (30) and TIGHTEN

SCREW (31).

24. CONNECT two air HOSES (1 and 3).

NOTE
Aline bottom of spring with stop
on spring cover.

25. INSTALL BOLT (32) and new lock nut (33) in

right spring rover (34).

26. INSTALL right parking brake wire ROPE (35),

bolt (36), new lock nut (37), and tie straps
(36).

6-9
 TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

NOTE
Aline bottom of spring with stop
on spring shackle.

27. INSTALL SCREW (39) and nut (40) in left

spring shackle (41).

28. INSTALL left parking brake wire ROPE (42),

two screws (43), two washers (44), and two
nuts (45).

29. INSTALL left parking brake wire ROPE (42) in

parking brake lever (46) with bolt (47) and
new lock nut (48).

30. CONNECT left rear shock ABSORBER (49)

and torsion bar LINK (50) at left rear shock
absorber mount (51) and INSTALL new lock
nut (52), washer (53), and SCREW (54).
TIGHTEN SCREW to 178 Ib-ft (240 N.m).

31. REPEAT STEP 30 for right rear shock

absorber.

CAUTION
Position control arm to avoid
interference with rear axle to
prevent damage to equipment.

32. INSTALL control ARM (55), new lock screw

(56), new lock washer (57), screw (58), and
new lock nut (59). TIGHTEN to 133 Ib-ft
(180 N.m).

6-10
 TM 5-2420-224-34

REAR AXLE ASSEMBLY REPLACEMENT (CONT)

33. CONNECT ALB valve SPRING (60) and

INSTALL BOLT (61), washer (62), two
spacers (63), washer (64), and nut (65).

NOTE
Follow-on Maintenance:
Install rear tires (TM 5-2420-
224-20).
Install spare tire and mount
(TM 5-2420-224-20).
Fill rear axle center housing with
oil (LO 5-2420-224-12).
Fill wheel hub drive with oil
(LO 5-2420-224-12).
Bleed and test brakes (TM 5-
2420-224-20).
Service ball joint (LO 5-2420-
224-12).
Adjust brake pressure regulator
(ALB valve) (page -).
Adjust parking brake (TM 5-2420-
224-20).

6-11
TM 5-2420-224-34

REAR AXLE THRUST ARMS REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Adhesive causes immediate
bonding on contact with eyes,
Washer, Lock (4) skin, or clothing and also gives
off harmful vapors. Wear
Washer, Lock (2)
protective goggles and use in
Compound, Sealing Appendix B, item 15 well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

REMOVAL

1. REMOVE two SCREWS (1), four lock

washers (2), and two nuts (3). DISCARD lock
WASHERS.

6-12
 TM 5-2420-224-34

REAR AXLE THRUST ARMS REPLACEMENT (CONT)

2. REMOVE nut (4), lock washer (5), screw (6),

index plate (7), washer (8), and left rear axle
thrust ARM (9). DISCARD lock WASHER.

3. REMOVE nut (10), lock washer (11), screw

(12), index plate (13), washer (14), and right
rear axle thrust ARM (15). DISCARD lock
WASHER.

INSTALLATION

1. APPLY COAT of SEALING COMPOUND to

SCREW (1) and INSTALL screw (1), washer
(2), right rear axle thrust ARM (3), index plate
(4), new lock washer (5), and nut (6).
TIGHTEN NUT to 184 Ib-ft (250 N.m).

6-13
TM 5-2420-224-34

REAR AXLE THRUST ARMS REPLACEMENT (CONT)

2. APPLY COAT of SEALING COMPOUND to

SCREW (7) and INSTALL screw (7), washer
(8), left rear axle thrust ARM (9), index plate
(10), new lock washer (11), and nut (12).
TIGHTEN NUT to 184 Ib-ft (250 N.m).

3. APPLY COAT of SEALING COMPOUND to

two SCREWS (13) and INSTALL two
SCREWS (13), four new lock washers (14),
and two nuts (15). TIGHTEN SCREWS to
184 Ib-ft (250 N.m).

6-14
 TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT
This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26 TM 9-214
Puller, P/N 000 589 35 33 00 LO 5-2420-224-12

Materials/Parts: Equipment Condition:

Washer, Spring Reference Condition Description
Tension
TM 5-2420-224-20 Rear Brake Calipers
Washer, Spring Removed
Tension
Seal General Safety Instructions:

Ring, Wear
WARNING
Bearing
Fuel and oil are slippery and
Compound, Sealing Appendix B, Item 15 can cause falls. To avoid
injury, wipe up spilled fuel or
Compound, Sealing Appendix B, Item 16 oil with rags.
Rags Appendix B, Item 40

REMOVAL

1. REMOVE drain PLUG (1) and DRAIN FLUID

into suitable container.

2. REMOVE 12 screws (2) and rear axle final

drive HOUSING (3).

6-15
TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT (CONT)

3. REMOVE axle SHAFT (4).

4. REMOVE and DISCARD spring tension

WASHER (5).

5. USING PULLER and suitable PULLER,

REMOVE GEAR (6) and bearing (7).

6. USING suitable PRESS, REMOVE

(7) and spacer (8) from gear (6).

6-16
 TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT (CONT)

7. REMOVE spring tension washer (9) and

SPACER(S) (10) from gear (11). DISCARD
spring tension WASHER.

8. USING suitable PRESS, REMOVE GEAR (11)

and any shim(s) (12).

9. REMOVE and DISCARD SEAL (13), wear

RING (14), and BEARING (15).

6-17
 TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT (CONT)

10. USING suitable PULLER, REMOVE BEARING

(16).

11. USING suitable PULLER, REMOVE BEARING

(17).

12. IF DAMAGED, REMOVE three PLUGS (18).

INSPECTION

1. Inspect housing for galling, cracks, or stripped

threads.

2. Inspect bearings (TM 9-214).

3. Inspect gears for worn or broken teeth.

4. inspect axle for cracks.

INSTALLATION

1. IF REMOVED, INSTALL three new PLUGS

(1).

2. MEASURE and RECORD depth of bearing

seat A.

3. USING suitable INSTALLER, INSTALL

BEARING (2).

6-18
 TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT (CONT)

4. USING suitable PRESS and suitable

INSTALLER, INSTALL BEARING (3).

5. USING suitable PRESS and suitable

INSTALLER, INSTALL GEAR (4).

6. INSTALL SPACER(S) (5) and new spring

tension washer (6).

6-19
 TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT (CONT)

7. USING suitable INSTALLER, INSTALL new

BEARING (7). DISCARD bearing RETAINER.

8. INSTALL new SEAL (8) and new wear RING

(9).

9. USING suitable PRESS, INSTALL BEARING

(10) and spacer (11) on gear (12).

6-20
 TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT (CONT)

10. USING suitable PRESS, INSTALL GEAR (12).

11. INSTALL new spring tension WASHER (13).

12. MEASURE and RECORD dimension B for

bearing (3).

6-21
TM 5-2420-224-34

REAR AXLE FINAL DRIVE HUB GEARS AND AXLE SHAFT

REPLACEMENT (CONT)

13. MEASURE and RECORD dimension C.

14. ADD A from step 2 and C from step 13.

15. SUBTRACT total in step 14 from B in step 12

to determine shim thickness.

16. INSTALL axle SHAFT (14).

17. INSTALL SHIM(S) (15) per step 15.

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

18. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 16) to mounting FLANGE
of rear axle final drive housing (16). APPLY
COAT of SEALING COMPOUND (Appendix B,
Item 15) to THREADS of 12 screws (17).
INSTALL rear axle final drive HOUSING (16)
and 12 screws (17). TIGHTEN SCREWS to
75 Ib-ft (100 N.m).

19. FILL rear axle final drive HUB with gear oil
(LO 5-2420-224-12).

20. INSTALL drain PLUG (18).

NOTE
Follow-on Maintenance:
Install rear brake calipers (TM 5-
2420-224-20).

6-22
 TM 5-2420-224-34

CHAPTER 7
BRAKE AND STEERING SYSTEMS MAINTENANCE

This chapter illustrates and describes procedures for maintenance of the brake and steering systems. A
list of tasks contained in this chapter is shown below.

Page

Brake Pressure Regulator (ALB Valve) Replacement . . . . . . . . . . . . . . . . . . . . . 7-1

Brake Pressure Regulator (ALB Valve) Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-5

Power Steering Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Power Steering Pump and Bracket Replacement.. . . . . . . . . . . . . . . . . . . . . . 7-14

Pitman Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

BRAKE PRESSURE REGULATOR (ALB VALVE) REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Backhoe (SEE) or Crane
Materials/Parts: (HMMH) in Three-Point
Stance
Washer, Spring
Tension (2) General Safety Instructions:
Seal (2)
Rags Appendix B, Item 40 WARNING
Fuel and oil are slippery and
References: can cause falls. To avoid
TM 5-2420-224-20 injury, wipe up spilled fuel or
oil with rags.

7-1
TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) REPLACEMENT (CONT)

REMOVAL

NOTE
• Procedure is the same for both
vehicles.
• Tag lines prior to disconnecting
to aid in connecting.
• Have suitable container
available to catch any brake
fluid that may spill out.

1. DISCONNECT two brake LINES (1) and brake

HOSE (2).

7-2
 TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) REPLACEMENT (CONT)

2. REMOVE nut (3), washer (4), two spacers (5),

SPRING (6), washer (7), and screw (8).

3. REMOVE two bolts (9), two spring tension

washers (10), access cover (11), and brake
pressure REGULATOR (ALB valve) (12).
DISCARD spring tension WASHERS.

4. REMOVE hollow bolt (13), two seals (14), and

FITTING (15). DISCARD SEALS.

INSTALLATION

NOTE
Procedure is the same for both
vehicles.

1. INSTALL FlTTING (1), two new seals (2), and

hollow bolt (3). DO NOT TIGHTEN hollow
BOLT (3).

7-3
TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) REPLACEMENT (CONT)

2. INSTALL brake pressure REGULATOR (ALB

valve) (4), access cover (5), two new spring
tension washers (6), and two bolts (7).

3. INSTALL screw (8), washer (9), SPRING (10),

two spacers (11), washer (12), and nut (13).

4. CONNECT two brake LINES (14) and brake

HOSE (15).

5. TIGHTEN hollow BOLT (3).

NOTE
Follow-on Maintenance:
Bleed brake system (TM 5-2420-
224-20).

7-4
 TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) ADJUSTMENT

This task covers: a. Installation b. Testing c. Adjustment d. Removal

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TooI Kit, SC 5180-90-CL-N26
Gage Panel, P/N 0005896421 00 TM 5-2420-224-20 Spare Tire and Mount
Removed
Personnel Required: (2)
TM 5-2420-224-20 Vehicle Blocked
References: Parking Brake Released
TM 5-2420-224-10
TM 5-2420-224-20 TM 5-2420-224-20 Outside Engine Hood
TM 5-2420-224-10 Removed

INSTALLATION

CAUTION
• Only silicone brake fluid may be used in gauge to prevent damage to
equipment.

• If gauge is used with silicone brake fluid, do not mix with standard brake fluid
to prevent damage to equipment.

NOTE
Procedure is the same for both vehicles.

1. CHECK that fuel TANK is full.

2. CHECK that hydraulic TOOLS are STORED on vehicle and FRONT LOADER (SEE) or FORKLIFT
(HMMH) and BACKHOE (SEE) or CRANE (HMMH) are STOWED in transport position.

3. CHECK that brake fluid LEVELS are at operating level. BEFORE CONNECTING GAUGE to brake
system, MARK brake fluid LEVEL on reservoirs.

4. CHECK that hydraulic RESERVOIRS are at operating level.

7-5
TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) ADJUSTMENT (CONT)

5. REMOVE BACKHOE (SEE) or CRANE

(HMMH) from TRANSPORT position and
PLACE in WORK position (TM 5-2420-224-
10).

6. REMOVE two CAPS (1) from test connections

(2 and 3).

7. INSTALL two male quick-coupler FlTTINGS

provided with gage panel.

8. CONNECT two pressure gage HOSES (4) to

test connections as follows:

a. PLACE pressure gage HOSE from

GAGE A of GAGE PANEL to
CONNECTION of CIRCUIT 1 (2) of
vehicle MODULATED test port.

b. PLACE pressure gage HOSE from

GAGE B of GAGE PANEL to
CONNECTION of CIRCUIT 2 (3)
vehicle UNMODULATED test port.

TESTING
1. Purge/bleed pressure gage at two bleed port
fittings (5 and 6) located on each side of
gauge by pressing brake pedal several times.

2. While pressing brake pedal to full actuation

(floor) and holding, open bleed port (5) on left
side of gage panel for gage A. Close bleed
port (5) for gage A.

3. Repeat until there is steady, clear flow of

brake fluid.

4. Repeat procedure for right side of gage panel

by bleeding port (6) for gage B.

5. After purging/bleeding gages, gage panel is

ready to be used to adjust ALB valve.

7-6
 TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) ADJUSTMENT (CONT)

ADJUSTMENT

NOTE
For fail-safe adjustment, rear axle
load must be released.

1. To release rear axle load, remove control

spring (1) connecting ALB valve (2) to rear
torque tube (3), or use backhoe (SEE) or
crane (HMMH) outriggers to raise rear tires
completely off the ground.

CAUTION
After spring tension has been
released, make sure air
pressure of vehicle brake
system is not below 90 psi (6
bar) as indicated on air
pressure gage located on
instrument panel to prevent
damage to equipment.

2. Position gage panel so gages can be read

accurately. Slowly press brake pedal until full
brake pedal pressure is achieved. Both
pressure gages should rise until gage A reads
modulated fall-safe pressure setting of 515 psi
(35 bar). Tolerance of ±44 psi (±3 bar) is
permissible. Gage B of unmodulated circuit
should read approximately 1924-2072 psi
(130-140 bar).

NOTE
Pressure of gage A must be set
to 515 psi (35 bar).
Do not apply brake pedal
pressure while adjusting ALB
valve.

3. To obtain setting for gage A, adjust screw (4)

on ALB valve (2) as necessary. Tolerance of
±44 psi (±3 bar) is permissible.

4. Loosen retainer lock nut (5) and turn screw

(4) clockwise to increase pressure or
counterclockwise to decrease pressure, to
obtain required setting. Tighten retainer lock
nut.

7-7
TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) ADJUSTMENT (CONT)

NOTE
If adjustment setting cannot be
obtained and gage readings
fluctuate after rechecking, it may
be necessary to bleed brake
system (TM 5-2420-224-20) and
repeat Adjustment steps 1 thru 5.

5. Press brake pedal several times to activate

brake system. Recheck gage reading for
proper pressure setting.

CAUTION
Before performing steps 6 thru
13, ALB fail-safe pressure
setting must be completed to
prevent damage to equipment.

6. Install spare tire (TM 5-2420-224-20).

7. If removed, install control spring (1) to rear
torque tube (3) or retract outriggers.
8. Place backhoe (SEE) or crane (HMMH) in
transport position (TM 5-2420-224-10).

CAUTION
Make sure air pressure of
vehicle brake system is not
below 90 psi (6 bar) as
indicated on air pressure gage
located on instrument panel to
prevent damage to equipment.

NOTE
Gage A indicates pressure of
modulated circuit 1. This pressure
is proportionate to rear axle load
with vehicle in transport position.

9. Position gage panel so gages can be read

accurately. Slowly press brake pedal until full
pedal pressure is achieved. Both pressure
gages should rise until gage A reads modulated
rear axle load pressure setting of 1352 psi
(92 bar). Tolerance of ±44 psi (±3 bar) is
permissible. Gage B of unmodulated circuit
should read approximately 1924-2072 psi
(130-140 bar).

7-8
 TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) ADJUSTMENT (CONT)

NOTE
Forward movement will
decrease spring tension, which
will drop ALB brake pressure.
Backward movement will
increase spring tension, which
will increase ALB brake
pressure.
Do not apply brake pressure
while adjusting spring.

10. If necessary, adjust ALB rear axle load

pressure to 1352 psi (92 bar) by loosening
and moving control spring mounting bolt (6)
on torque tube (3) forward or backward.
Tolerance of ±44 psi (±3 bar) is permissible.

11. Tighten mounting bolt (6).

12. If rear axle load pressure is too high and

control spring (1) is at maximum forward
position in elongated hole on torque tube (3),
perform the following:

a. Loosen two 19 mm bolts (7) on ALB

valve mounting bracket (8) located on
right side of frame rail behind fuel
tank.

b. Rotate ALB valve mounting bracket (8)

upward to gain additional adjustment
freeplay.

c. Tighten two ALB valve bracket

mounting bolts (7).

d. Adjust rear axle load pressure

according to specifications in step 10,
above.

NOTE
If adjustment setting cannot be
obtained and gage readings
fluctuate after rechecking, it may
be necessary to bleed brake
system (TM 5-2420-224-20) and
repeat Adjustment steps 6 thru 13.

13. Press brake pedal several times to activate

brake system. Recheck gage reading for
proper pressure setting.

7-9
TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) ADJUSTMENT (CONT)

NOTE
Procedure is the same for both
vehicles.

1. REMOVE BACKHOE (SEE) or CRANE

(HMMH) from TRANSPORT position and
PLACE in WORK position (TM 5-2420-
224-10).

2. REMOVE SPARE TIRE (TM 5-2420-224-20).

3. DISCONNECT pressure gage HOSES (1)

from vehicle test ports (2) and REMOVE two
male quick-coupler FlTTINGS from test ports
(2).

4. INSTALL two CAPS (3) and HAND-TIGHTEN.

5. PLACE two male quick-coupler FlTTINGS

back INSIDE gage panel.

6. CHECK that brake fluid LEVEL remains at

level previously marked.

7. PLACE BACKHOE (SEE) or CRANE (HMMH)

in TRANSPORT position (TM 5-2420-224-10).

NOTE
Follow-on Maintenance:
install spare tire and mount
(TM 5-2420-224-20).
Install outside engine hood (TM 5-
2420-224-20).
Unblock vehicle (TM 5-2420-
224-20).

7-10
 TM 5-2420-224-34

POWER STEERING GEAR REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26 LO 5-2420-224-12
Puller, P/N 406589053300
Equipment Condition:
Materials/Parts:
Reference Condition Description
Pin, Cotter
TM 5-2420-224-20 Cab Tilted
Seal (2)
LO 5-2420-224-12 Power Steering
Reservoir Drained

1. REMOVE cotter pin (1) and castellated NUT

(2) from power steering gear (3). DISCARD
cotter PIN.

2. USING PULLER, DISCONNECT pitman ARM

(4) from power steering gear assembly (3).

7-11
 TM 5-2420-224-34

POWER STEERING GEAR REPLACEMENT (CONT)

NOTE
Tag all lines prior to disconnecting
to aid in connecting.

3. DISCONNECT TUBE (5) from power steeling

gear assembly (3).

4. REMOVE hollow BOLT (6) and two seals (7)

and DISCONNECT TUBE (8). DISCARD
SEALS.

5. USING suitable HOIST, SUPPORT weight of

power steering GEAR assembly (3).

6. REMOVE four screws (9), four washers (10),

and power steering GEAR assembly (3).

INSPECTION

1. Inspect housings for galling, cracks, or

stripped threads.

Inspect splines on steering shaft for damage.

INSTALLATION
1. USING suitable HOIST, INSTALL power
steering GEAR assembly (1), four screws (2),
and four washers (3). TIGHTEN two
SMALLER SCREWS to 144 Ib-ft (195 N.m)
and two LARGER SCREWS to 173 Ib-ft
(235 N.m).

7-12
 TM 5-2420-224-34

POWER STEERING GEAR REPLACEMENT (CONT)

2. INSTALL hollow BOLT (4) and two new seals

(5) and CONNECT TUBE (6) to power
steering gear assembly (1).

3. CONNECT TUBE (7).

4. CONNECT pitman ARM (8) on power steering

gear assembly (1) and INSTALL castellated
NUT (9) and new cotter pin (10).

NOTE
Follow-on Maintenance:
Fill power steering reservoir
(LO 5-2420-224-12).
Lower cab (TM 5-2420-224-20).

7-13
TM 5-2420-224-34

POWER STEERING PUMP AND BRACKET REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20

TooI Kit, SC 5180-90-CL-N26 LO 5-2420-224-12

Materials/Parts: Equipment Condition:

Strap Reference Condition Description

Nut, Lock TM 5-2420-224-20 Cab Tilted
Washer, Spring LO 5-2420-224-12 Power Steering Reservoir
Tension (4) Drained
Washer, Lock TM 5-2420-224-20 Front Plate Removed

1. LOOSEN lock NUT (1).

2. REMOVE and DISCARD STRAP (2).

3. DISCONNECT HOSE assembly (3).

4. LOOSEN NUT (4) and NUT (5) and TURN

adjusting SCREW (6) in.

5. ROTATE power steering PUMP (7) toward

engine (8), DISCONNECT BELT’ (9), and
ROTATE power steering PUMP (7) away from
engine (8) as far as it will go.

7-14
 TM 5-2420-224-34

POWER STEERING PUMP AND BRACKET REPLACEMENT (CONT)

6. REMOVE lock nut (1) and PULLEY (10).

DISCARD lock NUT.

7. REMOVE four bolts (11), four spring tension

washers (12), and power steering PUMP (7).
DISCARD spring tension WASHERS.

8. REMOVE TUBE (13) and fitting (14).

9. REMOVE compression sleeve (15) and union

NUT (16) from tube (13).

10. REMOVE FlTTING (17).

11. REMOVE bolt (18), washer (19), and CLAMP

(20).

12. REMOVE nut (4), lock washer (21), screw

(22), and BRACKET (23). DISCARD lock
WASHER.

INSTALLATION

1. INSTALL BRACKET (1), screw (2), new lock

washer (3), and nut (4). HAND TIGHTEN.

7-15
TM 5-2420-224-34

POWER STEERING PUMP AND BRACKET REPLACEMENT (CONT)

2. INSTALL CLAMP (5), washer (6), and bolt (7).

3. INSTALL FlTTING (8).

4. INSTALL union NUT (9) and compression

sleeve (10) in tube (11).

5. INSTALL fillng (12) and TUBE (11).

6. INSTALL power steering PUMP (13), four new

spring tension washers (14), and four bolts
(15).

7. INSTALL PULLEY (16) and new lock nut (17).

8. ROTATE power steering PUMP (13) toward

engine (18), CONNECT BELT (19), and
TURN adjusting SCREW (20) out until belt
tension of 1/2 in. (10-15 mm) is attained.
TIGHTEN NUT (21).

9. CONNECT HOSE assembly (22).

10. INSTALL new STRAP (23).

11. TIGHTEN NUT (4) and lock NUT (17) to

66 Ib-ft (90 N.m).

NOTE
Follow-on Maintenance:
Install front plate (TM 5-2420-
224-20).
Fill power steering reservoir
(LO 5-2420-224-12).
Lower cab (TM 5-2420-224-20).

7-16
 TM 5-2420-224-34

PITMAN ARM REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP
Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20

TooI Kit, SC 5180-90-CL-N26
Puller, P/N 406 589 06 33 00 Equipment Condition:

Materials/Parts: Reference Condition Description

Washer TM 5-2420-224-20 Drag Link Removed

REMOVAL

1. REMOVE NUT (1) and washer (2). DISCARD

WASHER.

CAUTION
Do not loosen pitman arm
by means of hammer blows.
Damage to internal steering
components may result.

USING PULLER, REMOVE pitrnan ARM (3).

INSTALLATION

CAUTION
Do not install pitman arm
by means of hammer blows.
Damage to internal steering
components may result.

1. INSTALL pitman ARM (3), new washer (2),

and nut (1). TIGHTEN to 258-295 Ib-ft
(350-400 N.m).

2. BEND TAB on washer (2) toward pitman arm

(3).

NOTE
Follow-on Maintenance:
Install and adjust drag link (TM 5-
2420-224-20).

7-17/(7-18 Blank)
 TM 5-2420-224-34

CHAPTER 8
FRAME AND TOWING ATTACHMENTS MAINTENANCE

OVERVIEW

This chapter illustrates and describes procedures for maintenance of the frame and towing attachments.
A list of tasks contained in this chapter is shown below.

Page

Rear Frame Section and Subframe Replacement . . . . . . . . . . . . . . . . . . . . . . . 8-1

Forklift Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Left Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Right Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

REAR FRAME SECTION AND SUBFRAME REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP
Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Backhoe Assembly (SEE)
MateriaIs/Parts: Removed (HMMH)

Nut, Lock
TM 5-2420-224-20 Chassis Tool Box/Deck
Washer, Lock (4) Plate Removed
Compound, Sealing Appendix B, item 15 TM 5-2420-224-20 Backhoe Subframe Deck
(SEE) Removed
Personnel Required: (2)
TM 5-2420-224-20 Crane Travel Lock
References: (HMMH) Removed

TM 5-2420-224-20 TM 5-2420-224-20 Backhoe Latch Cylinder

(SEE) or Crane Latch
Cylinder (HMMH)
Removed

TM 5-2420-224-20 Fuel Tank Removed

TM 5-2420-224-20 Air Pressure Tanks
Removed
Page 8-9 Left Platform (SEE)
Removed
Page 8-13 Right Platform (SEE)
Removed

8-1
TM 5-2420-224-34

REAR FRAME SECTION AND SUBFRAME REPLACEMENT (CONT)

General Safety Instructions: General Safety Instructions (Cont):

WARNING WARNING
• SEE/HMMH should not be • Rear frame section and
operated with backhoe (SEE) subframe weigh 598 pounds
or crane (HMMH) removed, (272 kilograms). To avoid
except in a maintenance personaI injury, use a hoist
facility. When maintenance is or suitable lifting device
required and backhoe or when lifting frame section
crane is removed, never and subframe.
operate SEE/HMMH at
speeds greater than 5 mph. • Adhesive causes immediate
Tractor stability and handling bonding on contact with
characteristics are greatly eyes, skin, or clothing and
affected with either backhoe also gives off harmful vapors.
or crane removed. This could Wear protective goggles and
cause loss of control and use in well-ventilated area. If
injury to personnel or adhesive gets in eyes, try to
damage to vehicle. keep eyes open; flush eyes
with water for 15 minutes
and get immediate medical
attention.

NOTE
Procedure is the same for both
vehicles.

1. REMOVE lock nut (1), bolt (2), and BRACKET

(3). DISCARD lock NUT.

8-2
 TM 5-2420-224-34

REAR FRAME SECTION AND SUBFRAME REPLACEMENT (CONT)

NOTE
Steps 2 thru 4 are the same for
both sides of vehicle.

2. REMOVE nut (4), BOLT (5), and bushing (6)

from subframe (7).

3. REMOVE four SCREWS (8) and four washers

(9) from rear frame section (10).

4. REMOVE two nuts (11), two lock washers

(12), two capscrews (13), and BRACKET (14)
from rear frame section (10). DISCARD lock
WASHERS.

NOTE
Rear frame section and subframe
must be removed as an assembly.

5. REMOVE rear frame SECTION (10) and

SUBFRAME (7) as an assembly.

8-3
TM 5-2420-224-34

REAR FRAME SECTION AND SUBFRAME REPLACEMENT (CONT)

6. REMOVE two retaining rings (15), pin (16),

and rear frame SECTION (10) from subframe
(7).

7. IF DAMAGED, REMOVE lubrication FlTTING

(17).

INSTALLATION

NOTE
Procedure is the same for both
vehicles.

1. IF REMOVED, INSTALL new lubrication

FITTING (1).

8-4
 TM 5-2420-224-34

REAR FRAME SECTION AND SUBFRAME REPLACEMENT (CONT)

2. INSTALL rear frame SECTION (2), pin (3),

and two retaining rings (4) on subframe (5).

NOTE
Rear frame section and subframe
must be installed as an assembly.

3. INSTALL SUBFRAME (5) and rear frame

SECTION (2) as an assembly.

NOTE
Steps 4 thru 6 are the same for
both sides of vehicle.

4. INSTALL BRACKET (6), two capscrews (7),

two new lock washers (8), and two nuts (9) in
rear frame section (2).

5. APPLY COAT of SEALING COMPOUND to

four SCREWS (10) and INSTALL four
washers (11) and four SCREWS (10) in rear
frame section (2). TIGHTEN TOP SCREWS to
150 Ib-ft (203 N.m). TIGHTEN LOWER
SCREWS to 220 Ib-ft (298 N.m).

8-5
TM 5-2420-224-34

REAR FRAME SECTION AND SUBFRAME REPLACEMENT (CONT)

6. INSTALL BUSHING (12) in subframe (5).

7. APPLY COAT of SEALING COMPOUND to

BOLT (13) and INSTALL BOLT (13) and nut
(14) in subframe (5). TIGHTEN NUT to
600 lb-ft (814 N.m).

8. INSTALL BRACKET (15), bolt (16), and new

lock nut (17).

NOTE
Follow-on Maintenance:
Install right platform (SEE) (page
8-13).
Install left platform (SEE) (page
8-9).
Install fuel tank (TM 5-2420-
224-20).
Install air pressure tanks (TM 5-
2420-224-20).
Install backhoe latch cylinder
(SEE) or crane latch cylinder
(HMMH) (TM 5-2420-224-20).
Install crane travel lock (HMMH)
(TM 5-2420-224-20).
Install backhoe subframe deck
(SEE) (TM 5-2420-224-20).
Install chassis tool box/deck plate
(TM 5-2420-224-20).
Install backhoe assembly (SEE) or
crane (HMMH) (TM5-2420-224-20).

8-6
 TM 5-2420-224-34

FORKLIFT MOUNTING BRACKET REPLACEMENT

This task rovers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: General Safety Instructions:

HMMH

Tools and Special Equipment: WARNING

l HMMH should not be
Shop Equipment, SC 4910-95-CL-X31 operated with forklift
Tool Kit, SC 5180-90-CL-N26
removed, except in a
Materials/Parts: maintenance facility. When
maintenance is required and
Washer, Lock (2) forklift is removed, never
operate HMMH at speeds
Washer, Lock (2)
greater than 5 mph. Tractor
Personnel Required: (2) stability and handling
characteristics are greatly
References: affected with forklift removed.
This could cause loss of
TM 5-2420-224-20 control and injury to
personnel or damage to
Equipment Condition: vehicle.
Reference Condition Description . Forklift mounting bracket
TM 5-2420-224-20 Forklift Removed weighs 199 pounds (90
kilograms). To avoid personal
injury, use a hoist or suitable
lifting device when lifting
forklift mounting bracket.

8-7
TM 5-2420-224-34

FORLIFT MOUNTING BRACKET REPLACEMENT (CONT)

REMOVAL

1. REMOVE two capscrews (1), two lock washers (2), two eyebolts (3), and two PINS (4). DISCONNECT
two tilt CYLINDERS (5). DISCARD lock WASHERS.

2. REMOVE two capscrews (6), two lock washers (7), two eyebolts (8), two pins (9), and forklift mounting
BRACKET (10). DISCARD lock WASHERS.

INSTALLATION

1. INSTALL forklift mounting BRACKET (10), two pins (9), two eyebolts (8), two new lock washers (7),
and two capscrews (6).

2. CONNECT two tilt CYLINDERS (5). INSTALL two PINS (4), two eyebolts (3), two new lock washers
(2), and two capscrews (1).

NOTE
Follow-on Maintenance:
Install forklift (TM 5-2420-224-20).

8-8
 TM 5-2420-224-34

LEFT PLATFORM R E P L A C E M E N T
This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Applicable Configuration: Equipment Condition (Cont):

SEE Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Hydraulic Oil Cooler
Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 TM 5-2420-224-20 Hose Reel Assembly
Removed
Materials/Parts:
TM 5-2420-224-20 Front Hydraulic Tank
Nut, Lock (2) Removed
Nut, Lock (4) Page 11-5 Tilt and Latch Control
Valve Removed
Compound, Sealing Appendix B, Item 15
General Safety Instructions:
References:
TM 5-2420-224-20
WARNING
Equipment Condition: Left platform weighs 150
pounds (68 kilograms). To
Reference Condition Description avoid personal injury, use a
hoist or suitable lifting device
TM 5-2420-224-20 Backup Alarm Removed
when lifting left platform.
TM 5-2420-224-20 Left Rear Composite
Stoplight/Taillight Removed
TM 5-2420-224-20 Work Light Removed

REMOVAL

1. REMOVE four screws (1) and BOX (2).

8-9
TM 5-2420-224-34

LEFT PLATFORM REPLACEMENT (CONT)

2. REMOVE two lock nuts (3), two BOLTS (4),

and SET BRACKET (5) aside. DISCARD lock
NUTS.

3. REMOVE screw (6), nut (7), and BRACKET

(8).

4. DISCONNECT wiring HARNESS (9).

5. USING suitable HOIST, REMOVE six screws

(10), six washers (11), four lock nuts (12),
and left PLATFORM (13). DISCARD lock
NUTS.

8-10
 TM 5-2420-224-34

LEFT PLATFORM REPLACEMENT (CONT)

INSPECTION
1. Inspect for corrosion and damage.

2. Check mounting holes to chassis for

elongation.

3. Inspect non-slip surfaces for traction.

INSTATLLATION

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

1. APPLY COAT of SEALING COMPOUND to

six SCREWS (1). USING suitable HOIST,
INSTALL left PLATFORM (2), six screws (1),
six washers (3), and four new lock nuts (4).
TIGHTEN SCREWS to 220 Ib-ft (298 N.m).

2. CONNECT wiring HARNESS (5).

8-11
TM 5-2420-224-34

LEFT PLATFORM REPLACEMENT (CONT)

3. INSTALL BOX (6) and four screws (7).

4. INSTALL BRACKET (8), screw (9), and nut

(10).

5. INSTALL BRACKET (11), two bolts (12), and

two new lock nuts (13).

NOTE
Follow-on Maintenance:
Install backup alarm (TM 5-2420-
224-20).
Install left rear composite
stoplight/taillight (TM 5-2420-224-
20).
Install work light (TM 5-2420-224-
20).
Install hydraulic oil cooler (TM 5-
2420-224-20).
Install hose reel assembly (TM 5-
2420-224-20).
Install front hydraulic tank (TM 5-
2420-224-20).
Install tilt and latch control valve
(page 11-5).

8-12
 TM 5-2420-224-34

RIGHT PLATFORM REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description

Tools and Special Equipment: TM 5-2420-224-20 Right Rear Composite

Stoplight~Taillight Removed
Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26 TM 5-2420-224-20 Work Light Removed

Materials/Parts: TM 5-2420-224-20 Hydraulic Accessory Box

Removed
Nut, Lock (4)
TM 5-2420-224-20 Rear Hydraulic Tank
Compound, Sealing Appendix B, Item 15 Removed

References: General Safety Instructions:

TM 5-2420-224-20
WARNING
Right platform weighs 136
pounds (62 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting right platform.

REMOVAL

1. REMOVE four screws (1) and BOX (2).

8-13
 TM 5-2420-224-34

RIGHT PLATFORM REPLACEMENT (CONT)

2. REMOVE wiring HARNESS (3) from right platform (4).

3. USING suitable HOIST, REMOVE six screws (5), six washers (6), four lock nuts (7), and right
PLATFORM (4). DISCARD lock NUTS.

1. Inspect for corrosion and damage.

2. Check mounting holes to chassis for elongation.

3. Inspect non-slip surfaces for traction.

8-14
 TM 5-2420-224-34

RIGHT PLATFORM REPLACEMENT (CONT)

INSTALLATION

W A R N N G
Adhesive causes immediate bonding on contact with eyes, skin, or clothing and
also gives off harmful vapors. Wear protective goggles and use in
well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush eyes
with water for 15 minutes and get immediate medical attention.

1. APPLY COAT of SEALING COMPOUND to six SCREWS (1). USING suitable HOIST, INSTALL right
PLATFORM (2), six screws (1), six washers (3), and four new lock nuts (4). TIGHTEN SCREWS to
220 Ib-ft (298 N.m).

2. INSTALL wiring HARNESS (5) in right platform (2).

3. INSTALL BOX (6) and four screws (7).

NOTE
Follow-on Maintenance:
Install right rear composite stoplight/taiIlight (TM 5-2420-224-20).
Install work light (TM 5-2420-224-20).
Install hydraulic accessory box (TM 5-2420-224-20).
Install rear hydraulic tank (TM 5-2420-224-20).

8-15/(8-16 Blank)
 TM 5-2420-224-34

CHAPTER 9
SPRINGS MAINTENANCE

OVERVIEW
This chapter illustrates and describes procedures for maintenance of the springs. A list of tasks
contained in this chapter is shown below.

Page

Front Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Rear Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

FRONT SPRING REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Make sure both rear wheels
are blocked front and rear to
Nut , Lock prevent roll off. Failure to do
so could result in serious
References: personnel injury.
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Vehicle Blocked

9-1
TM 5-2420-224-34

FRONT SPRING REPLACEMENT (CONT)

NOTE
Procedure is the same for both
front springs.

1. USING suitable JACK or suitable LIFTING

DEVICE, LIFT VEHICLE enough to take entire
load off front spring (1).

2. REMOVE lock nut (2), screw (3), cover (4),

and front SPRING (1). DISCARD lock NUT.

REMOVE two nuts (5) and BUMPER (6).

INSPECTION

Measure spring length. Allowable spring length is

11.8 in. ±0.2 in. (300 mm ±5 mm). If spring is not
within measurements, replace spring.

9-2
 TM 5-2420-224-34

FRONT SPRING REPLACEMENT (CONT)

INSTALLATION

NOTE
Procedure is the same for both
front springs.

1. INSTALL BUMPER (1) and two nuts (2).

2. INSTALL front SPRING (3), cover (4), screw

(5), and new lock nut (6). TIGHTEN to
190 Ib-ft (140 N.m).

3. LOWER VEHICLE to the ground.

9-3
 TM 5-2420-224-34

REAR SPRING REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
WARNING
Materials/Parts: Make sure both front wheels
are blocked front and rear to
Nut, Lock prevent roll off. Failure to do
so could result in serious
Nut, Lock
personnel injury.
References:
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Vehicle Blocked

REMOVAL

NOTE
Procedure is the same for both
rear springs.

1. USING suitable JACK or suitable LIFTING

DEVICE, LIFT VEHICLE enough to take entire
load off two springs (1 and 2).

9-4
 TM 5-2420-224-34

REAR SPRING REPLACEMENT (CONT)

2. REMOVE lock nut (3), screw (4), two PLATES

(5 and 6), and PAWL (7). DISCARD lock
NUT.

3. REMOVE lock nut (8), screw (9), cover (10),

and two SPRINGS (1 and 2). DISCARD lock
NUT.

4. REMOVE auxiliary SPRING (2) from outer

spring (1).

INSPECTION
1. Measure outer spring length. Allowable spring
length is 14.4 in. ±0.2 in. (365 mm ±5 mm).

2. Measure auxiliary spring length. Allowable

spring length is 8.9 in. ±0.3 in. (225 mm
±8 mm).

3. If spring(s) are not within measurements,

replace spring(s).

NOTE
Procedure is the same for both
rear springs.

1. INSTALL auxiliary SPRING (1) in outer spring

(2).

9-5
TM 5-2420-224-34

REAR SPRING REPLACEMENT (CONT)

2. INSTALL two SPRINGS (1 and 2), cover (3),

screw (4), and new lock nut (5).

3. INSTALL PAWL (6), two PLATES (7 and 8),

screw (9), and new lock nut (10). TIGHTEN to
190 lb-ft (140 N.m).

4. LOWER VEHICLE to the ground.

9-6
 TM 5-2420-224-34

CHAPTER 10
BODY AND CAB MAINTENANCE

OVERVIEW
This chapter illustrates and describes procedures for maintenance of the body and cab. A list of tasks
contained in this chapter is shown below.

Page

Roll-Over Protection (ROPS) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18

Rear Windows Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20

ROLL-OVER PROTECTION (ROPS) REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition (Cont):

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Air Pressure Tanks
Materials/Parts: Removed

Nut, Lock (4) TM 5-2420-224-20 Hydraulic Pressure

Relieved
Compound, Sealing Appendix B, Item 15
Page 11-28 Front Loader Control
Personnel Required: (2) Valve and Bracket (SEE)
or Forklift Control Valve
References: and Bracket (HMMH)
Removed
TM 5-2420-224-20
Page 8-9 Left Platform (SEE)
Equipment Condition: Removed

Reference Condition Description Page 8-13 Right Platform (SEE)

Removed
TM 5-2420-224-20 Backhoe (SEE) or Crane
(HMMH) in Three-Point
Stance
TM 5-2420-224-20 Cab Tilted
TM 5-2420-224-20 Backhoe Travel Lock
(SEE) Removed

10-1
TM 5-2420-224-34

ROLL-OVER PROTECTION (ROPS) REPLACEMENT (CONT)

General Safety Instructions: General Safety Instructions (Cont):

WARNING WARNING
High pressure hydraulics [oil Adhesive causes immediate
under 2450 psi (16,893 kPa)] bonding on contact with eyes,
operate this equipment. Never skin, or clothing and also gives
disconnect any hydraulic line or off harmful vapors. Wear
fitting without first dropping protective goggles and use in
pressure to zero. A high well-ventilated area. If adhesive
pressure oil stream can pierce gets in eyes, try to keep eyes
b o d y a n d c a u s e s e v e re in ju ry open; flush eyes with water for
to personnel. 15 minutes and get immediate
medical attention.

REMOVAL

NOTE
Procedure is the same for both
vehicles.

1. REMOVE six BOLTS (1) and six nuts (2).

2. REPEAT STEP 1 for other side and REMOVE

BRACKET (3).

10-2
 TM 5-2420-224-34

ROLL-OVER PROTECTION (ROPS) REPLACEMENT (CONT)

3. REMOVE CLAMP (4) and DISCONNECT

MUFFLER (5).

4. SUPPORT frame SECTION and REMOVE

four screws (7) and protective BAR (6).

5. REMOVE two BOLTS (8) and two nuts (9)

and DISCONNECT BRACKET (10).

10-3
TM 5-2420-224-34

ROLL-OVER PROTECTION (ROPS) REPLACEMENT (CONT)

6. REMOVE screw (11), look nut (12), and two

BUSHINGS (13) from bracket (14). DISCARD
lock NUT.

7. SUPPORT BRACKET (14) and REMOVE

SCREW (15), lock nut (16), two bushings (17
and 18), and BRACKET (14). DISCARD lock
NUT.

8. REMOVE SCREW (19), washer (20), and nut

(21) and DISCONNECT STE/ICE-R
RESISTOR (22).

10-4
 TM 5-2420-224-34

ROLL-OVER PROTECTION (ROPS) REPLACEMENT (CONT)

9. LOOSEN two NUTS (23) and SLIDE fuel

TANK (24) forward enough to clear screw
(25).

10. REMOVE screw (25), lock nut (26), and

BUSHING (27) from bracket (28). DISCARD
lock NUT.

11. SUPPORT BRACKET (28) and REMOVE

screw (29), lock nut (30), two bushings (31
and 32), and BRACKET (28). DISCARD lock
NUT.

INSPECTION
1. Inspect all parts for cracks and corrosion.

2. Inspect hand grips for secure mounting points.

3. Inspect brackets for stripped threads.

INSTALLATION

NOTE
Procedure is the same for both
vehicles.

1. APPLY COAT of SEALING COMPOUND to

SCREW (1) and INSTALL BRACKET (2),
screw (1), two bushings (3 and 4), and new
lock nut (5). TIGHTEN lock NUT to 615 Ib-ft
(834 N.m).

10-5
TM 5-2420-224-34

ROLL-OVER PROTECTION (ROPS) REPLACEMENT (CONT)

2. APPLY COAT of SEALING COMPOUND to

SCREW (6) and INSTALL screw (6),
BUSHING (7), and new lock nut (8).
TIGHTEN lock NUT to 615 Ib-ft (834 N.m).

3. SLIDE fuel TANK (9) back and TIGHTEN two

NUTS (10).

4. CONNECT STE/lCE-R RESISTOR (11) and

INSTALL SCREW (12), washer (13), and nut
(14) on bracket (2).

5. INSTALL BRACKET (15), screw (16), two

bushings (17 and 18), and new lock nut (19).
TIGHTEN lock NUT to 615 Ib-ft (834 N.m).

10-6
 TM 5-2420-224-34

ROLL-OVER PROTECTION (ROPS) REPLACEMENT (CONT)

6. INSTALL screw (20), two BUSHINGS (21),

and new lock nut (22).

7. CONNECT BRACKET (23) and INSTALL two

BOLTS (24) and two nuts (25).

8. INSTALL protective BAR (26) and two screws

(27) on each side of frame section.

10-7
TM 5-2420-224-34

ROLL-OVER PROTECTION (ROPS) REPLACEMENT (CONT)

9. CONNECT MUFFLER (28) and INSTALL

CLAMP (29).

10. INSTALL BRACKET (30), six bolts (31), and

six nuts (32). TIGHTEN BOLTS to 179 Ib-ft
(244 N.m).

11. SUPPORT BRACKET (30) and INSTALL six

BOLTS (31) and six nuts (32) on other side.
TIGHTEN BOLTS to 179 Ib-ft (244 N.m).

NOTE
Follow-on Maintenance:
Lower cab (TM 5-2420-224-20).
Install left platform (SEE) (page
8-9).
Install right platform (SEE) (page
8-13).
Install front loader control valve
and bracket (SEE) or forklift
control valve and bracket (HMMH)
(page 11-28).
Install backhoe travel lock (SEE)
(TM 5-2420-224-20).
Install air pressure tanks (TM 5-
2420-224-20).

10-8
 TM 5-2420-224-34

CAB REPLACEMENT
This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition (Cont):

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Brake Booster and Air
Personnel Required: (4) Pressure Lines and
Fittings Removed
References:
TM 5-2420-224-20 Protection/Relay Valve
TM 5-2420-224-20 Lines and Fittings
Removed
Equipment Condition:
TM 5-2420-224-20 Tandem Valve Removed
Reference Condition Description TM 5-2420-224-20 Trailer Hand Brake Air
TM 5-2420-224-20 Front Loader (SEE) or Supply Lines and Fittings
Forklift (HMMH) Removed Removed

TM 5-2420-224-20 Fuse Holders Removed TM 5-2420-224-20 Spare Tire and Mount

Removed
TM 5-2420-224-20 Air Cleaner Removed
TM 5-2420-224-20 Canopy (FOPS) Removed
TM 5-2420-224-20 Air Cleaner Ducts
Removed TM 5-2420-224-20 Front Fenders and Splash
Guards Removed
TM 5-2420-224-20 Vertical Air Intake Pipe
Removed TM 5-2420-224-20 Cab Doors Removed

TM 5-2420-224-20 Master Light Switch TM 5-2420-224-20 Exterior Rear View Mirrors

Removed Removed

TM 5-2420-224-20 Relays Removed TM 5-2420-224-20 Windshield Wiper/Washer

Motor Removed
TM 5-2420-224-20 Headlights Removed
TM 5-2420-224-20 Windshield Wiper/Washer
TM 5-2420-224-20 Auxiliary Headlights Motor Linkage Removed
Removed
TM 5-2420-224-20 Defroster and Air Tubes
TM 5-2420-224-20 Horn Removed Removed
TM 5-2420-224-20 Air Brake Booster TM 5-2420-224-20 Clutch Pedal Removed
Removed
TM 5-2420-224-20 Brake Pedal Removed
TM 5-2420-224-20 Trailer Service Air Supply
Lines and Fittings TM 5-2420-224-20 Hand Throttle Removed
Removed TM 5-2420-224-20 Turn Signal Lever
TM 5-2420-224-20 Trailer Emergency Air Removed
Supply Lines and Fittings TM 5-2420-224-20 Press-to-Test Switch
Removed Removed
TM 5-2420-224-20 Air Pressure and TM 5-2420-224-20 Indicator (Gage) Removed
Accessory Air Supply
Lines and Finings TM 5-2420-224-20 Tachometer Removed
Removed
TM 5-2420-224-20 Ignition Switch Removed

10-9
TM 5-2420-224-34

CAB REPLACEMENT (CONT)

Equipment Condition (Cont): Equipment condition (Cont):

Reference Condition Description Reference Condition Description

TM 5-2420-224-20 Windshield Wiper/Washer TM 5-2420-224-20 Speedometer Removed

Switch Removed
TM 5-2420-224-20 Inclinometer (SEE)
TM 5-2420-224-20 Starter Switch Removed Removed

TM 5-2420-224-20 Hazard Warning Switch TM 5-2420-224-20 Cab Shock Absorbers and

Removed Mountings Removed

TM 5-2420-224-20 Ammeter Removed TM 5-2420-224-20 Clutch Hydraulic Reservoir

Lines and Fittings
TM 5-2420-224-20 Cold Start Switch Removed
Removed
TM 5-2420-224-20 Clutch Master Cylinder
TM 5-2420-224-20 Horn, Low Beam/High Removed
Beam Switch Removed
TM 5-2420-224-20 Cold Start Aid Removed
TM 5-2420-224-20 Instrument Cluster Panel
Light Removed TM 5-2420-224-20 Accelerator Pedal and
Linkage Removed
TM 5-2420-224-20 Windshield Heater Control
Switch Removed TM 5-2420-224-20 Windshield Wiper/Washer
Switch Relay Removed
TM 5-2420-224-20 Dome Light Removed
TM 5-2420-224-20 Warning Delay Relay
TM 5-2420-224-20 Parking Brake Controls Removed
Removed
TM 5-2420-224-20 Hydraulic Suspension
TM 5-2420-224-20 Trailer Hand Brake Valve Lockout Controls (HMMH)
Removed Removed
TM 5-2420-224-20 Trailer Hand Brake Valve TM 5-2420-224-20 Auxiliary Light Control
Lines and Fittings Switch Removed
Removed
TM 5-2420-224-20 Brake Light Diode
TM 5-2420-224-20 Cab Drain Plug Removed Removed
TM 5-2420-224-20 Steering Upper Shaft TM 5-2420-224-20 Front Blackout Light
Bearing Removed Removed
TM 5-2420-224-20 Operator Seat and TM 5-2420-224-20 Front Composite Lights
Framework Removed Removed
TM 5-2420-224-20 Passenger Seat and TM 5-2420-224-20 Turn Signal Flasher Relay
Framework Removed Removed
TM 5-2420-224-20 Seat Belts Removed TM 5-2420-224-20 Engine Start Switch
Removed
TM 5-2420-224-20 Sun Visors, Clothes
Hooks, and Grip Handles TM 5-2420-224-20 Brake Light Switch
Removed Removed
TM 5-2420-224-20 Roof Liner Removed TM 5-2420-224-20 Protection/Relay Valve
Removed
TM 5-2420-224-20 Interior Rear View Mirror
Removed TM 5-2420-224-20 Brake Master Cylinder
Hydraulic Lines and
TM 5-2420-224-20 Cab Heater Removed Fittings Removed

10-10
 TM 5-2420-224-34

CAB REPLACEMENT (CONT)

Equipment Condition (Cont): Equipment Condition (Cont):

Reference Condition Description Reference Condition Description

TM 5-2420-224-20 Steering Wheel Bracket Page 4-54 Fuse Holder to Hydraulic

and Seal Removed Suspension Lockout/Rear
Wall Wiring Harness
TM 5-2420-224-20 Cab Door Seals Removed (HMMH) Removed
TM 5-2420-224-20 Cab Floor Linings Page 4-58 Frame Wiring Harness
Removed Removed
TM 5-2420-224-20 Windshield Wipers Page 4-66 Suppressor Filter Electrical
Removed Lead Removed
TM 5-2420-224-20 Windshield Washer Page 4-68 Cap Plug Connector to
Reservoir Removed Heater Panel Switch and
Master Light Switch Wiring
TM 5-2420-224-20 Windshield Washer Pump
Harness Removed
Removed
Page 4-70 Chassis Wiring Harness
TM 5-2420-224-20 Heater Hoses and Removed
Clamps Removed
Page 4-38 Auxiliary Headlight, Front
TM 5-2420-224-20 Data Plates Removed
Composite Light, and
TM 5-2420-224-20 Front Loader (SEE) or Blackout Driving Light
Forklift (HMMH) Control Wiring Harness Removed
Valve Controls Removed
Page 4-10 Main Wiring Harness
TM 5-2420-224-20 Speedometer Drive Shaft Removed
Removed Windshield Removed
Page 10-18
Page 11-28 Front Loader (SEE) or
Page 10-20 Rear Windows Removed
Forklift (HMMH) Control
Valve and Bracket
General Safety Instructions:
Removed
WARNING
Page 4-28 Alternator Cable Assembly
Removed • SEE/HMMH should not be
operated with front loader
Page 4-34 Dome Light Cable (SEE) or forklift (HMMH)
Assembly Removed removed, except in a
Page 4-36 Hazard Warning Light maintenance facility. When
Wiring Harness Removed maintenance is required and
front loader or forklift is
Page 4-42 Forklift Wiring Harness removed, never operate
(HMMH) Removed
SEE/HMMH at speeds
Page 4-48 Forklift Connector to Fuse greater than 5 mph. Tractor
Holder Wiring Harness stability and handling
(HMMH) Removed characteristics are greatly
affected with either front
Page 4-52 Cab Floor Separation loader or forklift removed.
Point to Rear Wall Wiring
This could cause loss of
Harness (HMMH)
Removed control and injury to
personnel or damage to
vehicle.

10-11
TM 5-2420-224-34

CAB REPLACEMENT (CONT)

General Safety Instructions (Cont):

WARNING
• Cab weighs 618 pounds (281
kilograms). To avoid personal
injury, use a hoist or suitable
lifting device when lifting cab.

REM0VAL

NOTE
Procedure is the same for both
vehicles.

1. REMOVE cab mounting screw (1), washer (2),

and SPACER (3) from each side of vehicle.

2. REMOVE SCREW (4) and washer (5) from

front left side.

10-12
 TM 5-2420-224-34

CAB REPLACEMENT (CONT)

3. REMOVE screw (6), washer (7), and BODY

assembly (8) from front right side.

4. REMOVE CAB (9) from vehicle.

NOTE
Procedure is the same for both
vehicles,

1. INSTALL CAB (1) on vehicle.

10-13
TM 5-2420-224-34

CAB REPLACEMENT (CONT)

2. INSTALL BODY assembly (2), washer (3),

and screw (4) on front right side.

3. INSTALL washer (5) and SCREW (6) on front

left side.

10-14
 TM 5-2420-224-34

CAB REPLACEMENT (CONT)

4. INSTALL SPACER (7), washer (8), and cab mounting screw (9) on each side of vehicle.

NOTE
Follow-on Maintenance (Cont):
Install rear windows (page 10-20) Install front loader (SEE) or forklift
Install windshield (page 10-18). (HMMH) control valve and bracket
Install main wiring harness (page (page 11-28).
4-10. Install Speedometer drive shaft
Install auxiliary headlight, front (TM 5-2420-224-20).
composite light, and blackout Install front loader (SEE) or forklift
driving light wiring harness (page (HMMH) control valve controls
4-38). (TM 5-2420-224-20).
Install chassis wiring harness Install data plates (TM 5-2420-
(page 4-70). 224-20).
Install cap plug connector to Install heater hoses and clamps
heater panel switch and master (TM 5-2420-224-20).
light switch wiring harness (page Install windshield washer pump
4-68). (TM 5-2420-224-20).
Install suppressor filter electrical Install windshield washer reservoir
lead (page 4-66). (TM 5-2420-224-20).
Install frame wiring harness (page Install windshield wipers (TM 5-
4-58) . 2420-224-20).
Install fuse holder to hydraulic Install cab floor linings (TM 5-
suspension lockout/rear wall wiring 2420-224-20.
harness (HMMH) (page 4-54). Install cab door seals (TM 5-2420-
Install cab floor separation point to 224-20).
rear wall wiring harness (HMMH) Install steering wheel bracket and
(page 4-52). seal (TM 5-2420-224-20).
Install forklift connector to fuse Install brake master cylinder
holder wiring harness (HMMH) hydraulic lines and fittings (TM 5-
(page 4-48). 2420-224-20).
Install forklift wiring harness Install protection/relay valve
(HMMH) (page 4-42). (TM 5-2420-224-20).
Install hazard warning light wiring Install brake light switch (TM 5-
harness (page 4-36). 2420-224-20).
Install dome light cable assembly Install engine start switch (TM 5-
(page 4-34). 2420-224-20).
Install alternator cable assembly Install turn signal flasher relay
(page 4-28). (TM 5-2420-224-20).

10-15
TM 5-2420-224-34

CAB REPLACEMENT (CONT)

Follow-on Maintenance (Cont): Follow-on Maintenance (Cont):

Install front composite lights Install parking brake controls
(TM 5-2420-224-20). (TM 5-2420-224-20).
Install front blackout light (TM 5- Install dome light (TM 5-2420-224-
2420-224-20). 20).
Install brake light diode (TM 5- Install windshield heater control
2420-224-20). switch (TM 5-2420-224-20).
Install auxiliary light control switch install instrument cluster panel
(TM 5-2420-224-20). light (TM 5-2420-224-20).
Install hydraulic suspension lockout Install horn, low beam/high beam
controls (HMMH) (TM 5-2420-224- switch (TM 5-2420-224-20).
20). Install cold start switch (TM 5-
Install warning delay relay (TM 5- 2420-224-20).
2420-224-20). Install ammeter (TM 5-2420-224-
Install windshield wiper/washer 20).
switch relay (TM 5-2420-224-20). Install hazard warning switch
Install accelerator pedal and (TM 5-2420-224-20).
linkage (TM 5-2420-224-20). Install starter switch (TM 5-2420-
Install cold start aid (TM 5-2420- 224-20).
224-20). Install windshield wiper/washer
Install clutch master cylinder switch (TM 5-2420-224-20).
(TM 5-2420-224-20). Install ignition switch (TM 5-2420-
Install clutch hydraulic reservoir 224-20) .
lines and fittings (TM 5-2420-224- Install tachometer (TM 5-2420 -224-
20). 20).
Install cab shock absorbers and Install indicator (gage) (TM 5-
mountings (TM 5-2420-224-20). 2420-224-20).
Install inclinometer (SEE) (TM 5- Install press-to-test switch (TM 5-
2420-224-20). 2420-224-20).
Install speedometer (TM 5-2420- Install turn signal lever (TM 5-
224-20). 2420-224-20).
Install cab heater (TM 5-2420-224- Install hand throttle (TM 5-2420-
20). 224-20).
Install interior rear view mirror Install brake pedal (TM 5-2420-
(TM 5-2420-224-20). 224-20).
Install roof liner (TM 5-2420-224- Install clutch pedal (TM 5-2420-
20). 224-20).
Install sun visors, clothes hooks, Install defroster and air tubes
and grip handles (TM 5-2420-224- (TM 5-2420-224-20).
20). Install windshield wiper/washer
Install seat belts (TM 5-2420-224- motor linkage (TM 5-2420-224-20).
20). Install windshield wiper/washer
Install passenger seat and motor (TM 5-2420-224-20).
framework (TM 5-2420-224-20). Install exterior rear view mirrors
I n s t a l l (TM 5-2420-224-20).
framework (TM 5-2420-224-20). Install cab doors (TM 5-2420-
Install steering upper shaft bearing 224-20).
(TM 5-2420-224-20). Install front fenders and splash
Install cab drain plug (TM 5-2420- guards (TM 5-2420-224-20).
224-20) . Install canopy (FOPS) (TM 5-
Install trailer hand brake valve 2420-224-20),
lines and fittings (TM 5-2420-224- Install spare tire and mount
20). (TM 5-2420-224-20).
Install trailer hand brake valve
(TM 5-2420-224-20).

10-16
 TM 5-2420-224-34

CAB REPLACEMENT (CONT)

Follow-on Maintenance (Cont):

Install trailer hand brake air supply
lines and fittings (TM 5-
2420-224-20).
Install tandem valve (TM 5-2420-
224-20).
Install protection/relay valve lines
and fittings (TM 5-2420-224-20).
Install brake booster and air
pressure lines and fittings (TM 5-
2420-224-20).
Install air pressure and accessory
air supply lines and fittings (TM 5-
2420-224-20).
Install trailer emergency air supply
lines and fittings (TM 5-2420-224-
20).
Install trailer service air supply
lines and fittings (TM 5-2420-224-
20).
Install air brake booster (TM 5-
2420-224-20).
Install horn (TM 5-2420-224-20).
Install auxiliary headlights (TM 5-
2420-224-20).
Install headlights (TM 5-2420-224-
20).
Install relays (TM 5-2420-224-20).
Install master light switch (TM 5-
2420-224-20).
Install vertical air intake pipe
(TM 5-2420-224-20).
install air cleaner ducts (TM 5-
2420-224-20).
Install air cleaner (TM 5-2420-224-
20).
Install fuse holders (TM 5-2420-
224-20).
Install front loader (SEE) or forklift
(HMMH) (TM 5-2420-224-20).

10-17
TM 5-2420-224-34

WINDSHIELD REPLACEMENT
This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Tool Kit, SC 5180-90-CL-N26

Materials/Parts: WARNING
Do not connect or disconnect
Seal, Windshield any electrical connector
Chips, Soap Appendix B, Item 9 unless vehicle MASTER
disconnect switch is OFF. To
Twine, Cotton, Appendix B, Item 49 do so could result in injury
1/8-in.-Diameter to personnel.
Personnel Required: (2) • Edges of glass may be
sharp. To avoid personal
injury, wear protective gloves
when handling glass.

REMOVAL

NOTE
Tag electrical connectorsprior to
disconnecting to aid in connecting.

1. DISCONNECT three electrical CONNECTORS

(l).

10-18
 TM 5-2420-224-34

WINDSHIELD REPLACEMENT (CONT)

2. LIFT CORNER of windshield SEAL (2) and

PUSH WINDOW (3) out. DISCARD windshield
SEAL.

INSTALLATION
1. COAT EDGE of WINDOW (3) with SOAP and
WATER solution.

2. INSTALL new windshield SEAL (2) around

window (1).

3. COAT GROOVE on outside of SEAL (2) with

SOAP and WATER solution.

4. INSTALL 1/8-in. cotton TWINE in groove on

outside of seal (2).

5. APPLY SOAP and WATER solution around

FLANGE (4) in window opening (5).

6. INSTALL WINDOW (3) starting with bottom

edge, and work all the way around window
(3) by PULLING cotton TWINE from groove.

7. TAP WINDOW (3) all the way around to

make sure window (3) is seated in window
opening (5).

8. CONNECT three electrical CONNECTORS (1).

10-19
TM 5-2420-224-34

REAR WINDOWS REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Tool Kit, SC 5180-90-CL-N26 Reference Condition Description

Materials/Parts: Page 10-1 Roll-Over Protection

(ROPS) Removed
Seal, Window
General Safety instructions:
Chips, soap Appendix B, item 9
Twine, Cotton, Appendix B, Item 49
1/8-in.-Diameter WARNING
Edges of glass may be sharp.
Personnel Required: (2) To avoid personal injury, wear
protective gloves when handling
glass.

REMOVAL
NOTE
Procedure is the same for all rear windows.

LIFT corner of window SEAL (1) and PUSH WINDOW (2) out. DISCARD window SEAL.

10-20
 TM 5-2420-224-34

REAR WINDOWS REPLACEMENT (CONT)

INSTALLATION

NOTE
Procedure is the same for all rear windows.

1. COAT EDGE of WINDOW (2) with SOAP and WATER solution.

2. INSTALL new window SEAL (1) around window (2).

3. COAT GROOVE on outside of SEAL (1) with SOAP and WATER solution.

4. INSTALL 1/8-in. ootton TWINE in groove on outside of seal (1).

5. APPLY SOAP and WATER solution around FLANGE (3) in window opening (4).

6. INSTALL WINDOW (2) starting with bottom edge, and work all the way around window (2) by
PULLING cotton TWINE from groove.

7. TAP WINDOW (2) all the way around to make sure window (2) is seated in window opening (4).

NOTE
Follow-on Maintenance:
Install Roll-Over Protection (ROPS) (page 10-1).

10-21/(10-22 Blank)
 TM 5-2420-224-34

CHAPTER 11
HYDRAULIC SYSTEM MAINTENANCE

OVERVIEW

This chapter illustrates and describes procedures for maintenance of the hydraulic system. A list of tasks
contained in this chapter is shown below.
Page

Hydraulic Oil Cooler Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Tilt And Latch Control Valve Replacement and Adjustment . . . . . . . . . . . . . . . . . . 11-5

Backhoe Swing Cylinder Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . 11-10

Backhoe Stabilizer Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Backhoe Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15

Crane Flow Regulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22

Crane Valve Bank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24

Crane Valve Bank Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26

Front Loader/Forklift Control Valve and Bracket Replacement and Adjustment . . . . . . . 11-28

Forklift Valve Replacement . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 11-37

Forklift Mast Assembly Replacement . . . . . . . . . . . . . . . . . . . . . ... 11-40

Forklift Carriage Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44

Forklift Lift Cylinder Replacement, Bleeding, and Sequencing . . . . . . . . . . . . . . . . . 11-51

Forklift Bootstrap Chain Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . 11-57

Forklift Carriage Chain Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-67

11-1
 TM 5-2420-224-34

HYDRAULIC OIL COOLER FAN REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: References:

Tool Kit, SC 5180-90-CL-N26 TM 5-2420-224-20

Materials/Parts: Equipment Condition:

Washer, Lock (4)
Reference Condition Description
Washer, Lock (4)
TM 5-2420-224-20 Hydraulic Oil Cooler
Removed

REMOVAL

NOTE
Procedure is the same for both
fans.

1. REMOVE four nuts (1), four lock washers (2),

four washers (3), guard (4), and FAN (5).
DISCARD lock WASHERS.

2. REMOVE retaining ring (6) and IMPELLER

(7).

11-2
 TM 5-2420-224-34

HYDRAULIC OIL COOLER FAN REPLACEMENT (CONT)

3. REMOVE four screws (8), four lock washers

(9), two supports (10), and MOTOR (11).
DISCARD lock WASHERS.

INSTALLATION

NOTE

Procedure is the same for both

fans.

1. INSTALL two SUPPORTS (1), four lock

washers (2), and four screws (3) on motor (4).

2. INSTALL IMPELLER (5) and retaining ring (6).

11-3
 TM 5-2420-224-34

HYDRAULIC OIL COOLER FAN REPLACEMENT (CONT)

3. INSTALL FAN (7), guard (8), four washers

(9), four new lock washers (10), and four nuts
(11).

NOTE
Follow-on Maintenance:
Install hydraulic oil cooler (TM 5-
2420-224-20).

11-4
 TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPLACEMENT AND ADJUSTMENT

This task covers: a. Removal b. Installation c. Adjustment

INITIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
TOOl Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 WARNING
• High pressure hydraulics [oil
Materials/Parts: under 2450 psi (16,893 kPa)]
Packing (7) operate this equipment.
Never disconnect any
Caps and Plugs Appendix B, Item 8 hydraulic line or fitting
without first dropping
Rags Appendix B, Item 40
pressure to zero. A high
References: pressure oil stream can
pierce body and cause
TM 5-2420-224-20 severe injury to personnel.

Equipment Condition: • Fuel and oil are slippery and

can cause falls. To avoid
Reference Condition Description injury, wipe up spilled fuel or
TM 5-2420-224-20 oil with rags.
Hydraulic Pressure
Relieved

REMOVAL

1. REMOVE seven SCREWS (1) and seven

washers (2) from cover (3).

11-5
 TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPLACEMENT AND ADJUSTMENT

(CONT)

NOTE
Step 2 is for the SEE. Step 3 is
for the HMMH.

2. DISCONNECT WIRE (4) and set cover (3)

aside.

3. DISCONNECT two WIRES (4) and set cover

(3) aside.

CAUTION
Cap or plug ail ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

NOTE
• Tag lines prior to disconnecting
to aid in connecting.
• Have suitable container
available to catch oil.

4. DISCONNECT eight HOSES (5). INSTALL

CAPS or PLUGS.

5. LOOSEN two lock NUTS (6) and REMOVE

two HANDLES (7).

6. REMOVE three screws (8), three washers (9),

and control VALVE (10).

11-6
 TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPLACEMENT AND ADJUSTMENT

(CONT)

7. REMOVE six FITTINGS (11 ) and six packings

(12). DISCARD PACKINGS.

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

8. REMOVE fitting (13), control VALVE (14),

fitting (15), fitting (16), and packing (17).
INSTALL CAPS or PLUGS. DISCARD
PACKING.

INSTALLATION

1. REMOVE CAPS or PLUGS. INSTALL new

packing (1), fitting (2), fitting (3), control
VALVE (4), and fitting (5).

2. INSTALL six new packings (6) and six

FlTTINGS (7).

11-7
TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPLACEMENT AND ADJUSTMENT

(CONT)

3. INSTALL VALVE (8), three washers (9), and

three screws (10).

4. INSTALL two HANDLES (11) and tighten two

lock nuts (12).

5. REMOVE CAPS or PLUGS. CONNECT eight

HOSES (13).

6. PERFORM ADJUSTMENT.

ADJUSTMENT

NOTE
Vehicle must be parked on level
surface with front loader (SEE) or
forklift (HMMH) resting on flat
surface, and parking brake must
be set.

1. Connect 0-5000 psi (0-352.1 bar) gage to test

port on inlet section of control valve (1).

2. Perform following to achieve hydraulic oil

operating temperature:

a. Start and run engine at 2000 rpm

using hand throttle.

b. Place lock control lever (2) in u p

position and hold for 15 seconds.

c. Place lock control lever (2) in neutral

position for 30 seconds.

d. Repeat until hydraulic oil cooler turns

on.

3. While maintaining engine speed of 2000 rpm,

place lock control lever (2) in up position and
read pressure gage. Pressure must be 2450
psi (172.5 bar). If reading is not correct,
adjust control valve (1) according to following:

a. While holding adjusting screw (3),

loosen lock nut (4) on main relief
valve (5) on inlet section of control
valve (1).

11-8
 TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPLACEMENT AND ADJUSTMENT

(CONT)

b. To increase pressure setting, turn

adjusting screw (3) to right. To
decrease pressure setting, turn
adjusting screw (3) to left.

c. Tighten lock nut (4) while holding

adjusting screw (3).

d. Repeat steps 2 and 3 to check

pressure setting. Readjust, if
necessary.

4. Remove 0-5000 psi (0-352.1 bar) gage from

test port on inlet section of control valve (1).

NOTE
Step 5 is for the SEE. Step 6 is
for the HMMH.

5. Set cover (6) in place and connect wire (7).

6. Set cover (6) in place and connect two wires

(7).

7. Install cover (6), seven washers (8), and

seven screws (9).

