TM-5-4210-233-14-and-P-1

TM-5-4210-233-14-and-P-1
TM 5-4210-233-14&P-1
TECHNICAL MANUAL
OPERATOR'S, UNIT,
DIRECT SUPPORT
AND GENERAL SUPPORT
MAINTENANCE MANUAL
FIREFIGHTING TRUCK
100 FT AERIAL LADDER
1000 GPM
(NSN 4210-01-290-8755)
Approved for public release; Distribution is unlimited.
INTRODUCTION
PAGE 1-1
OPERATING INSTRUCTIONS
PAGE 2-1
OPERATOR MAINTENANCE
INSTRUCTIONS
PAGE 3-1
UNIT MAINTENANCE
PAGE 4-1
DIRECTOR SUPPORT MAINTENANCE
PAGE 5-1
GENERAL SUPPORT MAINTENANCE
PAGE 6-1
REFERENCES
PAGE A-1
MAINTENANCE ALLOCATION CHART
PAGE B-1
COMPONENTS OF END ITEM
BASIC ISSUE ITEMS LIST
PAGE C-1
ADDITIONAL AUTHORIZATION LIST
PAGE D-1
EXPENDABLE/DURABLE SUPPLIES
AND MATERIALS
PAGE E-1
ILLUSTRATED PARTS BREAKDOWN
PAGE F-1
AIR SYSTEM SCHEMATICS
PAGE G-1
WIRING DIAGRAMS
PAGE H-1
WATER/FOAM SYSTEM PIPING
PAGE I-1
HYDRAULIC SYSTEM SCHEMATICS
PAGE J-1
HEADQUARTERS, DEPARTMENT OF THE ARMY
15 DECEMBER 1992
TM 5-4210-233-14&P-1
WARNING
CARBON MONOXIDE (EXHAUST GAS) CAN CAUSE DEATH.
Carbon monoxide is without color or smell, but can cause death. Breathing air with carbon monoxide produces
symptoms of headache, dizziness, loss of muscular control, a sleepy feeling, and coma. Brain damage or
death can result from heavy exposure. Carbon monoxide occurs in the exhaust fumes of fuel-burning heaters
and internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of
no ventilation. Precautions must be followed to ensure crew safety when the personnel heater or engine of any
vehicle is operated for any purpose.
1. DO NOT operate personnel heater or engine of vehicle in a closed place without proper
ventilation.
2. DO NOT drive any vehicle with inspection plates, cover plates, or engine compartment covers
removed unless necessary for maintenance purposes.
3. BE ALERT at all times during vehicle operation for exhaust odors and exposure symptoms. If
either are present, IMMEDIATELY VENTILATE personnel compartments. If symptoms
persist, remove affected crew to fresh air and keep warm. DO NOT PERMIT PHYSICAL
EXERCISE. If necessary, give artificial respiration and get immediate medical attention. For
artificial respiration, refer to FM 21-11.
4.
BE AWARE that the gas particulate filter unit or the field protection mask for nuclearbiological-chemical protection WILL NOT offer safety from carbon monoxide poisoning.
THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION.
WARNING
Adhesives, solvents, and sealing compounds can burn easily, can give off harmful vapors, and are harmful to
skin and clothing. To avoid injury or death, keep away from open fire and use in well-ventilated area. If
adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.
WARNING
Never use the parking brake for normal braking or wheels will lock up causing severe skid. Skidding vehicle
could result in serious injury or death.
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death, keep fuel away from open fire
and keep fire extinguisher within easy reach when working with fuel. Do not work on fuel system when engine
is hot. Fuel can be ignited by hot engine. When working with fuel, post signs that read NO SMOKING WITHIN
50 FEET of vehicle.
WARNING
Remove rings, bracelets, wristwatches, neck chains, and any other jewelry before working around vehicle.
Jewelry can catch on equipment and cause injury, or may short across an electrical circuit and cause severe
burns or electrical shock.
a
TM 5-4210-233-14&P-1
WARNING
The radiator is very hot and pressurized during vehicle operation. radiator cool before removing cap. Failure
to do so can result in serious burns.
WARNING
The exhaust pipe and muffler can become very hot during vehicle operation. Be careful not to touch these
parts with bare hands, or allow body to come in contact with pipe or muffler. Exhaust system parts can become
hot enough to cause serious burns.
WARNING
Always use seatbelts when operating vehicle. Failure to use seatbelt can result in serious injury in case of
accident.
WARNING
When working inside the vehicle with power off, be sure to ground every capacitor likely to hold a dangerous
voltage potential.
WARNING
Be careful when working on or with electrical equipment. Do not be misled by the term "low-voltage". Voltages
as low as 50 volts may cause death. For artificial respiration, refer to FM 21-11.
WARNING
Be careful not to short out battery terminals. Do not smoke or use open flame near batteries. Batteries may
explode from a spark. Battery acid is harmful to skin and eyes.
WARNING
Starting fluid is toxic and flammable. Do not store in cab and do not breathe fumes. Do not puncture or burn
containers. Dispose of container following manufacturer's recommendations on the container.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi (207 kPa). Use only with effective chip
guarding and personal protective equipment, goggles, shield and gloves.
WARNING
After Nuclear, Biological or Chemical (NBC) exposure of vehicle, all air filters shall be handled with extreme
caution. Unprotected personnel can experience injury or death if residual toxic agents or radioactive materials
are present. If vehicle is exposed to chemical or biological agents, servicing personnel shall wear protective
mask, hood, protective over garments, and chemical protective gloves and boots in accordance with TM 1 0277. All contaminated air filters shall be placed in double-lined plastic bags and moved swiftly to a segregation
area away from the worksite. The same procedure applies for radioactive dust contamination. The Company
NBC team should measure the radiation prior to filter removal to determine the extent of safety procedures
required per the NBC Annex to the unit Standard Operating Procedures (SOP). The segregation area in which
the contaminated air filters are temporarily stored shall be marked with appropriate NBC placards. Final
disposal of contaminated air filters shall be in accordance with local SOP. Decontamination operation shall be
accordance with TM 3-220 and local SOP.
b
TM 5-4210-233-14&P-1
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 15 DECEMBER 1992
NO. 5-4210-233-14&P-1
TECHNICAL MANUAL
Operator's, Unit, Direct Support and General Support
Maintenance Manual
FIREFIGHTING TRUCK, 100 FT AERIAL LADDER, 1000 GPM
NSN 4210-01-290-8755
DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
This manual is divided into two volumes:
Volume 1, TM 5-4210-233-14&P-1 consists of Chapters 1 through 5 and Index.
Volume 2, TM 5-4210-233-14&P-2 consists of Chapter 6, Appendixes A through J and Index
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a way to improve
the procedures, please let us know. Mail your letter or DA Form 2028 (Recommended
Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this
manual directly to: Commander, US Army Aviation and Troop Command, ATTN: AMSAT-IMTS, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. A reply will be furnished directly to
you.
TABLE OF CONTENTS
PAGE
HOW TO USE THIS MANUAL
iii
CHAPTER 1.
Section I.
Section II.
Section III.
INTRODUCTION .................................................................................... 1-1
General Information ................................................................................ 1-1
Equipment Description ........................................................................... 1-3
Technical Principles of Operation............................................................ 1-15
CHAPTER 2.
Section I.
Section II.
Section III.
Section IV.
OPERATING INSTRUCTIONS ............................................................... 2-1
Description and Use of Operator's Controls and Indicators ..................... 2-2
Operator's Preventive Maintenance Checks and Services ...................... 2-27
Operation Under Usual Conditions .......................................................... 2-46
Operation Under Unusual Conditions ..................................................... 2-71
CHAPTER 3.
Section I.
Section II.
Section III.
OPERATOR MAINTENANCE INSTRUCTIONS ...................................... 3-1
Lubrication Instructions .......................................................................... 3-2
Operator Troubleshooting Procedures ..................................................... 3-10
Operator Maintenance Procedures .......................................................... 3-22
i
TM 5-4210-233-14&P-1
PAGE
CHAPTER 4.
Section I.
Section II.
Section III.
Section IV.
Section V.
UNIT MAINTENANCE............................................................................. 4-1
Repair Parts, Special Tools, TMDE, and Support Equipment .................. 4-5
Service Upon Receipt ............................................................................. 4-5
Unit PMCS .............................................................................................. 4-10
Unit Troubleshooting Procedures ............................................................ 4-18
Unit Maintenance Procedures ................................................................. 4-146
CHAPTER 5.
Section I.
Section II.
Section III.
DIRECT SUPPORT MAINTENANCE ...................................................... 5-1
Repair Parts, Special Tools, TMDE, and Support Equipment .................. 5-3
Service Upon Receipt ............................................................................. 5-3
Troubleshooting ...................................................................................... 5-3
CHAPTER 6.
Section I.
Section II.
APPENDIX A
APPENDIX B
APPENDIX C
APPENDIX D
APPENDIX E
APPENDIX F
APPENDIX G
APPENDIX H
APPENDIX I
APPENDIX J
GENERAL SUPPORT MAINTENANCE .................................................. 6-1
Repair Parts, Special Tools, TMDE, and Support Equipment .................. 6-2
Maintenance of the Fire Truck................................................................. 6-2
REFERENCES ....................................................................................... A-1
MAINTENANCE ALLOCATION CHART.................................................. B-1
COMPONENTS OF END ITEM BASIC ISSUE ITEMS LIST ................... C-1
ADDITIONAL AUTHORIZATION LIST .................................................... D-1
EXPENDABLEIDURABLE SUPPLIES AND MATERIALS LIST ............... E-1
ILLUSTRATED PARTS BREAKDOWN................................................... F-1
AIR SYSTEM SCHEMATICS .................................................................. G-1
WIRING DIAGRAMS .............................................................................. H-1
WATER/FOAM SYSTEM PIPING ........................................................... I-1
HYDRAULIC SYSTEM SCHEMATICS.................................................... J-1
ALPHABETICAL SUBJECT INDEX......................................................... INDEX-1
ii
TM 5-4210-233-14&P-1
HOW TO USE THIS MANUAL
ARRANGEMENT. This manual is divided into six chapters. The purpose of each chapter is listed below.
Chapter 1 - INTRODUCTION. Provides the user with information about standard data required in all manuals.
It also familiarizes the user with the truck and related equipment.
Chapter 2 - OPERATING INSTRUCTIONS.
effectively and efficiently operate the truck.
Presents instructions needed by the operator and crew to
Chapter 3 - OPERATOR MAINTENANCE INSTRUCTIONS. Presents the necessary information for the
operator to keep the truck and its components in good running condition.
Chapter 4 - UNIT MAINTENANCE. Presents the necessary procedures and instructions to perform
maintenance tasks allocated to Unit Maintenance.
Chapter 5 - DIRECT SUPPORT MAINTENANCE. Presents the necessary procedures and instructions to
perform maintenance tasks allocated to Direct Support Maintenance.
Chapter 6 - GENERAL SUPPORT MAINTENANCE. Presents the necessary procedures and instructions to
perform maintenance tasks allocated to General Support Maintenance.
An alphabetical subject index has been included at the rear of this manual to improve reader access to the
required information.
EXPLANATION OF NUMBERING SYSTEM.
Text. The information in this manual is numbered sequentially for easy access of data.
Example:
2-1.
The first number indicates the chapter number.
The second number (following the hyphen) indicates the paragraph
number within that chapter.
Example:
2-1.1
The third number (following the period) indicates the subordinate
paragraph number within a particular paragraph
Page and Table Numbers. All pages and tables are numbered sequentially within each chapter.
LOCATION OF NUMBERS.
Text. Numbers appear above and to the left of the related text.
Pages. Page numbers appear at the bottom right-hand corner for odd-numbered pages or the bottom left-hand
corner for even-numbered pages.
Tables. Table numbers appear directly above the related table.
iii
TM 5-4210-233-14&P-1
Figure 1-1. Firefighting Truck, 100 Ft Aerial Ladder, 1000 GPM, NSN 4210-01-290-8755
1-0
TM 5-4210-233-14&P-1
CHAPTER 1
INTRODUCTION
CONTENTS
Contents
Para
SCOPE................................................................................................................ 1-1
MAINTENANCE FORMS AND RECORDS .......................................................... 1-2
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR'S).... 1-3
PREPARATION FOR STORAGE OR SHIPMENT............................................... 1-4
DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE .................. 1-5
SAFETY, CARE AND HANDLING ....................................................................... 1-6
WARRANTY INFORMATION .............................................................................. 1-7
LIST OF ABBREVIATIONS ................................................................................. 1-8
EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES .............. 1-9
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS ........................... 1-10
EQUIPMENT DATA ............................................................................................ 1-11
ENGINE ............................................................................................................. 1-12
ENGINE THROTTLE CONTROL......................................................................... 1-13
TRANSMISSION AND DRIVE TRAIN.................................................................. 1-14
AIR SYSTEM ...................................................................................................... 1-15
BRAKE SYSTEM................................................................................................. 1-16
FIREFIGHTING SYSTEM.................................................................................... 1-17
AERIAL LADDER/WATER TOWER .................................................................... 1-18
AUXILIARY POWER CIRCUITS.......................................................................... 1-19
Page
1-1
1-1
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-4
1-11
1-15
1-17
1-17
1-17
1-18
1-19
1-20
1-20
SECTION I. GENERAL INFORMATION
1-1. SCOPE
a. This manual provides operator instructions, and Operator, Unit, Direct Support and General Support
maintenance instructions for the firefighting truck, 100 ft. aerial ladder, 1000 GPM, NSN 4210-01-290-8755.
The firefighting truck is designed for crash, fire and rescue operations. The truck is also capable of fighting
ground and structural fires.
b. This manual includes a detailed description of the truck and its control components as well as detailed
information for its operation and maintenance. Although the truck is supplied complete with firefighting
equipment, only brief descriptions of this equipment are provided, and no attempts are made to explain
firefighting techniques.
1-2. MAINTENANCE FORMS AND RECORDS
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).
1-1
TM 5-4210-233-14&P-1
1-3. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR'S)
If your firetruck needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell
us what you like and don't like about your equipment. Let us know why you don't like the design or
performance. Put it on an SF 368 (Product Quality Deficiency Report). Mail it to us at: Commander, U.S Army
Troop Support Command, ATTN: AMSTR-QS, 4300 Goodfellow Blvd., St. Louis, MO 63120-1798. We'll send
you a reply.
1-4. PREPARATION FOR STORAGE OR SHIPMENT
Refer to paragraph 4-220 for preparation for storage or shipment instructions.
1-5. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE
Refer to TM 750-244-2 and TM 750-244-3 for instructions covering the destruction of Army material to prevent
enemy use.
1-6. SAFETY,-CARE AND HANDLING
a. Do not drive the vehicle while low air pressure warning buzzer is sounding or red light is on. Air pressure in
brake system may be insufficient for normal operation of the brakes.
b. When operating the aerial ladder, ensure the outriggers are down on firm ground and that side slope does
not exceed five degrees.
c. Do not exceed 400 pound (181 kg) capacity on aerial ladder. If warning buzzer sounds, correct situation
immediately.
d. The ladder is designed to be self-supporting. Do not allow the ladder tip to contact or rest on anything.
Damage to the ladder may result.
e. Shut off engine and no smoking, sparks or open flames when refueling vehicle.
f. The vehicle is equipped with electronically controlled equipment. When welding anywhere on the vehicle, all
modules for electronically controlled equipment must be disconnected.
g. The outrigger hydraulic functions and ladder functions cannot be operated at the same time. Hydraulic oil
cannot be pumped to these areas at the same time.
1-7. WARRANTY INFORMATION
For warranty information, refer to TB 5-4210-233-24
1-2
TM 5-4210-23314&P-1
1-8. LIST OF ABBREVIATIONS
ac
APU
bhp
cc
cfm
comp
cu in.
dc
DDEC
diff
gal.
gen
gpm
Hg
Hz
in.
kg
kP/cm2
kPa
alternating current
auxiliary power unit
brake horsepower
cubic centimeter
cubic feet per minute
compartment
cubic inch
direct current
Detroit Diesel Electronic Control
differential
gallon
generator
gallons per minute
mercury (vacuum)
Hertz
inch
kilogram
kilopascals per square centimeter
kilopascal
kw
I
I/min
lb
max
min
mm
mph
N-m
PA
psi
pto
qt
rpm
sq in.
sq m
vac
VAC
VDC
kilowatt
liter
liters per minute
pound
maximum
minimum
millimeter
miles per hour
Newton meter
public address
pounds per square inch
power take-off
quart
revolutions per minute
square inch
square meter
vacuum
volts alternating current
volts direct current
SECTION II. EQUIPMENT DESCRIPTION
1-9. EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
a. Capabilities. The truck is capable of pumping 1 000 gpm (3785 I/min) of water and carrying 300 gallons
(1136 I) of water and 30 gallons (114 1) of foam liquid with necessary equipment and passengers to the scene
of a fire at highway speeds.
b. Features.
(1) Single diesel engine providing drive for vehicle power train, fire pump and hydraulic systems.
