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- TECHNlCAL MANUAL
- WARNING
- DIRECT SUPPORT, GENERAL
SUPPORT, AND DEPOT MAINTENANCE MANUAL
- By Order of the Secretary of
the Army:
- DIRECT SUPPORT, GENERAL
SUPPORT, AND DEPOT MAINTENANCE MANUAL
- Rocker Arm Cover
- Fugure 3-18.1. Control Lever
Adjustment.
- Steering Wheel
- Figure 5-12.2. Steering whee,
removal and installation.l
- figure 5-14-.1. rear
steering pump, removal and installation.
- Figure 5-22. Drag link
removal and installation.
- Figure 6-1.1. Tree-spool
valve, removal installation
- Adjustments
- Figure 6-2.1. Tilt Cylinder
removal and installation
- removal
- Installation
- Figure 6-10.1. Side shifter
roller chain, cylinder, and forks, and installlation
- Figure 6-11.1. Hydraulic
extention cylender, removal and installation
- Figure 6-15.1. main
hydraulic pump ramoval and installation
- Figure 6-17.1. Engine Driven
hydraulic pump, removal installation
- TABLE OF CONTENTS
- LIST OF ILLUSTRATIONS
- LIST OF ILLUSTRATIONS - CONT
- LIST OF ILLUSTRATIONS - CONT
- CHAPTER 1 INTRODUCTION
- Tabulated Data
- Tabulated Data
- Table 1-1. Repair and
Replacement Standards
- Table 1-1. Repair and
Replacement Standards - CONT
- CHAPTER 2 DIRECT SUPPORT AND
GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
- Table 2-2. Troubleshooting
- Table 2-2. Troubleshooting -
CONT
- Section III. REMOVAL AND
INSTALLATION OF MAJOR COMPONENTS AND ASSEMBLIES
- Axle Assemblies
- Figure 2-2. Torque converter
and transmission assembly, removal and installation.
- Figure 2-4. Boom assembly,
removal and installation.
- CHAPTER 3 REPAIR OF ENGINE
- Air Inlet Housing
- Blower Assembly
- Figure 3-4. Oil cooler,
disassembly and reassembly.
- Figure 3-5. Air inlet
housing and blower assembly, removal and installation.
- Figure 3-7. Blower,
disassembly and reassembly.
- Blower Drive and Coupling
- Figure 3-8. Blower drive and
coupling, removal and installation.
- Figure 3-9. Blower drive and
coupling, disassembly and reassembly (sheet 2 of 2).
- Disassembly of Cover
- Disassembly of Control
Housing.
- Figure 3-11. Governor
assembly, disassembly, and reassembly, (sheet 2 of 2)
- Radiator and Water Pump
- Cleaning and inspection.
- Figure 3-13. Radiator and
water pump, disassemble and reassembly (sheet 1 of 2).
- Water pump.
- Generator
- Figure 3-14. Generator,
disassembly and reassembly.
- Figure 3-15. Voltage
regulator adjustment (sheet 1 of 5).
- Figure 3-15. Voltage
regulator adjustment (sheet 2 of 5).
- Figure 3-15. Voltage
regulated adjustment (sheet 3 of 5).
- Figure 3-15. Voltage
regulator adjustment (sheet 4 of 5).
- Figure 8-15. Voltage
regulator adjustment (sheet 5 of 5).
- Figure 3-16. Starter,
on-equipment testing.
- Figure 3-17. Starter,
disassembly and reassembly.
- Fuel Injector Control Lever
and Tube Assembly
- Injector holding pressure
test. O p e r a t e
- Figure 3-20. Fuel injectors,
removal and installation.
- tests
- Figure 3-22. Defective fuel
injector plungers.
- Fuel injector filter,
removal and installation.
- Figure 3-25. Injector
follower, spring, and plunger, removal and installation.
- Figure 3-26. Reaming fuel
injector sprag tip.
- Figure 3-28. Cleaning fuel
injector nut spray tip seat.
- Rocker Arms and Push Rods
- Figure 3-30. Checking fuel
injector tip concentricity.
- Figure 3-31. Rocker arms and
push rods, removal and installation
- Fuel Pump
- Cleaning and Inspection.