11-9
TM 5-2420-224-34

BACKHOE SWING CYLINDER RELIEF VALVE REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: General Safety Instructions:

SEE

Tools and Special Equipment: WARNING

. High pressure hydraulics [oil
Shop Equipment, SC 4910-95-CL-A31
under 2450 psi (16,893 kPa)
TOOI Kit, SC 5180-90-CL-N26
operate this equipment.
Materials/Parts: Never disconnect any
hydraulic line or fitting
Packing without first dropping
pressure to zero. A high
Ring, Backup
pressure oil stream can
Packing pierce body and cause
severe injury to personnel.
Rags Appendix B, Item 40
. Fuel and oil are slippery and
References: can cause falls. To avoid
TM 5-2420-224-20 injury, wipe up spilled fuel or
oil with rags.
Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Hvdraulic Pressure
Relieved

R E Mo V A L

NOTE
Procedure is the same for both
relief valves.
Have suitable container
available to catch hydraulic fluid
upon removal of relief valve.

1. REMOVE relief VALVE (1) from swing cylinder

(2).

11-10
 TM 5-2420-224-34

BACKHOE SWING CYLINDER RELIEF VALVE REPLACEMENT (CONT)

2. REMOVE and DISCARD PACKING (3),

backup RING (4), and PACKING (5) from
relief valve (1).

INSTALLATION

NOTE
Procedure is the same for both
relief valves.

1. INSTALL new PACKING (3), new backup

RING (4), and new PACKING (5).

2. INSTALL relief VALVE (1) in swing cylinder

(2).

11-11
TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP
Applicable Configuration: General Safety Instructions:

SEE

Tools and Special Equipment: WARNING

• SEE should not be operated
Shop Equipment, SC 4910-95-CL-A31 with backhoe removed,
Tool Kit, SC 5180-90-CL-N26
except in a maintenance
Materials/Parts: facility. When maintenance is
required and backhoe is
Washer, Lock (2) removed, never operate SEE
at speeds greater than 5
Packing (6)
mph. Tractor stability and
Caps and Plugs Appendix B, item 8 handling characteristics are
greatly affected with backhoe
Rags Appendix B, Item 40 removed. This could cause
loss of control and injury to
References:
personnel or damage to
TM 5-2420-224-20 vehicle.

Equipment Condition: • High pressure hydraulics [oil

under 2450 psi (16,893 kPa)]
Reference Condition Description operate this equipment.
Never disconnect any
TM 5-2420-224-20 Backhoe Assembly hydraulic line or fitting
Removed
without first dropping
TM 5-2420-224-20 Backhoe Control Levers pressure to zero. A high
Disconnected pressure oil stream can
pierce body and cause
severe injury to personnel.

• Fuel and oil are slippery and

can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

11-12
 TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPLACEMENT (CONT)

REMOVAL

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination
of hydraulic oil. Failure to do so may result in damage to equipment.

NOTE
Tag lines prior to disconnecting to aid in connecting.

1. DISCONNECT six hydraulic TUBES (1). INSTALL CAPS or PLUGS,

2. REMOVE two bolts (2), two lock washers (3), stabilizer control VALVE (4), and four washers (5).
DISCARD lock WASHERS.

3. REMOVE six ADAPTERS (6) and six packings (7). DISCARD PACKINGS.

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

4. INSTALL six CAPS or PLUGS in stabilizer control valve (4).

11-13
TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPLACEMENT (CONT)

INSTALLATION

1. REMOVE six CAPS or PLUGS from stabilizer control valve (1).

2. INSTALL six new packings (2) and six ADAPTERS (3).

3. INSTALL four washers (4), stabilizer control VALVE (1), two new lock washers (5), and two bolts (6).

4. REMOVE CAPS or PLUGS. CONNECT six hydraulic LINES (7).

NOTE
Follow-on Maintenance:
Connect backhoe control levers (TM 5-2420-224-20).
Install backhoe assembly (TM 5-2420-224-20).

11-14
 TM 5-2420-224-34

BACKHOE CONTROL VALVE REPLACEMENT

This task covers: a. Removal b. Installation c. Testing d. Adjustment

INITIAL SETUP
Applicable Configuration: Equipment Condition:
SEE Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Backhoe Control Tower
Removed
Shop Equipment, SC 4910-95-CL-A31
TOOl Kit, SC 5180-90-CL-N26 TM 5-2420-224-20 Hydraulic Pressure
Tool Outfit (HSTRU), NSN 4940-01-036-5784 Relieved

Materials/Parts: General Safety Instructions:

Nut , Lock
Washer, Lock (3) WARNING
Packing (8) • High pressure hydraulics [oil
under 2450 psi (16,893 kPa)]
Packing (2) operate this equipment.
Never disconnect any
Caps and Plugs Appendix B, Item 8
hydraulic line or fitting
Rags Appendix B, Item 40 without first dropping
pressure to zero. A high
Personnel Required: (2) pressure oil stream can
pierce body and cause
References: severe injury to personnel.
TM 5-2420-224-20 • Wear safety goggles when
performing leakage tests on
valves. Failure to do so may
result in serious eye injury
due to high pressure oil.

• Fuel and oil are slippery and

can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

11-15
 M 5-2420-224-34

BACKHOE CONTROL VALVE REPLACEMENT (CONT)

REMOVAL

NOTE
• Have suitable container available to catch hydraulic fluid in hoses.

• Tag lines prior to disconnecting to aid in connecting.

1. DISCONNECT 10 TUBES (1).

11-16
 TM 5-2420-224-34

BACKHOE CONTROL VALVE REPLACEMENT (CONT)

2. REMOVE lock nut (2), washer (3), bolt (4), and STRAP (5). DISCARD lock NUT.

3. REMOVE three nuts (6), three lock washers (7), three washers (8), three screws (9), and backhoe
control VALVE (10). DISCARD lock WASHERS.

4. REMOVE 10 ADAPTERS (11) and 10 packings (12). DISCARD PACKINGS.

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

5. INSTALL 10 CAPS or PLUGS in fitting holes of backhoe control valve (10).

11-17
TM 5-2420-224-34

BACKHOE CONTROL VALVE REPLACEMENT (CONT)

INSTALLATION

1. REMOVE 10 CAPS or PLUGS from fitting

holes in backhoe control valve (1).

2. INSTALL 10 new packings (2) and 10

ADAPTERS (3).

3. INSTALL backhoe control VALVE (1), three

screws (4), three washers (5), three new look
washers (6), and three nuts (7).

4. INSTALL STRAP (8), bolt (9), washer (10),

and new lock nut (11).

5. CONNECT 10 TUBES (12).

11-18
 TM 5-2420-224-34

BACKHOE CONTROL VALVE REPLACEMENT (CONT)

Safety Relief Valve

1. Warm hydraulic oil by cycling circuits to be tested.

2. Place backhoe in three-point stance (TM 5-2420-224-20).

3. Shut off engine.

4. Disconnect hydraulic tube from port to be tested.

5. Connect hand pump in port to be tested.

6. Stroke hand pump until sufficient pressure is built up in circuit to open safety relief valve.

7. Continue to stroke hand pump until all air has been pumped out of lines.

8. Record highest pressure and compare with allowable pressures shown below:

Swing Section Valve

A and B Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1700-1900 psi (1 15.6-129,2 bar)

Boom Section Valve

A Port (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925-1075 psi (62.9-73.1 bar)
B Port (Lower) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400-2650 psi (163,2-1 80.2 bar)

Dipper Section Valve

A and B Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400-2650 psi (163.2-1 80.2 bar)

Bucket Section Valve

A and B Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400-2650 psi (163.2-180.2 bar)

11-19
TM 5-2420-224-34

BACKHOE CONTROL VALVE REPLACEMENT (CONT)

ADJUSTMENT

Safety Relief Valve

1. Loosen lock nut (1).

2. Turn adjusting screw (2) in to increase pressure. Turn adjusting screw (2) out to decrease pressure.

3. Repeat testing and adjustment until correct pressure is obtained.

4. If correct pressure cannot be obtained, replace safety relief valve.

5. When safety relief valve pressure is correct, perform leak test.

Leak Test

NOTE
Perform steps 1 thru 3 to check high-pressure safety relief valves.

1. Stroke pump until pressure is built up to less than opening pressure of safety relief valve.

NOTE
It normally takes minimum of 15-30 seconds to bleed down to approximately 1000 psi
(68 bar).

2. Allow pump to sit and monitor pressure for 30-45 seconds. Pressure should have, dropped to
approximately 500 psi (34 bar) and should not drop off to 0 for a few minutes.

11-20
 TM 5-2420-224-34

BACKHOE CONTROL VALVE REPLACEMENT (CONT)

3. If pressure drops off quicker, there is excessive leakage in circuit being tested. Check following:

Tube connections
Safety relief packings
Poppet seat in safety relief valve
Oil passing by valve spool
Valve spool not returning to neutral position
Possible cracks in backhoe control valve

NOTE
Perform steps 4 thru 6 to check low-pressure safety relief valves.

4. Stroke pump until pressure is built up to less than opening pressure of safety relief valve.

NOTE
It normally takes minimum of 15 seconds to bleed down to approximately 300 psi (20.4 bar).

5. Allow pump to sit and monitor pressure for 30-45 seconds. Pressure should not have dropped to, and
should not drop off to, 0 for a few minutes.

6. If pressure drops off quicker, there is excessive leakage in circuit being tested. Check following:

Tube connections
Safety relief packings
Poppet seat in safety relief valve
Oil passing by valve spool
Valve spool not returning to neutral position
Possible cracks in control valve

NOTE
Follow-on Maintenance:
Install backhoe control tower (TM 5-2420-224-20).

11-21
TM 5-2420-224-34

CRANE FLOW REGULATING VALVE REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane in Three-Point
Stance
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 TM 5-2420-224-20 Hydraulic Pressure
Relieved
Materials/Parts:
General Safety Instructions:
Packing
Packing
WARNING
Packing
• High pressure hydraulics [oil
Caps and Plugs Appendix B, Item 8 under 2450 psi (16,893 kPa)]
operate this equipment.
Rags Appendix B, Item 40 Never disconnect any
hydraulic line or fitting
References:
without first dropping
TM 5-2420-224-20 pressure to zero. A high
pressure oil stream can
pierce body and cause
severe injury to personnel.

• Fuel and oil are slippery and

can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

REMOVAL

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

1. DISCONNECT hydraulic HOSE (1), elbow (2), and tee (3). INSTALL CAP or PLUG.

2. REMOVE two bolts (4) and flow regulating VALVE (5).

3. REMOVE two ADAPTERS (6 and 7), elbow (8), and three packings (9, 10, and 11). DISCARD
PACKINGS.

11-22
 TM 5-2420-224-34

CRANE FLOW REGULATING VALVE REPLACEMENT (CONT)

INSTALLATION
1. INSTALL three new packings (11, 10, and 9), two ADAPTERS (6 and 7), and elbow (8) in flow
regulating valve (5).

2. INSTALL flow regulating VALVE (5) and two bolts (4).

3. REMOVE CAP or PLUG. CONNECT elbow (2), tee (3), and hydraulic HOSE (1).

11-23
TM 5-2420-224-34

CRANE VALVE BANK REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP
Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description

Tools and Special Equipment: TM 5-2420-224-20 Crane in Three-Point

Stance
Shop Equipment, SC 4910-95-CL-A31
Tool Outfit (HSTRU), NSN 4940-01-036-5784 TM 5-2420-224-20 Hydraulic Pressure
Relieved
Materials/Parts:
General Safety Instructions:
Pin, Cotter (8)
Nut, Lock (4)
WARNING
Packing
• High pressure hydraulics [oil
Packing under 2450 psi (16,893 kPa)]
operate this equipment.
Packing (16) Never disconnect any
Caps and Plugs Appendix B, Item 8 hydraulic line or fitting
without first dropping
Rags Appendix B, Item 40 pressure to zero. A high
pressure oil stream can
References: pierce body and cause
TM 5-2420-224-20 severe injury to personnel.

• Fuel and oil are slippery and

can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

1. REMOVE eight cotter pins (1) and eight straight PINS (2). DISCARD cotter PINS.

NOTE
Tag control rods prior to disconnecting to aid in connecting.

2. DISCONNECT eight control RODS (3) from valve bank (4).

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

11-24
 TM 5-2420-224-34

CRANE VALVE BANK REPLACEMENT (CONT)

3. REMOVE eight cotter pins (4) and eight straight PINS (5). DISCARD cotter PINS.

4. DISCONNECT eight control RODS (6) from valve bank(7).

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

NOTE
Tag lines prior to disconnecting to aid in connecting.

5. DISCONNECT 18 hydraulic HOSES (8). INSTALL CAPS or PLUGS.

6. REMOVE four lock nuts (9), four screws (1 0), and valve BANK (7). DISCARD lock NUTS.

7. REMOVE 18 FlTTINGS (11) AND 18 packings (12). INSTALL CAPS or PLUGS. DISCARD PACKINGS.

INSTALLATION

1. REMOVE CAPS or PLUGS. INSTALL 18 new packings (12) and 18 FITTINGS (11).

2. INSTALL valve BANK (7), four screws (10), and four new lock nuts (9).

3. REMOVE CAPS or PLUGS. CONNECT 18 hydraulic HOSES (8).

4. CONNECT eight control RODS (6) to valve bank (7).

5. INSTALL eight straight PINS (5) and eight new cotter pins (4).

6. INSTALL COVER (3), four new lock washers (2), and four capscrews (1).

11-25
TM 5-2420-224-34

CRANE VALVE BANK RELIEF VALVE REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: General Safety Instructions:

HMMH

Tools and Special Equipment: WARNING

• High pressure hydraulics [oil
Shop Equipment, SC 4910-95-CL-A31 under 2450 psi (16,893 kPa)]
TOOl Kit, SC 5180-90-CL-N26
operate this equipment.
Materials/Parts: Never disconnect any
hydraulic line or fitting
Packing without first dropping
pressure to zero. A high
Packing
pressure oil stream can
Packing pierce body and cause
severe injury to personnel.
Rags Appendix B, Item 40
• Fuel and oil are slippery and
References: can cause falls. To avoid
TM 5-2420-224-20 injury, wipe up spilled fuel or
oil with rags.
Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Hydraulic Pressure
Relieved

NOTE
Have large capacity container available to catch hydraulic fluid.

1. REMOVE crane valve bank relief VALVE (1) from crane valve bank (2).

2. REMOVE three PACKINGS (3, 4, and 5) from crane valve bank relief valve (1). DISCARD PACKINGS.

11-26
 TM 5-2420-224-34

CRANE VALVE BANK RELIEF VALVE REPLACEMENT (CONT)

INSTALLATION

1. INSTALL three new PACKINGS (5, 4, and 3) on crane valve bank relief valve (1).

2. lNSTALL crane valve bank relief VALVE (1) in crane valve bank (2).

11-27
TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT
This task covers: a. Removal b. Inspection c. Installation d. Adjustment

INITIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 WARNING
• High pressure hydraulics [oil
Materials/Parts: under 2450 psi (16,893 kPa)]
operate this equipment.
Packing (12)
Never disconnect any
Nut, Lock (4) hydraulic line or fitting
without first dropping
Pin, Cotter (2) pressure to zero. A high
Caps and Plugs Appendix B, Item 8 pressure oil stream can
pierce body and cause
Rags Appendix B, Item 40 severe injury to personnel.
References: • Fuel and oil are slippery and
can cause falls. To avoid
TM 5-2420-224-20
TM 5-2420-224-10 injury, wipe up spilled fuel or
oil with rags.
Equipment Condition:
• Do not connect or disconnect
Reference Condition Description any electrical connector
unless vehicle MASTER
TM 5-2420-224-20 Hydraulic Pressure disconnect switch is OFF. To
Relieved do so could result in injury
to personnel.

11-28
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

NOTE
Tag lines and electrical leads prior
to disconnecting to aid in
connecting.

1. DISCONNECT 10 hydraulic HOSES (1).

INSTALL CAPS or PLUGS.

2. DISCONNECT six electrical LEADS (2).

NOTE
• Steps 3 and 4 are for the SEE
tractor only.
• Tag lines prior to removal to aid
in installation.

3. REMOVE two tubes (3 and 4) and

MANIFOLD (5).

4. REMOVE ADAPTER (6), elbow (7), and two

packings (8). INSTALL CAPS or PLUGS.
DISCARD PACKINGS.

11-29
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

5. REMOVE two clips (9) and two PINS (10) to

DISCONNECT front loader/forkliftCONTROLS.

6. REMOVE two BOLTS (11) from Iever bracket

(12).

7. REMOVE four screws (13), four lock nuts

(14), and BRACKET (15). DISCARD lock
NUTS.

11-30
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

8. LOOSEN two SCREWS (16) and REMOVE

two CLAMPS (17).

9. REMOVE two cotter pins (18), two pins (19),

and LEVER (20). DISCARD cotter PINS.

10. REMOVE lubrication FlTTING (21).

11. REMOVE three bolts (22), three nuts (23),

and control VALVE (24) from bracket (15).

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

12. REMOVE 10 ADAPTERS (25) and 10

packings (26). INSTALL CAPS or PLUGS.
DISCARD PACKINGS.

INSPECTION
1. Inspect control valve for damage and stripped
threads.

2. Inspect solenoid valves for corrosion and bent

or broken connectors.

11-31
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

INSTALLATION

1. INSTALL control VALVE (1), three bolts (2),

and three nuts (3) on bracket (4).

2. lNSTALL lubrication FITTING.

3. INSTALL LEVER (6), two pins (7), and two

new cotter pins (8).

4. INSTALL two CLAMPS (9). DO NOT

TIGHTEN SCREWS (10).

5. INSTALL BRACKET (4), four screws (11 ), and

four new lock nuts (12).

11-32
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

6. INSTALL two BOLTS (13) in lever bracket

(14).

7. INSTALL two PINS (15) and two clips (16) on

front Ioader/forklift controls.

NOTE
Steps 8 and 9 are for the SEE
tractor only.

8. REMOVE CAPS or PLUGS. INSTALL two

new packings (17), ADAPTER (18), and elbow
(19).

9. INSTALL two TUBES (20 and 21) and

MANIFOLD (22).

10. REMOVE CAPS or PLUGS. INSTALL 10 new

packings (23) and 10 ADAPTERS (24).

11. CONNECT six electrical LEADS (25).

12. REMOVE CAPS or PLUGS. CONNECT 10

hydraulic HOSES (26).

13. ADJUST control VALVE.

11-33
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

ADJUSTMENT

Operator Controls

Loosen two jam nuts (1) and rotate rod (2) until measurement of 7 in. (178 mm) is attained between center
points of clevis (3).

Front Loader/Forklift Control Valve

1. Park vehicle on level surface and set parking brake.

2. Open front Ioader/forklift transport lock valves (TM 5-2420-224-10).

3. Leave front loader or forklift in transport position.

11-34
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

4. Remove cap (1) from fitting in inlet (2) of control valve (3) located behind cab.

5. Connect 0-5000 psi pressure gage to fitting in inlet (2) of control valve (3).

11-35
TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE AND BRACKET

REPLACEMENT AND ADJUSTMENT (CONT)

NOTE
Pressure gage must be calibrated. If not, performance of front loader/forklift circuits and
tool circuits will not be correct.

6. Operate control valve (3) until oil reaches operating temperature (120°F) by performing the following:

a. Start and run engine at 2000 rpm.

b. Move bucket control lever into rollback position and hold for 15 seconds.

c. Place control lever in neutral for 30 seconds.

d. Repeat until oil in hydraulic system is at operating temperature.

7. Keep engine running at 2000 rpm.

8. Move bucket control tilt lever into rollback/tilt back position. Hold bucket/forks in this position and read
pressure gage.

9. Pressure reading must be set at 2450 psi. If pressure reading is not correct, repeat steps 7 and 8
while holding bucket control lever in dump/forward tilt position. If pressure reading is still not correct,
adjust main relief valve by performing the following:

a. Loosen lock nut (4) on main relief valve adjusting screw (5).

b. Turn adjusting screw (5) into main relief valve to increase pressure setting; turn adjusting
screw (5) out of main relief valve to decrease pressure setting.

c. Tighten lock nut (4).

10. Check pressure setting for 2450 psi. Adjust or repair main relief valve as necessary.

11-36
 TM 5-2420-224-34

FORKLIFT VALVE REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: General Safety Instructions:

HMMH

Tools and Special Equipment: WARNING

• HMMH should not be
Shop Equipment, SC 4910-95-CL-A31 operated with forklift
Tool Kit, SC 5180-90-CL-N26
removed, except in a
Materials/Parts: maintenance facility. When
maintenance is required and
Packing (8) forklift is removed, never
operate HMMH at speeds
Caps and Plugs Appendix B, Item 8
greater than 5 mph. Tractor
Rags Appendix B, Item 40 stability and handlint
characteristics are greatly
References: affected with forklift removed.
This could cause loss of
TM 5-2420-224-20
control and injury to
Equipment Condition: personnel or damage to
vehicle.
Reference Condition Description
• High pressure hydraulics [oil
TM 5-2420-224-20 Forklift Removed under 2450 psi (16,893 kPa)]
operate this equipment.
TM 5-2420-224-20 Hydraulic Pressure Never disconnect any
Relieved
hydraulic line or fitting
without first dropping
pressure to zero. A high
pressure oil stream can
pierce body and cause
severe injury to personnel.

• Do not connect or disconnect

any electrical connector
unless vehicle MASTER
disconnect switch is OFF. To
do so could result in injury
to personnel.

• Fuel and oil are slippery and

can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

11-37
 TM 5-2420-224-34

FORKLIFT VALVE REPLACEMENT (CONT)

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

NOTE
Tag lines prior to disconnecting to aid in connecting.

1. DISCONNECT eight hydraulic HOSE ASSEMBLIES(1). lNSTALL CAPS or PLUGS.

2. REMOVE eight ELBOWS (2) and eight packings (3). INSTALL CAPS or PLUGS. DISCARD
PACKINGS.

11-38
 TM 5-2420-224-34

FORKLIFT VALVE REPLACEMENT (CONT)

NOTE
Tag electrical connections prior to disconnecting to aid in connecting.

3. DISCONNECT four electrical CONNECTIONS (4).

4. REMOVE two capscrews (5), two washers (6), and VALVE (7).

1. INSTALL VALVE (7), two washers (6), and two capscrews (5).

2. CONNECT four electrical CONNECTIONS (4).

3. REMOVE CAPS or PLUGS. INSTALL eight new packings (3) and eight ELBOWS (2).

4. REMOVE CAPS or PLUGS. CONNECT eight hydraulic HOSE ASSEMBLIES (1).

NOTE
Follow-on Maintenance:
Install forklift (TM 5-2420-224-20).

11-39
TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: General Safety Instructions:

HMMH

Tools and Special Equipment: WARNING

High pressure hydraulics [oil
Shop Equipment, SC 4910-95-CL-A31 under 2450 psi (16,893 kPa)]
TOOI Kit, SC 5180-90-CL-N26 operate this equipment.
Never disconnect any
Materials/Parts:
hydraulic line or fitting
Washer, Lock (2) without first dropping
pressure to zero. A high
Caps and Plugs Appendix B, Item 8
pressure oil stream can
Rags Appendix B, Item 40 pierce body and cause
severe injury to personnel.
Personnel Required: (2)
Forklift mast assembly
References: weighs 587 pounds (267
kilograms). To avoid personal
TM 5-2420-224-20 injury, use a hoist or suitable
lifting device when lifting
Equipment Condition:
forklift mast assembly.
Reference Condition Description Fuel and oil are slippery and
Page 11-51 Forklift Lift Cylinder can cause falls. To avoid
Removed injury, wipe up spilled fuel or
oil with rags.
Page 11-44 Forklift Carriage Assembly
Removed
TM 5-2420-224-20 Hydraulic Pressure
Relieved

1. ATTACH suitable LIFTING DEVICE to lift eyes

(1) on mast assembly (2).

11-40
 TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPLACEMENT (CONT)

2. REMOVE FORKLIFT TILT CYLINDERS (3)

(TM 5-2420-224-20).

3. DISCONNECT hydraulic hose QUICK

DISCONNECT (4).

11-41
 TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPLACEMENT (CONT)

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

NOTE
Tag lines prior to disconnecting to
aid in connecting.

4. DISCONNECT two hydraulic HOSES (5) from

valve (6). INSTALL CAPS or PLUGS.

5. REMOVE two screws (7), two lock washers

(8), two eye bolts (9), and two PINS (10).
DISCARD lock WASHERS.

6. MOVE MAST assembly (2) AWAY from

vehicle and set down on flat surface.

1. MOVE MAST assembly (1) TO VEHICLE and

INSTALL two PINS (2), two eye bolts (3), two
new lock washers (4), and two screws (5).

11-42
 TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPLACEMENT (CONT)

2. REMOVE CAPS or PLUGS. CONNECT two

hydraulic HOSES (6) to valve (7).

3. CONNECT hydraulic hose QUICK

DISCONNECT (8).

4. INSTALL FORKLIFT TILT CYLINDERS (9)

(TM 5-2420-224-20).

NOTE
Follow-on Maintenance:
Install forklift lift cylinder (page
11-51).
Install forklift carriage assembly
(page 11-44).

11-43
TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPLACEMENT

This task covers: a. Removal b. lnspection c. Installation

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description

Tools and Special Equipment: TM 5-2420-224-20 Forklift Forks Removed

Shop Equipment, SC 4910-95-CL-A31 General Safety Instructions:

TOOl Kit, SC 5180-90-CL-N26

Materials/Parts:
WARNING
Pin, Cotter (2) Forklift carriage assembly
Washer, Lock (2) weighs 356 pounds (162
kilograms). To avoid personal
Caps and Plugs Appendix B, item 8 injury, use a hoist or suitable
lifting device when lifting
Rags Appendix B, item 40
forklift carriage assembly.
Personnel Required: (2)
Fuel and oil are slippery and
References: can cause falls. To avoid
injury, wipe up spilled fuel or
TM 5-2420-224-20 oil with rags.
LO 5-2420-224-12

1. ATTACH suitable HOIST to carriage assembly

(1) and LIFT CARRIAGE assembly (1) enough
to clear chain anchors (2).

11-44
 TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPLACEMENT (CONT)

2. REMOVE two cotter pins (3) and two PINS

(4) and DISCONNECT two carriage CHAINS
(5). DISCARD cotter PINS.

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

NOTE
Tag lines prior to disconnecting to
aid in connecting.

3. DISCONNECT two hydraulic HOSES (6).

INSTALL CAPS or PLUGS.

4. LOWER CARRIAGE assembly (1) enough to

allow carriage roller screw assemblies (7) to
be below crosshead assembly (8).

5. BACK OUT two carriage roller SCREW

assemblies (7) enough to clear carriage rollers
(9).

11-45
TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPLACEMENT (CONT)

6. REMOVE two capscrews (10), two lock

washers (11), two access COVERS (12), and
two spacers (13) and SET two hvdraulic
H O S E S ( 6 ) A S I D E . D I S C A R D lock
WASHERS.

CAUTION
During step 7, be careful not to
allow hoses or chains to bind.
To do so could result in
damage to hoses and/or
chains.

7. LOWER CARRIAGE assembly (1) completely

to floor.

NOTE
If mast cylinder is inoperative, use
suitable lifting device to raise
mast.

8. RAISE MAST (14) until inner upright channel

(15) clears carriage load bearings (16 and
17).

9. BACK VEHICLE AWAY from carriage

assembly (1).

11-46
 TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPLACEMENT (CONT)

10. REMOVE four bolts (18), two retainers (19),

two carriage load BEARINGS (16 and 17),
and spacers (20).

11. REMOVE four bearings (21, 22, 23, and 24).

1. Inspect bearings for excessive wear, flat

spots, and cracks. If any of these conditions
are present, replace bearing.

2. Inspect roller bearings by turning them on

their shafts. Replace rollers with roughness or
noticeable restrictions to turning.

3. Inspect all welds in carriage. Replace carriage

assembly if any welds are cracked.

4. Inspect stub shafts for damage or cracks. If

either of these conditions are present, replace
carriage assembly.

5. Inspect forklift carriage chains (page 11-67).

11-47
TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPLACEMENT (CONT)

NOTE
Make sure inner upright
channels have been properly
lubricated (LO 5-2420-224-12).
Install equal number of spacers
with each bearing.

1. INSTALL spacers (1), carriage load BEARING

(2), retainer (3), and two bolts (4).

2. REPEAT STEP 1 for carriage load beating

(5).

3. INSTALL four BEARINGS (6, 7, 8, and 9).

11-48
 TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPLACEMENT (CONT)

4. USING SUITABLE HOIST, POSITION

CARRIAGE assembly (10) in front of vehicle.

5. RAISE MAST (11) until inner upright channel

(12) clears carriage load bearings (2 and 5).

6. CAREFULLY MOVE VEHICLE to position

where inner upright channel (12) can be
lowered onto carriage assembly (10).

7. LOWER MAST (11). REMOVE CAPS or

PLUGS. INSTALL two hydraulic HOSES (13)
over two outer rollers (14). INSTALL two
spacers (15), two access COVERS (16), two
new lock washers (17), and two capscrews
(18).

8. CHECK six BEARINGS (2, 5, 6, 7, 8, and 9)

for proper shimming. Total clearance should
be no greater than 0.030 in. (0.762 mm) at
the tightest point throughout the total mast
travel.

11-49
TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPLACEMENT (CONT)

9. INSTALL two carriage CHAINS (19) over two

inner bearings (20).

CAUTION
During step 10, make sure
chains and hoses do not bind
to prevent possible damage to
chains and hoses.

10. RAISE CARRIAGE assembly (10) enough to

clear chain anchors (21).

11. RUN IN two carriage roller SCREW

assemblies (22) and TIGHTEN to
100-110 Ib-ft (135-149 N.m).

12. CONNECT two carriage CHAINS (19) and

INSTALL two PINS (23) and four new cotter
pins (24).

13. REMOVE CAPS or PLUGS. CONNECT two

hydraulic HOSES (13).

NOTE
Follow-on Maintenance:
Install forklift forks (TM 5-2420-
224-20).
Adjust forklift carriage chains
(TM 5-2420-224-20).

11-50
 TM 5-2420-224-34

FORKLIFT LlFT CYLINDER REPLACEMENT, BLEEDING, AND

SEQUENCING
This task covers: a. Removal b. Installation c. Bleeding d. Sequencing

Applicable Configuration: General Safety Instructions:

HMMH

Tools and Special Equipment: WARNING

High pressure hydraulics [oil
Shop Equipment, SC 4910-95-CL-A31
under 2450 psi (16,893 kPa)]
Tool Kit, SC 5180-90-CL-N26
Tube, P/N 661507 operate this equipment.
Tubing, P/N 661922 Never disconnect any
Key, P/N 609T-3/16 hydraulic line or fitting
without first dropping
Materials/Parts: pressure to zero. A high
pressure oil stream can
Caps and Plugs Appendix B, Item 8 pierce body and cause
Rags Appendix B, item 40 severe injury to personnel.

Personnel Required: (2) Forklift lift cylinder weighs

101 pounds (46 kilograms).
References: To avoid personal injury, use
a hoist or suitable lifting
TM 5-2420-224-20 device when lifting forklift lift
LO 5-2420-224-12 cylinder.
Equipment Condition: Do not work on forklift lift
cylinder with load on forks or
Reference Condition Description while anyone is near forklift
Page 11-44 Forklift Carriage Assembly controls. To do so could
Removed result in injury to personnel.

TM 5-2420-224-20 Forklift Crosshead Fuel and oil are slippery and

Removed can cause falls. To avoid
TM 5-2420-224-20 Hydraulic Pressure injury, wipe up spilled fuel or
Relieved oil with rags.

11-51
TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPLACEMENT, BLEEDING, AND

SEQUENCING (CONT)

1. LOOSEN bleeder VALVE (1). USING TUBE

and TUBING, BLEED off hydraulic
PRESSURE in lift cylinder (2).

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

NOTE
Have suitable container available
to catch oil that may leak out.

2. DISCONNECT HOSE assembly (3) from base

of lift cylinder (2). INSTALL CAP or PLUG on
fitting (4).

11-52
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPLACEMENT, BLEEDING, AND

SEQUENCING (CONT)

3. USING suitable HOIST, LIFT Iift CYLINDER

(2) clear of mast (5).

1. USING suitable HOIST. INSTALL lift

CYLINDER (1) in mast (2).

11-53
TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPLACEMENT, BLEEDING, AND

SEQUENCING (CONT)

2. REMOVE CAP or PLUG from fitting (3).

CONNECT HOSE assembly (4) to base of lift
cylinder (1).

3. INSTALL FORKLIFT CROSSHEAD (TM 5-

2420-224-20).

4. INSTALL FORKLIFT CARRIAGE ASSEMBLY

(PAGE 11-44).

1. With no load on forks, extend and retract

mast thru one complete cycle.

2. With mast fully lowered, check vehicle

hydraulic tank and top off as necessary
(LO 5-2420-224-12).

3. Raise and retract mast completely at least

four more times. This will force air in system
to lift cylinder center cavity under bleeder
valve (1).

4. Raise carriage assembly approximately 10 in.

(25.4 cm) off ground.

5. Slide tubing through tube and onto bleeder

valve (1) located on top of lift cylinder (2).
Place other end of tubing in suitable container
to catch oil.

6. Open bleeder valve (1) no more than 1/4-turn

with tube. Weight of carriage assembly will
force air and hydraulic oil out of lift cylinder
through bleeder valve (1).

7. If carriage assembly reaches bottom of its

travel before all air is bled, close bleeder
valve (1) and repeat steps 4 thru 6.

8. When oil stream no longer contains air

bubbles, close bleeder valve (1) and tighten to
25-27 Ib-ft (44.9-46.6 N.m).

9. Fill hydraulic tank (LO 5-2420-224-12).

11-54
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPLACEMENT, BLEEDING, AND

SEQUENCING (CONT)

1. Remove bleeder valve (1) on top of slave

plunger (2).

2. Insert key into bleed hole and engage

adjusting nut (3).

NOTE
Adjusting nut is crimped slightly to
prevent free-turning, resulting in
stiff movement.

3. Turn adjusting nut (3) counterclockwise until it

bottoms. Do not force adjusting nut after it
bottoms.

4. Turn adjusting nut (3) clockwise two full turns

to provide initial adjustment. Remove key and
install bleeder valve (1).

11-55
TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPLACEMENT, BLEEDING, AND

SEQUENCING (CONT)

5. Operate lift cylinder with half-capacity bad to

check for proper sequencing. If slave plunger
(2) extends too fast and master plunger (4)
does not extend at all, sequence valve is not
opening. Turn adjusting nut (3) clockwise one
turn only. Repeat steps 1 thru 4.

6. Repeat step 5 until lift cylinder sequences

property. Turn adjusting nut (3) maximum of
10 turns.

7. When lift cylinder sequences properly, turn

adjusting nut (3) clockwise one turn only to
ensure positive adjustment.

8. Extend and retract lift cylinder completely. If

lift cylinder does not operate smoothly or
seems spongy, repeat steps 3 thru 8 of
BLEEDING, above.

11-56
 TM 5-2420-224-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

This task covers: a. Removal b. Installation c. Adjustment

Applicable Configuration: Personnel Required: (2)

HMMH General Safety Instructions:
Tools and Special Equipment:
Shop Equipment, SC 4910-95-CL-A31 WARNING
Tool Kit, SC 5180-90-CL-N26 Forklift rail upright weighs
172 pounds (78 kilograms).
Matertials/Parts:
To avoid personal injury, use
Washer, Lock (2) a hoist or suitable lifting
device when lifting forklift rail
Nut, Lock upright.
Washer, Lock (2)
Forklift upright weighs 196
Washer, Lock (2) pounds (89 kilograms). To
avoid personal injury, use a
Washer, Lock (2) hoist or suitable lifting device
Washer, Lock (6) when lifting forklift upright.

Washer, Lock (4) Forklift mast assembly

weighs 587 pounds (267
Pin, Cotter (4) kilograms). To avoid personal
Pin, Cotter (2) injury, use a hoist or suitable
lifting device when lifting
Nut, Lock (2) forklift mast assembly.
Washer, Lock (4) Fuel and oil are slippery and
Pin, Cotter (4) can cause falls. To avoid
injury, wipe up spilled fuel or
Pin, Cotter (4) oil with rags.
Caps and Plugs Appendix B, Item 8
Rags Appendix B, Item 40

11-57
 TM 5-2420-224-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

1. REMOVE two capscrews (1), two lock washers (2), and GUIDE (3). DISCARD lock WASHERS.

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

Note
Tag all lines prior to disconnecting to aid in connecting.

2. DISCONNECT HOSE assembly (4). INSTALL CAPS or PLUGS.

3. REMOVE two setscrews (5) and CLAMP (6) from hose assembly (4).

4. REMOVE lock nut (7), capscrew (8), and GUIDE (9). DISCARD lock NUT.

11-58
 TM 5-2420-224-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

5. REMOVE two capscrews (10), Iwo lock washers (11), and junction BLOCK (12). DISCARD lock
WASHERS.

11-59
TM 5-2420-224-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

6. REMOVE two capscrews (13), two lock washers (14), and two CLAMPS (15). DISCARD lock
WASHERS.

7. REMOVE two capscrews (16), two lock washers (17), and BRACKET (18). DISCARD lock WASHERS.

8. REMOVE six nuts (19), six lock washers (20), six capscrews (21), and three GUIDES (22). DISCARD
lock WASHERS.

CAUTION
Cap or plug all ports and ends of hoses and tubes to prevent contamination of
hydraulic oil. Failure to do so may result in damage to equipment.

9. DISCONNECT and REMOVE two HOSES (23). INSTALL CAPS or PLUGS.

10. DISCONNECT and REMOVE two HOSES (24). INSTALL CAPS or PLUGS.

11-60
 TM 5-2420-224-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

11. REMOVE two nuts (25) and two ELBOWS (26).

12. REMOVE retaining ring (27) and PULLEY (28).
13. REMOVE four capscrews (29), four lock washers (30), and two BRACKETS (31 and 32). DISCARD
lock WASHERS.
14. REMOVE rail UPRIGHT (33) from mast assembly (34).
15. REMOVE UPRIGHT (35) from outer upright (36).

Note
Steps 16 thru 21 are the same for both bootstrap chains.

16. REMOVE two cotter pins (37) and PIN (36) and DISCONNECT bootstrap CHAIN (39) from chain
anchor (40). DISCARD cotter PINS.
17. REMOVE cotter pin (41), lock nut (42), and chain ANCHOR (40). DISCARD cotter PIN and lock NUT.
18. REMOVE two capscrews (43), two lock washers (44), and ROLLER (45). DISCARD lock WASHERS.
19. REMOVE TWO cotter pins (46), pin (47), and bootstrap CHAIN (39). DISCARD cotter PINS.
20. REMOVE retaining ring (48), shim(s) (49), and STAKE (50).
21. REMOVE two cotter pins (51), pin (52), and connecting LINK (53) from stake (50). DISCARD cotter
PINS.

11-61
 TM 5-2420-224-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

NOTE
Steps 1 thru 7 are the same for both bootstrap chains.

1. INSTALL adapter LINK (1), pin (2), and two new ootter pins (3) in stake (4).

2. INSTALL STAKE (4), shim(s) (5), and retaining ring (6).

3. INSTALL bootstrap CHAIN (7), pin (8), and two new cotter pins (9).

11-62
 TM 5-2420-224-34

FORKLlFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

4. ROUTE bootstrap CHAIN (7) over bearing (10) as shown.

5. INSTALL ROLLER (11), two lock washers (12), and two capscrews (13).

6. INSTALL chain ANCHOR (14), new lock nut (15), and new cotter pin (16).

7. CONNECT bootstrap CHAIN (7) to chain anchor (14) and INSTALL PIN (17) and two new cotter pins (18).

11-63
 TM 5-2420-224-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

8. INSTALL UPRIGHT (19) in outer upright (20).

9. lNSTALL rail UPRIGHT (21) in upright (19).
10. TURN MAST assembly (22) OVER.
11. INSTALL two BRACKETS (23 and 24), four lock washers (25), and four capscrews (26).
12. INSTALL PULLEY (27) and retaining ring (28).
13. INSTALL two ELBOWS (29) and two nuts (30).
14. REMOVE CAPS or PLUGS. INSTALL and CONNECT two HOSES (31).
15. REMOVE CAPS or PLUGS. INSTALL and CONNECT two HOSES (32).
16. INSTALL three GUIDES (33), six capscrews (34), six new lock washers (35), and six nuts (36).
17. INSTALL BRACKET (37), two new lock washers (38), and two capscrews (39).
18. INSTALL two CLAMPS (40), two new lock washers (41), and two capscrews (42).

11-64
 TM 5-2420-224-34

FORKLlFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

19. INSTALL junction BLOCK (43), two new lock washers (44), and two capscrews (45).

11-65
 TM 5-2420-244-34

FORKLIFT BOOTSTRAP CHAIN REPLACEMENT AND ADJUSTMENT

(CONT)

20. INSTALL GUIDE (46), capscrew (47), and new lock nut (46).

21. INSTALL CLAMP (49) and two setscrews (50) on hose assembly (51).

22. REMOVE CAPS or PLUGS. CONNECT HOSE assembly (51).

23. INSTALL GUIDE (52), two new lock washers (53), and two capscrews (54).

1. Raise mast until chain adjusting nut is just above outer upright.

2. Tighten or loosen adjusting nut to adjust one bootstrap chain to achieve equal dimension. Adjust other
bootstrap chain until equal tension is achieved.

3. Lower mast and check adjustment. All channels should be even with each other at bottom within 1/6 in.
(4.17 mm).

11-66
 TM 5-2420-224-34

FORKLIFT CARRIAGE CHAIN REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

Applicable Configuration Materials/Parts:

HMMH Pin, Cotter (6)

Tools and Special Equipment: Nut, Lock (2)

Shop Equipment, SC 4910-95-CL-A31 Equipment Condition:

TooI Kit, SC 5180-90-CL-N26
Reference Condition Description
Page 11-44 Forklift Carriage Assembly
Removed

NOTE
Procedure is the same for both
carriage chains.

1. REMOVE two cotter pins (1) and PIN (2) and

DISCONNECT carriage CHAIN (3). DISCARD
cotter PINS.

2. REMOVE cotter pin (4), lock nut (5), and

chain ANCHOR (6). DISCARD rotter PIN and
lock NUT.

If either carriage chain must be replaced, replace

both chains.

11-67
TM 5-2420-224-34

FORKLIFT CARRIAGE CHAIN REPLACEMENT (CONT)

NOTE
Procedure is the same for both
carriage chains.

1. INSTALL chain ANCHOR (1), new lock nut

(2), and new cotter pin (3).

2. CONNECT carriage CHAIN (4) and INSTALL

PIN (5) and two new cotter pins (6).

NOTE
Follow-on Maintenance:
Install forklift carriage assembly
(page 11-44).

11-68
 TM 5-2420-224-34

CHAPTER 12
CRANES, SHOVELS, AND EARTHMOVING EQUIPMENT MAINTENANCE

This chapter illustrates and describes procedures for maintenance of the cranes, shovels, and
earthmoving equipment. A list of tasks contained in this chapter is shown below.

Page

Backhoe Main Frame Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . 12-1

Crane Mast Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

Crane Inner Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

Crane Outer Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

Crane Extension Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17

Crane Gear Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19

Crane Intermediate Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25

Crane Drive Gear and Bushings Replacement . . . . . . . . . . . . . . . . . . . . . . . . 12-29

Crane Pinion Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31

Crane Pinion Gear Bushings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

BACKHOE MAIN FRAME REPLACEMENT AND REPAIR

This task covers: a. Removal b. Inspection c. Repair d. Installation

Applicable Configuration: References:

SEE TM 5-2420-224-20
TM 9-237
Tools and Special Equipment:
Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 Reference Condition Description
Shop Equipment, Welding, SC 4940-95-CL-B19
TM 5-2420-224-20 Backhoe Stabilizers
Materials/Parts: Removed
Nut, Lock TM 5-2420-224-20 Backhoe Swing Cylinders
Removed
Personnel Required: (3)
TM 5-2420-224-20 Backhoe Control Tower
Removed
TM 5-2420-224-20 Pintle Assembly Removed

12-1
 TM 5-2420-224-34

BACKHOE MAIN FRAME REPLACEMENT AND REPAIR (CONT)

Equipment Condition (Cont): General Safety Instructions:

Reference Condition Description

Page 11-15 Backhoe Control Valve WARNING
Removed • Backhoe assembly without
Page 11-12 Backhoe Stabilizer Control main frame weighs 1,767
Valve Removed pounds (803 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting backhoe
assembly without main frame.

• Backhoe frame section

weighs 489 pounds (223
kilograms). To avoid personal
injury, use a hoist or suitable
lifting device when lifting
frame section.

1. REMOVE lock nut (1), capscrew (2), washer (3), PIN (4), and shim (5). DISCARD lock NUT.

2. REMOVE nut (6), pin (7), spacer (8), and DIPPER, BOOM, and swing TOWER assembly (9). MOVE
assembly (9) ASIDE.

12-2
 TM 5-2420-224-34

BACKHOE MAIN FRAME REPLACEMENT AND REPAIR (CONT)

3. REMOVE four retaining rings (10), two pins(n), and frame SECTION (12) from subframe (13).

4. IF DAMAGED, REMOVE two lubrication FITTlNGS (14).

If any parts are worn or damaged or if frame section is cracked, tag frame section for repair.

Weld any cracks found in frame (TM 9-237).

12-3
TM 5-2420-224-34

BACKHOE MAIN FRAME REPLACEMENT AND REPAIR (CONT)

1. IF REMOVED, INSTALL two new lubrication FITTINGS (1).

2. INSTALL frame SECTION (2), two pins (3), and four retaining rings (4) on subframe (5).

12-4
 TM 5-2420-224-34

BACKHOE MAIN FRAME REPLACEMENT AND REPAIR (CONT)

3. INSTALL DIPPER, BOOM, and swing TOWER assembly (6), spacer (7), pin (8), and nut (9).

4. INSTALL shim (10), PIN (11), washer (12), capscrew (13), and new lock nut (14).

NOTE
Follow-on Maintenance:
Install backhoe stabilizer control valve (page 11-12).
Install backhoe control valve (page 11-15).
Install pintle assembly (TM 5-2420-224-20).
Install backhoe control tower (TM 5-2420-224-20).
Install backhoe swing cylinders (TM 5-2420-224-20).
Install backhoe stabilizers (TM 5-2420-224-20).

12-5
 TM 5-2420-224-34

CRANE MAST REPLACEMENT AND REPAIR

This task covers: a. Removal b. Disassembly c. Assembly d. Installation

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: Page 12-13 Crane Inner Boom
Removed
Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26 TM 5-2420-224-20 Work Lights Removed
Shop Equipment, Welding, SC 4940-95-CL-B19
TM 5-2420-224-20 Crane Mast Locking
Materials/Parts: Cylinders Removed

Washer, Lock (15) General Safety Instructions:

Nut, Lock (4)
Capscrew (18) WARNING
Nut, Lock (4) • Crane mast weldment weighs
492 pounds (223 kilograms).
Personnel Required: (3) To avoid personal injury, use a
hoist or suitable lifting device
References: when lifting crane mast
weldment.
TM 5-2420-224-20
• Crane base weldment weighs
205 pounds (93 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting crane base
weldment.

1. REMOVE two capscrews (1), four lock

washers (2), and two hose STRAPS (3). SET
four HOSES (4, 5, 6, and 7) ASIDE.
DISCARD lock WASHERS.

2. REMOVE capscrew (8), lock washer (9), and

hose strap (10). DISCARD lock WASHER.

12-6
 TM 5-2420-224-34

CRANE MAST REPLACEMENT AND REPAIR (CONT)

NOTE
Tag all lines prior to removal to
aid in installation.

3. REMOVE lock nut (11) and hose STRAP (12).

SET two HOSES (13 and 14) ASIDE.
DISCARD lock NUT.

4. REMOVE two capscrews (15), four lock

washers (16), and two hose STRAPS (17).
SET four HOSES (4, 5, 13, and 14) and
electrical CABLE (18) ASIDE. DISCARD lock
WASHERS.

5. REMOVE lock nut (19) and hose STRAP (20).

DISCARD lock NUT.

6. REMOVE lock nut (21) and hose STRAP (22).

SET two HOSES (23 and 24) aside.
DISCARD lock NUT.

7. REMOVE two capscrews (25), four lock

washers (26), and two hose STRAPS (27).
SET four HOSES (6, 7, 23, and 24) and
electrical CABLE (28) ASIDE. DISCARD lock
WASHERS.

8. REMOVE lock nut (29) and hose STRAP (30).

DISCARD lock NUT.

12-7
TM 5-2420-224-34

CRANE MAST REPLACEMENT AND REPAIR (CONT)

9. REMOVE two capscrews (31), two lock

washers (32), two pins (33), and mast
WELDMENT (34). DISCARD lock WASHERS.

10. IF DAMAGED, REMOVE two lubrication

FlTTINGS (35) from two pins (33).

11. IF DAMAGED, REMOVE two lubrication

FITTINGS (36) from mast weldment (34).

12. REMOVE two spring pins (37) and hose

GUARD (38).

CAUTION
Feed hoses through hose
guards of base weldment very
carefully. Failure to do so
could result in damage to
hoses.

13. REMOVE 18 capscrews (39), 18 washers

(40), cover (41), and base WELDMENT (42).
DISCARD CAPSCREWS.

14. REMOVE four lock nuts (43), four capscrews

(44), and four hose GUARDS (45). DISCARD
lock NUTS.

15. REMOVE two hose GUARDS (46).

12-8
 TM 5-2420-224-34

CRANE MAST REPLACEMENT AND REPAIR (CONT)

1. REMOVE two BUSHINGS (1) from mast

weldment (2).

2. REMOVE two BUSHINGS (3) from base

weldment (4).

1. INSTALL two BUSHINGS (3) in base

weldment (4).

2. INSTALL two BUSHINGS (1) in mast

weldment (2).

12-9
TM 5-2420-224-34

CRANE MAST REPLACEMENT AND REPAIR (CONT)

1. INSTALL two hose GUARDS (1).

2. INSTALL four hose GUARDS (2), four

capscrews (3), and four new lock nuts (4).

CAUTION
Feed hoses through hose
guards of base weldment very
carefully. Failure to do so could
result in damage to hoses.

NOTE
Make sure cover is installed over
notch in base weldment.

3. INSTALL base WELDMENT (5), cover (6), 18

washers (7), and 18 new capscrews (8).

4. INSTALL hose GUARD (9) and two spring

pins (10).

5. IF REMOVED, INSTALL two new lubrication

FlTTINGS (11) in mast weldment (12).

6. IF REMOVED, INSTALL two new lubrication

FlTTlNGS (13) in two pins (14).

7. INSTALL mast WELDMENT (12), two pins

(14), two new lock washers (15), and two
capscrews (16).

12-10
 TM 5-2420-224-34

CRANE MAST REPLACEMENT AND REPAIR (CONT)

8. INSTALL hose STRAP (17) and new lock nut

(18).

9. INSTALL four HOSES (19, 20, 21, and 22),

electrical CABLE (23), two hose straps (24),
four new lock washers (25), and two
capscrews (26).

10. INSTALL two HOSES (19 and 20), hose strap

(27), and new lock nut (28).

11. INSTALL hose STRAP (29) and new lock nut

(30).

12. INSTALL four HOSES (31, 32, 33, and 34),

electrical CABLE (35), two hose straps (36),
four new lock washers (37), and two
capscrews (38).

13. INSTALL two HOSES (31 and 32), hose strap

(39), and new lock nut (40).

12-11
TM 5-2420-224-34

CRANE MAST REPLACEMENT AND REPAIR (CONT)

14. INSTALL hose STRAP (41), new lock washer

(42), and capscrew (43).

15. INSTALL four HOSES (21, 22, 33, and 34),

two hose straps (44), four new lock washers
(45), and two capscrews (46).

NOTE
Follow-on Maintenance:
Install crane mast locking cylinders
(TM 5-2420-224-20).
Install work lights (TM 5-2420-224-
20).
Install crane inner boom (page
12-13).

12-12
 TM 5-2420-224-34

CRANE INNER BOOM REPLACEMENT

This task covers: a. Removal b. Installation

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane Inner Boom Lift
Cylinders Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-9042L-N26 TM 5-2420-224-20 Crane Inner Boom Lift
Cylinder Hydraulic Lines
Personnel Required: (2) and Fittings Removed

References: Page 12-15 Crane Outer Boom

Removed
TM 5-2420-224-20
General Safety Instructions:

WARNING
Crane inner boom weighs 219
pounds (99 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting crane inner boom.

2. REMOVE two spring pins (5) and hose GUARD (6).

3. IF DAMAGED, REMOVE lubrication FlTTING (7).

12-13
TM 5-2420-224-34

CRANE INNER BOOM REPLACEMENT (CONT)

1. IF REMOVED, lNSTALL new lubrication FITTING (1).

2. INSTALL hose GUARD (2) and two spring pins (3).

3. USING suitable HOIST, INSTALL inner BOOM (4), pin (5), retainer plate (6), and capscrew (7).

NOTE
Follow-on Maintenance:
Install crane inner boom lift cylinders (TM 5-2420-224-20).
Install crane inner boom lift cylinder hydraulic lines and fittings (TM 5-2420-224-20).
Install crane outer boom (page 12-15).

12-14
 TM 5-2420-224-34

CRANE OUTER BOOM REPLACEMENT

This task covers: a. Removal b. Installation

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane Outer Boom
Cylinder Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 TM 5-2420-224-20 Crane Outer Boom
Cylinder Hydraulic Lines
Personnel Required: (2) and Fittings Removed
References: Page 12-17 Crane Extension Boom
Removed
TM 5-2420-224-20
General Safety Instructions:

WARNING
Crane outer boom weighs 119
pounds (89 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting crane outer boom.

1. USING suitable HOIST, REMOVE capscrew (1), washer (2), pin (3), and outer BOOM (4).
2. IF DAMAGED, REMOVE two lubrication FlTTINGS (5).

12-15
TM 5-2420-224-34

CRANE OUTER BOOM REPLACEMENT (CONT)

1. IF REMOVED, INSTALL two new lubrication FlTTINGS (1).

2. USING suitable HOIST, INSTALL outer BOOM (2), pin (3), washer (4), and capscrew (5).

NOTE
Follow-on Maintenance:
Install crane outer boom cylinder (TM 5-2420-224-20).
Install crane outer boom cylinder hydraulic lines and fittings (TM 5-2420-224-20).
Install crane extension boom (page 12-17).

12-16
 TM 5-2420-224-34

CRANE EXTENSION BOOM REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description

Tools and Special Equipment: TM 5-2420-224-20 Crane External End

Extension Cylinder
Shop Equipment, SC 4910-95-CL-A31 Removed
Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Crane Hook Assembly
Personnel Required: (2) Removed

References: General Safety Instructions:

TM 5-2420-224-20
WARNING
Crane extension boom weighs
172 pounds (78 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting crane extension
boom.

1. USING suitable HOIST, REMOVE extension

BOOM (1) from outer boom (2).

2. REMOVE two friction LININGS (3).

12-17
TM 5-2420-224-34

CRANE EXTENSION BOOM REPLACEMENT (CONT)

With friction linings installed, measure height of friction lining above level surface of extension boom.
Thickness of friction lining above metal surface should not be less than 0.04-0.06 in. (0.1-0.2 cm). If
measurement is less, replace friction lining.

1. INSTALL two friction LININGS (1).

2. USING suitable HOIST, carefully SLIDE extension BOOM (2) into outer boom (3).

NOTE
Follow-on Maintenance:
Install crane external end extension cylinder (TM 5-2420-224-20).
Install crane hook assembly (TM 5-2420-224-20).

12-18
 TM 5-2420-224-34

CRANE GEAR BEARING REPLACEMENT

This task covers: a. Removal b. Cleaning c. Installation

Applicable Configuration: General Safety Instructions:

HMMH

Tools and Special Equipment: WARNING

• High pressure hydraulics [oil
Shop Equipment, SC 4910-95-CL-AM under 2450 psi (16,893 kPa)]
Tool Kit, SC 5180-90-CL-N26
operate this equipment.
Materials/Parts: Never disconnect any
hydraulic line or fitting
Washer, Lock (4) without first dropping
pressure to zero. A high
Capscrew (36)
pressure oil stream can
Caps and Plugs Appendix B, Item 8 pierce body and cause
severe injury to personnel.
Compound, Seating Appendix B, Item 15
Ž Crane assembly weighs 1,625
Rags Appendix B, Item 40
pounds (738 kilograms). To
Personnel Required: (3) avoid personal injury, use a
hoist or suitable lifting device
References: when lifting crane assembly.

TM 5-2420-224-20 • Fuel and oil are slippery and

can cause fails. To avoid
Equipment Condition: injury, wipe up spilled fuel or
oil with rags.
Reference Condition Description
• Adhesive causes immediate
TM 5-2420-224-20 Hydraulic Pressure
Relieved bonding on contact with
eyes, skin, or clothing and
also gives off harmful vapors.
Wear protective goggles and
use in well-ventilated area. If
adhesive gets in eyes, try to
keep eyes open; flush eyes
with water for 15 minutes
and get immediate medical
attention.

12-19
TM 5-2420-224-34

CRANE GEAR BEARING REPLACEMENT (CONT)

1. PLACE CRANE (1) in position shown.

2. REMOVE four capscrews (2), four lock

washers (3), and COVER (4). DISCARD lock
WASHERS.

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

NOTE
Tag all lines prior to disconnecting
to aid in connecting.

3. DISCONNECT 16 hydraulic HOSES (5) from

valve body (6). INSTALL CAPS or PLUGS.

12-20
 TM 5-2420-224-34

CRANE GEAR BEARING REPLACEMENT (CONT)

CAUTION
Carefully feed hydraulic hoses
through opening to prevent
damage to hoses.

4. REMOVE 18 capscrews (7), 18 washers (8),

and CRANE assembly (1). DISCARD
CAPSCREWS.

5. DISCONNECT lubrication LINE (9) on gear

bearing (10) and set aside.

CAUTION
Support gear bearing to
prevent gear bearing from
dropping.

6. REMOVE 18 capscrews (11), 18 washers

(12), and gear BEARING (10). Discard
capscrews.

CLEANING

Thoroughly clean top of base and bottom of gear

bearing. Both mating surfaces must be completely
clean and dry with no oil or grease present.

12-21
TM 5-2420-224-34

CRANE GEAR BEARING REPLACEMENT (CONT)

INSTALLATION

1. lNSTALL gear BEARING (1) with ball loading

plug next to pinion gear(2).

2. APPLY COAT of SEALING COMPOUND to

18 new CAPSCREWS (3) and INSTALL 18
CAPSCREWS (3) and 18 washers (4). DO
NOT TIGHTEN CAPSCREWS.

3. USING feeler GAGE, CHECK BACKLASH

between gear bearing (1) and pinion gear (2).
PERMISSIBLE BACKLASH is 0.025-0.050 in.
(0.84-1.3 mm). MOVE gear BEARING (1) to
obtain desired backlash.

12-22
 TM 5-2420-224-34

CRANE GEAR BEARING REPLACEMENT (CONT)

4. WHEN desired BACKLASH has been SET,

TIGHTEN 18 CAPSCREWS (3) to 500 lb-ft
(678 N.m).

5. REPEAT STEP 3. If BACKLASH is OUT of

TOLERANCE, LOOSEN 18 CAPSCREWS (3).
REPEAT STEPS 3 and 4 until backlash is
correct.

6. CONNECT lubrication LINE (5) to gear

bearing (1).

CAUTION
Carefully feed hydraulic hoses
through opening to prevent
damage to hoses.

7. APPLY COAT of SEALING COMPOUND to

18 new CAPSCREWS (6) and INSTALL
CRANE assembly (7), 18 capscrews (6), and
18 washers (8). TIGHTEN CAPSCREWS to
500 Ib-ft (678 N.m).

12-23
 TM 5-2420-224-34

CRANE GEAR BEARING REPLACEMENT (CONT)

8. REMOVE CAPS or PLUGS from valve body

(9) and hydraulic hoses (10). CONNECT 16
hydraulic HOSES (10).

9. INSTALL COVER (11), four new lock washers

(12), and four capscrews (13).

NOTE
Follow-on Maintenance:
1. Start vehicle and purge air from hydraulic
system.
2. Attach crane to load equal to maximum rated
load for crane.
3. Lift full rated load and swing load completely
around in both directions. Actuate controls
very slowly and keep load as close as
possible to ground. Set load down.
4. Place crane in three-point stance (TM 5-2420-
224-20).
5. Shut down vehicle.

WARNING
After swinging full rated load,
all gear bearing mounting
capscrews must be checked to
ensure that capscrews were
tightened properly. Failure to
perform this check can result in
crane failure and/or serious
personnel injury or death.

6. Check tightness of all capscrews. Tighten

again, if necessary.

12-24
 TM 5-2420-224-34

CRANE INTERMEDIATE GEAR REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: General Safety Instructions:

HMMH

Tools and Special Equipment: WARNING

High pressure hydraulics [oil
Shop Equipment, SC 4910-95-CL-A31 under 2450 psi (16,893 kPa)]
Tool Kit, SC 5180-90-CL-N26
operate this equipment.
Materials/Parts: Never disconnect any
hydraulic line or fitting
Washer, Lock (4) without first dropping
pressure to zero. A high
Washer, Lock (2)
pressure oil stream can
Caps and Plugs Appendix B, item 8 pierce body and cause
severe injury to personnel.
Rags Appendix B, Item 40
Fuel and oil are slippery and
References: can cause falls. To avoid
TM 5-2420-224-20 injury, wipe up spilled fuel or
oil with rags.
Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Crane in Three-Point
Stance
Page 12-31 Crane Pinion Gear
Removed
TM 5-2420-224-20 Hydraulic Pressure
Relieved

REMOVAL

1. REMOVE four screws (1), four lock washers

(2), and COVER (3). DISCARD lock
WASHERS.

12-25
 TM 5-2420-224-34

CRANE INTERMEDIATE GEAR REPLACEMENT (CONT)

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

NOTE
Tag lines prior to disconnecting to
aid in connecting.

2. DISCONNECT 14 hydraulic HOSES (4) from

valve body (5). INSTALL CAPS or PLUGS.

3. PULL 14 hydraulic HOSES (4) through base

weldment (6) and SET ASIDE.

4. REMOVE two capscrews (7), two lock

washers (8), and COVER (9). DISCARD lock
WASHERS.

5. REMOVE intermediate GEAR (10) by

PUSHING intermediate GEAR (10) toward
LEFT SIDE of vehicle.

12-26
 TM 5-2420-224-34

CRANE INTERMEDIATE GEAR REPLACEMENT (CONT)

INSTALLATION

1. INSTALL intermediate GEAR (1) from left side

of vehicle.

2. INSTALL COVER (2), two new lock washers

(3), and two capscrews (4).

3. CAREFULLY PUSH 14 hydraulic HOSES (5)

back through base weldment (6).

4. REMOVE CAPS or PLUGS. CONNECT 14

hydraulic HOSES (5) to valve body (7).

12-27
TM 5-2420-224-34

CRANE INTERMEDIATE GEAR REPLACEMENT (CONT)

5. INSTALL COVER (8), four new lock washers

(9), and four screws (10).

NOTE
Follow-on Maintenance:
Install crane pinion gear (page
12-31).

12-28
 TM 5-2420-224-34

CRANE DRIVE GEAR AND BUSHINGS REPLACEMENT

This task covers: a. Removal b. installation

INITIAL SETUP

Applicable Configuration: References:

HMMH TM 5-2420-224-20
LO 5-2420-224-12
Tools and Special Equipment:
Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 Reference Condition Description
inserter and Remover, P/N 92091200
consisting of: TM 5-2420-224-20 Crane in Three-Point
Nut (2), P/N MS51967-23 Stance
Spacer, P/N 60102782
TM 5-2420-224-20 Crane Hydraulic Motor
Cylinder, P/N RCH-302
Removed
Extractor, P/N 60102777
Spacer, P/N 60102776
Bushing, P/N 60102784
Bushing, P/N 60100783
Ring, P/N 60102781

REMOVAL

1. INSTALL inserter and remover tools in

following order:
Spacer
Cylinder
Spacer
Nut
Extractor
Bushing
Nut

2. TIGHTEN NUT until puller is completely

SNUGGED UP.

3. APPLY hydraulic PRESSURE to jack until two

BUSHINGS (1 and 2) and drive GEAR (3)
have been REMOVED.

4. REMOVE TOOLS.

12-29
 TM 5-2420-224-34

CR ANE DRIVE GEAR AND BUS H I N G S R EPL A C EMEN T (C O N T )

INSTALLATION

1. INSTALL drive GEAR (1), two BUSHINGS (2

and 3), and tools in following order:
Extractor
Bushing (3)
Ring
Nut
Drive gear (1)
Bushing (2)
Bushing
Cylinder
Spacer
Nut

2. APPLY hydraulic PRESSURE until two

BUSHINGS (2 and 3) are completely
SEATED.

3. REMOVE TOOLS.

NOTE
Follow-on Maintenance:
Install crane hydraulic motor
(TM 5-2420-224-20).
Lubricate drive gear and two
bushings (LO 5-2420-224-12).

12-30
 TM 5-2420-224-34

CRANE PINION GEAR REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Applicable Configuration: Materials/Parts:

HMMH Washer, Lock (2)

Tools and Special Equipment:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26

REMOVAL

1. REMOVE two screws (1), two lock washers

(2), and COVER (3). DISCARD lock
WASHERS.

2. ROTATE CRANE until notch on base

weldment (4) is positioned over pinion gear
(5).

3. REMOVE two capscrews (6), two washers (7),

and COVER (8).

12-31
 TM 5-2420-224-34

CRANE PINION GEAR REPLACEMENT (CONT)

4. IF DAMAGED, REMOVE lubrication FITTING

(9).

5. REMOVE retaining ring (10) and pinion GEAR

(5).

INSTALLATION

1. INSTALL pinion GEAR (1) and retaining ring

(2).

12-32
 TM 5-2420-224-34

CRANE PINION GEAR REPLACEMENT (CONT)

2. IF REMOVED, INSTALL new lubrication

FlTTING (3).

3. INSTALL COVER (4), two washers (5), and

two capscrews (6).

4. INSTALL COVER (7), two new lock washers

(8), and two screws (9).

12-33
TM 5-2420-224-34

CRANE PINION GEAR BUSHINGS REPLACEMENT

This task covers: a. Removal b. Cleaning c. Installation

INITIAL SETUP

Applicable configuration: References:

HMMH LO 5-2420-224-12

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Coupling Assembly, P/N 9795 Page 12-25 Crane Intermediate Gear
Hose Assembly, P/N ST49D5 Removed
Inserter and Remover, P/N 92091200
consisting of: Page 12-31 Crane Pinion Gear
Nut, P/N 72062011 Removed
Spacer, P/N 60105358
Cylinder, P/N RCH-302
Stud, P/N 91565A736
Nut, P/N 01857-007
Plate, P/N 60105496
Stud, P/N 60102775
Ring (2), P/N 60102779
Bushing, P/N 60102778
Bushing, P/N 60102780

REMOVAL

1. INSTALL inserter and remover tools in

following order:
Plate
Stud
Nut
Cylinder
Stud
Spacer
Nut
Ring
Ring

2. TIGHTEN NUT until puller is completely

SNUGGED UP.

3. APPLY hydraulic PRESSURE to jack until two

pinion gear BUSHINGS (1 and 2) have been
REMOVED.

REMOVE TOOLS.

CLEANING

Clean cavity completely of all old lubricant.

12-34
 TM 5-2420-224-34

CRANE PINION GEAR BUSHINGS REPLACEMENT (CONT)

INSTALLATION

1. INSTALL two pinion gear BUSHINGS (1 and

2) and TOOLS in following order
Bushing (1)
(flat side facing intermediate gear)
Bushing
(flat side facing intermediate gear)
Spacer
Stud
Bushing (2)
Bushing
Cylinder
Nut

2. TIGHTEN NUT enough to apply SLIGHT

amount of PRESSURE on two pinion gear
bushings (1 and 2).

3. APPLY hydraulic PRESSURE until two pinion

gear BUSHINGS (1 and 2) are completely
SEATED.

4. REMOVE TOOLS.

NOTE
Follow-on Maintenance:
Install crane intermediate gear
(page 12-25).
Install crane pinion gear (page
12-31).
Lubricate crane pinion gear (LO 5-
2420-224-12).

12-35/(12-36 Blank)
 TM 5-2420-224-34

CHAPTER 13
ENGINE, FUEL, AND COOLING REPAIR INSTRUCTIONS

OVERVIEW

This chapter contains maintenance instructions for repair of the engine and fuel and cooling systems. A
list of sections contained in this chapter is shown below.
Page

Section I. Engine Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Section Il. Fuel System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65

Section III. Cooling System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71

Section I. ENGINE REPAIR

OVERVIEW

This section illustrates and describes procedures for repair of the engine. A list of tasks contained in this
section is shown below.
Page

Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Crankshaft, Main Bearings, and Rear Seals Replacement . . . . . . . . . . . . . . . . . . 13-15

Crankshaft Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24

Flywheel Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25

Flywheel End Bell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28

Flywheel Ring Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29

Pistons, Rings, Connecting Rods, and Bearings Replacement . . . . . . . . . . . . . . . . 13-31

Rocker Arms, Push Rods, and Tappets Replacement . . . . . . . . . . . . . . . . . . . . 13-37

Camshaft and Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-43

Cylinder Block Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-48

Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58

Oil Pump Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60

13-1
TM 5-2420-224-34

CYLINDER HEAD REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP

Tools and Special Equipment: Materials/Parts:

Shop Equipment, SC 4910-95-CL-A31 Kit, Parts

TooI Kit, SC 5180-90-CL-N26
Drift Pin, P/N 615 589 01 15 00 Grease, Silicone Appendix B, Item 25
Gauge, P/N 001 589 53 21 00 Oil, Lubricating Appendix B, Item 30
Installation Tool, P/N 346 589 03 15 00
Installation Tool, P/N 352 589 00 43 00 References:
Mandrel, P/N 117 589 03 23 00
Mandrel, P/N 617 589 05 23 00 TM 5-2420-224-20
Puller, P/N 352 589 00 33 00
Reamer, P/N 000 589 11 53 00 Equipment Condition:
Reamer, P/N 000 589 10 53 00
Reamer, P/N 000 589 18 53 00 Reference Condition Description
Removal Tool, P/N 110 589 02 15 00
Socket, P/N 000 589 75 09 00 TM 5-2420-224-20 Fuel Tank Lines and
Wrench, P/N 346 589 00 07 00 Fittings Removed
Page 3-25 Cylinder Head Removed

DISASSEMBLY

1. USING SOCKET, REMOVE six injector nozzle

HOLDERS (1).

2. USING PULLER, REMOVE six INJECTORS

(2) and seal rings (3). DISCARD seal RINGS.

13-2
 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

3. USING WRENCH, REMOVE six stepped

SPACERS (4) and six packings (5). DISCARD
PACKINGS.

NOTE
Procedure is the same for all
valves.

4. COMPRESS SPRING (6) and REMOVE

COLLET (7).

NOTE
Tag valves after removal to aid in
installation.

5. RELEASE SPRING (6) and REMOVE retainer

(8), spring (6), washer (9), and VALVE (10).