(2) 100-foot aerial ladder/water tower with 360 degree rotation. Can be elevated from -6 to +75 degrees.
(3) Spring-applied, hydraulically released disc-type brake for positive holding of the turntable assembly.
(4) The aerial ladder/water tower is equipped with an emergency back-up hydraulic pump which allows for
limited ladder functions in case of prime mover failure.
(5) Telescopic waterway capable of continuous water flow through 360 degrees of rotation at all elevations.
(6) Ladder tip monitor with nozzle can be electronically controlled from either the control console or the
ladder tip.
(7) 110 VAC power available.
(8) On-board 30 gallon (114 1) foam tank.
(9) Diesel engine driven auxiliary power unit provides 110 VAC in emergencies.
(10) Automatic transmission and simple driveline system for transfer of power to tractive wheels.
1-3
TM 5-4210-233-14&P-1
1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
(11) Easy access to all vital components and equipment.
a. Cab, Body, and Aerial.
(1) The cab is divided into two sections. The front portion of the cab (the cockpit) is equipped with an airride driver's seat and one passenger seat. The back portion of the cab (the canopy) is equipped with
four jump seats. The cockpit is equipped with a complete set of gauges and controls. Access to the
engine compartment can be gained through the canopy.
(2) The pump compartment portion of the truck is located between the cab and hose body. The street side
pump panel is equipped with a complete set of controls and gauges for operation of the pump and APU.
The curbside pump panel is equipped with suction and discharge outlets. A pull-out step is attached to
the running board on the streetside.
(3) The hosebody portion of the truck includes ail equipment storage compartments and hose bins. The
aerial hydraulic tank, foam tank, and water tank are also located in the hosebody.
(4) The aerial portion of the truck includes: the aerial ladder and nozzle, turntable, control panels and
outriggers. A hydraulic system powers the aerial ladder.
b. Lights and Safety Equipment.
(1) The lights are grouped as follows: driving lights, warning lights, work lights, and auxiliary lights.
(2) The headlights, parking lights, tail lights, marker lights, and license plate light make up the driving lights
group. These lights are controlled and operated by the driver from the dash panel.
(3) The signal lights, consisting of the turn signal lights, stop lights, and back-up lights are used to indicate
to other traffic that the truck is about to change direction, slow down, or stop. The turn signal lights are
directly controlled by the driver. The stop lights automatically illuminate when the brake pedal is
applied. The back-up lights together with a back-up alarm, operate when the transmission is shifted into
reverse gear. In addition to normal turn indication, all the turn signal lights can be selected to flash
simultaneously. This feature is used to indicate road hazard conditions.
(4) The warning lights include the rotating roof beacons, crossfire lights, and rear strobe lights. These
lights are designed to warn other traffic and pedestrians of approaching emergency vehicle.
(5) The work lights include: two cab mounted spotlights, two rear deck spotlights, four aerial mounted
spotlights, and two 110 VAC hose body mounted portable spotlights. The cab mounted spotlights can
be aimed individually from the cab.
(6) The auxiliary lights include: dash panel lights, pump panel lights, cab maplights, engine compartment
lights, storage compartment lights, and step lights. These lights are provided for crew convenience and
safety.
(7) Rear view mirrors including two rectangular mirrors and two convex mirrors are attached to the front
cab doors.
(8) Grab handles, located at all crew stations, are provided for safety when climbing on and off of truck.
(9) An electronic siren/PA (public address) unit is installed in the cab accessible to both driver and
crewmember. The speaker is mounted behind the front bumper. The two air horns located on the cab
roof are controlled by a pull rope from inside the cab.
1-4
TM 5-4210-233-14&P-1
1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
Figure 1-2. Cab, Body and Aerial Components
1-5
TM 5-4210-233-14&P-1
1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
Figure 1-3. Lights and Safety Equipment
1-6
TM 5-4210-233-14&P-1
1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
c. Engine.
(1)
The truck is equipped with a turbocharged, V-configuration, eight-cylinder, water-cooled, two-cycle
diesel engine. The engine develops 450 horsepower (336 kw) at a governed speed of 2100 rpm.
(2) Access to the engine oil dipstick can be gained through an access door located inside the curbside
passenger compartment of the cab.
Figure 1-4. Truck Engine
d. Fuel, Air Intake, and Exhaust Systems.
(1) The fuel system includes: a sixty-five gallon (246 1) fuel tank, engine fuel pump, primary and secondary
fuel filters, and supply and return lines between fuel tank and engine.
(2) The air intake system includes: the air filter, turbocharger compressor, and engine blower. The air filter
is mounted above the engine and connected to the turbocharger.
(3) The exhaust system includes: exhaust piping, turbocharger turbine, muffler, and spark arrester. The
exhaust pipe is mounted to the turbocharger. The spark arrestor and the muffler are mounted to the
frame with hanger brackets.
1-7
TM 5-4210-233-14&P-1
1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
Figure 1-5. Fuel, Air Intake and Exhaust Systems
e. Electrical System.
(1) Refer to Electrical Schematics in Appendix H. The fire truck is equipped with a 12 VDC main electrical
system and a 110 VAC auxiliary system. All components and subsystems used to operate and control
the truck and firefighting equipment are powered from the 12 VDC system. The 110 VAC system is
used to operate auxiliary power tools, lights, and accessories.
(2) The 110 VAC system is powered by the auxiliary power unit (APU) The truck is equipped with five 110
VAC outlets. There are two double receptacles on each side of the hose body and one single receptacle
at the ladder tip.
(3) The 12 VDC system is equipped with two 12-volt batteries. Each battery is located in a separate battery
compartment. The batteries are connected to a four-position battery switch in the cab. The batteries
charge is maintained by one 160-amp engine-driven alternator. All major components and circuits are
protected by automatic reset circuit breakers.
1-8
TM 5-4210-233-14&P-1
1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
f. Air System.
(1)
(2)
(3)
(4)
(5)
(6)
Refer to Air System Schematics in Appendix G. The air system includes a main engine driven
compressor, an air dryer, six reservoirs, and a variety of valves and hoses. Pressure protection valves
ensure the reservoirs are filled successively.
The three rear service reservoirs supply air to the rear brakes.
The single front service reservoir supplies air to the front brakes and the parking brake release.
The supply reservoir provides air to the air horns and air system gauges located in cab.
The spring brake release reservoir supplies air to the emergency spring brake release system.
Air system pressure gauges are located in the cab. Audiovisual alarm lamps indicate when pressure is
low. Manual draincocks are fitted to each reservoir.
g. Auxiliary Power Unit.
(1) The Auxiliary Power Unit (APU) consists of a vertical four-stroke, overhead-valve diesel engine. The
APU engine is air-cooled and governor-equipped to maintain constant speed and output. The APU is
equipped with an electric starting motor and draws its fuel from the main engine fuel tank.
(2) The APU is located in the hosebed, directly above the curbside pump panel. The APU engine exhaust
is connected to a muffler located under the curbside, front outrigger.
(3) The APU can be started and stopped from any one of three locations. Controls are located on the pump
panel (street side), cab dash panel, and on the APU itself.
1-9
TM 5-4210-233-14&P-1
1-10. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
Figure 1-6. Auxiliary Power Unit (APU)
1-10
TM 5-4210-233-14&P-1
1-11. EQUIPMENT DATA
a.
Truck Weights and Dimensions
Weight Loaded ...................................................................................................... 53,220 lb (24140 kg)
Front ........................................................................................................................ 15,720 lb (7130 kg)
Rear ...................................................................................................................... 37,500 lb (17010 kg)
Maximum Allowable Gross
Totals............................................................................................................... 60,500 lb (27443 kg)
Front.................................................................................................................. 16,500 lb (7484 kg)
Rear................................................................................................................. 44,000 lb (19958 kg)
Length ...........................................................................................................455.6 in. (11572 mm)
Height .....................................................................................................................134.0 in. (3403 mm)
Width ........................................................................................................................96.0 in. (2438 mm)
Wheel Base ............................................................................................................240.0 in. (6096 mm)
b.
Engine
Make......................................................................................................................Detroit Diesel Allison
Model.........................................................................................................................................8V92TA
Type..................................................................................................................two-stroke, water cooled
Displacement .............................................................................................................. 736 cu in. (12 1)
Maximum Horsepower (at 21 00 rpm) ........................................................................ 450 bhp (336 kW)
Engine Idle................................................................................................................................ 600 rpm
Oil Capacity ..................................................................................................................... 25 qt ( 23.7 1)
Operating Temperature (coolant) ........................................................................170-1950 F (77-900 C)
Compression Ratio.......................................................................................................................... 17:1
Coolant Capacity (includes radiator)................................................................................14.8 gal. (56 1)
Lube Oil Pressure (at 1800-2100 rpm)............................................................... 50-70 psi (345-485 kPa)
Primary Fuel ....................................................................................................................................DF2
Emergency Alternate Fuels ........................................................................................JP-4, JP-5 or JP-8
c.
Transmission
Make......................................................................................................................Detroit Diesel Allison
Model..........................................................................................................................................HT 740
Type........................................................................................................ 4-speed automatic with lockup
Oil Capacity (excluding external circuit) ............................................................................ 33 qt (31.2 1)
Operating Temperature (Oil Pump) ....................................................................160-2000 F (71-930 C)
Shifter .................................................................................................................... remote cable control
Gear Ratios...........................................................................................................................1st - 3.69:1
......................................................................................................................................2nd - 2.02:1
...................................................................................................................................... 3rd - 1.38:1
.......................................................................................................................................4th - 1.00:1
..................................................................................................................................... Rev - 6.04:1
d.
Axles
Make........................................................................................................................................ Rockwell
Front
Model..................................................................................................................................... FL941
Type ...............................................................................................................................non-driving
1-11
TM 5-4210-233-14&P-1
1-11. EQUIPMENT DATA-Continued
Rear
Model................................................................................................................................... R22145
Type ........................................................................................................................single reduction
Ratio.......................................................................................................................................4.56:1
Oil Capacity .................................................................................................forward 26 pints (12.3 l)
......................................................................................................................... rear 29 pints (13.7 l)
e.
U-Joints and Yokes
Make...................................................................................................................................Dana-Spicer
f.
Tires and Rims
Front Tires
Make................................................................................................................................. Goodyear
Model......................................................................................................................... G291 Unisteel
Size ............................................................................................................................ 315180R22.5
Pressure ............................................................................................................... 120 psi (823 kPa)
Rear Tires
Make................................................................................................................................. Goodyear
Model............................................................................................................................ .Unisteel TD
Size ................................................................................................................................... 11 R22.5
Pressure .............................................................................................................. 110 psi (754 kPa)
Front Rims
Make...................................................................................................................................Accuride
Material.....................................................................................................................................steel
Size ............................................................................................................................ 9.00 x 22.5 in
Rear Rims
Make........................................................................................................................................ Budd
Material.....................................................................................................................................steel
Size ............................................................................................................................ 8.25 x 22.5 in
g.
Suspension
Front Spring
Make.....................................................................................................................Duluth Spring Co.
Rear Suspension
Make............................................................................................................................. Hendrickson
Model................................................................................................................................... RS-460
h.
Steering System
Steering Type .................................................................................................... integral hydraulic assist
Steering Gear
Make........................................................................................................................................ TRW
Model.................................................................................................................................... HFB70
Steering Pump
Make.....................................................................................................................................Vickers
Model......................................................................................................................................V20-F
Type ..................................................................................................................... gear driven, vane
Fluid Capacity.................................................................................................................. 6 qt (5.7 I)
1-12
TM 5-4210-233-14&P-1
1-11. EQUIPMENT DATA- Continued
j.
Brake System
Service Brakes
Type ................................................................................................................................... air/drum
Air Chamber Make...................................................................................................................MGM
Shoe Size ............................................................................................................16.5 in. (419 mm)
k.
Air System
Air Compressor
Make........................................................................................................................... Midland Ross
Model.................................................................................................................................NT7210E
Capacity .............................................................................................................16 cfm (450 I/min)
Air Drier
Make......................................................................................................................................Bendix
Model....................................................................................................................................... AD-9
Air Tanks
Four...................................................................................................... Bendix-1454 cu in. (23.8 l)
Two........................................................................................................... Bendix-836 cu in. (13.7 l)
m.
Fuel System
Tank Capacity ..................................................................................................................65 gal. (246 1)
Primary and Secondary Fuel Filters ..........................................................Detroit Diesel Allison spin-on
n.
Cooling System
Radiator
Make................................................................................................................Thermal Cooling Inc.
Type .......................................................................... fin and tube (includes transmission oil cooler)
Frontal Area ........................................................................................................1197 sq in. (0.77 sq m)
Capacity (including engine) ..........................................................................................14.5 gal. (54.9 1)
p. Electrical System
Type...................................................................................................................12-volt negative ground
Protection............................................................................................ automatic thermal reset breakers
Batteries
Make....................................................................................................................................Douglas
Model......................................................................................................................................... 8D3
Number of Batteries....................................................................................................................... 2
Alternator
Make....................................................................................................................................... Delco
Model....................................................................................................................................... 21-SI
Output.................................................................................................................................160 amp
q.
Firefighting System
Agent Tanks
Construction................................................................................................................stainless steel
Water Tank Capacity .............................................................................................. 300 gal. (1136 l)
Foam Tank Capacity...................................................................................................30 gal. (114 l)
1-13
TM 5-4210-233-14&P-1
1-11. EQUIPMENT DATA- Continued
Fire Pump
Make................................................................................................................................. Waterous
Model................................................................................................................................... CSYBX
Type ............................................................................................................ centrifugal/single stage
Oil Type................................................................................................automatic transmission fluid
Oil Capacity ............................................................................................................12.25 qt (11.6 1)
Pumping Rate...................................................................................................................1000 gpm
Foam Proportioners
Make.....................................................................................................................................Feecon
Model............................................................................................................................... A.H.P. 1.5
Type ......................................................................................................................around the pump
Nozzle
Make....................................................................................................................................... Akron
Model........................................................................................................................................3478
Control.................................................................................................................................. electric
r.
Auxiliary Power Unit
Engine
Make...................................................................................................................................... ONAN
Model.........................................................................................................................................DJA
Type ...............................................................................................single-cylinder, air cooled diesel
Displacement........................................................................................................30 Cu in. (492 cc)
Horsepower.........................................................................................5.7 bhp (4.2 kW) at 1800 rpm
Oil Capacity ............................................................................................................... 2.5 qt (2.36 1)
Primary Fuel ..............................................................................................................................DF2
Emergency Alternate Fuels .................................................................................JP-4, JP-5 or JP-8
1-14
TM 5-4210-233-14&P-1
SECTION III. TECHNICAL PRINCIPLES OF OPERATION
1-12. ENGINE. The engine is an eight-cylinder, V-configuration, turbocharged, watercooled two-cycle diesel
engine. The engine develops 450 horsepower (336 kw) at 2100 rpm. It is equipped with a 12 VDC electrical
system including an electric starter motor and a battery charging alternator.
a. Starting System. The starter is mounted on the left side of the engine. When current is applied to the
starter, the starter rotates. The starter pinion engages the flywheel ring gear and rotates the engine, allowing
the diesel fuel and air to enter the cylinders and start the engine.
Figure 1-7. Engine - Front View
b. Alternator and Charging System. The alternator is mounted at the rear top of the engine and is belt driven.
The 12 VDC system consists of two free batteries located in the battery compartments. The batteries are
connected to a battery switch in the cab.
c. Fuel, Air Intake and Exhaust Systems.
(1) The fuel system is comprised of a 65-gallon (246 l) fuel tank, 12 VDC electric priming pump, engine fuel
pump, primary and secondary fuel filters, and supply and return lines between the tank and engine. The
fuel filters have replaceable filter elements.
1-15
TM 5-4210-233-14&P-1
1-12. ENGINE - Continued
(2) The air system consists of the air cleaner, turbocharger compressor and engine blower. The exhaust
system consists of exhaust piping, turbocharger turbine, muffler and spark arrestor. The air cleaner is
mounted above and across the top of the engine. Air is drawn through a plenum chamber mounted on
the radiator shroud. The exhaust pipe is clamp-mounted to the turbocharger. The spark arrestor and
muffler are mounted below the right side of the frame, suspended on a spring-loaded hanger brackets.
(3) Air from the air cleaner is delivered to the compressor side of the turbocharger. Exhaust gases spin
the turbine and compressor blades. The compressed air enters the blower assembly and from the
blower assembly it is forced into the intake manifold.
(4) Fuel from the primary fuel filter enters the fuel pump and is delivered through secondary fuel filter
to the fuel injectors. The injectors pressurize and meter the diesel fuel and deliver it to the cylinders.