- Figure 3-34. Cam roller wear
and clearance diagram.
- Fuel Tank
- Figure 3-36. Fuel pump,
disassembly
- Figure 3-37. Fuel tank,
removal and installation.
- Figure 3-38. Fuel tank,
disassembly and reassembly.
- Section III. CYLINDER HEAD,
VALVES, FLYWHEEL, AND FLYWHEEL HOUSING
- Figure 3-40. Cylinder head,
disassembly and reassembly.
- Figure 3-41. Minimum
distance between top and bottom faces of cylinder head.
- Install Cylinder Head.
- Exhaust Valves, Springs,
Guides, and seats
- Figure 3-44. Valves and
injector operating mechanism,
- Remove Valve Seat Insert
- Flywheel
- Remove ring gear from
flywheel
- Flywheel Housing
- housing concentricity in
relation to the crankshaft as follows:
- Figure 3-47. Flywheel
housing bolt, tightening sequence (operation 2).
- Section IV. OIL PAN, OIL
PUMP SCREEN, INLET PIPE, CONNECTING RODS AND PISTONS
- Figure 3-49. Oil pan, oil
pump screen and inlet pipe, disassembly and reassembly.
- Piston, Rings, Connecting
Rod, and Cylinder liner
- Piston, rings, connecting
rod, and cylinder liner, disassembly and reassembly,
- Wear limits. For allowable
wear limits refer to table 1-1.
- Fitting cylinder liner to
bore in block:
- Section V. CAMSHAFT, BALANCE
SHAFT, AND CRANKSHAFT
- Engine Front Cover (Upper)
- Camshaft, Balance Shaft and
Bearings
- Figure 3-54. Camshaft or
balance shaft nut, removal and installation
- Figure 3-55. Camshaft and
balance shaft, disassembly and reassembly
- Idler Gear Assembly
- Figure 3-57. Installing
idler gear hub.
- Removal (Crankshaft in
Place).
- Figure 3-61. Rear main
bearing thrust washer and mounting
- Crankshaft
- Figure 3-62. Crankshqft,
removal and installation
- Gear Train and Engine Timing
- Figure 3-63. Gear train and
timing marks.
- Section VI. CYLINDER BLOCK
- Figure 3-64. Cylinder block,
disassembly and reassembly.
- Inspection of end plates.
- CHAPTER 4 REPAIR OF
TRANSMISSION
- Figure 4-1. Torque
converter, exploded view.
- Figure 4-2. Torque converter
and transmission assembly, disassembly and reassembly (Sheet 1 of
19).
- Transmission Input Oil Pump.
- F o r w a r d a n d r e v e
r s e c o m p o n e n t s
- Forward planetary carrier
and components
- Transfer housing assembly.
- Figure 4-2. Torque converter
and transmission assembly, disassembly and reassembly (sheet 6 of
13).
- Figure 4-2. Torque converter
and transmission assembly disassembly and reassembly (sheet 7 of
13).
- Figure 4-2. Torque converter
and transmission assembly, disassembly and reassembly (sheet 8 of
13).
- Converter-out-pressure
check.
- Figure 4-2. Torque converter
and transmission assembly, disassembly and reassembly (sheet 10 of
13).
- Figure 4-2. Torque converter
and transmission assembly,disassembly and reassembly (sheet 11 of
13).
- Transmission disconnect
control
- Torque Converter Stall Test
- Figure 43. Removal and
installation of torque converter
- Transmission Main Oil
Pressure Regulating Valve
- Transmission Control Valve
- Figure 4-8. Transmission
control valve, removal and instalation
- Figure 4-9. Transmission
control valve, disassembly and reassembly.
- CHAPTER 5 REPAIR OF DRIVE
COMPONENTS
- Reassembly.
- Adjust backlash 0.008-0.011
as follows:
- Differential Lockout Shift
Control
- Figure 5-3. Engine propeller
shaft, disassembly and reas-
- Parking Brake
- Figure 5-4. Axle assembly,
disassembly and reassembly (sheet 2 of 9).