NOTE
Perform steps 6 thru 11 to
determine if valve guides are to
be replaced.

6. USING 9-mm REAMER, REMOVE carbon

DEPOSITS from intake valve guide (11).
7. INSTALL 9-mm MANDREL in intake valve
guide (11). Fit should be SNUG. There is NO
allowable TOLERANCE.
8. REPEAT STEPS 6 and 7 for each intake
valve guide.
9. USING 10-mm REAMER, REMOVE carbon
DEPOSITS from exhaust valve guide (12).

13-3
TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

10. INSTALL 10-mm MANDREL in exhaust valve

guide (12). Fit should be SNUG. There is NO
allowable TOLERANCE.

11. REPEAT STEPS 9 and 10 for each exhaust

valve guide.

NOTE
Perform steps 12 thru 16 only if fit
was not snug in steps 7 and 10.

12. USING REMOVAL TOOL and DRIFT PIN,

REMOVE intake and exhaust valve GUIDES
(11 and 12).

CAUTION
Do not ream through thickness
of valve seat as the
counterbore will be damaged.
Leave 0.0394-in. (1-mm)
thickness.

13. REAM valve SEAT (13) to REMOVE seating

FACE.

14. UNDERCUT valve SEAT (13) as shown.

13-4
 TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

CAUTION
Use protector pads under puller
supports to prevent damage to
cylinder head.

15. USING suitable PULLER, REMOVE valve

SEAT (13).

16. REPEAT STEPS 13 thru 15 for each valve

seat.

1. Test fuel injector nozzles (page 13-65).

2. Inspect stepped spacers for damaged threads,

pits, scoring, or damaged slots. Replace if
damaged.

3. Inspect injector nozzle holders for damaged

threads and/or damaged flats. Replace if
damaged.

4. Measure valve spring (1) length. Acceptable

length is 2.382 in. (60.5 mm).

5. Measure valve spring (1) length with

62.9 -69.8 Ibf (280-310 N) applied. Acceptable
length is 1.838 in. (46.70 mm).

6. Measure valve spring (1) length with

125.7-138.9 Ibf (559-618 N) applied.
Acceptable length is 1.385 in. (35.18 mm).

13-5
TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

7. Inspect each valve (2) for cracks, burns,

warpage, wear, or bent stems. Replace if
damaged.

8. Measure each valve (2) in accordance with

following table. If valves do not meet
specifications, replace valves.

Valve Specifications

Intake Exhaust
In. In.
(mm) (mm)

Valve Stem 0.3518-0.3523 0.3907-0.3913

Diameter A (8.935-8.950) (9.925-9.940)
Valve Seat 1.732 1.417
Diameter B (44.0) (36.0)
Valve Head 1.728-1.736 1.413-1.421
Diameter C (43.9-44.1) (35.9-36.1)
Height D 0.098-0.110 0.098-0.110
New (2.5-2.8) (2.5-2,8)
Valve Seat 0.110-0.138 0.138-0.165
Width E (2.8-3.5) (3.5-4.2)
Valve Seat 45 degrees 45 degrees
Angle F + 10 minutes + 10 minutes
Valve Length 5.524-5.539 5.524-5.539
(140.3-140.7) (140.3-140.7)

13-6
 TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

9. Inspect cylinder head (3) for cracks in valve

areas and injector areas. Replace cylinder
head if cracked.
10. Measure cylinder head (3) height, warpage,
and water jacket thickness as shown. Check
warpage and height at 2-in. intervals.

Cylinder Head

In. (mm)

Standard New 3.625 (92.1)

Head Height A 3.618 (91.9)
Minimum Height 3.579 (90.9)
Max Warpage 0.002 (0.05)
Cylinder Block
Mating Surface
(lengthwise) B
Max Warpage 0 (0)
Cylinder Block
Mating Surface
(crosswise) C
Min Wall Thickness 0.23 (6.0)
of Water Jacket

11. If cylinder head (3) shows warpage or gasket

surface shows pit marks or pin holes,
machine cylinder head gasket surface.

12. Inspect valve seat counterbores (4) for pitting,

cracks, bums, warpage, and blow-by on valve
contact face. If any of these conditions exist,
tag cylinder head for repair.

13-7
TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

1. USING REAMER, REAM valve guide BORE

(1) to next higher repair stage as shown in
following table.

Valve Guide Specifications

Bore in Valve Guide Valve Guide Inside

Cylinder Outside Diameter B, Final
Repair Head A Diameter A,
Interference Fit Intake Exhaust
Stage
In. In. In. In.
(mm) (mm) (mm) (mm)

Standard 0.5906-0.5913 0.5917-0.5924 0.3543-0.3552 0.3937-0.3946

(15.000-15.018) (15.026-15.046) (9.000-9.022) (10.000-10.022)
Stage I 0.5984-0.5991 0.5995-0.6002 0.3543-0.3552 0.3937-0.3946
(15.200-15.218) (1 5.228-15.246) (9.000-9.022) (10.000-1 0.022)

WARNING
Cylinder head will be hot
enough to burn you on contact.
Wear heat-resistant gloves
when handling hot cylinder
head.

2. HEAT cylinder HEAD (2) to 212°F (100°C)

and FREEZE new valve GUIDES.

3. APPLY light COAT of LUBRICATING OIL to

new valve GUIDES (3).

4. USING INSTALLATION TOOL, INSTALL valve

GUIDES (3) in cylinder head (2).

13-8
 TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

5. USING 9-mm and 10-mm REAMERS, REAM

all new valve GUIDES (3).

6. AFTER REAMING, USING 9-mm and 10-mm

MANDRELS, CHECK valve GUIDES (3).

NOTE
Make sure valve guides are within
specifications, or new, before
checking valve seat counterbore
irregularity. The common center is
lost when new guides are
installed. Therefore, check valve
seat counterbore irregularity
whenever valve guides are
replaced, and reface counterbores
as necessary.

7. INSTALL each VALVE (4) in its guide. USING

GAUGE, MEASURE DISTANCE between
valve (4) face and cylinder head (2).
ACCEPTABLE DISTANCE is 0.028-0.047 in.
(0.7-1.2 mm).

13-9
TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

8. CHECK valve seat COUNTERBORES (5) for

irregularity USING GAUGE and irregularity
control DEVICE. MAXIMUM IRREGULARITY
between valve guide (3) and valve seat
counterbore (5) is 0.0012 in. (0.03 mm).

9. USING following TABLE, CHECK WIDTH of

each valve seat COUNTERBORE (5). IF
NECESSARY, REFACE counterbore (step 13).

Valve Seat Counterbores

OM 352 (all) and OM 352A OM 352A (from 812344)

(through 812343)
Intake Exhaust Intake Exhaust
In. In. In. In.
(mm) (mm) (mm) (mm)

Diameter A 1.708-1.710 1.392-1.394 1.575 1.339

(43.370-43.400) (35.379-35.400) (40.0) (34.0)

Valve Seat Angle B 45° 45° 29° 55’-30° 44°50’-45°

Seat Width C 0.063-0.079 0.079-0.098 0.051-0.094 0.071-0.118

(1.6-2.0) (2.0-2.5) (1.3-2.4) (1.8-3.0)

Valve Seat Insert Recess 0.110-0.118 0.102-0.110 0.142-0.154 0.114-0.126

from Cylinder Head D (2.8-3.0) (2.6-2.8) (3.6-3.9) (2.9-3.2)

Reference Dimension E — — 0.154-0.161 0.154-0.161

(3.9-4.1) (3.9-4.1)

Valve Face Recess from 0.028-0.047 0.028-0.047 0.028-0.047 0.028-0.047

Cylinder Head (0.7-1.2) (0.7-1.2) (0.7-1.2) (0.7-1.2)

Maximum Concentricity 0.0012 0.0012 0.0012 0.0012

Deviation of Valve Seat (0.03) (0.03) (0.03) (0.03)
to Valve Guide

*If valve seat machining causes dimension to be exceeded, valve seat insert must be replaced.

13-10
 TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

WARNING
Cylinder head will be hot
enough to burn you on contact.
Wear heat-resistant gloves
when handling hot cylinder
head.

10. HEAT cylinder HEAD (2) to 212°F (100°C)

and COOL valve SEATS-in liquid nitrogen for
5 minutes.

WARNING
Do not touch liquid nitrogen or
valve seats with bare hands.
Severe frostbite will result.

11. CAREFULLY REMOVE valve SEATS (6) from

coolant and QUICKLY INSTALL them in
heated cylinder head (2).

12. USING INSTALLATION TOOL, TAP valve

SEATS (6) into cylinder head (2).

13. USING 90-degree REAMER or GRINDSTONE

with correct size pilot shaft, REFACE intake
and exhaust valve seat COUNTERBORES (5).
REMOVE ONLY ENOUGH material to obtain
smooth seat.

14. USING TABLE on page 13-10, CHECK

WIDTH of each valve seat COUNTERBORE
(5).

13-11
TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

15. TO CORRECT exhaust valve seat

COUNTERBORE width (7), USE 150-degree
REAMER or GRINDSTONE to remove
material from face of counterbore (5).

16. TO CORRECT intake valve seat

COUNTERBORE width (8), USE plane
REAMER to remove material from face of
counterbore (5).

17. REMOVE all CHIPS and GRIT from valve

seat counterbores (5).

18. CHECK all valve seat COUNTERBORES (5)

for irregularity (step 8).

NOTE
Procedure is the same for all
valves.

19. APPLY COAT of LUBRICATING OIL to valve

STEM (9).

20. INSTALL VALVE (10), washer (11), spring

(12), and retainer (13).

21. COMPRESS SPRING (12) and INSTALL

COLLET (14). The split must be equal on
both sides of collet.

22. LIGHTLY TAP all valve STEMS to ensure

proper seating of entire valve assembly.

13-12
 TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

23. APPLY COAT of SILICONE GREASE to six

new PACKINGS (15) and INSTALL six
PACKINGS (15).

24. USING WRENCH, INSTALL six stepped

SPACERS (16) and TIGHTEN to 37 Ib-ft
(50 N.m).

NOTE
Make sure new seal rings are
same thickness as ones removed.

25. INSTALL six new seal RINGS (17).

26. INSTALL six INJECTORS (18).

27. USING SOCKET, INSTALL six injector nozzle

HOLDERS (19) and TIGHTEN to 43-50 Ib-ft
(60-70 N.m).

13-13
TM 5-2420-224-34

CYLINDER HEAD REPAIR (CONT)

28. MEASURE injector nozzle PROJECTION (20)

below surface of cylinder head (2). Nozzle tip
PROJECTION MUST be 0.070-0.098 in.
(1.8-2.5 mm). If measurement is GREATER,
ADD washer(s). If measurement is LESS,
REMOVE washer(s).

NOTE
Follow-on maintenance:
Install cylinder head (page 3-25).
Install fuel tank lines and fittings
(TM 5-2420-224-20).

13-14
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

This task rovers: a. Removal b. inspection c. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Gauge, P/N 001 589 53 21 00 Page 3-2 Engine Removed
Holder, P/N 363 589 02 21 00
Installing Tool, P/N 352 589 01 31 00 Page 13-25 Flywheel Removed
Puller, P/N 312 589 07 33 00 Page 13-28 Flywheel End Bell
Removed
Materials/Parts:
Page 13-60 Oil Pump Removed
Seal (2)
Page 3-56 Timing Gear Cover,
Pin (2) Gears, and Case
Adhesive Appendix B, Item 2 Removed

Grease, Automotive Appendix B, Item 23 Page 3-41 Fuel Injector Nozzles

and Artillery (GAA) Removed

NOTE
Steps 1 and 2 are the same for
all connecting rods.

1. REMOVE two bolts (1), lower half of

connecting ROD (2), and bearing half (3).

2. REMOVE each bearing HALF (4) BEFORE

PUSHING connecting RODS (5) into cylinders
(6) far enough to clear counterweights (7).

13-15
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

NOTE
Steps 3 through 6 are the same
for all crankshaft bearing caps.

3. REMOVE two bolts (8), bearing CAP (9), and

bearing half (10).

4. REMOVE CRANKSHAFT (11) and seven

bearing halves (12) from crankcase (13).

5. REMOVE rear oil SEAL (14) and pin (15)

from crankcase (13). DISCARD SEAL and
PIN.

6. REMOVE rear oil SEAL (16) and pin (17)

from rear bearing cap (18). DISCARD SEAL
and PIN.

13-16
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

NOTE
Tag counterweights prior to
removal to aid in installation.
Perform step 7 only with engine
serial numbers under 941675.

7. REMOVE 12 bolts (19) and 6

COUNTERWEIGHTS (20).

8. REMOVE bearing (21) and COVER (22).

9. USING PULLER, REMOVE GEAR (23),

intermediate piece (24), and key (25).

1. Inspect crankshaft for pitting, gouges, and scratches. If any of these conditions exist, tag crankshaft for
repair and install new crankshaft.

2. Inspect crankshaft for cracks. If crankshaft is cracked, reject crankshaft assembly.

3. Make all journal measurements listed in following table. If any measurements are not within any stage
listed, tag crankshaft assembly for repair and install new crankshaft assembly. If any journal
measurement is less than lowest dimension in stage IV, reject crankshaft assembly.

4. Make all other measurements in table. If any measurement is lower than minimum shown, reject
crankshaft assembly.

13-17
TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

Crankshaft Repair Stage Specifications

Connecting Main Bearing Thrust Bearing Main Journal Shaft Diameter

Rod Journal Journal Journal Width C Width D E
Repair Diameter A Diameter B (Fit 0) (6 places)
Stage
In. In. In. In. In.
(mm) (mm) (mm) (mm) (mm)
Standard 2.3620-2.3628 3.4642-3.4649
(59.995-60.015) (87.99-88.01)
Standard I 2.3581-2.3588 3.4602-3.4610
(59.895-59.915) (87.89-87.91)
Stage I 2.3522-2.3530 3.4543-3.4551
(59.745-59.765) (87.74-87.76) 1.2598-1.2623 1.2598-1.2677 1.9686-1.9692
(32.000-32.062) (32.000-32.200) (50.002-50.018)
Stage II 2.3423-2.3431 3.4445-3.4453
(59.495-59.515) (87.49-87.51)
Stage Ill 2.3325-2.3333 3.4346-3.4354
(59.245-59.265) (87.24-87.26)
Stage IV 2.3226-2.3234 3.4248-3.4256
(58.995-59.015) (86.99-87.01)

Shaft Diameter F Flange Diameter G Connecting Rod

Repair Journal Width H
Stage In. In. In.
(mm) (mm) (mm)
Standard
Standard I
Stage I 3.5777-3.5798 5.1210-5.1220 1.4933-1.5012
(90.874-90.928) (129.975-130.000) (37.930-38.130)
Stage II
Stage III
Stage IV

13-18
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

CAUTION
Make sure oil holes in bearings
are alined with holes in
crankcase to prevent damage
to equipment.

1. INSTALL flanged bearing HALF (1) in center

position of crankcase (2) and six unflanged
bearing HALVES (3) in remaining positions.

2. INSTALL two new PINS (4) in rear beating

cap (5) and rear of crankcase (2).

13-19
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

USING INSTALLING TOOL, INSTALL two

new SEALS (6) in rear bearing cap (5) and
crankcase (2) and APPLY COAT of GAA.

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

4. FILL GROOVES in rear bearing cap (5) with

ADHESIVE.

13-20
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

5. INSTALL flanged bearing HALF (7) on center

bearing cap (8) and six unflanged bearing
HALVES (9) on remaining bearing caps (10).

6. INSTALL six bearing HALVES (11) on

connecting rods (12) and six bearing HALVES
(13) on six lower connecting rods (14).

7. CHECK LENGTH of 14 bolts (15). MAXIMUM

ALLOWABLE length is 4.84 in. (123 mm).
REPLACE BOLT(S) that exceed allowable
length.

NOTE
Bearing caps are numbered and
must be installed in order with
numbers toward front.

8. INSTALL CRANKSHAFT (16), 7 bearing caps

(8 and 10), and 14 bolts (15). TIGHTEN
BOLTS to 37-44 lb-ft (50-60 N.m). Starling
from center cap and working toward ends
alternately, TIGHTEN a SECOND TIME
90-110 degrees.

13-21
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

9. USING GAUGE and HOLDER. MEASURE

crankshaft END PLAY. MAXIMUM
ALLOWABLE end play is 0.008-0.011 in.
(0.19-0.29 mm).

CAUTION
Numbers on each upper and
lower connecting rod must be
the same to prevent damage to
equipment.

10. PULL six connecting RODS (17) to crankshaft

and INSTALL six lower connecting RODS
(18). TIGHTEN 12 BOLTS (19) to 30-37 Ib-ft
(40-50 N.m). TIGHTEN a SECOND TIME
90-110 degrees.

11. INSTALL key (20), intermediate piece (21),

and GEAR (22).

13-22
 TM 5-2420-224-34

CRANKSHAFT, MAIN BEARINGS, AND REAR SEALS REPLACEMENT

(CONT)

NOTE
Perform step 12 only with engine
serial numbers under 941675.

12. INSTALL 6 COUNTERWEIGHTS (23) and 12

bolts (24). TIGHTEN BOLTS for counterweight
marked 11 to 59-66 Ib-ft (80-90 N.m).
TIGHTEN REMAINING BOLTS to 22 +7 Ib-ft
(30 +10 N.m). TIGHTEN a SECOND TIME
90 +20 degrees.

13. INSTALL COVER (25) and bearing (26).

NOTE
Follow-on Maintenance:
Install flywheel end bell (page
13-28).
Install flywheel (page 13-25).
Install oil pump (page 13-60).
Install timing gear cover, gears,
and case (page 3-56).
Install fuel injector nozzles (page
3-41).
Install engine (page 3-2).

13-23
TM 5-2420-224-34

CRANKSHAFT PULLEY REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Fan Impeller Removed
References:
TM 5-2420-224-20

REMOVE bolt (1) and PULLEY (2).

INSTALL PULLEY (2) and bolt (1). TIGHTEN BOLT to 369-406 Ib-ft (500-550 N.m).

NOTE
Follow-on Maintenance:
lnstall fan impeller (TM 5-2420-224-20).

13-24
 TM 5-2420-224-34

FLYWHEEL REPLACEMENT AND REPAIR

This task covers: a. Removal b. Inspection c. Repair d. Installation

Tools and Special Equipment: Personnel Required: (2)

Shop Equipment, SC 4910-95-CL-A31 Equipment Condition:

Tool Kit, SC 5180-90-CL-N26
Gauge, 001 5895321 00 Reference Condition Description
Holder, 3635890221 00
Page 3-2 Engine Removed
Materials/Parts:
Page 3-63 Clutch Removed
Compound, Sealing Appendix B, Item 15

REMOVE eight screws (1) and FLYWHEEL (2).

1. Inspect flywheel friction surface (1) for scoring,

cracks, burnt areas, and rough spots.

2. Inspect flywheel ring gear (2) for damaged

teeth and replace ring gear if necessary
(page 13-29.)

3. Inspect screws for damaged threads and/or

excessive stretch. Maximum acceptable length
is 1.035 in. (26.3 mm). If either condition
exists, replace screw(s). The two types of
screws (A is new; B is old, and no longer
available) should not be mixed on the same
engine.

13-25
 TM 5-2420-224-34

FLYWHEEL REPLACEMENT AND REPAIR (CONT)

1. Prior to machining flywheel friction surface (1),

measure distance from friction surface (1) to
mounting area (2). Record measurement.

2. Machine flywheel friction surface (1) to repair

any damage. Do not exceed dimensional limit
of 0.0394 in. (1 mm).

3. Machine mounting area (2) to maintain

measurement taken-in step 1.

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

1. APPLY COAT of SEALING COMPOUND to

eight SCREWS (1). INSTALL F LYWHEEL (2)
on crankshaft flange (3) and INSTALL eight
SCREWS (1). TIGHTEN SCREWS to 22-29
Ib-ft (29-39 N.m) in sequence shown.

13-26
 TM 5-2420-224-34

FLYWHEEL REPLACEMENT AND REPAIR (CONT)

2. TIGHTEN eight SCREWS (1) an additional

90-110 degrees using same sequence.

3. USING GAUGE and HOLDER, MEASURE

flywheel lateral RUNOUT. MAXIMUM
ALLOWABLE runout is 0.004 in. (0.10 mm).

4. USING GAUGE and HOLDER, MEASURE

flywheel radial RUNOUT. MAXIMUM
ALLOWABLE runout is 0.0099 in.

NOTE
Follow Maintenance:
Install clutch (page 3-63).
Install engine (page 3-2).

13-27
 TM 5-2420-224-34

FLYWHEEL END BELL REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference
Tool Kit, SC 5180-90-CL-N26 Condition Description
Page 3-2 Engine Removed
Materials/Parts:
TM 5-2420-224-20 Starter Removed
Washer, Lock (4)
Page 13-25 Flywheel Removed
References:

TM 5-2420-224-20

1. REMOVE four screws (1), four lock washers

(2), and flywheel end BELL (3). DISCARD
lock WASHERS.

2. REMOVE two PINS (4).

1. INSTALL two PINS (4).

2. INSTALL flywheel end BELL (3), four new

lock washers (2), and four screws (1).

NOTE
Follow-on Maintenance:
Install flywheel (page 13-25).
Install starter (TM 5-2420-224-20).
Install engine (page 3-2).

13-28
 TM 5-2420-224-34

FLYWHEEL RING GEAR REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Gauge, P/N 001 589 53 21 00 Page 13-25 Flywheel Removed
Holder, P/N 363 589 02 21 00
General Safety Instructions:
Materials/Parts:
Indicator, Temperature Appendix B, Item 26
WARNING
Gear will be hot enough to
burn you on contact. Wear
heat-resistant gloves when
handling hot gear.

HEAT outer portion of FLYWHEEL (1) and STRIKE

ring GEAR (2) EVENLY around the top until ring
gear falls off.

13-29
TM 5-2420-224-34

FLYWHEEL RING GEAR REPLACEMENT (CONT)

1. APPLY COAT of TEMPERATURE

INDICATOR every few inches on outer edge
of ring GEAR (1).

2. HEAT ring GEAR (1) until temperature

indicator turns to LIQUID. HEAT from INSIDE
diameter at 400° F (204°C).

3. PRESS ring GEAR (1) onto ffywheel (2) with

recess in ring gear (1) facing flywheel
shoulder.

4. USING GAUGE and HOLDER, CHECK lateral

RUNOUT of ring gear (1). Runout CANNOT
be more than 0.020 in. (0.5 mm).

NOTE
Follow-on Maintenance:
Install flywheel (page 13-25).

13-30
 TM 5-2420-224-34

PISTONS, RINGS, CONNECTING RODS, AND BEARINGS REPLACEMENT

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Socket, P/N 352 589 01 09 00 Page 3-2 Engine Removed

Materiais/Parts: Page 13-60 Oil Pump Removed

Kit; Parts Page 3-25 Cylinder Head Removed

Kit, Parts

NOTE
Rotate crankshaft for access for
removal of bolts and lower
connecting rods.

1. Using SOCKET, REMOVE two bolts (1) and

lower connecting ROD (2).

NOTE
Both halves of connecting rod are
a matched set. Tag parts for
installation.

2. REMOVE PISTON (3) and upper connecting

rod (4) by PUSHING from bottom of
crankcase (5).

13-31
TM 5-2420-224-34

PISTONS, RINGS, CONNECTING RODS, AND BEARINGS REPLACEMENT

(CONT)

3. REMOVE and DISCARD two bearing HALVES

(6 and 7) from upper and lower connecting
rods (4 and 2).

4. REMOVE two retaining rings (8), pin (9), and

PISTON (3) from upper connecting rod (4).

5. IF DAMAGED, REMOVE BUSHING (10).

6. REMOVE and DISCARD four RINGS (11, 12,

13, and 14).

7. REPEAT STEPS 1 thru 6 for remaining pistons.

Check ring grooves and make sure all carbon

deposits have been removed.

Connecting Rod Bushings

1. Inspect connecting rods for cracks, bends, In. (mm)

and warpage. If any of these conditions exist,
replace connecting rod with connecting rod of Normal 1.540 (39.075)
same color code. Maximum permissible 1.538 (39.045)
difference in weight between any two
connecting rods is 0.7 oz (20 g). OD Repair Stage I 1.547 (39.275)
1.546 (39.245)
2. Measure inside diameter of small end
bushing. Measurement should be 1.42 in, Repair Stage II 1.559 (39.575)
(36.03-36.04 mm). If measurement is 1.558 (39.545)
exceeded, replace bushing with appropriate
Rough Dimension 1.391 (35.300)
size bushing.
ID 1.389 (35.250)
Finished 1.420 (36.040)
Dimension 1.419 (36.030)

13-32
 TM 5-2420-224-34

PISTONS, RINGS, CONNECTING RODS, AND BEARINGS REPLACEMENT

(CONT)

Crankshaft Repair Stage Specifications

3. If bushing measurement is acceptable, inspect

bushing for scratches, gouges, nicks, and
cracks. If any of these conditions exist,
replace bushing.
Standard 2.3620-2.3628
4. Measure connecting rod journals on crankshaft (59.995-60.015)
and compare with following table. If any Standard I 2.3581-2.3588
measurements are not within any stage listed,
(59.895-59.915)
remove crankshaft and tag for repair. Install
new crankshaft. If any measurements are less Stage I 2.3522-2.3530
than lowest dimension in stage IV, reject (59.745-59.7651
crankshaft assembly.

Stage IV 2.3226-2.3234
(58.995-59.015)

Piston Rings

Piston Ring No. Groove Width

In. (mm)
5. Inspect pistons for excessive wear, burn 0.119
spots, cracks, and gouges. If any of these I (3.030)
conditions exist, reject piston assembly. 0.118 (3.015)
0.121 (3.060)
6. Check ring groove width. If not within II
0.120 (3.045)
tolerance, reject piston.
0.121 (3.060)
Ill
0.120 (3.045)
0.218 (5.540)
Iv
0.217 (5.525)

13-33
TM 5-2420-224-34

PISTONS, RINGS, CONNECTING RODS, AND BEARINGS REPLACEMENT

(CONT)

NOTE
Perform steps 1 thru 3 only if
installing new bushing.

1. USING suitable PRESS, INSTALL new

BUSHING (1) in upper connecting rod (2).

2. USING upper connecting ROD (2) as a guide,

DRILL a 0.12-in. (3-mm) oil HOLE through
bushing (1).

3. REAM inside diameter of BUSHING (1) to

1.419-1.420 in. (36.030-36.040 mm).

4. IF cylinder BORE in crankcase (3) has been

BORED OUT, SELECT appropriate
replacement PISTON from following table.

5. INSTALL PISTON (4), pin (5), and two

retaining rings (6) on ‘upper connecting rod
(2).

Replacement Pistons

Cylinder Bore Total Height, Crankcase Piston Diameter

Repair Stage
In. (mm) In. (mm) In. (mm)

13-34
 TM 5-2420-224-34

PISTONS, RINGS, CONNECTING RODS, AND BEARINGS REPLACEMENT

(CONT)

NOTE
Rings are packaged in order in
which they are to be installed. Do
not remove a ring until ready to
install.

6. INSTALL four new RINGS (7, 8, 9, and 10)

on piston (4) starting at the bottom, with
openings 180 degrees apart.

7. AFTER rings are installed, CHECK ring GAP

and VERTICAL clearance with following table.
If gap is NOT WITHIN tolerance, REPLACE
with new SET.

NOTE
Make sure tang snaps into slot of
connecting rod.

8. INSTALL new upper connecting rod bearing

HALF (11).

NOTE
Make sure tang snaps into slot of
connecting rod.

9. INSTALL new lower connecting rod bearing

HALF (12).

Rings

Groove I II Ill IV

Compression Rings Oil Scraper Rings

Piston Ring Designation Taper Face Bevelled Ring with

Keystone Ring Compression Ring Spring Expander
In. (mm) In. (mm) In. (mm)
Gap Clearance 0.021 (0.55) 0.021 (0.55) 0.015 (0.40)
0.013 (0.35) 0.013 (0.35) 0.001 (0.25)
Vertical Clearance 0.003 (0.808) 0.003 (0.082) 0.002 (0.062)
0.002 (0.044) 0.002 (0.055) 0.001 (0.035)

13-35
TM 5-2420-224-34

PISTONS, RINGS, CONNECTING RODS, AND BEARINGS REPLACEMENT

(CONT)

10. INSTALL PISTON (4) and upper connecting

rod (2) in crankcase (3) from top with
ARROW on piston POINTING FORWARD

CAUTION
When installing connecting rods
and caps, make sure numbers
match. Failure to do so will
result in damage to engine.

11. Using SOCKET, INSTALL lower connecting

ROD (13) and two bolts (14). TIGHTEN
BOLTS to 30-37 Ib-ft (40-50 N.m). TIGHTEN
a SECOND TIME 90-100 degrees.

12. REPEAT STEPS 1 thru 11 for remaining

pistons.

NOTE
Follow-on Maintenance:
Install cylinder head (page 3-25).
Install oil pump (page 13-60).
Install engine (page 3-2).

13-36
 TM 5-2420-224-34

ROCKER ARMS, PUSH RODS, AND TAPPETS REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP
Tools and Special Equipment: Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description:
Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Valve Cover and Gasket
References: Removed
TM 5-2420-224-20 Page 3-29 Push Rod Cover
Removed

REMOVAL

1. REMOVE four bolts (1), two bolts (2), spacer (3), spring (4), spring (5), nipple (6), two rocker ARMS
(7 and 8), and shim (9) if present.

13-37
TM 5-2420-224-34

ROCKER ARMS, PUSH RODS, AND TAPPETS REPLACEMENT (CONT)

NOTE
Tag rocker arm assemblies prior
to removal to aid in installation.

2. REMOVE clip (10), spring (11), six rocker

ARM assemblies (12), setscrew (13), three
brackets (14), and two springs (15) from
spindle (16).

3. REPEAT STEP 2 for other rocker arm.

NOTE
Step 4 is the same for all rocker
arm assemblies.

4. REMOVE nut (17), SETSCREW (18), and

BUSHING (19) IF DAMAGED, from each
rocker arm assembly (12).

NOTE
Step 5 is the same for both
spindles.

5. REMOVE expansion PLUG (20) from spindle

(16).

13-38
 TM 5-2420-224-34

ROCKER ARMS, PUSH RODS, AND TAPPETS REPLACEMENT (CONT)

NOTE
Tag push rods after removal to
aid in installation.

6. REMOVE 12 push RODS (21).

NOTE
Tag tappets after removal to aid in
installation.

7. REMOVE 12 TAPPETS (22).

1. Inspect springs for cracks.

2. Inspect rocker arm assembly bushings for wear and gouges.

3. Inspect push rods for bends.

4. Inspect tappets for external wear and scoring on sides and wear on push rod contact area.

13-39
TM 5-2420-224-34

ROCKER ARMS, PUSH RODS, AND TAPPETS REPLACEMENT (CONT)

5. Check tappet face for excessive wear and nonperpendicularity to sides. Maximum deviation is 0.012 in.
(0.03 mm). See table below.

NOTE
• Replace tappets if worn or maximum nonperpendicularity is exceeded. Slight pit
marks on tappet face are not cause for replacement, except if pitting is on the edge.

• Always install new tappets if new camshaft has been installed.

6. Measure clearance between tappet and engine block bore. Allowable clearance is 0.0004-0.0020 in.
(0.010-0.053 mm). If clearance is less than 0.0004 in. (0.010 mm), enlarge engine block bore. If
clearance is greater than 0.0020 in. (0.053 mm), reject engine block.

INSTALLATION

1. INSTALL 12 TAPPETS (1).

13-40
 TM 5-2420-224-34

ROCKER ARMS, PUSH RODS, AND TAPPETS REPLACEMENT (CONT)

2. INSTALL 12 push RODS (2).

NOTE
Step 3 is the same for both
spindles.

3. INSTALL expansion PLUG (3) in spindle (4).

NOTE
• Steps 4 and 5 are the same for
ail rocker arm assemblies.
• Make sure oil holes in bushing
and rocker arm are alined.

4. IF REMOVED, INSTALL new BUSHING (5).

5. INSTALL SETSCREW (6) and nut (7) in

rocker arm assembly (8).

13-41
TM 5-2420-224-34

ROCKER ARMS, PUSH RODS, AND TAPPETS REPLACEMENT (CONT)

6. INSTALL two springs (9), three brackets (10), setscrew (11), six rocker ARM assemblies (8), spring
(12), and clip (13).

7. REPEAT STEP 6 for other rocker arm.

8. IF REMOVED, INSTALL SHIM (14).

9. INSTALL two rocker ARMS (15 and 16), spring (17), nipple (18), spring (19), spacer (20), two bolts
(21), and four bolts (22). TIGHTEN BOLTS to 74-81 Ib-ft (100-110 N.m).

NOTE
Follow-on Maintenance:
Install push rod cover (page 3-29).
Adjust valves (TM 5-2420-224-20).
Install valve cover and gasket (TM 5-2420-224-20).

13-42
 TM 5-2420-224-34

CAMSHAFT AND BEARINGS REPLACEMENT

This task covers: a. Removal b. Inspection c. Installation

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Gauge, P/N 001 5695321 00 Page 3-2 Engine Removed
Holder, P/N 3635890221 00
Page 3-56 Timing Gear Cover,
Materials/Parts: Gears, and Case
Removed
Oil, Lubricating Appendix B, Itern 30
Page 3-25 Cylinder Head Removed
Page 3-29 Push Rod Cover
Removed
Page 13-60 Oil Pump Removed
Page 3-34 Air Compressor Removed

REMOVAL

CAUTION
Screws used on thrust plate
must not be used anywhere
else due to difference of
threads. Damage to equipment
could occur.

1. REMOVE thrust washer (1), four screws (2),

and thrust BEARING (3).

13-43
TM 5-2420-224-34

CAMSHAFT AND BEARINGS REPLACEMENT (CONT)

2. REMOVE CAMSHAFT (4) from crankcase (5).

3. REMOVE sleeve BEARING (6) from front of crankcase (5).

4. REMOVE three camshaft BEARINGS (7) from crankcase (5).

INSPECTION

1. Using gauge and holder, check camshaft radial runout at cam bearing joumals (1). If runout exceeds
0.0009 in. (0.025 mm), replace camshaft (2).

13-44
 TM 5-2420-224-34

CAMSHAFT AND BEARINGS REPLACEMENT (CONT)

2. If cam lobes (3) and/or cam bearing journals (1) show pitting, scoring, flat areas, bums, or excessive
wear, replace camshaft (2).
3. Measure inner diameter of four bearings (4) using following table.

NOTE
To obtain proper inner diameter for bearing(s), bearing(s) must be installed in cylinder
block and be line bored to proper diameter for each journal.

4. To use table, determine journal diameter code. Using code, determine standard to be used. Once
standard has been determined, refer to table for proper bearing inner diameter.

13-45
 TM 5-2420-224-34

CAMSHAFT AND BEARINGS REPLACEMENT (CONT)

INSTALLATION

NOTE
Make sure camshaft journal holes
are thoroughly cleaned and free of
any foreign material.

1. INSTALL three camshaft BEARINGS (1) in

crankcase (2).

2. INSTALL sleeve BEARING (3) in front of

crankcase (2).

3. APPLY COAT of LUBRICATING OIL to four

JOURNALS (4) and CAREFULLY INSTALL
CAMSHAFT (5) in crankcase (2).

4. INSTALL thrust BEARING (6), four screws (7),

and thrust washer (8). TIGHTEN SCREWS to
26 Ib-ft (35 N.m).

13-46
 TM 5-2420-224-34

CAMSHAFT AND BEARINGS REPLACEMENT (CONT)

5. INSTALL TIMING GEARS (page 3-56).

6. USING GAUGE and HOLDER, MEASURE

camshaft END PLAY. End play reading should
be 0.004-0.20 in. (0.11-0.52 mm). If end play
is MORE than 0.20 in. (0.52 mm), REPLACE
thrust BEARING (6).

NOTE
Follow-on Maintenance:
Install air compressor (page 3-34).
Install oil pump (page 13-60).
Install push rod cover (page 3-29).
Install cylinder head (page 3-25).
Install timing gear cover (page
3-56).
Install engine (page 3-2).

13-47
TM 5-2420-224-34

CYLINDER BLOCK REPAIR

This task covers: a. Disassembly b. Inspection c. Repair d. Assembly

INITIAL SETUP
Tools and Special Equipment: Equipment Condition (Cont):
Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TooI Kit, SC 5180-90-CL-N26
STE/lCE-R, NSN 4910-00-124-2554 Page 13-37 Rocker Arms, Push Rods,
Tool Set A, P/N 419-000-7458 and Tappets Removed
Tool Set B, P/N 419-000-7558
Tool Set C, P/N 419-000-7658 Page 13-60 Oil Pump Removed
Page 13-15 Crankshaft, Main Bearings,
Materials/Parts:
and Rear Seals Removed
Kit, Parts Page 13-31 Pistons, Rings,
Chips, Soap Appendix B, Item 9 Connecting Rods, and
Bearings Removed
Cloth, Emery Appendix B, Item 10
Page 3-56 Timing Gear Cover,
Oil, Lubricating Appendix B, Item 30 Gears, and Case
Removed
Equipment Condition:
Page 3-34 Air Compressor Removed
Reference Condition Description Page 3-29 Push Rod Cover
Page 3-2 Engine Removed Removed

Page 3-63 Clutch Removed Page 3-30 Oil Cooler and Gasket
Removed
Page 3-25 Cylinder Head Removed
Page 3-43 Fuel Injection Pump
Page 13-28 Flywheel End Bell Removed
Removed
Page 13-43 Camshaft and Bearings
Removed

13-48
 TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

DISASSEMBLY

NOTE
Discard seal.

REMOVE all PARTS from crankcase USING ILLUSTRATION and LEGEND as a guide.

INSPECTION
1. Inspect all parts for wear, thread damage, bends, and cracks. Replace parts if any of these conditions
are present, except as noted.

2. If any threads in crankcase have been damaged, attempt to renew using thread chaser. If thread
pattern cannot be renewed, replace crankcase.

13-49
TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

3. Using straightedge and feeler gage, check warpage of top of crankcase at 1-in. intervals along length.
Maximum allowable warpage cannot exceed 0.0007 in. (0.17 mm). If warpage exceeds maximum limit,
tag crankcase for repair.

4. Using straightedge and feeler gage, check warpage of top of crankcase at 1-in. intervals along width.
Maximum allowable warpage cannot exceed 0.0012 in. (0.030 mm). If warpage exceeds maximum limit,
tag crankcase for repair.

5. Measure total height of crankcase and refer to following table. If measurement is between repair
stages, tag crankcase for repair. If measurement is less than 14.11 in. (358.15 mm), replace
crankcase.

6. Inspect top of crankcase for peaks and valleys. If any are present, measure distance between each
peak and valley. Acceptable depth of each valley is 0.0001-0.0002 in. (0.003-0.005 mm). If maximum
depth is exceeded, tag crankcase for repair. if repair would cause total height to be less than allowable
in step 5, replace crankcase.

7. Inspect honing pattern of each cylinder bore. if pattern has been even slightly destroyed, tag crankcase
for repair.

13-50
 TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

8. Measure inside diameter of each cylinder bore at two points 90 degrees apart, at six locations along
length of bore. Maximum amount bore can be out-of-round or tapered is 0.0004 in. (0.01 mm). If
measurement is exceeded, tag crankcase for repair.

9. Compare diameter measurements from step 8 with following table. If measurements are between repair
stages, tag crankcase for repair. If any measurement is larger than 3.881 in. (98.510 mm), replace
crankcase.

10. Inspect each cylinder bore for peaks and valleys. If any are present, measure distance between each
peak and valley. Acceptable depth of each valley is 0.0001-6.0002 in. (0.003-0.005 mm). If maximum
depth is exceeded, tag crankcase for repair. If repair would exceed maximum diameter shown in table,
replace crankcase.

11. Measure diameter of camshaft bearing bores. Diameter must be 2.364-2.365 in. (60.000-60.030 mm). If
any bore exceeds 2.365 in. (60.030 mm), replace crankcase.

13-51
TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

12. Measure diameter of tappet bores and refer to following table. If measurements are between repair
stages, tag crankcase for repair. If any measurement exceeds 1.134 in. (28.783 mm), replace
crankcase.

REPAIR

WARNING
Before machining crankcase, make sure crankcase is properly secured.
Failure to do so could result in injury to personnel.

1. If crankcase top is warped or has peaks and valleys, machine deck to next repair stage shown in
Crankcase table in Inspection, above. If machining deck will bring height of crankcase below allowable
limits, replace crankcase.

2. If crankcase height is between repair stages, machine to next repair stage, unless that machining will
bring height of crankcase below allowable limits.

13-52
 TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

NOTE
If inspection shows that cylinder boring is required, bore all six cylinders to next repair
stage.

3. Secure crankcase on drill press.

4. Aline cylinder to be bored with drill. Center drill above return point of first piston ring at TDC.

CAUTION
Bore crankcase cylinders in following order: 1-3-5-2-4-6. Failure to do so could
cause thermal stress on cylinder walls.

5. Clamp boring tool onto drill. Using the two following tables, bore cylinder to within 0.002 in. (0.05 mm)
of final diameter.

13-53
TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

6. After boring cylinders, inspect top of cylinder block in accordance with inspection steps 3 and 4. if
necessary, machine top to next repair stage.

7. Bevel inner top edge of cylinder to 30 degrees.

NOTE
Properly honed cylinder has dull, unglazed surface with roughness of 118-197 pin
(3-5 Urn).

8. Hone cylinders to finished dimension using Machining Specifications table above. Honing pattern must
be 40-60 degrees as shown.

9. Use emery cloth to remove any burrs or sharp edges from bottom of cylinders.

13-54
 TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

CAUTION
Make sure all machining residue is removed before assembling engine. Failure
to do so could result in increased engine wear and reduced service life of
engine.

10. Clean cylinder block thoroughly with soap and water. Dry cylinder bores immediately after cleaning and
apply light coat of lubricating oil.

11. If top of engine requires machining, remove only amount of material necessary to obtain measurements
of next repair stage shown on page 13-53.

12. If dfferent size tappet is to be installed upon assembly of engine, bore tappet holes in cylinder block
so that clearance between tappet and engine bled bore is 0.004-0.0020 in. (0.10-0.053 mm).

13-55
 TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

ASSEMBLY

13-56
 TM 5-2420-224-34

CYLINDER BLOCK REPAIR (CONT)

NOTE
Install new seal.

INSTALL all PARTS in crankcase using ILLUSTRATION and LEGEND as a guide.

NOTE
Follow-on Maintenance:
Install camshaft and bearings (page 13-43).
Install fuel injection pump (page 3-43).
Install oil cooler and gasket (page 3-30).
install push rod cover (page 3-29).
Install air compressor (page 3-34).
Install timing gear cover, gears, and case (page 3-56).
Install pistons, rings, connecting rods, and bearings (page 13-31).
Install crankshaft, main bearings, and rear seals (page 13-15).
Install oil pump (page 13-60).
Install rocker arms, push rods, and tappets (page 13-37).
Install flywheel end bell (page 13-28).
Install cylinder head (page 3-25).
Install clutch (page 3-63).
Install engine (page 3-2).

13-57
TM 5-2420-224-34

OIL PAN REPLACEMENT

This task covers: a. Removal b. Installation

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Packing
Page 3-2 Engine Removed
Seal
TM 5-2420-224-20 Accelerator Pedal
Packing and Linkage Removed
(Engine Linkage Only)
Kit, Gasket
Adhesive Appendix B, Item 2

REMOVAL
1. REMOVE gage ROD (1), cap (2), and spacer (3).

2. REMOVE nut (4), bolt (5), washer (6), clamp (7), guide TUBE (8), and packing (9). DISCARD
PACKING.

3. REMOVE bolt (10) and BRACKET (11).

4. REMOVE 4 nuts (12), 2 screws (13), 16 screws (14), 2 long screws (15), 2 washers (16), oil PAN
(17), and 4 gaskets (18, 19, 20, and 21). DISCARD GASKETS.

5. REMOVE PLUG (22) and seal (23). DISCARD SEAL.

6. REMOVE PLUG (24) and packing (25). DISCARD PACKING.

7. REMOVE four STUDS (26) from cylinder block.

INSTALLATION
1. INSTALL four STUDS (26) in cylinder block.

2. INSTALL PLUG (24) and new packing (25).

3. INSTALL PLUG (22) and new seal (23).

Adhesive causes immediate bonding on contact with eyes, skin, or clothing and
also gives off harmful vapors. Wear protective goggles and use in
well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush eyes
with water for 15 minutes and get immediate medical attention.

13-58
 TM 5-2420-224-34

OIL PAN REPLACEMENT (CONT)

CAUTION
Make sure all gasket material has been removed from all mating surfaces to
prevent damage to equipment.

4. INSTALL two new GASKETS (18 and 20). APPLY ADHESIVE to ENDS of gaskets.

NOTE
Make sure ends of two gaskets (18 and 20) are coated with adhesive and in contact
with two gaskets (19 and 21).

5. INSTALL two new GASKETS (19 and 21).

6. INSTALL oil PAN (17), 4 nuts (12), 2 screws (13), 2 washers (16), 2 long screws (15), and 16 screws
(14).
7. INSTALL BRACKET (17) and bolt (10).
8. INSTALL new packing (9), guide TUBE (8), clamp (7), bolt (5), washer (6), and nut (4).
9. INSTALL spacer (3), cap (2), and gage ROD (1).

NOTE
Follow-on Maintenance:
Install engine (page 3-2).
Install accelerator pedal and linkage (engine linkage only) (TM 5-2420-224-20)

13-59
TM 5-2420-224-34

OIL PUMP REPLACEMENT AND REPAIR

This task covers: a. Removal b. Disassembly c. Inspection d. Assembly e. Installation

INITIAL SETUP
Tools and Special Equipment: Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Page 3-2 Engine Removed
Materials/Parts:
Page 13-58 Oil, Pan Removed
Compound, Sealing Appendix B, Item 14
TM 5-2420-224-20 Engine Oil Fitter Element
References: Removed

TM 5-2420-224-20

Adhesive causes immediate

bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

REMOVAL

REMOVE three screws (1) and oil PUMP (2).

DISASSEMBLY

1. REMOVE retaining ring (1) and suction

CHAMBER (2).

2. REMOVE screw (3), bolt (4), and suction

PIPE (5).

13-60
 TM 5-2420-224-34

OIL PUMP REPLACEMENT AND REPAIR (CONT)

3. REMOVE plug (6), spring (7), piston (8), and

HOUSING (9) from cover (10).

4. REMOVE three screws (11), bolt (12), and

COVER (10).

CAUTION
Make sure puller is centered
on tab of drive shaft. Failure to
do so could result in damage
to tab.

5. USING suitable PULLER, REMOVE GEAR

(13) from drive shaft (14).

6. REMOVE GEAR (15) and SHAFT (16) from

housing (17).

7. USING suitable PRESS, REMOVE GEAR (15)

from shaft (16).

13-61
TM 5-2420-224-34

OIL PUMP REPLACEMENT AND REPAIR (CONT)

8. USING suitable PRESS, REMOVE GEAR (18)

and drive SHAFT (14) from housing (17).

9. USING suitable PRESS, REMOVE GEAR (18)

from drive shaft (14).

INSPECTION
1. Check gears for worn or broken teeth.

2. Check housing and cover for cracks or

damage.

ASSEMBLY
1. USING suitable PRESS, INSTALL GEAR (1)
on drive shaft (2).

2. USING suitable PRESS, INSTALL drive

SHAFT (2) and GEAR (1) in housing (3).

WARNING
Gear will be hot enough to
burn you on contact. Wear
heat-resistant gloves when
handling hot gear.

3. HEAT GEAR (4) to 176°F (80°C) and

INSTALL on drive shaft (2).

4. USING feeler GAGE, CHECK END PLAY of

drive shaft (2) and gear (4). End play should
be 0.0012-0.0028 in. (0.30-0.07 mm).

13-62
 TM 5-2420-224-34

OIL PUMP REPLACEMENT AND REPAIR (CONT)

5. USING suitable PRESS, INSTALL GEAR (5)

on shaft (6).

6. USING suitable PRESS, INSTALL GEAR (5)

and SHAFT (6) in housing (3).

7. USING feeler GAGE and STRAIGHTEDGE,

CHECK CLEARANCE between gears (1 and
5) and housing (3). Clearance should be
0.0010-0.0035 in. (0.025-0.089 mm).

8. USING feeler GAGE, CHECK radial

CLEARANCE between gears (1 and 5) and
sides of housing (3). Radial clearance should
be 0.001-0.005 in. (0.030-0.130 mm).

13-63
TM 5-2420-224-34

OIL PUMP REPLACEMENT AND REPAIR (CONT)

9. APPLY COAT of SEALING COMPOUND to

THREADS of housing (7) and INSTALL
HOUSING (7), piston (8), spring (9), and pIug
(10) in cover (11). TIGHTEN to 11-18 Ib-ft
(15-25 N.m).

10. INSTALL COVER (11), three screws (12), and

bolt (13). TIGHTEN SCREWS and BOLT to
25 Ib-ft (35 N.m).

11. INSTALL suction PIPE (14), screw (15), and

bolt (16). TIGHTEN SCREW and BOLT to
15-18 Ib-ft (20-25 N.m).

12. INSTALL suction CHAMBER (17) and

retaining ring (18).

INSTALLATION

APPLY COAT of SEALING COMPOUND to three

SCREWS (1) and INSTALL oil PUMP (2) and three
screws (1). TIGHTEN SCREWS to 25 Ib-ft
(35 N.m).

NOTE
Follow-on Maintenance:
Install oil pan (page 13-58).
Install engine (page 3-2).
Install engine oil filter element
(TM 5-2420-224-20).

13-64
 TM 5-2420-224-34

Section II. FUEL SYSTEM REPAIR

OVERVIEW
This section illustrates and describes procedures for repair of the fuel system. A list of tasks contained
in this section is shown below.

Page

Fuel injector Nozzle Test and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65

Fuel Tank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69

FUEL INJECTOR NOZZLE TEST AND REPAIR

This task covers: a. Test b. Disassembly c. Cleaning d. Assembly

INITIAL SETUP

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26 WARNING
Shop Equipment, Fuel and Electrical,
When testing fuel injector
SC 4910-95-CL-A01
Holding Device, P/N 403 589 00 31 00 nozzles, wear safety goggles
Test Set, NSN 4910-00-317-8265 and keep hands and fingers
Wrench, P/N 000 589 01 13 00 away from the spray of fluid
being ejected. The spray is
Materials/Parts: under extreme pressure and
could penetrate deeply into the
Fuel, Diesel Appendix B, Item 22
body tissues, causing injury
Equipment Condition: and illness.

Reference Condition Description

Page 3-41 Fuel Injector Nozzles
Removed

T E S T

NOTE
Test the complete set of injector nozzles, even if only one nozzle is suspect.

Nozzle Preparation
1. Using wire brush, carefully remove any carbon residue from injector nozzles.
2. Install an injector nozzle on test set.

13-65
TM 5-2420-224-34

FUEL INJECTOR NOZZLE TEST AND REPAIR (CONT)

Opening Pressure Test

1. Work pump lever slowly until nozzle begins to spray; read opening pressure. Opening pressure should
read 2610 psi (180 bar).

2. If opening pressure is too high or too low, disassemble, clean, and adjust injector nozzle.

NOTE
To lower pressure, use thinner washers. To raise pressure, use thicker washers. Use no
more than two washers in any injector nozzle. If more than two washers are needed,
replace pressure spring.

3. If necessary, replace injector nozzle.

Leak Test

1. Work pump Iever slowly until pressure gage reads 2320 psi (160 bar). Nozzle does not leak if drops
do not appear at nozzle mouth within 10 seconds. If injector nozzle leaks, disassemble and clean.

CAUTION
Increase pressure slowly and release pressure slowly, to avoid damaging test
set.

2. If nozzle still leaks after cleaning nozzle body and needle, replace both nozzle body and needle.

Spray Pattern and Chatter Behavior

1. Spray Pattern: To use test set correctly, gently depress lever several times until resistance is felt on
each stroke. Then apply one full stroke slowly and observe the spray. At very low test pressure, spray
pattern should be spread with rough atomization. in the chatterless range, spray pattern should be
tighter but anatomized. As the pressure increases, spray pattern should become complete and finely
atomized.

2. Chatter Behavior: Good chatter during fast and slow lever motion; short chatterless ranges can occur
in between.

If spray pattern or chatter is not as described above, disassemble, clean, and adjust injector nozzle. If
necessary, replace injector nozzle.

13-66
 TM 5-2420-224-34

FUEL INJECTOR NOZZLE TEST AND REPAIR (CONT)

1. INSTALL injector NOZZLE (1) in HOLDING

DEVICE.

2. USING WRENCH, REMOVE NUT (2) from

body (3).

3. REMOVE spacer disc (4), PLUNGER (5),

spring (6), and spacer (7) from body (3).

4. REMOVE nozzle (8) and nozzle BODY (9)

from nut (2).

CLEANING

1. Clean body, nozzle body, and nozzle using

clean diesel fuel.
2. Place nozzle in nozzle body.
3. Lift nozzle one-third of the way out of nozzle
body and release nozzle.
4. Nozzle should seat in nozzle body by itself. If
nozzle does not seat, clean both parts again.
If nozzle still does not seat in nozzle body,
replace both nozzle and nozzle body.

5. Clean remaining parts in clean diesel fuel.

Make sure all carbon deposits have been
removed.

13-67
TM 5-2420-224-34

FUEL INJECTOR NOZZLE TEST AND REPAIR (CONT)

ASSEMBLY

1. INSTALL nozzle BODY (1) in nut (2).

2. INSTALL NOZZLE (3) in nozzle body (1).

NOTE
Quantity of spacer discs may vary
to obtain proper opening pressure.

3. INSTALL spacer (4), spring (5), PLUNGER

(6), and spacer disc (7) in body (8).

4. USING WRENCH, INSTALL NUT (2) in body

(8).

5. INSTALL injector NOZZLE (9) in HOLDING

DEVICE. TIGHTEN BODY (8) to 43-50 Ib-ft
(60-70 N.m).

6. TEST fuel INJECTOR (TEST, above).

NOTE
Follow-on Maintenance:
Install fuel injector nozzles (page
3-41 ).

13-68
 TM 5-2420-224-34

FUEL TANK REPAIR

This task covers: a. Disassembly b. Cleaning c. Inspection d. Assembly

INITIAL SETUP

Tools and Special Equipment: Generel Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26
Shop Equipment, Welding, SC 4940-95-CL-B19 WARNING
• Fuel is very flammable and
Materials/Parts: can explode easily. To avoid
serious injury or death, clean
Chips, Soap Appendix B, item 9
fuel tank to purge any
Personnel Required: (2) flammable liquid or vapors
before welding, grinding, or
References: using any heat producing
device near the fuel tank.
TM 5-2420-224-20
• Fuel vapors are toxic. Avoid
Equipment Condition: prolonged exposure or
breathing of fumes. Work in
Reference Condition Description
well-ventilated area. Failure
TM 5-2420-224-20 Fuel Tank Removed to do so could result in
injury to personnel.

REMOVE fuel filler CAP and strainer element

assembly (1).

13-69
TM 5-2420-224-34

FUEL TANK REPAIR (CONT)

1. Using soap, thoroughly steam clean fuel tank

including upper portion of fuel tank where rust
may have formed.

WARNING
To prevent injury, compressed
air used for cleaning and
drying purposes will not exceed
30 psi (207 kPa). Use only
with effective chip guarding and
personal protective equipment
(goggles/ shield, gloves, etc.).

2. Completely dry fuel tank with compressed air.

3. Thoroughly clean fuel filler cap and strainer

element assembly.

4. Remove and clean fuel filter pre-sediment

bowl and filter (TM 5-2420-224-20).

INSPECTION
Inspect fuel tank for damage or cracks.

ASSEMBLY
INSTALL fuel filler CAP and strainer element
assembly (1).

NOTE
Follow-on Maintenance:
Install fuel tank (TM 5-2420-224-
20).
Replace fuel filters (TM 5-2420-
224-20).

13-70
 TM 5-2420-224-34

Section Ill. COOLING SYSTEM REPAIR

OVERVIEW
This section illustrates and describes procedures for repair of the cooling system. A list of tasks
contained in this section is shown below.

Page

Radiator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71

Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73

RADIATOR REPAIR
This task covers: a. Disassembly b. Cleaning c. Inspection d. Repair e. Assembly

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26 TM 750-254
Shop Equipment, Radiator, SC 4940-95-CL-A76 FM 43-2
Plug Set, Radiator, NSN 4910-00-273-3660
Equipment Condition:
Materials/Parts:
Reference Condition Description
Compound, Sealing Appendix B, Item 17
TM 5-2420-224-20 Radiator Removed

DISASSEMBLY

REMOVE DRAINCOCK (1) from radiator (2).

13-71
TM 5-2420-224-34

RADIATOR REPAIR (CONT)

CLEANING

Reverse flush radiator core (TM 750-254).

1. Inspect all parts for breaks, cracks, rust, and

corrosion.

2. inspect radiator core for leaks.

REPAIR
Repair leaks in radiator core (TM 750-254 and
FM 43-2).

ASSEMBLY

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

APPLY COAT of SEALING COMPOUND to

THREADS of draincock (1) and INSTALL
DRAINCOCK (1) in radiator (2).

NOTE
Follow-on Maintenance:
Install radiator (TM 5-2420-224-
20).

13-72
 TM 5-2420-224-34

WATER PUMP REPAIR

This task covers: a. Disassembly b. Inspection c, Assembly

TooI S and Special Equipment: References:

Tool Kit, SC 5180-90-CL-N26 TM 5-2420-224-20
Shop Set, SC 4910-95-CL-A31 TM 9-214

Materials/Parts: Equipment Condition:

Kit, Gasket Reference Condition Description
TM 5-2420-224-20 Water Pump Removed

1. REMOVE four bolts (1), rear COVER (2), and

gasket (3). DISCARD GASKET.

2. USING suitable PULLER, REMOVE INSERT

(4).

3. REMOVE six screws (5), RETAINER (6),

gasket (7), packing (8), and seal (9).
DISCARD GASKET, PACKING, and SEAL.

13-73
TM 5-2420-224-34

WATER PUMP REPAIR (CONT)

4. USING suitable PRESS, REMOVE SHAFT

(10).

5. REMOVE IMPELLER (11) and seal (12) from

pump (13). DISCARD IMPELLER and SEAL.

6. USING suitable PRESS, REMOVE large

BEARING (14) and small BEARING (15) from
shaft (10).

7. REMOVE seal (16), SPRING (17), and seal

(18). DISCARD SEALS.

INSPECTION

1. Inspect hub, impeller, and shaft for cracks and

damage.

2. Inspect bearings (TM 9-214).

13-74
 TM 5-2420-224-34

WATER PUMP REPAIR (CONT)

ASSEMBLY

1. INSTALL new seal (1), SPRING (2), and new

seal (3) in pump (4).

2. USING suitable PRESS, INSTALL small

BEARING (5) and large BEARING (6) on
shaft (7).

3. INSTALL SHAFT (7) in pump (4).

4. INSTALL new SEAL (8) in retainer (9).

5. INSTALL new PACKING (10) around large

bearing (6).

13-75
TM 5-2420-224-34

WATER PUMP REPAIR (CONT)

CAUTION
Make sure all gasket material
has been removed from both
mating surfaces to prevent
damage to equipment.

6. INSTALL RETAINER (9), new gasket (11),

and six screws (12).

7. INSTALL new seal (13) and new IMPELLER

(14) on shaft (7).

8. USING feeler GAGE, CHECK CLEARANCE

between impeller (14) and pump (4).
Clearance should be 0.012-0.043 in.
(0.30-1.1 mm).

CAUTION
Make sure all gasket material
has been removed from both
mating surfaces to prevent
damage to equipment.

9. INSTALL rear COVER (15), new gasket (16),

and four bolts (17).

13-76
 TM 5-2420-224-34

WATER PUMP REPAIR (CONT)

10. USING suitable PRESS, INSTALL INSERT

(18).

NOTE
Follow-on Maintenance:
Install water pump (TM 5-2420-
224-20).

13-77/(13-78 Blank)
 TM 5-2420-224-34

CHAPTER 14
ELECTRICAL SYSTEM REPAIR INSTRUCTIONS

OVERVIEW

This chapter contains maintenance instructions for repair of the electrical system. A list of sections
contained in this chapter is shown below.

Page

Section I. Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Section Il. Starter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8

Section Ill. Battery Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17

Section I. ALTERNATOR REPAIR

ALTERNATOR REPAIR
This task covers: a. Disassembly b. Testing c. Inspection d. Assembly

INITIAL SETUP
Tools and Special Equipment: References:
Shop Equipment, SC 4910-95-CL-A3I TM 9-214
TooI Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Washer, Spring
Tension (4) Page 4-4 Regulator Removed
Washer, Spring
Tension

14-1
TM 5-2420-224-34

ALTERNATOR REPAIR (CONT)

1. REMOVE nut (1), retaining ring (2), washer (3), retainer (4), pulley (5), spacer (6), spacer (7), and
IMPELLER (8).
2. MATCHMARK front HOUSING (9), STATOR (10), and rear HOUSING (11).
3. REMOVE four nuts (12), four spring tension washers (13), four capscrews (14), four screws (15), and
front HOUSING (9). DISCARD spring tension WASHERS.
4. REMOVE ROTOR (16).

NOTE
Tag wires and solder points prior to disconnecting to aid in connecting.

5. DISCONNECT four LEADS (17) and REMOVE STATOR (10).

6. DISCONNECT CONNECTOR (18) and REMOVE screw (19), spring tension washer (20), and
CONDENSER (21). DISCARD spring tension WASHER.

14-2
 TM 5-2420-224-34

ALTERNATOR REPAIR (CONT)

7. REMOVE four nuts (22), two washers (23), and four insulators (24).

8. REMOVE nut (25), washer (26), nut (27), two washers (28), and two INSULATORS (29).

9. REMOVE two NUTS (30) and washer (31).

10. REMOVE two screws (32), two washers (33), and RECTIFIER (34).

11. REMOVE two washers (35), two INSULATORS (36), and two INSULATORS (37) from rear housing (11).

14-3
TM 5-2420-224-34

ALTERNATOR REPAIR (CONT)

1. Test rotor assembly (1) as follows:

a. With ohmmeter connected between rotor end (2) and either of two slip rings (3), no
reading should be obtained. If any reading is obtained, rotor coil (4) is grounded and must
be replaced.
b. Check rotor coil (4) resistance by connecting ohmmeter across both slip rings (3). If
resistance is greater than 9.0 ohms, rotor assembly (1) must be replaced.

2. Test stator (5) as follows (note each reading):

a. Connect one ohmmeter lead to bare metal surface on stator lamination (6). Connect other
lead to each of four stator (5) terminals. High resistance reading should be obtained each
time. If there is no reading or ohmmeter reads zero, replace stator (5).

14-4
 TM 5-2420-224-34

ALTERNATOR REPAIR (CONT)

b. Connect ohmmeter leads as follows:

A and B
A and C
A and D
B and C
B and D
C and D
Each measurement should be approximately equal. If difference is great between any two
readings, or if any reading exceeds 0.24 ohms, replace stator (5).

INSPECTION

1. Inspect for burned or charred components (i.e., stator, rotor, etc.).

2. Inspect bearings (TM 9-214).

ASSEMBLY

1. INSTALL two INSULATORS (1), two INSULATORS (2), and two washers (3) in rear housing (4).

14-5
TM 5-2420-224-34

ALTERNATOR REPAIR (CONT)

2. INSTALL RECTIFIER (5), two washers (6), and two screws (7).

3. INSTALL washer (8) and two NUTS (9).

4. INSTALL two INSULATORS (10), two washers (11), nut (12), washer (13), and nut (14).

5. INSTALL four INSULATORS (15), two washers (16), and four nuts (17).

14-6
 TM 5-2420-224-34

ALTERNATOR REPAIR (CONT)

6. INSTALL CONDENSER (18), new spring tension washer (19), and screw (20) and CONNECT
CONNECTOR (21).
7. INSTALL STATOR (22) and SOLDER four LEADS (23).
8. INSTALL ROTOR (24).
9. ALINE MATCHMARKS on rear HOUSING (4), STATOR (22), and front HOUSING (25).
10. INSTALL front HOUSING (25), four screws (26), four capscrews (27), four new spring tension washers
(28), and four nuts (29).
11. INSTALL IMPELLER (30), spacer (31), spacer (32), pulley (33), retainer (34), washer (35), retaining
ring (36), and nut (37).

NOTE
Follow-on Maintenance:
Install regulator (page 4-4).

14-7
TM 5-2420-224-34

Section Il. STARTER REPAIR

STARTER REPAIR
This task covers: a. Disassembly b. Inspection c. Testing d. Assembly

Tools and Special Equipment: References:

TOOl Kit, SC 5180-90-CL-N26 TM 5-2420-224-20

Shop Equipment, SC 5180-95-CL-B08
Shop Equipment, SC 4910-95-CL-A01 Equipment Condition:
Dowel (4), Appendix C, item 1
Flat Washer, 9/16 ID Reference Condition Description

Materials/Parts: TM 5-2420-224-20 Starter Solenoid Removed

Screw (2)
Gasket
Washer, Lock

1. REMOVE two screws (1), end BELL (2), and gasket (3) from end bell (4). DISCARD SCREWS and
GASKET.

NOTE
Shims and washers may or may not be present. if present, note quantity of shims and
washers removed to aid in assembly.

2. REMOVE and DISCARD lock washer RING (5), SHIM(S) (6), and WASHER(S) (7) from armature (8).

3. REMOVE two nuts (9), two washers (10), and end BELL (4) from housing (11).

4. IF DAMAGED, REMOVE BUSHING (12) from end bell (4).

14-8
 TM 5-2420-224-34

STARTER REPAIR (CONT)

5. REMOVE HOUSING (11) from housing (13) until brush set bracket (14) is approximately HALF-WAY
off armature (8).

CAUTION
Install and remove dowels carefully to prevent damage to brushes.

6. INSTALL four DOWELS in brush holder (15). HOLD four DOWELS together and REMOVE HOUSING
(11).

7. REMOVE four DOWELS from brush holder (15).

NOTE
Brush set bracket may be attached to brush holder and housing with screws or it may
be soldered. If brush set bracket is soldered, do not perform step 8 until inspection has
been performed and replacement of brush holder is determined to be necessary.

8. IF DAMAGED, REMOVE brush set BRACKET (14) from brush holder (15) and housing (11).

14-9
TM 5-2420-224-34

STARTER REPAIR (CONT)

9. REMOVE nut (16), look washer (17), bolt (18), ARMATURE (8), and lever (19) from housing (13).
DISCARD lock WASHER.

10. REMOVE RING (20) from snap ring (21).

11. REMOVE snap ring (21), ring (20), PINION (22), and intermediate plate (23) from armature (8).
DISCARD snap RING.

12. IF DAMAGED, REMOVE sleeve BEARING (24) from pinion (22).

13. IF DAMAGED, REMOVE BUSHING (25) from intermediate plate (23).

14. REMOVE two RODS (26) from housing (13).

15. REMOVE starting COIL (27) from housing (11).

16. IF DAMAGED, REMOVE BUSHING (28) from housing (13).

14-10
 TM 5-2420-224-34

STARTER REPAIR (CONT)

Measure length of all four starter brushes. Replace all four brushes if any one brush is worn to length of
0.34 in. (9 mm) or less.

TESTING

1. Place armature (1) in growler of armature test set and turn on power.

2. Touch first test probe to armature core (2) and other test probe to commutator bars (3). If lamp lights,
armature winding or commutator is grounded; replace armature.

3. Hold steel blade parallel with and touching armature core (2).

4. Slowly rotate armature (1) one or more revolutions. If steel blade vibrates, armature (1) is shorted;
replace armature.

14-11
TM 5-2420-224-34

STARTER REPAIR (CONT)

5. Following directions provided with tester and using probe, test commutator bars (3) for abnormal
readings that will indicate a short, open, or poor connection. If any of these conditions are present,
replace armature (1).

NOTE
If brush holder has not been removed, make sure brush holder does not contact housing
while performing step 6.

6. Using multimeter set to check continuity, check between field connector (4) and housing (5). Meter
reading should be infinity. If meter deflects toward zero, replace housing.

7. Repeat step 6 for field connector (6) on opposite side of housing (5).

14-12
 TM 5-2420-224-34

STARTER REPAIR (CONT)

1. IF REMOVED, INSTALL new BUSHING (1) in housing (2).

2. INSTALL starting COIL (3) on housing (4).
3. INSTALL two RODS (5) in housing (2).
4. IF REMOVED, INSTALL new BUSHING (6) in intermediate plate (7).
5. IF REMOVED, INSTALL new sleeve BEARING (8) in pinion (9).
6. INSTALL intermediate plate (7), PINION (9), ring (10), and new snap ring (11) on armature (12).

7. USING 9/16 ID FLAT WASHER and two pairs of PLIERS, INSTALL RING (10) over snap ring (11), as
shown.

14-13
TM 5-2420-224-34

STARTER REPAIR (CONT)

8. INSTALL LEVER (13) on pinion (9) and INSTALL LEVER (13) and ARMATURE (12) in housing (2).

9. INSTALL BOLT (14), new lock washer (15), and nut (16) in housing (2) through Iever (13).

10. IF REMOVED, INSTALL new brush set BRACKET (17) in brush holder (18) and housing (4).

CAUTION
Use care to avoid damaging brushes.

11. INSTALL BRUSH in its bracket on brush holder (18). INSTALL DOWEL in brush holder (18)
approximately half the width of brush to hold brush in place.

12. REPEAT STEP 11 for remaining three brushes in brush set bracket (17).

13. HOLD four DOWELS together and INSTALL HOUSING (4) and brush holder (18) over armature (12).

14. REMOVE four DOWELS and completely INSTALL HOUSING (4) in housing (2).

14-14
 TM 5-2420-224-34

STARTER REPAIR (CONT)

15. IF REMOVED, INSTALL new BRUSHING (19) in end bell (20).

16. INSTALL end BELL (20), two nuts (22) on housing (4).

17. INSTALL new washer(s) (23), new shim)s) (24), and new lock wahser RING (25) as noted during
Removal.

18. USING feeler GAGE, MEASURE GAP between shim(s) (24) and end bell (20). Measurement MUST be
0.002-016 in. (0.05-0.4 mm). If measurement is NOT correct, ADD or REMOVE SHIM(S) to achieve
correct measurement.

14-15
 TM 5-2420-224-34

STARTER REPAIR (CONT)

19. INSTALL new gasket (26), end BELL (27), and two new screws (28) on end bell (20).

NOTE
Follow-on Maintenance:
Install starter solenoid (TM 5-2420-224-20).