Figure 1-8. Engine - Left Side View
1-16
TM 5-4210-233-14&P-1
1-13. ENGINE THROTTLE CONTROL. The fuel metering in the injectors is controlled electronically. When
the
engine is shut off the fuel injectors are automatically positioned to the advance fuel position for starting. To
stop the engine, the fuel supply is shut off. The stop control lever is engaged by the electrically-operated shutoff solenoid which is controlled via the ignition switch. The solenoid is always engaged when the engine is
running.
a. Throttle Control - Driving Mode. The engine speed is controlled electronically from the electronic foot
pedal assembly to the DDEC which electronically controls the fuel injectors.
b. Throttle Control - Firefighting Mode. Variable, stabilized engine speed is required to provide infinite
control of the water pump pressure. To achieve this, an electronic vernier throttle control (located on the pump
control panel) is connected to the DDEC to regulate engine speed during firefighting operations.
1-14. TRANSMISSION AND DRIVE TRAIN
a. Transmission. The transmission is a four-speed automatic unit providing four forward gear ranges, neutral
and reverse.
b. Controlled Traction Differential. The tandem rear axles are both provided with Controlled Traction
Differentials (differential locks). The differential locks incorporate a friction plate assembly (clutch) which is
under constant spring pressure. When engaged, the differential lock prevents one wheel from slipping in
relation to the other wheel on the same axle. When disengaged, conventional differential action for normal road
conditions is restored. When engaged, the differential lock will slip sufficiently for the vehicle to negotiate turns
in a normal manner.
c. Differential Lock Control. The differential locks are engaged and disengaged by air-operated shift units. Air
flow to these units is controlled by a selector valve in the cab. The differential locks can be actuated at any time
except when one or more wheels are spinning.
1-15. AIR SYSTEM. In this paragraph, only that part of the air system comprising air supply and storage, and
driving accessory operation is covered. The air brake system is described in paragraph 1-16.
a. Air Supply and Storage System.
(1) Refer to Air System Schematics in Appendix G. Filtered air is supplied from the engine air box to the
compressor. Here the air is compressed and discharged via the drier into the supply reservoir.
(2) The air flow from the supply reservoir to the three rear service, front service, and isolated emergency
spring brake release reservoirs is restricted by pressure protection valves. These valves isolate the
supply reservoir until sufficient pressure is available to permit vehicle operation. When sufficient
pressure is obtained, pressurization of the remaining reservoirs takes place. The check valves prevent
backflow from the reservoirs once these are charged.
(3) The supply reservoir is open to the rear service reservoir whenever the ignition switch is set to ON.
(4) To provide quick pressurization of the rear service and front service reservoirs immediately after startup, the supply reservoir is maintained fully charged and isolated when the ignition is OFF.
(5) While the system is charging, the air flowing through the air drier is dehumidified. T he moisture is
precipitated and collected in the bottom of the drier. When the compressor unloads, the discharge air
opens a valve in the bottom of the drier and the accumulated moisture is blown out by a backflow of
pressurized air. This air, still hot from compression, also removes residual moisture from the drying
element.
(6) Pressure gauges and low pressure indicator lights for the front and rear reservoirs are provided in the
cab.
1-17
TM 5-4210-233-14&P-1
1-15. AIR SYSTEM - Continued
b. Driving Accessory Air System. Air supply for operation of the air horns is provided from the supply
reservoir via a manifold.
1-16. BRAKE SYSTEM. Air pressure to operate the service and parking brakes is supplied from the rear
service, rear service EXT. 1, rear service EXT. 2, front service and isolated emergency spring brake release
reservoirs. During normal operations, air in the front system is used to apply the front brakes and release the
parking brake; the air in the rear system is used to apply the rear brakes.
a. Parking Brakes.
(1) To release the parking brakes, the parking brake control is pushed IN. Air from the rear service
reservoir flows from the control valve via the spring brake valve, double check valve and quick release
valve, and service relay to the rear brake air chambers. To engage the brakes, the parking brake
control is pulled OUT to vent the brake air chamber to the atmosphere. As the air pressure is relieved,
spring pressure from the spring chambers engages the brakes.
(2) If the rear service air supply is depleted the brakes can be released by pressure from the isolated
emergency spring brake release reservoir. By pushing and holding the parking brake control IN, the
front service is isolated and the emergency reservoir is opened to pressurize the system.
b. Rear Brake System.
(1) When the brake pedal is depressed, pilot pressure is supplied from the rear service reservoir via the
service brake valve and pressure protection valves to the relay valve. The pilot pressure opens the
relay valve and allows brake application air from the rear service reservoir to enter and pressurize the
spring brake chambers. The combined force of air and spring pressure suppresses the parking brake
release pressure in the opposing air chambers, and engages the brakes.
(2) To prevent excessive brake force, the continuously balanced pilot and spring chamber air pressures are
regulated to a maximum 45 psi (310 kPa). Below this limit the pressures are infinitely controlled.
(3) When the brake pedal is released, the pilot pressure is exhausted. The relay valve shuts off the brake
application air and vents the spring chambers to atmosphere. The opposing air chambers remain
pressurized and thus disengage the brakes.
(4)
To prevent jamming of the brakes if the service brakes are applied while the parking brakes are
engaged, counteracting pressure is provided to the air chambers. This air pressure is provided via the
double check valve and quick release valve simultaneously with the application of air pressure to the.
spring chambers.
(5) If the rear service system becomes depleted of air, the front service is indirectly used to apply the rear
brakes. The shift from rear service to front service air is automatic and carried out in the spring brake
valve when the brakes are applied.
(6) Normally, primary air pressure, supplied via the relay valve, keeps the secondary (control) air supply
port in the spring brake valve closed. This action keeps the valve function neutral.
(7) With no primary air available, secondary air pressure causes the spring brake to partially close and
reduce the air pressure that keeps the parking brakes disengaged. When this occurs, the quick release
valve automatically opens and momentarily vents the air chambers to the atmosphere. The reduction
in pressure in the air chambers is proportional to the secondary air pressure applied to the spring brake
valve.
1-18
TM 5-4210-233-14&P-1
1-16. BRAKE SYSTEM - Continued
c. Front Brake System.
(1) To engage the front brakes, air pressure is supplied from the front service reservoir via the brake valve
assembly (front), quick release valve, to the front wheel brake air chambers. When the brake pedal is
released, the air pressure exhausts. Without pressure, the quick release valve opens and vents the air
chambers to atmosphere, thereby releasing the brakes.
(2) The front brake system is operational only when the front service reservoir is pressurized.
1-17. FIREFIGHTING SYSTEM Controls are provided in the cab and on the structural control panel to enable
firefighting. The system is controlled from the operator station. Pump engagement and disengagement,
however, is always controlled from the cab.
CAUTION
To prevent inrush surges and engine overspeeding, water must
always be available at the pump before it is engaged. While
operating, water supply to the pump must be continuous. If
discontinued, the pump must be shut down immediately to
prevent damage.
The pump must be disengaged immediately when the watertank
is emptied. Failure to do this can cause vehicle damage due to
engine overspeeding.
a. Water supply and discharge system.
(1) Water supply can be from tank or alternative sources via the suction manifold. The alternative sources
may be fire hydrants, remote pumping units or an open reservoir. If water is drawn from tank a
continuous supply must be secured via the automatic tank fill valve.
(2) Automatic priming of the fire pump takes place if the pump is void of water when initially engaged. The
priming pump, driven by the fire pump, evacuates the fire pump suction. As soon as water pressure is
available, the priming pump automatically disengages.
(3) From the pump the water flows via the discharge manifold to the aerial and hand line valves.
b. Foam Induction System.
(1) Foam concentrate is released from the foam tank and metered into the water flow to the pump. The
control valves through which the concentrate is released and metered are operated from the operator's
station. To produce foam, water (derived from the pump discharge) is cycled through the eductor and
into the pump suction. In the eductor, the water draws foam concentrate into the flow by venturi action.
(2) To remove residual foam from the foam lines after firefighting, the foam tank valve is closed and the
flush valve is opened. Water from the pump discharge is then cycled through the metering valve and
the eductor.
1-19
TM 5-4210-233-14&P-1
1-18. AERIAL LADDER/WATER TOWER. The firetruck is equipped with a hydraulic-powered, telescoping,
aerial ladder equipped with a remote nozzle.
a. Hydraulic System. The hydraulic system used to actuate the aerial ladder/water tower consists of the
following:
(1) A hydraulic reservoir with an internal filter.
(2) A pressure-compensated variable displacement hydraulic pump that is engine-driven via a power takeoff. A throttle control on the pump control panel controls engine speed during aerial operations.
(3)
Each of the four outriggers use hydraulic cylinders for the extend/retract functions and for the
raise/lower functions. These functions are controlled by the outrigger cylinder controls located at the
back of the truck.
(4) The ladder hydraulics consist of the ladder lift cylinders, ladder extension retraction cylinders and a
turntable rotation motor and brake. The ladder hydraulic system is supplied by hydraulic lines that are
fed through a swivel to allow for continuous 360 degree rotation of the ladder. The truck has the ability
to operate all three ladder functions simultaneously with a minimum loss of speed or power.
(5) The turntable is rotated by a hydraulic motor with a planetary gear drive' assembly. A hydraulicallyreleased, spring-actuated brake provides positive stops of the aerial ladder rotation. The brake is
automatically disengaged by the same valve that controls the turntable rotation motor.
(6)
For safety reasons, the outrigger hydraulic functions and the ladder hydraulic functions cannot be
operated at the same time. Hydraulic oil is either pumped to the outriggers or the ladder. This routing
of hydraulic oil is controlled by an electrically-actuated diverter valve operated from the outrigger
control panel on the back of the truck.
(7) The outriggers must be extended at least 18" and supporting the weight of the truck before the diverter
valve will direct oil flow to the ladder and make the ladder functions operable. Once the diverter valve
is switched to aerial operation, the outriggers cannot be operated until the ladder is in the bedded
position.
(8) In case of failure of the main hydraulic pump, an electrically powered back-up pump can be used. This
back-up pump is driven by a 12 VDC electric motor powered by the truck batteries. The emergency
pump provides for limited functions, and is activated by switches located on the outrigger and ladder
control panels.
1-19. AUXILIARY POWER CIRCUITS The auxiliary power circuit includes: the generator (auxiliary power unit
or APU), a load center, five 110-volt receptacle outlets and various switches and meters.
a. Auxiliary Power Unit (APU). The APU is a vertical four-stroke,
overhead-valve diesel engine. This air-cooled APU is equipped with
a governor to maintain constant speed and output. A 4-pole
regulated, self-excited generator serves as both a starting motor for
the diesel engine and the power source for the APU circuit. The
generator generates 110 VAC when the diesel engine is running. The
APU can be started from any one of three locations: the cab, the
street side pump panel or from the APU itself. The APU must be
preheated prior to starting. When the preheat switch is depressed, a
manifold heater heats the intake air in the engine manifold and a
glow plug heats the pre-combustion chamber.
1-20
TM 5-4210-233-14&P-1
1-19. AUXILIARY POWER CIRCUITS - Continued
b. Load Center. The load center receives the 110-Volts AC generated by the APU generator. The load center
contains five 20-amp circuits, two DC-AC relays, a 12-volt in-line fuse, and an AC current transformer. Each
circuit is equipped with one circuit breaker and provides power to one 110-volt AC receptacle outlet.
Figure 1-10. 110-Volt AC Load Center
c. 110-Volt AC Receptacles. The truck is equipped with five 11 O-volt AC receptacle outlets. Four of the
receptacle outlets are located on the hosebody, two on each side. The fifth receptacle outlet is located at the
ladder tip and controlled by a switch on the aerial control console. The receptacle outlets are designed to
provide power for lights and other accessories. The truck is equipped with two 110-volt AC work lights. These
lights are plugged into the receptacles at the top of the hosebody. Power to these two receptacle outlets is,
controlled by on/off switches located in the cab.
Figure 1-11. 110-Volt AC Receptacles
1-21/(1-22 Blank)
TM 5-4210-233-14&P-1
CHAPTER 2
OPERATING INSTRUCTIONS
Contents
Contents
Para
OPERATOR'S CONTROLS AND INDICATORS.................................................. 2-1
CAB INTERIOR CONTROLS AND INDICATORS................................................ 2-2
DRIVER SIDE PUMP CONTROL PANEL............................................................ 2-3
PASSENGER SIDE PUMP CONTROL PANEL ................................................... 2-4
OUTRIGGER CONTROLS AND INDICATORS ................................................... 2-5
AERIAL LADDER/WATER TOWER CONTROLS AND INDICATORS................. 2-6
LADDERTIP CONTROLS AND INDICATORS..................................................... 2-7
GENERAL (SECTION II) ..................................................................................... 2-8
OPERATOR PMCS PROCEDURES ................................................................... 2-9
ASSEMBLY AND PREPARATION FOR USE ...................................................... 2-10
INITIAL ADJUSTMENTS ..................................................................................... 2-11
OPERATING PROCEDURES.............................................................................. 2-12
FIREFIGHTING OPERATIONS ........................................................................... 2-13
AERIAL LADDER SET-UP .................................................................................. 2-14
EMERGENCY AERIAL PROCEDURES .............................................................. 2-15
OPERATING THE AUXILIARY POWER UNIT (APU).......................................... 2-16
AFTER MISSION PROCEDURES....................................................................... 2-17
OPERATING INSTRUCTIONS ON DECALS AND
INSTRUCTION PLATES ..................................................................................... 2-18
OPERATION IN EXTREME COLD ...................................................................... 2-19
OPERATING IN EXTREME HEAT ...................................................................... 2-20
OPERATION IN AREAS WITH SALT AIR AND MIST ......................................... 2-21
OPERATION IN SNOW....................................................................................... 2-22
OPERATION IN MUDDY AND SWAMPY AREAS ............................................... 2-23
OPERATION IN DUST PRONE AREAS.............................................................. 2-24
OPERATION IN HIGH ALTITUDES..................................................................... 2-25
2-1
Page
2-2
2-3
2-12
2-19
2-20
2-23
2-26
2-27
2-27
2-46
2-46
2-46
2-48
2-53
2-60
2-63
2-64
2-66
2-71
2-71
2-71
2-71
2-72
2-72
2-72
TM 5-4210-233-14&P-1
SECTION 1. DESCRIPTION AND USE OF OPERATOR'S CONTROLS AND INDICATORS
2-1. OPERATOR'S CONTROLS AND INDICATORS. Controls and indicators for operation of the truck and for
firefighting are located on the truck as shown below.
Controls and Indicators - Locator View
2-2
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS
ITEM
CONTROL/INDICATOR
FUNCTION
1
Spot Light On-Off Toggle
Switches and Control Handles
Control exterior illumination. Permit 360° horizontal
and
1200 vertical rotation of spotlights.
2
Warning Light (Red)
Indicates compartment doors are open.
3
Map/Dome Light
Illuminates cab.
4
Map/Dome Light On-Off Switches
Control operation of Map/Dome Light.
5
Horn Button
Warns pedestrians or other drivers of approach or
intended movement. Push to sound horn.
6
Instrument Panel
Contains operating gauges, controls, switches and
lights. Described in detail on following pages.
7
Turn Signal Switches
Signal left/right turn and activate emergency flashers.
8
Air Brake Pedal
Engages service air brakes.
9
Accelerator Pedal
Control speed of engine.
10
MECHANICAL SIREN Foot Pedal
Operate siren from either side of cab.
Switches
11
Bell Rope
PuII rope to sound bell.
12
Air Horn Rope
Pull rope to sound air horn.
13
Air Intake Restriction Indicator
Indicates condition of engine air cleaner element.
Replace air filter when red indicator shows fully.
2-3
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS
ITEM
CONTROL/INDICATOR
FUNCTION
14
Headlight Dimmer Switch
Controls Lo-Beam and Hi-Beam headlight functions.
(Illustrated on page 2-3)
15
ENGINE START Pushbutton Switch
Depress both pushbuttons at the same time to start
engine.
16
STOP ENGINE Indicator Light (Red)
Indicates truck engine must be stopped immediately to
prevent serious engine damage.
17
Dashboard Light Dimmer Rotary Switch
Controls brightness of dashboard lights.
18
LIGHTS Switch
Pull to turn on headlights, push to turn off.
19
Ignition ON/OFF Knob/TEST
Rotary Switch
Turn to ON before starting engine. Turn to TEST to
check operation of warning lights.
20
CHECK ENGINE Indicator Light (Amber)
Indicates problem with truck engine.
21
JACOBS ENGINE BRAKE Switch
Switch to Hi, Max Effort.
Switch to LO, As Required.
Switch to OFF, Not needed.
22
AERIAL HOURS Meter
Indicates hours of operation of aerial ladder for
maintenance service checks.
2-4
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
23
24
25
26
27
28
29
30
31
32
33
34
35
Engine OIL PRESS Gauge
Engine WATER TEMP Gauge
Left/Right Turn Indicator Lights
Hi BEAM Indicator Light (Blue)
FRONT AIR Pressure Gauge
REAR AIR Pressure Gauge
FUEL Gauge
Transmission OIL TEMP Gauge
Speedometer/Odometer
PARKING BRAKE Indicator Light
IGNITION SWITCH Indicator Light
BATTERY SWITCH Indicator Light
Tachometer
36
VOLTS Meter
37
ENGINE HOURS Meter
Indicates engine oil pressure in Psi.
Indicates engine cooling system temperature.