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 3 OF 9)
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 4 OF 9)
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 5 OF 9)
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 5 OF 9)
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 6 OF 9)
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 7 OF 9)
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 8 OF 9)
- Figure 5-4. Axle assembly,
disassembly and reassembly. (SHEET 9 OF 9)
- Figure 5-5. Differential
lockout shift control, disassembly and reassembly
- Figure 5-6. Parking brake,
removal and disassembly.
- Section III. HYDRAULIC BRAKE
SYSTEM
- Figure 5-7. Brake assembly,
disassembly and reassembly.
- Recement expander tube
shields
- Brake Applicator Valve and
Differential Pressure Switch
- Figure 5-8. Automatic slack
adjuster, disassembly and reassembly.
- Figure 5-9. Differential
pressure switch and brake valve, removal and installation.
- Figure 5-10. Brake valve,
disassembly and reassemble.
- Hydraulic Brake Accumulator
Cylinder
- Figure 5-11. Hydraulic brake
accumulator cylinder, removal and installation.
- Section IV. STEERING SYSTEM
- Packing drag test.
- Rear Steering Pump
- Figure 5-14. Three-position
cylinder, disassembly and reassembly
- Figure 5-15. Rear steering
pump, disassembly and reassembly
- Steering Mode Selector Valve
- Steering Gear Assembly
- Figure 5-17. Steering mode
selector valve, disassembly and reassembly
- Figure 5-18. Steering gear
assembly, disassembly and reassembly (sheet 1 of 2)-Continued.
- Figure 5-18. Steering gear
assembly, disassembly and reassembly (sheet 2of 2)
- Hydraulic Power Steering
Valve (Rear Steer)
- Steering System Adjustment
- Rear Drag link
- Figure 5-21. Rear drag link,
disassembly and reassembly.
- CHAPTER 6 R E P A I R OF
MAIN HYDRAULIC SYSTEM
- Figure 6-1. Three-spool
valve, disassembly and reassembly.
- Hydraulic Tilt Cylinder
- Figure 6-3. Dual overcenter
relief and replenishing valve, disassembly and reassembly.
- Figure 6-4. Two-spool valve,
disassembly and reassembly.
- Figure 65. Hydraulic tilt
cylinder, disassembly and
- Hydraulic Lift Cylinder
- Figure 6-6. Hydraulic lift
cylinder, disassembly and reas-
- Figure 6-7. Hydraulic
oscillating cylinder, disassembly and
- Oscillating Cylinder Check
Valve
- Figure 6-9. Hydraulic slave
cylinder, disassembly and reassembly
- Figure 6-10. Hydraulic side
shift cylinder, disassembly and
- Hydraulic Oil Reservoir
- Figure 611. Hydraulic
extension cylinder, disassembly and reassembly
- Figure 6-13. Hydraulic
reservoir, disassembly and reas-
- Figure 6-14. Contamination
indicator, removal, disassembly reassembly and installation.
- Figure 6-15. Hydraulic
manifold, removal, disassembly, reassembly and installation
- Hydraulic Manifold
- Figure 6-16. Main hydraulic
pump, disassembly and reas-
- Figure 6-17. Engine driven
pump, disassembly and reas-
- CHAPTER 7 REPAIR OF CARRIAGE
ASSEMBLY, BOOM ASSEMBLY, FRAME, HOOD, AND PANELS
- Figure 7-1. Carriage
assembly, disassembly and reassem-
- Figure 7-2. Boom assembly,
disassembly and reassembly.
- Section II. FRAME, HOOD, AND
PANELS
- Figure 7-3. Frame, hood, and
panels, disassemble and reasSSEMBLY (SHEET 1 OF 2)
- Figure 7-3. Frame, hood, and
panels, disassemble and reasSSEMBLY (SHEET 2 OF 2)
- APPENDIX A REFERENCES
- APPENDIX A REFERENCES - CONT
- INDEX
- INDEX- CONT
- INDEX- CONT
- INDEX- CONT
- BLANK PAGE
- TM-10-3930-242-34
- BLANK PAGE
- BLANK PAGE
- BLANK PAGE
- By Order of the Secretary of
the Army:
- BLANK PAGE
- BLANK PAGE
- By Order of the Secretary of
the Army:
- BLANK PAGE
- BLANK PAGE
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