14-16
 TM 5-2420-224-34

Section Ill. BATTERY REPAIR

BATTERY REPAIR
This task covers: Repair

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TooI Kit, SC 5180-90-CL-N26
Shop Equipment, Battery, SC 4940-95-CL-A38 TM 5-2420-224-20 Battery Removed

References:
TM 5-2420-224-20
TM 9-6140-200-14

Repair battery (1) (TM 9-6140-200-14).

NOTE
Follow-on Maintenance:
Install battery (TM 5-2420-224-20).

14-17/(14-18 Blank)
 TM 5-2420-224-34

CHAPTER 15
TRANSMISSION REPAIR INSTRUCTIONS

This chapter contains maintenance instructions for repair of the transmission. A list of sections contained
in this chapter is shown below.

Page

Section I. Transmission Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Section Il. Transmission Top Cover Repair . . . . . . . . . . . . . . . . . . . . . . . . . 15-54

Section Ill. Transmission Access Cover Repair . . . . . . . . . . . . . . . . . . . . . . . 15-65

Section lV. Power Take-Off (PTO) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 15-70

Section I. TRANSMISSION REPAIR

TRANSMISSION REPAIR
This task covers: a. Disassembly b. Inspection c. Assembly

Tools and Special Equipment: Materials/Parts:

Shop Equipment, SC 4910-95-CL-A31 Gasket
Tool Kit, SC 5180-90-CL-N26
Blocking TooI, P/N 406 589 06 63 00 Gasket
Bushing Guide, P/N 406 589 01 07 02
Packing
Dial Gage, P/N 001 589 53 21 00
Dial Gage Holder, P/N 363 589 02 21 00 Seal
Fabricated Tool, Appendix C, Item 2
Fabricated Tool, Appendix C, Item 3 Packing
Fabricated Tool, Appendix C, item 4
Installer, P/N 406 589 03 14 00 Gasket
Installer, P/N 406 589 06 43 00 Packing (2)
Installer, P/N 406 589 02 61 00
Installer, P/N 406 589 12 43 00 Gasket
Installer, P/N 441 589 00 33 00
Puller, P/N 001 589 45 33 00 Sleeve, Crushable
Puller, P/N 000 589 35 33 00
Puller, P/N 000 589 34 33 00 Seal
Puller, P/N 000 589 82 33 00 Washer, Spring
Puller, P/N 000 589 52 34 00 Tension
Slotted Nut Wrench, P/N 406 589 01 07 01
Slotted Nut Wrench, P/N 406 589 02 07 00 Ring, Seal
Test Mandrel, P/N 406 589 00 21 00
Pin, Cotter (2)
Gasket (2)
Seal

15-1
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

Materials/Parts (Cont): Equipment Condition:

Packing Reference Condition Description
Washer, Lock Page 3-66 Transmission Removed
Packing and Mounted on Stand

Plug Page 3-96 Transmission Shift Controls

Installed
Packing
Page 3-66 Clutch Release Lever and
Gasket Shaft Removed

Seal General Safety Instructions:

Seal
Compound, Sealing Appendix B, item 14 WARNING
Adhesive causes immediate
Compound, Sealing Appendix B, item 16 bonding on contact with eyes,
Grease, Automotive Appendix B, item 23 skin, or clothing and also gives
and Artillery (GAA) off harmful vapors. Wear
protective goggles and use in
Grease, Molybdenum Appendix B, item 24 well-ventilated area. If adhesive
Disulfide
gets in eyes, try to keep eyes
Oil, Lubricating Appendix B, item 30 open; flush eyes with water for
15 minutes and get immediate
References: medical attention.
TM 9-214

NOTE
Power flow in cascade box must
not be interrupted.

1. ENGAGE first GEAR and, USING SLOTTED

NUT WRENCH, BUSHING GUIDE,
BLOCKING TOOL and BAR, and BLOCKING
TOOL HANDLE, REMOVE slotted NUT (1)
and plug (2).

2. REMOVE retaining ring (3), two washers (4),

clip (5), and front-wheel drive PLUNGER (6).

15-2
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

3. USING BUSHING GUIDE and suitable

PULLER, REMOVE FLANGE (7).

NOTE
Oil ring may have separate
retaining plate.

4. REMOVE two bolts (8), two washers (9), oil

RING (10), and gasket (11). DISCARD
GASKET.

5. ENGAGE front-wheel drive LEVER and,

USING SLOTTED NUT WRENCH, BUSHING
GUIDE, BLOCKING TOOL HANDLE, and
BLOCKING TOOL BAR, REMOVE NUT (12)
from front drive output.

6. USING BUSHING GUIDE and suitable

PULLER, REMOVE output FLANGE (13) from
front drive output.

15-3
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

7. REMOVE CLIP (14), DISCONNECT SOCKET

(15), and REMOVE eight screws (16),
POWER TAKE-OFF (17), and gasket (18).
DISCARD GASKET.

NOTE
Make sure manual control levers
are in neutral position.

8. REMOVE 12 screws (19) and COVER

assembly (20).

9. REMOVE six SCREWS (21) and PRY OFF

access COVER (22).

15-4
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

10. REMOVE screw (23), LOCK (24), and lock

(25).

11. REMOVE rod (26), shifter FORK (27), and

packing (28). DISCARD PACKING.

NOTE
Be careful not to lose ball and
spring.

12. REMOVE BALL (29) and spring (30) from

shifter fork (27).

15-5
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

13. REMOVE five screws (31), INSERT (32),

spacer(s) (33), and seal (34). DISCARD
SEAL.

14. REMOVE six screws (35) and bearing

COVER (36).

15. REMOVE two retaining RINGS (37 and 38).

16. USING PULLER, REMOVE BEARING (39)

and spacer(s) (40).

15-6
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

17. REMOVE SCREW (41), screw (42), washer

(43), and nut (44).

Cascade box housing weighs

78 pounds (36 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting cascade box
housing.

18. REMOVE seven screws (45) and cascade box

HOUSING (46).

19. REMOVE BEARING (47), two screws (48),

lock (49), and plug (50).

20. IF DAMAGED, REMOVE two PINS (51).

15-7
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

21. REMOVE PTO GEAR (52) and front input

SHAFT assembly (53).

22. REMOVE synchronizer (54), flat spring (55),

COLLAR (56), and bearing (57) from gear (58).

23. REMOVE SCREW (59) and washer (60).

24. USING PULLER, REMOVE bearing (61),

spacer (62), and GEAR (63).

25. REMOVE gear (64) and intermediate GEAR

(65).

15-8
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

26. REMOVE synchronizer (66), flat spring (67),

and BEARING (68) from gear (64).

27. USING suitable PRESS, REMOVE SHAFT

(69), two bearings (70 and 71), packing (72),
two piston rings (73 and 74), and spacer (75)
from intermediate gear (65). DISCARD
PACKING.

28. REMOVE five screws (76) and two retaining

RINGS (77 and 78).

29. USING PULLER, REMOVE BEARING (79),

spacer (80), and thrust bearing washer (81).

15-9
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

30. REMOVE eight screws (82), eight washers

(83), two capscrews (84), two washers (85),
COVER (86), and gasket (87). DISCARD
GASKET.

31. REMOVE CLIP (88) and LEVER (89) from

lever (90).

32. REMOVE two SOCKETS (15 and 91) and two

nuts (92) from lever (89).

33. REMOVE screw (93), two washers (94),

sleeve bearing (95), two packings (96),
bushing (97), and LEVER (90) from cover
(86). DISCARD PACKINGS.

15-10
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

34. REMOVE three SCREWS (98).

35. USING PULLER, REMOVE HOUSING (99),

gasket (100), crushable sleeve (101), bearing
(102), and seal (103). DISCARD GASKET,
crushable SLEEVE, and SEAL.

36. LOOSEN SCREW (104) in output shaft (105).

37. USING PULLER, REMOVE BEARING (106).

REMOVE rear input SHAFT (107) from
housing (108).

38. REMOVE SYNCHRONIZER (109) and flat

spring (110) from rear input shaft (107).

39. REMOVE SCREW (104) from output shaft

(105).

15-11
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

40. REMOVE main gear SHAFT (111) and output

shaft (105).

41. REMOVE RETAINER and ROLLER (112) from

main gear shaft (111).

42. REMOVE retaining ring (113), bearing ring

(114), and GEAR (115).

43. REMOVE synchronizer (116), flat spring (117),

retaining ring (118), washer (119), and GEAR
(120).

44. REMOVE bearing RACE (121) from main gear

shaft (111).

15-12
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

45. REMOVE fourth gear COLLAR (122) from

output shaft (105) gear.

46. REMOVE spring tension washer (123), spacer

(124), two-piece BEARING (125). and
shoulder washer (126) from output shaft (105)
DISCARD spring tension WASHER.

47. USING PULLERS, REMOVE BEARING (127)

from output shaft (105).

15-13
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

48. REMOVE screw (128), washer (129), thrust

bearing washer (130), and PIN (131) from
initial stage shaft assembly (132).

49. REMOVE four screws (133), cap (134), and

metallic HOSE (135).

NOTE
Shaft is installed in a three-piece
bearing. During removal, bearing
cover may come off bearing.

50. USING PULLER and FABRICATED TOOL

(Appendix C, Item 3), REMOVE primary
SHAFT (136) and bearing (137).

15-14
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

51. REMOVE gear (138), bearing (139), and

reverse GEAR (140) from housing (108).

52. REMOVE GEAR assembly (141) from housing

(108).

53. REMOVE synchronizer (142), flat spring (143),

BEARING (144), and bearing (145) from
reverse gear (140).

54. REMOVE two BEARINGS (146).

55. REMOVE COLLAR (147).

56. REMOVE retaining ring (148) and GEAR

(149).

15-15
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

57. REMOVE synchronizer (150), flat spring (151),

and forward-low range GEAR (152).

56. REMOVE RETAINER and ROLLER (153) from

spur gear (154).

59. REMOVE retaining ring (155), two-piece

BEARING (156), and spacer (157) from spur
gear (154).

15-16
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

60. IF DAMAGED, REMOVE PIN (158) from

primary shaft (136).

61. REMOVE BEARING (159) from primary shaft

(136).

62. REMOVE PLUG (160) and seal ring (161).

DISCARD seal RING.

63. REMOVE cotter pin (162), nut (163), 16

conical spring washers (164), FORK (165),
and rod (166). DISCARD rotter PIN.

15-17
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

64. REMOVE three screws (167), FLANGE (166),

and spacer washer (169).

65. USING SLOTTED NUT WRENCH, REMOVE

slotted NUT (170).

66. INSTALL FABRICATED TOOL (Appendix C,

Item 4) between third gear CLUSTER (171)
and housing (108).

15-18
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

NOTE
During performance of step 67,
when countershaft is removed, all
pieces will drop into bottom of
housing.

67. USING PULLER and FABRICATED TOOL

(Appendix C, Item 2), REMOVE COUNTER-
SHAFT (172) and bearing (173).

68. REMOVE pin (174), rod (175), two FORKS

(176 and 177), third gear cluster (171), first
and second gears cluster (178), tube spacer
(179), and two thrust bearing washers (180).

69. REMOVE spur gear (181) and GEAR (182)

from third gear (183).

15-19
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

70. REMOVE SYNCHRONIZER (184) and flat

spring (185) from third gear (183).

71. REMOVE roller (186), spacer (187), roller

(188), and BUSHING (189) from third gear
(183).

72. REMOVE two rollers (190) and sleeve

BUSHING (191).

73. REMOVE second GEAR (192) from first and

second gears cluster (178).

74. REMOVE SYNCHRONIZER (193) and flat

spring (194) from second gear (192).

15-20
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

75. REMOVE COLLAR (195) and first gear (196)

from gear (197).

76. REMOVE synchronizer (198), flat spring (199),

and two BEARINGS (200) from gear (197).

77. REMOVE two SCREWS (201) from flange

(202).

CAUTION
Use care removing flange to
prevent damage to mating
surface.

78. USING PULLER, REMOVE FLANGE (202),

spacer (203), and gasket (204). DISCARD
GASKET.

15-21
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

79. REMOVE packing (205), retaining ring (206),

BEARING (207’), and seal (208) from flange
(202). DISCARD PACKING and SEAL.

80. REMOVE four SCREWS (209) and PRY OFF

COVER (210).

81. REMOVE and DISCARD GASKET (211).

82. REMOVE three RETAINERS and ROLLERS

(212) and spacer (213) from output shaft
(214).

15-22
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

83. REMOVE output SHAFT (214) from cover

(210).

84. USING PULLER, REMOVE BEARING (215)

from cover (210).

85. REMOVE screw (216), lock washer (217),

LEVER (21 8), and packing (219). DISCARD
lock WASHER and PACKING.

86. REMOVE shifter fork (220), two pins (221),

synchronizer (222), and front-wheel drive
GEAR (223).

87. REMOVE BEARING (224) and nut (225) from

lever (218).

15-23
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

88. REMOVE PLUG (226), screw (227), and nut

(228). DISCARD PLUG.

89. REMOVE PIN (229) and packing (230) from

front-wheel drive idler gear (231). DISCARD
PACKING.

90. REMOVE two BEARINGS (232), ring (233),

two bearing cups (234), and two retaining
rings (235) from front-wheel drive idler gear
(231).

91. REMOVE nut (236), bushing (237), sleeve

bushing (238), and SHAFT (239).

92. REMOVE 12 screws (240), 12 washers (241),

COVER (242), gasket (243), 2 drain plugs
(244 and 245), and 2 seaIs (246 and 247).
DISCARD GASKET and SEALS.

15-24
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

93. REMOVE three BEARINGS (248, 249, and 250).

94. IF DAMAGED, REMOVE two PINS (251) and

drain PLUG (252).

1. Inspect housings for cracks, galling, and

stripped threads.

2. Inspect gears for galling, cracks, and worn or

broken teeth.

3. Inspect bearings (TM 9-214).

NOTE
• Apply coat of lubricating oil to
bearings prior to assembly.
Ž Bearings (1 and 3) must be
installed with flange facing front
of housing.

1. INSTALL three BEARINGS (1, 2, and 3).

2. IF REMOVED, INSTALL two new PINS (4)

and new drain PLUG (5).

3. INSTALL bushing (6), sleeve bushing (7),

SHAFT (8), and nut (9).

15-25
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

4. INSTALL new PACKING (10) on pin (11).

5. INSTALL two retaining rings (12), two bearing

cups (13), two BEARINGS (14), and ring (15)
in front-wheel drive idler gear (16).

6. INSTALL front-wheel drive idler GEAR (16)

assembly in housing (17).

7. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 14) to SCREW (18) and
INSTALL PIN (11), screw (18), and nut (19).
TIGHTEN SCREW to 36 Ib-ft (49 N•m).

8. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 14) to PLUG (20) and
INSTALL PLUG.

NOTE
Install synchronizer with collar
facing front-wheel drive gear.

9. INSTALL front-wheel drive GEAR (21),

synchronizer (22), two pins (23), and shifter
fork (24).

10. INSTALL new PACKING (25) in housing (17).

11. INSTALL BEARING (26) and nut (27) on lever

(28).

12. INSTALL LEVER (28) in shifter fork (24).

POSITION LEVER so half of hole in shifter
fork (24) is visible when lever (28) is in
contact with housing (17).

NOTE
Screw must pass through groove
in lever.

13. INSTALL new lock washer (29) and SCREW

(30).

15-26
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

14. INSTALL bearing (31 ) and output SHAFT (32)

in cover (33).

15. INSTALL three RETAINERS and ROLLERS

(34) and spacer (35) on output shaft (32).

16. INSTALL new gasket (36) and COVER (33).

17. INSTALL four SCREWS (37) and TIGHTEN to

36 Ib-ft (49 N•m).

18. INSTALL SPACER (38) on output shaft (32).

19. INSTALL BEARING (39), retaining ring (40),

and new packing (41) in flange (42).

20. INSTALL new gasket (43), FLANGE (42), and

two screws (44).

15-27
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

21. APPLY COAT of GAA to new SEAL (45).

USING INSTALLERS, INSTALL SEAL (45).

22. APPLY COAT of MOLYBDENUM DISULFIDE

GREASE to output SHAFT (32).

23. USING INSTALLER, INSTALL output FLANGE

(46) and nut (47).

CAUTION
Sixteen conical spring washers
must be installed in pairs
inside-face to inside-face to
make eight pairs to prevent
damage to equipment.

24. INSTALL rod (46), 16 conical spring washers

(49), FORK (50), nut (51), and new cotter pin
(52). DO NOT BEND cotter PIN.

15-28
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

25. IF REMOVED, INSTALL new PIN (53) in

primary shaft (54).

26. INSTALL BEARING (55) on primary shaft

(54).

27. INSTALL spacer (56), two-piece BEARING

(57), and retaining ring (58) in spur gear (59).

28. INSTALL RETAINER and ROLLER (60).

29. INSTALL forward-low range gear (61),

SYNCHRONIZER (62), and flat spring (63).

15-29
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

30. INSTALL GEAR (64) and retaining ring (65).

31. INSTALL two bearings (66) and COLLAR (67).

NOTE
Make sure collar engages in fork.

32. INSTALL GEAR assembly (66) from step 31

in housing (17) and INSTALL primary SHAFT
(54) enough to hold gears in place.

15-30
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

33. INSTALL bearing (69), BEARING (70),

synchronizer (71), and flat spring (72) on
reverse gear (73).

34. INSTALL GEAR assembly (74) from step 33

on primary shaft (54).

35. INSTALL GEAR (75) with bearing (76) toward

front of housing (17).

15-31
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

36. COMPLETE INSTALLATION of primary shaft

(54) and INSTALL BEARING (77).

37. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 14) to SCREW (78) and
INSTALL thrust bearing WASHER (79),
washer (80), and screw (78). TIGHTEN
SCREW to 36 lb-ft (49 N•m), and STAKE.

38. INSTALL PIN (81) flush with primary shaft

(54).

39. INSTALL cap (82), metallic HOSE (83), and

four screws (84). TIGHTEN SCREWS to 18
Ib-ft (25 N•m).

15-32
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

40. INSTALL synchronizer (85), flat spring (86),

and two BEARINGS (87) on first gear (88).

41. INSTALL two ROLLERS (89) and sleeve

bushing (90) in second gear (91).

42. INSTALL SYNCHRONIZER (92) and flat

spring (93) on second gear (91).

15-33
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

43. INSTALL collar (94) and GEAR (95) on first

gear (88).

44. INSTALL first GEAR (88) on second gear

(91).

45. INSTALL roller (96), spacer (97), roller (98),

and BUSHING (99) in third gear (100).

46. INSTALL SYNCHRONIZER (101) and flat

spring (102) on third gear (100).

15-34
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

47. INSTALL gear (103) and spur GEAR (104) on

third gear (100).

48. INSTALL first and second gears CLUSTER

(105), and INSTALL COUNTERSHAFT (106)
enough to hold gears in place.

49. INSTALL thrust bearing WASHER (107) with

flange toward rear of housing (17).

50. PUSH COUNTERSHAFT (106) through

bearing (2) in housing (17) and INSTALL
thrust bearing WASHER (108) with flange
toward front of housing (17).

15-35
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

51. INSTALL third gear CLUSTER (109) on

countershaft (106).

52. INSTALL tube SPACER (110) on countershaft

(106) and PUSH COUNTERSHAFT all the
way through.

53. INSTALL BEARING (111) on countershaft

(106) at rear of housing (17).

15-36
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

54. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 14) to slotted NUT (112).
USING SLOTTED NUT WRENCH, INSTALL
slotted NUT (112), TIGHTEN to 125 lb-ft (170
N•m), and STAKE.

55. INSTALL spacer washer (113), FLANGE

(114), and three screws (115). TIGHTEN
SCREWS to 18 Ib-ft (25 N•m).

56. INSTALL two forks (116 and 117), ROD

(118), and pin (119).

15-37
TM 5-2420-224-34

57. INSTALL BEARING (120) on output shaft

(121).

58. INSTALL shoulder washer (122), two-piece

BEARING (123), spacer (124), and new spring
tension washer (125) in output shaft (121).

59. INSTALL fourth gear COLLAR (126) on output

shaft (121) gear.

15-38
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

60. INSTALL bearing RING (127) and retaining

ring (128) on main gear shaft (129).

61. INSTALL GEAR (130), washer (131), and

retaining ring (132) on main gear shaft (129).

62. INSTALL SYNCHRONIZER (133) and flat

spring (134).

63. INSTALL bearing RACE (135) on main gear

shaft (129).

64. INSTALL GEAR assembly (136) from step 59

on gear assembly (137) from step 63.

65. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 14) to SCREW (138).
INSTALL SCREW (138) and TIGHTEN to
36 lb-ft (49 N.m).

66. INSTALL main gear SHAFT assembly (129)

from step 65.

15-39
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

67. INSTALL flat spring (139), synchronizer (140),

and GEAR (141) on main gear shaft assembly
(129).

68. INSTALL RETAINER and ROLLER (142) on

rear input shaft (143).

69. INSTALL rear input SHAFT (143) on main

gear shaft assembly (129) in housing (17).
Make sure SYNCHRONIZER (140) MESHES
with rear input shaft (143).

70. INSTALL BEARING (144) in housing (17) with

outside groove toward front of transmission.

71. INSTALL two retaining RINGS (145 and 146)

and five screws (147). TIGHTEN SCREWS to
18 Ib-ft (25 N.m).

15-40
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

72. INSTALL thrust bearing WASHER (148) on

spacer (149).

73. INSTALL SPACER assembly (150) from step

72 on rear input shaft (143) with thrust
bearing washer (148) toward front of
transmission.

74. USING INSTALLER, INSTALL BEARING (151)

on rear input shaft (143).

NOTE
Tapered end of gear teeth must
be facing forward end of
transmission.

75. INSTALL bearing (152), GEAR (153), flat

spring (154), synchronizer (155), and gear
(156) on rear input shaft (143).

15-41
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

76. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 14) to THREADS of screw
(157) and INSTALL COLLAR (158), spacer
(159), bearing (160), washer (161 ), and screw
(157). TIGHTEN SCREW to 51 Ib-ft (70 N•m).

77. INSTALL two piston rings (162 and 163) and

SPACER (164) in intermediate gear (165).

78. USING suitable PRESS, INSTALL BEARING

(166) on shaft (167).

79. INSTALL SHAFT (167) in intermediate gear

(165).

80. INSTALL BEARING (168) and new packing

(169) on shaft (167).

81. INSTALL BEARING (170), synchronizer (171),

and flat spring (172) in front input shaft (173).

15-42
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

82. INSTALL front input SHAFT (173).

83. INSTALL bearing (174) and PLUG (175) in

cascade box housing (176).

84. IF REMOVED, INSTALL two new PINS (177).

85. INSTALL PTO GEAR (178) in cascade box

housing (176).

NOTE
Make sure notch on intermediate
gear shaft is facing toward bottom
of cascade box housing.

86. INSTALL intermediate GEAR (165) in cascade

box housing (176).

87. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 16) to two SCREWS (179)
and INSTALL LOCK (180) and two screws
(179). TIGHTEN SCREWS to 18 Ib-ft (25
N•m).

15-43
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

WARNING
Cascade box housing weighs
78 pounds (36 kilograms). To
avoid personal injury, use a
hoist or suitable lifting device
when lifting cascade box
housing.

88. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 16) to cascade box housing
(176) FLANGE and seven SCREWS (181)
and INSTALL cascade box HOUSING (176)
and seven screws (181). TIGHTEN SCREWS
to 36 Ib-ft (49 N•m

89. INSTALL SCREW

Ib-ft (49 N•m).

90. INSTALL SCREW (183), washer (184), and

nut (185). TIGHTEN SCREW to 18 Ib-ft
(25 N•m).

91. INSTALL BEARING (186) until center of

bearing contacts shaft shoulder with outside
groove toward front of transmission.

92. INSTALL retaining RING (187).

93. USING feeler GAGE, MEASURE DISTANCE

between retaining ring (187) and bearing
(186).

94. TO DETERMINE spacer THICKNESS,

SUBTRACT 0.004 in. (0.1 mm) from
measurement obtained in STEP 93.

95. REMOVE retaining RING (187) and INSTALL

SPACER(S) (188).

96. REINSTALL retaining RING (187).

15-44
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

NOTE
Perform step 97 only if outer
retaining ring groove of bearing is
not exposed enough to allow
installation of outer retaining ring.

97. USING PULLER and FABRICATED TOOL

(Appendix C, Item 2), PULL primary SHAFT
(54) only enough to expose outer retaining
ring groove on bearing (186).

98. INSTALL retaining RING (189) on bearing

(186).

99. APPLY COAT of SEALING COMPOUND

(Appedix B, Item 16) to THREADS of six
screws (190) and bearing COVER (191).
INSTALL bearing COVER (191) and six
screws (190). TIGHTEN SCREWS to 18 Ib-ft
(25 N•m).

100. USING INSTALLER, INSTALL new SEAL

(192) in insert (193).

15-45
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

NOTE
Make sure bearing is seated prior
to taking measurement.

101. MEASURE PROJECTION of BEARING

(174).

102. MEASURE DEPTH of bearing SEAT in insert

(193) to determine spacer thickness to obtain
AXIAL play of 0.01-0.02 in. (0.5-0.6 mm).

103. SUBTRACT measurement obtained in STEP

101 from measurement obtained in STEP
102.

104. SUBTRACT 0.022 in. (0.55 mm) from result

obtained in STEP 103 to determine spacer
thickness.

105. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 16) to INSERT (193) and
INSTALL INSERT (193), spacer(s) (194), and
five screws (195). TIGHTEN SCREWS to 18
Ib-ft (25 N•m).

106. INSTALL BALL (196) and spring (197) in

shifter fork (198).

107. INSTALL new PACKING (199) on rod (200).

108. INSTALL shifter FORK (198) and rod (200)

while pressing ball (196) downward.

15-46
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

109. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 16) to THREADS of screw
(201) and INSTALL look (202), LOCK (203),
and screw (201 ).

110. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 16) to access COVER
(204) and COAT of SEALING COMPOUND
(Appendix B, Item 14) to THREADS of six
screws (205). INSTALL access COVER (204)
and six screws (205). TIGHTEN SCREWS to
18 Ib-ft (25 N•m).

111. INSTALL new crushable sleeve (206), new

gasket (207), HOUSING (208), and three
screws (209). TIGHTEN SCREWS evenly to
36 lb-ft (49 N•m).

15-47
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

112. USING INSTALLER, INSTALL BEARING

(210).

113. APPLY COAT of GAA to new SEAL (211).

USING INSTALLERS, INSTALL SEAL (211).

114. USING INSTALLER, INSTALL FLANGE

(212).

115. INSTALL slotted NUT (213) and

HAND-TIGHTEN.

116. SET both shift LEVERS in cover assembly

(214) in neutral position.

117. APPLY COAT of SEALING COMPOUND

(Appendix B, Item 16) to COVER assembly
(214) and THREADS of 12 screws (215).
INSTALL COVER assembly (214) and 12
screws (215). TIGHTEN SCREWS to 18 Ib-ft
(25 N•m).

15-48
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

NOTE
Install slotted nut wrench with
notch in position to be easily
visible.

118. INSTALL BUSHING GUIDE, BLOCKING

TOOL, SLOTTED NUT WRENCH and
BLOCKING TOOL HANDLE.

119. ENGAGE first GEAR and TURN main gear

SHAFT assembly (129) in CLOCKWISE
direction until resistance is felt.

120. REMOVE SLOTTED NUT WRENCH.

NOTE
Dial gage plunger must be against
bushing guide flange.

121. INSTALL DIAL GAGE, DIAL GAGE HOLDER,

and test MANDREL on housing (17).

122. PUSH TEST MANDREL FORWARD and

ZERO DIAL GAGE.

123. PULL TEST MANDREL BACK and NOTE

READING of end play measurement.

124. REMOVE TEST MANDREL and DIAL

GAGE.

125. INSTALL SLOTTED NUT WRENCH and

BLOCKING TOOL BAR.

NOTE
One division on scale of dial gage
is equal to one division on scale
of bushing guide, which is
0.0004 in. (0.01 mm).

126. MARK INCREMENT on BUSHING GUIDE

that is in line with notch on SLOTTED NUT
WRENCH.

127. DIVIDE READING obtained in STEP 123 by

Two.

15-49
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

128. FROM notch in SLOTTED NUT WRENCH,

COUNT to RIGHT number of increments on
BUSHING GUIDE, as determined in STEP
127, and MARK BUSHING GUIDE.

129. ENGAGE first GEAR and TURN main gear

SHAFT assembly (129) to RIGHT until notch
on SLOTTED NUT WRENCH alines with
mark determined in STEP 128.

130. REPEAT STEPS 120 thru 125.

131. ADD 0.0008 in. (0.02 mm) to reading from

STEP 123. This equals number of
increments to be counted on BUSHING
GUIDE.

132. FROM MARK made in STEP 126, COUNT

to RIGHT number of increments on
BUSHING GUIDE, as determined in STEP
131, and MARK BUSHING GUIDE.

133. ENGAGE first GEAR and TURN main gear

SHAFT assembly (129) to RIGHT until
increment marked in STEP 132 is at notch
on BUSHING GUIDE. If main gear shaft is
turned too far, REPLACE crushable SLEEVE
(206) and REPEAT STEPS 119 thru 132.

134. INSTALL PLUG (21 6) in rear of main gear

shaft assembly (129).

135. REMOVE cotter PIN (52) and POSITION

shift controls to neutral. DISCARD cotter
PIN.

136. SELECT forward and reverse GEARS and

MEASURE GAPS A and B with feeler
GAGE.

15-50
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

NOTE
Gaps for forward and reverse
must be identical.

137. IF forward and reverse GAPS are NOT

equal, TURN ROD (48) while HOLDING
NUT (51).

138. REPEAT STEPS 136 and 137 until equal

measurement is obtained.

139. INSTALL new cotter PIN (52).

140. INSTALL PLUG (217) and new seal ring (218).

141. INSTALL new gasket (219), POWER

TAKE-OFF (220), and eight screws (221).
TIGHTEN SCREWS to 36 Ib-ft (49 N•m).

142. INSTALL new gasket (222), COVER (223),

eight screws (224), eight washers (225), two
capscrews (226), and two washers (227).

15-51
TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

143. INSTALL LEVER (228), bushing (229), two

new packings (230), sleeve bearing (231),
two washers (232), and screw (233).

144. INSTALL two nuts (234) and two SOCKETS

(235) on lever (236).

145. ROTATE two SOCKETS (235) until overall

length of 8.46 in. (215 mm) is attained.
TIGHTEN two NUTS (234) against two
sockets (235).

146. CONNECT LEVER (236) to lever (228) and

Power Take-Off (220) and INSTALL two
CLIPS (237).

15-52
 TM 5-2420-224-34

TRANSMISSION REPAIR (CONT)

147. INSTALL front-wheel drive PLUNGER (238),

two washers (239), and retaining ring (240).

NOTE
Transmission must be in low-range
first gear with front-wheel drive
lever engaged.

148. USING SLOTTED NUT WRENCH,

BLOCKING TOOL HANDLE and BAR, and
BUSHING GUIDE, TIGHTEN and STAKE
NUT (241).

149. INSTALL SOCKET (242) of front-wheel drive

plunger (238) and clip (243) on lever (28).

NOTE
Oil ring may have separate
retaining plate.

150. INSTALL new gasket (244), oil RING (245),

two washers (246), and two bolts (247).

151. INSTALL new gasket (248), COVER (249),

12 washers (250), and 12 screws (251).

152. INSTALL two new seals (252) and two drain

PLUGS (253 and 254).

NOTE
Follow-on Maintenance:
Remove transmission shift controls
(page 3-96).
Install clutch release lever and
shaft (page 3-66).
Remove transmission from stand
and install (page 3-68).

15-53
TM 5-2420-224-34

Section II. TRANSMISSION TOP COVER REPAIR

TRANSMISSION TOP COVER REPAIR

This task covers: a. Disassembly b. Assembly

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Shift Tester Plate, P/N 441 5890021 00 Page 3-86 Transmission Top Cover
Removed
Materials/Parts:
Ring, Seal
Compound, Sealing Appendix B, Item 14

Oil, Lubricating Appendix B, Item 30

1. REMOVE four tee head bolts (1), four

retaining rings (2), two BUSHINGS (3), and
pin (4).

2. REMOVE BREATHER (5) and seal ring (6).

DISCARD seal RING.

3. REMOVE pressure SWITCH (7) and washer

(8).

4. REMOVE PIN (9) from pressure switch port

(10).

5. TURN ASSEMBLY OVER.

15-54
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

6. REMOVE PIN (11) from shifting frame (12).

7. REMOVE LEVER (13) from cover (14).

8. REMOVE two BALLS (15).

9. REMOVE SPRING (16) and plug (17) from

cover (14).

15-55
TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

10. REMOVE PIN (18) from follower (19).

11. REMOVE two setscrews (20 and 21) and shift

FORK (22) from lever (23).

12. REMOVE LEVER (23), shifting frame (12),

and follower (24) from cover (14).

13. REMOVE spring (25) and PLUG (26) from

cover (14).

15-56
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

14. REMOVE PIN (27) from follower (28) and

REMOVE two SETSCREWS (29 and 30) from
shifter fork (31).

15. REMOVE two setscrews (32 and 33) and

shifter FORK (34) from lever (35).

16. REMOVE two BALLS (36) from cover (14).

17. REMOVE FOLLOWER (28) from lever (35).

18. REMOVE LEVER (35) and shifter FORK (31)

from cover (14).

19. REMOVE spring (37) and PLUG (38) from

cover (14).

15-57
TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

20. REMOVE retaining ring (39), PIN (40), and

spring (41) from follower (42).

21. REMOVE PIN (43) from follower (42).

22. REMOVE two SETSCREWS (44 and 45) from

shifting tongue (46).

23. REMOVE LEVER (47), follower (42), and

shifting tongue (46) from cover (14).

24. REMOVE spring (48) and PLUG (49) from

rover (14).

15-58
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

25. REMOVE plug (50), pin (51), LEVER (52),

spring (53), and washer (54) from cover (14).

26. REMOVE BUSHING (55) from lever (52).

1. APPLY COAT of LUBRICATING OIL to

BUSHING (1).

2. INSTALL BUSHING (1) in lever (2).

3. INSTALL washer (3), spring (4), LEVER (2),

pin (5), and plug (6) in cover (7).

15-59
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

4. INSTALL spring (8) and PLUG (9) in cover

(7).

5. INSTALL LEVER (10), follower (11), shifting

tongue (12), two setscrews (13), and pin (14)
in cover (7).

6. ALINE HOLES and INSTALL PIN (15), spring

(16), and retaining ring (17) in follower (11).

15-60
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

7. INSTALL PLUG (18) and spring (19) in cover

(7).

8. INSTALL LEVER (20) and shifter FORK (21)

in cover (7) and through shifting tongue (12).

9. INSTALL FOLLOWER (22) on lever (20).

10. INSTALL two BALLS (23) in cover (7).

11. COMPLETE INSTALLATION of LEVER (20) in

cover (7).

12. INSTALL shifter FORK (24) and two

setscrews (25) on lever (20).

13. ALINE HOLES and INSTALL PIN (26) in

follower (22) and INSTALL two SETSCREWS
(27) in shifter fork (21).

15-61
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

14. INSTALL PLUG (28) and spring (29) in cover

(7).

15. INSTALL LEVER (30), shifting frame (31), and

follower (32) in cover (7).

16. INSTALL shifter FORK (33) and two

setscrews (34) on lever (30).

17. INSTALL PIN (35) in follower (32).

15-62
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

18. INSTALL PLUG (36) and spring (37) in cover

(7).

19. INSTALL LEVER (38) in cover (7) and

through shifting frame (31).

20. INSTALL two BALLS (39) in cover (7).

21. COMPLETE INSTALLATION of LEVER (38) in

cover (7).

22. ALINE HOLES and INSTALL PIN (40) in

shifting frame (31).

23. TURN ASSEMBLY OVER.

24. INSTALL PIN (41) in pressure switch port

(42).

15-63
 TM 5-2420-224-34

TRANSMISSION TOP COVER REPAIR (CONT)

25. INSTALL pressure SWITCH (43) and washer

(44).

26. INSTALL BREATHER (45) and new seal ring

(46).

27. INSTALL two BUSHINGS (47), four tee head

bolts (48), four retaining rings (49), and pin
(50).

28. REMOVE two knurled SCREWS from shift

tester plate.

29. MOUNT SHIFT TESTER PLATE on underside

of cover (7) by INSTALLING one cover
mounting BOLT (51) and two knurled
SCREWS through top of cover (7).

30. REMOVE eight SETSCREWS (13, 25, 27,

AND 34) and APPLY COAT of SEALING
COMPOUND to SETSCREWS. RE-INSTALL
eight SETSCREWS (13, 25, 27, and 34) but
DO NOT TIGHTEN setscrews.

31. TO ADJUST shift FORKS and shift FINGERS,

one setscrew must be screwed OUT and the
other setscrew screwed IN. REPEAT until
settings In following table are obtained with
eight setscrews (13, 25, 27, and 34)
tightened.

Designation Setting

A. Shift fork for 4th speed sliding sleeve on main shaft 12.539 ±0.004 in. (318.5 ±0.1 mm)
B. Shift finger 1st/2nd speed sliding sleeve on countershaft 8.878 ± in. (225.5 ±0.1 mm)
C. Shift fork for fast group (stage II) sliding sleeve on main shaft 3.258 ±0.004 in. (82.75 ±0.1 mm)
D. Shift finger for 3rd speed sliding sleeve on countershaft 2.783 ±0.004 in. (70.7 ±0.1 mm)

NOTE
Follow-on Maintenance:
Install transmission top cover
(page 3-86).

15-64
 TM 5-2420-224-34

Section Ill. TRANSMISSION ACCESS COVER REPAIR

TRANSMISSION ACCESS COVER REPAIR

This task covers: a. Disassembly b. Assembly c. Adjustment

Tools and Special Equipment: Materials/Parts (Cont):

Shop Equipment, SC 4910-95-CL-A31 Packing (2)
TOOI Kit, SC 5180-90-CL-N26
Shift Tester Plate, P/N 441 589 00 21 00 Oil, Lubricating Appendix B, Item 30

Materials/Parts: Equipment Condition:

Seal Reference Condition Description

Gasket Page 3-83 Transmission Access
Cover Removed
Packing

1. REMOVE differential SWITCH (1) and seal (2)

from access cover (3). DISCARD SEAL.

NOTE
Gasket quantity may vary, as
gaskets are used as shims.

2. REMOVE four screws (4), COVER (5), and

gasket(s) (6). DISCARD GASKET(S).

3. REMOVE PLUG (7), packing (8), and

spacer(s) (9). DISCARD PACKING.

15-65
TM 5-2420-224-34

TRANSMISSION ACCESS COVER REPAIR (CONT)

4. REMOVE pin (10) and shifting FINGER (11).

5. REMOVE PISTON (12) from access cover (3).

6. REMOVE and DISCARD two PACKINGS (13

and 14) from piston (12).

1. APPLY COAT of LUBRICATING OIL to two

new PACKINGS (1) and (2).

2. INSTALL two PACKINGS (1 and 2) on piston

(3).

15-66
 TM 5-2420-224-34

TRANSMISSION ACCESS COVER REPAIR (CONT)

3. INSTALL PISTON (3) in access cover (4).

4. INSTALL shifting FINGER (5) and pin (6) in

piston (3).

5. INSTALL PLUG (7) and new packing (8) in

access cover (4).

6. INSTALL COVER (9) and four screws (10).

7. INSTALL differential SWITCH (11) and new

seal (12) in access cover (4).

15-67
TM 5-2420-224-34

TRANSMISSION ACCESS COVER REPAIR (CONT)

1. Attach shift tester plate using two knurled

screws.

2. Check that cover and screw plug are firmly

seated.

3. Move shifting finger (1) into shift position

“engage”. Measure and determine spacer(s) (2)
on plug (3). Set dimension 2.835 ±0.004 in.
(72.0 ±0.1 mm).

4. Remove plug (3).

5. install previously determined number of

spacer(s) (2).

6. Install plug (3).

15-68
 TM 5-2420-224-34

TRANSMISSION ACCESS COVER REPAIR (CONT)

7. Move shifting finger (1) into shift position

“disengage”.

8. Measure and determine gasket(s) (4) on cover

(5). Set dimension 3.543 ±0.004 in.
(90.0 ±0.1 mm).

9. Remove four screws (6) and cover (5).

10. Install previously determined number of new

gasket(s) (4).

11. Install cover (5) and four screws (6).

12. Recheck setting dimensions.

NOTE
Follow-on Maintenance:
Install transmission access cover
(page 3-83).

15-69
TM 5-2420-224-34

Section IV. POWER TAKE-OFF (PTO) REPAIR

POWER TAKE-OFF (PTO) REPAIR

This task covers: a. Disassemble b. lnspection c. Assembly

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

TOOI Kit, SC 5180-90-CL-N26
Page 3-79 Power Take-Off (PTO)
Materials/Parts: Removed

Seal
Packing
Packing
Oil, Lubricating Appendix B, Item 30

1. REMOVE six screws (1), flange (2), and push

SWITCH (3) from Power Take-Off assembly
(4).

2. REMOVE SEAL (5) from flange (2). DISCARD

SEAL.

15-70
 TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPAIR (CONT)

3. MARK POSITION of lever (6) to housing (7).

4. REMOVE socket head screw (8) and LEVER

(6).

NOTE
Spring and ball will fall out with
removal of shaft.

5. REMOVE pin (9), SHAFT (10), spring (11),

and ball (12).

6. REMOVE two PACKINGS (13 and 14) from

shaft (10). DISCARD PACKINGS.

7. REMOVE GEAR (15) from housing (7).

15-71
TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPAIR (CONT)

8. REMOVE LOCK (16) and thrust washer (17)

from gear (15).

9. REMOVE BUSHING (18) and two retainers

and rollers (19 and 20) from gear (15).

10. REMOVE bushing (21) and selector ROD

(22).

11. REMOVE PIN (23) from selector rod (22).

15-72
 TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPAIR (CONT)

12. REMOVE ring (24), BEARING (25), and ring

(26).

13. REMOVE gear SHAFT (27).

14. USING suitable PULLER, REMOVE BEARING

(28) from housing (7).

INSPECTION
1. Inspect gear shaft for scratches or scoring.

2. Inspect gear and bearings for wear or

damage.

3. Inspect housing for cracks.

15-73
TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPAIR (CONT)

ASSEMBLY

NOTE
Apply coat of lubricating oil to
packings and seal prior to
assembly.

1. INSTALL BEARING (1) in housing (2).

2. INSTALL gear SHAFT (3).

3. INSTALL ring (4), BEARING (5), and ring (6).

15-74
 TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPAIR (CONT)

4. INSTALL PIN (7) in selector rod (8).

5. INSTALL selector ROD (8) and bushing (9) in

housing (2).

6. INSTALL two retainers and rollers (10 and 11)

and BUSHING (12) in gear (13).

7. INSTALL thrust washer (14) and LOCK (15) in

gear (13).

8. INSTALL two new PACKINGS (16 and 17) on

shaft (18).

15-75
TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPAIR (CONT)

9. INSTALL GEAR (13) in housing (2).

NOTE
Make sure pin in selector rod is
positioned properly on gear.

10. INSTALL SHAFT (18), spring (19), ball (20),

and pin (21) in housing (2).

11. USING alinement MARKS made during

Disassembly, INSTALL LEVER (22) and
socket head screw (23).

12. INSTALL new SEAL (24) in flange (25).

15-76
 TM 5-2420-224-34

POWER TAKE-OFF (PTO) REPAIR (CONT)

13. INSTALL push SWITCH (26).

14. INSTALL FLANGE (25) and six screws (27).

NOTE
Follow-on Maintenance:
Install Power Take-Off (PTO)
(page 3-79).

15-77/(15-78 Blank)
 TM 5-2420-224-34

CHAPTER 16
FRONT AND REAR AXLES REPAIR INSTRUCTIONS

OVERVIEW

This chapter contains maintenance instructions for repair of the front and rear axles. A list of sections
contained in this chapter is shown below.

Page

Section l. Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Section Il. Steering Knuckle and Front Axle Final Drive Repair . . . . . . . . . . . . . . . 16-25

Section I. AXLE REPAIR

AXLE REPAIR
This task covers: a. Disassembly b. Inspection c. Assembly

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit. SC 5180-90-CL-N26
Shop Equipment, SC- 4910-95-CL-A63 Axle Mounted on Stand
Adjusting Tool, P/N 425 589 00 21 00
Holding Device, P/N 425 589 00 31 00 General Safety Instructions:
installation Tool, P/N 406 569 03 14 00
Installing Tool, P/N 406 589 02 43 00
Installing Tool, P/N 406 589 03 43 00 WARNING
Installing Tool, P/N 441 589 06 43 00 Adhesive causes immediate
Mandrel, P/N 406 589 04 15 00
bonding on contact with eyes,
Puller, P/N 000 589 35 33 00
Puller, P/N 000 589 68 33 00 skin, or clothing and also gives
Test Device, P/N 401 589 01 25 00 off harmful vapors. Wear
Wrench, P/N 000 589 64 03 00 or protective goggles and use in
PIN W0-00640-300 well-ventilated area. If adhesive
Wrench, P/N 001 589 80 21 00 gets in eyes, try to keep eyes
open; flush eyes with water for
Materials/Parts: 15 minutes and get immediate
medical attention.
Packing
Spacer, Tube
Cord, Sealing
Ring, Seal
Packing (2)
Kit, Parts Repair
Compound, Sealing Appendix B, Item 16
Oil, Lubricating Appendix B, Item 30

16-1
TM 5-2420-224-34

AXLE REPAIR (CONT)

1. REMOVE STEERING KNUCKLE AND FRONT

AXLE FINAL DRIVE or REAR AXLE FINAL
DRIVE HUB GEARS AND AXLE SHAFT
(page 5-16 or 6-15).

NOTE
Procedure is the same for both
front and rear axles.

2. REMOVE pinion SHAFT (1).

3. REMOVE retaining ring (2), LOCK (3), and

packing (4). DISCARD PACKING.

4. INSTALL pinion SHAFT (1) in holding device.

5. USING WRENCH, REMOVE NUT (5).

16-2
 TM 5-2420-224-34

AXLE REPAIR (CONT)

CAUTION
Support bevel gear under press
to avoid dropping through and
causing damage to equipment.

6. USING suitable PRESS, REMOVE bevel

GEAR (6).

7. REMOVE ring spacer (7), bearing (8), tube

SPACER (9), washer(s) (10), and sealing cord
(11) from bearing body (12). DISCARD tube
SPACER and sealing CORD.

16-3
TM 5-2420-224-34

AXLE REPAIR (CONT)

8. USING PULLER, REMOVE BEARING (13)

from bevel gear (6).

9. USING PULLERS, REMOVE bearing RACE

(14) from bearing body (12).

16-4
 TM 5-2420-224-34

AXLE REPAIR (CONT)

10. ROTATE AXLE 90 DEGREES to vertical, with

long axle tube housing (15) up.

11. REMOVE nine bolts (16), nine nuts (17), two

screws (18), and long axle tube HOUSING
(15).

12. REMOVE FITTING (19) and seal RING (20).

DISCARD seal RING.

13. USING PULLERS, REMOVE bearing RACE

(21) and washer(s) from long axle tube
housing (15).

16-5
TM 5-2420-224-34

AXLE REPAIR (CONT)

14. REMOVE mechanical housing DIFFERENTIAL

(23) from mechanical differential housing (24).

15. USING PULLER, REMOVE BEARING (25)

from mechanical housing differential (23).

16. REPEAT STEP 15 for other bearing (26).

NOTE
To aid in assembly, mark heads of
screws to match white marks on
housing.

17. REMOVE eight screws (27), eight nuts (28),

and bevel GEAR (29).

16-6
 TM 5-2420-224-34

AXLE REPAIR (CONT)

18. REMOVE disc (30) and WHEEL (31) from bevel gear (29). DISCARD DISC and WHEEL.

19. REMOVE two half-axles (32), axle (33), four GEARS (34), and four discs (35) from housing (36).
DISCARD two HALF-AXLES, AXLE, four GEARS, and four DISCS.

20. REMOVE WHEEL (37) and disc (38) from housing (36). DISCARD WHEEL and DISC.

16-7
TM 5-2420-224-34

AXLE REPAIR (CONT)

21. IF DAMAGED, REMOVE two PLUGS (39) from mechanical differential housing (24).

22. REMOVE two screws (40) and mechanical differential HOUSING (24).

23. REMOVE spring (41), follower (42), brass bearing(s) (43), PISTON (44), packing (45) from PISTON
(44), and packing (46) from short axle tube housing (47). DISCARD PACKINGS.

16-8
 TM 5-2420-224-34

AXLE REPAIR (CONT)

24. USING PULLERS, REMOVE bearing race (48)

and SPACER(S) (49) from short axle tube
housing (47).

1. Inspect housings for galling, cracks, or

stripped threads.

2. Inspect gears for cracks or missing teeth.

3. Inspect pinion for damaged splines.

ASSEMBLY

NOTE
Procedure is the same for both
front and rear axles.

1. APPLY COAT of LUBRICATING OIL to new

PACKING (1) and INSTALL PACKING (1)
. . on
piston (2).

CAUTION
Make sure slot on piston is
alined with dowel in short axle
tube housing to prevent
damage to equipment.

2. INSTALL PISTON (2) in short axle tube

housing (3).

3. INSTALL brass bearing (4) and FOLLOWER

(5) in short axle tube housing (3).

16-9
 TM 5-2420-224-34

AXLE REPAIR (CONT)

4. INSTALL ADJUSTING TOOL to short axle tube housing (3). UNSCREW T-HANDLE on ADJUSTING
TOOL 0.4 in. (10 mm).

5. USING TEST DEVICE, CHECK differential LOCK for leaks. APPLY 42.5-70.8 psi (3-5 bar) of pressure
and HOLD for a FEW minutes. IF PRESSURE DROPS off, REPAIR LEAK by REPEATING STEPS 1
thru 3 INSTALLING new PACKINGS.

6. INSTALL new disc (6) and new WHEEL (7) in housing (8).

7. INSTALL four new discs (9), four new GEARS (10), two new half-axles (11), and new axle (12) in
housing (8).

8. INSTALL new disc (13) and new WHEEL (14) in housing (8).

16-10
 TM 5-2420-224-34

AXLE REPAIR (CONT)

CAUTION
If bevel gear is replaced, pinion
shaft must also be replaced.
Make sure serial numbers are
the same to prevent damage to
equipment.

9. INSTALL bevel GEAR (15), eight screws (16),

and eight nuts (17), observing marks on
screws. TURN HALF-AXLES (11) to accept
screws (16). TIGHTEN SCREWS to 88 Ib-ft
(120 NŽm).

NOTE
• All measurements are in mm.
• If dimension amounts to two
places, it will be necessary to
prefix dimension “A” with the
constant 74 (“A” = 74.XX).

10. CHECK DIMENSION etched on mechanical

differential HOUSING (18) and RECORD in
Table 2 (page 16-24) for A dimension.

11. CHECK DIMENSION etched on short axle

tube HOUSING (3) and RECORD in Table 2
(page 16-24) for B dimension.

16-11
 TM 5-2420-224-34

AXLE REPAIR (CONT)

12. MEASURE overall HEIGHT of large differential

BEARING (19) and RACE (20) and RECORD
in Table 2 (page 16-24) for C dimension.

13. CHECK DIMENSION etched on ring GEAR

(21) and RECORD in Table 2 (page 16-24)
for D dimension.

14. USING DIMENSIONS recorded in Table 2

(page 16-24), DETERMINE S1 ( s p a c e r
thickness) and RECORD in Table 2
(page 16-24).

NOTE
Use original spacer(s) if
dimensions are equal to original
spacers. If not, discard and
replace with new.

15. USING MANDREL and INSTALLING TOOL,

INSTALL SPACER(S) (22) (thickness
determined in step 14) and bearing race (20)
in short axle tube housing (3).

16-12
 TM 5-2420-224-34

AXLE REPAIR (CONT)

16. PLACE BEARING (19) in race (20).

17. MEASURE DISTANCE between top of

BEARING (19) and top of FLANGES on
follower (5) and RECORD in Table 2 (page
16-24) for E dimension.

18. MEASURE DISTANCE between top of bevel

GEAR (15) and contact surface of bearing
SEAT (23) and RECORD in Table 2 (page
16-24) for F dimension. ADD F and a
DIMENSIONS.

19. SUBTRACT DIMENSION F + a from E to

determine S2 (bearing thickness).

20. REMOVE FOLLOWER (5) and brass bearing

(4) from short axle tube housing (3). ADD
BEARING(S) (24) determined in step 19 AND
RE-INSTALL brass bearing (4) and
FOLLOWER (5).

16-13
TM 5-2420-224-34

AXLE REPAIR (CONT)

21. USING MANDREL and INSTALLING TOOL,

INSTALL BEARING (19).

22. USING MANDREL and INSTALLING TOOL,

INSTALL BEARING (25) half the bearing
height.

23. INSTALL mechanical differential HOUSING

(18) on short axle tube housing (3). INSTALL
two SCREWS (26), but DO NOT TIGHTEN.

16-14
 TM 5-2420-224-34

AXLE REPAIR (CONT)

24, CAREFULLY POSITION and INSTALL

mechanical housing DIFFERENTIAL (27) in
mechanical differential housing (18).

25. USING MANDREL, INSTALLATION TOOL,

and INSTALLING TOOL, INSTALL bearing
RACE (28) in long axle tube housing (29).

26. POSITION long axle tube HOUSING (29) on

mechanical differential housing (18). INSTALL
four diagonally opposite BOLTS (30) and four
nuts (31) and SLOWLY TIGHTEN to 100 Ib-ft
(135 NŽm), STEADILY TURNING ring GEAR
to PULL axle tube HOUSING (29) and
differential HOUSING (18) together.

27. AFTER TIGHTENING BOLTS (30),

CONTINUE to TURN ring GEAR while
TAPPING (with plastic-headed hammer) flange
part of long axle tube housing (29) SEVERAL
TIMES to RELIEVE any STRESSES.

28. REMOVE four bolts (30), four nuts (31), and

long axle tube HOUSING (29).

16-15
TM 5-2420-224-34

AXLE REPAIR (CONT)

29. USING PULLERS, REMOVE bearing RACE

(28) from long axle tube housing (29).

30. MEASURE DISTANCE between bottom of

BEARING (25) and bearing surface SEAT
(32). This measurement will be the S4 washer
thickness for step 33.

31. REMOVE mechanical housing DIFFERENTIAL

(27) from mechanical differential housing (18).

16-16
 TM 5-2420-224-34

AXLE REPAIR (CONT)

32. USING MANDREL and INSTALLING TOOL,

SEAT BEARING (25) on mechanical housing
differential (27).

33. USING MANDREL, INSTALLING TOOL, and

INSTALLATION TOOL, INSTALL washer(s)
(33) from step 30 and bearing RACE (28) in
long axle tube housing (29).

34. REMOVE two screws (26) and mechanical

differential HOUSING (18) from short axle
tube housing (3).

16-17
TM 5-2420-224-34

AXLE REPAIR (CONT)

35. INSTALL SPRING (34) in short axle tube

housing (3). APPLY COAT of SEALING
COMPOUND to outer mating SURFACE 01
axle tube housing.

36. INSTALL mechanical differential HOUSING

(18) and two screws (26) on short axle tube
housing (3).

37. INSTALL mechanical housing DIFFERENTIAL

(27) in mechanical differential housing (18).

38. APPLY COAT of SEALING COMPOUND to

mating SURFACES of long axle tube housing
(29) and mechanical differential housing (18).

39. POSITION long axle tube HOUSING (29) on

mechanical differential housing (18) and
INSTALL two SCREWS (35), nine BOLTS
(30), and nine NUTS (31). TIGHTEN
SCREWS to 66 Ib-ft (90 N•m) and BOLTS to
100 Ib-ft (135 N•m).

40. IF REMOVED, INSTALL two new PLUGS (36)

in mechanical differential housing (18).

16-18
 TM 5-2420-224-34

AXLE REPAIR (CONT)

41. USING MANDREL and INSTALLING TOOL,

INSTALL bearing RACE (37) in bearing body
(38).

CAUTION
Pinion shaft must have same
serial number as bevel gear to
prevent damage to equipment.

42. USING suitable PRESS, INSTALL BEARING

(39) on bevel gear (40).

43. USING suitable PRESS, INSTALL ring spacer

(41), new tube spacer (42), and bevel GEAR
and bearing (43) in bearing body (38).

16-19
TM 5-2420-224-34

AXLE REPAIR (CONT)

44. INSTALL NUT (44) on bevel gear (40).

45. INSTALL pinion SHAFT (45) in holding device.

46. USING WRENCH, TIGHTEN NUT (44) until

there is no play.

47. INSTALL ADJUSTING TOOL and WRENCH

on pinion shaft (45).

NOTE
If specified breakaway force is
exceeded, repeat steps 42 thru
47, instaIling new tube spacer.

48. TIGHTEN NUT (44) until breakaway force of

26-31 lb-in. (3.0-3.5 N•cm) is obtained.

49. REMOVE bevel GEAR (40) from holding

device and adjusting tool.

16-20
 TM 5-2420-224-34

AXLE REPAIR (CONT)

50. INSTALL new packing (46), LOCK (47), and

retaining ring (48) on bevel gear (40).

51. USING suitable INDICATOR, MEASURE

DISTANCE from base of bearing BODY (38)
and end of bevel GEAR (40) and RECORD in
Table 2 (page 16-24) for H dimension.

52. CHECK DIMENSION etched on end face of

bevel GEAR (40) and RECORD in Table 2
(page 16-24) for G dimension. ADD G and H
DIMENSIONS and RECORD in Table 2
(page 16-24).

16-21
TM 5-2420-224-34

AXLE REPAIR (CONT)

53. CHECK DIMENSION etched on top of

mechanical differential HOUSING (18) and
RECORD in Table 2 (page 16-24) for
J dimension.

NOTE
If dimension amounts to only two
places (XX), it will be necessary
to prefix this with the constant
176 (“J” = 176.XX). If dimension
x x = 00, you will require the
constant 177.

54. TO DETERMINE washer THICKNESS for

bevel gear, SUBTRACT J DIMENSION from
G + H DIMENSION in accordance with Table
2 (page 16-24).

55. INSTALL washer(s) (49) (determined in step

54), new sealing cord (50), and bevel GEAR
(40) in mechanical differential housing (18)
with oil ports to top of housing (18).

56. INSTALL new seal RING (51) and FlTTING

(52).

57. INSTALL STEERING KNUCKLE AND FRONT

AXLE FINAL DRIVE or REAR AXLE FINAL
DRIVE HUB GEARS AND AXLE SHAFT
(page 5-16 or 6-15).

16-22
 TM 5-2420-224-34

AXLE REPAIR (CONT)

Table 1. Worksheet for Spacer, Bearing, and Washer Thickness

EXPLANATIONS (dimensions in mm)

A Etched in center axle housing (1) e.g., 0.35 in. (0.90 mm)

B Stamped in axle tube at lock side (2) e.g., 1.30 in. (33.15 mm)

C Overall height of large taper roller bearing race, measured

on a surface plate e.g., 1.14 in. (29.00 mm)
D Etched in ring gear (3) e.g. 3.02 in. (76.90 mm)
E Measurement from collar of inner bearing race to upper
edge of follower, measured with depth gage e.g., 1.37 in. (34.80 mm)
F Measurement from upper claw edge of ring gear to contact
surface of bearing at ring gear e.g., 1.31 in. (33.40 mm)

G Measurement from end face of drive pinion to center of

differential etched in end face of drive pinion (4) e.g., 3.39 in. (86.15 mm)

16-23
TM 5-2420-224-34

AXLE REPAIR (CONT)

Table 1. Worksheet for Spacer, Bearing, and Washer Thickness (Cont)

H Measurement from end face of drive pinion to pinion flange;

measured with depth gage e.g., 3.62 in. (92.15 mm)

J Measurement from center of differential to flange is stamped

in top side of axle at center of axle housing (5)* e.g., 0.03 in. (0.77 mm)

K Measurement from inner bearing race to contact surface of

bearing at differential housing

Important: All readings differ from axle to axle.

* Insert the constant 176 before the measurement (e.g., 0.77 mm), and constant 177 for dimension 00.

Table 2. Formula to Determine Spacer, Bearing, and Washer Thickness

Note readings and calculate spacer, bearing, and washer thickness.

1. Spacer thickness S1 , for large taper roller bearing at lock side determines backlash and contact
pattern together with washer thickness S 3 .

S 1 =(A+B)-(C+D) A = C = (A + B) =

+ B = + D = -(C+ D)=
(A + B) = (C + D) = S1 =

2. Bearing thickness S2 between piston and differential lock determines claw play (a) of differential lock
at off position.

S 2 =E-(F+a) E = F=

-( F + a) = + a = (a = claw play 0.001 in.

S2 = F + a = ±0.007 in. (0.5 ±0.2 mm))

3. Bearing thickness S3 at flange of dirve pinion dearing determines amount by which dirve pinion
engages ring gear.

S 3 =(G+H)-J G = (G + H)=
+ H = - J =
(G + H)= S3=s.

4. W a s h e r t h i c k n e s s S4 at small taper roller bearing for front and rear axles S 4 = K.

16-24
 TM 5-2420-224-34

Section Il. STEERING KNUCKLE AND FRONT AXLE

FINAL DRIVE REPAIR

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 9-214
TooI Kit, SC 5180-90-CL-N26
Shop Equipment, SC 4910-95-CL-A63 Equipment Condition:
Installing Tool, P/N 38758901 1500
Installation Tool, P/N 38758902 1500 Reference Condition description
Installing Tool, P/N 42458901 4300
Installing Tool, P/N 406589034300 Page 5-16 Steering Knuckle and
Mandrel, P/N 40658904 1500 Front Axle Final Drive
Removed
Materials/Parts:
General Safety Instructions:
Seal
Ring, Spacer
WARNING
Seal Adhesive causes immediate
bonding on contact with eyes,
Bearing skin, or clothing and also gives
Compound, Sealing Appendix B, Item 16 off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

DISASSEMBLY

NOTE
Procedure is the same for both
sides of axle.

1. REMOVE 11 screws (1), bracket (2), and

HOUSING (3).

16-25
TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPAIR (CONT)

2. REMOVE retaining ring (4) and any

WASHER(S) (5) from yoke (6). DISCARD
WASHER(S), if present (no longer required).

CAUTION
Support yoke to prevent
dropping and causing damage
to equipment.

3. USING suitable PRESS, REMOVE YOKE (6).

16-26
 TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPAIR (CONT)

4. USING suitable PULLER, REMOVE bearing

(7), washer(s) (8), and SEAL (9). DISCARD
SEAL.

CAUTION
Support yoke to prevent
dropping and causing damage
to equipment.

5. USING suitable PRESS, REMOVE spacer

RING (10) from yoke (6). DISCARD spacer
RING.

6. REMOVE retaining ring (11) and SPACER

(12) from gear (13).

16-27
TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPAIR (CONT)

7. USING suitable PRESS, REMOVE GEAR

(13), seal (14), and bearing (15). DISCARD
SEAL and BEARING.

8. USING INSTALLING TOOL, REMOVE

BEARING (16).

9. USING suitable PULLER, REMOVE BEARING

(17).

1. Inspect housings for galling, cracks, or

stripped threads.

2. Inspect gears for cracks or missing teeth.

3. Inspect bearings (TM 9-214).

16-28
 TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPAIR (CONT)

NOTE
Procedure is the same for both
sides of axle.

1. USING MANDREL, INSTALL BEARING (1).

2. USING suitable PRESS, INSTALL bearing (2)

and GEAR (3).

3. INSTALL SPACER (4) and retaining ring (5)

on gear (3).

4. TURN ASSEMBLY OVER.

16-29
TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPAIR (CONT)

5. USING INSTALLING TOOL and MANDREL,

INSTALL new BEARING (6). DISCARD plastic
roller RETAINER.

6. USING INSTALLING TOOL and MANDREL in

step 5, INSTALL new SEAL (7).

7. USING INSTALLING TOOL and MANDREL,

INSTALL new SEAL (8).

8. MEASURE and RECORD DIMENSION A for

bearing (9).

9. MEASURE and RECORD DIMENSIONS B

and C.

10. ADD B and C.

11. SUBTRACT TOTAL of B and C in STEP 10

from dimension A in STEP 8 to determine
washer thickness.

16-30
 TM 5-2420-224-34

STEERING KNUCKLE AND FRONT AXLE FINAL DRIVE REPAIR (CONT)

WARNING
Spacer ring will be hot enough
to burn you on contact. Wear
heat-resistant gloves when
handling hot ring.

12. HEAT new spacer RING (10) to 195°F

(90* C).

13. INSTALL spacer RING (10) on yoke (11),

14. INSTALL WASHER(S) (12) determined in step

11.

15. USING suitable PRESS and MANDREL,

INSTALL BEARING (9), gear (13), and yoke
(11).

16. INSTALL retaining RING (14).

17. APPLY COAT of SEALING COMPOUND to

mating SURFACE of housing (15) and
INSTALL HOUSING (15), bracket (16), and 11
screws (17). TIGHTEN SCREWS evenly to
66-73 Ib-ft (90-100 N•m).

NOTE
Follow-on Maintenance:
Install steering knuckle and front
axle final drive (page 5-16).

16-31/(16-32 Blank)
 TM 5-2420-224-34

CHAPTER 17
BRAKE SYSTEM AND TIRES REPAIR INSTRUCTIONS

This chapter contains maintenance instructions for repair of the brake system and tires. A list of sections
contained in’ this chapter is shown below.

Page

Section I. Brake Disc Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

Section Il. Front and Rear Brake Calipers Repair . . . . . . . . . . . . . . . . . . . . . 17-3

Section III. Brake Master Cylinder Repair... . . . . . . . . . . . . . . . . . . . . . . . 17-17

Section IV. Brake Pressure Regulator (ALB Valve) Repair . . . . . . . . . . . . . . . . . 17-22

Section V. Air Brake Booster Repair, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-24

Section VI. Fluid Regulating Valve Repair... . . . . . . . . . . . . . . . . . . . . . . . 17-28

Section VIl. Antifreeze Device Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-39

Section VIII. Tandem Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44

Section IX. Tire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-48

Section I. BRAKE DISC REPAIR

BRAKE DISC REPAIR

This task covers: Repair

Tools
Shop Equipment, SC 4910-95-CL-A31

References:
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Brake Disc and Hub
Removed

17-1
TM 5-2420-224-34

BRAKE DISC REPAIR (CON’T)

NOTE
Procedure is the same for all
brake discs.

1. Measure thickness of disc (1) at deepest

groove on each side. If either of these
measurements or combination of both is less
than minimum allowable thickness, reject disc
(l). Minimum allowable thickness is stamped
on inside surface of disc (1).

2. If thickness of disc (1) is greater than

minimum allowable, machine disc (1) evenly
on both sides to minimum thickness allowed.

NOTE
Follow-on Maintenance:
Install brake disc and hub (TM 5-
2420-224-20).

17-2
 TM 5-2420-224-34

Section Il. FRONT AND REAR BRAKE CALIPERS REPAIR

This section illustrates and describes procedures for repair of the front and rear brake calipers. A list of
tasks contained in this section is shown below.

Page

Front Brake Caliper Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3

Rear Brake Caliper Repair... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7

FRONT BRAKE CALlPER REPAIR

This task covers: a. Disassembly b. Assembly

Tools and Special Equipment: General Safety Instructions:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit; SC 5180-90-CL-N26
WARNING
Holder, P/N 406 589 04 31 00
Installation Tool, P/N 406 589 09 43 00 Adhesive causes immediate
Installation Tool, P/N 000 589 00 40 00 bonding on contact with eyes,
Installation Tool, P/N 406 589 09 43 00 skin, or clothing and also gives
off harmful vapors. Wear
Materials/Parts: protective goggles and use in
well-ventilated area. If adhesive
Kit
gets in eyes, try to keep eyes
References: open; flush eyes with water for
15 minutes and get immediate
TM 5-2420-224-20 medical attention.

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Front Brake Calipers
Removed

NOTE
Procedure is the same for all four
front brake calipers.

1. REMOVE and DISCARD two CAPS (1 and 2).

17-3
TM 5-2420-224-34

FRONT BRAKE CALlPER REPAIR (CONT)

2. INSTALL brake CALlPER (3) on holder.

WARNING
Place small block of wood
between pistons during removal
to prevent injury to personnel.

3. USING regulated AIR SUPPLY of 5 psi

(34.5 kPa) APPLIED into brake LINE
connecting point, REMOVE PISTON (4).

4. INSTALL INSTALLATION TOOLS over open

side of brake caliper (3).

5. USING regulated AIR SUPPLY of 5 psi

(34.5 kPa) APPLIED into brake LINE
connecting point, REMOVE PISTON (5).

6. IF DAMAGED, REMOVE bleeder VALVE (6).

7. REMOVE four SCREWS (7).

17-4
 TM 5-2420-224-34

FRONT BRAKE CALlPER REPAIR (CONT)

8. REMOVE and DISCARD two PACKINGS (8).

9. REMOVE and DISCARD two PACKINGS (9).

NOTE
Procedure is the same for all four
front brake calipers.

1. APPLY COAT of SILICONE (in Kit), to two

new PACKINGS (1) and BORES (2) and
INSTALL two PACKINGS (1).

2. INSTALL two new PACKINGS (3).

3. INSTALL four SCREWS (4) and TIGHTEN to

55-61 Ib-ft (75-83 N•m).

4. IF REMOVED, INSTALL new bleeder VALVE

(5),

5. INSTALL brake CALIPER (6) on holder.

17-5
TM 5-2420-224-34

FRONT BRAKE CALlPER REPAIR (CONT)

6. USING INSTALLATION TOOLS, INSTALL

PISTON (7) in brake caliper (6) up to groove
on piston (7).

7. REPEAT STEP 6 for piston (8).

8. APPLY COAT of SILICONE (in Kit) to two

new CAPS (9 and 10) and INSTALL in brake
caliper (6) and groove on pistons (7 and 8).

NOTE
Follow-on Maintenance:
Install front brake calipers (TM 5-
2420-224-20).
Bleed brake system (TM-5-2420-
224-20).

17-6
 TM 5-2420-224-34

REAR BRAKE CALIPER REPAIR

This task covers: a. Disassembly b. Assembly

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Bushing, P/N 406 589 04 14 00 Equipment Condition:
Bushing P/N 406 589 13 43 00
Holder, P/N 406 589 04 31 00 Reference Condition Description
Installation Tool, P/N 000 589 52 43 00
Installation Tool. P/N 000 589 00 40 00 TM 5-2420-224-20 Rear Brake Calipers
Installation Tool; P/N 406 589 11 43 00 Removed
Installation Tool, P/N 406 589 08 43 00
Installing Tool, P/N 406 589 12 43 00 General Safety Instructions:
Wrench, P/N 001 589 70 09 00

Materials/Parts: WARNING
Fuel and oil are slippery and
Nut, Lock
can cause falls. To avoid
Kit injury, wipe up spilled fuel or
oil with rags.
Kit
Kit
Kit
Rags Appendix B, Item 40

NOTE
Procedure is the same for both
rear brake calipers except as
noted.