Indicates left or right turn indicator activated.
Indicates headlights on Hi-beam.
Indicates air pressure in front brake system.
Indicates air pressure in rear brake system.
Indicates level of fuel in fuel tank.
Indicates temperature of oil in transmission.
Indicates vehicle speed and accumulated miles.
Illuminates when parking brake is engaged.
Illuminates when ignition switch is ON.
Illuminates when battery switch is ON.
Indicates engine speed in revolutions per minute
(RPM).
Indicates
battery
condition
and
rate
of
charge/discharge.
Indicates total hours of engine operation.
2-5
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
38
EMERG MASTER Switch
39
40
41
42
43
44
ROOF LIGHT Switch
FRONT WARNING Switch
SIDE FLASH Switch
REAR WARNING Switch
SIREN BRAKE Switch
HIGH IDLE Switch
45
46
PTO ENGAGED Light
AERIAL PTO Switch
47
48
AERIAL MASTER Switch
ELECTRIC PUMP SHIFT Switch
Provides electrical power to all emergency light
circuits.
Tums roof light on and off.
Tums front warning lights on and off.
Tums side flashing lights on and off.
Turns rear warning lights on and off.
Shuts off mechanical siren.
Shifts engine to high idle when ON. Engine returns to
normal idle when OFF.
Indicates aerial PTO engaged.
Shifts PTO to drive hydraulic pump for aerial when
ON.
Provides electrical power to ail aerial circuits.
Engages fire pump when in down (PUMP) position.
Returns truck to driving mode when in up (ROAD)
position. (Lift cover to operate.)
49
PUMP NOT IN GEAR Indicator
Light (Red)
OK TO PUMP Indicator Light (Green)
50
2-6
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
51
52
Tums passenger side hosebed floodlight on and off.
Indicates one or more outriggers are extended.
53
54
55
PASS FLOOD Light Switch
OUTRIGGER EXTENDED Indicator
Light (Red)
ENGINE COMPT LIGHTS Switch
DRIVERS FLOOD Light Switch
GEN PRE-HEAT Switch
56
57
GEN START/STOP Switch
REAR SCENE Lights Switch
Turns lights on in engine compartment.
Turns driver's side hosebed floodlight on and off.
Energizes glow plug and preheater for cold starting of
APU.
Starts and stops APU.
Tums rear scene lights on and off.
2-7
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
58
59
60
61
62
63
Heater HI/LO/OFF Switch
DEFROST OFF/MAX Lever
HEATING OFF/MAX Lever
VOLTS Indicator Light/Alarm
ETHER START Switch
WIPER/WASHER Switch
64
65
DIFF LOCKED Indicator Light (Red)
INTER-AXLE DIFFERENTIAL
LOCK/UNLOCK Control
Controls speed of cab heater fan.
Regulates temperature for windshield defroster.
Regulates temperature for cab heater.
Indicates below normal voltage in battery circuit.
Injects ether into engine for cold starting.
Rotate clockwise to turn on windshield wipers.
Push to activate windshield washer.
Indicates when axle differentials are locked.
Slide lever left to engage differential locks.
Slide lever right to disengage.
2-8
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
66
67
68
Shift Lock Lever
Transmission Shift Selector Lever
Battery Selector Switch
69
PARKING BRAKE Control
70
EMERGENCY PARKING BRAKE
Locks transmission [ever in gear selected.
Used to select desired gear of transmission.
Selects which battery current is drawn from: left (1),
right (2) or both.
Controls the application and release of the parking
brake.
Temporarily releases brakes allowing truck to be
moved in the event of a brake system failure.
71
RELEASE Control
FRONT WHEEL LOCK Control
72
73
A-C AMPERES Meter
A-C VOLTS Meter
Locks front wheel brakes. Pull PARKING BRAKE knob
out and push FRONT WHEEL LOCK button in.
To release, push PARKING BRAKE button in.
Indicates current flow from APU.
Indicates voltage output of APU.
2-9
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS
ITEM
CONTROL/INDICATOR
FUNCTION
74
75
PA VOL Knob
RADIO/STANDBY/WAIL/YELP/
HI-LO Switch
Microphone Switch
MANUAL Button
AIR HORN Button
Controls PA speaker volume.
Selects mode of operation.
76
77
78
Push to talk.
Wail tone is produced when button is pressed.
Air horn tone is produced when button is pressed.
2-10
TM 5-4210-233-14&P-1
2-2. CAB INTERIOR CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
79
Driver's Seat Lumbar Adjustment
Rotate handle forward to increase, or rearward to
decrease, support in lumbar area to one of three
positions.
80
Driver's Seat Fore and Aft Adjustment
Slide lever left to move seat forward or rearward.
Slide lever right to lock.
81
Driver's Seat Back Angle Adjustment
Hold handle rearward to adjust back angle to any
position within range.
82
Driver's Air Seat Control
Push to raise seat, pull to lower seat.
83
Driver's Seat Belt
Three-point seat belt with quick exit release button.
84
Passenger Seat Belt
Three-point seat belt with quick exit release button.
2-11
TM 5-4210-233-14&P-1
2-3. DRIVER SIDE PUMP CONTROL PANEL
ITEM
CONTROL/INDICATOR
FUNCTION
1
AIR SUPPLY VALVE
Opens and closes accessory air outlet valve port.
2
METERING VALVE DRAIN
Opens and closes valve when flushing foam system.
3
Y-STRAINER DRAIN
Opens and closes foam system strainer drain valve.
4
METERING VALVE
Sets numerical setting for foam/water mix.
5
OPERATING INSTRUCTIONS
Indicates the pump proportioner percent of water/foam
mix per numerical setting on metering valve.
6
FLUSH Valve
Opens and closes valve for flushing foam system.
7
SPECIFICATIONS Date
Indicates fire pump pressure (psi) and flow (gpm) at
operating rpm.
8
No. 2 CROSSLAY VALVE
Opens and closes No. 2 crosslay valve.
9
No. 1 CROSSLAY VALVE
Opens and closes No. 2 crosslay valve.
10
WATER Valve (Eductor)
Opens and closes water supply valve for foam system.
2-12
TM 5-4210-233-14&P-1
2-3. DRIVER SIDE PUMP CONTROL PANEL- Continued
ITEM
CONTROL/INDICATOR
FUNCTION
11
FOAM Valve (Concentrate)
12
NO. 4 DISCHARGE Valve
Opens and closes foam concentrate supply valve for
foam system.
Opens and closes No. 4 discharge valve.
13
NO. 3 DISCHARGE Valve
Opens and closes No. 3 discharge valve.
14
TANK FILL AND RECIRCULATE Valve
Opens and closes tank fill and recirculate valve.
15
AERIAL DISCHARGE Valve
Opens and closes aerial discharge valve.
16
TANK DRAIN Valve
Opens and closes tank drain.
17
NO. 1 DISCHARGE Valve
Opens and closes No. 1 discharge valve.
18
NO. 1 DISCHARGE Connection
Discharge connection for use with 2-1/2" hoses.
19
NO. 2 DISCHARGE Valve
Opens and closes No. 2 discharge valve.
20
NO. 2 DISCHARGE Connection
Discharge connection for use with 2-1/2" hoses.
21
Driver's Side Suction Connection
6" supply connection for use with suction hoses.
2-13
TM 5-4210-233-14&P-1
2-3. DRIVER SIDE PUMP CONTROL PANEL- Continued
ITEM
CONTROL/INDICATOR
FUNCTION
22
DRIVER'S SIDE AUX. SUCTION Valves
2-1/2" ball-type valves used to open or close waterflow.
23
AERIAL DISCHARGE Drain Valve
Opens and closes drain valve for aerial discharge pipes.
24
#2 DISCHARGE VALVE Drain
Opens and closes drain valve for discharge #2 piping.
25
#1 DISCHARGE VALVE Drain
Opens and closes drain valve for discharge #1 piping.
26
AIR OUTLET Coupling
27
Relief Valve ON/OFF
28
STRAINER
Accessory air outlet connection with quick-disconnect
fitting.
Turns water pressure relief valve on and off. Left for ON,
right for OFF.
Acts as filter for water.
29
RELIEF VALVE
Acts as speed/pressure regulator and safety valve.
30
RELIEF VALVE OPEN/CLOSED
Indicator Lights
Amber light indicates relief valve is open; green
light indicates relief valve is closed.
2-14
TM 5-4210-233-14&P-1
2-3. DRIVER SIDE PUMP CONTROL PANEL - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
31
TEST GAUGE Panel
Connections for testing vacuum and pressure gauges.
32
ENGINE COOLER
33
PRIMER Valve
Opens and closes valve to circulate engine coolant
during pumping operations.
Primes fire pump when valve handle is pulled out.
34
TANK DISCHARGE Valve
35
Throttle Warning Light
Controls flow of water from on-board tank into
pumping system.
Light MUST be ON before throttle is advanced.
36
THROTTLE Control
Controls truck engine speed from pump control panel.
37
RPM COUNTER Coupler
For attachment of external tachometer.
38
PUMP DRAIN Valve
Opens and closes valve to drain fire pump.
2-15
TM 5-4210-233-14&P-1
2-3. DRIVER SIDE PUMP CONTROL PANEL- Continued
NOTE: Items 39, 40, 41, and 42 are illustrated on page 2-15.
ITEM
CONTROL/INDICATOR
FUNCTION
39
MANUAL PUMP SHIFT Control
Engages and disengages fire pump. Pull for driving mode,
push for pumping operations.
40
ELECTRIC SHIFT Control
Pull to disengage electric pump shift.
41
FRONT SUCTION Control Wheel
Opens and closes front suction valve.
42
PuIl-Out Tread Plate
Provides platform for operator. Pull handle to release lock.
Pull shelf out until it locks.
43
VACUUM Gauge
Indicates vacuum in suction system in psi.
44
Audio Alarm
Emits electronic signal when transmission oil temperature
is above the maximum.
45
Panel Lights
Illuminate pump control panel when PANEL LIGHT switch
is ON.
46
NO. 1 CROSSLAY Gauge
Indicates water pressure in the No. 1 crosslay (psi).
47
NO. 2 CROSSLAY Gauge
Indicates water pressure in the No. 2 crosslay (psi).
48
NO. 1 DISCHARGE Gauge
Indicates water pressure at the No. 1 discharge (psi).
49
NO. 2 DISCHARGE Gauge
Indicates water pressure at the No. 2 discharge (psi).
50
NO. 3 DISCHARGE Gauge
Indicates water pressure at the No. 3 discharge (psi).
51
NO. 4 DISCHARGE Gauge
Indicates water pressure at the No. 4 discharge (psi).
52
AERIAL DISCHARGE Gauge
Indicates water pressure at the aerial discharge (psi).
2-16
TM 5-4210-233-14&P-1
2-3. DRIVER SIDE PUMP CONTROL PANEL - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
53
WATER LEVEL Gauge
Indicates water level in water tank.
E = Empty
3/4 = 3/4 Full
1/4= 1/4Full
F-Full
1/2 = 1/2 Full
54
PUMP PRESSURE Gauge
Indicates pressure in system.
55
PANEL LIGHT Switch
Turns panel lights on and off.
56
OIL TEMP
(TRANS. TEMP)
Indicates operating temperature of transmission oil.
57
FUEL Gauge
Indicates fuel level in fuel tank.
58
VOLTS Gauge
Indicates status of batteries.
59
OIL PRESS Gauge
Indicates oil pressure (psi) in truck engine.
60
WATER TEMP Gauge
Indicates temperature of coolant in truck engine.
61
Tachometer
Indicates truck engine speed in revolutions per
minute (rpm).
2-17
TM 5-4210-233-14&P-1
2-3. DRIVER SIDE PUMP CONTROL PANEL - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
62
AC VOLTMETER
Indicates output voltage of APU.
63
GENERATOR RUNNING Indicator Light
Indicates generator (APU) is running.
64
GENERATOR START/STOP Switch
Push up to start APU, down to stop.
65
GENERATOR PRE-HEAT Switch
Energizes APU pre-heater and glow plug.
66
STOP ENGINE Light (Red)
Indicates truck engine must be stopped immediately to
prevent serious engine damage.
67
CHECK ENGINE Light (Amber)
Indicates problem with truck engine.
68
AC AMMETER
Indicates output current of APU.
2-18
TM 5-4210-233-14&P-1
2-4. PASSENGER SIDE PUMP CONTROL PANEL
ITEM
CONTROL/INDICATOR
FUNCTION
1
Passenger Side Suction Connection
6" supply connection for use with suction hoses.
2
NO. 4 DISCHARGE Connection
Discharge connection for use with 2-1/2" hose.
3
NO. 3 DISCHARGE Connection
Discharge connection for use with 2-1/2" hose.
4
Pump Prime Tank and Foam
Tank Drain Valve Access Door
Release and rotate latch, pull door open.
5
NO. 3 DISCHARGE Drain Valve
Opens and closes drain valve for #3 discharge piping.
6
FRONT INLET Drain Valve
Opens and closes drain valve for front suction piping.
7
NO. 4 DISCHARGE Drain Valve
Opens and closes drain valve for #4 discharge piping.
8
RELIEF VALVE Drain Valve
Turn knurled knob clockwise to open relief valve drain;
counter-clockwise to close.
Observe CAUTION Instructions.
9
SUCTION Drain Valve
Opens and closes drain valve for suction piping.
10
Pump OIL PRESSURE Gauge
Indicates oil pressure in priming pump.
11
Foam Tank Drain Valve
Opens and closes drain valve for foam tank and
piping.
2-19
TM 5-4210-233-14&P-1
2-5. OUTRIGGER CONTROLS AND INDICATORS
ITEM
CONTROL/INDICATOR
FUNCTION
1
LEFT FRONT OUTRIGGER
DOWN Indicator Light (Green)
Indicates ieft front outrigger is supporting the weight of
the truck.
2
Panel Lights
Illuminate outrigger control panel.
3
RIGHT FRONT OUTRIGGER
DOWN Indicator Light (Green)
Indicates right front outrigger is supporting the weight of
the truck.
4
Manual Diverter Valve Control
Pull T-handle to divert hydraulic power to either aerial
or outrigger modes. Use when electrically operated
diverter valve doesn't function.
5
DO NOT ACTIVATE HIGH IDLE
UNLESS LIGHT IS ON Warning Light
Indicates when high idle mode can be activated.
6
HIGH IDLE Switch and Indicator Light
Switches truck engine to high idle mode. Push toggle
switch up to engage, down to disengage. Light indicates
which truck engine is operating on high idle mode.
7
LEFT REAR OUTRIGGER
DOWN Indicator Light
Indicates left rear outrigger is supporting the weight of the
truck.
8
Angle Indicator
Indicates angle of truck tilt side-to-side. Used to aid in
leveling truck when setting outriggers.
2-20
TM 5-4210-233-14&P-1
2-5. OUTRIGGER CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
9
OVERRIDE ACTIVATED Indicator Light
Indicates manual diverter T-handle is in aerial or
outrigger position.
10
PTO ENGAGED Indicator Light
Indicates PTO is engaged.
11
RIGHT REAR OUTRIGGER
DOWN Indicator Light
Indicates right rear outrigger is supporting the weight of
the truck.
12
HYDRAULIC EMERGENCY
POWER Indicator Light
Indicates electric emergency hydraulic pump is operating.
13
HYDRAULIC EMERGENCY
POWER Toggle Switch
When held in on position, activates electric emergency
hydraulic pump.
14
DIVERTER VALVE
OUTRIGGER/AERIAL Toggle Switch
Operates electric valve to route hydraulic pressure
to either aerial or outrigger systems.
15
Outrigger Diverter Indicator Light
Indicates electric diverter valve in OUTRIGGER position.
16
Aerial Diverter Indicator Light
Indicates electric diverter valve in AERIAL position.
2-21
TM 5-4210-233-14&P-1
2-5. OUTRIGGER CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
17
LEFT FRONT OUTRIGGER IN/OUT
Control Lever
Control IN/OUT functions of outriggers.
18
LEFT REAR OUTRIGGER IN/OUT
Control Lever
19
RIGHT FRONT OUTRIGGER IN/OUT
Control Lever
20
RIGHT REAR OUTRIGGER INIOUT
Control Lever
21
LEFT FRONT OUTRIGGER UP/DOWN
Control Lever
22
LEFT REAR OUTRIGGER UP/DOWN
Control Lever
23
RIGHT FRONT OUTRIGGER UP/DOWN
Control Lever
24
RIGHT REAR OUTRIGGER UP/DOWN
Control Lever
Control UP/DOWN functions of outriggers.
2-22
TM 5-4210-233-14&P-1
2-6. AERIAL LADDER/WATER TOWER CONTROLS AND INDICATORS
ITEM
CONTROL/INDICATOR
FUNCTION
1
Intercom
Used to communicate with person at ladder tip.
2
110 VAC 60 HZ Switch
On/off switch for 110 VAC receptacle at ladder tip.
3
Control Panel Light
Illuminates control panel.
4
AUDIO ALERT Buzzer
Sounds when person on ladder tip wants to communicate.