1. INSTALL brake CALIPER (1) on holder.

17-7
TM 5-2420-224-34

REAR BRAKE CALlPER REPAIR (CONT)

2. REMOVE PLUG (2), seal ring (3), and lock

nut (4). DISCARD seal RING and lock NUT.

3. TO REMOVE two CAPS (5 and 6) on LEFT

caliper, TURN adjusting SHAFT (7) and
adjusting PIN (8) to LEFT until two pistons (9
and 10) are fully drawn in. REMOVE and
DISCARD two CAPS (5 and 6).

4. TO REMOVE two CAPS (5 and 6) on RIGHT

caliper, TURN adjusting SHAFT (7) and
adjusting PIN (8) to RIGHT until two pistons
(9 and 10) are fully drawn in. REMOVE and
DISCARD two CAPS (5 and 6).

5. REMOVE two PISTONS (9 and 10) by

REVERSING either STEP 3 or 4 depending
on which caliper is being disassembled.

6. IF DAMAGED, REMOVE bleeder VALVE (11).

17-8
 TM 5-2420-224-34

REAR BRAKE CALIPER REPAIR (CONT)

7. ON LEFT CALlPER, REMOVE nut (12),

retaining ring (13), adjusting PIN (8), and
packing (14). DISCARD PACKING.

8. REMOVE lock ring (15), shim (16), adjusting

SHAFT (7), and packing (17). DISCARD
PACKING.

9. USING WRENCH, REMOVE four SCREWS

(18).

17-9
 TM 5-2420-224-34

REAR BRAKE CALlPER REPAIR (CONT)

10. REMOVE and DISCARD four PACKINGS (19 and 20)

WARNING
Parts are under spring tension. Wear safety goggles and clear area of
unnecessary personnel. Failure to do so could result in injury to personnel.

11. USING BUSHING, REMOVE retaining ring (21), spring seat (22), spring (23), adjusting gear (24),
packing (25), seal (26), and ADJUSTER (27). DISCARD PACKING and SEAL.

17-10
 TM 5-2420-224-34

REAR BRAKE CALlPER REPAIR (CONT)

12. USING 0.39-in. (10-mm) DRILL, DRILL HOLE

into center of sealing washer (28). PRY
sealing WASHER out USING PUNCH.
DISCARD sealing WASHER.

13. REMOVE retaining ring (29), washer (30), and

LEVER (31).

14. REMOVE and DISCARD SEAL (32).

17-11
TM 5-2420-224-34

REAR BRAKE CALIPER REPAIR (CONT)

NOTE
Procedure is the same for both
rear brake calipers except as
noted.

1. USING INSTALLING TOOLS, INSTALL new

SEAL (1).

2. APPLY COAT of OIL (in Kit) to SHAFT of

lever (2) and INSTALL LEVER (2), washer
(3), and retaining ring (4).

17-12
 TM 5-2420-224-34

REAR BRAKE CALlPER REPAIR (CONT)

3. INSTALL ADJUSTER (5), new seal (6), new packing (7), adjusting gear (8), spring (9), spring seat
(10), and retaining ring (11).

4. INSTALL new packing (12), adjusting SHAFT (13), shim (14), and lock ring (15).

17-13
TM 5-2420-224-34

REAR BRAKE CALlPER REPAIR (CONT)

5. FILL CAVITY with oil (in Kit).

6. USING INSTALLING TOOL and hydraulic

PRESS, INSTALL new sealing WASHER (16).

7. INSTALL four new PACKINGS (17 and 18).

17-14
 TM 5-2420-224-34

REAR BRAKE CALlPER REPAIR (CONT)

8. INSTALL brake caliper HALF (19) on holder.

9. INSTALL brake caliper HALF (20) and four

screws (21). USING WRENCH, TIGHTEN
SCREWS to 206 Ib-ft (280 N•m).

10. ON LEFT CALIPER assembly, INSTALL new

packing (22), adjusting PIN (23), retaining ring
(24), and nut (25).

17-15
TM 5-2420-224-34

REAR BRAKE CALlPER REPAIR (CONT)

11. IF REMOVED, INSTALL new bleeder VALVE

(26).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

12. APPLY COAT of SILICONE (in Kit) to two

PISTONS (27 and 28) and INSIDE of brake
caliper.

13. INSTALL two PISTONS (27 and 28) on

adjusting pin (23) and adjusting shaft (13) on
left caliper assembly, or on right caliper
assembly, and RETRACT two PISTONS (27
and 28) to groove on pistons.

14. INSTALL two new CAPS (29 and 30).

15. USING INSTALLATION TOOLS, PUSH two

PISTONS (27 and 28) into caliper until flush.

16. INSTALL new seal ring (31), PLUG (32), and

new lock nut (33).

NOTE
Follow-on Maintenance:
Install rear brake calipers (TM 5-
2420-224-20).
Adjust parking brakes (TM 5-
2420-224-20).

17-16
 TM 5-2420-224-34

Section Ill. BRAKE MASTER CYLINDER REPAIR

BRAKE MASTER CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Kit, Parts Repair
TM 5-2420-224-20 Brake Master Cylinder
Removed

1. REMOVE and DISCARD lock RING (1) and

stop RING (2).

2. REMOVE PISTON (3).

3. REMOVE wiper (4), sleeve (5), seal (6), and

DISC (7) from piston (3). DISCARD WIPER,
SLEEVE, SEAL, and DISC.

17-17
TM 5-2420-224-34

BRAKE MASTER CYLINDER REPAIR (CONT)

4. REMOVE BOLT (8) and seal ring (9).

DISCARD seal RING.

5. USING regulated AIR SUPPLY of 5 psi

(34.5 kPa), REMOVE PISTON (10) and stop
(11).

6. REMOVE backup ring (12), disc SEAL (13),

and two seals (14) from piston (10).
DISCARD backup RING, disc SEAL, and
SEALS.

7. REMOVE stop ROD (15) from stop (11).

17-18
 TM 5-2420-224-34

BRAKE MASTER CYLINDER REPAIR (CONT)

8. IF DAMAGED, REMOVE two bleeder VALVES

(16) and two protective CAPS (17).

9. REMOVE two ELBOWS (18) and two

bushings (19).

1. INSTALL two bushings (1) and two ELBOWS

(2).

2. IF REMOVED, INSTALL two new bleeder

VALVES (3) and two new protective CAPS
(4).

3. INSTALL stop ROD (5) in stop (6).

17-19
 TM 5-2420-224-34

BRAKE MASTER CYLINDER REPAIR (CONT)

4. INSTALL two new seals (7), new disc SEAL

(8), and new backup ring (9) on piston (10).

5. INSTALL stop (6) and PISTON (10).

NOTE
Piston and stop must be all the
way into master cylinder housing
prior to performing step 6.

6. INSTALL new seal ring (11) and BOLT (12).

17-20
 TM 5-2420-224-34

BRAKE MASTER CYLINDER REPAIR (CONT)

7. INSTALL new seal (13), new sleeve (14), new

wiper (15), and new DISC (16) on piston (17).

8. INSTALL PISTON (17).

9. INSTALL new stop RING (18) and new lock

RING (19).

NOTE
Follow-on Maintenance:
Install brake master cylinder
(TM 5-2420-224-20).

17-21
TM 5-2420-224-34

Section IV. BRAKE PRESSURE REGULATOR (ALB VALVE) REPAIR

BRAKE PRESSURE REGULATOR (ALB VALVE) REPAIR

This task covers: a. Disassembly b. Repair c. Assembly

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20

Tool Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Kit, Repair
Page 7-1 Brake Pressure Regulator
(ALB Valve) Removed

1. REMOVE two capscrews (1), holder (2),

washer (3), spring (4), and LEVER (5).

2. REMOVE retaining ring (6) and protective

CAP (7).

3. REMOVE BOLT assembly (8).

4. PRESS down PISTON (9) and REMOVE

CIRCLIP (10).

5. REMOVE PISTON (9), grooved ring (11), and

spring (12).

6. REMOVE PLUG (13) and sealing ring (14).

DISCARD sealing RING.

7. INSTALL air HOSE in lower hole (15) on ALB

valve (16). APPLY APPROXIMATELY 5 psi
(34.5 kPa) and REMOVE PISTON (17).

8. REMOVE PACKING (18) from piston (17).

DISCARD PACKING.

9. REMOVE PISTON assembly (19) from ALB

valve (16).

10. REMOVE protective CAP (20) from vent

screw (21).

11. IF DAMAGED, REMOVE lock NUT (22) and

adjusting SCREW (23).

17-22
 TM 5-2420-224-34

BRAKE PRESSURE REGULATOR (ALB VALVE) REPAIR (CONT)

If any parts not found in Repair Kit are damaged or defective, replace ALB valve.

1. INSTALL protective CAP (20) on vent screw (21).

2. INSTALL PISTON assembly (19).

3. INSTALL new packing (18) and PISTON (17).

4. INSTALL new sealing ring (14) and PLUG (13).

5. INSTALL spring (12), grooved ring (11), and PISTON (9).

6. PRESS down PISTON (9) and INSTALL CIRCLIP (10).

7. INSTALL BOLT assembly (8).

8. INSTALL protective CAP (7) and retaining ring (6).

9. INSTALL LEVER (5), spring (4), washer (3), holder (2), and two capscrews (1) on ALB valve (16).

10. IF REMOVED, INSTALL new adjusting SCREW (23) and new lock NUT (22).

NOTE
Follow-on Maintenance:
Install brake pressure regulator (ALB valve) (page 7-1).
Bleed brake system (TM 5-2420-224-20).
Adjust brake pressure regulator (ALB valve) (page 7-5).

17-23
TM 5-2420-224-34

Section V. AIR BRAKE BOOSTER REPAIR

AIR BRAKE BOOSTER REPAIR

This task covers: a. Disassembly b. Assembly

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
TM 5-2420-224-20 Air Brake Booster
Materials/Parts: Removed
Kit, Parts

References:
TM 5-2420-224-20

DISASSEMBLY

1. REMOVE retaining ring (1), thrust piece (2),

packing (3), and SPRING (4). DISCARD
retaining RING, PACKING, and SPRING.

2. REMOVE and DISCARD VALVE (5).

3. REMOVE SCREW (6) and washer (7).

17-24
 TM 5-2420-224-34

AIR BRAKE BOOSTER REPAIR (CONT)

WARNING
To prevent personnel injury,
use extreme care during
removal of flange because of
pressure of spring in case.

4. REMOVE FLANGE (8) and retaining wire (9)

by turning flange (8) to left.

5. REMOVE spring (10) and CASE (11).

6. SEPARATE two HOUSINGS (12 and 13) by

PULLING them apart.

7. REMOVE and DISCARD five PACKINGS (14,

15, 16, 17, and 18).

8. REMOVE and DISCARD RING (19).

17-25
TM 5-2420-224-34

AIR BRAKE BOOSTER REPAIR (CONT)

9. REMOVE two retaining rings (20) and two

VALVES (21). DISCARD VALVES.

1. INSTALL two new VALVES (1) and two

retaining rings (2) in flange (3).

2. INSTALL new RING (4).

3. INSTALL five new PACKINGS (5, 6, 7, 8, and

9).

4. INSTALL HOUSING (10) in housing (11).

17-26
 TM 5-2420-224-34

AIR BRAKE BOOSTER REPAIR (CONT)

5. INSTALL CASE (12) and spring (13).

6. INSTALL FLANGE (3) in case (12) and line

up hole in flange (3) with hole in case (12).
INSTALL end of retaining WIRE (14) in hole
of flange (3) and ROTATE FLANGE (3) to
right until retaining wire (14) is completely
installed.

7. INSTALL SCREW (15) and washer (16).

8. INSTALL new VALVE (17).

9. INSTALL new SPRING (18), new packing (19),

thrust piece (20), and new retaining ring (21).

NOTE
Follow-on Maintenance:
Install air brake booster (TM 5-
2420-224-20).

17-27
TM 5-2420-224-34

Section VI. FLUID REGULATION VALVE REPAIR

This section illustrates and describes procedures for repair of the fluid regulating valve. A list of tasks
contained in this section is shown below.

Page

Fluid Regulating Valve Repair (P/N 0 481 039 202) . . . . . . . . . . . . . . . . . . . . . 17-28

Fluid Regulating Valve Repair (P/N 975 303 447 0) . . . . . . . . . . . . . . . . . . . . . 17-35

FLUID REGULATING VALVE (P/N 0 481 039 202) REPAIR

This task covers: a. Disassemble b. Assembly

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TooI Kit, SC 5180-90CL-N26
TM 5-2420-224-20 Fluid Regulating Valve
Materials/Parts: Removed
Kit, Parts

References:
TM 5-2420-224-20

1. PLACE fluid regulating VALVE (1) in

soft-jawed VISE, as shown, and REMOVE
four SCREWS (2).

17-28
 TM 5-2420-224-34

FLUID REGULATING VALVE (P/N 0 481 039 202) REPAIR (CONT)

WARNING
Cover is under spring pressure.
Wear safety goggles. Pressure
must be relieved slowly. Failure
to do so could cause cover to
fly off resulting in injury to
personnel.

2. OPEN VISE SLOWLY and REMOVE

regulating valve HOUSING (3) and cover (4)
from vise.

3. REMOVE spring seat (5), spring (6), and

DIAPHRAGM assembly (7) from regulating
valve housing (3).

4. REMOVE nut (8), plate washer (9),

DIAPHRAGM (10), plate washer (11), spring
(12), and cup seal (13) from screw (14).
DISCARD DIAPHRAGM and cup SEAL.

17-29
TM 5-2420-224-34

FLUID REGULATING VALVE (P/N O 481 039 202) REPAIR (CONT)

5. REMOVE disc (15), spring (16), and valve

CONE (17) from regulating valve housing (3).
DISCARD valve CONE.

6. PLACE regulating valve HOUSING (3) in

soft-jawed VISE, as shown, and REMOVE
retaining RING (18).

17-30
 TM 5-2420-224-34

FLUID REGULATING VALVE (P/N O 481 039 202) REPAIR (CONT)

WARNING
Vent housing is under spring pressure. Wear safety goggles. Pressure must be
relieved slowly. Failure to do so could cause housing to fly off resulting in injury
to personnel.

7. OPEN VISE SLOWLY and REMOVE regulating valve HOUSING (3), vent housing (19), spring (20),
piston valve (21), ring (22), packing (23), filter screen (24), and filter (25). DISCARD PACKING.

8. REMOVE and DISCARD PACKING (26) from piston valve (21).

9. REMOVE cap (27), fitting (28), seal ring (29), tappet (30), PISTON (31), valve plate (32), and spring
(33) from regulating valve housing (3). DISCARD seal RING and valve PLATE.

10. REMOVE and DISCARD PACKING (34) from tappet (30).

17-31
TM 5-2420-224-34

FLUID REGULATING VALVE (P/N O 481039 202) REPAIR (CONT)

ASSEMBLY

1. INSTALL new PACKING (1) on tappet (2).

2. INSTALL spring (3), new valve plate (4), PISTON (5), tappet (2), new seal ring (6), fitting (7), and cap
(8) in regulating valve housing (9).

3. INSTALL new PACKING (10) on piston valve (11).

4. INSTALL filter (12), filter screen (13), new packing (14), ring (15), piston valve (11), spring (16), and
vent HOUSING (17) in regulating valve housing (9).

17-32
 TM 5-2420-224-34

FLUID REGULATING VALVE (P/N 0 481 039 202) REPAIR (CONT)

5. PLACE regulating valve HOUSING (9) in

soft-jawed VISE, as shown. COMPRESS
SPRING (16) and INSTALL retaining RING
(18).

6. OPEN VISE SLOWLY and REMOVE

regulating valve HOUSING (9) from vise.

7. INSTALL new valve CONE (19), spring (20),

and disc (21) in regulating valve housing (9).

17-33
TM 5-2420-224-34

FLUID REGULATING VALVE (P/N 0 481 039 202) REPAIR (CONT)

NOTE
Plate washers should face
diaphragm, as shown.

8. INSTALL new cup seal (22), spring (23), plate

washer (24), new DIAPHRAGM (25), plate
washer (26), and nut (27) on screw (28).

9. INSTALL DIAPHRAGM assembly (29), spring

(30), spring seat (31), and cover (32) on
regulating valve housing (9).

10. PLACE regulating valve HOUSING (9) in

soft-jawed VISE, COMPRESS SPRING (30),
and INSTALL four SCREWS (33).

11. REMOVE fluid regulating VALVE (34) from

vise.

NOTE
Follow-on Maintenance:
Install fluid regulating valve (TM 5-
2420-224-20).

17-34
 TM 5-2420-224-34

FLUID REGULATING VALVE (P/N 975 303 447 0) REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP
Tools and Special Equipment: References:
Tool Kit, SC 5180-90-CL-N26 TM 5-2420-224-20

Materials/Parts Equipment Condition:

Kit, Parts Reference Condition Description
TM 5-2420-224-20 Fluid Regulating Valve
Removed

WARNING
Cover is under spring pressure.
Wear safety goggles. Pressure
must be relieved slowly. Failure
to do so could cause cover to
fly off resulting in injury to
personnel.

1. REMOVE four screws (1) and COVER (2)

from regulating valve housing (3).

2. REMOVE cap (4), SPRING (5), cap (6), nut

(7), and packing (8) from cover (2). DISCARD
PACKING.

3. REMOVE DIAPHRAGM assembly (9) from

regulating valve housing (3).

4. REMOVE circlip (10), cap (11), DIAPHRAGM

(12), cap (13), spring (14), and valve CONE
(15) from piston (16). DISCARD DIAPHRAGM
and valve CONE.

17-35
TM 5-2420-224-34

FLUID REGULATING VALVE (P/N 975 303 447 0) REPAIR (CONT)

5. REMOVE and DISCARD SPRING (17) and VALVE (18).

6. IF DAMAGED, REMOVE PLUG (19) and GASKET (20).

7. PLACE regulating valve HOUSING (3) in soft-jawed VISE, as shown, and REMOVE retaining RING (21).

WARNING
Vent housing is under spring pressure. Wear safety goggles. Pressure must be
relieved slowly. Failure to do so could cause housing to fly off resulting in injury
to personnel.

8. OPEN VISE SLOWLY and REMOVE regulating valve HOUSING (3), housing (22), packing (23), cap
(24), spring (25), shims (26), piston (27), and valve (28). DISCARD PACKING and VALVE.

9. REMOVE and DISCARD PACKING (29) from piston (27).

10. REMOVE protective cap (30), adapter (31), gasket (32), PLUNGER (33), valve (34), spring (35), cap
(36), and filter (37) from regulating valve housing (3). DISCARD VALVE and FILTER.

17-36
 TM 5-2420-224-34

FLUID REGULATING VALVE (P/N 975 303 447 0) REPAIR (CONT)

ASSEMBLY

1. INSTALL new filter (1), cap (2), spring (3), new valve (4), PLUNGER (5), gasket (6), adapter (7), and
protective cap (8) in regulating valve housing (9).

2. INSTALL new PACKING (10) on piston (11).

3. INSTALL new valve (12), piston (11), shims (13), spring (14), cap (15), new packing (16), and
HOUSING (17) in regulating valve housing (9).

4. PLACE regulating valve HOUSING (9) in soft-jawed VISE, as shown. COMPRESS SPRING (14) and
INSTALL retaining RING (18).

17-37
TM 5-2420-224-34

FLUID REGULATING VALVE (P/N 975 303 447 0) REPAIR (CONT)

5. OPEN VISE SLOWLY and REMOVE

regulating valve HOUSING (9) from vise.

6. IF REMOVED, INSTALL new GASKET (19)

and new PLUG (20) in regulating valve
housing (9).

7. INSTALL new VALVE (21) and new spring

(22) in regulating valve housing (9).

8. INSTALL new valve CONE (23), spring (24),

cap (25), new DIAPHRAGM (26), cap (27),
and circlip (28) on piston (29).

9. INSTALL DIAPHRAGM assembly (30) in

regulating valve housing (9).

10. INSTALL new packing (31 ), nut (32), cap (33),

SPRING (34), and cap (35) in cover (36).

11. INSTALL COVER (36) and four screws (37)

on regulating valve housing (9).

NOTE
Follow-on Maintenance:
Install fluid regulating valve (TM 5-
2420-224-20).

17-38
 TM 5-2420-224-34

Section VII. ANTIFREEZE DEVICE REPAIR

OVERVIEW
This section illustrates and describes procedures for repair of the antifreeze device. A list of tasks
contained in this section is shown below.

Page

Antifreeze Device (P/N 000 431 57-15 BI.1) Repair . . . . . . . . . . . . . . . . . . . . . 17-39

Antifreeze Device (P/N 932 002 000 0) Repair . . . . . . . . . . . . . . . . . . . . . . . . 17-42

ANTIFREEZE DEVICE (P/N 000 431 57 15 BI.1) REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Tools and Special Equipment:

Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26

Materials/Parts:
Kit, Repair
Compound, Sealing Appendix B, Item 15
Oil, Lubricating Appendix B, Item 30

References:
TM 5-2420-224-20

Equipment Condition:

Reference Condition Description

TM 5-2420-224-20 Antifreeze Device
Removed

17-39
TM 5-2420-224-34

ANTIFREEZE DEVICE (P/N 000 431 57 15 BI.1) REPAIR (CONT)

17-40
 TM 5-2420-224-34

ANTIFREEZE DEVICE (P/N 000431 5715 BI.1) REPAIR (CONT)

DISASSEMBLY

1. REMOVE and DISCARD SCREEN (1) from antifreeze pump (2).

2. REMOVE retaining ring (3), seat (4), PISTON (5), and spring (6). DISCARD retaining RING and SPRING.
3. REMOVE and DISCARD two backing RINGS (7) and four PACKINGS (8).
4. REMOVE four SCREWS (9) and four washers (10).
5. REMOVE HOUSING (11).
6. REMOVE spring (12), spring COVER (13), valve cone (14), and gasket (15). DISCARD SPRING, valve
CONE, and GASKET. -
7. REMOVE screw (16), PLATE (17), two screws (18), and COVER (19).
8. ROTATE KNOB (20) 1/4 turn and REMOVE.
9. REMOVE and DISCARD three KEEPERS (21).
10. REMOVE INSERT (22).

1. INSTALL INSERT (22) in antifreeze pump (2).

2. INSTALL three new KEEPERS (21) in knob (20).
3. INSTALL KNOB (20) on antifreeze pump (2) and ROTATE KNOB (20) 1/4 turn.
4. INSTALL COVER (19), two screws (18), PLATE (17), and screw (16) on knob (20).
5. INSTALL new spring (12), spring COVER (13), and new valve cone (14).
6. INSTALL new gasket (15) and HOUSING (11).

WARNING
Adhesive causes immediate bonding on contact with eyes, skin, or clothing and
also gives off harmful vapors. Wear protective goggles and use in
well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush eyes
with water for 15 minutes and get immediate medical attention.

7. APPLY COAT of SEALING COMPOUND to four WASHERS (10) and four SCREWS (9) and INSTALL
four washers (10) and four SCREWS (9).
8. INSTALL four new PACKINGS (8) and two new backing rings (7).
9. APPLY light COAT of LUBRICATING OIL to four PACKINGS (8) and two backing RINGS (7) to aid in
piston installation.
10. INSTALL new spring (6), PISTON (5), seat (4), and new retaining ring (3).
11. INSTALL new SCREEN (1) on antifreeze pump (2).

NOTE
Follow-on Maintenance:
Install antifreeze device (TM 5-2420-224-20).

17-41
TM 5-2420-224-34

ANTIFREEZE DEVICE (P/N 932 002 000 0) REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20

TOOI Kit, SC 5180-90-CL-N26
Equipment Condition:
MateriaIs/Parts:
Reference Condition Description
Kit, Repair
TM 5-2420-224-20 Antifreeze Device
Compound, Sealing Appendix B, Item 15 Removed
Oil, Lubricating Appendix B, Item 30

17-42
 TM 5-2420-224-34

ANTIFREEZE DEVICE (P/N 932 002 000 0) REPAIR (CONT)

WARNING
Membrane cover is under tension. Wear safety goggles. Remove cover
carefully. Failure to do so could result in injury to personnel.

1. REMOVE four socket head screws (l), four washers (2), and membrane COVER (3). DISCARD WASHERS.

2. REMOVE membrane (4), POPPET (5), backing ring (6), packing (7), spring (8), and packing (9).
DISCARD MEMBRANE, backing RING, PACKINGS, and SPRING.

3. REMOVE rollpin (10), KNOB (11), and two packings (12). DISCARD ROLLPIN and PACKINGS.

4. REMOVE retaining ring (13), COVER (14), and packing (15). DISCARD retaining RING and PACKING.

5. REMOVE spring cover (16), spring (17), and VALVE (18). DISCARD SPRING and VALVE.

6. REMOVE and DISCARD keeper (19) and SCREEN (20).

ASSEMBLY

1. INSTALL new SCREEN (20) and new keeper (19).

2. INSTALL new VALVE (18), new spring (17), and spring cover (16).

3. APPLY COAT of LUBRICATING OIL to new PACKING (15) and INSTALL packing (15), COVER (14),
and new retaining ring (13).

4. APPLY COAT of LUBRICATING OIL to two new PACKINGS (12) and INSTALL two packings (12),
KNOB (11), and new rollpin (10).

5. APPLY COAT of LUBRICATING OIL to new PACKING (9) and new PACKING (7) and INSTALL packing
(9), new Spring (8), packing (7), new backing ring (6), POPPET (5), and new membrane (4).
6. INSTALL membrane COVER (3) and four new washers (2).

WARNING
Adhesive causes immediate bonding on contact with eyes, skin, or clothing and
also gives off harmful vapors. Wear protective goggles and use in
well-ventilated area. If adhesive gets in eyes, try to keep eyes open; flush eyes
with water for 15 minutes and get immediate medical attention.

7. APPLY COAT of SEALING COMPOUND to THREADS of four socket head screws (1) and INSTALL
four socket head SCREWS (1).

NOTE
Follow-on Maintenance:
Install antifreeze device (TM 5-2420-224-20).

17-43
TM 5-2420-224-34

Section Vlll. TANDEM VALVE REPAIR

TANDEM VALVE REPAIR

This task covers: a. Disassembly b. Repair c. Assembly

INITIAL SETUP
Tools and Special Equipment: References:
Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Kit, Parts
TM 5-2420-224-20 Tandem Valve Removed

DISASSEMBLY

NOTE
Matchmark cover and tandem
valve housing prior to removal to
ensure proper installation of cover
on tandem valve housing.

1. REMOVE two screws (1) and COVER (2)

from tandem valve housing (3).

2. REMOVE seal RiNG (4) and washer (5) from

cover (2). DiSCARD seal RING and
WASHER.

3. REMOVE sleeve SPACER (6) from tandem

valve housing (3).

NOTE
Note position of plunger assembly
prior to removal to aid in
installation.

4. REMOVE PLUNGER assembly (7) from

sleeve spacer (6).

5. REMOVE slotted RING (8) and two seal rings

(9) from tandem valve housing (3). DISCARD
slotted RING and seal RINGS.

17-44
 TM 5-2420-224-34

TANDEM VALVE REPAIR (CONT)

NOTE
Matchmark cover and tandem
valve housing prior to removal to
ensure proper installation of cover
on tandem valve housing.

6. REMOVE two screws (10), COVER (11), and

spring (12) from tandem valve housing (3).

7. REMOVE sleeve SPACER (13) and slotted

ring (14) from tandem valve housing (3).
DISCARD slotted RING.

NOTE
Note position of spool valve prior
to removal to aid in installation.

8. REMOVE spool VALVE (15) and two seal

rings (16) from tandem valve housing (3).
DISCARD seal RINGS.

9. REMOVE and DISCARD seal RING (17) from

tandem valve housing (3).

10. REMOVE SPACER (18) and three seal rings

(19, 20, and 21) from tandem valve housing
(3).

11. REMOVE and DISCARD seal RING (22) from

tandem valve housing (3).

12. REMOVE SPACER (23) and three seal rings

(24, 25, and 26) from tandem valve housing
(3).

13. REMOVE breather CAP (27) from tandem

valve housing (3).

REPAIR
If any parts not found in Parts Kit are damaged,
replace tandem valve.

17-45
TM 5-2420-224-34

TANDEM VALVE REPAIR (CONT)

ASSEMBLY

1. INSTALL breather CAP (1) in tandem valve

housing (2).

2. INSTALL three seal rings (3, 4, and 5) and

SPACER (6) in tandem valve housing (2).

3. INSTALL new seal RING (7) in tandem valve

housing (2).

4. INSTALL three seal rings (8, 9, and 10) and

SPACER (11) in tandem valve housing (2).

5. INSTALL new seal RING (12) in tandem valve

housing (2).

6. INSTALL two new seal rings (13) and spool

VALVE (14), in position noted during
Removal, in tandem valve housing (2).

7. INSTALL new slotted ring (15) and sleeve

SPACER (16) in tandem valve housing (2).

8. INSTALL spring (17), COVER (18), and two

screws (19) on tandem valve housing (2).

17-46
 TM 5-2420-224-34

TANDEM VALVE REPAIR (CONT)

9. INSTALL two new seal rings (20) and new

slotted RING (21) in tandem valve housing
(2).

10. INSTALL PLUNGER assembly (22), in position

noted during Removal, in sleeve spacer (23).

11. INSTALL sleeve SPACER (23) in tandem

valve housing (2).

12. INSTALL new WASHER (24) and new seal

ring (25) in cover (26).

13. INSTALL COVER (26) and two screws (27)

on tandem valve housing (2).

NOTE
Follow-on Maintenance:
Install tandem valve (TM 5-2420-
224-20).

17-47
TM 5-2420-224-34

Section IX. TIRE REPAIR

TIRE REPAIR
This task covers: Repair

INITIAL SETUP

Tools and Special Equipment: Equipment condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Set, Tire Repair, SC 5180-95-CL-B14
TM 9-2610-200-24 Tire Removed from
Personnel Required: (2) Wheel Rim

References:
TM 9-2610-200-24

REPAIR

Repair tire (1) (TM 9-2610-200-24).

NOTE
Follow-on Maintenance:
Install tire on wheel rim (TM 9-
2610-200-24).

17-48
 TM 5-2420-224-34

CHAPTER 18
CAB REPAIR INSTRUCTIONS

OVERVIEW
This chapter contains maintenance instructions for repair of the cab.

CAB REPAIR
This task covers: a. Removal b. Repair c. Installation

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 FM 43-2

Tool Kit, SC 5180-90-CL-N26 TM 9-237
Shop Equipment, Welding, SC 4940-95-CL-B19
Tool Kit, Body and Fender Repair,
SC 5180-90-CL-N62

REMOVAL
NOTE
If any metal panels are to be removed, removal must be performed in accordance
with TM 9-237.

Discard lock washer(s).

REMOVE cab COMPONENTS using illustration and legend as a guide.

REPAIR
If any body repair, other than removal of metal panels (i.e., dents), is to be performed, perform repair in
accordance with FM 43-2.

INSTALLATION

NOTE
If any metal panels are to be installed, installation must be performed in accordance
with TM 9-237.

Install new lock washer(s).

INSTALL cab COMPONENTS using illustration and legend as a guide.

18-1
TM 5-2420-224-34

CAB REPAIR (CONT)

LEGEND

1 Capscrew (2) 9 Straight pin (2) 17 Washer (3)

2 Cap (2) 10 Door hinge (2) 18 Lock washer (3)
3 Instrument panel cover 11 Paneling 19 Pad
4 Bumper (8) 12 Screw (3) 20 Screening
5 Fastener 13 Washer (3) 21 Ventilation panel
6 Structural panel 14 Lock washer (3) 22 Structural panel
7 Structural post 15 Deflector 23 Reinforcement
8 Pillar 16 Screw (3)

18-2
 TM 5-2420-224-34

CHAPTER 19
ACCESSORY ITEMS REPAIR INSTRUCTIONS

OVERVIEW
This chapter contains maintenance instructions for repair of accessory items.

CAB HEATER REPAIR

This task covers: a. Disassemble b. Repair c. Assembly

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Washer, Lock (4)
TM 5-2420-224-20 Cab Heater Removed
Washer, Lock (3)
Washer, Spring
Tension
Washer, Lock (2)

1. REMOVE four screws (1), four lock washers

(2), and COVER (3). DISCARD lock
WASHERS.

19-1
 TM 5-2420-224-34

CAB HEATER REPAIR (CONT)

NOTE
Tag all wires prior to
disconnecting to aid in connecting.

2. DISCONNECT two WIRES (4 and 5).

3. REMOVE three screws (6), three lock

washers (7), and MOTOR (8). DISCARD lock
WASHERS.

4. LOOSEN SCREW (9) and REMOVE KNOB

(10).

5. REMOVE screw (11), washer (12), spring

tension washer (13), cover (14), and
RADIATOR (15). DISCARD spring tension
WASHER.

6. DISCONNECT three WIRES (16, 17, and 18)

and REMOVE SWITCH (19).

7. DISCONNECT two WIRES (20 and 21).

8. BEND BRACKET (22) and REMOVE

RESISTOR (23).

9. REMOVE wiring HARNESS (24) and flap (25).

19-2
 TM 5-2420-224-34

CAB HEATER REPAIR (CONT)

10. REMOVE KNOB (26).

11. REMOVE keeper (27) and SHUTTER (28).

12. REMOVE clip (29) and IMPELLER (30).

13. REMOVE two nuts (31), two lock washers

(32), condenser (33), HOUSING (34), and
washer (35). DISCARD lock WASHERS.

14. REMOVE two nuts (36), circuit BOARD (37),

two spacers (38), and two screws (39).

REPAIR
Using low-heat soldering iron, replace brushes if
worn and not making proper contact with motor
armature.

19-3
 TM 5-2420-224-34

CAB HEATER REPAIR (CONT)

ASSEMBLY
1. INSTALL two screws (1), two spacers (2),
circuit BOARD (3), and two nuts (4).

2. INSTALL washer (5), HOUSING (6),

condenser (7), two new lock washers (8), and
two nuts (9).

3. INSTALL IMPELLER (10) and clip (11).

4. INSTALL SHUTTER (12) and keeper (13).

5. INSTALL KNOB (14).

19-4
 TM 5-2420-224-34

CAB HEATER REPAIR (CONT)

6. INSTALL wiring HARNESS (15) and flap (16).

7. INSTALL RESISTOR (17). BEND BRACKET

(18) down and CONNECT two WIRES (19
and 20).

8. INSTALL SWITCH (21) and CONNECT three

WIRES (22, 23, and 24).

9. INSTALL RADIATOR (25), cover (26), new

spring tension washer (27), washer (28), and
screw (29).

10. INSTALL KNOB (30) and TIGHTEN SCREW

(31).

19-5
TM 5-2420-224-34

CAB HEATER REPAIR (CONT)

11. CONNECT two WIRES (32 and 33).

12. INSTALL MOTOR (34), three new lock

washers (35), and three screws (36).

13. INSTALL COVER (37), four new look washers

(38), and four screws (39).

NOTE
Follow-on Maintenance:
Install cab heater (TM 5-2420-224-
20).

19-6
 TM 5-2420-224-34

CHAPTER 20
HYDRAULIC SYSTEM REPAIR INSTRUCTIONS

OVERVIEW
This chapter contains maintenance instructions for repair of the hydraulic system. A list of sections
contained in this chapter is shown below.

Page

Section I. Front Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

Section Il. Rear Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . 20-6

Section Ill. Hydraulic Suspension Lockout Motor And Pump Repair . . . . . . . . . 20-9

Section IV. Front Loader/Forklift Control Valve Repair . . . . . . . . . . . . . . . 20-14

Section V. Tilt And Latch Control Valve Repair . . . . . . . . . . . . . . . . . . . . . 20-33

Section VI. Backhoe Control Valve Repair.. . . . . . . . . . . . . . . . . . . . . . . . 20-41

Section VIl. Backhoe Swing Cylinder Relief Valve Repair . . . . . . . . . . . . . . . ‘20-80

Section Vlll. Backhoe Stabilizer Control Valve Repair . . . . . . . . . . . . . . . . 20-82

Section IX. Loader Boom Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . 20-88

Section X. Loader Bucket Rollback Cylinder Repair . . . . . . . . . . . . . . . . . 20-94

Section Xl. Backhoe Boom Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . 20-100

Section XII. Backhoe Swing Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . 20-105

Section XIII. Backhoe Bucket Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . 20-112

Section XIV. Backhoe Dipper Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . 20-119

Section XV. Backhoe Stabilizer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . 20-125

Section XVI. Backhoe/Crane Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . 20-131

Section XVII. Backhoe/Crane Latch Cylinder Repair . . . . . . . . . . . . . . . . . 20-142

Section XVIII. Hydraulic Oil Cooler Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 20-148

Section XIX. Crane Valve Bank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151

Section XX. Forklift Mast Assembly Repair... . . . . . . . . . . . . . . . . . . . . . . 20-155

Section XXI. Forklift Carriage Assembly Repair. . . . . . . . . . . . . . . . . . . . . . . 20-171

Section XXII. Forklift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176

Section XXIII. Forklift Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180

20-1
TM 5-2420-224-34

Page

Section XXIV. Foklift Rotator Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . 20-187

Section XXV. Forklift Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 20-192

Section XXVI. Crane External End Extension Cylinder Repair . . . . . . . . . . . . . . . 20-206

Section XXVII. Crane inner Boom Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . 20-212

Section XXVIII. Crane Mast Locking Cylinder Repair . . . . . . . . . . . . . . . . . . . . 20-219

Section XXIX. Crane Outer Boom Cylinder Repair . . . . . . . . . . . . . . . . . . . . . 20-225

Section XXX. Crane Horizontal Outrigger Cylinder Repair . . . . . . . . . . . . . . . . . 20-232

Section XXXI. Crane Vertical Outrgger Cylinder Repair . . . . . . . . . . . . . . . . . . 20-237

Section XXXII. Crane Hydraulic Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . 20-243

20-2
 TM 5-2420-224-34

Section I. FRONT HYDRAULIC PUMP REPAIR

FRONT HYDRAULIC PUMP REPAIR

This task covers: a. Disassembly b. Repair c. Assembly

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 TM 5-2420-224-20 Front Hydraulic Pump
Removed
Materials/Parts:
General Safety Instructions:
Kit, Parts
Kit, Parts
WARNING
Oil, Lubricating Appendix B, Itern 30 Fuel and oil are slippery and
Rags can cause falls. To avoid
Appendix B, Item 40
injury, wipe up spilled fuel or
References: oil with rags.

TM 5-2420-224-20

20-3
TM 5-2420-224-34

FRONT HYDRAULIC PUMP REPAIR (CONT)

DISASSEMBLY

1. REMOVE two nuts (1), two washers (2), two screws (3), and COVER (4).

2. REMOVE retaining ring (5), seal ring (6), two retainer springs (7), and SEAL (8) from cover (4).
DISCARD seal RING and SEAL.

3. REMOVE PLATE (9) and O-ring (10) from housing (11). DISCARD O-RING.

4. REMOVE segment CARRIER (12) from housing (11).

5. REMOVE GEAR (13), sealing segment (14), two segment springs (15), and two sealing rolls (16) from
segment carrier (12). DISCARD sealing SEGMENT, segment SPRINGS, and sealing ROLLS.

6. REMOVE PIN (17) and gear ring (18).

7. REMOVE PLATE (19), two retainer springs (20), and seal (21) from housing (11). DISCARD SEAL.

REPAIR

If any parts not found in Parts Kits are damaged, replace pump.

20-4
 TM 5-2420-224-34

FRONT HYDRAULIC PUMP REPAIR (CONT)

NOTE
Apply coat of lubricating oil to O-ring and seals prior to assembly.

1. INSTALL new seal (21), two retainer springs (20), and PLATE (19) in housing (11).

2. INSTALL gear RING (18).

3. INSTALL PIN (17) with narrow chamfer toward outside of housing (11).

4. INSTALL two new sealing rolls (16), two new segment SPRINGS (15), and new sealing segment (14)
on segment carrier (12).

5. INSTALL GEAR (13) and segment carrier (12) in housing (11).

6. INSTALL new O-ring (10) and PLATE (9) in housing (11).

7. INSTALL new SEAL (8), two retainer springs (7), new seal ring (6), and retaining ring (5) in cover (4).

8. INSTALL COVER (4), two screws (3), two washers (2), and two nuts (1).

NOTE
Follow-on Maintenance:
Install front hydraulic pump (TM 5-2420-224-20).

20-5
TM 5-2420-224-34

Section Il. REAR HYDRAULIC PUMP REPAIR

REAR HYDRAULIC PUMP REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TOOI Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 TM 5-2420-224-20 Rear Hydraulic Pump
Removed
Materials/Parts:
General Safety Instructions:
Washer, Lock (4)
Kit
WARNING
Oil, Lubricating Appendix B, Item 30 Fuel and oil are slippery and
Rags Appendix 6, Item 40 can cause falls. To avoid
injury, wipe up spilled fuel or
References: oil with rags.

TM 5-2420-224-20

20-6
 TM 5-2420-224-34

REAR HYDRAULIC PUMP REPAIR (CONT)

DISASSEMBLY

1. REMOVE four bolts (1), four lock washers (2), COVER (3), flange (4), and two seals (5). DISCARD
lock WASHERS and SEALS.

2. REMOVE and DISCARD SEAL (6) from flange (4).

NOTE
Tag each bush prior to removal to aid in installation.

3. REMOVE BUSH (7) from rear of body (8).

4. REMOVE and DISCARD two backup WASHERS (9 and 10) and two lobe SEALS (11) from bush (7).

5. REMOVE bush (12) and gear PAIR (13) from body (8).

6. REMOVE BUSH (12) from gear pair (13).

7. REPEAT STEP 4 for bush (12).

20-7
TM 5-2420-224-34

REAR HYDRAULIC PUMP REPAIR (CONT)

ASSEMBLY

NOTE
. Apply coat of lubricating oil to seals prior to assembly.

. Make sure backup washers are flush after installation.

1. INSTALL two new lobe SEALS (1) and two new backup washers (2 and 3) on bush (4).

2. INSTALL BUSH (4) in body (5).

3. INSTALL gear PAIR (6) in body (5).

4. REPEAT STEP 1 for bush (7).

5. INSTALL BUSH (7).

6. INSTALL new SEAL (8) in flange (9).

7. INSTALL two new seals (10), flange (9), COVER (11), four new lock washers (12), and four bolts (13).

8. TIGHTEN BOLTS (13) in diagonal pattern to 34-36 Ib-ft (46-49 N.m).

NOTE
Follow-on Maintenance:
Install rear hydraulic pump (TM 5-2420-224-20).

20-8
 TM 5-2420-224-34

Section Ill. HYDRAULIC SUSPENSION L O C K O U T M O T O R

AND PUMP REPAIR

HYDRAULIC SUSPENSION LOCKOUT MOTOR AND PUMP REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP
Applicable Configuration: References:
HMMH TM 5-2420-224-20
LO 5-2420-224-12
Tools and Special Equipment:
Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 Reference Condition Description
Materials/Parts: TM 5-2420-224-20 Hydraulic Suspension
Lockout Pump Removed
Packing, Preformed
Packing, Preformed General Safety Instructions:

Packing, Preformed
WARNING
Packing, Preformed Fuel and oil are slippery and
Washer, Lock (2) can cause falls. To avoid
injury, wipe up spilled fuel or
Kit, Parts oil with rags.
Kit, Parts
Oil, Lubricating Appendix B, Item 30

Rags Appendix B, Item 40

20-9
TM 5-2420-224-34

HYDRAULIC SUSPENSION LOCKOUT MOTOR AND PUMP REPAIR (CONT)

20-10
 TM 5-2420-224-34

HYDRAULIC SUSPENSION LOCKOUT MOTOR AND PUMP REPAIR (CONT)

1. REMOVE PLUG (1) and COMPLETELY DRAIN hydraulic OIL from oil pan (2) into suitable container.

2. REMOVE screw (3), clamp (4), and oil PAN (2) from manifold (5).

3. REMOVE and DISCARD PACKING (6) from manifold (5).

4. REMOVE pressure SWITCH (7) from manifold (5).

5. REMOVE and DISCARD PACKING (8) from pressure switch (7).

6. REMOVE VALVE (9) from manifold (5).

7. REMOVE and DISCARD PACKING (10) from valve (9).

NOTE
Filter may remain inside either hollow screw or manifold.

8. REMOVE and DISCARD hollow SCREW (11) from pressure relief valve (12).

9. REMOVE and DISCARD pressure relief VALVE (12), two PACKINGS (13), and FILTER (14) from manifold (5).

10. REMOVE return FILTER (15) and packing (16) from return tube (17). DISCARD PACKING.

11. REMOVE and DISCARD intake FILTER (18). intake PIPE (19). and PACKING (20) from threaded
bushing (21).

12. REMOVE threaded BUSHING (21) and washer (22) from hydraulic suspension lockout pump (23).

NOTE
. If repairing hydraulic suspension lockout pump motor electrical plug, perform steps 13
thru 17.

. If replacing hydraulic suspension lockout pump motor, perform steps 18 and 19.

13. REMOVE four screws (24) and four washers (25) and hydraulic suspension lockout PUMP (23).

14. SLIDE union NUT (26) and washer (27) toward hydraulic suspension lockout pump motor (28).

15. CAREFULLY ROLL GROMMET (29) from plug housing (30).

NOTE
Note wire location in relation to locator pin on plug housing to aid in assembly.

16. REMOVE two electrical CONTACTS (31) from plug housing (30).

17. REMOVE two electrical CONTACTS (31) from two electrical wires (32).

18. REMOVE GROMMET (29), washer (27), and union nut (26) from cable assembly (33).

19. REMOVE two capscrews (34), two lock washers (35), and hydraulic suspension lockout pump MOTOR
(28) from manifold (5). DISCARD lock WASHERS.

20. REMOVE drive COUPLER (36) from manifold (5).

21. REMOVE PLUG (37) and packing (38) from manifold (5). DISCARD PACKING.

20-11
TM 5-2420-224-34

HYDRAULIC SUSPENSION LOCKOUT MOTOR AND PUMP REPAIR (CONT)

ASSEMBLY

20-12
 TM 5-2420-224-34

HYDRAULIC SUSPENSION LOCKOUT MOTOR AND PUMP REPAIR (CONT)

NOTE
If replacing hydraulic suspension lockout pump motor, perform steps 1 and 2.

If repairing hydraulic suspension lockout pump motor electrical plug, perform steps 3 thru 7.

Apply coat of lubricating oil to packings prior to assembly.

1. INSTALL drive COUPLER (1) in manifold (2).

2. INSTALL hydraulic suspension lockout pump MOTOR (3), two new lock washers (4), and two
capscrews (5) in manifold (2).
3. INSTALL union nut (6), washer (7), and GROMMET (8) on cable assembly (9).
4. INSTALL two electrical CONTACTS (10) on two electrical wires (11).
5. INSTALL two electrical CONTACTS (10) in plug housing (12) in position noted during Disassembly.
6. CAREFULLY ROLL GROMMET (8) over plug housing (12).
7. SLIDE washer (7) and union NUT (6) over grommet (8).
8. INSTALL hydraulic suspension lockout PUMP (13), four screws (14), and four washers (15) in manifold (2).
9. INSTALL washer (16) and threaded BUSHING (17) in hydraulic suspension lockout pump (13).
10. INSTALL new PACKING (18) on new intake pipe (19).
11. INSTALL intake PIPE (19) in threaded bushing (17).
12. INSTALL new intake FILTER (20) on intake pipe (19).
13. INSTALL new packing (21) and return FILTER (22) on return tube (23).
14. INSTALL two new PACKINGS (24) in new pressure relief valve (25).
15. INSTALL pressure relief VALVE (25) on manifold (2).
16. INSTALL new FILTER (26) in pressure relief valve (25).
17. INSTALL new hollow SCREW (27) in pressure relief valve (25).
18. INSTALL new PACKING (28) on valve (29).
19. INSTALL VALVE (29) in manifold (2).
20. INSTALL new PACKING (30) on pressure switch (31).
21. INSTALL pressure SWITCH (31) in manifold (2).
22. INSTALL new PACKING (32) on manifold (2).
23. INSTALL oil PAN (33), clamp (34), and screw (35) on manifold (2).
24. FILL oil PAN (33) (LO 5-2420-224-12) and INSTALL PLUG (36).
25. INSTALL new packing (37) and PLUG (38) in manifold (2).

NOTE
Follow-on Maintenance:
Install hydraulic suspension lockout pump (TM 5-2420-224-20).

20-13
TM 5-2420-224-34

Section IV. FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Tools and Special Equipment: References:

Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20
Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 Equipment Condition:

Materials/Parts: Reference Condition Description

Washer, Lock (6) Page 11-28 Front Loader Control
Valve and Bracket (SEE)
Packing (8) or Forklift Control Valve
Packing (8) and Bracket (HMMH)
Removed
Packing (2)
General Safety Instructions:
Packing (2)
Packing (3)
WARNING
Washer, Lock (2) Fuel and oil are slippery and
can cause falls. To avoid
Rod, Tie (3)
injury, wipe up spilled fuel or
Set, Packing oil with rags.

Kit, Parts
Kit, Parts (3)
Kit, Parts (2)
Kit, Seal (2)
Kit, Seal (2)
Oil, Lubricating Appendix B, Item 30
Rags Appendix B, Item 40

20-14
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

DISASSEMBLY

NOTE
Procedure is the same for both
vehicles.

FRONT LOADER/FORKLIFT CONTROL VALVE

1. REMOVE three nuts (1) and three lock

washers (2) from three tie RODS (3).
DISCARD lock WASHERS.

2. REMOVE outlet BODY (4).

3. REMOVE four packings (5) and

solenoid-operated hand tool valve BODY (6).
DISCARD PACKINGS.

4. REMOVE four packings (7) and front

loader/forklift control valve body SECTION (8).
DISCARD PACKINGS.

20-15
TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

5. REMOVE four packings (9), blanking plate

(10), and low body section valve BODY (11).
DISCARD PACKINGS.

6. REMOVE four packings (12) and

solenoid-operated front loader/forklift valve
BODY (13). DISCARD PACKINGS.

7. REMOVE four packings (14) and intake

manifold BODY (15). DISCARD PACKINGS.

20-16
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

8. REMOVE three lock washers (16) and three

nuts (17) from three tie RODS (3). DISCARD
lock WASHERS and tie RODS.

Outlet Body Disassembly

1. REMOVE PLUG (1) and packing (2) from

outlet body (3). DISCARD PACKING.

2. REMOVE CARTRIDGE assembly (4), packing

(5), backup ring (6), and packing (7).
DISCARD PACKINGS.

3. REMOVE PLUG (8), packing (9), spring (10),

and disc (11) from cartridge assembly (4).
DISCARD PACKING.

Outlet Body Assembly

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL disc (11), spring (10), new packing

(9), and PLUG (8) in cartridge assembly (4).

2. INSTALL new packing (7), backup ring (6),

new packing (5), and CARTRIDGE assembly
(4) in outlet body (3).

3. INSTALL new packing (2) and PLUG (1).

20-17
TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Front Loader/Forklift Relief Valve Disassembly

REMOVE front attachment relief VALVE (1) and

two packings (2) from valve manifold (3). DISCARD
PACKINGS.

Front Loader/Forklift Relief Valve Assembly

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

INSTALL two new packings (2) and front

attachment relief VALVE (1) in valve manifold (3).

Solenoid-Operated Hand Tool Valve Body

Disassembly

1. REMOVE button (1), retaining nut (2), cover

(3), and solenoid CASE and SOLENOID (4
and 5).

2. REMOVE TUBE assembly (6), packing (7),

push pin (8), spool (9), and spring (10).
DISCARD PACKING.

3. REMOVE cartridge BODY (11), two packings

(12 and 13), two backup rings (14 and 15),
and packing (16). DISCARD PACKINGS and
backup RINGS.

4. REMOVE PLUG (17).

20-18
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

5. REMOVE eight capscrews (18), two HEADS (19), and six packings (20 and 21), DISCARD
PACKINGS.

6. REMOVE two springs (22), two washers (23), and SPOOL (24).

7. REMOVE cylinder lock valve (25), two packings (26), and RAM (27) from valve body (28). DISCARD
PACKINGS.

8. REMOVE cap (29), packing (30), spring (31), and POPPET (32) from valve (25). DISCARD PACKING.

9. TURN valve BODY (28) OVER and REMOVE load check plug (33), packing (34), spring (35), and
PISTON (36). DISCARD PACKING.

20-19
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Solenoid-Operated Hand Tool Valve Body

Assembly

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL PISTON (1), spring (2), new packing

(3), and load check plug (4) in bottom of
valve body (5).

2. INSTALL POPPET (6), spring (7), new

packing (8), and cap (9) in cylinder lock valve
(10).

3. INSTALL RAM (11), two new packings (12),

and valve (10) in valve body (5).

4. INSTALL SPOOL (13), two washers (14), and

two springs (15).

5. INSTALL six new packings (16 and 17), two

HEADS (18), and eight capscrews (19).

6. INSTALL new packing (20), two new backup

rings (21 and 22), two new packings (23 and
24), and cartridge BODY (25).
7. INSTALL spring (26), spool (27), push pin
(26), new packing (29), and TUBE assembly
(30).
8. INSTALL SOLENOID and solenoid CASE (31
and 32), cover (33), retaining nut (34), and
button (35).
9. INSTALL PLUG (36).

20-20
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Front Loader/Forklift Control Valve Body Section Disassembly

1. HOLD SCREW (1) and LOOSEN jam NUT (2).

NOTE
Note number of turns necessary to remove screw.

2. HOLD jam NUT (2) and REMOVE SCREW (1).

3. REMOVE spring (3) and BALL (4).
4. REMOVE two screws (5) and spring HOLDER (6).
5. TURN valve BODY (7) OVER and REMOVE plug (8), packing (9), spring (10), and PISTON (11).
DISCARD PACKING.
6. REMOVE SPOOL (12) from valve body (7).
7. REMOVE and DISCARD PACKING (13) from valve body (7).

20-21
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Front Loader/Forklift Control Valve Body Section Assembly

NOTE
Apply coat of lubricating oil to packings prior to assembly.

1. INSTALL new PACKING (1) in valve body (2).

2. INSTALL SPOOL (3) in valve body (2).

3. INSTALL PISTON (4), spring (5), new packing (6), and plug (7) in bottom of valve body (2).

4. INSTALL spring HOLDER (8) and two screws (9).

5. INSTALL BALL (10) and spring (11).

6. HOLD jam NUT (12) and INSTALLSCREW (13) number of turns noted.

7. HOLD SCREW (13) and TIGHTEN jam NUT (12).

20-22
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Low Body Section Valve Body Disassembly

1. TURN valve BODY (1) OVER and REMOVE PLUG (2) and packing (3). DISCARD PACKING.

2. REMOVE two screws (4), two lock washers (5), and COVER (6). DISCARD lock WASHERS.

3. REMOVE SPACER (7) from cover (6).

4. REMOVE valve SPOOL (8).

5. REMOVE and DISCARD two PACKINGS (9).

Low Body Section Valve Body Assembly

NOTE
Apply coat of lubricating oil to packings prior to assembly.

1. INSTALL two new PACKINGS (9).

2. INSTALL valve SPOOL (8).

3. INSTALL SPACER (7) in cover (6).

4. INSTALL COVER (6), two new lock washers (5), and two screws (4).

5. INSTALL new packing (3) and PLUG (2) in valve body (1).

20-23
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Solenoid-Operated Front Loader/Forklift Valve Body Disassembly

1. REMOVE button (1), retaining nut (2), cover (3), and solenoid CASE and SOLENOID (4 and 5).

2. REMOVE TUBE assembly (6), packing (7), push pin (8), spool (9), and spring (10). DISCARD
PACKING.

3. REMOVE cartridge BODY (11), two packings (12 and 13), two backup rings (14 and 15), and packing
(16). DISCARD PACKINGS and backup RINGS.

4. REPEAT STEPS 1 thru 3 for solenoid (17).

20-24
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

REMOVE eight capscrews (18), two HEADS (19), and six packings (20 and 21). DISCARD
PACKINGS.

REMOVE two springs (22), two washers (23), and SPOOL (24).

REMOVE cylinder lock valve (25), two packings (26), and RAM (27) from valve body (28). DISCARD
PACKINGS.

REMOVE cap (29), packing (30), spring (31), and POPPET (32) from valve (25). DISCARD PACKING.

TURN valve BODY (28) OVER and REMOVE load check plug (33), packing (34), spring (35), and
PISTON (36). DISCARD PACKING.

20-25
TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Solenoid-Operated Front Loader/Forklift Valve Body Assembly

NOTE
Apply coat of lubricating oil to packings prior to assembly.

1. INSTALL PISTON (1), spring (2), new packing (3), and load check plug (4) in bottom of valve body
(5).

2. INSTALL POPPET (6), spring (7), new packing (8), and cap (9) in cylinder lock valve (10).

3. INSTALL RAM (11), two new packings (12), and valve (10) in valve body (5).

4. INSTALL SPOOL (13), two washers (14), and two springs (15).

5. INSTALL six new packings (16 and 17), two HEADS (18), and eight capscrews (19).

20-26
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

6. INSTALL new packing (20), two new backup rings (21 and 22), two new packings (23 and 24), and
cartridge BODY (25).

7. INSTALL spring (26), spool (27), push pin (28), new packing (29), and TUBE assembly (30).

8. INSTALL SOLENOID and solenoid CASE (31 and 32), cover (33), retaining nut (34), and button (35).

9. REPEAT STEPS 6 thru 8 for solenoid (36).

20-27
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Intake Manifold Body Disassembly

1. REMOVE capnut (1), ADAPTER (2), and

packing (3) from intake manifold body (4).
DISCARD PACKING.

2. REMOVE valve BODY (5), packing (6), and

backup ring (7). DISCARD PACKING and
backup RING.

3. REMOVE retaining RING (8) from valve body

(5).

4. HOLD adjusting SCREW (9) and LOOSEN

jam NUT (10).

NOTE
Note number of turns necessary to
remove adjusting screw.

5. HOLD jam NUT (10) and REMOVE adjusting

SCREW (9).

6. REMOVE valve BODY (11) from valve body

(5).

7. REMOVE and DISCARD PACKING (12).

8. REMOVE packing (13), spring seat (14),

spring (15), POPPET (16), seat (17), packing
(18), spring (19), and piston (20). DISCARD
PACKINGS.

20-28
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

Intake Manifold Body Assembly

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL piston (1), spring (2), new packing

(3), seat (4), POPPET (5), spring (6), spring
seat (7), and new packing (8).

2. INSTALL new PACKING (9) on valve body

(10).

3. INSTALL valve BODY (10) in valve body (11).

4. HOLD jam NUT (12) and INSTALL adjusting

SCREW (13) number of turns noted.

5. HOLD adjusting SCREW (13) and TIGHTEN

jam NUT (12).

6. INSTALL retaining RING (14) in valve body

(11).

7. INSTALL backup ring (15) and new PACKING

(16) on valve body (11).

8. INSTALL valve BODY (11) in intake manifold

body (17).

9. INSTALL new packing (18), ADAPTER (19),

and capnut (20).

20-29
TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

FRONT LOADER/FORKLIFT CONTROL VALVE

CAUTION
Make sure all packings
between valve sections are
replaced whenever nuts on tie
rods are loosened for any
reason. Failure to do so could
result in leaks and possible
damage to valve.

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL three nuts (1) and three new lock

washers (2) on three new tie RODS (3).

2. INSTALL intake manifold BODY (4) and four

new packings (5).

3. INSTALL solenoid-operated front loader/forklift

valve BODY (6) and four new packings (7).

20-30
 TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

4. INSTALL low body section valve BODY (8),

four new packings (9), and blanking plate
(10).

5. INSTALL front loader/forklift control valve body

SECTION (11) and four new packings (12).

6. INSTALL solenoid-operated hand tool valve

BODY (13) and four new packings (14).

20-31
TM 5-2420-224-34

FRONT LOADER/FORKLIFT CONTROL VALVE REPAIR (CONT)

7. lNSTALL outlet BODY (15).

NOTE
Before tightening nuts, make sure
equal amount of threads are
exposed on each end of tie rods.

8. INSTALL three new lock washers (16) and

three NUTS (17). TIGHTEN NUTS to 16 ±2
Ib-ft (32.5 ±2.7 N•m).

NOTE
Follow-on Maintenance:
Install front loader control valve
and bracket (SEE) or forklift
control valve and bracket (HMMH)
(page 11-28).
Adjust front loader control valve
(SEE) or forklift control valve
(HMMH) pressure settings (page
11 -28).
Adjust front loader (SEE) or forklift
(HMMH) linkage (TM5-2420-
224-20).
Adjust front loader (SEE) or forklift
(HMMH) float (TM 5-2420-224-20).

20-32
 TM 5-2420-224-34

Section V. TILT AND LATCH CONTROL VALVE REPAIR

TILT AND LATCH CONTROL VALVE REPAIR

This task covers: a. Disassembly b. Assembly

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TooI Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 Page 11-5 Tilt and Latch Control
Valve Removed
Materials/Parts:
General Safety Instructions:
Nut, Lock
Kit Parts
WARNING
Kit Parts Fuel and oil are slippery and
Kit Parts can cause falls. To avoid
injury, wipe up spilled fuel or
Kit Parts oil with rags.
Oil, Lubricating Appendix B, Item 30
Rags Appendix B, Item 40

CAUTION
All packings between each
valve must be replaced
whenever valve tie rods are
loosened. Failure to do so may
result in hydraulic fluid leaks
and/or equipment damage.

1. REMOVE four nuts (1) and four tie RODS (2).

DISCARD NUTS.

20-33
TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPAIR (CONT)

2. REMOVE four PACKINGS (3) from inlet

section (4). DISCARD PACKINGS.

3. REMOVE plug COCK (5) and packing (6).

DISCARD PACKING.

4. REMOVE PLUG (7).

5. REMOVE relief VALVE (8), two packings (9

and 10), and backup ring (11). DISCARD
PACKINGS.

6. HOLD SCREW (12) and LOOSEN lock NUT

(13).

7. REMOVE SCREW (12) and NOTE number of

turns necessary for removal.

8. REMOVE thread SEAL (14), washer (15), and

lock nut (13) from screw (12). DISCARD
thread SEAL and lock NUT.

9. REMOVE spring (16) and POPPET (17).

10. REMOVE BODY (18) and packing (19).

DISCARD PACKING.

11. REMOVE POPPET (20) from body (18).

12. REMOVE PISTON (21) from poppet (20).

13. REMOVE SPRING (22) and packing (23) from

piston (21). DISCARD PACKING.

20-34
 TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPAIR (CONT)

NOTE
Procedure is the same for both tilt
and latch control valve sections.

14. REMOVE and DISCARD four PACKINGS (24).

15. REMOVE two cotter pins (25), two pins (26),

and BRACKET (27). DISCARD cotter PINS.

16. LOOSEN NUT (28) and REMOVE PIVOT (29).

17. REMOVE two screws (30) and RETAINER

(31).

18. REMOVE SPOOL (32) from valve body (33).

19. REMOVE and DISCARD two PACKINGS (34

and 35) from valve body (33).

20. REMOVE spool END (36) from spool (32).

WARNING
Assembly is spring loaded.
Wear safety goggles. Failure to
do so could result in injury to
personnel.

21. USING spring compression TOOL, completely

COMPRESS SPRING (37) and REMOVE
END (38).
22. CAREFULLY RELEASE TENSION on spring
(37) and REMOVE spring compression TOOL.
23. REMOVE guide (39), SPRING (37), and guide
(40).

20-35
TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPAIR (CONT)

24. REMOVE plug COCK (41) and O-ring (42).

DISCARD O-RING.

25. REMOVE spring (43) and POPPET (44).

26. REMOVE PLUG (45) from outlet valve

manifold (46).

27. REMOVE SLEEVE assembly (47).

28. REMOVE and DISCARD two PACKINGS (48

and 49) and backup RING (50).

29. REMOVE PLUG (51) and packing (52).

DISCARD PACKING.

20-36
 TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
packings, O-ring, and seal prior to
assembly.

1. INSTALL new packing (1) and PLUG (2) in

outlet valve manifold (3).

2. INSTALL two new PACKINGS (4 and 5) and

new backup ring (6) on sleeve assembly (7).

3. INSTALL SLEEVE assembly (7).

4. INSTALL PLUG (8).

NOTE
Procedure is the same for both tilt
and latch control valve sections.

5. INSTALL POPPET (9) and spring (10) in

valve body (11).

6. INSTALL new O-ring (12) and plug COCK

(13).

20-37
TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPAIR (CONT)

7. INSTALL guide (14), SPRING (15), and guide

(16) on spool (17).

8. USING spring compression TOOL, completely

COMPRESS SPRING (15).

9. INSTALL END (18) and REMOVE spring

compression TOOL.

10. INSTALL spool END (19) on spool (17).

11. INSTALL two new PACKINGS (20 and 21) in

valve body (11).

12. INSTALL SPOOL (17) in valve body (11).

13. INSTALL RETAINER (22) and two screws

(23).

14. INSTALL PIVOT (24) and TIGHTEN NUT

(25).

15. INSTALL BRACKET (26), two pins (27), and

two new cotter pins (28).

16. INSTALL four new PACKINGS (29).

20-38
 TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPAIR (CONT)

17. INSTALL new packing (30) and SPRING (31)

in piston (32).

18. INSTALL PISTON (32) in poppet (33).

19. INSTALL POPPET (33) in body (34).

20. INSTALL new packing (35) and BODY (34) in

relief valve (36).

21. INSTALL POPPET (37) and spring (38) in

body (34).

22. INSTALL new lock nut (39), washer (40), and

new thread SEAL (41) on screw (42).

23. INSTALL SCREW (42), and TIGHTEN number

of turns noted during Disassembly.

24. HOLD SCREW (42) and TIGHTEN lock NUT

(39).

25. INSTALL two new PACKINGS (43 and 44)

and backup ring (45) on relief valve (36).

26. INSTALL relief VALVE (36) in inlet section

(46).

27. INSTALL PLUG (47).

20-39
TM 5-2420-224-34

TILT AND LATCH CONTROL VALVE REPAIR (CONT)

28. INSTALL new packing (48) and plug COCK

(49).

29. INSTALL four new PACKINGS (50).

30. INSTALL four tie RODS (51) and four new

nuts (52) through ail four valve sections.
TIGHTEN NUTS to 288 lb-in. (32.5 N•m).

NOTE
Follow-on Maintenance:
Install tilt and latch control valve
(page 11-5).
Adjust tilt and latch control valve
pressure settings (page 11-5).

20-40
 TM 5-2420-224-34

Section VI. BACKHOE CONTROL VALVE REPAIR

This section illustrates and describes procedures for repair of the backhoe control valve. A list of tasks
contained in this section is shown below.

Page

Backhoe Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41

Backhoe Control Valve, Intake Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . 20-47

Backhoe Control Valve, Outlet Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . 20-49

Backhoe Control Valve, Swing Section Valve Repair . . . . . . . . . . . . . . . . . . . . . 20-51

Backhoe Control Valve, Boom Section Valve Repair . . . . . . . . . . . . . . . . . . . . . 20-59

Backhoe Control Valve, Dipper and Bucket Section Valves Repair . . . . . . . . . . . . . 20-69

BACKHOE CONTROL VALVE REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description
Tools and Special Equipment: Page 11-15 Backhoe Control Valve
Removed
Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
Packing (15)
Packing (5)
Oil, Lubricating Appendix B, item 30

20-41
TM 5-2420-224-34

BACKHOE CONTROL VALVE REPAIR (CONT)

NOTE
Number each valve section prior
to removal to aid in installation.

1. REMOVE four NUTS (1) from four rods (2).

2. REMOVE intake MANIFOLD (3), two shims

(4), and four packings (5). DISCARD
PACKINGS.

3. REMOVE swing section VALVE (6), two shims

(7), and four packings (8). DISCARD
PACKINGS.

20-42
 TM 5-2420-224-34

BACKHOE CONTROL VALVE REPAIR (CONT)

4. REMOVE bucket section VALVE (9), two

shims (1 O), and four packings (11). DISCARD
PACKINGS.

5. REMOVE dipper section VALVE (12), two

shims (13), and four packings (14). DISCARD
PACKINGS.

6. REMOVE boom section VALVE (15), two

shims (16), and four packings (17). DISCARD
PACKINGS.

20-43
TM 5-2420-224-34

BACKHOE CONTROL VALVE REPAIR (CONT)

7. REMOVE outlet MANIFOLD (18).

8. REMOVE four NUTS (19) from four rods (2).

1. Inspect valves and manifolds for cracks or

damage.

2. Inspect threads on rods for wear or damage.

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL four NUTS (1) on four rods (2).

2. INSTALL outlet MANIFOLD (3).

20-44
 TM 5-2420-224-34

BACKHOE CONTROL VALVE REPAIR (CONT)

3. INSTALL two shims (4), four new packings

(5), and boom section VALVE (6).

4. INSTALL two shims (7), four new packings

(8), and dipper section VALVE (9).

5. INSTALL two shims (10), four new packings

(11), and bucket section VALVE (12).

20-45
TM 5-2420-224-34

BACKHOE CONTROL VALVE REPAIR (CONT)

6. INSTALL two shims (13), four new packings

(14), and swing section VALVE (15).

7. INSTALL two shims (16), four new packings

(17), and intake MANIFOLD (18).

NOTE
Before tightening nuts, be sure
equal amount of threads are
exposed on both ends of rods.

8. INSTALL four NUTS (19) on four rods (2).

TIGHTEN eight NUTS (1 and 19) to 20-30
Ib-ft (27-41 N•m).

NOTE
Follow-on Maintenance:
Install backhoe control valve (page
11-15).

20-46
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, INTAKE MANIFOLD REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description

Tools and Special Equipment: Page 20-41 Intake Manifold Removed

from Backhoe Control
Shop Equipment, SC 4910-95-CL-A31 Valve
Tool Kit, SC 5180-90-CL-N26
TooI Outfit, HSTRU) NSN 4940-01-036-5784

Materials/Parts:
Packing
Oil, Lubricating Appendix B, Item 30

1. REMOVE PLUG (1) and packing (2).

DISCARD PACKING.

2. REMOVE SPRING (3).

3. REMOVE valve DISC (4).

NOTE
Remove seat only if damaged.

4. IF SEAT (5) is DAMAGED, INSTALL

MANIFOLD (6) in drill PRESS. USING
21/32-in. (17-mm) diameter DRILL, DRILL
SEAT to depth of 11/32 in. (8.7 mm).

5. REMOVE remainder of SEAT (5).

Check spring length. Free length is 2.04 in. (51.8

mm); compressed length is 1.56 in. (39.6 mm) at
0.95 +1.1 lb (0.43 ±0.018 kg). If spring does not
meet these length requirements, replace spring.

20-47
TM 5-2420-224-34

BACKHOE CONTROL VALVE, INTAKE MANIFOLD REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
packing prior to assembly.

1. IF SEAT (1) was REMOVED, INSTALL new

SEAT (1) with chamfer toward inside of bore.

2. INSTALL valve DISC (2).

3. INSTALL SPRING (3).

4. INSTALL new packing (4) and PLUG (5).

NOTE
Follow-on Maintenance:
Install intake manifold in backhoe
control valve (page 20-41).

20-48
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, OUTLET MANIFOLD REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description

Tools and Special Equipment: Page 20-41 Outlet Manifold Removed

from Backhoe Control
Shop Equipment, SC 4910-95-CL-A31 Valve
TOOI Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
Packing
Packing
Oil, Lubricating Appendix B, Item 30

1. REMOVE PLUG (1) and packing (2).

DISCARD PACKING.

2. REMOVE SPRING (3).

3. REMOVE SLIDE (4).

4. REMOVE PIN (5).

5. REMOVE PACKING (6) from bore of outlet

manifold (7). DISCARD PACKING.

Check spring length. Free length is 2.097 in. (53.26

mm); compressed length is 1.61 in. (41 mm) at 62
±4 lb (28 ±1.8 kg). If spring does not meet these
length requirements, replace spring.

20-49
TM 5-2420-224-34

BACKHOE CONTROL VALVE, OUTLET MANIFOLD REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL new PACKING (1) in bore of outlet

manifold (2).

2. INSTALL PIN (3).

3. APPLY COAT of LUBRICATING OIL to SLIDE

(4) and INSTALL SLIDE (4) in outlet manifold
(2).

4. INSTALL SPRING (5).

5. INSTALL new packing (6) and PLUG (7).

NOTE
Follow-on Maintenance:
Install outlet manifold in backhoe
control valve (page 20-41).

20-50
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description

Tools and Special Equipment: Page 20-41 Swing Section Valve

Removed from Backhoe
Shop Equipment, SC 4910-95-CL-A31 Control Valve
TOOI Kit, SC 5180-90-CL-N26
TOOl Outfit (HSTRU), NSN 4940-01-036-5784
Fabricated Tool, Appendix C, Item 5

Materials/Parts:
Packing (2)
Packing (2)
Packing (2)
Seal
Kit, Repair
Oil, Lubricating Appendix B, Item 30

1. REMOVE PLUG (1) and packing (2).

DISCARD PACKING.

2. REMOVE spring (3) and valve DISC (4).

3. TURN SPRING (3) and REMOVE SPRING (3)

from valve disc (4).

4. REPEAT STEPS 1 thru 3 for plug (5).

20-51
TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR (CONT)

NOTE
Tag safety relief valves prior to
removal to aid in installation.

5. REMOVE safety relief VALVE (6) and three

packings (7, 8, and 9). DISCARD PACKINGS.

6. REPEAT STEP 5 for opposite safety relief

valve (10).

NOTE
Steps 7 thru 10 are the same for
both safety relief valves.

7. HOLD SETSCREW (11) and LOOSEN NUT

(12).

NOTE
Note number of turns necessary to
remove setscrew.

8. REMOVE SETSCREW (11) and washer (13).

20-52
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR (CONT)

9. REMOVE retaining RING (14).

10. REMOVE retainer (15), piston (16), packing

(17), pin (18), spring (19), POPPET (20), and
packing (21) from valve body (22). DISCARD
PACKINGS.

11. REMOVE PLUG (23).

12. REMOVE SPOOL (24), ring (25), and packing

(26). DISCARD PACKING.

20-53
TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR (CONT)

13. INSTALL valve BODY (27) on end in

soft-jawed VISE. USING FABRICATED TOOL,
REMOVE load check PLUG (28) by
INSERTING TOOL and TURNING it until it
SLIPS into SLOTS on both sides of load
check plug (28).

14. REMOVE and DISCARD PACKING (29).

15. REMOVE spring (30) and POPPET (31).

16. REPEAT STEPS 13 thru 15 for load check

plug hole on other end of valve body (27).

17. REMOVE and DISCARD SEAL (32) and

PACKING (33).

20-54
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR (CONT)

18. COMPRESS SPRING (34) and REMOVE

retaining RING (35).

19. SLOWLY RELEASE SPRING (34) and

REMOVE retainer (36), SPRING (34), and
retainer (37) from spool (24).

1. Check secondary relief valve spring length.

Free length is 1.785 in. (45.3 mm);
compressed length is 1.51 in. (38.4 mm) at
137 ±16 lb (627.25 kg).

2. Check spool spring length. Free length is

2.27 in. (57.6 mm); compressed length is
0.87 in. (22 mm) at 35 ±2.1 lb (15.9 ±1 kg).

3. If either spring does not meet length

requirements above, replace spring.

NOTE
Apply coat of lubricating oil to
packings and seal prior to
assembly.

1. INSTALL retainer (1), SPRING (2), and

retainer (3) on spool (4).

2. COMPRESS SPRING (2) and INSTALL

retaining RING (5).

3. INSTALL new packing (6) and new SEAL (7).

TAP SEAL with soft-faced hammer until it is
even with the top.

20-55
TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR (CONT)

4. INSTALL POPPET (8) and spring (9).

5. lNSTALL new PACKING (10).

6. INSERT FABRICATED TOOL into both slots

on load check plug (11) and INSTALL load
cheek PLUG (11) in valve body (12).

7. TURN valve BODY (12) OVER and REPEAT

STEPS 4 thru 6 for other load check plug
hole.

8. INSTALL new packing (13) and RING (14) on

spool (4).

9. INSTALL SPOOL (4) in valve body (12).

10. INSTALL PLUG (15) and TIGHTEN to

20-30 Ib-ft (27-41 N.m).

20-56
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR (CONT)

CAUTION
Check tags to be sure correct
safety relief valve is installed in
correct place, otherwise valve
section will not work properly.

NOTE
Steps 11 thru 14 are the same for
both safety relief valves.

11. INSTALL new packing (16). POPPET (17),

spring (18), pin (19), new packing (20), piston
(21), and retainer (22) in valve body (23).

12. INSTALL retaining RING (24).

13. INSTALL washer (25) and SETSCREW (26).

TIGHTEN SETSCREW number of turns noted
during Disassembly.

14. HOLD SETSCREW (26) and TIGHTEN NUT

(27) to 50-80 lb-in. (5.6-9.0 N.m).

20-57
TM 5-2420-224-34

BACKHOE CONTROL VALVE, SWING SECTION VALVE REPAIR (CONT)

15. lNSTALL three new packings (28, 29, and 30)

and safety relief VALVE (31) and TIGHTEN to
65-85 lb-ft (85-115 N.m).

16. REPEAT STEP 15 for opposite safety relief

valve (32).

17. INSTALL SPRING (33) In valve disc (34) by

turning spring (33).

18. INSTALL spring (33) and valve DISC (34) in

valve body (12).

19. INSTALL new packing (35) and PLUG (36).

20. REPEAT STEPS 17 thru 19 for plug (37).

21. PERFORM safety relief VALVE TESTING and

ADJUSTMENT (page 20-69).

NOTE
Follow-on Maintenance:
Install swing section valve in
backhoe control valve (page
20-41).

20-58
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description
Tools and Special Equipment: Page 20-41 Boom Section Valve
Removed from Backhoe
Shop Equipment, SC 4910-95-CL-A31 Control Valve
TOOI Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784
Fabricated Tool, Appendix C, Item 5

Materials/Parts:
Packing (2)
Packing (2)
Packing (2)
Seal
Kit, Repair
Kit, Repair
Oil, Lubricating Appendix B, Item 30

1. REMOVE PLUG (1) and packing (2).

DISCARD PACKING.

2. REMOVE spring (3) and DISC (4).

3. TURN SPRING (3) and REMOVE SPRING (3)

from disc (4).

4. REPEAT STEPS 1 thru 3 for plug (5).

20-59
TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

NOTE
Tag both relief valves prior to
removal to aid in installation.

5. REMOVE safety relief VALVE (6) and three

packings (7, 8, and 9). DISCARD PACKINGS.

6. HOLD SETSCREW (10) and LOOSEN NUT

(11).

NOTE
Note number of turns necessary to
remove setscrew.

7. REMOVE SETSCREW (10) and washer (12).

20-60
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

8. REMOVE retaining RING (13).

9. REMOVE retainer (14), piston (15), packing

(16), pin (17), spring (18), POPPET (19), and
packing (20) from valve body (21). DISCARD
PACKINGS.

10. REMOVE pressure relief VALVE (22) and

three packings (23, 24, and 25). DISCARD
PACKINGS.

20-61
TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

11. HOLD SETSCREW (26) and LOOSEN NUT

(27).

NOTE
Note number of turns necessary to
remove setscrew.

12. REMOVE SETSCREW (26) and washer (28).

13. REMOVE retaining RING (29).

14. REMOVE retainer (30), piston (31), packing

(32), spring (33), spring (34), POPPET (35),
and packing (36) from valve body (37).
DISCARD PACKINGS.

20-62
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

15. REMOVE PLUG (36).

16. REMOVE SPOOL (39), washer (40), and

packing (41). DISCARD PACKING.

17. INSTALL valve BODY (42) on end in

soft-jawed VISE. USING FABRICATED TOOL,
REMOVE load check PLUG (43) by
INSERTING TOOL and TURNING if until it
SLIPS into slots on both sides of load check
plug (43).

18. REMOVE and DISCARD PACKING (44).

19. REMOVE spring (45) and POPPET (46).

20. REPEAT STEPS 17 thru 19 for load check

plug hole on other end of valve body (42).

20-63
TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

21. REMOVE and DISCARD SEAL (47) and

PACKING (48).

22. COMPRESS SPRING (49) and REMOVE

retaining RING (50).

23. SLOWLY RELEASE SPRING (49) and

REMOVE retainer (51), SPRING (49), and
retainer (52) from spool (39).

1. Check secondary relief valve spring length.

Free length is 1.78 in. (45.3 mm); compressed
length is 1.51 in. (38.4 mm) at 137 ±16 lb
(627.25 kg).

2. Check spool spring length. Free length is 2.27

in. (57.6 mm); compressed length is 0.87 in.
(22 mm) at 35 ±2.1 lb (15.9 ±1 kg).

3. If either spring does not meet length

requirements above, replace spring.

NOTE
Apply coat of lubricating oil to
packings and seal prior to
assembly.

1. INSTALL retainer (1), SPRING (2), and

retainer (3) on spool (4).

2. COMPRESS SPRING (2) and INSTALL

retaining RING (5).

20-64
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

3. lNSTALL new packing (6) and new SEAL (7).

TAP SEAL with soft-faced hammer until it is
even with the top.

4. INSTALL POPPET (8) and spring (9).

5. INSTALL new PACKING (10).

6. INSERT FABRICATED TOOL into both slots

on load check plug (11) and INSTALL load
check PLUG (11) in valve body (12).

7. TURN valve BODY (12) over and REPEAT

STEPS 4 thru 6 for other load check plug
hole.

20-65
TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

8. lNSTALL new PACKING (13) and washer (14)

on spool (4).

9. INSTALL SPOOL (4) in valve body (12).

10. INSTALL PLUG (15) and TIGHTEN to 20-30

Ib-ft (27-41 N.m).

11. INSTALL new packing (16), POPPET (17),

spring (18), pin (19), new packing (20), piston
(21), and retainer (22) in valve body (23).

12. INSTALL retaining RING (24) in valve body

(23).

20-66
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

13. INSTALL washer (25) and SETSCREW (26).

TIGHTEN SETSCREW number of turns noted
during Disassembly.

14. HOLD SETSCREW (26) and TIGHTEN NUT

(27) to 50-80 lb-in. (5.6-9.0 N.m).

15. INSTALL new packing (28), POPPET (29),

Spring (30), spring (31), new packing (32),
piston (33), and retainer (34) in valve body
(35).

16. INSTALL retaining RING (36) in valve body

(35).

17. INSTALL washer (37) and SETSCREW (38).

TIGHTEN SETSCREW (38) number of turns
noted during Disassembly.

18. HOLD SETSCREW (38) and TIGHTEN NUT

(39) to 50-80 lb-in. (5.6-9.0 N.m).

20-67
TM 5-2420-224-34

BACKHOE CONTROL VALVE, BOOM SECTION VALVE REPAIR (CONT)

CAUTION
Check tags to be sure correct
relief valve is installed in
correct place, otherwise valve
section will not work properly.

19. INSTALL six new packings (40, 41, 42, 43,

44, and 45), safety relief VALVE (46), and
pressure relief valve (47). TIGHTEN to 65-85
Ib-ft (85-115 N.m).

20. INSTALL SPRING (48) in disc (49) by turning

spring (48).

21. INSTALL spring (48) and DISC (49) in valve

body (12).

22. INSTALL new packing (50) and PLUG (51).

23. REPEAT STEPS 20 thru 22 for plug (52).

NOTE
Follow-on Maintenance:
Install boom section valve in
backhoe control valve (page
20-41 ).

20-68
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR
This task covers: a. Disassembly b. Inspection c. Assembly d. Testing e. Adjustment

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description

Tools and Special Equipment: Page 20-41 Dipper Section Valve or
Bucket Section Valve
Shop Equipment, SC 4910-95-CL-A31 Removed from Backhoe
Tool Kit, SC 5180-90-CL-N26 Control Valve
Tool Outfit (HSTRU), NSN 4940-01-036-5784
Fabricated Tool, Appendix C, Item 5 General Safety Instructions:
Materials/Parts:
Packing (2) WARNING
Packing (2) Wear safety goggles when
performing leakage tests on
Kit, Repair (4) valves. Failure to do so may
result in serious eye injury
Caps and Plugs Appendix B, Item 8
due to high pressure oil.
Oil, Lubricating Appendix B, Item 30
Fuel and oil are slippery and
Rags Appendix B, Item 40 can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

DISASSEMBLY

NOTE
Procedure is the same for both
dipper section valve and bucket
section valve.
Tag safety relief valves prior to
removal to aid in installation.

1. REMOVE safety relief VALVE (1) and three

packings (2, 3, and 4). DISCARD PACKINGS.

2. REPEAT STEP 1 for opposite safety relief

valve (5).

20-69
TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

NOTE
Steps 3 thru 6 are the same for
both safety relief valves.

3. HOLD SETSCREW (6) and LOOSEN NUT

(7).

NOTE
Note number of turns necessary to
remove setscrew.

4. REMOVE SETSCREW (6) and washer (8).

5. REMOVE retaining RING (9).

6. REMOVE retainer (10), piston (11), packing

(12), spring (13), spring (14), POPPET (15),
and packing (16) from valve body (17).
DISCARD PACKINGS.

20-70
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

7. REMOVE PLUG (18).

8. REMOVE SPOOL (19), washer (20), and

packing (21). DISCARD PACKING.

9. INSTALL valve BODY (22) on end in

soft-jawed VISE. USING FABRICATED TOOL,
REMOVE load check PLUG (23) by
INSERTING TOOL and TURNING it until it
SLIPS into slots on both sides of load check
plug (23).

10. REMOVE and DISCARD PACKING (24).

11. REMOVE spring (25) and POPPET (26).

12. REPEAT STEPS 9 thru 11 for load check

plug hole on other end of valve body (22).

20-71
TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

13. REMOVE and DISCARD SEAL (27) and

PACKING (28).

14. COMPRESS SPRING (29) and REMOVE

retaining RING (30).

15. S L O W L Y R E L E A S E SPRING (29) and

REMOVE retainer (31), SPRING (29), and
retainer (32).

1. Check secondary relief valve spring length.

Free length is 1.78 in. (45.3 mm); compressed
length is 1.51 in. (38.4 mm) at 137 ±16 lb
(627.25 kg).

2. Check spool spring length. Free length is 2.27

in. (57.6 mm); compressed length is 0.87 in.
(22 mm) at 35 ±2.1 lb (15.9 ±1 kg).

3. If either spring does not meet length

requirements above, replace spring.

Procedure is the same for both

dipper section valve and bucket
section valve.
Apply coat of lubricating oil to
packings and seal prior to
assembly.

1. INSTALL retainer (1), SPRING (2), and

retainer (3) on spool (4).

2. COMPRESS SPRING (2) and INSTALL

retaining RING (5).

20-72
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

3. INSTALL new packing (6) and new SEAL (7).

TAP SEAL with soft-faced hammer until it is
even with the top.

4. INSTALL POPPET (8) and spring (9).

5. INSTALL new PACKING (10).

6. INSERT FABRICATED TOOL into both

SLOTS on bad check plug (11) and INSTALL
bad check PLUG (11) in valve body (12).

7. TURN valve BODY (12) OVER and REPEAT

STEPS 4 thru 6 for other load check plug
hole.

20-73
TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

8. INSTALL new PACKING (13) and washer (14)

on spool (4).

9. INSTALL SPOOL (4) in valve body (12).

10. INSTALL PLUG (15) and TIGHTEN to

20-30 Ib-ft (27-41 N.m).

CAUTION
Check tags to be sure correct
safety relief valve is installed in
correct place, otherwise valve
section will not work properly.

NOTE
Steps 11 thru 14 are the same for
both safety relief valves.

11. INSTALL new packing (16), POPPET (17),

spring (18), spring (19), new packing (20),
piston (21), and retainer (22) in valve body
(23).

12. INSTALL retaining RING (24).

20-74
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

13. INSTALL washer (25) and SETSCREW (26).

TIGHTEN SETSCREW number of turns noted
during Disassembly.

14. HOLD SETSCREW (26) and TIGHTEN NUT

(27) to 50-80 lb-in. (5.6-9.0 N.m).

15. INSTALL three new packings (28, 29, and 30)

and safety relief VALVE (31) and TIGHTEN to
65-85 Ib-ft (85-115 N.m).

16. REPEAT STEP 15 for opposite safety relief

valve (32).

20-75
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

20-76
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

Safety Relief Valve

CAUTION
Caps or plugs must be installed in any ports not being tested to prevent
hydraulic oil leakage.

1. Connect hand pump in port to be tested.

2. Stroke hand pump until sufficient pressure is built up in circuit to open safety relief valve.

3. Continue to stroke hand pump until all air has been pumped out of lines.

4. Record highest pressure and compare with acceptable ranges shown below:

Swing Section Valve

A and B ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1700-1900 psi
(115.6-129.2 bar)
Boom Section Valve
Abort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..925-1075 psi
(62.9-73.1 bar)
B port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2400-2650 psi
(163.2-180.2 bar)
Dipper Section Valve
A and B ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2400-2650 psi
(163.2-180.2 bar)
Bucket Section Valve
A and B ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..2400-2650 psi
(163.2 -180.2 bar)

20-77
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

Safety Relief Valve

1. Loosen lock nut (1).

2. Turn adjusting screw (2) in to increase pressure, or out to decrease pressure.

3. Repeat testing and adjustment until correct pressure is obtained.

4. If correct pressure cannot be obtained, replace safety relief valve.

5. When safety relief valve pressure is correct, perform leak test.

20-78
 TM 5-2420-224-34

BACKHOE CONTROL VALVE, DIPPER AND BUCKET SECTION VALVES

REPAIR (CONT)

Leak Test

NOTE
Perform steps 1 thru 3 to check high-pressure safety relief valves.

1. Stroke pump until pressure is built up to less than opening pressure of safety relief valve.

NOTE
It normally takes minimum of 15-30 seconds to bleed down to approximately 1000 psi
(68 bar).

2. Allow pump to sit and monitor pressure for 30-45 seconds. Pressure should have dropped to
approxirnately 500 psi (34 bar) and should not drop off to 0 for a few minutes.

3. If pressure drops off quicker, there is excessive leakage in circuit being tested. Check following:
Tube connections
Safety relief packings
Poppet seat in safety relief valve
Oil passing by valve spool
Valve spool not returning to neutral position
Possible cracks in backhoe control valve

NOTE
Perform steps 4 thru 6 to check low-pressure safety relief valves.

4. Stroke pump until pressure is built up to less than opening pressure of safety relief valve.

NOTE
It normally takes minimum of 15 seconds to bleed down to approximately 300 psi (20.4
bar).

5. Allow pump to sit and monitor pressure for 30-45 seconds. Pressure should not have dropped to, and
should not drop off to, 0 for a few minutes.

6. If pressure drops off quicker, there is excessive leakage in circuit being tested. Check following:
Tube connections
Safety relief packings
Poppet seat in safety relief valve
Oil passing by valve spool
Valve spool not returning to neutral position
Possible cracks in backhoe control valve

NOTE
Follow-on Maintenance:
Install dipper section valve or bucket section valve in backhoe control valve (page
20-41 ).

20-79
 TM 5-2420-224-34

Section VII. BACKHOE SWING CYLINDER RELIEF VALVE REPAIR

BACKHOE SWING CYLINDER RELIEF VALVE REPAIR

This task covers: a. Disassembly b. Assembly

Applicable configuration: Materials/Parts (Cont):

SEE Packing

Tools and Special Equipment: Packing

Shop Equipment, SC 4910-95-CL-A31 Oil, Lubricating Appendix B, Item 30

TOOl Kit, SC 5180-90-CL-N26
Equipment Condition:
Materials/Parts:
Reference Condition Description
Packing
Page 11-10 Backhoe Swing Cylinder
Packing Relief Valve Removed
Packing

NOTE
Procedure is the same for both swing cylinder relief valves.

1. REMOVE two PACKINGS (1) and backup ring (2). DISCARD PACKINGS.
2. REMOVE PLUG (3) and packing (4). DISCARD PACKING.
3. IF PRESENT, REMOVE DISC(S) (5) and SHIM(S) (6).
4. REMOVE spring HOLDER (7), two packings (8), and spring (9). DISCARD PACKINGS.
5. REMOVE two valve SEATS (10 and 11) from valve body (12).

20-80
 TM 5-2420-224-34

BACKHOE SWING CYLINDER RELIEF VALVE REPAIR (CONT)

NOTE
Procedure is the same for both swing cylinder relief valves.

Apply coat of lubricating oil to packings prior to assembly.

1. INSTALL two valve SEATS (10 and 11) in valve body (12).

2. INSTALL spring (9), two new packings (8), and spring HOLDER (7).

3. IF REMOVED, INSTALL same amount of SHIM(S) (6) and DISC(S) (5).

4. INSTALL PLUG (3) and new packing (4).

5. INSTALL backup ring (2) and two new PACKINGS (1).

NOTE
Follow-on Maintenance:
Install backhoe swing cylinder relief valve (page 11-10).

20-81
 TM 5-2420-224-34

Section VIII. BACKHOE STABILIZER CONTROL VALVE REPAIR

BACKHOE STABILIZER CONTROL VALVE REPAIR

This task covers: a. Disassembly b. Inspection c. Repair d. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description
Tools and Special Equipment: Page 11-12 Backhoe Stabilizer Control
Valve Removed
Shop Equipment, SC 4910-95-CL-A31
TOOl Kit,- SC 5180-90-CL-N26
TOOl Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
Ring (2)
Packing (4)
Packing (2)
Packing (2)
Oil, Lubricating Appendix B, item 30

1. REMOVE RING (1) from body (2). DISCARD

RING.

2. REMOVE spring (3) and DISC (4).

20-82
 TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPAIR (CONT)

3. REMOVE SEAT (5) from bore of body (2).

4. REMOVE PACKING (6) from seat (5).

DISCARD PACKING.

5. REMOVE DISC (7) and packing (8).

DISCARD PACKING.

6. REMOVE CAP (9).

20-38
 TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPAIR (CONT)

7. REMOVE SPOOL (10).

8. REMOVE packing (11) and BUSHING (12)

from spool (10). DISCARD PACKING.

WARNING
Assembly is spring loaded.
Wear safety goggles. Failure to
do so could result in injury to
personnel.

9. COMPRESS SPRING (13) and REMOVE

retaining RING (14).

10. REMOVE flat washer (15), SPRING (13),

spacer (16), and flat washer (17).

20-84
 TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPAIR (CONT)

11. REMOVE and DISCARD PACKING (18).

12. REPEAT STEPS 1 thru 11 for removal of
other spool and spool disc.

1. Check spools and spool bores in body for

damage. If a spool bore is damaged, replace
backhoe stabilizer control valve.
2. Check discs and seats of check valves. If discs
or seats are damaged, replace with new parts.
3. Check springs for distortion or damage.

If spool or spool bore is damaged, replace spool or

backhoe stabilizer control valve as needed.

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL new PACKING (1) in bore of body (2).

Packing groove is half the distance down bore.

2. INSTALL DISC (3), large end first, in bore.

20-85
 TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPAIR (CONT)

3. INSTALL new PACKING (4) on seat (5).

4. INSTALL SEAT (5), packing end first, in bore

of body (2).

5. INSTALL DISC (6), small end first, in bore.

6. INSTALL SPRING (7) in body (2).

7. INSTALL new RING (8) and TIGHTEN to

35-40 Ib-ft (47-54 N.m).

8. INSTALL flat washer (9), spacer (10),

SPRING (11), and flat washer (12) on spool
(13).

9. COMPRESS SPRING (11) on spool (13) and

INSTALL retaining RING (14).

10. INSTALL BUSHING (15) on spool (13).

11. INSTALL new PACKING (16) on bushing (15).

20-86
 TM 5-2420-224-34

BACKHOE STABILIZER CONTROL VALVE REPAIR (CONT)

12. INSTALL new PACKING (17) in spool bore.

13. INSTALL SPOOL (13) in body (2).

14. INSTALL CAP (18) in body (2) and TIGHTEN

to 35-40 Ib-ft (47-54 N.m).

15. REPEAT STEPS 1 thru 14 for installation of

other spool and spool disc.

NOTE
Follow-on Maintenance:
Install backhoe stabilizer control
valve (page 1 1-12).

20-87
TM 5-2420-224-34

Section IX. LOADER BOOM CYLINDER REPAIR

LOADER BOOM CYLINDER REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP

Applicable Configuration: References:

SEE TM 5-2420-224-20

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 TM 5-2420-224-20 Loader Boom Cylinder
Removed
Materials/Parts:
General Safety Instructions:
Nut, Lock
Kit, Parts
WARNING
Oil, Lubricating Appendix B, Item 30 Fuel and oil are slippery and
Rags Appendix B, Item 40 can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

1. USING spanner WRENCH, REMOVE

BEARING (1) from barrel (2).

2. REMOVE rod end CONNECTOR (3) from

barrel (2).

20-88
 TM 5-2420-224-34

LOADER BOOM CYLINDER REPAIR (CONT)

3. REMOVE lock NUT (4) from rod end

connector (3). DISCARD lock NUT.

4. REMOVE PISTON (5) and seal (6) from rod

end connector (3). DISCARD SEAL.

5. REMOVE and DISCARD two wear RINGS (7),

SEAL (8), and PACKING (9) from piston (5).

20-89
 TM 5-2420-224-34

LOADER BOOM CYLINDER REPAIR (CONT)

6. REMOVE BEARING (1) from rod end

connector (3).

7. REMOVE and DISCARD PACKING (10),

baokup RING (11), WIPER (12), PACKING
(13), and nylon PLUG (14) from bearing (1).

8. USING suitable PRESS, REMOVE BUSHING

(15) from eye of rod end connector (3).

9. IF DAMAGED, REMOVE lubrication FlTTING

(16).

20-90
 TM 5-2420-224-34

LOADER BOOM CYLINDER REPAIR (CONT)

10. USING suitable PRESS, REMOVE BUSHING

(17) from barrel (2).

11. IF DAMAGED, REMOVE lubrication FITTING

(18).

1. Inspect piston, rod end connector, and interior

of barrel for scratches or scoring.

2. Inspect threads on rod end connector, barrel,

and bearing for wear or damage.

NOTE
Apply coat of lubricating oil to
packings and seals prior to
assembly.

1. IF REMOVED, INSTALL new lubrication

FlTTING (1) in eye of barrel (2).

2. USING suitable PRESS, INSTALL BUSHING

(3) in eye of barrel (2).

3. IF REMOVED, INSTALL new lubrication

FlTTING (4) in eye of rod end connector (5).

4. USING suitable PRESS, INSTALL BUSHING

(6) in eye of rod end connector (5).

20-91
TM 5-2420-224-34

LOADER BOOM CYLINDER REPAIR (CONT)

5. INSTALL new backup ring (7) and new

PACKING (8) on bearing (9).

6. INSTALL new packing (10) and new WIPER

(11) in bearing (9).

7. INSTALL new nylon PLUG (12) in bearing (9).

8. INSTALL BEARING (9) on rod end connector

(5).

9. INSTALL new SEAL (13) on rod end

connector (5).

10. INSTALL new PACKING (14) on piston (15).

11. INSTALL new SEAL (16) and two new wear

rings (17) on piston (15).

20-92
 TM 5-2420-224-34

LOADER BOOM CYLINDER REPAIR (CONT)

CAUTION
Ring compressor must be used
to prevent damage to rings and
packings.

12. USING ring COMPRESSOR, INSTALL

PISTON (15) on rod end connector (5).

13. INSTALL new lock NUT (18) on rod end

connector (5). TIGHTEN lock NUT to 200-250
Ib-ft (271 .2-339.0 N.m).

14. INSTALL rod end CONNECTOR (5) in barrel

(2).

15. INSTALL BEARING (9) in barrel (2). USING

spanner WRENCH, TIGHTEN BEARING to
100-200 Ib-ft (136-271 N.m).

NOTE
Follow-on Maintenance:
install loader boom cylinder
(TM 5-2420-224-20).

20-93
TM 5-2420-224-34

Section X. LOADER BUCKET ROLLBACK CYLINDER REPAIR

LOADER BUCKET ROLLBACK CYLINDER REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: References:

SEE TM 5-2420-224-20
TM 9-214
Tools and Special Equipment:
Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 Reference Condition Description
TOOI Outfit (HSTRU), NSN 4940-01-036-5784
TM 5-2420-224-20 Loader Bucket Rollback
Materials/Parts: Cylinder Removed
Nut, Lock General Safety Instructions:
Packing, Preformed
Kit, Parts WARNING
Fuel and oil are slippery and
Oil, Lubricating Appendix B, Item 30
can cause falls. To avoid
Rags Appendix B, Item 40 injury, wipe up spilled fuel or
oil with rags.

1. USING spanner WRENCH, REMOVE

BEARING (1) from barrel (2).

20-94
 TM 5-2420-224-34

LOADER BUCKET ROLLBACK CYLINDER REPAIR (CONT)

2. REMOVE rod end CONNECTOR (3) from

barrel (2).

3. REMOVE lock NUT (4) from rod end

connector (3). DISCARD lock NUT.

4. REMOVE PISTON (5) and seal (6) from rod

end connector (3). DISCARD SEAL.

5. REMOVE and DISCARD wear RING (7),

SEAL (8), and PACKING (9) from piston (5).

20-95
TM 5-2420-224-34

LOADER BUCKET ROLLBACK CYLINDER REPAIR (CONT)

6. REMOVE BEARING (1) from rod end

oonnector (3).

7. REMOVE and DISCARD PACKING (10),

backup RING (11), WIPER (12), PACKING
(13), and nylon PLUG (14) from bearing (1).

8. USING suitable PRESS, REMOVE BEARING

(15) from eye of rod end connector (3).

9. IF DAMAGED, REMOVE lubrication FITTING

(16).

20-96
 TM 5-2420-224-34

LOADER BUCKET ROLLBACK CYLINDER REPAIR (CONT)

10. REMOVE retaining RING (17) from eye of

barrel (2).

11. USING suitable PRESS, REMOVE BEARING

(18) from barrel (2).

12. IF DAMAGED, REMOVE lubrication FlTTING

(19).

1. Inspect piston, rod end connector, and interior

of barrel for scratches or scoring.

2. Inspect threads on rod end connector, barrel,

and bearing for wear or damage.

3. Inspect bearings (TM 9-214).

NOTE
Apply coat of lubricating oil to
packings and seals prior to
assembly.

1. IF REMOVED, INSTALL new lubrication

FlTTING (1) in eye of barrel (2).

2. USING suitable PRESS, INSTALL BEARING

(3) in eye of barrel (2).

3. INSTALL retaining RING (4) in eye of barrel

(2).

4. IF REMOVED, INSTALL new lubrication

FlTTING (5) in eye of rod end connector (6).

5. USING suitable PRESS, INSTALL BEARING

(7) in eye of rod end connector (6).

20-97
TM 5-2420-224-34

LOADER BUCKET ROLLBACK CYLINDER REPAIR (CONT)

6. INSTALL new backup ring (8) and new

PACKING (9) on bearing (10).

7. INSTALL new packing (11) and new WIPER

(12) in bearing (10).

8. INSTALL new nylon PLUG (13) in bearing

(10).

9. INSTALL BEARING (10) on rod end connector

(6).

10. INSTALL new SEAL (14) on rod end

oonnector (6).

11. INSTALL new wear RING (15) on piston (16).

12. INSTALL new packing (17) and new SEAL

(18) on piston (16).

20-98
 TM 5-2420-224-34

LOADER BUCKET ROLLBACK CYLINDER REPAIR (CONT)

13. INSTALL PISTON (16)

. . on rod end connector
(6).

14. INSTALL new lock NUT (19) on rod end

c o n n e c t o r ( 6 ) . T I G H T E N l o c k NUT to
200-250 Ib-ft (271.2-339.0 N.m).

15. INSTALL rod end CONNECTOR (6) in barrel

(2).

16. INSTALL BEARING (10) in barrel (2). USING

spanner WRENCH, TIGHTEN BEARING to
100-200 Ib-ft (136-271 N.m).

NOTE
Follow-on Maintenance:
Install loader bucket rollback
cylinder (TM 5-2420-224-20).

20-99
TM 5-2420-224-34

Section Xl. BACKHOE BOOM CYLINDER REPAIR

BACKHOE BOOM CYLINDER REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: References:

SEE TM 5-2420-224-20

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
TOOI Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 TM 5-2420-224-20 Backhoe Boom Cylinder
Removed
Materials/Parts:
General Safety Instructions:
Kit, Parts
Compound, Sealing Appendix B, Item 15
WARNING
Oil, Lubricating Appendix B, item 30 Fuel and oil are slippery and
Rags Appendix B, item 40 can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

1. REMOVE self-tapping SCREW (1).

2. USING spanner WRENCH, REMOVE

RETAINER (2) from tube (3).

20-100
 TM 5-2420-224-34

BACKHOE BOOM CYLINDER REPAIR (CONT)

3. REMOVE piston ROD (4) from tube (3).

4. REMOVE SCREW (5) and washer (6) from

piston rod (4).

5. REMOVE PISTON (7) from piston rod (4).

6. REMOVE and DISCARD two wear RINGS (8),

RETAINER (9), and PACKING (10) from
piston (7).

20-101
TM 5-2420-224-34

BACKHOE BOOM CYLINDER REPAIR (CONT)

7. REMOVE RETAINER (2) from piston rod (4).

8. REMOVE and DISCARD PACKING (11) and

backup RING (12) from retainer (2).

9. REMOVE and DISCARD SEAL (13), SEAL

(14), WIPER (15), and BUSHING (16) from
retainer (2).

1. Inspect piston, piston rod, and tube for

scratches or scoring.

2. Inspect threads on piston rod, piston screw,

tube, and retainer for wear or damage.

20-102
 TM 5-2420-224-34

BACKHOE BOOM CYLINDER REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
packings and seals prior to
assembly.

1. INSTALL new bushing (1), new WIPER (2),

new seal (3), and new seal (4) in retainer (5).

2. INSTALL new backup ring (6) and new

PACKING (7) on retainer (5).

3. INSTALL RETAINER (5) on piston rod (8).

20-103
TM 5-2420-224-34

BACKHOE BOOM CYLINDER REPAIR (CONT)

4. INSTALL new PACKING (9), new retainer

(10), and two new wear rings (11) on piston
(12).

5. INSTALL PISTON (12) on piston rod (8).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

6. APPLY COAT of SEALING COMPOUND to

THREADS of screw (13) and INSTALL
SCREW (13) and washer (14) on piston rod
(8). TIGHTEN SCREW to 475-525 Ib-ft
(644-712 N.m).

7. INSTALL piston ROD (8) in tube (15).

8. USING spanner WRENCH, THREAD

RETAINER (5) into tube (15) and TIGHTEN to
100-200 Ib-ft (135-271 N.m).

9. INSTALL self-tapping SCREW (16).

NOTE
Follow-on Maintenance:
Install backhoe boom cylinder
(TM 5-2420-224-20).

20-104
 TM 5-2420-224-34

Section XII. BACKHOE SWING CYLINDER REPAIR

BACKHOE SWING CYLINDER REPAIR

This task rovers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Backhoe Swing Cylinder
Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety Instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
WARNING
Kit, Parts Repair Fuel and oil are slippery and
can cause falls. To avoid
Compound, Sealing Appendix B, Item 15 injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.

Rags Appendix B, Item 40

References:
TM 5-2420-224-20

1. REMOVE self-tapping SCREW (1) from tube

(2).

2. USING spanner WRENCH, REMOVE GLAND

assembly (3).

20-105
TM 5-2420-224-34

BACKHOE SWING CYLINDER REPAIR (CONT)

3. REMOVE piston ROD (4) from tube (2).

WARNING
Pin is under spring pressure.
Wear safety goggles. Remove
bolt carefully to avoid possible
injury.

4. REMOVE BOLT (5), washer (6), pin (7),

spring (8), and ball (9) from piston rod (4).

5. REMOVE PISTON (10) from piston rod (4).

6. REMOVE and DISCARD two wear RINGS

(11), RETAINER (12), and PACKING (13)
from piston (10).

20-106
 TM 5-2420-224-34

BACKHOE SWING CYLINDER REPAIR (CONT)

7. REMOVE GLAND (3) from piston rod (4).

8. REMOVE two packings (14 and 15), seal

(16), packing (17), WIPER (18), and bearing
(19) from gland (3). DISCARD PACKINGS,
SEAL, WIPER, and BEARING.

9. USING suitable PRESS, REMOVE two

BUSHINGS (20) from eye of piston rod (4).

20-107
 TM 5-2420-224-34

BACKHOE SWING CYLINDER REPAIR (CONT)

10. USING suitable PULLER, REMOVE two

BUSHINGS (21) from tube (2).

11. IF DAMAGED, REMOVE three lubrication

FITTINGS (22).

1. Inspect piston, piston rod, and tube for

scratches or scoring.

2. Inspect threads on piston rod, bolt, tube, and

gland for wear or damage.

NOTE
Apply coat of lubricating oil to
packings and seal prior to
assembly.

1. IF REMOVED. INSTALL three new fabrication

FlTTINGS (1).

2. USING suitable PRESS, INSTALL two

BUSHINGS (2) on tube (3).

3. USING suitable PRESS, INSTALL two

BUSHINGS (4) in eye of piston rod (5).

20-108
 TM 5-2420-224-34

BACKHOE SWING CYLINDER REPAIR (CONT)

4. INSTALL new bearing (6) and new WIPER (7)

in gland (8).

5. INSTALL new seal (9) and new PACKING

(10) in gland (8).

6. INSTALL two new PACKINGS (11 and 12) in

gland (8).

7. INSTALL GLAND (8) on piston rod (5).

8. INSTALL two new wear RINGS (13) on piston

(14).

9. INSTALL new PACKING (15) and new

retainer (16) on piston (14).

20-109
TM 5-2420-224-34

BACKHOE SWING CYLINDER REPAIR (CONT)

10. INSTALL PISTON (14) on piston rod (5).

11. INSTALL BALL (17), SPRING (18), and PIN

(19), as an assernbly, in piston rod - (5).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

12. APPLY COAT of SEALING COMPOUND to

THREADS of bolt (20) and INSTALL BOLT
(20) and washer (21) in piston rod (5).
TIGHTEN BOLT to 700-750 Ib-ft (949-1017
N.m).

13. INSTALL piston ROD (5) in tube (3).

20-110
 TM 5-2420-224-34

BACKHOE SWING CYLINDER REPAIR (CONT)

14. USING spanner WRENCH, THREAD GLAND

(8) into tube (3) and TIGHTEN to 100-200
Ib-ft (135-271 N.m).

15. INSTALL self-tapping SCREW (22) in tube (3).

NOTE
Follow-on Maintenance:
Install backhoe swing cylinder
(TM 5-2420-224-20).

20-111
TM 5-2420-224-34

Section XIII. BACKHOE BUCKET CYLINDER REPAIR

BACKHOE BUCKET CYLINDER REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description

TOOIS and Special Equipment: TM 5-2420-224-20 Backhoe Bucket Cylinder

Removed
Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26 General Safety Instructions:
TooI Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts: WARNING
Kit, Parts Fuel and oil are slippery and
can cause falls. To avoid
Compound, Sealing Appendix B, Item 15 injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.

Rags Appendix B, Item 40

References:
TM 5-2420-224-20

1. REMOVE self-tapping SCREW (1) from

cylinder (2).

2. USING spanner WRENCH, REMOVE GLAND

assembly (3).

20-112
 TM 5-2420-224-34

BACKHOE BUCKET CYLINDER REPAIR (CONT)

3. REMOVE piston ROD (4) from cylinder (2).

4. REMOVE SCREW (5) and washer (6) from

piston rod (4).

5. REMOVE PISTON (7) from piston rod (4).

20-113
TM 5-2420-224-34

BACKHOE BUCKET CYLINDER REPAIR (CONT)

6. REMOVE and DISCARD two wear RINGS (8),

PACKING (9), and backup RING (10) from
piston (7).

7. REMOVE GLAND (3) from piston rod (4).

8. REMOVE and DISCARD PACKING (11) and

backup RING (12) from gland (3).

20-114
 TM 5-2420-224-34

BACKHOE BUCKET CYLINDER REPAIR (CONT)

9. REMOVE and DISCARD SEAL (13), RING

(14), SEAL (15), and BEARING (16) from
gland (3).

10. USING suitable PRESS, REMOVE two

BUSHINGS (17) from piston rod (4) and two
BUSHINGS (18) from cylinder (2).

11. IF DAMAGED, REMOVE Iubrication FlTTINGS

(19 and 20).

1. Inspect piston, piston rod, and cylinder for

scratches or scoring.

2. Inspect threads on piston rod, piston screw,

cylinder, and gland for wear or damage.

20-115
 TM 5-2420-224-34

BACKHOE BUCKET CYLINDER REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
packing and seals prior to
assembly.

1. IF REMOVED, INSTALL new lubrication

FlTTING (1).

2. USING suitable PRESS, INSTALL two

BUSHINGS (2) in cylinder (3).

3. IF REMOVED, INSTALL new lubrication

FlTTING (4).

4. USING suitable PRESS, INSTALL two

BUSHINGS (5) in piston rod (6).

5. INSTALL new ring (7) and new BEARING (8)

in gland (9).

6. INSTALL new SEAL (10) and new SEAL (11)

in gland (9).

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 TM 5-2420-224-34

BACKHOE BUCKET CYLINDER REPAIR (CONT)

7. INSTALL new backup RING (12) and new

packing (13) on gland (9).

8. INSTALL GLAND (9) on piston rod (6) with

wiper ring toward piston rod eye.

9. INSTALL new packing (14) and new backup

RING (15) on piston (16).

10. INSTALL two new wear RINGS (17) on piston

(16).

20-117
TM 5-2420-224-34

BACKHOE BUCKET CYLINDER REPAIR (CONT)

11. INSTALL PISTON (16) on piston rod (6).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

12. APPLY COAT of SEALING COMPOUND to

THREADS of screw (18) and INSTALL
SCREW (18) and washer (19) in piston rod
(6). TIGHTEN SCREW to 475-525 Ib-ft
(644-712 N.m).

13. INSTALL piston ROD (6) in cylinder (3).

14. USING spanner WRENCH, THREAD GLAND

(9) into cylinder (3) and TIGHTEN to 100-200
Ib-ft (135-271 N.m). Each half of hole for
self-tapping screw must now be in alinement.

15. INSTALL self-tapping SCREW (20) in cylinder

(3).

NOTE
Follow-on Maintenance:
Install backhoe bucket cylinder
(TM 5-2420-224-20).

20-118
 TM 5-2420-224-34

Section XIV. BACKHOE DIPPER CYLINDER REPAIR

BACKHOE DIPPER CYLINDER REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Backhoe Dipper Cylinder
Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety Instructions:
TOOl Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
WARNING
Kit, Parts Fuel and oil are slippery and
can cause falls. To avoid
Compound, Sealing Appendix B, Item 15 injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.

Rags Appendix B, Item 40

References:
TM 5-2420-224-20

1. REMOVE self-tapping SCREW (1).

2. USING spanner WRENCH, REMOVE GLAND

assembly (2).

20-119
 TM 5-2420-224-34

BACKHOE DIPPER CYLINDER REPAIR (CONT)

3. REMOVE piston ROD (3) from cylinder (4).

4. REMOVE bolt (5), washer (6), and PISTON

(7) from piston rod (3).

5. REMOVE and DISCARD PACKING (8),

RETAINER (9), and two wear RINGS (10)
from piston (7).

20-120
 TM 5-2420-224-34

BACKHOE DIPPER CYLINDER REPAIR (CONT)

6. REMOVE GLAND (2) from piston rod (3).

7. REMOVE and DISCARD three PACKINGS

(11, 12, and 13) and SEAL (14) from gland
(2).

8. REMOVE and DISCARD WIPER (15) and

BEARING (16) from gland (2).

9. USING suitable PRESS, REMOVE BUSHING

(17) from eye of piston rod (3).

10. IF DAMAGED, REMOVE lubrication FlTTING

(18).

20-121
TM 5-2420-224-34

BACKHOE DIPPER CYLINDER REPAIR (CONT)

11. USING suitable PRESS, REMOVE two

BUSHINGS (19) from cylinder (4).

12. IF DAMAGED, REMOVE lubrication FITTING

(20).

1. Inspect piston, piston rod, and cylinder for

scratches or scoring.

2. Inspect threads on piston rod, bolt, cylinder,

and gland for wear or damage.

NOTE
Apply coat of lubricating oil to
packings and seal prior to
assembly.

1. IF REMOVED, INSTALL new lubrication

FlTTING (1).

2. USING suitable PRESS, INSTALL BUSHING

(2) in eye of piston rod (3).

3. IF REMOVED, INSTALL new lubrication

FITTING (4).

4. USING suitable PRESS, INSTALL two

BUSHINGS (5) in cylinder (6).

20-122
 TM 5-2420-224-34

BACKHOE DIPPER CYLINDER REPAIR (CONT)

5. INSTALL new BEARING (7) and new wiper

(8) in gland (9).

6. INSTALL new PACKING (10) and new

PACKING (11) in gland (9).

7. INSTALL new seal (12) and new PACKING

(13) in gland (9).

8. INSTALL GLAND (9) on piston rod (3).

9. INSTALL two new wear RINGS (14) on piston

(15).

10. INSTALL new retainer (16) and new

PACKING (17) on piston (15).

20-123
TM 5-2420-224-34

BACKHOE DIPPER CYLINDER REPAIR (CONT)

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

11. APPLY COAT Of SEALING COMPOUND to

THREADS of bolt (18) and INSTALL PISTON
(15), washer (19), and bolt (18) on piston rod
(3). TIGHTEN BOLT to 1000-1200 Ib-ft
(1356-1627 N•m).

12. INSTALL PISTON rod (3) in cylinder (6).

13. USING spanner WRENCH, THREAD GLAND

(9) into cylinder (6) and TIGHTEN to 100-200
Ib-ft (136-271 N•m).

14. INSTALL self-tapping SCREW (20).

NOTE
Follow-on Maintenance:
Install backhoe dipper cylinder
(TM 5-2420-224-20).

20-124
 TM 5-2420-224-34

Section XV. BACKHOE STABILIZER CYLINDER REPAIR

BACKHOE STABILIZER CYLINDER REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

Applicable Configuration: Equipment Condition:

SEE Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Backhoe Stabilizer
Cylinder Removed
Shop Equipment, SC 4910-95-CL-A31
TooI Kit, SC 5180-90-CL-N26 General Safety Instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
WARNING
Kit, Parts Fuel and oil are slippery and
can cause falls. To avoid
Compound, Sealing Appendix B, Item 15
injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.

Rags Appendix B, Item 40

References:
TM 5-2420-224-20

1. REMOVE self-tapping SCREW (1) from tube

(2).

2. USING spanner WRENCH, REMOVE GLAND

assembly (3).

20-125
TM 5-2420-224-34

BACKHOE STABILIZER CYLINDER REPAIR (CONT)

3. REMOVE linear PISTON (4) from tube (2).

4. REMOVE SCREW (5) and washer (6) from

linear piston (4).

5. REMOVE PISTON (7) from linear piston (4).

6. REMOVE and DISCARD SEAL (8), backup

RING (9), and two wear RINGS (10) from
piston (7).

20-126
 TM 5-2420-224-34

BACKHOE STABILIZER CYLINDER REPAIR (CONT)

7. REMOVE GLAND (3) from linear piston (4).

8. REMOVE and DISCARD three PACKINGS

(11, 12, and 13), SEAL (14), WIPER (15),
and BEARING (16) from gland (3).

9. USING suitable PRESS, REMOVE two

BUSHINGS (17) from tube (2).

10. IF DAMAGED, REMOVE lubrication FITTING

(18).

1. Inspect piston, linear piston, and tube for

scratches or scoring.

2. Inspect threads on linear piston, screw, tube,

and gland for wear or damage.

20-127
TM 5-2420-224-34

BACKHOE STABILIZER CYLINDER REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
packings and seal prior to
assembly.

1. IF REMOVED, INSTALL new lubrication

FlTTING (1).

2. USING suitable PRESS, INSTALL two

BUSHINGS (2) in tube (3).

3. INSTALL new BEARING (4) and new wiper

(5) in gland (6).

4. INSTALL two new PACKINGS (7 and 8).

5. INSTALL new seal (9) and new PACKING

(lo).

6. INSTALL GLAND (6) on linear piston (11).

20-128
 TM 5-2420-224-34

BACKHOE STABILIZER CYLINDER REPAIR (CONT)

7. INSTALL two new wear RINGS (12) on piston

(13).

8. INSTALL new backup RING (14) and new

SEAL (15).

9. INSTALL PISTON (13) on linear piston (11).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

10. APPLY COAT of SEALING COMPOUND to

THREADS of screw (16) and INSTALL washer
(17) and SCREW (16) in linear piston (11).

11. INSTALL linear PISTON (11) in tube (3).

20-129
TM 5-2420-224-34

BACKHOE STABILIZER CYLINDER REPAIR (CONT)

12. USING spanner WRENCH, THREAD GLAND

(6) in tube (3) and TIGHTEN to 100-200 Ib-ft
(135-271 NŽm)

13. INSTALL self-tapping SCREW (18) in tube (3).

NOTE
Follow-on Maintenance:
Install backhoe stabilizer cylinder
(TM 5-2420-224-20).

20-130
 TM 5-2420-224-34

Section XVI. BACKHOE/CRANE TILT CYLINDER REPAIR

OVERVIEW

This section illustrates and describes procedures for repair of the backhoe/crane tilt cylinder. A list of
tasks contained in this section is shown below.

Page

Backhoe/Crane Tilt Cylinder (J.I. Case) Repair . . . . . . . . . . . . . . . . . . . . . . . 20-131

Backhoe/Crane Tilt Cylinder (Aeroquip) Repair . . . . . . . . . . . . . . . . . . . . . . . . 20-137

BACKHOE/CRANE TILT CYLINDER (J.I. CASE) REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description

Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 TM 5-2420-224-20 Backhoe Tilt Cylinder
(SEE) or Crane Tilt
Materials/Parts: Cylinder (HMMH)
Removed
Kit, Parts
General Safety Instructions:
Compound, Sealing Appendix B, Item 15

Oil, Lubricating Appendix B, Item 30

WARNING
Rags Appendix B, Item 40
Fuel and oil are slippery and
can cause falls. To avoid
References:
injury, wipe up spilled fuel or
TM 5-2420-224-20 oil with rags.

DISASSEMBLY

NOTE
Procedure the same for both
vehicles.

1. REMOVE SCREW (1).

2. USING spanner WRENCH, REMOVE GLAND

(2) from tube (3).

20-131
TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (J.I. CASE) REPAIR (CONT)

3. REMOVE connecting LINK (4) from tube (3).

4. REMOVE SCREW (5) and washer (6) from

connecting link (4).

5. REMOVE PISTON (7) from connecting link

(4).

6. REMOVE two wear rings (8), gasket (9), and

SEAL (10) from piston (7). DISCARD SEAL.

20-132
 TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (J.I. CASE) REPAIR (CONT)

7. REMOVE GLAND (2) from connecting link (4).

8. REMOVE and DISCARD O-RING (11) and

PACKING (12) from gland (2).

9. REMOVE and DISCARD SEAL (13), WIPER

(14), and BEARING (15) from gland (2).

20-133
TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (J.I. CASE) REPAIR (CONT)

10. IF DAMAGED, REMOVE two lubrication

FllTINGS (16).

INSPECTION

1. Inspect piston, connecting link, and tube for

scratches or scoring.

2. Inspect threads on connecting link, piston

screw, tube, and gland for wear or damage.

ASSEMBLY

NOTE
Procedure is the same for both
vehicles.

Apply coat of lubricating oil to

packing, O-ring, and seals prior
to assembly.

1. IF REMOVED, INSTALL two new lubrication

FITTINGS (1).

2. INSTALL new BEARING (2), new wiper (3),

and new seal (4) in gland (5).

20-134
 TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (J.I. CASE) REPAIR (CONT)

3. INSTALL new PACKING (6) and new O-RING

(7) on gland (5).

4. INSTALL GLAND (5) on connecting link (8).

5. INSTALL new SEAL (9), gasket (10), and two

wear rings (11) on piston (12).

20-135
TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (J.I. CASE) REPAIR (CONT)

6. INSTALL PISTON (12) on connecting link (8).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

7. APPLY COAT of SEALING COMPOUND to

THREADS of screw (13) and INSTALL
SCREW (13) and washer (14) in connecting
link (8). TIGHTEN SCREW to 300-400 Ib-ft
(221-295 N.m).

8. INSTALL connecting LINK (8) in tube (15).

9. USING spanner WRENCH, INSTALL GLAND

(5) in tube (15) and TIGHTEN to 100-200 Ib-ft
(136-271 N.m).

10. INSTALL SCREW (16).

NOTE
Follow-on Maintenance:
Install backhoe tilt cylinder (SEE)
or crane tilt cylinder (HMMH)
(TM 5-2420-224-20).

20-136
 TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (Aeroquip) REPAR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit. SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5984 TM 5-2420-224-20 Backhoe Tilt Cylinder
(SEE) or Crane Tilt
Materials/Parts: Cylinder (HMMH)
Removed
Kit
Compound, Sealing Appendix B, item 15 General Safety Instructions:

Oil, Lubricating Appendix B, item 30

Rags WARNING
Appendix B, item 40
Fuel and oil are slippery and
References: can cause falls. To avoid
injury, wipe up spilled fuel or
TM 5-2420-224-20
oil with rags.

Adhesive causes immediate

bonding on contact with
eyes, skin, or clothing and
also gives off harmful vapors.
Wear protective goggles and
use in well-ventilated area. If
adhesive gets in eyes, try to
keep eyes open; flush eyes
with water for 15 minutes
and get immediate medical
attention.

DISASSEMBLY

NOTE
Procedure is the same for both
vehicles.

1. REMOVE HEAD (1) from cylinder tube (2).

20-137
 TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (AEROQUIP) REPAIR (CONT)

2. REMOVE piston ROD (3) from cylinder tube

(2).

NOTE
It may be necessary to place
piston rod in soft-jawed vise to
perform steps 3 and 5.

3. IF DAMAGED, REMOVE PISTON (4) from

piston rod (3).

4. REMOVE and DISCARD PACKING (5) from

piston (4).

5. REMOVE rod clevis (6) and HEAD (1) from

piston rod (3).

6. IF DAMAGED, REMOVE two sleeve

BUSHINGS (7) from rod clevis (6).

20-138
 TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (AEROQUIP) REPAIR (CONT)

7. REMOVE and DISCARD O-RING (8), backup

WASHER (9), rod WIPER (10), rod BEARING
(11), and PACKING (12) from head (1).

8. IF DAMAGED, REMOVE lubrication FlTTING

(13) from cylinder tube (2).

9. IF DAMAGED, REMOVE sleeve BUSHING

(14) from cylinder tube (2).

ASSEMBLY

NOTE
Procedure is the same for both
vehicles.
Apply coat of lubricating oil to
packings and O-ring prior to
assembly.

1. IF REMOVED, INSTALL new sleeve

BUSHING (1) in cylinder tube (2).

2. IF REMOVED, INSTALL new lubrication

FITTING (3) in cylinder tube (2).

20-139
 TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (AEROQUIP) REPAIR (CONT)

3. INSTALL new packing (4), new rod BEARING

(5), new rod wiper (6), new backup washer
(7), and new O-ring (8) in head (9).

IF REMOVED, INSTALL two new sleeve

BUSHINGS (10) in rod clevis (11).

NOTE
It may be necessary to place
piston rod in soft-jawed vise to
perform steps 5 and 7.

5. INSTALL HEAD (9) and rod clevis (11) on

piston rod (12).

6. INSTALL new PACKING (13) on piston (14).

7. IF REMOVED, apply COAT of SEALING

COMPOUND to THREADS of piston rod (12)
and INSTALL new PISTON (14) on piston rod
(12).

20-140
 TM 5-2420-224-34

BACKHOE/CRANE TILT CYLINDER (AEROQUIP) REPAIR (CONT)

8. INSTALL piston ROD (12) in cylinder tube (2).

9. APPLY COAT of SEALING COMPOUND to

THREADS of head (9) and INSTALL HEAD
(9) in cylinder tube (2).

NOTE
Follow-on Maintenance:
Install backhoe tilt cylinder (SEE)
or crane tilt cylinder (HMMH)
(TM 5-2420-224-20).

20-141
TM 5-2420-224-34

Section XVII. BACKHOE/CRANE LATCH CYLINDER REPAIR

BACKHOE/CRANE LATCH CYLINDER REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 TM 5-2420-224-20 Backhoe Latch Cylinder
(SEE) or Crane Latch
Materials/Parts: Cylinder (HMMH)
Removed
Kit, Parts
General Safety Instructions:
Compound, Sealing Appendix B, Item 15
Oil, Lubricating Appendix B, Item 30
WARNING
Rags Appendix B, Item 40 Fuel and oil are slippery and
References: can cause falls. To avoid
injury, wipe up spilled fuel or
TM 5-2420-224-20 oil with rags.

DISASSEMBLY

NOTE
Procedure is the same for both
vehicles.
Procedure is the same for both
latch cylinders.

1. LIFT lock RING (1) clear of slot in latch

cylinder (2).

NOTE
Lock ring will come out during
gland removal.

2. REMOVE GLAND (3) and lock ring (1) from

latch cylinder (2).

20-142
 TM 5-2420-224-34

BACKHOE/CRANE LATCH CYLINDER REPAIR (CONT)

3. REMOVE piston ROD (4) from latch cylinder

(2).

4. REMOVE nut (5) and PISTON (6) from piston

rod (4).

5. REMOVE and DISCARD slipper RING (7) and

PACKING (8) from piston (6).

20-143
 TM 5-2420-224-34

BACKHOE/CRANE LATCH CYLINDER REPAIR (CONT)

6. REMOVE GLAND (3) from piston rod (4).

7. REMOVE and DISCARD PACKING (9) and

WASHER (10) from gland (3).

8. REMOVE and DISCARD SEAL (11) and

SEAL (12) from gland (3).

9. IF DAMAGED, REMOVE FITTING (13).

1. Inspect piston, piston rod, and cylinder for

scratches or scoring.

2. Inspect threads on piston rod, cylinder, and

gland for wear or damage.

20-144
 TM 5-2420-224-34

BACKHOE/CRANE LATCH CYLINDER REPAIR (CONT)

ASSEMBLY

NOTE
Procedure is the same for both
vehicles.
Procedure is the same for both
latch cylinders.
Apply coat of lubricating oil to
packings and seals prior to
assembly.

1. IF REMOVED, INSTALL new FITTING (1).

2. INSTALL new SEAL (2) and new SEAL (3) in

gland (4).

3. INSTALL new washer (5) and new PACKING

(6) on gland (4).

4. INSTALL GLAND (4) on piston rod (7).

20-145
 TM 5-2420-224-34

BACKHOE/CRANE LATCH CYLINDER REPAIR (CONT)

5. INSTALL new PACKING (8) and new slipper

ring (9) on piston (10).

WARNING
Adhesive causes immediate
bonding on contact with eyes,
skin, or clothing and also gives
off harmful vapors. Wear
protective goggles and use in
well-ventilated area. If adhesive
gets in eyes, try to keep eyes
open; flush eyes with water for
15 minutes and get immediate
medical attention.

6. APPLY COAT of SEALING COMPOUND to

THREADS of piston rod (7) and INSTALL
PISTON (10) and nut (11) on piston rod (7).
TIGHTEN NUT to 45-50 Ib-ft (33-36 N.m).

7. INSTALL piston ROD (7) in latch cylinder

(12).

20-146
 TM 5-2420-224-34

BACKHOE/CRANE LATCH CYLINDER REPAIR (CONT)

NOTE
Lock ring cannot be installed
until gland is almost completely
tightened.
When completely tightened, both
fitting holes must be in line with
each other.

8. WHEN GLAND (4) is ALMOST completely

tightened, INSTALL lock RING (13) in hole
and COMPLETE TIGHTENING until lock ring
(13) snaps into slot on latch cylinder (12).

NOTE
Follow-on Maintenance:
Install backhoe latch cylinder
(SEE) or crane latch cylinder
(HMMH) (TM 5-2420-224-20).

20-147
 TM 5-2420-224-34

Section XVIII. HYDRAULIC OIL COOLER REPAIR

HYDRAULIC OIL COOLER REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Tools and Special Equipment: Equipment Condition:

Tool Kit, SC 5180-90-CL-N26
Reference Condition Description
Materials/Parts: TM 5-2420-224-20 Hydraulic Oil Cooler
Washer, Lock (6) Removed
TM 5-2420-224-20 Hydraulic Oil Cooler
Washer, Lock (6)
Thermal Switches
Washer, Lock (6) Removed

References:
TM 5-2420-224-20

DISASSEMBLY

1. REMOVE FAN IMPELLER (TM 5-2420-224-

20).

2. REMOVE two screws (1) and TERMINAL (2).

3. REMOVE 12 screws (3), 12 lock washers (4),

12 washers (5), and PLATE (6). DISCARD
lock WASHERS.

4. REMOVE four SCREWS (7).

5. REMOVE screw (8), washer (9), and

HOUSING (10).

20-148
 TM 5-2420-224-34

HYDRAULIC OIL COOLER REPAIR (CONT)

CAUTION
Support oil cooler (11) to
prevent damage to fins.

6. REMOVE six SCREWS (12) and six lock

washers (13). DISCARD lock WASHERS.

7. REMOVE oil COOLER (11) from housing (14).

8. IF DAMAGED, REMOVE six PLUGS (15) and

six tee nuts (16).

ASSEMBLY

1. IF REMOVED, INSTALL six new tee nuts (1)

and six new PLUGS (2).

20-149
 TM 5-2420-224-34

HYDRAULIC OIL COOLER REPAIR (CONT)

CAUTION
Support oil cooler to prevent
damage to fins.

2. INSTALL oil COOLER (3) in housing (4).

3. INSTALL six SCREWS (5) and six new lock

washers (6).

4. INSTALL HOUSING (7), screw (8), and

washer (9).

5. INSTALL four SCREWS (10).

6. INSTALL PLATE (11), 12 washers (12). 12

new lock washers (13), and 12 screws (14).

7. INSTALL TERMINAL (15) and two screws

(16).

8. INSTALL FAN IMPELLER (TM 5-2420-224-

20).

NOTE
Follow-on Maintenance:
Install hydraulic oil cooler thermal
switches (TM 5-2420-224-20).
Install hydraulic oil cooler (TM 5-
2420-224-20).

20-150
 TM 5-2420-224-34

Section XIX. CRANE VALVE BANK REPAIR

CRANE VALVE BANK REPAIR

This task covers: a. Disassemble b. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: Page 11-24 Crane Valve Bank
Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety Instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
WARNING
Washer, Lock (6) Fuel and oil are slippery and
can cause falls. To avoid
Washer, Lock (2) injury, wipe up spilled fuel or
Kit oil with rags.

Kit
Oil, Lubricating Appendix B, Item 30
Rags Appendix B, Item 40

DISASSEMBLY

CRANE VALVE BANK

1. REMOVE three nuts (1), three lock washers

(2), and outlet MANIFOLD (3). DISCARD lock
WASHERS.

2. REMOVE four packings (4) and tilt valve

SECTION (5). DISCARD PACKINGS.

3. REPEAT STEP 2 for these valve sections:

right outrigger (6), left outrigger (7), horizontal
(8), extension (9), outer boom (10), inner
boom (11), and rotator (12).

4. REMOVE four packings (13) and inlet

MANIFOLD (14). DISCARD PACKINGS.

5. REMOVE three NUTS (15) and three lock

washers (16) from three tie rods (17).
DISCARD lock WASHERS.

20-151
TM 5-2420-224-34

CRANE VALVE BANK REPAIR (CONT)

Outlet Manifold Disassembly

REMOVE and DISCARD two PLUG (1 and 2).

Outlet Manifold Assembly

INSTALL two new PLUGS (1 and 2).

Valve Section Disassembly

NOTE
Procedure is the same for all eight
valve sections.

1. REMOVE plug (1), packing (2), spring (3),

and PISTON (4). DISCARD PACKING.

2. REMOVE two screws (5), two lock washers

(6), and RETAINER (7). DISCARD lock
WASHERS.

3. REMOVE SPACER (8) from retainer (7).

4. REMOVE SPOOL (9) from body (10).

5. REMOVE and DISCARD two O-RINGS (11).

6. COMPRESS SPRING (12) and REMOVE

SCREW (13).

7. CAREFULLY RELEASE SPRING (12) and

REMOVE holder (14), SPRING (12), and
holder (15).

8. REMOVE STEM (16).

20-152
 TM 5-2420-224-34

CRANE VALVE BANK REPAIR (CONT)

Valve Section Assembly

NOTE
Procedure is the same for all
eight valve sections.
AppIy coat of Iubricating oil to
packing and O-rings prior to
assembly.

1. INSTALL STEM (1) on spool (2).

2. INSTALL holder (3), SPRING (4), and holder

(5).

3. COMPRESS SPRING (4) and INSTALL

SCREW (6).

4. INSTALL two new O-RINGS (7) in body (8).

5. INSTALL SPOOL (2) in body (8).

6. INSTALL SPACER (9) in retainer (10).

7. INSTALL RETAINER (10), two new lock

washers (11), and two screws (12).

8. INSTALL PISTON (13), Spring (14), new

packing (15), and plug (16).

Inlet Manifold Disassembly

1. REMOVE PLUG (1).

2. REMOVE safety relief VALVE (2) and two

packings (3). DISCARD PACKINGS.

Inlet Manifold Assembly

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL two new packings (3) and safety

relief VALVE (2).

2. INSTALL PLUG (1).

20-153
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CRANE VALVE BANK REPAIR (CONT)

ASSEMBLY

CRANE VALVE BANK

NOTE
Apply coat of lubricating oil to packings prior to assembly.

1. INSTALL three new lock washers (1) and three NUTS (2) on three tie rods (3).

CAUTION
All packings between valve sections must be replaced any time the tie rod nuts
are loosened or removed. Failure to do so may result in hydraulic fiuld leaks
and/or equipment damage.

2. INSTALL inlet MANIFOLD (4) and four new packings (5).

NOTE
Procedure is the same for all eight valve sections.

3. INSTALL rotator valve SECTION (6) and four new packings (7).
4. REPEAT STEP 3 for these valve sections: inner boom (8), outer boom (9), extension (10), horizontal
(11), left outrigger (12), right outrigger (13), and tilt (14).
5. INSTALL outlet MANIFOLD (15).

NOTE
Before tightening nuts, make sure equal amount of threads are exposed on both ends of
crane valve bank.

6. INSTALL three new lock washers (16) and three NUTS (17).

NOTE
Follow-on Maintenance:
Install crane valve bank (page 11-24).

20-154
 TM 5-2420-224-34

Section XX. FORKLIFT MAST ASSEMBLY REPAIR

FORKLIFT MAST ASSEMBLY REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description

Tools and Special Equipment: Page 11-40 Forklift Mast Assembly

Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety Instructions:

Materials/Parts:
Washer, Look (2) WARNING
Forklift rail upright weighs
Nut, Lock
172 pounds (78 kilograms).
Washer, Lock (2) To avoid personal injury, use
a hoist or suitable lifting
Washer, Lock (2)
device when lifting forklift rail
Washer, Lock (2) upright.

Washer, Lock (6) Forklift upright weighs 196

pounds (89 kilograms). To
Washer, Lock (4) avoid personal injury, use a
Washer, Look (2) hoist or suitable lifting device
when lifting forklift upright.
Washer, Look (2)
Forklift mast assembly
Washer, Lock (4) weighs 587 pounds (267
Washer, Lock (2) kilograms). To avoid personal
injury, use a hoist or suitable
Personnel Required: (2) lifting device when lifting
forklift mast assembly.

20-155
 TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPAIR (CONT)

DISASSEMBLY

1. REMOVE two capscrews (1), two lock washers (2), and GUIDE (3). DISCARD lock WASHERS.

NOTE
Tag all lines prior to disconnecting to aid in connecting.