5
Signal Button
Push to alert person on ladder tip.
6
Flowminder Meter
Indicates water flow in gallons per minute (gpm).
7
Nozzle Control Switches
STREAM/SHAPE
RIGHT/LEFT
RAISE/LOWER
Toggle switches control movement of nozzle
(raise, lower, right, left) and shape of stream (fog to sharp).
8
LADDER TIP LIGHT Switch
Turns ladder fly section tip lights on and off.
9
PANEL LIGHT Switch
Turns control panel lights on and off.
10
RUNG ALIGNMENT Light
Indicates overlapping ladder section rungs aligned.
11
Angle Indicator
(Mounted at base of ladder
on driver's side)
Indicates angle of ladder relative to horizontal.
2-23
TM 5-4210-233-14&P-1
2-6. AERIAL LADDERIWATER TOWER CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
12
CHECK ENGINE Indicator Light (Amber)
Indicates problem with truck engine.
13
STOP ENGINE Indicator Light (Red)
Indicates truck engine must be stopped immediately to
prevent serious engine damage.
14
Water Pressure Gauge
Indicates water pressure in aerial system.
15
AERIAL DISCHARGE Switch
Allows water flow to aerial discharge nozzle.
16
HYDRAULIC EMERGENCY
POWER Switch
Push up and hold to activate electric emergency hydraulic
pump.
17
HYDRAULIC EMERGENCY
POWER Light
Indicates electric emergency hydraulic pump is operating.
2-24
TM 5-4210-233-14&P-1
2-6. AERIAL LADDERIWATER TOWER CONTROLS AND INDICATORS - Continued
ITEM
CONTROL/INDICATOR
FUNCTION
18
TRACKING LIGHTS Switch
Turns ladder base section tracking lights on and off.
19
Ladder Operating Levers
20
RUN/LOCK Lever
Operate individual levers in direction indicated to move
ladder (right/left, extend/retract, raise/lower).
Push lever forward to advance engine to hi-idle and enable
hydraulics to operating control valves. Pull lever rearward
to return to slow idle and to lock ladder controls.
21
LADDER LOAD Gauge
Indicates safe/unsafe operating load.
22
SYSTEM PRESSURE Gauge
Indicates hydraulic pressure in psi.
2-25
TM 5-4210-233-14&P-1
2-7. LADDERTIP CONTROLS AND INDICATORS
ITEM
CONTROL/INDICATOR
FUNCTION
1
PA Speaker
Used to communicate with person at operator's station.
2
STREAM/SHAPE Switch
Controls shape of water stream at aerial nozzle from
fog to sharp.
3
RIGHT/LEFT Switch
Moves aerial nozzle right or left.
4
RAISE/LOWER Switch
Moves aerial nozzle up or down.
5
SIGNAL BUTTON
Push to alert person at operator's station.
2-26
TM 5-4210-233-14&P-1
SECTION II. OPERATOR'S PREVENTIVE MAINTENANCE CHECKS AND SERVICES
2-8.
GENERAL. Operator's Preventive Maintenance Checks and Services (PMCS) are required
inspections and care of your fire truck necessary to keep it in good working order. All instructions are
mandatory.
2-9.
OPERATOR PMCS PROCEDURES
a. General.
(1)
After You Operate. Be sure to perform your After (A) PMCS after the equipment has been taken
out of its mission mode or returned to its containment area.
(2)
Daily. Be sure to perform your Daily (D) PMCS every day, even Hf the equipment has not been
used.
(3)
Weekly. Be sure to perform your Weekly (W) PMCS every week, even if the equipment has not
been used.
b. PMCS Procedures.
(1)
Purpose. Your preventive maintenance checks and services table lists the inspections and care of
your equipment required to keep it in good operating condition.
(2)
Interval Column. The interval column of your PMCS table tells you when to do a particular check
or service.
(3)
Procedure Column. The procedure column of your PMCS table tells you how to do the required
checks and services. Carefully follow these instructions. If you do not have the tools, or if the
procedure tells you to, have unit maintenance do the work.
(4)
Reporting and Correcting Deficiencies. If your equipment does not perform as required, referto
Chapter 3 under troubleshooting for possible corrections. Report any malfunctions or failures on
DA Form 2404, or refer to DA Pam 738-750.
(5)
Equipment Is Not Ready/Available If: This column tells you when and why your equipment cannot
be used.
2-27
TM 5-4210-233-14&P-1
2-9.
OPERATOR PMCS PROCEDURES - Continued
(6)
Special Instructions. Perform "weekly" as well as "daily" PMCS if:
(a)
You are the assigned operator and have not operated the equipment since the last weekly
PMCS were performed.
(b)
You are operating the equipment for the first time.
(7)
Leakage. Leakage definitions for operator/crew PMCS shall be classified as follows:
Class I
Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II
Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item
being checked/inspected.
Class III
Leakage of fluid great enough to cause drops to fall from item being checked/inspected.
CAUTION
Equipment operation is allowable with minor leakages (Class I or
11). Of course you must consider the fluid capacity in the
item/system being checked/inspected. When in doubt, notify
your supervisor.
When operating with Class I or II leaks, continue to check fluid
levels as required in your PMCS.
Class III leaks should be reported to your supervisor or unit
maintenance.
2-28
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures
Item
Interval
No. A D W
1
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
ACCESSORIES
Hard Suctlon Hoses
•
•
Inspect hose for tears, cuts and missing or damaged
gaskets. Inspect couplings for thread damage. Report
any failed hose to Unit Maintenance for repair.
Soft Suction Hoses
•
•
Inspect hose for kinks, tears, cuts, burns, chemical
damage and missing or damaged gaskets. Report
any failed hose to Unit Maintenance for repair.
Axes
•
•
Inspect handle for cracks, damage, loose head.
Replace any damaged axe.
Pike Poles
•
•
Inspect for loose head, damaged pole. Replace any
damaged pike pole.
Ladders
•
•
Inspect for distorted or cracked side rails and rungs,
loose rungs or inoperative locking mechanisms.
Replace any damaged ladder.
Strainer, Reducer
•
•
Check if missing. Inspect for thread damage,
distortion, cracks. Replace if necessary.
2-29
- Hose missing or
severely damaged.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures
Item
Interval
No. A D W
2
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
PUMP COMPARTMENT
Lights
•
Set pump panel light switch to on position.
Check that pump panel lights illuminate. Check that
following gauge back lights illuminate:
WATER TEMPERATURE
OIL PRESSURE
TRANSMISSION OIL TEMPERATURE
VOLTS
FUEL
ENGINE RPM
Check that each compartment light illuminates.
Check that each step light illuminates.
Hose Bin Rollers, Dividers
•
Confirm rollers move freely. Check dividers for
damage.
Gauges
•
Inspect gauge for visible damage. Check that all
segments of water tank level gauge illuminate when
water tank is full.
- Any gauge is damaged
or inoperable.
Pump Panel Lights, Switches
•
Inspect for visible damage. Check that rubber toggle
switch boots are in place, free of cracksldamage.
Pump Panel Throttle Control
•
Inspect for visible damage.
•
Relief Valve
With water pump operating, turn relief valve to ON
position. Increase and/or decrease setting and check
that OPEN and CLOSED lights illuminate. If lights do
not illuminate, notify Unit Maintenance to troubleshoot.
2-30
- Any switch is damaged
or inoperable.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
2
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
PUMP COMPARTMENT - Contlnued
•
Relief Valve Strainer
Remove strainer and clean screen. Inspect screen for
damage. If screen is damaged, it must be replaced
(see Parts List, Appendix F).
Discharge ConnectionslChrome Adapters
•
Inspect for visible distortion, thread damage, cracks.
Report any damage to Unit Maintenance.
Street/Curb Side Panel, Pump Panel, Enclosure
Cover and Runnlng Boards
•
Inspect for visible damage. Be sure attaching
hardware is in place. Tug on pump panel enclosure
cover handle to ensure cover is fastened securely.
boards.
Pull-Out Tread Plate
•
Inspect cables and latches, adjust if necessary. Be
sure slides are greased and work easily.
Prlmlng Pump Oil Tank
•
Check level of fluid in priming tank. Top up with
correct weight oil as required.
3
PROPELLER SHAFT ASSEMBLY
Drive Shafts
•
4
Grasp each drive shaft and attempt to rotate and
move up and down. There should be no slack. Report
any movement to Unit Maintenance.
PUMP, PIPING SYSTEM, AND VALVES
Fire Pump
•
Examine pump for signs of oil or water leaks.
2-31
- Attaching hardware
totally missing from panel
cover, or running
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures - Continued
Item
Interval
No. A D W
4
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
PUMP, PIPING SYSTEM AND VALVES - Continued
Prlmlng Pump
•
Examine pump for signs of oil or water leaks. Report
any leak to Unit Maintenance.
- Priming pump leaks.
Water Tank Assembly
•
With water tank empty, open water tank cover. Look
for any sign of corrosion or leaks.
- Tank leaks.
Start main engine and connect AUX. suction valve to
pressurized water supply.
Open TANK FILL AND RECIRCULATE valve and
check water tank starts to fill. Listen for water
splashing inside of tank. If valve leaks report to Unit
Maintenance. Close TANK FILL AND RECIRCULATE
valve. Close cover and remove hose connection to
AUX. SUCTION valve.
5
HOSE BODY ASSEMBLY
Hose Body
•
•
Check hose body ior dents and scratches. Clean
paint work as required. Be sure all fasteners are tight.
Ensure equipment is correctly in the ladder rack.
- Equipment securing
hardware broken or
severely damaged.
Lights
•
Check that portable worklights (11O VAC) illuminate.
Check that rear strobe light flashes properly.
Check that hosebed floodlights illuminates.
Check for proper operation of Stop, Turn, Tail,
Marker, and Back-Up lights.
Check that compartment lights illuminate.
2-32
- Any driving lights are
inoperable.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
5
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
HOSE BODY ASSEMBLY - Contlnued
Llghts - Contlnued
•
Report any failed lamps to Unit Maintenance.
Handralls
•
Inspect for missing attaching hardware or iooseness.
Report any loose handrail or missing attaching
hardware to Unit Maintenance.
Rear Step Platforms and Tread Plates
•
Inspect for visible damage or missing attaching
hardware.
- Attaching hardware
totally missing from step
plafform or tread plate.
Report visible damage or missing attaching hardware
to Unit Maintenance.
Upper and Lower Compartment Doors
•
•
Check each compartment for the following:
a.
Hatch holder holds door in open position.
b.
Lamp illuminates when switch is depressed.
c.
Door latches easily and does not open when
tugged.
d.
Door seal is intact and securely in place.
e.
Equipment is stowed correctly and fixtures are in
place.
Report any deficiencies to Unit Maintenance.
2-33
- Door will not latch
securely.
- Heavy equipment
stowing fixtures missing or
loose.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
5
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
HOSE BODY ASSEMBLY - Contlnued
Rear Roll-Up Door
•
Check that rear roll-up door operates smoothly,
without binding.
•
Check compartment to see that equipment is stowed
correctly and fixtures are in place.
loose.
- Equipment stowing
fixtures missing or
•
Inspect ladder keeper door for missing attaching
hardware or looseness. Report loose keeper door or
missing attaching hardware to Unit Maintenance.
- Ladder keeper door
missing or will not latch
securely.
Air Bottle Rack and Slide Tray
•
Check that locking pin and locking pin retainer chain
are in place.
•
Check that slide tray works smoothly, and slide locks
function properly.
•
Inspect air bottle rack for visible damage.
Report any deficiencies to Unit Maintenance.
6
CAB ASSEMBLY, LIGHTS AND CONTROLS
Cab Roof Panel
•
•
Check that attaching hardware is in place, panel is
not severely bent, scratched, or damaged. Check
inside of cab for signs of water leakage.
- Attaching hardware
totally missing.
Cab Doors
•
•
Ensure both cab doors latch. Check inner and outer
handles operate.
Be sure door seals are in place.
2-34
- Cab door will not latch.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
6
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
CAB ASSEMBLY, LIGHTS AND CONTROLS Contlnued
Cab Door Glass, Windshield
•
•
Check window regulators move windows up and
down smoothly. Be sure windows are unbroken.
Ensure all seals are in place.
Cab Mirrors
•
•
Check mirrors are not cracked and mounting is
secure.
Cab Lights
•
Check all lamps function:
Headlights
Marker Lights
Turn Signal Lights
Warning Lights
Roof Beacon Light
Cab Dome Lights
Cab Step Lights
- Any driving lights are
inoperable.
•
Check both cab spotlights illuminate. Swivel handle
and check that lamp swivels smoothly to extent of its
travel.
Siren and PA System
•
•
Check operation of the siren/PA unit mounted in the
cab.
Check siren, radio rebroadcast and PA functions.
Back-up Alarm
•
Check operation of back-up alarm with main engine
running and shift lever in reverse.
2-35
- Siren/PA unit does not
operate in one or more of
its functions.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
6
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
CAB ASSEMBLY, LIGHTS AND CONTROLS Contlnued
Air Horns
•
Check operation of air horns. Be sure pressure in air
reservoir is sufficient for proper operation.
Cab Exterior Trim and Scuff Plates
•
Check missing or damaged trim and scuff plates. Be
sure attaching hardware is in place.
Cab Instrument Panel Gauges, Swltches, Indlcator
Lights
•
•
Check gauges operate. Check for visible damage to
gauges, switches, or indicator lights. Check switches
for proper operation. Be sure indicator lamps
illuminate.
- Any gauges, switches or
indicator lights are
inoperable.
Dashboard Compartment Doors
•
Be sure compartment door latches work properly.
Clean glove compartment. Check for loose or missing
attaching hardware.
Transmlssion Shift Control
•
•
Check operation of shift unit with main engine
running. All gear ranges should be selectable and
movement of handle should be free and smooth. Be
sure truck will not start unless seiected to Neutral.
Heater/Defroster
•
With main engine running, set HI/LO/OFF switch to
HI. Set HEATER and DEFROST levers to MAX.
Check for adequate hot air tlow.
2-36
- Any range is not
operable.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
6
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
CAB ASSEMBLY, LIGHTS AND CONTROLS Contlnued
Seats and Seat Belts
•
Check operation of all seat position levers to ensure
each seat is fully adjustable.
- Seats loose, or any seat
adjuster fails to lock.
•
Check operation of seat belts and check fabric is not
worn or torn.
- Seat belts missing or
severely damaged.
•
Check ail seat and belt fasteners are tight.
•
Check operation of driver's seat adjustment levers
and valve to ensure seat is fully adjustable.
properly.
- Seats loose, or any seat
controls fail to operate
•
Check operation of seat belts and check fabric is not
worn or torn.
- Seat belts missing or
severely damaged.
•
Check ail seat and belt fasteners are tight.
Windshleld Washer/Wlper
•
•
Check fluid level in wash bottle is up to the fuII mark.
Replenish as required.
•
•
Check wiper and washer controls. Wiper speed
should be fully adjustable between slow and fast
speed. Washer nozzles should spray fluid into path of
wipers. Clean nozzles as required.
2-37
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
7
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
1 2-VOLT DC ELECTRICAL SYSTEM
Batterles/Battery Boxes
WARNING
Explosive gasses are always present in the
cells of a lead-acid battery. Keep sources of
ignition away from batteries.
WARNING
Electrocution is possible if the positive
battery terminal is touched. Avoid contact
with the conducting surfaces of the battery
terminals.
•
Inspect battery boxes for visible damage. Be sure all attaching hardware is in place and tight. Check that battery
is secure and free of cracks/leaks, and that terminals
are tight. Report any deficiencies to Unit Maintenance.
•
Check electrolyte ievel in each celi. If water level is
below top of plates, fill cells to just above top of
plates. Use distilled water only.
8
11O-VOLT ELECTRICAL SYSTEM
110 VAC, 60 Hz Receptacles
•
9
Check 1 1 O-volt electrical system with APU running.
Check cab and pump panel voltmeters and ammeters
for proper operation. Check 1 10 VAC, 60 Hz
receptacles using portable floodlights. Check aerial
circuit operation and on/off switch.
ENGINE ENCLOSURE
Engine Covers
•
Check engine covers on both sides of the engine are
in place. Tug on both handles to ensure cover is
fastened securely.
Inspect engine enclosure insulation for tears or
missing. Check latches and hinge for smooth
operation, missing affaching hardware.
2-38
- Battery leaks or is
damaged.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
10
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
ENGINE AND ACCESSORIES
Air Cleaner Assembly
•
Check for looseness or open latches. Inspect flexible
duct for cracks or torn.
Oil Cooler, Filter
•
Check for looseness or leaks. Report any leaks to
Unit Maintenance.
Fuel Fllter and Piping
•
Check for leaks or visible damage. Report any
deficiencies to Unit Maintenance.
- Fuel is leaking.
Radiator, Hoses, and Piping
WARNING
When the engine is hot, the coolant can
cause serious burns. To prevent injury,
allow engine to cool before carrying out
the following inspection.
•
Inspect radiator for leaks, secure mounting and
physical damage. RePport any deficiencies to Unit
Maintenance.