2. DISCONNECT HOSE assembly (4).

3. REMOVE two setscrews (5) and CLAMP (6) from hose assembly (4).

4. REMOVE lock nut (7), capscrew (8), and GUIDE (9). DISCARD lock NUT.

20-156
 TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPAIR (CONT)

5. REMOVE two capscrews (10), two lock washers (11), and junction BLOCK (12). DISCARD lock
WASHERS.

20-157
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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

6. REMOVE two capscrews (13), two lock washers (14), and two CLAMPS (15). DISCARD lock
WASHERS.

7. REMOVE two capscrews (16), two lock washers (17), and BRACKET (18). DISCARD lock WASHERS.

8. REMOVE six nuts (19), six lock washers (20), six capscrews (21), and three GUIDES (22). DISCARD
lock WASHERS.

9. DISCONNECT and REMOVE two HOSES (23).

10. DISCONNECT and REMOVE two HOSES (24).

11. REMOVE two nuts (25) and two ELBOWS (26).

12. REMOVE retaining ring (27) and PULLEY (28).

13. REMOVE four capscrews (29), four lock washers (30), and two BRACKETS (31 and 32). DISCARD
lock WASHERS.

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 TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPAIR (CONT)

14. TURN MAST assembly (33) OVER.

15. REMOVE rail UPRIGHT (34) from mast assembly (33).

16. REMOVE two load BEARINGS (35) and spacer(s) (36).

17. REMOVE two capscrews (37), two lock washers (38), and BLOCK (39). DISCARD lock WASHERS.

20-159
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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

18. REMOVE UPRIGHT (40) from outer upright (41).

19. REMOVE FORKLIFT BOOTSTRAP CHAIN (42) (page 11-57).

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 TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPAIR (CONT)

20. REMOVE four load BEARINGS (43) and spacer(s) (44).

21. REMOVE two retaining rings (45), two bearings (46), two outer TIRES (47), and two PULLEYS (48).

22. REMOVE two screws (49), two lock washers (50), and CUSHION (51). DISCARD lock WASHERS.

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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

23. REMOVE two load ROLLER assemblies (52) and shim(s) (53) from outer upright (41).

24. REMOVE four screws (54), four lock washers (55), and two CUSHIONS (56). DISCARD lock
WASHERS.

25. REMOVE two quick-release pins (57) and two PLATES (58).

26. REMOVE two CAPSCREWS (59) and two lock washers (60). DISCARD lock WASHERS.

27. REMOVE two BUSHINGS (61).

20-162
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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

ASSEMBLY

1. INSTALL two new lock washers (1) and two CAPSCREWS (2).

2. INSTALL two PLATES (3) and two quick-release pins (4).

3. INSTALL two CUSHIONS (5), four new lock washers (6), and four screws (7).

4. INSTALL shim(s) (8) and two load ROLLER assemblies (9) on outer upright (10).

5. INSTALL two BUSHINGS (11).

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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

6. INSTALL CUSHION (12), two new lock washers (13), and two screws (14).

7. INSTALL two PULLEYS (15), two outer TIRES (16), two bearings (17), and two retaining rings (18).

8. INSTALL spacer(s) (19) and four load BEARINGS (20).

20-164
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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

9. INSTALL FORKLl~ BOOTSTRAP CHAIN (21) (page 11-57).

10. INSTALL UPRIGHT (22) in outer upright (10).

20-165
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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

11. INSTALL BLOCK (23), two new lock washers (24), and two capscrews (25).

12. INSTALL spacer(s) (26) and two load BEARINGS (27).

13. INSTALL rail UPRIGHT (28) in upright (22).

20-166
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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

14. CHECK CLEARANCE between load roller (9), bearings (20 and 27), and channels of uprights (10, 22,
and 28) by PRYING BETWEEN upright and load roller or bearing so that opposite Ioad roller or
bearing is tight against upright. MEASURE CLEARANCE between load roller or bearing and upright.
Clearance should be 0.030 in. (0.076 cm).

15. IF CLEARANCE is GREATER than 0.030 in. (0.076 cm), REPEAT APPROPRIATE Disassembly steps
for load roller or bearing being measured and ADD SHIM(S) or SPACER(S) as required to achieve
0.030 in. (0.076 cm) clearance; perform appropriate Assembly steps and repeat clearance check.

16. IF CLEARANCE is LESS than 0.030 in. (0.076 cm), REPEAT APPROPRIATE Disassembly steps for
load roller or bearing being measured and REMOVE SHIM(S) or SPACER(S) as required to achieve
0.030 in. (0.076 cm) clearance; perform appropriate Assembly steps and repeat clearance check.

17. REPEAT STEPS 14 thru 16 for each load roller or bearing.

20-167
TM 5-2420-224-34

FORKLIFT MAST ASSEMBLY REPAIR (CONT)

18. TURN MAST assembly (29) OVER.

19. INSTALL two BRACKETS (30 and 31), four new lock washers (32), and four capscrews (33).

20. INSTALL PULLEY (34) and retaining ring (35).

21. INSTALL two ELBOWS (36) and two nuts (37).

22. INSTALL and CONNECT two HOSES (38).

23. INSTALL and CONNECT two HOSES (39).

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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

24. INSTALL three GUIDES (40), six capscrews (41), six new lock washers (42), and six nuts (43).

25. INSTALL BRACKET (44), two new lock washers (45), and two capscrews (46).

26. INSTALL two CLAMPS (47), two new lock washers (46), and two capscrews (49).

27. INSTALL junction BLOCK (50), two new lock washers (51), and two capscrews (52).

20-169
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FORKLIFT MAST ASSEMBLY REPAIR (CONT)

28. INSTALL GUIDE (53), capscrew (54), and new lock nut (55).
29. INSTALL CLAMP (56) and two setscrews (57) on hose assembly (58).
30. CONNECT HOSE assembly (58).
31. INSTALL GUIDE (59), two new lock washers (60), and two capscrews (61).

NOTE
Follow-on Maintenance:
Install forklift mast assembly (page 11-40).
Bleed forklift lift cylinder (page 11-51).
Sequence forklift lift cylinder (page 11-51).

20-170
 TM 5-2420-224-34

Section XXI. FORKLIFT CARRIAGE ASSEMBLY REPAIR

FORKLIFT CARRIAGE ASSEMBLY REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Forklift Rotator Removed
Shop Equipment, SC 4910-95-CL-A31 TM 5-2420-224-20 Forklift Rotator Cylinder
Tool Kit, SC 5180-90-CL-N26 Removed

Materials/Parts: General Safety Instructions:

Screw, Lock (8)
Pin, Cotter (2) WARNING
Pin, Cotter (2) Forklift rotator assembly
weighs 356 pounds (162
Seal (2) kilograms). To avoid personal
injury, use a hoist or suitable
Adhesive, Rubber Appendix B, item 4
lifting device when lifting
Compound, Sealing Appendix B, Item 15 forkiift rotator assembly.

Oil, Lubricating Appendix B, item 30 Adhesive causes immediate

bonding on contact with
Personnel Required: (2) eyes, skin, or clothing and
also gives off harmful vapors.
References:
Wear protective goggles and
TM 5-2420-224-20 use in well-ventilated area. If
TM 9-214 adhesive gets in eyes, try to
keep eyes open; flush eyes
with water for 15 minutes
and get immediate medical
attention.

20-171
 TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPAIR (CONT)

DISASSEMBLY

1. REMOVE eight lock screws (1) and BEARING

assembly (2) from carriage (3). DISCARD lock
SCREWS.

2. REMOVE four cotter pins (4), two pins (5),

and two CHAINS (6). DISCARD cotter PINS.

20-172
 TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPAIR (CONT)

3. REMOVE two retaining rings (7), two spacers

(8), and two chain anchor STAKES (9).

NOTE
Tag lines prior to removal to aid
in installation.

4. REMOVE two HOSE assemblies (1 0).

5. REMOVE two nuts (11) and two ELBOWS

(12).

6. REMOVE pin (13) and PLUG (14).

7. HOLD BEARING assembly (2) on its SIDE

with plug (14) hole on top, ROTATE inner
RACE (15), and REMOVE 63 BALLS (16).

8. REMOVE inner RACE (15) from outer race

(17).

9. REMOVE and DISCARD two SEALS (18).

10. IF DAMAGED, REMOVE two lubrication

FITTINGS (19).

INSPECTION
Inspect bearings (TM 9-214).

20-173
TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPAIR (CONT)

ASSEMBLY
NOTE
Apply coat of lubricating oil to
seals prior to assembly.

1. IF REMOVED, INSTALL two new lubrication

FITTINGS (1).

2. APPLY COAT of RUBBER ADHESIVE to

GROOVES of inner race (2) and outer race (3).
3. INSTALL two new SEALS (4).

CAUTION
Allow adhesive to set up for 1
hour before assembling inner
and outer races. Failure to do
so may cause seals to fail.

4. INSTALL inner RACE (2) in outer race (3).

5. INSTALL 63 BALLS (5).
6. INSTALL PLUG (6) and pin (7).

7. INSTALL two ELBOWS (8) and two nuts (9).

8. INSTALL two HOSE assemblies (10).
9. INSTALL two chain anchor STAKES (11), two
spacers (12), and two retaining rings (13).

20-174
 TM 5-2420-224-34

FORKLIFT CARRIAGE ASSEMBLY REPAIR (CONT)

10. INSTALL two CHAINS (14), two pins (15),

and four new cotter pins (16).

11. APPLY COAT of SEALING COMPOUND to

THREADS of eight new lock screws (17).
INSTALL BEARING assembly (18) and eight
lock screws (17) on carriage (19). TIGHTEN
lock SCREWS in crisscross pattern to 43-46
lb-ft (60-66 N.m).

NOTE
Follow-on Maintenance:
Install forklift rotator cylinder
(TM 5-2420-224-20).
Install forklift rotator (TM 5-2420-
224-20).

20-175
TM 5-2420-224-34

Section XXII. FORKLIFT VALVE REPAIR

FORKLIFT VALVE REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Applicable Configuration: References:

HMMH LO 5-2420-224-12

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Page 11-37 Forklift Valve Removed
Materials/Parts:
General Safety Instructions:
Kit, Parts (2)
Kit, Parts
WARNING
Kit, Parts (2) Fuel and oil are slippery and
Appendix B, Item 30 can cause falls. To avoid
Oil, Lubricating
injury, wipe up spilled fuel or
Rags Appendix B, Item 40 oil with rags.

DISASSEMBLY

CAUTION
Note direction of diode prior to removal to aid in installation. Failure to do so
could result in damage to equipment when diode is installed.

1. REMOVE DIODE assembly (1) from coil (2).

NOTE
Steps 2 thru 4 are the same for both solenoid valves.

2. REMOVE nut (3) and COIL (2).

3. REMOVE solenoid VALVE (4) from valve body (5).
4. REMOVE and DISCARD backup RING (6), O-RING (7), backup RING (8), backup RING (9), O-Ring
(10), backup RING (11), and O-RING (12) from solenoid valve (4).

NOTE
Steps 5 and 6 are the same for both globe valves.

5. REMOVE globe VALVE (13) from valve body (5).

20-176
 TM 5-2420-224-34

FORKLIFT VALVE REPAIR (CONT)

6. REMOVE and DISCARD backup RING (14), O-RING (15), backup RING (16), and O-RING (17) from
globe valve body (18).

NOTE
Steps 7 and 8 are the same for all flow regulating valves.

7. REMOVE flow regulating VALVE (19) from valve body (5).

8. REMOVE and DISCARD O-RING (20), backup RING (21), backup RING (22), O-RING (23), backup
RING (24), and O-RING (25) from flow regulating valve body (26).

20-177
TM 5-2420-224-34

FORKLIFT VALVE REPAIR (CONT)

ASSEMBLY

20-178
 TM 5-2420-224-34

FORKLIFT VALVE REPAIR (CONT)

NOTE
• Steps 1 and 2 are the same for all flow regulating valves.

• Apply coat of lubricating oil to O-rings prior to assembly.

1. INSTALL new O-RING (1), new backup RING (2), new O-RING (3), new backup RING (4), new
backup RING (5), and new O-RING (6) on flow regulating valve body (7).

2. INSTALL flow regulating VALVE (8) in valve body (9).

NOTE
Steps 3 and 4 are the same for both globe valves.

3. INSTALL new O-RING (10), new backup RING (11), new O-RING (12), and new backup RING (13) on
globe valve body (14).

4. INSTALL globe VALVE (15) in valve body (9).

NOTE
Steps 5 thru 7 are the same for both solenoid valves.

5. INSTALL new O-RING (16), new backup RING (17), new O-RING (18), new backup RING (19), new
backup RING (20), new O-RING (21), and new backup RING (22) on solenoid valve (23).

6. INSTALL solenoid VALVE (23) in valve body (9).

7. INSTALL COIL (24) and nut (25).

8. INSTALL DIODE assembly (26) on coil (24).

NOTE
Follow-on Maintenance:
Install forklift valve (page 11-37).
Bleed forklift lift cylinder (page 11-51).
Fill front and rear hydraulic tanks (LO 5-2420-224-12).

20-179
 TM 5-2420-224-34

Section XXIII. FORKLIFT TILT CYLINDER REPAIR

FORKLIFT TILT CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Forklift Tilt Cylinder
Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5764
Spanner Wrench, P/N 678602

Materials/Parts: WARNING
Fuel and oil are slippery and
Nut, Lock can cause falls. To avoid
injury, wipe up spilled fuel or
Kit
oil with rags.
Oil, Lubricating Appendix B, Item 30
Rags Appendix B, Item 40

References:
TM 5-2420-224-20

1. USING SPANNER WRENCH, REMOVE

RETAINER (1) from housing (2).

20-180
 TM 5-2420-224-34

FORKLIFT TILT CYLINDER REPAIR (CONT)

2. REMOVE ROD (3) from housing (2).

3. REMOVE lock nut (4), PISTON (5), and

O-ring (6). DISCARD lock NUT and O-RING.

4. REMOVE and DISCARD SEAL (7) and

O-RING (8) from piston (5).

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TM 5-2420-224-34

FORKLIFT TILT CYLINDER REPAIR (CONT)

5. REMOVE RETAINER (1) from rod (3).

6. REMOVE and DISCARD SEAL (9), O-RING

(10), backup RING (11), and WIPER (12)
from retainer (1).

NOTE
Note number of turns necessary to
remove rod end connector.

7. REMOVE rod end CONNECTOR (13) and jam

nut (14) from rod (3).

20-182
 TM 5-2420-224-34

FORKLIFT TILT CYLINDER REPAIR (CONT)

8. USING suitable PRESS, REMOVE BUSHING

(15) from rod end connector (13).

9. USING suitable PRESS, REMOVE two

BUSHINGS (16) from housing (2).

ASSEMBLY

NOTE
Apply coat of lubricating oil to
O-rings and seals prior to
assembly.

1. USING suitable PRESS, INSTALL two

BUSHINGS (1) in housing (2).

20-183
 TM 5-2420-224-34

FORKLIFT TILT CYLINDER REPAIR (CONT)

2. USING suitable PRESS, INSTALL BUSHING

(3) in rod end connector (4).

3. INSTALL jam NUT (5) on rod end connector

(4).

4. INSTALL rod end CONNECTOR (4) in rod (6)

number of turns noted and TIGHTEN jam
NUT (5) against rod (6).

5. INSTALL new wiper (7), new backup ring (8),

new O-ring (9), and new SEAL (10) on
retainer (11).

20-184
 TM 5-2420-224-34

FORKLIFT TILT CYLINDER REPAIR (CONT)

6. INSTALL RETAINER (11) on rod (6).

7. INSTALL new O-RING (12) and new seal (13)

on piston (14).

8. INSTALL new O-ring (15), PISTON (14),

new lock nut (16) on rod (6). TIGHTEN
NUT to 200-225 Ib-ft (271-305 N.m).

20-185
TM 5-2420-224-34

FORKLIFT TILT CYLINDER REPAIR (CONT)

9. INSTALL ROD (6) in housing (2). USING

SPANNER WRENCH, THREAD RETAINER
(11) into housing (2) and TIGHTEN to
300-350 Ib-ft (407-475 N.m).

NOTE
Follow-on Maintenance:
Install forklift tilt cylinder (TM 5-
2420-224-20).

20-186
 TM 5-2420-224-34

Section XXIV. FORKLIFT ROTATOR CYLINDER

FORKLIFT ROTATOR CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Forklift Rotator Cylinder
Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety Instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5784

Materials/Parts:
WARNING
Nut, Lock Fuel and oil are slippery and
can cause falls. To avoid
Kit injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.

Rags Appendix B, Item 40

References:
TM 5-2420-224-20

DISASSEMBLY

1. REMOVE retaining RING (1).

2. PUSH RETAINER (2) APPROXIMATELY 2 in.

into shell (3) and REMOVE retaining RING
(4).

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 TM 5-2420-224-34

FORKLIFT ROTATOR CYLINDER REPAIR (CONT)

3. REMOVE ROD (5) from shell (3).

4. REMOVE lock nut (6) and PISTON (7) from

rod (5). DISCARD lock NUT.

5. REMOVE and DISCARD SEAL (8) and

backup RING (9) from piston (7).

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 TM 5-2420-224-34

FORKLIFT ROTATOR CYLINDER REPAIR (CONT)

6. REMOVE RETAINER (2) from rod (5).

7. REMOVE and DISCARD O-RING (10), backup

RING (11), WIPER (12), and SEAL (13).

NOTE
Apply coat of lubricating oil to
O-ring and seals prior to
assembly.

1. INSTALL new SEAL (1), new WIPER (2), new

backup RING (3), and new O-RING (4) on
retainer (5).

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TM 5-2420-224-34

FORKLIFT ROTATOR CYLINDER REPAIR (CONT)

2. INSTALL RETAINER (5) on rod (6).

3. INSTALL new backup RING (7) and new

SEAL (8) on piston (9).

4. INSTALL PISTON (9) and new lock nut (10)

on rod (6). TIGHTEN look NUT to 70-75 Ib-ft
(95-102 N.m).

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 TM 5-2420-224-34

FORKLIFT ROTATOR CYLINDER REPAIR (CONT)

5. INSTALL ROD (6) in shell (11).

6. PUSH RETAINER (5) APPROXIMATELY 2 in.

(50 mm) into shell (11) and lNSTALL retaining
RING (12).

7. lNSTALL retaining RING (13).

NOTE
Follow-on Maintenance:
Install forklift rotator cylinder
(TM 5-2420-224-20).

20-191
TM 5-2420-224-34

Section XXV. FORKLIFT LIFT CYLINDER REPAIR

FORKLIFT LIFT CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Applicable Configuration: Personnel Required: (2)

HMMH References:

Tools and Special Equipment: LO 5-2420-224-12

Shop Equipment, SC 4910-95-CL-A31 Equipment Condition:

Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 Reference Condition Description
Materials/Parts: Page 11-51 Forklift Lift Cylinder
Removed
Nut, Lock
General Safety Instructions:
Pin, Cotter
Nut, Lock
WARNING
Kit Fuel and oil are slippery and
Kit can cause falls. To avoid
injury, wipe up spilled fuel or
Caps and Plugs Appendix B, Item 8 oil with rags.
Oil, Lubricating Appendix B, Item 30
Rags Appendix B, Item 40

DISASSEMBLY

1. USING spanner WRENCH, REMOVE RETAINER (1) from tube (2).

2. REMOVE and DISCARD WIPER (3), RING (4), SEAL (5), backup RING (6), and O-RING (7) from
retainer (1).
3. USING spanner WRENCH, REMOVE RETAINER (8) from tube (9).
4. REMOVE and DISCARD WIPER (10), RING (11), SEAL (12), backup RING (13), and O-RING (14)
from retainer (8).
5. USING spanner WRENCH, REMOVE RETAINER (15) from housing (16).
6. REMOVE and DISCARD WIPER (17), RING (18), SEAL (19), backup RING (20), and O-RING (21)
from retainer (15).

NOTE
All three tubes must be removed as an assembly.

7. REMOVE TUBE assembly (22) from housing (16).

20-192
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

20-193
TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

8. REMOVE VALVE (23) and O-ring (24).

DISCARD O-RING.

9. DEPRESS and HOLD WASHER (25) at

bottom of tube (9). USING spanner WRENCH,
REMOVE PISTON (26). When piston (26)
clears tube (9), BE PREPARED to CATCH
washer (25), spacer (27), spring (28), and ball
(29).

10. REMOVE and DISCARD backup RING (30),

O-RING (31), SEAL (32), RING (33), and
BEARING (34) from piston (26).

11. REMOVE plug (35), lock nut (36), PLUNGER

(37), and spring (38) from cap (39). DISCARD
lock NUT, SPRING, and PLUNGER.

20-194
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

12. REMOVE TUBE (40) from tube (2).

13. REMOVE four piston rings (41) and sleeve

BUSHING (42) from tube (40).

14. REMOVE CAP (39) from tube (40).

20-195
TM 5-2420-224-34

FORKLlFT LIFT CYLINDER REPAIR (CONT)

15. REMOVE ootter pin (43), adjustment lock nut

(44), spring (45), PLATE (46), and spacer (47)
from cap (39). DISCARD cotter PIN and
adjustment lock NUT.

16. REMOVE TUBE (2) from tube (9).

20-196
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

17. REMOVE two piston rings (48) and sleeve

BUSHING (49) from tube (2).

18. REMOVE threaded bushing (50), O-ring (51),

check VALVE (52), and disc (53). DISCARD
O-RING.

19. REMOVE elbow fitting (54), spacer (55),

SPRING (56), and washer (57) from housing
(16).

20-197
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FORKLIFT LIFT CYLINDER REPAIR (CONT)

20. IF DAMAGED, REMOVE bleeder VALVE (58)

from tube (40).

NOTE
Apply coat of lubricating oil to
O-rings and seals prior to
assembly.

1. IF REMOVED, INSTALL new bleeder VALVE

(1) in tube (2) and TIGHTEN to 25-27 Ib-ft
(34-37 N.m).

CAUTION
Cap or plug all ports and ends
of hoses and tubes to prevent
contamination of hydraulic oil.
Failure to do so may result in
damage to equipment.

2. INSTALL washer (3), SPRING (4), spacer (5),

and elbow fitting (6) in housing (7). INSTALL
CAP or PLUG on elbow fitting (6).

20-198
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FORKLIFT LIFT CYLINDER REPAIR (CONT)

NOTE
Disc is symmetrical and may be
installed in either direction.

3. INSTALL disc (8), check VALVE (9), new

O-ring (10), and threaded bushing (11).
TIGHTEN threaded BUSHING to 40-50 Ib-ft
(54-68 N.m).

4. APPLY COAT of LUBRICATING OIL to

INSIDE of sleeve bushing (12) and two piston
RINGS (13).

NOTE
Make sure lip of sleeve bushing is
toward threaded end of tube.

5. INSTALL sleeve BUSHING (12) and two

piston rings (13) on tube (14).

6. INSTALL TUBE (14) in tube (15).

20-199
TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

7. INSTALL spacer (16), PLATE (17), spring

(18), new adjustment lock nut (19), and new
cotter pin (20) on cap (21).

NOTE
Make sure square end of cap
protrudes through plate at bottom
of tube.

8. INSTALL CAP (21) in tube (14).

NOTE
Make sure lip of sleeve bushing is
toward top of tube.

9. APPLY COAT of LUBRICATING OIL to

INSIDE of sleeve bushing (22) and four piston
RINGS (23).

10. INSTALL sleeve BUSHING (22) and four

piston rings (23) on tube (2).

20-200
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

11. INSTALL TUBE (2) in tube (14).

12. INSTALL cap (21), new spring (24), new

PLUNGER (25), and new lock nut (26) in
piston (27). TIGHTEN lock NUT to 7.5-9.0
lb-ft (10-12 N.m).

13. INSTALL PLUG (28) and TIGHTEN to 50-55

Ib-ft (68-75 N.m).

14. INSTALL new BEARING (29), new ring (30),

new seal (31), new O-ring (32), and new
backup ring (33) on piston (27).

20-201
TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

15. INSTALL BALL (34), spacer (35), spring (36),

and washer (37). THREAD PISTON (27) into
tube (15) until washer (37) pops into hole in
tube (15). DEPRESS WASHER (37) and
CONTINUE to THREAD PISTON (27) into
tube (15) until it bottoms out. BACK PISTON
(27) OUT until washer (37) POPS into hole.

16. INSTALL new O-ring (38) and VALVE (39)

and TIGHTEN to 15-20 Ib-ft (20-27 N.m).

17. INSTALL new O-RING (40), new backup

RING (41), new SEAL (42), new RING (43),
and new WIPER (44) on retainer (45).

18. INSTALL new O-RING (46), new backup

RING (47), new SEAL (48), new RING (49),
and new WIPER (50) on retainer (51).

19. INSTALL new O-RING (52), new backup

RING (53), new SEAL (54), new RING (55),
and new WIPER (56) on retainer (57).

20-202
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

CAUTION
Kit comes with four loaders
ranging in size from large to
small. Loaders must be used
during installation of retainers
to prevent damage to seals,
backup rings, etc.

NOTE
Apply coat of Iubricating oil to all
loaders and inside areas of all
retainers prior to assembly.

20. INSTALL largest LOADER in housing (58).

21. INSTALL TUBE assembly (59) in housing

(58).

22. REMOVE LOADER from housing (58).

20-203
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FORKLIFT LIFT CYLINDER REPAIR (CONT)

23. INSTALL second largest LOADER over

threads of tube (15).

24. USING spanner WRENCH, INSTALL

RETAINER (45) on housing (58) and
TIGHTEN RETAINER to 200-250 Ib-ft
(271-339 N.m).

25. REMOVE LOADER from tube (15).

26. INSTALL third largest LOADER over threads

of tube (14).

20-204
 TM 5-2420-224-34

FORKLIFT LIFT CYLINDER REPAIR (CONT)

27. USING spanner WRENCH, INSTALL

RETAINER (51) on tube (15) and TIGHTEN
RETAINER to 100-150 Ib-ft (136-203 N.m).

28. REMOVE LOADER from tube (14).

29. INSTALL smallest LOADER on tube (2).

30. USING spanner WRENCH, INSTALL

RETAINER (57) on tube (14) and TIGHTEN
RETAINER to 100-150 Ib-ft (136-203 N.m).

31. REMOVE LOADER from tube (2).

NOTE
Follow-on Maintenance:
Install forklift lift cylinder (page
11-51).
Bleed forklift lift cylinder (page
11-51).
Sequence forklift cylinder (page
11-51).
Fill front and rear hydraulic tanks
(LO 5-2420-224-12).

20-205
 TM 5-2420-224-34

Section XXVI. CRANE EXTERNAL END EXTENSION CYLINDER REPAIR

CRANE EXTERNAL END EXTENSION CYLINDER REPAIR

This task covers: a. Disassemble b. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane External End
Extension Cylinder
Shop Equipment, SC 4910-95-CL-A31 Removed
Tool Kit, SC 5180-90-CL-N26
Tool Outfit (HSTRU), NSN 4940-01-036-5784 General Safety Instructions:
Spanner Wrench, P/N 3Y140510

Materials/Parts:
WARNING
Kit Fuel and oil are slippery and
can cause falls. To avoid
Kit (2) injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.

Rags Appendix B, Item 40

References:
TM 5-2420-224-20

DISASSEMBLY

1. USING SPANNER WRENCH, REMOVE

HEAD (1) from housing (2).

20-206
 TM 5-2420-224-34

CRANE EXTERNAL END EXTENSION CYLINDER REPAIR (CONT)

2. REMOVE ROD assembly (3) from housing

(2).

3. USING SPANNER WRENCH, REMOVE

PISTON (4) and lock ring (5) from rod
assembly (3). DISCARD bck RING.

20-207
 TM 5-2420-224-34

CRANE EXTERNAL END EXTENSION CYLINDER REPAIR (CONT)

4. REMOVE and DISCARD two piston RINGS

(6), O-RING (7), and SEAL (8) from piston
(4).

5. REMOVE two cap tubes (9), wafer lock (10),

and HEAD (1) from rod assembly (3).
DISCARD wafer LOCK.

6. REMOVE and DISCARD O-RING (11), backup

RING (12), WIPER (13), and SEAL (14) from
head (1).

20-208
 TM 5-2420-224-34

CRANE EXTERNAL END EXTENSION CYLINDER REPAIR (CONT)

7. REMOVE two counterbalance VALVES (15)

from housing (2).

8. REMOVE and DISCARD backup RING (16),

PACKING (17), backup RING (18), PACKING
(19), backup RING (20), and PACKING (21)
from each counterbalance valve (15).

NOTE
Apply coat of lubricating oil to
packings, O-rings, and seals prior
to assembly.

1. INSTALL new SEAL (1), new WIPER (2), new

backup RING (3), and new O-RING (4) on
head (5).

20-209
 TM 5-2420-224-34

CRANE EXTERNAL END EXTENSION CYLINDER REPAIR (CONT)

2. INSTALL HEAD (5), new wafer lock (6), and

two cap tubes (7) on rod assembly (8).

3. INSTALL new SEAL (9), new O-RING (10),

and two new piston RINGS (11) on piston
(12).

4. USING SPANNER WRENCH, INSTALL

PISTON (12) on rod assembly (8) and
TIGHTEN PISTON to 250 Ib-ft (339 N.m).

5. INSTALL new lock RING (13) in piston (12).

20-210
 TM 5-2420-224-34

CRANE EXTERNAL END EXTENSION CYLINDER REPAIR (CONT)

6. INSTALL ROD assembly (8) in housing (14).

7. USING SPANNER WRENCH, THREAD HEAD

(5) into housing (14) and TIGHTEN to 250
Ib-ft (339 N.m).

8. INSTALL new PACKING (15), new backup

RING (16), new PACKING (17), new backup
RING (18), new PACKING (19), and new
backup RING (20) on each counterbalance
valve (21).

9. INSTALL two counterbalance VALVES (21) in

housing (14).

NOTE
Follow-on Maintenance:
Install crane external end
extension cylinder (TM 5-2420-
224-20).

20-211
TM 5-2420-224-34

Section XXVII. CRANE INNER BOOM LIFT CYLINDER REPAIR

CRANE INNER BOOM LIFT CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP
Applicable Configuration: Equipment Condition:
HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane inner Boom Lift
Cylinder Removed
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety Instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5784
Spanner Wrench, P/N 3Y140510
WARNING
Materials/Parts:
Fuel and oil are slippery and
Kit can cause falls. To avoid
injury, wipe up spilled fuel or
Kit
oil with rags.
Oil, Lubricating Appendix B, item 30
Rags Appendix B, item 40

References:
TM 5-2420-224-20

DISASSEMBLY

NOTE
Procedure is the same for both
inner boom lift cylinders.

1. USING SPANNER WRENCH, REMOVE

HEAD (1) from crane inner boom lift cylinder
(2).

20-212
 TM 5-2420-224-34

CRANE INNER BOOM LIFT CYLINDER REPAIR (CONT)

2. REMOVE ROD assembly (3) from crane inner

boom lift cylinder (2).

3. USING SPANNER WRENCH, REMOVE

PISTON (4).

4. IF DAMAGED, REMOVE lock RING (5) from

piston (4).

5. REMOVE and DISCARD two piston RINGS

(6), O-RING (7), and SEAL (8).

20-213
TM 5-2420-224-34

CRANE INNER BOOM LIFT CYLINDER REPAIR (CONT)

6. REMOVE two cap tubes (9 and 10), wafer

lock (11), and HEAD (1) from rod assembly
(3). DISCARD wafer LOCK.

7. REMOVE and DISCARD O-RING (12), backup

RING (13), WIPER (14), and SEAL (15) from
head (1).

8. USING suitable PRESS, REMOVE two

BUSHINGS (16) from rod assembly (3).

9. IF DAMAGED, REMOVE lubrication FlTTING

(17).

20-214
 TM 5-2420-224-34

CRANE INNER BOOM LIFT CYLINDER REPAIR (CONT)

10. USING suitable PRESS, REMOVE two

BUSHINGS (18) from crane inner boom lift
cylinder (2).

11. REMOVE three PLUGS (19).

12. REMOVE counterbalance VALVE (20) from

crane inner boom lift cylinder (2).

13. REMOVE and DISCARD backup RING (21),

PACKING (22), backup RING (23), PACKING
(24), backup RING (25), and PACKING (26)
from counterbalance valve (20).

ASSEMBLY

NOTE
• Procedure is the same for both
inner boom lift cylinders.
• Apply coat of lubricating oil to
packings, O-rings, and seals
prior to assembly.

1. INSTALL new PACKING (1), new backup

RING (2), new PACKING (3), new backup
RING (4), new PACKING (5), and new
backup RING (6) on counterbalance valve (7).

2. INSTALL counterbalance VALVE (7) in crane

inner boom lift cylinder (8).

3. INSTALL three PLUGS (9).

20-215
TM 5-2420-224-34

CRANE INNER BOOM LIFT CYLINDER REPAIR (CONT)

4. USING suitable PRESS, INSTALL two

BUSHINGS (10) in crane inner boom lift
cylinder (8).

5. IF REMOVED, INSTALL new lubrication

FlTTING (11) in rod assembly (12).

6. USING suitable PRESS, INSTALL two

BUSHINGS (13) in rod assembly (12).

7. INSTALL new SEAL (14), new WIPER (15),

new backup RING (16), and new O-RING (17)
on head (18).

20-216
 TM 5-2420-224-34

CRANE INNER BOOM LIFT CYLINDER REPAIR (CONT)

8. INSTALL HEAD (18), new wafer lock (19),

and two cap tubes (20 and 21) on rod
assembly (12).

9. INSTALL new SEAL (22), new O-RING (23),

and two new piston RINGS (24) on piston
(25).

10. IF REMOVED, INSTALL new lock RING (26)

in piston (25).

11. USING SPANNER WRENCH, INSTALL

PISTON (25) on rod assembly (12) and
TIGHTEN to 250 Ib-ft (339 N.m).

20-217
TM 5-2420-224-34

CRANE INNER BOOM LlFT CYLINDER REPAIR (CONT)

12. INSTALL ROD assembly (12) in crane inner

boom lift cylinder (8).

13. USING SPANNER WRENCH, THREAD HEAD

(18) into crane Inner boom lift cylinder (8) and
TIGHTEN to 250 Ib-ft (339 N.m).

NOTE
Follow-on Maintenance:
Install crane inner boom lift
cylinder (TM 5-2420-224-20).

20-218
 TM 5-2420-224-34

Section XXVIII. CRANE MAST LOCKING CYLINDER REPAIR

CRANE MAST LOCKING CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane Mast Locking
Cylinder Removed -
Shop Equipment, SC 4910-95-CL-A31
Tool Kit, SC 5180-90-CL-N26 General Safety Instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5784
Spanner Wrench, P/N 3Y140510
WARNING
Materials/Parts:
Fuel and oil are slippery and
Kit can cause falls. To avoid
injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30
oil with rags.
Rags Appendix B, Item 40

References:
TM 5-2420-224-20

DISASSEMBLY

1. USING SPANNER WRENCH, REMOVE

HEAD (1) from housing (2).

20-219
 TM 5-2420-224-34

CRANE MAST LOCKING CYLINDER REPAIR (CONT)

2. REMOVE ROD assembly (3) from housing

(2).

3. USING SPANNER WRENCH, REMOVE

PISTON (4).

4. REMOVE and DISCARD lock RING (5) from

piston (4).

5. REMOVE and DISCARD two piston RINGS

(6), O-RING (7), and SEAL (8).

20-220
 TM 5-2420-224-34

CRANE MAST LOCKING CYLINDER REPAIR (CONT)

6. REMOVE bushing (9), wafer lock (10), and

HEAD (1) from rod assembly (3). DISCARD
wafer LOCK.

7. REMOVE and DISCARD O-RING (11), backup

RING (12), WIPER (13), and SEAL (14) from
head (1).

8. IF DAMAGED, REMOVE lubrication FITTING

(15).

9. REMOVE PLUG (16) from housing (2).

20-221
 TM 5-2420-224-34

CRANE MAST LOCKING CYLINDER REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
O-rings and seals prior to
assembly.

1. INSTALL PLUG (1) in housing (2).

2. IF REMOVED, INSTALL new lubrication

FITTING (3) in rod assembly (4).

3. INSTALL new SEAL (5), new WIPER (6), new

backup RING (7), and new O-RING (8) on
head (9).

20-222
 TM 5-2420-224-34

CRANE MAST LOCKING CYLINDER REPAIR (CONT)

4. INSTALL HEAD (9), new wafer lock (10), and

bushing (11) on rod assembly (4).

5. INSTALL new SEAL (12), new O-RING (13),

and two new piston RINGS (14) on piston
(15).

20-223
TM 5-2420-224-34

CRANE MAST LOCKING CYLINDER REPAIR (CONT)

6. INSTALL new look RING (16) in piston (15).

7. USING SPANNER WRENCH, INSTALL

PISTON (15) on rod assembly (4) and
TIGHTEN to 250 Ib-ft (339 N.m).

8. INSTALL ROD assembly (4) in housing (2).

9. USING SPANNER WRENCH, THREAD HEAD

(9) into housing (2) and TIGHTEN to 250 Ib-ft
(339 N.m).

NOTE
Follow-on Maintenance:
Install crane mast locking cylinder
(TM 5-2420-224-20).

20-224
 TM 5-2420-224-34

Section XXIX. CRANE OUTER BOOM CYLINDER REPAIR

CRANE OUTER BOOM CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane Outer Boom
Cylinder Removed
Shop Equipment, SC 4910-95-CL-A31
TOOl Kit, SC 5180-90-CL-N26 General Safety instructions:
TOOl Outfit (HSTRU), NSN 4940-01-036-5784
Spanner Wrench, P/N 3Y140510

Materials/Parts: WARNING
Fuel and oil are slippery and
Kit can cause falls. To avoid
injury, wipe up spilled fuel or
Kit
oil with rags.
Oil, Lubricating Appendix B, Item 30
Rags Appendix B, Item 40

References:
TM 5-2420-224-20

1. USING SPANNER WRENCH, REMOVE

HEAD (1) from housing (2).

20-225
TM 5-2420-224-34

CRANE OUTER BOOM CYLINDER REPAIR (CONT)

2. REMOVE ROD assembly (3) from housing

(2).

3. USING SPANNER WRENCH, REMOVE

PISTON (4).

4. REMOVE and DISCARD lock RING (5) from

piston (4).

5. REMOVE and DISCARD two piston RINGS

(6), O-RING (7), and SEAL (8).

20-226
 TM 5-2420-224-34

CRANE OUTER BOOM CYLINDER REPAIR (CONT)

6. REMOVE two cap tubes (9 and 10), wafer

lock (11), and HEAD (1) from rod assembly
(3). DISCARD wafer LOCK.

7. REMOVE and DISCARD O-RING (12), backup

RING (13), WIPER (14), and SEAL (15) from
head (1).

8. USING suitable PRESS, REMOVE two

BUSHINGS (16) from rod assembly (3).

9. IF DAMAGED, REMOVE lubrication FITTING

(17) from rod assembly (3).

20-227
 TM 5-2420-224-34

CRANE OUTER BOOM CYLINDER REPAIR (CONT)

10. USING suitable PRESS, REMOVE two

BUSHINGS (18) from housing (2).

11. IF DAMAGED, REMOVE lubrication FlTTING

(19) from housing (2).

12. REMOVE counterbalance VALVE (20) from

housing (2).

13. REMOVE and DISCARD backup RING (21),

PACKING (22), backup RING (23), PACKING
(24), backup RING (25), and PACKING (26)
from counterbalance valve (20).

NOTE
Apply coat of lubricating oil to
packings, O-rings, and seals prior
to assembly.

1. IF REMOVED, INSTALL new lubrication

FITTING (1) in housing (2).

2. USING suitable PRESS, INSTALL two

BUSHINGS (3) in housing (2).

20-228
 TM 5-2420-224-34

CRANE OUTER BOOM CYLINDER REPAIR (CONT)

3. IF REMOVED, INSTALL new lubrication

FlTTING (4) in rod assembly (5).

4. USING suitable PRESS, INSTALL two

BUSHINGS (6) in rod assembly (5).

5. INSTALL new SEAL (7), new WIPER (8), new

backup RING (9), and new O-RING (10) on
head (11).

6. INSTALL HEAD (11), new wafer lock (12),

and two cap tubes (13 and 14) on rod
assembly (5).

20-229
TM 5-2420-224-34

CRANE OUTER BOOM CYLINDER REPAIR (CONT)

7. INSTALL new SEAL (15), new O-RING (16),

and two new piston RINGS (17) on piston
(18).

8. INSTALL new lock RING (19) in piston (18).

9. USING SPANNER WRENCH, INSTALL

PISTON (18) on rod assembly (5) and
TIGHTEN to 250 Ib-ft (339 N.m).

10. INSTALL ROD assembly (5) in housing (2).

20-230
 TM 5-2420-224-34

CRANE OUTER BOOM CYLINDER REPAIR (CONT)

11. USING SPANNER WRENCH, THREAD HEAD

(11) into housing (2) and TIGHTEN to 250
Ib-ft (339 N.m).

12. INSTALL new PACKING (20), new backup

RING (21), new PACKING (22), new backup
RING (23), new PACKING (24), and new
backup RING (25) on counterbalance valve
(26).

13. INSTALL counterbalance VALVE (26) in

housing (2).

NOTE
Follow-on Maintenance:
Install crane outer boom cylinder
(TM 5-2420-224-20).

20-231
TM 5-2420-224-34

Section XXX. CRANE HORIZONTAL OUTRIGGER CYLINDER REPAIR

CRANE HORIZONTAL OUTRIGGER CYLINDER REPAIR

This task covers: a. Disassembly b. Assembly

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description

Tools and Special Equipment: TM 5-2420-224-20 Crane Horizontal Outrigger

Cylinder Removed
Shop Equipment, SC 4910-95-CL-A31
TOOl Kit, SC 5180-90-CL-N26 General Safety instructions:
Tool Outfit (HSTRU), NSN 4940-01-036-5784
Spanner Wrench, P/N 3Y140510
WARNING
Materials/Parts:
Fuel and oil are slippery and
Kit can cause falls. To avoid
injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.
Rags Appendix B, Item 40

References:
TM 5-2420-224-20

1. REMOVE retaining RING (1) from crane

horizontal outrigger cylinder (2).

2. REMOVE ROD assembly (3) from crane

horizontal outrigger cylinder (2).

20-232
 TM 5-2420-224-34

CRANE HORIZONTAL OUTRIGGER CYLINDER REPAIR (CONT)

3. USING SPANNER WRENCH, REMOVE

PISTON (4).

4. REMOVE and DISCARD SEAL (5) and

O-RING (6) from piston (4).

5. REMOVE HEAD (7) and retaining ring (1)

from rod assembly.

20-233
 TM 5-2420-224-34

CRANE HORIZONTAL OUTRIGGER CYLINDER REPAIR (CONT)

6. REMOVE and DISCARD O-RING (8), backup

RING (9), WIPER (10), and SEAL (11) from
head (7).

NOTE
Apply coat of lubricating oil to
O-rings and seals prior to
assembly.

1. INSTALL new SEAL (1), new WIPER (2), new

backup RING (3), and new O-RING (4) on
head (5).

2. INSTALL retaining ring (6) and HEAD (5) on

rod assembly (7).

20-234
 TM 5-2420-224-34

CRANE HORIZONTAL OUTRIGGER CYLINDER REPAIR (CONT)

3. INSTALL new O-RING (8) and new SEAL (9)

on piston (10).

4. USING SPANNER WRENCH, INSTALL

PISTON (10) on rod assembly (7) and
TIGHTEN to 35 Ib-ft (47 N.m).

20-235
 TM 5-2420-224-34

CRANE HORIZONTAL OUTRIGGER CYLINDER REPAIR (CONT)

5. INSTALL ROD assembly (7) in crane

horizontal outrigger cylinder (11).

6. INSTALL HEAD (5) in crane horizontal

outrigger cylinder (11) and INSTALL retaining
RING (6).

NOTE
Follow-on Maintenance:
Install crane horizontal outrigger
cylinder (TM 5-2420-224-20).

20-236
 TM 5-2420-224-34

Section XXXI. CRANE VERTICAL OUTRIGGER CYLINDER REPAIR

CRANE VERTICAL OUTRIGGER CYLINDER REPAIR

This task covers: a. Disassemble b. Assembly

Applicable Configuration: Equipment Condition:

HMMH Reference Condition Description
Tools and Special Equipment: TM 5-2420-224-20 Crane Vertical Outrigger
Cylinder Removed
Shop Equipment, SC 4910-95-CL-A31
TOOl Kit, SC 5180-90-CL-N26 General Safety Instructions:
TOOI Outfit (HSTRU), NSN 4940-01-036-5784
Spanner Wrench, P/N 3Y140510
WARNING
Materials/Parts:
Fuel and oil are slippery and
Kit can cause falls. To avoid
injury, wipe up spilled fuel or
Kit oil with rags.
Oil, Lubricating Appendix B, [tern 30
Rags Appendix B, Item 40

References:
TM 5-2420-224-20

NOTE
Procedure is the same for both
vertical outrigger cylinders.

1. USING SPANNER WRENCH, REMOVE

HEAD (1) from crane vertical outrigger
cylinder (2).

20-237
 TM 5-2420-224-34

CRANE VERTICAL OUTRIGGER CYLINDER REPAIR (CONT)

2. REMOVE ROD assembly (3) from crane

vertical outrigger cylinder (2).

3. USING SPANNER WRENCH, REMOVE

PISTON (4).

4. REMOVE and DISCARD lock RING (5) from

piston (4).

5. REMOVE and DISCARD SEAL (6) and

O-RING (7).

20-238
 TM 5-2420-224-34

CRANE VERTICAL OUTRIGGER CYLINDER REPAIR (CONT)

6. REMOVE stop tube (8), wafer lock (9), and

HEAD (1) from rod assembly (3). DISCARD
wafer LOCK.

7. REMOVE and DISCARD backup RING (10),

O-RING (11), WIPER (12), and SEAL (13)
from head (1).

8. REMOVE six capscrews (14), valve BLOCK

(15), and three packings (16). DISCARD
PACKINGS.

20-239
 TM 5-2420-224-34

CRANE VERTICAL OUTRIGGER CYLINDER REPAIR (CONT)

9. REMOVE valve BODY (17) from valve block

(15).

10. REMOVE and DISCARD PACKING (18), two

backup RINGS (19 and 20), two PACKINGS
(21 and 22), and backup RING (23) from
valve body (17).

ASSEMBLY

NOTE
Procedure is the same for both
vertical outrigger cylinders.
Apply coat of lubricating oil to
packings, O-rings, and seals
prior to assembly.

1. INSTALL new backup RING (1), two new

PACKINGS (2 and 3), two new backup
RINGS (4 and 5), and new PACKING (6) on
valve body (7).

2. INSTALL valve BODY (7) in valve block (8).

3. INSTALL three new packings (9), valve

BLOCK (8), and six capscrews (10) on crane
vertical outrigger cylinder (11).

20-240
 TM 5-2420-224-34

CRANE VERTICAL OUTRIGGER CYLINDER REPAIR (CONT)

4. INSTALL new SEAL (12), new WIPER (13),

new O-RING (14), and new backup RING (15)
on head (16).

5. INSTALL HEAD (16), new wafer lock (17),

and stop tube (18) on rod assembly (19).

6. INSTALL new O-RING (20) and new SEAL

(21) on piston (22).

20-241
 TM 5-2420-224-34

CRANE VERTICAL OUTRIGGER CYLINDER REPAIR (CONT)

7. INSTALL new lock RING (23) in piston (22).

8. USING SPANNER WRENCH, INSTALL

PISTON (22) on rod assembly (19) and
TIGHTEN to 250 Ib-ft (339 N.m).

9. INSTALL ROD assembly (19) in crane vertical

outrigger cylinder (11 ).

10. USING SPANNER WRENCH, THREAD HEAD

(16) into crane vertical outrigger cylinder (11)
and TIGHTEN to 250 Ib-ft (339 N.m).

NOTE
Follow-on Maintenance:
Install crane vertical outrigger
cylinder (TM 5-2420-224-20).

20-242
 TM 5-2420-224-34

Section XXXII. CRANE HYDRAULIC MOTOR REPAIR

CRANE HYDRAULIC MOTOR REPAIR

This task covers: a. Disassembly b. Assembly

INITIAL SETUP
Applicable Configuration: References:
HMMH TM 5-2420-224-20

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A74 Reference Equipment Condition
TOOl Kit, SC 5280-90-CL-A74
Socket, P/N 5422 TM 5-2420-224-20 Crane Hydraulic Motor
Removed
Materials/Parts:
General Safety Instructions:
Kit, Parts
Caps and Plugs Appendix B, Item 8
WARNING
Cloth, Emery Appendix B, Item 10 Fuel and oil are slippery and
can cause falls. To avoid
Compound, Sealing Appendix B, Item 16
injury, wipe up spilled fuel or
Oil, Lubricating Appendix B, Item 30 oil with rags.
Rags Appendix B, Item 40

20-243
 TM 5-2420-224-34

CRANE HYDRAULIC MOTOR REPAIR (CONT)

CAUTION
Cleanliness is extremely
important when repairing crane
hydraulic motor. Perform
maintenance in a clean, dry
area to prevent damage to
equipment.

1. USING suitable CONTAINER, DRAIN OIL and

INSTALL PLUGS in ports of crane hydraulic
motor.

2. THOROUGHLY CLEAN outside of crane

hydraulic motor.

3. PLACE crane hydraulic MOTOR in soft-jawed

VISE by CLAMPING ACROSS mounting
FLANGE (1) with output shaft (2) down.

4. USING SOCKET, REMOVE seven capscrews

(3), end CAP (4), and seal (5) from gear rotor
set (6). DISCARD SEAL.

5. REMOVE GEAR ROTOR SET (6) and seal

(7). RETAIN ROLLERS in outer gear rotor
ring. DISCARD SEAL.

20-244
 TM 5-2420-224-34

CRANE HYDRAULIC MOTOR REPAIR (CONT)

6. REMOVE spacer PLATE (8), seal (9), and

drive shaft (10) from manifold housing (11).
DISCARD SEAL.

CAUTION
Do not overtighten vise jaws.
Excessive clamping force may
distort housing.

7. REPOSITION crane hydraulic MOTOR in

soft-jawed vise by CLAMPING across PORTS.

CAUTION
Do not use impact wrench on
screws to break torque. This
could result in rounded heads
or broken sockets.

8. USING SOCKET, REMOVE four SCREWS

(12).

9. REMOVE crane hydraulic MOTOR from

soft-jawed vise and, using twisting motion,
REMOVE mounting FLANGE (1).

10. REMOVE SEAL (13), seal (14), retaining ring

(15), and seal (16) from mounting flange (1).
DISCARD SEALS (13, 14, and 16).

20-245
 TM 5-2420-224-34

CRANE HYDRAULIC MOTOR REPAIR (CONT)

11. REMOVE output SHAFT (2) from manifold

housing (11).

12. REMOVE retainer and roller (17) and PLATE

(18) from output shaft (2).

NOTE
Coat all seals with lubricating oil
prior to assembly.

1. APPLY coat of lubricating OIL to output shaft

(1).

CAUTION
Do not allow lubricating oil to
enter tapped holes to prevent
damage to equipment.

2. INSTALL output SHAFT (1) in manifold

housing (2).

3. INSTALL retainer and roller (3) and PLATE

(4) on output shaft (1). PULL output S H A F T
(1) partially out of manifold housing (2) and
PUSH retainer and roller (3), PLATE (4), and
output SHAFT (1) into manifold housing (2)
together.

20-246
 TM 5-2420-224-34

CRANE HYDRAULIC MOTOR REPAIR (CONT)

4. IF INSTALLING new mounting FLANGE (5),

BREAK seal seat CORNER with emery cloth.

5. INSTALL retaining ring (6), new SEAL (7),

and new seal (8) in mounting flange (5).

6. INSTALL new SEAL (9) in mounting flange

(5).

7. APPLY three or four drops of SEALING

COMPOUND to threads of manifold HOUSING
(2).

8. APPLY COAT of LUBRICATING OIL to output

SHAFT (1), SEAL (7), and SEAL (9).

CAUTION
Make sure seals are not
inverted or damaged.

9. INSTALL mounting FLANGE (5), ROTATING

SLOWLY while pushing down over output
shaft (1).

CAUTION
Do not overtighten vise jaws.
Excessive clamping force may
distort housing.

10. PLACE crane hydraulic MOTOR in soft-jawed

vise by CLAMPING across PORTS.

11. USING SOCKET, INSTALL four SCREWS

(10) and ALTERNATELY TIGHTEN to
250 lb-in. (28 N.m).

20-247
 TM 5-2420-224-34

CRANE HYDRAULIC MOTOR REPAIR (CONT)

12. REPOSITION crane hydraulic MOTOR in

soft-jawed vise by CLAMPING across
mounting FLANGE (5) with output shaft (1)
down.

13. POUR approximately 35 cc of lubricating OIL

in output shaft (1) cavity.

14. INSTALL new seal (11), drive SHAFT (12),

and spacer plate (13) to manifold housing (2)
without twisting seal. ALINE screw HOLES so
timing DOT on output shaft (1) is VISIBLE
through one of the screw holes.

15. INSTALL new SEAL (14) on gear rotor set

(15) without twisting seal.

16. INSTALL GEAR ROTOR SET (15) on spacer

plate (13), POSITIONING any STAR POINT
over screw HOLE alined with timing DOT.

20-248
 TM 5-2420-224-34

CRANE HYDRAULIC MOTOR REPAIR (CONT)

17. ROTATE GEAR ROTOR SET (15) to line up

screw holes WITHOUT DISENGAGING star
from drive shaft (12) or disturbing seal (14).

18. INSTALL new SEAL (16) on gear rotor set

(15) without twisting seal.

NOTE
Make sure seals (14 and 16) are
properly seated and not pinched.

19. USING SOCKET, INSTALL end CAP (17) and

seven capscrews (18) on manifold housing
(2). TIGHTEN CAPSCREWS to 15-40 lb-in.
(2-5 N.m).

20. TIGHTEN CAPSCREWS (18) to 300 lb-in.

(34 N.m) using sequence shown.

20-249/(20-250 Blank)
 TM 5-2420-224-34

CHAPTER 21
MACHINE TOOLS REPAIR INSTRUCTIONS

OVERVIEW

This chapter contains maintenance instructions for repair of the machine tools. A list of sections
contained in this chapter is shown below.

Page

Section I. Hammer Drill Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1

Section Il. Impact Wrench Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-15

Section Ill. Pavement Breaker Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24

Section IV. Chain Saw Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37

Section I. HAMMER DRILL REPAIR

HAMMER DRILL REPAIR

This task covers: a. Disassembly b. Assembly c. Charging d. Testing

INITIAL SETUP

Applicable Configuration: Materials/Parts:

SEE Nut, Lock (2)

Tools and Special Equipment: Kit, Seal Pads

Shop Equipment, SC 4910-95-CL-A31 Nitrogen Appendix B, Item 29

Tool Kit, SC 5180-90-CL-N26 Appendix B, Item 30
Oil, Lubricating
Bearing Installing Tool, P/N 05044
Bearing Installing Tool, P/N 05061 Rags Appendix B, Item 40
Installing and Removal Tool, P/N 04337
Latch Installing Tool, P/N 05879 GeneraI Safety Instructions:
Latch Installing Tool, P/N 05062
Pipe, P/N 04910
Removal Tool, P/N 05045 WARNING
Remover, P/N 04919
Fuel and oil are slippery and
Sleeve, P/N 01120
Test Set, P/N 02835 can cause falls. To avoid
injury, wipe up spilled fuel or
oil with rags.

21-1
TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

DISASSEMBLY

NOTE
Tag all lines prior to removal to
aid in installation.

1. REMOVE HOSE assembly (1) and packing

(2). DISCARD PACKING.

2. REMOVE HOSE assembly (3) and packing

(4). DISCARD PACKING.

3. REMOVE quick-disconnect COUPLING (5)

and packing (6). DISCARD PACKING.

4. REMOVE quick-disconnect COUPLING (7)

and packing (8). DISCARD PACKING.

5. REMOVE PLUG (9) and packing (10),

DISCARD PACKING.

When discharging nitrogen from

accumulator, stand to one side
and keep face away from front
of charging valve to prevent
personal injury.

6. PRESS charging VALVE (11) and

DISCHARGE all NITROGEN from housing
(12).

21-2
 TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

7. REMOVE two socket head capscrews (13),

two lock nuts (14), two RODS (15), and
handle grip (16). DISCARD lock NUTS.

8. REMOVE two spring pins (17) and TRIGGER

(18).

9. REMOVE charging VALVE (11) from handle

grip (16).

10. REMOVE DIAPHRAGM (19).

11. REMOVE wiper (20), packing (21), bushing

(22), packing (23), valve SPOOL (24), and
spring (25). DISCARD PACKINGS.

12. REMOVE HOUSING (26) from flow sleeve

tube (27) by TAPPING GENTLY with
PLASTIC or RUBBER hammer.

13. REMOVE HOUSING (12) from flow sleeve

tube (27) by TAPPING GENTLY with
PLASTIC or RUBBER hammer.

14. USING slide HAMMER and SLEEVE,

REMOVE porting BLOCK (28) from housing
(12).

15. REMOVE orifice PLUG (29) from housing

(12).

16. REMOVE and DISCARD PACKING (30) and

backup RING (31 ) from porting block (28).

21-3
TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

17. REMOVE PISTON (32) from flow sleeve (33).

18. REMOVE PIN (34) from valve body (35).

19. PLACE flow sleeve TUBE (27) with valve

BODY (35) down onto PIPE and REMOVER.

CAUTION
• During step 20, cover flow
sleeve tube with suitable disc
to prevent damage to flow
sleeve tube.

• Insert rag into pipe to

prevent damage to valve
body.

20. USING suitable PRESS, REMOVE valve

BODY (35), automatic valve (36), and flow
sleeve (33).

21. REMOVE four PINS (37) from flow sleeve

(33).

22. REMOVE PIN (38) and two PINS (39) from

valve body (35).

23. REMOVE and DISCARD backup RING (40)

and PACKING (41) from flow sleeve tube
(27).

21-4
 TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

24. REMOVE pin (42), packing (43), cup SEAL

(44), washer (45), and cup SEAL (46) from
housing (26). DISCARD PACKING and cup
SEALS.

25. PLACE HOUSING (26) on metal plate in

press with latch (47) UP.

26. ROTATE LATCH (47) to OPEN position.

USING REMOVAL TOOL, PRESS DOWN on
spring backup (48) and REMOVE retaining
RING (49).

27. REMOVE spring backup (48), four wave

springs (50), washer (51), four wave springs
(50), washer (51), and LATCH (47).

21-5
TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

CAUTION
During step 28, do not use any type of pry tool to prevent damage to
equipment.

28. REMOVE four socket head CAPSCREWS (52 and 53).

29. REMOVE mounting FLANGE (54) from housing (55) and REMOVE HOUSING (55) from housing (26).
30. REMOVE idler gear (56), drive GEAR (57), woodruff key (58), and hex drive (59).
31. REMOVE two BEARINGS (60).
32. REMOVE plug (61), BEARING (62), quad ring (63), and backup ring (64) from mounting flange (54).
DISCARD quad RING and backup RING.
33. REMOVE BEARING (65), setscrew (66), two pins (67), two pins (88), packing (69), and two packings
(70) from housing (55). DISCARD PACKINGS.
34. REMOVE WASHER (71) and thrust washer (72) from hex drive (59).
35. REMOVE quad RING (73), backup RING (74), and GASKET (75) from housing (26). DISCARD quad
RING, backup RING, and GASKET.
36. REMOVE setscrew (76), PLUG (77), and two pins (78).
37. REMOVE setscrew (79), LEVER (80), retaining ring (81), spacer ring (82), packing (83), and valve (84).
DISCARD PACKING.

21-6
 TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

ASSEMBLY

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL new backup RING (1) and new

quad RING (2) in mounting flange (3).

NOTE
Make sure mounting flange is
level to ensure bearings are
properly seated.

2. USING suitable PRESS and BEARING

INSTALLING TOOLS, INSTALL two
BEARINGS (4 and 5) in mounting flange (3)
with split sides facing each other.

3. PLACE mounting FLANGE (3) on metal plate

in PRESS, latch side UP, and INSTALL
LATCH (6), washer (7), four wave springs (8),
washer (7), four wave springs (8), spring
backup (9), LATCH INSTALLING TOOLS, and
retaining ring (10). PRESS with LATCH
INSTALLING TOOLS until retaining ring (10)
snaps into place. REMOVE LATCH
INSTALLING TOOLS.

21-7
TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

4. INSTALL PLUG (11) in mounting flange (3).

5. INSTALL two PINS (12) in housing (13).

6. USING suitable PRESS and BEARING

INSTALLING TOOLS, INSTALL two
BEARINGS (14 and 15) in housing (13) with
split sides facing each other.

7. INSTALL hex drive (16), woodruff key (17),

drive GEAR (18), idler gear (19), and new
packing (20).

8. INSTALL mounting FLANGE (3) and two

socket head capscrews (21) on housing (13).
TIGHTEN CAPSCREWS to 25 Ib-ft (34 N.m).

9. INSTALL washer (22) and thrust WASHER

(23) on hex drive (16).

21-8
 TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

10. INSTALL new quad RING (24), new backup ring (25), and new GASKET (26) on housing (27).
11. INSTALL two new PACKINGS (28) and two pins (29) in housing (13).
12. INSTALL HOUSING (27), two socket head capscrews (30), and setscrew (31) on housing (13).
TIGHTEN CAPSCREWS to 60 Ib-ft (81 N.m).

NOTE
Lever must be installed with narrow portion toward handles, and setscrew must be
seated in hole of valve.

13. INSTALL two pins (32), VALVE (33), new packing (34), spacer ring (35), retaining ring (36), lever (37),
and setscrew (38).
14. INSTALL pin (39), PLUG (40), and setscrew (41).
15. INSTALL new cup SEAL (42) with lips facing inward, washer (43), new cup SEAL (44) with lips facing
outward, and new packing (45).
16. INSTALL new backup RING (46) and new PACKING (47) on flow sleeve tube (48).

21-9
TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

CAUTION
To prevent damage to flow
sleeve, cover end with eight
holes with piece of metal.

NOTE
Flow sleeve tube must be installed
in press with packing end up.

17. USING suitable PRESS, INSTALL flow

SLEEVE (49) in flow sleeve tube (48) from
packing end until flow sleeve (49) is flush with
flow sleeve tube (48).

18. INSTALL four PINS (50) in flow sleeve (49).

19. INSTALL PIN (51) and two PINS (52) in valve

body (53).

20. INSTALL automatic VALVE (54) in valve body

(53).

21. INSTALL valve BODY (53) on flow sleeve

(49), alining pin (51) with pin holes.

22. USING suitable PRESS, PRESS valve BODY

(53) onto flow sleeve tube (48) until shoulder
of valve body (53) is flush with flow sleeve
tube (48).

21-10
 TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

23. INSTALL PISTON (55), solid end first, in valve body (53).

24. INSTALL PIN (56) in valve body (53).

25. INSTALL new PACKING (57) and new backup RING (58) on porting block (59).

26. INSTALL porting BLOCK (59) in valve body (53).

NOTE
Make sure all three holes aline.

27. ALINE PIN (39) with hole in flow sleeve (49) and INSTALL flow sleeve TUBE (48) in housing (27).

21-11
TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

28. INSTALL HOUSING (60) on flow sleeve tube (46) so that oil ports are alined with Iever (37).

29. INSTALL orifice plug (61), spring (62), valve SPOOL (63), new packing (64), bushing (65), new packing
(66), and wiper (67) in housing (60). Bushing (65) should project approximately 0.200 in. (5 mm) from
housing (60).

30. APPLY light COAT of LUBRICATING OIL to DIAPHRAGM (66) and INSTALL DIAPHRAGM in housing
(60).

31. INSTALL TRIGGER (69) and two spring pins (70).

32. INSTALL handle GRIP (71), two rods (72), two new lock nuts (73), and two socket head capscrews
(74). TIGHTEN lock NUTS alternately in 15 Ib-ft (20 N.m) increments to 100 Ib-ft (135 N.m). TIGHTEN
socket head CAPSCREWS alternately in 15 Ib-ft (20 N.m) increments to 75 Ib-ft (100 N.m).

33. INSTALL charging VALVE (75).

34. INSTALL new packing (76) and PLUG (77).

21-12
 TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

35. INSTALL quick-disconnect COUPLING (78)

and new packing (79).

36. INSTALL quick-disconnect COUPLING (80)

and new packing (81).

37. INSTALL new packing (82) and HOSE

assembly (83).

38. INSTALL new packing (84) and HOSE

assembly (85).

39. CHARGE hammer DRILL with nitrogen using

Charging procedure.

21-13
TM 5-2420-224-34

HAMMER DRILL REPAIR (CONT)

1. Remove plug (1).

2. Rotate gage end of test set fully to left to

make sure stem is fully retracted.

3. Install test set in handle of hammer drill (2)

by rotating chuck end only.

4. Rotate gage end of test set slowly to right

until pressure is indicated on gage. Pressure
reading should be 500-700 psi (34-48 bar).

5. Connect nitrogen supply line (3) to charging

valve (4) on test set.

6. Adjust regulator (5) on nitrogen bottle (6) to

delivery pressure of 600 psi (42 bar).

7. Open valve (7) on nitrogen supply line (3).

8. When accumulator is fully charged, close

valve (7) on nitrogen supply line (3) and
disconnect from test set.

9. Rotate gage end of test set fully to left and

remove tester at chuck end.

10. Install plug (1).

TESTING

1. Perform steps 1 thru 4 of Charging, above.

2. If pressure is low, charge accumulator using

Charging procedure, above.

3. Rotate gage end of test set fully to left and

remove tester at chuck end.

4. Install plug (1).

21-14
 TM 5-2420-224-34

Section II. IMPACT WRENCH REPAIR

IMPACT WRENCH REPAIR

This task covers: a. Disassembly b. Cleaning c. Inspection d. Assembly

INITIAL SETUP

Applicable Configuration: Materials/Parts (Cont):

HMMH Kit, Parts

Tools and Special Equipment: Cloth, Lint-Free Appendix B, Item 11

Shop Equipment, SC 4910-95-CL-A31 Grease, Automotive Appendix B, Item 23

Tool Kit, SC 5180-90-CL-N26 and Artillery (GAA)
Installing and Removal Tool, P/N 04337
Oil, Lubricating Appendix B, Item 30
Materials/Parts: Solvent, Drycleaning Appendix B, Item 42
Washer, Lock (4)
Washer, Lock (8)
Nut, Lock

DISASSEMBLY

1. REMOVE HOSE (1), coupling HALF (2), and

two packings (3). DISCARD PACKINGS.

2. REMOVE HOSE (4), coupling half (5), and

two packings (6). DISCARD PACKINGS.

21-15
 TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

3. REMOVE four SCREWS (7) and four lock washers (8). DISCARD lock WASHERS.

4. HOLD impact WRENCH pointing DOWN. PULL on hammer CASE (9) and TRIGGER and REMOVE
hammer CASE (9) and gasket (10). DISCARD GASKET.

5. REMOVE bearing (11), retainer and roller (12), bearing (13), and valve SEAT (14).

6. REMOVE hammer case BUSHING (15) from hammer case (9).

7. REMOVE two hammer pins (16), hammer (17), and ANVIL (18) from hammer frame (19).

8. REMOVE retaining RING (20).

21-16
 TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

9. REMOVE retaining RING (21), flat waher (22), and two packings (23 and 24). DISCARD PACKINGS.

10. REMOVE eight socket head SCREWS (25) and eight lock washers (26). DISCARD lock WASHERS.

11. REMOVE motor CAP assembly (27) from main housing (28).

CAUTION
Do not pry or in any way force motor cap assembly off main housing to prevent
damage to equipment.

12. REMOVE packing (29), idler gear (30), idler shaft (31), and worm SHAFT (32) from motor cap
assembly (27). DISCARD PACKING.

13. REMOVE two BUSHINGS (33) and idler gear bushing (34).

NOTE
Note number of turns necessary to remove relief adjustment screw.

14. REMOVE relief adjustment SCREW (35), nut (36), and packing (37) from motor cap assembly (27).
DISCARD PACKING.

15. REMOVE setscrew (38), lever (39), spacer ring (40), packing (41), and reversing SPOOL (42).
DISCARD PACKING.

16. REMOVE retaining RING (43), spacer ring (44), and packing (45). DISCARD PACKING.

21-17
 TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

17. REMOVE lock nut (46), screw (47), and TRIGGER (48). DISCARD lock NUT.

18. REMOVE roller BEARING (49), packing (50), spool cap (51), and packing (52). DISCARD PACKINGS.

NOTE
Valve sleeve is not removable and will remain in main housing. If valve sleeve is
damaged, return main housing to depot maintenance.

19. REMOVE valve spool (53), seat valve (54), valve disc (55), spring (56), spring seat (57), and SPRING
(58) from main housing (28).

21-18
 TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

CLEANING

WARNING
• Drycleaning solvent P-D-680 is toxic and flammable. Wear protective
goggles and gloves and use only in well-ventilated area. Avoid contact with
skin, eyes, and clothes and do not breathe vapors. Do not use near open
flame or excessive heat, Flash point is 100°-138°F (38°-50°C). If you
become dizzy while using drycleaning solvent, get fresh air immediately and
get medical aid. If contact with eyes is made, wash your eyes with water
and get medical aid immediately.

• To prevent injury, compressed air used for cleaning and drying purposes
will not exceed 30 psi (207 kPa), Use only with effective chip guarding and
personal protective equipment (goggles/ shield, gloves, etc.).

Clean all parts with drycleaning solvent. Dry with compressed air and wipe clean. Use only lint-free cloths.

1. Inside of bushings should be grey. If color is mostly yellow-bronze, replace bushing.

2. Inspect shafts for wear and replace as required.

3. Motor cap gear chamber bores and end faces around bores should be polished, not rough or grooved.

4. Flat surfaces around chamber and bolt holes should be flat and free of nicks and burrs.

5. Gears should have flat, straight tips without nicks.

6. Gears should have smooth, even polish on teeth and end faces.

7. If cracks are present, discard gear.

8. Gear running surfaces of main housing should show two interconnecting polished circles without a step
or roughness.

9. Main shaft diameter at bushing locations must be smooth.

21-19
TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

NOTE
Apply coat of lubricating oil to packings prior to assembly.

1. APPLY COAT of GAA to seat VALVE (1) and INSTALL seat VALVE (1) in valve spool (2), notched
end alined with strut.

2. INSTALL valve disc(3), SPRING (4), and spring seat (5).

3. INSTALL SPRING (6) on open end of spring seat (5).

4. INSTALL COMPONENTS assembled in STEPS 1 thru 3 in main housing (7).

5. INSTALL two new PACKINGS (8 and 9) on spool cap (10) and INSTALL spool CAP in main housing
(7).

6. APPLY COAT of GAA to roller BEARING (11) and INSTALL roller BEARING (11) in spool cap (10).

7. INSTALL TRIGGER (12), screw (13), and new lock nut (14) in main housing (7).

21-20
 TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

8. INSTALL new packing (15), nut (16), and relief adjustment SCREW (17) in motor cap (18). INSTALL
relief adjustment SCREW (17) number of turns noted to maintain correct impact force. TIGHTEN NUT
(16).

9. INSTALL BUSHING (19) in main housing (7).

10. INSTALL BUSHING (20) and idler gear BUSHING (21) in motor cap (18).

11. INSTALL worm shaft (22), idler GEAR assembly (23), and idler shaft (24).

12. INSTALL new PACKING (25) in groove of motor cap (18).

13. SLIDE main HOUSING (7) over worm shaft (22) until housing seats securely against motor cap (18).

14. APPLY COAT of GAA to eight socket head SCREWS (26) and INSTALL eight socket head SCREWS
(26) and eight new lock washers (27). TIGHTEN socket head SCREWS to 22-25 Ib-ft (29.8-33.9 N.m).

15. INSTALL two new PACKINGS (28 and 29), flat washer (30), and retaining ring (31).

21-21
 TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

16. INSTALL retaining RING (32).

NOTE
Inside of hammer case should be free of grease to avoid overlubrication.