- Radiator is leaking or
damaged.
•
Examine ail hoses and air lines for signs of leakage,
cuts, or abrasions. Report any deficiencies to Unit
Maintenance.
- Any hose is leaking or
has serious cuts or
abrasions.
Starter Motor
•
Check cables for chafing and/or loose insulation.
Follow cables from battery boxes through to starter
motor.
•
Check all connections for tightness and corrosion.
Report any deficiencies to Unit Maintenance.
2-39
- Starter motor will not
operate.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures -Continued
Item
Interval
No. A D W
11
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
TRANSMISSION ASSEMBLY
Transmisslon
•
12
Check transmission for leaks, smooth shifting. Report
any deficiencies to Unit Maintenance.
- Any range is not
operable.
WHEEL ASSEMBLY
Tlres and Rims
•
•
Check pressure of all tires; 120 psi (823 kPa) front, - Pressure low.
I10 psi (754 kPa) rear.
•
Check each tire for large objects in tread, remove.
•
Check for deep cuts, uneven wear, or signs of tread
separation.
- Deep cuts or tread
separation.
Report any deficiencies to Unit Maintenance.
13
STEERING SYSTEM
•
Check for oil leaks on all hoses and fittings between
reservoir and pump in engine compartment and
steering gear (left hand wheel).
•
Check steering column and miter box for grease
leaks.
•
Check, while operating thevehicle and turning the
steering wheel lock-to-lock, that the steering is free
turning and even.
SUSPENSION SYSTEM
Shock Absorbers
14
•
Check for oil leaks. Report any leak to Unit
Maintenance.
2-40
- Large oil leaks or hose
damage.
- Failed universal joints or
stiff steering.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures - Continued
Item
Interval
No. A D W
15
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
EXHAUST SYSTEM
Exhaust Pipe, Muffler, Spark Arrestor, Tall Pipe,
Clamps and Hangers
•
Check that all components are in place and free of
damage. Be sure all clamps and hangers are tight.
gasses leaking.
•
Check for holes, severe corrosion, loose connections.
16
- Any component is at
ground level; exhaust
FUEL TANK ASSEMBLY
Fuel Lines and Piping
•
Check for chaffing or nicks. Report any deficiencies to
Unit Maintenance.
- Fuel is leaking.
Fuel Tank
•
Check fuel level after every mission. A minimum of
3/4 tank must be maintained. Ensure cap is tightened.
•
Check for any signs of fuel leakage. Report any leaks - Fuel tank leaks.
to Unit Maintenance.
Fuel Tank Mounting Straps
•
17
Check that straps are tight and free of damage,
cracks, or severe corrosion.
- Fuel tank mounting
strap missing or
broken.
FRAME AND BUMPER ASSEMBLY
Front Bumper
•
•
Be sure bumper is not severely scratched, scored or
dented. Clean as required. Be sure all nuts and bolts
are tight. Refer to Unit Maintenance for repair.
.
2-41
- Attaching hardware
totally missing from
one end of bumper.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures - Continued
Item
Interval
No. A D W
17
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
FRAME AND BUMPER ASSEMBLY Continued
Tow Hooks
•
Be sure tow hooks are not bent out of shape and
attaching hardware is tight. Refer to Unit Maintenance
for repair.
Front Frame Extension
•
Check that attaching hardware is tight. Ensure
extension is free of damage or distortion.
one
- Attaching hardware
totally missing from
end of frame extension.
Wheel Chock Brackets
•
18
Check brackets are tight and attaching hardware is in
place. Inspect for visible damage or distortion.
AERIAL LADDER AND WATER TOWER
ASSEMBLY
Ladder Treads, Safety Railings
•
Check ladder treads for damage/missing.
•
Check that safety railings are securely fastened,
attaching hardware is in place.
Report deficiencies to Unit Maintenance.
OutriggerWarning/Compartment Lights
•
Check that all iamps illuminate properly. Check
lenses are not cracked and mountings are secure.
Aerial Ladder Spotlights
•
Check that lamps illuminate. Check switches function
properly. Ensure rubber boots on switches are not
damaged/missing. Check that spotlight housing is not
damaged. Check lens is not cracked or broken.
2-42
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures - Continued
Item
Interval
No. A D W
18
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
AERIAL LADDER AND WATER TOWER
ASSEMBLY - Contlnued
Control Panel Indicator Llghts, Swltches
•
•
Check for visible damage. Check that lamps
illuminate. Check switches for proper operation.
Ensure that rubber boots are in place and free of
cracks. Report any deficiencies to Unit Maintenance.
- Any switches or
indicator lights are
inoperable.
Ladder Load Gauge, System Pressure Gauge
(0-3000 PSI), Water Pressure Gauge (0-600 PSI)
•
•
Check gauges for damage, cracked or broken face,
broken indicator. Report any broken gauge to Unit
Maintenance.
- Any gauges
inoperable.
Flow Minder
•
•
Check for cracked or broken display panel. Be sure
attaching hardware is in piace.
- Flow Minder inoperable.
Hoist Cylinders, Swlng Motor Planetary $peed
Reducer
•
Check for any signs of hydraulic oil leakage. Check
lines for signs of abrasion.
Swlng Brake
•
Operate swing motor on aerial ladder. Ladder swing
should stop immediately on release of swing control.
Report any deficiencies to Unit Maintenance.
- Swing brake does not
work.
Emergency Hydraullc Pump
•
Activate emergency hydraulic pump switch and listen
to confirm pump is running.
2-43
- Emergency hydraulic
pump is inoperable.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures - Continued
Item
Interval
No. A D W
18
ITEM TO BE INSPECTED/Procedures
Equipment Is Not
Ready/Available If:
AERIAL LADDER AND WATER TOWER
ASSEMBLY - Continued
Aerlal Ladder Intercom
•
Operate aerial ladder intercom. Ensure proper
operation. Check toggle switch boot is in place and
free of cracks. Check attaching hardware is in place.
Report any deficiencies to Unit Maintenance.
- Intercom does not work.
Monitor and Nozzle, Controls
•
Operate monitor and nozzle functions. Check for
smooth operation through full range of motion.
Ensure nozzle end rotates smoothly.
- Monitor and nozzle does
not work.
Front and Rear Extension Cylinders, Hoses, Tubes
and Fittings
•
Visually inspect for leaks.
•
Check hoses for signs of abrasion, kinks, pinching.
- Major hydraulic oil
leaks.
Report any deficiencies to Unit Maintenance.
Aerial Ladder Tension Cables
•
Inspect for fraying, tightness. Check cables are
tracking properly in sheaves. Report any deficiencies
to Unit Maintenance.
- Cables are sagging or
frayed.
Aerial Ladder Electrical Cables
•
19
Inspect for broken insulation, proper tension. Check
cables do not sag, track properly in sheaves. Report
any deficiencies to Unit Maintenance.
AUXILIARY POWER UNIT (APU)
APU Inspect
•
Check for oil/fuel leaks, blocked or clogged cooling air
inlet. Clean as required.
2-44
- Cable or insulation
broken, major sagging.
TM 5-4210-233-14&P-1
Table 2-1. Operator PMCS Procedures - Continued
Item
Interval
No. A D W
19
ITEM TO BE INSPECTED/Procedures
AUXILIARY POWER UNIT (APU) - Continued
APU Inspect - Continued
•
Check for tightness of electrical connections. Check
cables for damaged insulation.
Report any oil or fuel leak, loose electrical connection
or damaged cable to Unit Maintenance for repair.
•
Visually inspect exhaust pipe and muffler for leaks.
Check muffler is secure and intact. Report any
deficiencies to Unit Maintenance.
APU Test
•
Start APU as detailed in para 2-16. Let engine
run for 15 minutes. Check ammeter and voltmeter
indicate smooth 110 VAC output. Report fluctuating
output to Unit Maintenance.
2-45
Equipment Is Not
Ready/Available If:
TM 5-4210-233-14&P-1
SECTION Ill. OPERATION UNDER USUAL CONDITIONS
2-10. ASSEMBLY AND PREPARATION FOR USE. Before starting, driving and testing the truck, carry out the
lubrication instructions detailed in Chapter 3. Fuel up the truck, and fill the water and foam tanks.
2-11. INITIAL ADJUSTMENTS. All subsystems and components requiring adjustments are pre-set by the
manufacturer and no special procedures are required. Carry out all routine checks and inspections as detailed
in Operators PMCS Procedures (para 2-9).
2-12. OPERATING PROCEDURES
a.
Starting the Engine.
(1) Set battery switch to BOTH.
(2) Be sure that the parking brakes are engaged:
the PARKING BRAKE button is pulled OUT.
(3) Be sure that the transmission shift lever is in N
(neutral) position.
NOTE
The transmission neutral start switch prevents
starting unless the transmission is in neutral.
(4) Turn the IGNITION ON/OFF switch to ON.
(5) Depress the two START buttons until the
engine starts, or a maximum of 30 seconds. If
the engine fails to start, wait one to two
minutes and repeat the starting attempt.
Waiting between starting attempts is
necessary to prevent overheating of the
starter motor.
NOTE
If starting in cold weather, depress ETHER
START switch button for 1-2 seconds. If the
engine fails to start after several starting
attempts, consult the troubleshooting chart in
Chapter 3, Section II.
NOTE
The alarm lamps will sound and illuminate
when the engine is started and the air system
pressure is below 65 psi (450 kPa). The
audiovisual signals will cease once the air
system pressure exceeds 65 psi (450 kPa) as
indicated on gauges.
2-46
TM 5-4210-233-14&P-1
2-12. OPERATING PROCEDURES - Continued
(6)
When the engine is started, observe the OIL PRESS gauge. After the first few seconds of operation,
the oil pressure alarm lamp should cease indicating and the oil pressure remain above 10 psi (70 kPa).
If the oil pressure remains below 10 psi (70 kPa), stop the engine and refer to Unit Maintenance.
(7) Observe the VOLTS meter to ensure that the batteries are being charged.
b. Driving the Vehicle.
WARNING.
When the air system alarm lamps are indicating, the service
brakes are not very effective and driving may be hazardous.
Commence safe driving ONLY when the alarm lamp indication
ceases.
(1) Adjust the drivers seat and rear view mirrors, and switch ON lights, beacons, siren and other
accessories as required. Fasten your seat belt.
(2) Depress the brake pedal to engage the service brakes.
(3) Release the parking brakes by pushing the PARKING BRAKE button IN.
(4) Be sure that the INTERAXLE DIFFERENTIAL lever is set to UNLOCK.
(5) Select desired gear or gear range using transmission shift lever.
(6) Release the brake pedal and depress the accelerator pedal.
(7) If driving in wet conditions (rain, snow, mud), set the INTERAXLE DIFFERENTIAL lever
to the LOCK position. Use of the INTERAXLE DIFFERENTIAL lever engages the drive
mode of both tandem axles, thus providing increased traction.
(8) To aid in slowing the vehicle, set the ENGINE JAKE BRAKE switch to LO or HI positions.
CAUTION
Operating a Jacob Brake on slippery roads may result in skidding.
2-47
TM 5-4210-233-14&P-1
2-12. OPERATING PROCEDURES - Continued
c.
Shutting Down the Engine.
(1) After stopping the truck, engage the parking brakes by pulling the PARKING BRAKE knob OUT.
(2) Place the transmission shift lever in N (neutral) position.
CAUTION
The turbocharger can be damaged unless the engine is idled for
at least 2 minutes. The turbocharger normally operates at 40 to
60,000 rpm and is lubricated by the engine oil pump. Therefore,
to prevent lack of lubrication, reduction in speed is necessary
before the engine is stopped.
(3) Idle the engine at least 2 minutes, then turn the IGNITION ON/OFF switch to OFF.
(4) Switch OFF all lights and accessory controls.
(5) Set BATTERY switch to OFF.
2-13. FIREFIGHTING OPERATIONS
a.
Before Pumping.
(1) Put transmission shift lever in N (neutral) position, set parking brake and block wheels.
(2) Relief valve should be in the OFF position when the pump is first put into use.
(3) Close discharge valves and drain openings.
(4) Unless pumping from water tank, connect suction hose to pump suction connection.
(5) When connecting discharge hoses, make sure they are free of kinks and sharp bends.
(6) Make sure all hose connections are tight. For proper operation, suction and discharge gaskets
must be clean and in good condition.
b.
Pumping from Hydrant or in Relay.
(1) Close all valves.
(2) Connect suction hose between hydrant or relaying pump and pump suction connection.
(3) Open suction, hydrant, or other valves as necessary to allow water to enter pump.
(4) With the engine at idle speed, select PUMP mode using the ELECTRIC PUMP SHIFT switch on
the cab instrument panel.
NOTE
OK TO PUMP panel light (Green) will illuminate when pump
transmission is engaged.
2-48
TM 5-4210-233-14&P-1
2-13. FIREFIGHTING OPERATIONS-Continued
(5) Depress brake pedal and move truck transmission selector lever into D (drive).
CAUTION
Do not put truck transmission selector lever in R (reverse)
position. Damage to water pump will result.
NOTE
If the green OK TO PUMP light does not illuminate, or a grinding
noise occurs, move the transmission selector lever back to N
(neutral) position, pause for several seconds and move the
selector lever to D (drive) position.
NOTE
When pump is engaged, truck speedometer should indicate
approximately 18 MPH.
(6) Turn RELIEF VALVE lever to ON position and rotate INCREASE/DECREASE handle to obtain
desired pump output pressure.
(7) Open discharge valves slowly and accelerate engine with THROTTLE control on pump panel to
obtain desired discharge pressure and capacity.
CAUTION
Monitor engine coolant temperature. If the temperature exceeds
210 deg. F (99 deg. C), or the alarm sounds, open ENGINE
COOLER control valve gradually until temperature stabilizes at
200 deg. F (93 deg. C). Failure to heed this caution may cause
engine damage.
Do not attempt to pump more water than is available from
hydrant or relaying pumper. Always make sure compoundgauge reading stays above zero. Some fire departments
operate at a minimum suction pressure of 1O psi (69 kPa) when
pumping from a hydrant or in relay to prevent a "soft" suction
hose from collapsing.
c.
Priming the Pump.
(1) Start the engine (see para 2-12).
(2) Engage the water pump transmission (see para b. above).
CAUTION
Do not run the primer motor for longer than 30 seconds. Stop
priming operation and allow priming motor to cool for 1 minute
before operating primer again. Damage to primer motor may
result.
2-49
TM 5-4210-233-14&P-1
2-13. FIREFIGHTING OPERATIONS - Continued
NOTE
If pumping from vehicle water tank, be sure water tank is full.
When pumping from draft, all valves must be closed to prevent
air leaks.
d. Pumping from Draft.
(1) Close all valves.
(2) Connect "hard" suction hose to SUCTION connection, and attach suction strainer to intake end of
hose.
(3) To get full capacity and a quick prime, and to maintain pump efficiency:
(a) Position vehicle as near as possible to water supply.
(b) Use side inlet to attain full capacity.
(c) Avoid humps or sharp bends in suction hose. Make sure no part of hose is higher than pump
suction inlet
NOTE
Air pockets in suction hose may cause loss of prime or erratic
pump action, and may reduce pump capacity.
(d) Make sure all suction connections and suction caps are tight, and all discharge and drain
valves are closed.
(e) Immerse suction strainer at least two feet below water surface to prevent pump from drawing
air.
NOTE
Whirlpools forming above suction strainer indicate that strainer
is too close to surface of water.
(f) Make sure suction strainer is far enough from bottom to prevent pumping sand, gravel,
and other foreign matter.
NOTE
The amount of material in suspension in lakes, ponds, and
streams will gradually wear impeller hubs and wear-ring
surfaces. Under favorable operating conditions, these parts
have a long life; however, the presence of sand and gravel in
the drafted water may seriously impair pump efficiency and life.
(4) With the engine at idle speed, select PUMP mode using the ELECTRIC PUMP SHIFT switch on
the cab instrument panel.
2-50
TM 5-4210-233-14&P-1
2-13. FIREFIGHTING OPERATIONS-Continued
(5) Depress the brake pedal and engage truck transmission into D (drive).
CAUTION
Do not put truck transmission in reverse.
pump may result.-
Damage to water
NOTE
If the green OK TO PUMP light does not illuminate, or a grinding
noise occurs, move the transmission back to N (neutral), pause
for several seconds and then move the selector to D (drive).
NOTE
When pump is engaged, truck speedometer should indicate
approximately 18 MPH.
(6) Prime the pump by pulling PRIMER control handle out.
(7) Turn RELIEF VALVE lever to ON position and rotate INCREASE/DECREASE handle to obtain
desired pump output pressure.
(8) Open DISCHARGE valves slowly and accelerate engine with THROTTLE control on pump panel
to obtain desired discharge pressure and capacity.
CAUTION
Monitor engine coolant temperature. If the temperature exceeds
210 deg. F (99 deg. C), or the alarm sounds, open ENGINE
COOLER control valve gradually until temperature stabilizes at
200 deg. F (93 deg. C). Failure to heed this caution may cause
engine damage.
e. Pumping from Water Tank.