17. APPLY COAT of GAA to INSIDE of hammer frame (33) and INSTALL hammer (34), ANVIL (35), and
two hammer pins (36).

18. APPLY COAT of GAA to hammer case BUSHING (37) and SLIDE onto anvil (35).

19. APPLY COAT of GAA to BEARING (38), RETAINER and ROLLER (39), and BEARING (40) and
INSTALL on worm shaft (22) in that order.

20. INSTALL valve SEAT (41) in main housing assembly (7).

21. ALINE two hammer PINS (36) with valve seat (41) and INSTALL in worm shaft (22).

22. INSTALL new GASKET (42) in main housing (7).

23. SLIDE hammer CASE assembly (43) onto anvil (35) and INSTALL four new lock washers (44) and four
SCREWS (45). TIGHTEN SCREWS to 13-15 Ib-ft (47-54 N.m).

24. INSTALL new PACKING (46) and spacer ring (47) on reversing spool (48).
-

21-22
 TM 5-2420-224-34

IMPACT WRENCH REPAIR (CONT)

25. INSTALL reversing SPOOL (48) in main housing (7) far enough to INSTALL new PACKING (49) and
spacer ring (50).

26. CENTER reversing SPOOL (46) and INSTALL retaining RING (51).

27. TURN reversing SPOOL (46) so hole is pointed UP. INSTALL LEVER (52) by alining hole in lever with
hole in reversing spool. INSTALL SETSCREW (53).

28. INSTALL two new packings (54), HOSE (55), and coupling HALF (56).

29. INSTALL two new packings (57), HOSE (58) and coupling HALF (59).

21-23
TM 5-2420-224-34

Section Ill. PAVEMENT BREAKER REPAIR

PAVEMENT BREAKER REPAIR

This task covers: a. Disassembly b. Assembly c. Charging d. Testing

INITIAL SETUP

Applicable Configuration: Materials/Parts (Cont):

SEE Nitrogen Appendix B, Item 29

Tools and Special Equipment: Oil, Lubricating Appendix B, item 30

Shop Equipment, SC 4910-95-CL-A31 Rags Appendix B, Item 40

Tool Kit, SC 5180-90-CL-N26
Disassembly Tool, P/N 05508 General Safety Instructions:
Installing and Removal Tool, P/N 04337
Pipe, P/N 04910
Puller Kit, P/N 11275 WARNING
Ring, P/N 04908 Fuel and oil are slippery and
Spacer, P/N 04909 can cause falls. To avoid
Test Set, P/N 02835 injury, wipe up spilled fuel or
oil with rags.
Materials/Parts:
Nut, Lock
Kit, Seal Parts
Grease, Automotive Appendix B, Item 23
and Artillery (GAA)

1. REMOVE HOSE assembly (1) and packing

(2). DISCARD PACKING.

2. REMOVE HOSE assembly (3) and packing

(4). DISCARD PACKING.

3. REMOVE quick-disconnect coupling HALF (5)

and packing (6). DISCARD PACKING.

4. REMOVE quick-disconnect coupling HALF (7)

and packing (8). DISCARD PACKING.

5. REMOVE valve CAP (9) and packing (10).

DISCARD PACKING.

21-24
 TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

WARNING
When discharging nitrogen from
accumulator, stand to one side
and keep face away from front
of charging valve to prevent
personal injury.

6. LOOSEN charging VALVE (11) 1-1/2 turns,

REMOVE valve CAP (12), and DRAIN
ACCUMULATOR assembly (13) to 20 psi
(1.4 bar).

7. REMOVE four side rod NUTS (14).

8. REMOVE FOOT assembly (15) by TAPPING

with RUBBER or PLASTIC hammer.

9. REMOVE lock nut (16), washer (17), bushing

(18), bolt (19), latch (20), detent PLUNGER
(21), spring (22), bushing (23), and washer
(24). DISCARD lock NUT.

10. REMOVE and DISCARD PACKING (25), cup

SEAL (26), and WIPER (27).

NOTE
Hexagon bushing is tapered
toward flange end of foot
assembly.

11. USING 50-ton PRESS, REMOVE hexagon

BUSHING (28).

21-25
TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

12. REMOVE four side RODS (29).

13. REMOVE HANDLE assembly (30) by

TAPPING with RUBBER or PLASTIC hammer.

NOTE
If automatic body (31) remains in
handle assembly, go to step 22. If
automatic body remains in flow
sleeve tube (32), go to step 14.

14. REMOVE backup washer (33), cup seal (34),

washer (35), and PISTON (36). DISCARD
backup WASHER and cup SEAL.

15. INSTALL RING between automatic body (31)

and flow sleeve tube (32).

16. WITH RING in place, INSTALL flow sleeve

TUBE (32) on PIPE with automatic body (31)
DOWN.

CAUTION
To prevent possible damage to
flow sleeve tube, place metal
disc on top of flow sleeve tube
before pressing flow sleeve.

17. USING suitable PRESS, PRESS flow SLEEVE

(37) to REMOVE automatic BODY (31).

21-26
 TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

18. REMOVE four pins (38) and PIN (39).

19. REMOVE and DISCARD PACKING (40) from

flow sleeve tube (32).

20. REMOVE packing (41) and two PINS (42)

from automatic body (31). DISCARD
PACKING.

21. GO to STEP 30.

22. REMOVE piston (36) and automatic VALVE

(43) from handle end of flow sleeve (37).

23. REMOVE four pins (38) and PIN (39) from

flow sleeve (37).

24. REMOVE two PINS (42) from automatic body

(31).

25. INSTALL RING on top of PIPE and PLACE

flow sleeve TUBE (32) on top of RING.

CAUTION
To prevent possible damage to
flow sleeve tube, place metal
disc on top of flow sleeve tube
before pressing flow sleeve.

26. USING suitable PRESS, PUSH flow SLEEVE

(37) from flow sleeve tube (32).

27. REMOVE and DISCARD PACKING (40).

21-27
TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

NOTE
Accumulator cylinder (45) may
remain in handle if accumulator
charge is below 20 psi (1.4 bar).

28. PLACE 3/4-hex deep socket with 6-in. (15-cm)

EXTENSION over charging valve (44) and
TAP EXTENSION with PLASTIC or RUBBER
hammer to REMOVE ACCUMULATOR
assembly (13) and automatic body (31).

29. REMOVE and DISCARD PACKING (41) from

automatic body (31).

30. IF accumulator CYLINDER (45) is still in

handle assembly (30), INSTALL PULLER KIT
and remove accumulator CYLINDER (45).

31. REMOVE and DISCARD PACKING (46) from

accumulator cylinder (45).

WARNING
When discharging nitrogen from
accumulator, stand to one side
and keep face away from front
of charging valve to prevent
personal injury.

32. DISCHARGE remaining NITROGEN from

accumulator assembly (13).

21-28
 TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

33. ASSEMBLE DISASSEMBLY TOOL and PIPE

and PLACE ACCUMULATOR assembly (13)
on assembly.

CAUTION
To prevent damage to charging
valve, cover with 3/4-hex deep
socket.

34. USING suitable PRESS, REMOVE

accumulator CHAMBER (47) and accumulator
diaphragm valve (48).

35. SQUEEZE diaphragm VALVE (48) and SLIDE

off accumulator chamber (47).

36. REMOVE charging VALVE (44) and packing

(49). DISCARD PACKING.

37. REMOVE pin (50) and LEVER (51).

38. REMOVE two pins (52), washer (53), wiper

(54), bushing (55), packing (56), packing (57),
valve SPOOL (58), spring (59), and plug (60).
DISCARD PACKINGS.

21-29
 TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL plug (1), spring (2), valve SPOOL

(3), new packing (4), new packing (5),
bushing (6), wiper (7), and washer (8).

2. PRESS DOWN assembly from step 1 and

INSTALL two PINS (9).

3. INSTALL LEVER (10) and pin (11).

4. INSTALL new packing (12) and charging

VALVE (13) in accumulator chamber (14).

5. APPLY light COAT of LUBRICATING OIL on

accumulator CHAMBER (14) and INSTALL
accumulator diaphragm VALVE (15) over
accumulator chamber (14) from charging valve
(13) end.

CAUTION
If press is necessary to complete
step 6, do not use powered
press and use short strokes to
prevent equipment damage.

6. APPLY light COAT of GAA to OUTSIDE of

accumulator diaphragm valve (15) and INSIDE
of accumulator cylinder (16). INSTALL
ASSEMBLY from STEP 5 in accumulator
cylinder (16) from chamfered end of
accumulator cylinder (16).

7. TEST charge ACCUMULATOR assembly (17)

from STEP-6 as follows:

a. Place accumulator assembly (17) in

soft-jawed vise.

b. Loosen valve (18) 1-1/2 turns.

c. Charge accumulator assembly (17)

with nitrogen to 600 psi (41 bar).

d. Check for leaks.

21-30
 TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

When discharging nitrogen from

accumulator, stand to one side
and keep face away from front
of charging valve to prevent
personal injury.

e. Discharge accumulator assembly (17)

completely.

8. INSTALL new backup washer (19) and new

cup SEAL (20), with lips facing out, in
accumulator chamber (14).

9. INSTALL new PACKING (21) on accumulator

cylinder (16).

10. USING suitable PRESS, INSTALL

ACCUMULATOR assembly (17) in handle
(22).

21-31
TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

11. PLACE SPACER on base of press. APPLY

COAT of GAA to entire BORE of flow sleeve
TUBE (23) and PLACE on SPACER with
packing groove facing up.

12. PRESS flow SLEEVE (24), wide groove end

first, into flow sleeve tube (23) until top of
flow sleeve (24) is FLUSH with top of flow
sleeve tube (23).

13. INSTALL four PINS (25), tapered end first, in

flow sleeve tube (23).

14. INSTALL new PACKING (26) on flow sleeve

tube (23).

15. INSTALL two PINS (27), tapered end up, in

automatic body (28).

16. INSTALL automatic VALVE (28) In automatic

body (28).

17, INSTALL PIN (30) In flow sleeve tube (23).

18, INSTALL automatic BODY (28) in flow sleeve

tube (23), ALLOW automatic VALVE (28) to
DROP and pilot Into bore of flow sleeve tube
(23).

19. USING suitable PRESS, with metal plate on

top of automatic body (28), INSTALL
automatic BODY (28) in flow sleeve tube (23)
until bottom edge of side holes in automatic
body (28) are TOUCHING flow sleeve tube
(23).

21-32
 TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

20. INSTALL new PACKING (31) on automatic

body (28).

21. INSTALL PISTON (32), large end first, in flow

sleeve (24) from automatic body (28).

22. APPLY heavy COAT of GAA to WASHER

(33) and INSTALL on piston (32), small end
first.

23. INSTALL four side RODS (34) in handle (22).

24. PLACE flow sleeve TUBE (23) in soft-jawed

VISE and INSTALL HANDLE (22) on flow
sleeve tube (23) by TAPPING with PLASTIC
or RUBBER hammer.

25. INSTALL new WIPER (35), new cup SEAL

(36), with lips facing out, and new PACKING
(37) in foot (36).

26. USING 50-ton PRESS, INSTALL hexagon

BUSHING (39), tapered end first, in foot (38).

21-33
TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT’)

27. INSTALL washer (40), bushing (41), bolt (42), spring (43), detent plunger (44), LATCH (45), bushing
(46), washer (47), and new lock nut (48).

28. INSTALL FOOT (38) on flow sleeve tube (23) with latch (45) in line with in and out ports on handle
(22).

21-34
 TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

29. INSTALL new packing (49) and quick-disconnect coupling HALF (50).

30. INSTALL new packing (51) and quick-disconnect coupling HALF (52).

31. INSTALL new packing (53) and HOSE assembly (54).

32. INSTALL new packing (55) and HOSE assembly (56).

33. INSTALL four side rod NUTS (57) and TIGHTEN in 20 Ib-ft (25 N.m) increments to 75 Ib-ft (100 N.m).

34. CHARGE ACCUMULATOR using Charging procedure, below.

35. INSTALL valve CAP (58), new packing (59), and valve CAP (60).

21-35
TM 5-2420-224-34

PAVEMENT BREAKER REPAIR (CONT)

CHARGING
1. Remove valve cap (1).

2. Rotate gage end of test set fully to left to

make sure stem is fully retracted.

3. Install test set in handle of pavement breaker

by rotating chuck end only.

4. Rotate gage end of test set slowly to right

until pressure is indicated on gage. Pressure
reading should be 500-700 psi (34-46 bar).

5. Connect nitrogen supply line (2) to charging

valve (3) on test set.

6. Adjust regulator (4) on nitrogen bottle (5) to

delivery pressure of 600 psi (42 bar).

7. Open valve (6) on nitrogen supply line (2).

8. When accumulator is fully charged, close

valve (6) on nitrogen supply line (2) and
disconnect from test set.

9. Rotate gage end of test set fully to left and

remove test set at chuck end.

10. Install valve cap (1).

TESTING
1. Perform steps 1 thru 4 of Charging, above.

2. If pressure is low, charge accumulator using

Charging procedure, above.

3. Rotate gage end of test set fully to left and

remove test set at chuck end.

4. Install valve cap (1).

21-36
 TM 5-2420-224-34

Section IV. CHAIN SAW REPAIR

CHAIN SAW REPAIR

This task covers: a. Disassembly b. Inspection c. Assembly

INITIAL SETUP

Applicable Configuration: References:

SEE TM 5-2420-224-20

Tools and Special Equipment: Equipment Condition:

Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N26
Installing and Removal Tool, P/N 04337 TM 5-2420-224-20 Chain Saw Chain and
Bar Removed
Materials/Parts:
TM 5-2420-224-20 Chain Saw Hoses
Kit, Parts Removed

Kit, Seal TM 5-2420-224-20 Chain Saw Trigger,

Guard, and Handle Bar
Grease, Automotive Appendix B, Item 23 Removed
and Artillery (GAA)
Oil, Lubricating Appendix B, Item 30

DISASSEMBLY

NOTE
Nut is left-hand thread.

1. PREVENT SPROCKET (1) from TURNING

and REMOVE nut (2), washer (3),
SPROCKET (1), and adapter (4).

2. REMOVE retaining RING (5) from handle

assembly (6).

CAUTION
Lift housing straight up. Do not
tilt housing, or pry on flat
surface inside surrounding
groove, to avoid damage to
sealing surface.

3. REMOVE eight screws (7), HOUSING (8), and

packing (9) from handle assembly (6).
DISCARD PACKING.

21-37
TM 5-2420-224-34

CHAIN SAW REPAIR (CONTl

4. REMOVE two PINS (10 and 11) from housing

(8).

5. IF WORN or DAMAGED, REMOVE two

sleeve BEARINGS (12 and 13).

6. REMOVE screw PLUG (14).

7. REMOVE gear (15), pin (16), gear (17), and

roller KEY (18).

8. REMOVE drive SHAFT (19) and BEARING

(20) as an assembly.

9. REMOVE BEARING (20) from drive shaft

(19).

21-38
 TM 5-2420-224-34

CHAIN SAW REPAIR (CONT)

10. IF WORN OR DAMAGED, REMOVE two

sleeve BEARINGS (21 and 22).

NOTE
Note position of seal and seal
backup washer prior to
disassembly to aid in assembly.

11. REMOVE retaining ring (23), seal backup

washer (24), and SEAL (25) from handle
assembly (6). DISCARD SEAL.

12. IF INSTALLED, REMOVE PLUG (26).

13. REMOVE spring PIN (27).

14. REMOVE assembled VALVE (28).

21-39
TM 5-2420-224-34

CHAIN SAW REPAIR (CONT)

15. DISASSEMBLE assembled VALVE (28) by

REMOVING retaining ring (29), spring washer
(30), spring (31), spring washer (32), packing
(33), VALVE (34), and packing (35).
DISCARD PACKINGS.

16. IF WORN or DAMAGED, REMOVE two

sleeve BEARINGS (36 and 37).

17. REMOVE two screw PLUGS (38 and 39).

INSPECTION
1. Gear chamber bores and bottoms around
drive shaft sleeve bearings should be
polished, not rough or grooved.

2. Sleeve bearings should be grey in color;

replace if bores are yellow-bronze.

3. Flat surface around gear chamber and bolt

holes should be flat and free of nicks.

4. Gears should have straight tips without nicks,

square tooth ends, and smooth even polish
on teeth and end surfaces. Check for cracks
at groove in drive gear bore.

21-40
 TM 5-2420-224-34

CHAIN SAW REPAIR (CONT)

5. Surface on handle assembly near gears

should show two interconnecting polished
circles without a step; packing groove and
surface should be smooth.

6. Handle assembly sleeve bearing bores should

be grey in color; replace if bores are
yellow-bronze.

7. Drive shaft diameter should be smooth on

each side of V-groove keyway; signs of
polishing are normal.

a. If drive shaft wear is in excess of normal

polishing, or if drive shaft is grooved or rough,
replace sleeve bearings, drive shaft, and seal.

ASSEMBLY

NOTE
Apply coat of lubricating oil to
packings prior to assembly.

1. INSTALL two screw PLUGS (1 and 2) in

handle assembly (3).

2. IF REMOVED, INSTALL two new sleeve

BEARINGS (4 and 5).

3. INSTALL two new packings (6 and 7), spring

washer (8), SPRING (9), spring washer (10),
and retaining ring (11) on valve (12).

21-41
TM 5-2420-224-34

CHAIN SAW REPAIR (CONT)

4. INSTALL assembled VALVE (13) in handle

assembly (3).

5. INSTALL spring PIN (14).

6. IF REMOVED, INSTALL PLUG (15).

CAUTION
Make sure lips of seal face
gear face to prevent damage to
equipment.

7. INSTALL new SEAL (16), seal backup washer

(17), and retaining ring (18) in handle
assembly (3).

8. IF REMOVED, INSTALL two new sleeve

BEARINGS (19 and 20).

21-42
 TM 5-2420-224-34

CHAIN SAW REPAIR (CONT)

9. INSTALL BEARING (21) on drive shaft (22).

CAUTION
Do not press on drive shaft to
seat bearing to prevent
damage to equipment.

10. USING suitable SLEEVE and PRESS,

INSTALL assembled BEARING (21) and drive
SHAFT (22) in handle assembly (3).

NOTE
Apply light coat of GAA on roller
key for retention during assembly.

11. INSTALL roller key (23) and GEAR (24) on

drive shaft (22).

12. INSTALL pin (25) and GEAR (26) in handle

assembly (3).

13. INSTALL screw PLUG (27) in housing (28).

14. IF REMOVED, INSTALL two new sleeve

BEARINGS (29 and 30).

15. INSTALL two PINS (31 and 32).

21-43
TM 5-2420-244-34

CHAIN SAW REPAIR (CONT)

CAUTION
Turn shaft manually to check
for free rotation before and
after installing screws to
prevent damage to equipment.

16. INSTALL new packing (33), HOUSING (28),

and eight screws (34) on handle assembly
(3).

17. INSTALL retaining RING (35) in handle

assembly (3).

NOTE
Nut is left-hand thread.

18. INSTALL adapter (36), SPROCKET (37),

washer (38), and nut (39). Do not tighten nut.

19. PREVENT SPROCKET (37) from TURNING

and TIGHTEN NUT (39).

NOTE
Follow-on Maintenance:
Install chain saw trigger, guard,
and handle bar (TM 5-2420-
224-20) .
Install chain saw hoses (TM 5-
2420-224-20).
Install chain saw chain and bar
(TM 5-2420-224-20).

21-44
 TM 5-2420-224-34

APPENDIX A
REFERENCES

PUBLICATION INDEXES

The following index should be consulted frequently for latest changes or revisions and for new
publications relating to material covered in this technical manual:

Consolidated Index of Army Publications and Blank Forms . . . . . . . . . DA Pam 25-30

FORMS
The following forms pertain to this material. (Refer to DA Pam 25-30 for index of blank forms.)

DD Form 6, Packaging Improvement Report

SF Form 46, U.S. Government Motor Vehicle Operator’s Identification Card

DA Form 91, Operator’s Report of Motor Vehicle Accident

SF Form 368, Quality Deficiency Report

DD Form 1397, Processing and Reprocessing Records for Shipment, Storage, and Issue of
Vehicles and Spare Engines

DA Form 2028, Recommended Changes to Publications and Blank Forms

DA Form 2028-2, Recommended Changes to Equipment Technical Manuals

DA Form 2404, Equipment Inspection and Maintenance Worksheet

DA Form 2408-9, Equipment Control Record

Refer to DA Pam 738-750, The Army Maintenance Management Systems (TAMMS), for instructions
on the use of maintenance forms pertaining to this material.

OTHER PUBLICATIONS

The following publications contain information pertinent to the major item material and associated
equipment:

Operating Vehicle

Operator’s Manual for SEE/HMMH Wheeled Tractors . . . . . . . . . TM 5-2420-224-10

Driver Selection and Training (Wheeled Vehicles) . . . . . . . . . . . FM 21-300

Army Motor Transport Units and Operation . . . . . . . . . . . . . . . FM 55-30

Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . FM 21-305

Prevention of Motor Vehicle Accidents . . . . . . . . . . . . . . . . . . AR 385-55

Accident Reporting and Records . . . . . . . . . . . . . . . . . . . . . AR 385-40

A-1
TM 5-2420-224-34

OTHER PUBLICATIONS (CONT)

Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-725

Vehicle Recovery Operations . . . . . . . . . . . . . . . . . . . . . . . FM 20-22

Maintenance and Repair

Unit Maintenance for SEE/HMMH Wheeled Tractors . . . . . . . . . . TM 5-2420-224-20

Unit, Direct Support, and General Supped Maintenance

Repair Parts and Special Tools List for SEE/HMMH
Wheeled Tractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM5-2420-224-24P

Lubrication Order for SEE/HMMH Wheeled Tractors . . . . . . . . . . LO 5-2420-224-12

Operator’s and Organizational Maintenance Manual

Including Repair Parts and Special Tools List for
Decontaminating Apparatus, Portable . . . . . . . . . . . . . . . . . . . TM 3-4230-214-12&P

Operator’s, Organizational, Direct Support, and

General Support Maintenance Manual for Lead-Acid
Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14

Organizational Care, Maintenance, and Repair of

Pneumatic Tires and inner Tubes . . . . . . . . . . . . . . . . . . . . TM 9-2610-200-24

Description, Use, Bonding Techniques, and Properties

of Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB ORD 1032

Materials Used for Cleaning, Preserving, Abrading,

and Cementing Ordnance Material and Related
Materials, including Chemicals . . . . . . . . . . . . . . . . . . . . . . TM 9-247

Metal Body Repair and Related Operations . . . . . . . . . . . . . . . FM 43-2

Painting instructions for Field Use . . . . . . . . . . . . . . . . . . . . TM 43-0139

Inspection, Care, and Maintenance of Anti-Friction

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214

Use of Antifreeze Solutions and Cleaning Compounds

in Engine Cooling Systems. . . . . . . . . . . . . . . . . . . . . . . . TB 750-651

Rust Proofing Procedures for Truck, Utility . . . . . . . . . . . . . . . TB 43-0213

Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . . . . . . . . TM 750-254

Functional Grouping Codes . . . . . . . . . . . . . . . . . . . . . . . . TB 750-93-1

Solder and Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . TB SIG 222

Operator’s Manual for Welding Theory and Application . . . . . . . TM 9-237

STE/ICE Technical Manual . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-4910-571-12&P

Safety inspection and Testing of Lifting Devices . . . . . . . . . . . . TB 43-0142

A-2
 TM 5-2420-224-34

OTHER PUBLICATIONS (CONT)

Operator’s Manual for Repair of Seat Cover and Pad . . . . . . . . FM 10-16

Fuel Tank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 43-2

Cold Weather Operation and Maintenance

Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70

Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71

Personnel Heater and Winterization Kit Policy for

Tank-Automotive Construction and Material
Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 9-16

Operation and Maintenance of Ordnance Material in

Extreme Cold Weather (0°F to -65° F) . . . . . . . . . . . . . . . . . . FM 9-207

Decontamination

Chemical, Biological, and Radiological (CBR)

Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-220

Chemical, Biological, Radiological, and Nuclear Defense . . . . . . . FM 21-40

NBC Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-5

General

Artificial Respiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-11

Principles of Automotive Vehicles . . . . . . . . . . . . . . . . . . . . . TM 9-8000

Camouflage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-20

Procedures for Destruction of Tank-Automotive

Equipment to Prevent Enemy Use. . . . . . . . . . . . . . . . . . . . TM 750-244-6

Administrative Storage of Equipment . . . . . . . . . . . . . . . . . . . TM 740-90-1

Color and Marking of Army Material . . . . . . . . . . . . . . . . . . . TB 43-0209

Preservation, Packaging, and Packing of Military TM 38-230-1

Supplies and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . &TM 38-230-2

Storage Serviceability Standard, Tracked Vehicles,

Wheeled Vehicles, and Component Parts . . . . . . . . . . . . . . . . SB 740-98-1

Vehicle, Wheeled, Preparation for Shipment and

Limited Storage of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-V-62038D

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 5-2420-224-15

Expendable/Durable Items (Except Medical, Class V,

Repair Parts, and Heraldic items) . . . . . . . . . . . . . . . . . . . . CTA 50-970

Army Medical Department Expendable/Durable Items . . . . . . . . . CTA 8-100

A-3/(A-4 Blank)
 TM 5-2420-224-34

APPENDIX B
EXPENDABLE SUPPLIES AND MATERIALS LIST

Section I. INTRODUCTION

SCOPE
This appendix lists expendable consumable maintenance supplies you will need to operate and
maintain the SEE/HMMH. This listing is for informational purposes only and is not authority to requisition
the listed items. These items are authorized to you by CTA 50-970. Expendable/Durable Items (except
Medical, Class V, Repair Parts, and Heraldic ltems) or CTA 8-100, ARMY Medical Department
Expendable/Durable Items.

EXPLANATION OF COLUMNS

Column (1) — Item Number. This number is assigned to the entry in the listing and is referenced in
the narrative instructions to identify the material (e.g., “Use sealing compound, Appendix B, Item 14).

Column (2) — Level. This column identifies the lowest level of maintenance that requires the listed
item.
C — Operator/Crew
O — Unit Maintenance
F — Direct Support Maintenance
H — General Support Maintenance

Column (3) — National Stock Number. This is the National Stock Number assigned to the item;
use it to request or requisition the item.

Column (4) — Description. Indicates the Federal item name and, if required, a description to identify
the item. The last line for each item indicates the Contractor and Government Entity (CAGE) Code in
parentheses followed by the part number.

Column (5) — Unit of Measure (U/M). Indicates the measure used in performing the actual
maintenance function. This measure is expressed by a two-character alphabetical abbreviation (e.g., ea,
in, pr). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will
satisfy your requirements.

B-1
TM 5-2420-224-34

Section II. EXPENDABLE SUPPLIES AND MATERIALS

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

1 C Additive, Diesel Fuel with

Biocide
(81349) MIL-S-53021

6850-01-246-6544 5 Gal Can

2 F 8040-01-140-0954 Adhesive, Type 2, Class 3

(81349) MIL-A-46050

3 O Adhesive, Type 1, Black

(81349) MIL-A-46106

8040-00-851-0211 100 ml Tube ML

4 O 8040-00-455-5359 Adhesive, Rubber

(04963) 8011

5 O Alcohol
(81348) OE760

6810-00-543-7415 1 Gal Can GAL

6 C Antifreeze, Permanent, Glycol,

Inhibited
(81348) MIL-A-46153

6850-00-181-7929 1 Gal Can GAL

6850-00-181-7933 5 Gal Can GAL
6850-00-181-7930 55 Gal Drum GAL

7 C Antifreeze, Permanent, Glycol,

Inhibited, Arctic
(81349) MlL-A-11755

8 O Caps and Plugs, Protective,

Dust

Caps
5340-00-324-9158 0.413 ID, 0.438 OD EA
(96906) MS90376-8Y

5340-00-208-1989 0.480 ID, 0.540 OD EA

(96906) MS90376-8R

B-2
 TM 5-2420-224-34

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

Caps (Cont)
5340-00-449-4491 0.530 ID, 0.595 OD EA
(96906) MS90736-10Y

5340-00-211-8188 0.605 ID, 0.665 OD EA

(96906) MS90376-10R

5340-00-213-8881 0.720 ID, 0.775 OD EA

(96906) MS90376-12R

5340-00-481-8934 0.785 ID, 0.845 OD EA

(96906) MS90376-14Y

5340-00-493-5835 0.850 ID, 0.905 OD EA

(96906) MS90376-14R

5340-00-496-5832 0.893 ID, 0.963 OD EA

(96906) MS90376-16Y

5340-00-200-5904 0.973 ID, 1.035 OD EA

(96906) MS90376-16R

5340-00-171-2436 1.078 ID, 1.085 OD EA

(96906) MS90376-18Y

5340-00-193-0783 1.093 ID, 1.155 OD EA

(96906) MS90376-18R

5340-00-051-0029 1.150 ID, 1.215 OD EA

(96906) MS90376-20Y

5340-00-213-8893 1.231 ID, 1.301 OD EA

(96906) MS90376-20R

5340-00-191-4898 1.390 ID, 1.460 OD EA

(96906) MS90376-24Y

5340-00-889-8677 1.463 ID, 1.533 OD EA

(96906) MS90376-24R

Plugs
5340-00-804-1228 0.500-20 THD, 0.438 DIA EA
(81349) M5501/1-5

5340-00-292-3292 0.5625-18 THD, 0.500 DIA EA

(81349) M5501/1-6

B-3
TM 5-2420-224-34

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

Plugs (Cont)
5340-00-828-8802 0.750-16 THD, 0.675 DIA EA
(81349) M5501/1-8

5340-00-804-1245 1.3125-12 THD, 1.219 DIA EA

(81349) M5501/1-16

5340-00-804-1238 0.4375-20 THD, 0.660 DIA EA

(81349) M5501/2-4

5340-00-804-1243 0.5625-18 THD, 0.800 DIA EA

(81349) M5501/2-4

5340-00-804-1241 0.750-16 THD, 1.00 DIA EA

(81349) M5501/2-6

5340-01-138-2169 1.0625-12 THD, 1.28 DIA EA

(81349) M5501/2-12

5340-00-804-1222 1.3125-12 THD, 1.53 DIA EA

(81349) M5501/2-16

5340-01-120-9526 1.875-12 THD, 2.33 DIA EA

(81349) M5501/2-24

9 O 7930-00-634-3935 Chips, Soap

(81348) P-S-1792

10 O Cloth, Emery
(81348) P-C-1673

5350-00-584-4654 50-Sheet Pack EA

11 O Cloth, Lint-Free

12 O 8030-00-597-5367 Compound, Antiseize EA

(81349) MIL-A-907A

13 O Compound, Flight Deck,

Non-Slip, Type 3
(81349) MIL-D-23003

14 O Compound, Sealing, Grade N,

Type 2
(81349) MIL-S-46163

8030-01-014-5869 5 ml Tube ML

B-4
 TM 5-2420-224-34

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

15 F Compound, Sealing, Grade K,

Type 1
(81349) MIL-S-46163

8030-00-148-9833 10 cc Bottle CC
8030-01-158-6070 50 cc Bottle CC

16 F Compound, Sealing
(05972) 515-31

8030-01-137-6964 50 ml Tube ML

17 F Compound, Sealing
(05972) 567-47

8030-01-166-0675 50 ml Tube ML

18 C 6850-01-160-3868 Extender, Antifreeze

(81349) MIL-A-53009

19 O Fluid, Brake, Silicone

(81349) MIL-B-46176

9150-01-102-9455 1 Gal Can GAL

9150-01-123-3152 5 Gal Can GAL

20 C Fluid, Windshield Washing

(81348) O-C-1901

6850-00-926-2275 1 Gal Bottle GAL

21 C Fuel, Diesel, Winter

(81348) VV-F-800

9140-00-286-5286 Bulk GAL

9140-00-286-5287 5 Gal Can GAL
9140-00-286-5288 55 Gal Drum, 16 GAGE GAL
9140-00-286-5289 55 Gal Drum, 18 GAGE GAL

22 C Fuel, Diesel, Regular

(81348) VV-F-800

9140-00-286-5294 Bulk GAL

9140-00-286-5295 5 Gal Can GAL
9140-00-286-5296 55 Gal Drum, 16 GAGE GAL
9140-00-286-5297 55 Gal Drum, 18 GAGE GAL

B-5
TM 5-2420-224-34

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

23 C Grease, Automotive and

Artillery (GAA)
(81349) MIL-G-10924

9150-01-197-7788 2.5 Oz Tube OZ

9150-01-197-7693 14 Oz Cartridge OZ
9150-01-197-7690 1 Lb Can LB
9150-01-197-7652 5 Lb Can LB
9150-01-197-7692 35 Lb Can LB
9150-01-197-7691 120 Lb Drum LB

24 F Grease, Molybdenum Disulfide

(81349) MIL-G-21164

9150-00-935-4018 14 Oz Tube OZ
9150-00-965-2003 35 Lb Can LB

25 F 6850-00-664-4959 Grease, Silicone

(81349) MIL-C-21567

26 F 6685-00-269-4892 Indicator, Temperature EA

(82682) Tempilstik

27 C Inhibitor, Corrosion, Cooling

System
(81348) 0-1-490

6850-00-753-4967 6 Oz Can OZ
6850-00-584-2707 8.5 Oz Can OZ
6850-01-076-8810 12 Oz Can OZ

28 O 9150-00-948-6912 Lubricant, Solid

9150-00-948-7025 (81349) MIL-L-46010

29 F Nitrogen, Technical
BB-N-411

6830-00-764-8964 380 Cu Ft EA

30 C Oil, Lubricating, OE/HDO 10

(81349) MIL-L-2104

9150-00-189-6727 1 Qt Can QT
9150-00-186-6668 5 Gal Can GAL
9150-00-191-2772 55 Gal Drum, 18 GAGE GAL

B-6
 TM 5-2420-224-34

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

31 C Oil, Lubricating, OE/HDO 30

(81 349) MIL-L-2104

9150-00-265-9433 1 Qt Can QT
9150-00-265-9435 5 Gal Can GAL
9150-00-265-9436 55 Gal Drum, 16 GAGE GAL
9150-00-265-9437 55 Gal Drum, 18 GAGE GAL

32 C Oil, Lubricating, OE/HDO 50

(81 349) MIL-L-2104

9150-00-265-9864 1 Qt Can QT
9150-00-265-9865 5 Gal Can GAL
9150-00-265-9866 55 Gal Drum, 16 GAGE GAL

33 C Oil, Lubricating, OE/HDO 15/40

(81349) MIL-L-2104

9150-01-152-4117 1 Qt Can QT
9150-01-152-4118 5 Gal Can GAL
9150-01-152-4119 55 Gal Drum GAL

34 C Oil, Lubricating, GO 75
(81 349) MIL-L-2105

9150-00-035-5390 1 Qt Can QT
9150-00-035-5391 5 Gal Can GAL
9150-00-035-5392 55 Gal Drum GAL

35 C Oil, Lubricating, GO 80/90

(81349) MIL-L-2105

9150-01-035-5392 1 Qt Can QT
9150-01-035-5393 5 Gal Can GAL
9150-01-035-5394 55 Gal Drum GAL

36 C Oil, Lubricating, GO 85/140

(81349) MIL-L-2105

9150-01-048-4581 1 Qt Can QT
9150-01-035-5345 5 Gal Can GAL
9150-01-035-5396 55 Gal Drum GAL

B-7
TM 5-2420-224-34

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

37 O Oil, Lubricating, Gear,

Subzero, GOS
(81349) MIL-L-10324

9150-00-261-7904 1 Qt Can QT
9150-00-257-5440 5 Gal Can GAL
9150-00-257-5443 55 Gal Drum GAL

38 O Oil, Lubricating, ICE, Subzero

(OEA)
(81349) MIL-L-46167

9150-00-402-4478 1 Qt Can QT
9150-00-402-2372 5 Gal Can GAL
9150-00-491-7197 55 Gal Drum, 16 GAGE GAL

39 O Preventive, Corrosion
(81349) MIL-C-16173

40 O Rags
(81348) DDD-R-30

7920-00-205-1711 Bundle BDL

41 O Sodium Bicarbonate (Technical)

(Baking Soda)
(81348) O-5-576

6810-00-264-6618 1 Lb Container LB

42 C Solvent, Drycleaning (SD),

Type II
(81348) P-D-680

6850-00-664-5685 1 Qt Can QT
6850-00-281-1985 1 Gal Can GAL
6850-00-285-8011 55 Gal Drum GAL

43 O 5975-00-984-6582 Strap, Tiedown, Electrical EA

(81349) MIL-S-23190

44 O Strap, Tiedown, Electrical

(96906) MS3367-1-9

5975-00-074-2072 Bundle BDL

B-8
 TM 5-2420-224-34

(1) (2) (3) (4) (5)

ITEM NATIONAL
NO. LEVEL STOCK NUMBER DESCRIPTION U/M

45 O Strap, Tiedown, Electrical

(96906) MS3367-3-9

5975-00-451-5001 Bundle BDL

46 O Tag, Identification
(81349) MIL-T-12755

9905-00-537-8954 Bundle of 50 EA

47 O Tape, Insulation, Electrical

(81349) MIL-L-15126

5970-00-543-1154 Roll RL

48 O Towel, Shop
(58536) A-A-531

49 F Twine, Cotton, l/8-in. Diameter

50 O Water, Distilled
(96906) Ml L-STD-1444

6610-00-682-6867 1 Gal GAL

8810-00-356-4936 5 Gal GAL

51 O 9505-00-191-3680 Wire, Nonelectrical

B-9)/(B-10 Blank)
 TM 5-2420-224-34

APPENDIX C
ILLUSTRATED LIST OF MANUFACTURED ITEMS

INTRODUCTION

This appendix includes complete instructions for making items authorized to be manufactured at direct
support and general support maintenance.

A Part No. Index in numeric order is provided for cross-referencing the part number of the item to be
manufactured to the table which covers fabrication criteria.

All bulk materials needed for manufacture of an item are listed by part number or specification
number.

PART NO. NAME TABLE NO.

000 429 07 01X580 LINE C-1

000 429 23 01X170 LINE C-1
000 429 23 01X250 LINE C-1
000 429 23 01X300 LINE C-1
000 429 23 01X350 LINE C-1
000 429 23 01X450 HOSE C-1
000 429 23 01X520 HOSE C-1
000 429 23 01X850 LINE C-1
000 429 23 01X1250 LINE C-1
000 429 23 01X1300 LINE C-1
000 429 23 01X1311 TUBE, METALLIC C-1
000 429 62 01X0.7 HOSE, NONMETALLIC C-1
000 429 62 01X460 LINE, HYDRAULIC C-1
000 429 62 01X580 HOSE, NONMETALLIC C-1
000 429 62 01X700 HOSE, NONMETALLIC C-1
000 435 20 82X60 HOSE, NONMETALLIC C-1
000 551 40 56X430 TUBING, NONMETALLIC C-1
000 551 62 56X2000 TUBE C-1
000 985 45 30X94 SEAL, NONMETALLIC C-1
000 985 45 30X530 SEAL, NONMETALLIC C-1
001 987 06 52X512 SEAL, RUBBER CHANNEL C-1
000 987 07 72X220 GUARD, EDGE SECTION C-1
001 987 22 72X320 GUARD, EDGE C-1
001 987 36 25 CHANNEL, NONMETALLIC C-1
001 987 42 57X365 SEAL, RUBBER STRIP C-1
001 989 95 85X440 TAPE, RUBBER ADHESIVE C-1
008 997 54 82X207 HOSE C-1
008 997 54 82X522 HOSE C-1
008 997 60 82X24 HOSE C-1
008 997 60 82X25 HOSE C-1
008 997 60 82X29 HOSE C-1
008 997 60 82X36 HOSE C-1
008 997 60 82X46 HOSE C-1
008 997 60 82X190 HOSE C-1
008 997 60 82X310 HOSE C-1
008 997 60 82X490 HOSE C-1
008 997 60 82X500 HOSE C-1

C-1
TM 5-2420-224-34

PART NO. NAME TABLE NO.

008 997 60 82X890 HOSE C-1

008 997 60 82X940 HOSE C-1
008 997 60 82X1480 HOSE C-1
008 997 60 82X1524 HOSE C-1
008 997 60 82X2500 HOSE C-1
008 997 90 82X700 HOSE, NONMETALLIC C-1
009 997 93 82X262 HOSE C-1
376 987 01 27X500 PIPE, NONMETALLIC C-1
376 987 01 27X860 TUBE, NONMETALLIC C-1
376 987 01 27X920 TUBE, NONMETALLIC C-1
376 987 01 27X960 TUBE, NONMETALLIC C-1
376 987 74 27 PIPE, PLASTIC C-1
376 987 74 27X350 LINE C-1
419 546 70 31X12.5 CONDUIT, SHIELDED C-1
419 546 71 31X26.2 CONDUIT, SHIELDED C-1
442 987 11 43X500 MM SLEEVE, RUBBER C-1
47-02188-001X1960 MOLDING, PLASTIC C-1
47-02188-001X3250 MOLDING, PLASTIC C-1
48-00100-010X1300 TUBE, NONMETALLIC C-1
48-00100-010X1700 TUBING, NONMETALLIC C-1
48-00101-020X1725 HOSE, NONMETALLIC C-1
48-00102-003X18.49 LOOM, NONMETALLIC C-1
48-00102-004X6.0 LOOM, NONMETALLIC C-1
48-00102-004X8.5 LOOM, NONMETALLIC C-1
48-00102-005X20.49 LOOM, NONMETALLIC C-1
48-00102-007X11.48 LOOM, NONMETALLIC C-1
48-00102-013X1.48 LOOM, NONMETALLIC C-1
48-02223-160X9.5 LOOM, NONMETALLIC C-1
48-02223-169X9.5 LOOM, NONMETALLIC C-1
48-02461-012X0.13 INSULATION, SLEEVING C-1
48-02461-012X1.64 TUBE C-1
48-02461-050X0.49 TUBE C-1
48-02461-100X0.49 TUBE C-1

C-2
 TM 5-2420-224-34

Table C-1. Manufactured Items

PART NUMBER NAME MFG FROM DESCRIPTION

000 429 07 01X580 LINE 000 429 07 01 580 mm LONG

000 429 23 01X170 LINE 000 429 23 01 170 mm LONG

000 429 23 01X250 LINE 000 429 23 01 250 mm LONG

000 429 23 01X300 LINE 000 429 23 01 300 mm LONG

000 429 23 01X350 LINE 000 429 23 01 350 mm LONG

000 429 23 01X450 HOSE 000 429 23 01 450 mm LONG

000 429 23 01X520 HOSE 000 429 23 01 520 mm LONG

000 429 23 01X850 LINE 000 429 23 01 850 mm LONG

000 429 23 01X1250 LINE 000 429 23 01 1250 mm LONG

000 429 23 01X1300 LINE 000 429 23 01 1300 mm LONG

000 429 23 01X1311 TUBE, METALLIC 000 429 23 01 1311 mm LONG

000 429 62 01X0.7 HOSE, NONMETALLIC 000 429 62 01 0.7 mm LONG

000 429 62 01X460 LINE, HYDRAULIC 000 429 62 01 460 mm LONG

000 429 62 01X580 HOSE, NONMETALLIC 000 429 62 01 580 mm LONG

000 429 62 01X700 HOSE, NONMETALLIC 000 429 62 01 700 mm LONG

000 435 20 82X60 HOSE, NONMETALLIC 000 435 20 82 60 mm LONG

000 551 40 56X430 TUBING, NONMETALLIC 000 551 40 56 430 mm LONG

000 551 62 56X2000 TUBE 000 551 62 56 2000 mm LONG

000 985 45 30X94 SEAL, NONMETALLIC 000 985 45 30 94 mm RIGHT

000 985 45 30X530 SEAL, NONMETALLIC 000 985 45 30 530 mm LEFT

001 987 06 52X512 SEAL, RUBBER CHANNEL 001 987 06 52 512 mm LONG

000 987 07 72X220 GUARD, EDGE SECTION 000 987 07 72 220 mm LONG

001 987 22 72X320 GUARD, EDGE 001 987 22 72 320 mm LONG

001 987 36 25 CHANNEL, NONMETALLIC 001 987 36 25

001 987 42 57X365 SEAL, RUBBER STRIP 001 987 42 57 365 mm LONG

001 989 95 85X440 TAPE, RUBBER ADHESIVE 001 989 95 85 440 mm LONG

008 997 54 82X207 HOSE 008 997 54 82 207 mm LONG

008 997 54 82X522 HOSE 008 997 54 82 522 mm LONG

C-3
TM 5-2420-224-34

Table C-1. Manufactured Items (Cont)

PART NUMBER NAME MFG FROM DESCRIPTION

008 997 60 82X24 HOSE 008 997 60 82 24 mm LONG

008 997 60 82X25 HOSE 008 997 60 82 25 mm LONG

008 997 60 82X29 HOSE 008 997 60 82 29 mm LONG

008 997 60 82X36 HOSE 008 997 60 82 36 mm LONG

008 997 60 82X46 HOSE 008 997 60 82 46 mm LONG

008 997 60 82X190 HOSE 008 997 60 82 190 mm LONG

008 997 60 82X310 HOSE 008 997 60 82 310 mm LONG

008 997 60 82X490 HOSE 008 997 60 82 490 mm LONG

008 997 60 82X500 HOSE 008 997 60 82 500 mm LONG

008 997 60 82X890 HOSE 008 997 60 82 890 mm LONG

008 997 60 82X940 HOSE 008 997 60 82 940 mm LONG

008 997 60 82X1480 HOSE 008 997 60 82 1480 mm LONG

008 997 60 82X1524 HOSE 008 997 60 82 1524 mm LONG

008 997 60 82X2500 HOSE 008 997 60 82 2500 mm LONG

008 997 90 82X700 HOSE, NONMETALLIC 008 997 90 82 700 mm LONG

009 997 93 82X262 HOSE 009 997 93 82 262 mm LONG

376 987 01 27X500 PIPE, NONMETALLIC 376 987 01 27 500 mm LONG

376 987 01 27X860 TUBE, NONMETALLIC 376 987 01 27 860 mm LONG

376 987 01 27X920 TUBE, NONMETALLIC 376 987 01 27 920 mm LONG

376 987 01 27X960 TUBE, NONMETALLIC 376 987 01 27 960 mm LONG

376 987 74 27 PIPE, PLASTIC 376 987 74 27

376 987 74 27X350 LINE 376 987 74 27 350 mm LONG

419 546 70 31X12.5 CONDUIT, SHIELDED 419 546 70 31 12.5 FT LONG

419 546 71 31X26.2 CONDUIT, SHIELDED 419 546 71 31 26.2 FT LONG

442 967 11 43X500 MM SLEEVE, RUBBER 442 987 11 43 500 mm LONG

47-02188-001X1960 MOLDING, PLASTIC 47-02188-001 1960 mm LONG

47-02188-001X3250 MOLDING, PLASTIC 47-02188-001 3250 mm LONG

48-00100-010X1300 TUBE, NONMETALLIC 48-00100-010 1300 mm LONG

C-4
 TM 5-2420-224-34

Table C-1. Manufactured Items (Cont)

PART NUMBER NAME MFG FROM DESCRIPTION

48-00100-010X1700 TUBING, NONMETALLIC 48-00100-010 1700 mm LONG

48-00101-020X1725 HOSE, NONMETALLIC 48-00101-020 1725 mm LONG

48-00102-003X18.49 LOOM, NONMETALLIC 48-00102-003 18.49 FT LONG

48-00102-004X6.0 LOOM, NONMETALLIC 48-00102-004 6.0 FT LONG

48-00102-004X8.5 LOOM, NONMETALLIC 48-00102-004 8.5 FT LONG

48-00102-005X20.49 LOOM, NONMETALLIC 48-00102-005 20.49 FT LONG

48-00102-007X11.48 LOOM, NON METALLIC 48-00102-007 11.48 FT LONG

48-00102-013X1.48 LOOM, NON METALLIC 48-00102-013 1.48 FT LONG

48-02223-160X9.5 LOOM, NONMETALLIC 48-02223-160 9.5 FT LONG

46-02223-169X9.5 LOOM, NONMETALLIC 48-02223-169 9.5 FT LONG

48-02461-012X0.13 INSULATION, SLEEVING 48-02461-012 0.13 FT LONG

48-02461-012X1.64 TUBE 48-02461-012 1.64 FT LONG

48-02461-050X0.49 TUBE 48-02461-050 0.49 FT LONG

48-02461-100X0.49 TUBE 48-02461-100 0.49 FT LONG

C-5
TM 5-2420-224-34

FABRICATED TOOLS

ITEM 1

MATERIALS:

WOOD DOWEL (4)

3 IN. (76.2 mm) X 0.18 IN. (4.7 mm)

NOTE:
CUT 0.18-IN. (4.7-mm) DOWEL TO 3-IN. (76.2-mm) LENGTH.

C-6
 TM 5-2420-224-34

FABRICATED TOOLS (CONT)

ITEM 2

MATERIALS:

BOLT, HEXAGON (2)

M10X1,5 8.8 GR

NOTE:
WELD TWO BOLTS TOGETHER PER TM 9-237.

C-7
 TM 5-2420-224-34

FABRICATED TOOLS (CONT)

ITEM 3

MATERIALS:

BOLT, HEXAGON
M12X1,5 8.8 GR (1)
M14X1,5 8.8 GR (1)

NOTE :
WELD TWO BOLTS TOGETHER PER TM 9-237.

C-8
 TM 5-2420-224-34

FABRICATED TOOLS (CONT)

ITEM 4

MATERIALS:

WOOD DOWEL
4.25 IN. (107.9 mm) X 1 IN. (25.4 mm)

NOTE:
CUT 1-IN. (25.4-mm) DOWEL TO 4.25-IN. (107.9-mm) LENGTH.

C-9
TM 5-2420-224-34

FABRICATED TOOLS (CONT)

ITEM 5

MATERIALS:

BOLT, HEXAGON
3/8-16 X 3 NC

NOTE:
1. GRIND TWO SIDES OF HEAD EVENLY TO 15/32 IN. (11.9 mm).
2. GRIND HEAD TO 1/8 IN. (3.2 mm).

C-10
 TM 5-2420-224-34

APPENDIX D
TORQUE LIMITS

Use the torque values listed in the maintenance procedures, if they are given. When no torque values
are given in the maintenance procedures, use the following guides.

Table D-1. Torque Value Guide (Pound-Feet)

Torque Lb-Ft Torque Lb-Ft Torque Lb-Ft

Screw No Dashes 3 Dashes 6 Dashes Socket
Diameter (SAE Grade 2) (SAE Grade 5) (SAE Grade 8) Size

1/4-20 UNC 3-5 6-8 10-12 7/16

1/4-28 UNF 4-6 8-10 9-14 7/16

4/16-18 UNC 7-11 13-17 19-24 1/2

5/16-24 UNF 7-11 14-19 23-28 1/2

3/8-16 UNC 14-18 26-31 39-44 9/16

3/8-24 UNF 15-19 30-35 46-51 9/16

7/16-14 UNC 23-28 44-49 65-70 5/8

7/16-20 UNF 23-28 44-54 69-79 5/8

1/2-13 UNC 32-37 65-75 95-105 3/4

1/2-20 UNF 34-41 73-83 113-123 3/4

9/16-12 UNC 46-56 100-110 145-155 13/16

9/16-18 UNF 47-57 107-117 165-175 13/1 6

5/8-11 UNC 62-72 140-150 200-210 15/16

5/8-18 UNF 67-77 153-163 235-245 15/16

3/4-10 UNC 106-116 200-270 365-375 1-1/4

3/4-16 UNF 115-125 268-278 417-427 1-1/4

7/8-9 UNC 165-175 385-395 595-605 1-5/16

7/8-14 UNF 178-188 424-434 663-673 1-5116

1-8 UNC 251-261 580-590 900-910 1-1/2

1-14 UNF 255-265 585-634 943-993 1-1/2

1-1/4-7 UNC 441-461 1070-1120 1767-1817 1-7/8

1-1/4-12 UNF 488-498 1211-1261 1963-2013 1-7/8

1-1/2-6 UNC 727-737 1899-1949 3111-3161 2-1/4

1-1/2-12 UNF 816-826 2144-2194 3506-3556 2-1/4

D-1
TM 5-2420-224-34

Table D-2. Torque Value Guide (Newton-Meters)

Torque N.m Torque N.m Torque N.m

Screw No Dashes 3 Dashes 6 Dashes Socket
Diameter (SAE Grade 2) (SAE Grade 5) (SAE Grade 8) Size

1/4-20 UNC 4-7 8-11 14-16 7/16

1/4-28 UNF 5-8 11-14 12-19 7/16

5/16-18 UNC 9-15 18-23 26-33 1/2

5/1 6-24 UNF 9-15 19-26 31-38 1/2

3/8-16 UNC 19-24 35-42 53-60 9/16

3/8-24 UNF 20-26 41-47 62-69 9/1 6

7/16-14 UNC 31-38 60-66 88-95 5/8

7/1 6-20 UNF 31-38 60-73 94-107 5/8

1/2-13 UNC 43-50 88-102 129-142 3/4

1/2-20 UNF 46-56 99-113 153-167 3/4

9/16-12 UNC 62-76 136-149 197-210 13/16

9/16-18 UNF 64-77 145-159 224-237 13/1 6

5/8-11 UNC 84-98 190-203 271-285 15/16

5/8-18 UNF 91-104 207-221 319-332 15/16

3/4-10 UNC 144-157 353-366 495-508 1-1/4

3/4-16 UNF 156-169 363-377 565-579 1-1/4

7/8-9 UNC 224-237 522-536 807-820 1-5/16

7/8-14 UNF 241-255 575-588 899-912 1-5/16

1-8 UNC 340-354 786-800 1220-1234 1-1/2

1-14 UNF 346-359 793-860 1279-1346 1-1/2

1-1/4-7 UNC 611-625 1451-1518 2396-2463 1-7/8

1-1/4-12 UNF 662-675 1642-1710 2661-2729 1-7/8

1-1/2-6 UNC 986-999 2575-2642 4218-4286 2-1/4

1-1/2-12 UNF 1106-1120 2907-2975 4753-4821 2-1/4

D-2
 TM 5-2420-224-34

Table D-3. Torque Value Guide (Pound-Feet)

Screw Torque Lb-Ft Torque Lb-Ft Socket

Diameter * Class 8.8 * Class 10.9 Size

M6-1 3 4 10 mm

M8-1.25 8 8 13 mm

M10-1.5 30 40 16 mm

M12-1.75 55 75 18 mm

M14-2 85 115 21 mm

M16-2 130 180 24 mm

M20-2.5 250 350 30 mm

M24-3 435 615 36 mm

M30-3.5 900 1250 46 mm

Table D-4. Torque Value Guide (Newton-Meters)

Screw Torque N.m Torque N.m Socket

Diameter * Class 8.8 * Class 10.9 Size

M6-1 8 11 10 mm

M8-1.25 20 28 13 mm

M10-1.5 41 54 16 mm

M12-1.75 75 102 18 mm

M14-2 115 156 21 mm

M16-2 176 244 24 mm

M20-2.5 339 475 30 mm

M24-3 590 834 36 mm

M30-3.5 1220 1695 46 mm

* Grade class is stamped on bolt head.

D-3
TM 5-2420-224-34

TORQUE SEQUENCE

If the maintenance procedures do not specify a tightening order, use the following guides:
• Unless otherwise specified, lubricate threads of fasteners with oil (OE/HDO-10 or OEA).
• When tightening fasteners above 30 Ib-ft (41 N.m), use the torque pattern but only tighten
to 70 percent of final value (multiply final value by 0.7); then repeat the pattern until final
value is reached.

• Tighten circular patterns using the circular torque pattern, and straight patterns using the
straight torque pattern.

D-4
 TM 5-2420-224-34

INDEX

Subject Page

A
Air Brake Booster Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-24
Air Compressor Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Air Shift Solenoid Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Air Shift Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Alternator Bearings Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Alternator Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Alternator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1
Antifreeze Device (P/N 000 431 57 15 BI.1) Repair . . . . . . . . . . . . . . . . . . . . . . . . 17-39
Antifreeze Device (P/N 932002 0000) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-42
Arm, Pitman, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Auxiliary Headlight, Front Composite Light, and Blackout Driving Light Wiring Harness
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Axle Assembly, Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Axle Assembly, Rear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Axle Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1
Axle Thrust Tube Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105

B
Backhoe Boom Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100
Backhoe Bucket Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Backhoe Control Valve, Boom Section Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . 20-59
Backhoe Control Valve, Dipper and Bucket Section Valves Repair . . . . . . . . . . . . . . . 20-69
Backhoe Control Valve, Intake Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
Backhoe Control Valve, Outlet Manifold Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
Backhoe Control Valve Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
Backhoe Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Backhoe Control Valve, Swing Section Valve Repair . . . . . . . . . . . . . . . . . . . . . . . 20-51
Backhoe/Crane Latch Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-142
Backhoe/Crane Tilt Cylinder (Aeroquip) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
Backhoe/Crane Tilt Cylinder (J.I. Case) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
Backhoe Dipper Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Backhoe Main Frame Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Backhoe Stabilizer Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
Backhoe Stabilizer Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Backhoe Stabilizer Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
Backhoe Swing Cylinder Relief Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80
Backhoe Swing Cylinder Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Backhoe Swing Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Battery Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Bearings, Alternator, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Bearings, Connecting Rods, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31
Bearings, Crankshaft Main, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Bell, Flywheel End, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
Block, Cylinder, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-48

Index-1
TM 5-2420-224-34

Subject Page

B (CONT)
Boom, Crane Extension, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Boom, Crane inner, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Boom, Crane Outer, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Bracket, Forklift Mounting, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Brake Booster, Air, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-24
Brake Disc Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Brake Master Cylinder Repair... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-17
Brake Pressure Regulator (ALB Valve) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Brake Pressure Regulator (ALB Valve) Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-22
Brake Pressure Regulator (ALB Valve) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Brushes, Starter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Bushings, Crane Pinion Gear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34

C
Cab Floor Separation Point to Hydraulic Suspension Lockout Wiring Harness Replacement 4-50
Cab Floor Separation Point to Rear Wall Wiring Harness Replacement . . . . . . . . . . . . 4-52
Cab Heater Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Cab Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1
Cab Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Cable Assembly, Alternator, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Cable Assembly, Dome Light, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Cable, Forklift Power, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Caliper, Front Brake, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Caliper, Rear Brake, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7
Camshaft and Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-43
Cap Plug Connector to Heater Panel Switch and Master Light Switch Wiring Harness
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Carriage Assembly, Forklift, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171
Carriage Assembly, Forklift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
Case, Timing Gear Cover, Gears, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Chain, Forklift Bootstrap, Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . 11-57
Chain, Forklift Carriage, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-67
Chain Saw Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37
Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Clutch Release Lever and Shaft Replacement and Adjustment. . . . . . . . . . . . . . . . . . 3-66
Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Compressor, Air, Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Controls, Transmission Shift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Cooler and Gasket, Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Cooler, Hydraulic Oil, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-148
Cover, Push Rod, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Cover, Transmission Access, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-65
Cover, Transmission Access, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Cover, Transmission Top, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-54
Cover, Transmission Top, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Crane Drive Gear and Bushings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29

Index-2
 TM 5-2420-224-34

Subject Page

C (CONT)
Crane Extension Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Crane External End Extension Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
Crane Flow Regulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
Crane Gear Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Crane Horizontal Outrigger Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
Crane Hydraulic Motor Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-243
Crane inner Boom Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Crane inner Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
Crane intermediate Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25
Crane Mast Floodlight Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Crane Mast Locking Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
Crane Mast Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Crane Outer Boom Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-225
Crane Outer Boom Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Crane Pinion Gear Bushings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
Crane Pinion Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
Crane Valve Bank Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
Crane Valve Bank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
Crane Valve Bank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
Crane Vertical Outrigger Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-237
Crankshaft, Main Bearings, and Rear Seals Replacement . . . . . . . . . . . . . . . . . . . . . 13-15
Crankshaft Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24
Cylinder (Aeroquip), Backhoe/Crane Tilt, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
Cylinder Block Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-48
Cylinder Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Cylinder (J.I. Case), Backhoe/Crane Tilt, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
Cylinder, Backhoe Boom, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100
Cylinder, Backhoe Bucket, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Cylinder, Backhoe/Crane Latch, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-142
Cylinder, Backhoe Dipper, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Cylinder, Backhoe Stabilizer, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125
Cylinder, Backhoe Swing, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Cylinder, Brake Master, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-17
Cylinder, Crane External End Extension, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 20-206
Cylinder, Crane Horizontal Outrigger, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-232
Cylinder, Crane inner Boom Lift, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Cylinder, Crane Mast Locking, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-219
Cylinder, Crane Outer Boom, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-225
Cylinder, Crane Vertical Outrigger, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-237
Cylinder, Forklift Lift, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-192
Cylinder, Forklift Lift, Replacement, Bleeding, and Sequencing . . . . . . . . . . . . . . . . . . 11-51
Cylinder, Forklift Rotator, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-187
Cylinder, Forklift Tilt, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180
Cylinder, Loader Boom, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-88
Cylinder, Loader Bucket Rollback, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-94

Index-3
TM 5-2420-224-34

Subject Page

D
Device (P/N 000 431 57 15 BI.1), Antifreeze, Repair . . . . . . . . . . . . . . . . . . . . . . 17-39
Device (P/N 932 002 000 0), Antifreeze, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 17-42
Disc, Brake, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1
Dome Light Cable Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Drill, Hammer, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1

E
Electrical Lead, Suppressor Filter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Electrical Leads, Throttle Solenoid, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Engine Oil Filter Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

F
Fan, Hydraulic Oil Cooler, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Filter, Engine Oil, Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Final Drive, Front Axle, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-25
Final Drive, Front Axle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Final Drive Hub Gears and Axle Shaft, Rear Axle, Replacement . . . . . . . . . . . . . . . . 6-15
Fluid Regulating Valve (P/N 0 481 039 202) Repair. . . . . . . . . . . . . . . . . . . . . . . . 17-28
Fluid Regulating Valve (P/N 975 303 447 0) Repair. . . . . . . . . . . . . . . . . . . . . . . . 17-35
Flywheel End Bell Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28
Flywheel Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-25
Flywheel Ring Gear Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
Forklift Bootstrap Chain Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 11-57
Forklift Carriage Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171
Forklift Carriage Assembly Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-44
Forklift Carriage Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-67
Forklift Connector to Fuse Holder Wiring Harness Replacement . . . . . . . . . . . . . . . . . 4-48
Forklift Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-192
Forklift Lift Cylinder Replacement, Bleeding, and Sequencing . . . . . . . . . . . . . . . . . . 11-51
Forklift Mast Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-155
Forklift Mast Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Forklift Mounting Bracket Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Forklift Power Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Forklift Rotator Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-187
Forklift Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180
Forklift Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
Forklift Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37
Forklift Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Forklift Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Frame Section and Subframe, Rear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Frame Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Front Axle Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Front Axle Thrust Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Index-4
 TM 5-2420-224-34

Subject Page

F (CONT)
Front Brake Caliper Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3
Front Hydraulic Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Front Loader/Forklift Control Valve and Bracket Replacement and Adjustment . . . . . . . . 11-28
Front Loader/Forklift Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
Front Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Fuel Injection Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Fuel Injector Nozzle Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Fuel Injector Nozzle Test and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65
Fuel Tank Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring Harness Replacement . . . 4-54
Fuse Holder to Hydraulic Suspension Lockout/Rear Wall Wiring Harness Replacement . . . 4-56

G
Gear and Bushings, Crane Drive, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
Gear Bearing, Crane, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
Gear, Crane Intermediate, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-25
Gear, Crane Pinion, Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
Gear, FIywheel Ring, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-29
Gear, Power Steering, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

H
Hammer Drill Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1
Hazard Warning Light Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Head, Cylinder, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
Head, Cylinder, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Heater, Cab, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1
Hydraulic Oil CooIer Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
Hydraulic Oil Cooler Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-148
Hydraulic Suspension Lockout Motor and Pump Repair . . . . . . . . . . . . . . . . . . . . . . 20-9

I
Impact Wrench Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-15

L
Left Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Lever and Shaft, Clutch Release, Replacement and Adjustment . . . . . . . . . . . . . . . . . 3-66
Lines, Transmission Shift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Linkage, Power Take-Off (PTO) Control, Replacement and Adjustment . . . . . . . . . . . . . 3-81
Loader Boom Cylinder Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-88
Loader Bucket Rollback Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-94

M
Main Frame, Backhoe, Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Main Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Index-5
TM 5-2420-224-34

Subject Page

M (CONT)
Manifold, Exhaust, Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Mast Assembly, Forklift, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-155
Mast Assembly, Forklift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-40
Mast, Crane, Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Motor, Crane Hydraulic, Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-243
Mount, Engine, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Mount, Transmission, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

N
Nozzle, Fuel lnjector, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Nozzle, Fuel Injector, Test and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-65

O
Oil Cooler and Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Oil Pan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
Oil Pump Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60

P
Pan, Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-58
Pavement Breaker Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-24
Pistons, Rings, Connecting Rods, and Bearings Replacement . , . . . . . . . . . . . . . . . . 13-31
Pitman Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Platform, Left, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Platform, Right, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Power Steering Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Power Steering Pump and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Power Take-Off (PTO) Control Linkage Replacement and Adjustment . . . . . . . . . . . . . . 3-81
Power Take-Off (PTO) Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-70
Power Take-Off (PTO) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Propeller Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Pulley, Crankshaft, Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-24
Pump and Bracket, Power Steering, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Pump, Front Hydraulic, Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Pump, Fuel Injection, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Pump, Fuel Injection, Timing... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Pump, Oil, Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-60
Pump, Rear Hydraulic, Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Pump, Water, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73
Push Rod Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Push Rods, Rocker Arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37

R
Radiator Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-71
Rear Axle Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Rear Axle Final Drive Hub Gears and Axle Shaft Replacement . . . . . . . . . . . . . . . . . 6-15

Index-6
 TM 5-2420-224-34

Subject Page

R (CONT)
Rear Axle Thrust Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Rear Brake Caliper Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-7
Rear Frame Section and Subframe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Rear Hydraulic Pump Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Rear Spring Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Rear Windows Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Regulator (ALB Valve), Brake Pressure, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Regulator (ALB Valve), Brake Pressure, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-22
Regulator (ALB Valve), Brake Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . 7-1
Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Right Platform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Rings, Piston, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31
Rocker Arms, Push Rods, and Tappets Replacement . . . . . . . . . . . . . . . . . . . . . . . 13-37
Rods, Piston Connecting, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31
Roll-Over Protection (ROPS) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

S
Saw, Chain, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37
Seals, Crankshaft Rear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-15
Shaft, Propeller, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Spring, Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Spring, Rear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Starter Brushes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Starter Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8
STE/lCE-R Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Steering Knuckle and Front Axle Final Drive Repair . . . . . . . . . . . . . . . . . . . . . . . . 16-25
Steering Knuckle and Front Axle Final Drive Replacement . . . . . . . . . . . . . . . . . . . . 5-16
Suppressor Filter Electrical Lead Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

T
Tandem Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44
Tank, Fuel, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-69
Tappets, Rocker Arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37
Throttle Solenoid Electrical Leads Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Thrust Arms, Front Axle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Thrust Arms, Rear Axle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Thrust Tube, Axle, Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
Tilt and Latch Control Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Tilt and Latch Control Valve Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . 11-5
Timing Gear Cover, Gears, and Case Replacement . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Tire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-48
Trailer Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Transmission Access Cover Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-65
Transmission Access Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Transmission Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

Index-7
TM 5-2420-224-34

Subject Page

T (CONT)
Transmission Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Transmission Shift Controls Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Transmission Shift Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Transmission Top Cover Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-54
Transmission Top Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86

U
U-Joint Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

V
Valve (P/N 0 481 039 202), Fluid Regulating, Repair. . . . . . . . . . . . . . . . . . . . . . . 17-28
Valve (P/N 975 303 447 0), Fluid Regulating, Repair . . . . . . . . . . . . . . . . . . . . . . . 17-35
Valve, Air Shift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
Valve, Air Shift Solenoid, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Valve, Backhoe Control, Boom Section Valve, Repair . . . . . . . . . . . . . . . . . . . . . . . 20-59
Valve, Backhoe Control, Dipper and Bucket Section Valves, Repair . . . . . . . . . . . . . . 20-69
Valve, Backhoe Control, intake Manifold, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
Valve, Backhoe Control, Outlet Manifold, Repair. . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
Valve, Backhoe Control, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41
Valve, Backhoe Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Valve, Backhoe Control, Swing Section Valve, Repair . . . . . . . . . . . . . . . . . . . . . . . 20-51
Valve, Backhoe Stabilizer Control, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-82
Valve, Backhoe Stabilizer Control, Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Valve, Backhoe Swing Cylinder Relief, Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . 20-80
Valve, Backhoe Swing Cylinder Relief, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Valve, Crane Flow Regulating, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
Valve, Forklift, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
Valve, Forklift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-37
Valve, Front Loader/Forklift Control, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
Valve, Tandem, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-44
Valve, Tilt and Latch Control, Repair.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
Valve, Tilt and Latch Control, Replacement and Adjustment . . . . . . . . . . . . . . . . . . . 11-5
Valve and Bracket, Front Loader/Forklift Control, Replacement and Adjustment . . . . . . . . 11-28
Valve Bank, Crane, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
Valve Bank, Crane, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24

W
Water Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-73
Windows, Rear, Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Wiring Harness, Auxiliary Headlight, Front Composite Light, and Blackout Driving Light,
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Wiring Harness, Cab Floor Separation Point to Hydraulic Suspension Lockout,
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Wiring Harness, Cab Floor Separation Point to Rear Wall, Replacement . . . . . . . . . . . 4-52

lndex-8
 TM 5-2420-224-34

Subject Page

W (CONT)
Wiring Harness, Cap Plug Connector to Heater Panel Switch and Master Light Switch,
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Wiring Harness, Chassis, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Wiring Harness, Crane Mast Floodlight, Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-30
Wiring Harness, Forklift Connector to Fuse Holder, Replacement . . . . . . . . . . . . . . . . 4-48
Wiring Harness, Forklift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Wiring Harness, Forklift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Wiring Harness, Fuse Holder to Hydraulic Suspension Lockout/Rear Wall, Replacement . . 4-54
Wiring Harness, Fuse Holder to Hydraulic Suspension Lockout/Rear Wall, Replacement . . 4-56
Wiring Harness, Hazard Warning Light, Replacement . . . . . . . . . . . . . . . . . . . . . . . 4-36
Wiring Harness, Main, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Wiring Harness, STE/lCE-R, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Wiring Harness, Trailer, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Wrench, Impact, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-15

lndex-9/(lndex-10 Blank)
 By Order of the Secretary of the Army:

GORDON R. SULLIVAN
General, United States Army
Chief of Staff

Official:

MILTON H. HAMILTON
Administrative Assistant to the
Secretary of the Army
04673

Distribution:
To be distributed in accordance with DA Form 12-38-E (Block 0974) requirements for
TM5-2420-224-34.

*U.S. GOVERNMENT PRINTING OFFICE: 1993-746-017/80225

PIN: 071467-000