(1) Make sure all caps are tight on pump side suction connections.
(2) Engage pump transmission. Engage truck transmission into D (drive).
CAUTION
Do not put truck transmission shift lever in R (reverse) position.
Damage to water pump may result.
(3) Open valves in piping between watertank and pump suction, and at least one DISCHARGE
valve.
2-51
TM 5-4210-233-14&P-1
2-13. FIREFIGHTING OPERATIONS-Continued
NOTE
Priming the pump may be necessary under some conditions
because of air trapped in the piping. Some fire departments
prime their pumps whenever pumping from water tank as a
general policy.
(4) Turn RELIEF VALVE lever to ON position and rotate INCREASE/DECREASE knob to obtain
desired pump output pressure.
(5) Open DISCHARGE valves and accelerate engine with THROTTLE control on pump panel to
obtain desired discharge pressure and capacity.
CAUTION
Monitor engine coolant temperature. If the temperature exceeds
210 deg. F (99 deg. C), or the alarm sounds, open ENGINE
COOLER control valve gradually until temperature stabilizes at
200 deg. F (93 deg. C). Failure to heed this caution may cause
engine damage.
f. Operating Foam System.
(1) Engage and prime the pump as described above.
(2) Open eductor valve (labeled WATER on pump panel).
(3) Rotate METERING VALVE handle to desired setting.
(4) Open FOAM valve.
(5) Open desired DISCHARGE valve(s) and nozzle(s).
NOTE
Residual pressure (as indicated by VACUUM gauge) must not
exceed 10 psi (69 kPa) when pumping from hydrant or relay
during foam operations.
2-52
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP
WARNING
If overload horn sounds, immediate action should be taken to
correct the overload condition. Failure may result in damage to
equipment or injury to personnel.
a.
General Safety Guidelines. The aerial ladder is designed to support a maximum of 400 pounds live
load at the ladder tip. If loading capacity exceeds the safety limit (a red line condition) a warning horn
will sound. The horn will continue to sound until the overload situation is corrected.
(1) Use one or more of the following procedures to correct the overload condition:
a. Remove or reposition ladder occupant(s).
b. Retract ladder sections.
c.
Slowly increase ladder elevation.
WARNING
Do not rest the ladder on any type of support (window ledge,
overhang, or other structure). Pressure on the laddertip may
result in equipment damage or injury personnel.
(2) The ladder is designed as a cantilevered structure. It is intended to be supported only by its own lift
system.
(3) The ladder operator should remain in constant visual (and if possible, radio) contact with ladder
occupant(s). The ladder operator should remember that the conditions at the ladder tip can vary
greatly and change rapidly from those at the operator's station.
(4) Use extreme caution when operating the ladder beneath overhead obstructions.
WARNING
Avoid overhead electrical power lines. Ladder or occupant
contact with electrical cables can result in serious injury or death
to ladder occupants, ladder operator and/or bystanders.
(5) Notify the local utility company for assistance when overhead power lines cannot be totally avoided.
(6) Ladder operator should remain at the operator's station during ladder use. No one should occupy
ladder until ladder operator gives authorization.
2-53
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP - Continued
WARNING
Ladder occupant(s) should not rely on "leg-lock" techniques.
The ladder extension system is powerful enough to cause
severe injury to arms or legs that are caught between rungs of
ladder sections.
(7) Ladder occupants must use approved ladder safety belts.
(8) When using the aerial ladder in sub-freezing weather, ice build-up on ladder sections can cause
dangerous loading conditions. Avoid positioning aerial ladder in water overspray to help minimize
ice build-up. The ladder load gauge should be checked often to assure ladder load does not enter
red line condition. If ice build-up becomes excessive, the ladder should be put in bedded position
and taken to a warm environment to thaw. It is recommended that when freezing conditions exist a
deicer agent be used on the ladder sections.
b.
Locating the Truck. It is important to position the truck in the best location for safe aerial ladder
operation. Rescue and firefighting operations vary greatly. Following the guidelines below will help to
provide safe operation under most situations.
WARNING
Avoid overhead electrical power lines. Severe injury or death
may occur to ladder occupant(s) who come in contact with
power lines. When electrical power lines cannot be avoided,
contact the local utility company for assistance.
(1) Position truck far enough away from building to avoid danger in case building collapses.
(2) Block the front wheels in both directions.
(3) The outriggers extend to form a sixteen-foot base. Allow enough room for full outrigger extension.
WARNING
Do not rotate ladder to side that does not have outriggers fully
extended. Truck can tip causing injury or death to personnel
and damage to equipment.
(4) If space is limited, position truck so outriggers on the side of ladder operation can be fully extended.
(5) Position truck on a hard surface (paved road) whenever possible. If it is not possible to park on a
hard surface, use a sufficient shoring under outrigger pads.
(6) If parking on a slope, position aerial ladder turntable on downhill side.
2-54
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP - Continued
(7) Do not set outriggers on or near manhole covers,
storm sewers, etc.
(8) Avoid overhead obstructions (cables, structures, etc.).
c. Engaging PTO.
(1) Shift the transmission into N (neutral).
(2) Set the PARKING BRAKE (pull up).
(3) Block the front wheels in both directions.
(4) Activate the AERIAL MASTER switch.
(5) Activate the AERIAL PTO switch.
d. Setting Outriggers. The outrigger control panels and
aerial control panel are located at the rear of the truck.
(1) Open aerial/outrigger control panel door.
(2) Set DIVERTER VALVE OUTRIGGER/AERIAL switch
to OUTRIGGER position For safety reasons, the
outrigger hydraulic functions and the ladder hydraulic
functions cannot be operated at the same time.
NOTE
For safety reasons, the outrigger hydraulic
functions and the ladder hydraulic functions
cannot be operated at the same time.
(3) Activate engine HIGH IDLE switch.
(4) Open outrigger control panel doors.
WARNING
Be sure area around truck is clear of all
personnel
before
extending
outriggers.
Crushing injury may result.
(5) Fully extend front and rear outriggers.
2-55
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP - Continued
(6) Position outrigger plates (with handles facing truck)
under outrigger pads.
(7) Lower rear outriggers. Level truck from side to side.
When the outriggers are set properly, the
LEFT/RIGHT REAR OUTRIGGER DOWN lights in
the aerial/outrigger control panel will light.
(8) Lower front outriggers. Level truck side to side.
When the outriggers are set properly the
LEFT/RIGHT FRONT OUTRIGGER DOWN lights in
the aerial/outrigger control panel will light.
WARNING
Do not rotate ladder to side of truck that does not
have outriggers fully extended. Truck can tip
causing injury or death to personnel and damage
to equipment.
WARNING
In situations where space does not permit full
outrigger extension, the truck must be positioned
to allow for full extension of outriggers on the side
that the aerial ladder will be used. The outriggers
on the opposite side should be extended as far as
space allows. The outriggers must be extended a
minimum of 18 inches (457 mm) and supporting
the weight of the truck before the diverter switch
will activate the aerial ladder controls.
Failure to heed this warning can result in injury
or death to operator and damage to equipment.
(9) Move HIGH IDLE switch to off position.
(10)
(11)
Install outrigger locking pins in jack stands.
Move DIVERTER VALVE OUTRIGGER/
AERIAL switch to AERIAL position.
2-56
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP - Continued
e. Positioning Ladder. Before starting to position ladder, the
ladder operator should make a thorough inspection of the
area around the ladder. The outriggers must be securely
positioned and the surrounding area should be clear of
obstructions.
WARNING
Ladder must not be occupied during ladder
positioning. Crushing injury can occur during
ladder extension or retraction. Sudden ladder
movement may cause personnel to fall. An
operator must be at the tumtable controls at all
times when the aerial ladder is in use.
NOTE
Refer to para 2-15 for emergency aerial operating
procedures.
(1) Open aerial control panel cover.
(2) Move SYSTEM LOCK lever to RUN position.
(3) Using the LOWER/RAISE aerial control lever, raise the
ladder enough to clear ladder bed locks.
CAUTION
The ladder controls should be operated slowly and smoothly.
Sudden ladder movement is magnified at the ladder tip. This
may damage the equipment.
The ladder control operator should always keep visual contact
with ladder. If operator's attention is diverted, ladder movement
should be stopped and SYSTEM LOCK lever moved to LOCK
position.
WARNING
Do not allow personnel to climp or descend ladder unless RUNG
ALIGNMENT light is on. Injury or death may result.
(4) Operate ladder controls until ladder is in position.
simultaneously.
All three ladder controls can be operated
(5) When aerial ladder is in position for rescue/firefighting operation, move SYSTEM LOCK lever to
LOCK position.
2-57
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP - Continued
f. Operating Aerial Discharge.
(1)
(2)
(3)
Refer to paragraph 2-13 for appropriate pump setup instructions (pumping from draft, pumping
from hydrant or in relay, pumping from water tank).
With the engine at idle speed, select PUMP mode with ELECTRIC PUMP SHIFT switch on cab
dashboard.
Depress the brake pedal and shift the truck transmission into D (drive).
CAUTION
Do not put the truck transmission selector lever into R (reverse)
position. Damage to the water pump may result.
NOTE
If the green OK TO PUMP light does not illuminate, or a grinding
noise occurs, move the transmission selector lever back to N
(neutral) position; pause for several seconds and move the
selector to D (drive) position.
(4)
When pump is engaged, truck speedometer should indicate approximately 18 MPH.
(5)
Open AERIAL DISCHARGE valve on pump operator's panel and set AERIAL DISCHARGE
OPEN/CLOSED switch on aerial platform to OPEN.
(6)
Turn the RELIEF VALVE lever to the ON position and adjust knob to obtain desired discharge
pressure.
CAUTION
Monitor engine coolant temperature. if the temperature exceeds 21 0 deg. F (99 deg. C), or the alarm sounds, open the
ENGINE COOLER control valve gradually until the temperature stabilizies at 200 deg. F (93 deg. C). Failure to heed this
caution my cause engine damage.
Do not attempt to pump more water than is available from
hydrant or relaying pumper. Always make sure compoundgauge reading stays above zero. Some fire departments
operate at a minimum suction pressure of 10 psi (69 kPa) when
pumping from hydrant or relay to prevent a soft suction hose
from collapsing.
2-58
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP - Continued
g. Bedding the Ladder.
CAUTION
Lower the ladder only until it makes contact with the ladder bed
locks.
It is possible to exert downward force with the
RAISE/LOWER control and cause possible damage to the truck.
(1) Fully retract and lower the ladder into the ladder bed locks.
(2) Turn off all lights and accessories.
(3) Close aerial control panel cover.
h. Retracting Outriggers.
(1) Remove outrigger pins from all outriggers and store pins in their holders.
(2) Switch DIVERTER VALVE OUTRIGGER/AERIAL switch on the outrigger control panel to the
OUTRIGGER position.
(3) Set HIGH IDLE switch up to on position.
WARNING
To avoid possible crushing injury, be sure ail personnel are clear
of outriggers before retracting.
(4) Raise and retract all outriggers completely. Close and latch doors on outrigger controls.
(5) Set HI IDLE switch to off position.
(6) Close and latch door on outrigger control panel.'
(7) Store outrigger pads and wheel chocks in their storage brackets on underside of truck frame.
(8) Switch the AERIAL PTO and AERIAL MASTER switches in the cab to the QFF position.
2-59
TM 5-4210-233-14&P-1
2-14. AERIAL LADDER SET-UP - Continued
i. Disengaging PTO.
(1)
Use the THROTTLE CONTROL to bring the engine speed to idle.
(2)
Shift the transmission into N (neutral).
(3)
Shift the ELECTRIC PUMP SHIFT switch to the ROAD position and wait for the green OK TO PUMP
light to go off and the red PUMP NOT IN GEAR light to come on.
(4)
Activate the HIGH IDLE switch.
(5)
Bed the ladder and retract the outriggers.
(6)
Deactivate the HIGH IDLE switch.
(7)
Deactivate the AERIAL PTO switch.
(8)
Deactivate the AERIAL MASTER switch.
2-15. EMERGENCY AERIAL PROCEDURES. In the event that the main hydraulic pump becomes inoperable
a emergency hydraulic pump is available that can be used to assure continued operation of hydraulic functions.
a.
General Information. The emergency hydraulic pump is driven by an electric motor that is
powered by 1 2-volt batteries. It is activated by the switches located on the ladder and outrigger control panels.
Because the emergency pump is not an on-demand, variable displacement type pump, it should not be
operated unless a hydraulic function is required. This prevents possible burn-out of the electric motor that
drives the hydraulic pump. The emergency pump runs at a slower speed than the main hydraulic pump.
Because of this, the hydraulic functions will operate at a slower speed when the emergency hydraulic pump is
used.
CAUTION
To avoid equipment damage, do not operate emergency
hydraulic pump without the proper hydraulic valves engaged.
To prevent the emergency hydraulic pump from burning out, it
should only be used a maximum of five minutes and then
allowed to cool for 60 minutes, or damage will result.
The manual diverter valve is only intended to allow operation of
hydraulic functions if the electric valve system malfunctions. To
avoid equipment damage, do not use manual diverter valve to
override the electrical interlock system.
2-60
TM 5-4210-233-14&P-1
2-15. EMERGENCY AERIAL PROCEDURES - Continued
b. Using Emergency Hydraulic Pump.
(1) Move SYSTEM LOCK lever to RUN position.
CAUTION
To avoid damaging emergency hydraulic pump, actuate desired
function before turning emergency hydraulic pump on.
Do not operate emergency hydraulic pump for more than 5
minutes at a time. Allow motor to cool for 1 minute before
reactivating emergency hydraulic pump.
(2) Engage desired hydraulic control lever.
(3) Push HYDRAULIC EMERG. POWER switch and hold (a maximum of five minutes) until hydraulic
function is completed.
(4) Release HYDRAULIC EMERG. POWER switch.
NOTE
If the main hydraulic pump and emergency hydraulic pump
malfunction, provisions have been made to allow for manually
lowering ladder and retracting outriggers. See para (b thru e)
below.
The manual operation of the hydraulic functions is intended only
to permit transportation of the aerial ladder to repair facilities.
b.
Retracting Ladder Sections.
(1) On the aluminum valve block located on top end of
the lower two extension cylinders, loosen the 3/4 inch
lock-nut and remove protection cap. Turn allen screw
out
WARNING
To prevent possible injury, be certain all
personnel are clear of ladder before
retracting ladder.
(2) Move EXTEND/RETRACT hydraulic control lever to
RETRACT position. Ladder will retract.
(3) Unless the ladder is elevated to a high angle, a rope
will have to be used to provide full retraction of ladder
sections.
2-61
TM 5-4210-233-14&P-1
2-15. EMERGENCY AERIAL PROCEDURES - Continued
c. Rotating Ladder Turntable.
WARNING
The ladder must be secured to prevent
rotation of turntable in either direction
before the hydraulic motor and brake
assembly are removed. This prevents the
ladder from rotating out of control when
brake is removed. The guy ropes should be
placed on the lower chords of the ladder
sections.
(1)
Secure ladder with guy ropes to prevent turntable
rotation when brake is removed.
(2)
Remove the hydraulic motor and brake assembly
from planetary drive.
(3)
Use the hand crank provided (located under the
ladder control panel) to align ladder with bed locks.
NOTE
Be sure to position ladder in line with bed
locks; ladder cannot conveniently be lifted
manually.
d.
Lowering Ladder.
(1)
Turn the black knob on the hydraulic hoist manifold
block, located under the step at the base of the
aerial ladder. Turn the knob counterclockwise.
This will slowly lower the ladder.
(2)
To stop lowering the ladder, tighten the black knob.
e.
Raising Outriggers.
(1)
Remove cover on each jack stand. Loosen the two
bolts slowly and evenly, one revolution at a time.
This breaks the seal on the cylinder inlet and allows
oil to be released.
(2)
The outriggers can now be lifted manually.
(3)
Tighten the two bolts. This will keep the outriggers
raised after a vacuum forms in the cylinders.
NOTE
The outriggers can be manually retracted by engaging the
hydraulic valve and pushing in the corresponding outrigger
beam.
2-62
TM 5-4210-233-14&P-1
2-16. OPERATING THE AUXILIARY POWER UNIT (APU)
a. Bleed Fuel System (Initial Start-Up).
(1) Remove the fuel return line located in floor of APU
compartment. Place the fuel return line in a suitable
container.
(2) Operate the priming lever on the fuel transfer pump
until bubbles cease to appear in the fuel.
(3) Connect the fuel return line.
NOTE
If the fuel pump lobe on the camshaft is up, crank
the engine one revolution to permit hand priming.
When finished, return the priming lever to the
disengaged (inward) position.
b. Starting. Check the engine to make sure the fuel system has
been bled and it has been filled with oil. if necessary, prime
the fuel system as described above.
(1) When starting a cold engine in ambient temperatures
above 55°F, preheat with GENERATOR PREHEAT
switch for 20 seconds.
NOTE
Low temperatures may require longer preheating. If
engine fails to start quickly, allow 30 seconds for
starter to cool. Apply preheat for 1 minute, and
repeat starting procedures.
(2) Continue to hold GEN. PREHEAT switch.
(3) Press the GENERATOR START/STOP switch to
start position.
(4) Release the GENERATOR START/STOP switch
after the engine starts and reaches speed.
CAUTION
If oil pressure does not reach operating pressure,
stop engine immediately and troubleshoot. Failure
to heed this caution can result in damage to APU
engine.
(5) Check oil pressure on gauge mounted on APU. Oil
pressure should read approximately 20 psi.
2-63
TM 5-4210-23314&P-1
2-16. OPERATING THE AUXILIARY POWER UNIT (APU) - Continued
c. Stopping.
(1) Push the GENERATOR START-STOP switch to the STOP position.
(2) Release switch when APU engine stops.
(3) If stop circuit fails, close fuel supply valve at APU.
2-17. AFTER MISSION PROCEDURES
a.Flushing of Foam Piping and Hoses. After foam has been used, the foam and water pipes, including fire
hoses and/or nozzles, must be flushed with clean water. If necessary, drain and fill the water tank prior to
flushing.
NOTE
Valves and controls listed are on pump operating panel.
(1) Be sure the FOAM valve is closed. Start the fire pump (see para 2-13).
(2) Fully open the FLUSH valve, WATER valve and FOAM METERING valve on the pump
operating panel.
(3) Regulate pump discharge pressure to 150 psi (1035 kPa) using THROTTLE control.
(4) Open DISCHARGE valves and hose nozzles, including the aerial nozzle, in turn until clean water
discharges from each nozzle.
(5) Close FLUSH and WATER valves.
(6) Shut down the firefighting system.
NOTE
Steps (7) and (8) need only be carried out when the temperature
is less than 32 deg. F (0 deg. C).
(7) Drain residual water from the aerial nozzle, fire pump and hose piping.
8) Install all fire hose and hose nozzles in storage position on the truck. Install all caps.
b. Draining Water and Foam Tanks.
NOTE
Valves and controls listed are on pump operating panel.
(1) To drain the water tank, pull out the TANK DRAIN valve lever. Water may be drained directly
onto the ground.
NOTE
Be sure the TANK DRAIN valve is closed, (lever pushed in)
after draining.
2-64
TM 5-4210-233-14&P-1
2-17. AFTER MISSION PROCEDURES - Continued
(2) To drain the foam tank, open foam tank drain valve.
NOTE
Foam tank drain valve is located inside pump compartment. To
gain access to valve, open priming tank access door on curb
side of vehicle.
Collect the foam concentrate in clean
containers and retain it for subsequent use. Be sure the foam
tank drain valve is closed after draining.
c. Filling the Foam Tank.
(1) Open the foam tank cover and pour foam concentrate into the tank capacity is 30 gal. (114 1).
(2) Close the foam tank cover.
d. Filling the Water Tank.
(1)
(2)
(3)
(4)
Open the tankfill cover.
If the tank is filled through the top opening, any pressurized water supply can be used.
The water tank can be filled via a suction inlet using the pump system.
Monitor the water level gauge and stop when the gauge shows FULL. The truck ignition must be
ON for the indicator to work.
(5) Remove fill hose. Close the tank fill cover.
NOTE
The tank can also be filled via the suction manifold if the fire
pump is running and the TANK FILL AND RECIRCULATE valve
is open. If from draft, use the 6-inch suction ports. If from
pressure supply (e.g., hydrant) use the left side or right side
AUX. SUCTION ports.
oil
e. Filling the Fire Pump Priming Tank. Check the level of fluid in the priming tank. Fill tank with engine
if temperature is above 0 deg. F (-18 deg. C). Use 5W or SAE 5W-20 if temperature is below 0 deg. F
(-18 deg. C).
2-65
TM 5-4210-233-14&P-1
2-18. OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES
2-66
TM 5-4210-233-14&P-1
2-18. OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES - Continued
2-67
TM 5-4210-233-14&P-1
2-18. OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES - Continued
2-68
TM 5-4210-233-14&P-1
2-18. OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES - Continued
2-69
TM 5-4210-233-14&P-1
2-18. OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES - Continued
2-70
TM 5-4210-233-14&P-1
SECTION IV. OPERATION UNDER UNUSUAL CONDITIONS
2-19. OPERATION IN EXTREME COLD
a. After firefighting, remember to drain residual water from all piping as detailed.
b. Be sure that all procedures and lubrication recommendations to maintain the vehicle operational in cold
weather are followed.
WARNING
Doors and access panels may freeze shut and walking surfaces
become slippery and hazardous from formation of ice in freezing
weather. Be sure that all ice is removed as quickly as possible.
2-20. OPERATING IN EXTREME HEAT
a. When operating in a very hot environment, pay extra attention to the engine and transmission
temperature and oil pressure gauges. Open ENGINE COOLER valve handle located above PRIMER
valve handle on pump panel when pumping.
b. Be sure that lubricant and coolant recommendations for operation under extreme heat conditions are
followed.
2-21. OPERATION IN AREAS WITH SALT AIR AND MIST
a. In areas where salt air and sea spray are common, measures must be taken to protect the vehicle from
corrosion. Use wax and/or other surface protection agents frequently on painted and chrome plated
surfaces. Coat all other exposed metallic surfaces with protective oil as necessary.
b. If salt water is used for firefighting, the firefighting system, including ail hoses used, should be flushed
with potable water on return to base.
CAUTION
The pump is designed for use with fresh water. Therefore, if salt
water is used, the pump must be flushed with fresh water to
prevent corrosion of pump components.
2-22. OPERATION IN SNOW
a. Operating in areas with heavy snowfall can cause problems unless walkways, hose beds, and control
equipment are continuously cleared of snow. If not cleared frequently, the equipment including exposed
controls may become difficult to operate.
b. When driving through deep snow or snow banks, engage the interaxle differential lock.
2-71
TM 5-4210-233-14&P-1
2-23.
OPERATION IN MUDDY AND SWAMPY AREAS
a. When traveling off-road in rough terrain, water holes, ditches, creeks, and swampy areas may be
negotiated. This will cause a build-up of dirt and debris on the vehicle. Be sure to thoroughly clean the
truck immediately after the mission.
b. Engage the interaxle differential lock to maintain traction before negotiating rough terrain.
2-24. OPERATION IN DUST PRONE AREAS. In areas where dust and sand storms are frequent, extra
attention must be paid to lubrication and maintenance of the vehicle. This includes checking or replacing
filters and cleaning inside the engine compartment and pump body. Removal of gritty dust from
components such as valves and control lever linkages and other moving parts is essential. Unless
removed, fine dust may cause excessive component wear.
2-25. OPERATION IN HIGH ALTITUDES. Normally, operation in higher altitudes will cause loss of engine
power; however, since the truck is equipped with a turbocharged engine, this loss will not be appreciable.
2-72
TM 5-4210-233-14&P-1
CHAPTER 3
OPERATOR MAINTENANCE INSTRUCTIONS
Contents
Para
LUBRICATION ..............................................................................................................3-1
SYMPTOM INDEX ........................................................................................................3-2
PRIMING TANK ............................................................................................................3-3
WINDSHIELD WIPER ...................................................................................................3-4
BATTERIES ..................................................................................................................3-5
RADIATOR/COOLING SYSTEM ...................................................................................3-6
TIRES AND RIMS .........................................................................................................3-7
POWER STEERING RESERVOIR................................................................................3-8
APU AIR CLEANER ......................................................................................................3-9
3-1
Page
3-2
3-10
3-22
3-23
3-24
3-25
3-27
3-28
3-29
TM 5-4210-233-14&P-1
SECTION 1. LUBRICATION INSTRUCTIONS
3-1. LUBRICATION INSTRUCTIONS
NOTE
These instructions are mandatory
Table 3-1. Lubrication Chart -Truck
ITEM
NO.
TASK
LUBRICATION
POINTS
LUBRICANT
ITEM NO.
(APPENDIX E)
INTERVAL: After Each Mission
1
Check Engine Oil Level
NA
20 (Add AR)
2
Check Transmission Oil
Level
NA
12 or 16 (Add AR)
3
Check Power Steering
Fluid Level
NA
21 (Add AR)
4
Check Priming Tank Oil
Level
NA
20 (Add AR)
INTERVAL: After every 150 hours of operation or quarterly, whichever comes florist.
5
Lube Slack Adjuster
4
15 (One pump)
6
Lube U-Joints
6
15 (One pump)
7
Lube Steering Column
1
15 (One pump)
8
Lube Draglink
2
15 (One pump)
9
Lube Leaf Springs
8
15 (One pump)
10
Lube Miter Box
1
15 (One pump)
3-2
TM 5-4210-233-14&P-1
Table 3-1. Lubrication Chart - Truck - Continued
3-3
TM 5-4210-233-14&P-1
Table 3-1. Lubrication Chart - Truck - Continued
ITEM
NO.
TASK
LUBRICATION
POINTS
LUBRICANT
ITEM NO.
(APPENDIX E)
INTERVAL: After 150 hours of operation or quarterly, whichever comes florist - Continued
11
Lube Brake Linkage
(Front)
4
15 (One pump)
12
Lube Brake Linkage
(Rear)
4
15 (One pump)
13
Lube Kingpins
4
15 (One pump)
14
Lube Tie Rod Ends
2
15 (One pump)
15
Lube Steering Shaft
3
15 (One pump)
16
Lube Rear Suspension
2
15 (One pump)
17, 18
Change Engine Oil and
Filter
NA
20 (Fill to level)
21
Check Oil Level In
Front Wheel Bearings
2
20 (Add AR)
INTERVAL: After every 1500 hours of operation or annually, whichever comes florist.
19, 20
Change Main Transmission
Oil and Filter
21
Change Oil in Front
Wheel Bearings
3-4
NA
12, 13 or 14 (Fill to level)
2
30 (Fill to level)
TM 5-4210-233-14&P-1
Table 3-1. Lubrication Chart - Truck - Continued
3-5
TM 5-4210-233-14&P-1
Table 3-2. Lubrication Chart - Aerial
ITEM
NO.
TASK
LUBRICATION
POINTS
LUBRICANT
ITEM NO.
(APPENDIX E)
INTERVAL: After Every 10 Hours of Operation, or Monthly (Whichever Comes First).
2
Ladder Pivot
2
18 (One pump)
3
Upper Hoist Cylinder
Pivot
2
18 (One shot)
4
Lower Hoist Cylinder
Pivot
2
18 (One shot)
6
Rear Base Section
Sheaves
2
17 (One shot)
7
Rear Lower-Mid Section
Sheaves
2
17 (One shot)
8
Rear Upper-Mid Section
Sheaves
2
17 (One shot)
9
Front Base Section
Sheaves
2
17 (One shot)
10
Front Lower-Mid Section
Sheaves
2
17 (One shot)
11
Front Upper-Mid Section
Sheaves
2
17 (One shot)
12
Extension Cylinder Butt
Sheaves
2
17 (One shot)
13
Extension Traveling Block
Sheaves
2
17 (One shot)
14
Extension Traveling Block
Guides
NA
17 (Light coating)
15
Base Section Water Pipe
Wear Pad
1
17 (One shot)
16
Lower-Mid Section Water Pipe
Wear Pad
1
17 (One shot)
17
Upper-Mid Section Water Pipe
Wear Pad
1
17 (One shot)
18
Monitor Horizontal
Movement Pivot
2
17 (One shot)
3-6
TM 5-4210-233-14&P-1
Table 3-2. Lubrication Chart - Aerial - Continued
3-7
TM 5-4210-233-14&P-1
Table 3-2. Lubrication Chart - Aerial - Continued
ITEM
NO.
TASK
LUBRICATION
POINTS
LUBRICANT
ITEM NO.
(APPENDIX E)
INTERVAL: After Every 10 Hours of Operation, or Monthly (Whichever Comes First) - Continued
19
Lower-Mid Section
Top of Retaining Tube
and Bottom of Lower Chord
NA
17 (Light coating)
20
Upper-Mid Section
Top of Retaining Tube
and Bottom of Lower Chord
NA
17 (Light coating)
21
Fly Section
Top of Retaining Tube
and Bottom of Lower Chord
NA
17 (Light coating)
22
Base Section Ladder Guides
NA
17 (Light coating)
23
Lower-Mid Section Ladder
Guides
NA
17 (Light coating)
24
Upper-Mid Section Ladder
Guides
NA
17 (Light coating)
INTERVAL: After Every 50 Hours of Operation, or Quarterly (Whichever Comes First)
5A
Swing Unit (Pinion Gear)
1
1 (Medium coating)
-
Extension and Retraction
Cables
NA
20 (A light coatapprox. 2% of cables'
weight of lubricant)
INTERVAL: After Every 1 00 Hours of Operation or Semi-Annually (Whichever Comes First)
1
Turntable Bearing
3
18 (4 pumps)
5B
Swing Unit (Planetary Speed
Reducer)
1
19 (Fill AR)
5C
Swing Unit (Bearing in Unit)
1
18 (2 shots)
3-8
TM 5-4210-233-14&P-1
Table 3-2. Lubrication Chart - Aerial - Continued
3-9
TM 5-4210-233-14&P-1
SECTION II. OPERATOR TROUBLESHOOTING PROCEDURES
3-2. SYMPTOM INDEX. Troubleshooting at the operator level requires you to locate any trouble as quickly as
possible. Once the trouble Is located, perform the corrective action required. If the malfunction Is not listed,
notify your supervisor. Refer to Table 3-3, OPERATOR TROUBLESHOOTING under the number against the
system in this Index to determine the test and corrective action required.
SYMPTOM
Page No.
APU
FAILS TO CRANK .............................................................................................................................. 3-12
CRANKS BUT WILL NOT START .................................................................................................... 3-12
RUNNING UNEVEN AND STALLS FREQUENTLY ............................................................................ 3-12
FIRE PUMP
WILL NOT PRIME .............................................................................................................................. 3-13
WILL NOT ENGAGE .......................................................................................................................... 3-13
VALVES
AIR OPERATED VALVE FAILS TO OPEN OR CLOSE...................................................................... 3-14
VALVES LEAKING WATER/AGENT .................................................................................................. 3-14
WATER PIPING
WATER/AGENT REMAINS IN PIPING AFTER DRAIN OPENED ...................................................... 3-14
DISCHARGE HOSE
WON'T DE-PRESSURIZE.................................................................................................................. 3-14
FOAM DISCHARGE
NO FOAM DISCHARGE AT ANY NOZZLE ........................................................................................ 3-15
WATER TANK
FOAM ENTERING WATER TANK ..................................................................................................... 3-15
FOAM TANK
WATER ENTERING FOAM TANK ..................................................................................................... 3-15
AIR SYSTEM
ALARM SOUNDINGS......................................................................................................................... 3-16
LIGHTS
FAIL TO OPERATE............................................................................................................................ 3-16
3-10
TM 5-4210l233-14&P-1
3-2.SYMPTOM INDEX - Continued
STEERING
WHEEL STEERING HARD IN ONE OR BOTH DIRECTIONS ............................................................ 3-17
ERRATIC STEERING OR NO STEERING AT ALL ............................................................................ 3-17
TRANSMISSION
OVERHEATING .................................................................................................................................3-17
ENGINE
STARTER WILL NOT CRANK MAIN ENGINE ................................................................................... 3-17
CRANKS BUT WILL NOT START ...................................................................................................... 3-18
DIFFICULTY IN STARTING ............................................................................................................... 3-18
STARTS THEN STOPS...................................................................................................................... 3-18
RUNS UNEVENLY OR STALLS FREQUENTLY ................................................................................ 3-19
WILL NOT REACH WORKING TEMPERATURE ............................................................................... 3-19
OVERHEATING WHEN PUMPING .................................................................................................... 3-19
ENGINE FOOT THROTTLE WILL NOT OPERATE............................................................................ 3-20
EXCESSIVE BLACK OR GREY EXHAUST SMOKE .......................................................................... 3-20
TIRES
EXCESSIVE WEAR ........................................................................................................................... 3-20
BRAKES
BRAKE SHOES SMELL OF BURNING .............................................................................................. 3-20
BRAKE GRAB OR TRUCK PULLS TO ONE SIDE ............................................................................. 3-21
BRAKES OPERATE SLOWLY OR ERRATICALLY............................................................................ 3-21
PARKING BRAKES
WILL NOT RELEASE......................................................................................................................... 3-21
3-11
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
APU
1
APU FAILS TO CRANK
Step 1. Check for battery switch in cab set to OFF.
Set battery switch to BOTH.
Step 2. Check for batteries low on charge.
Charge batteries.
2
APU CRANKS BUT WILL NOT START
Step 1. Check for empty fuel tank.
Refuel vehicle.
Step 2. Check for intake air too cold to enable initial combustion.
Use manifold preheater (see para 2-16 .).
3
APU RUNNING UNEVEN AND STALLS FREQUENTLY
Step 1. Check for almost empty fuel tank.
Refuel vehicle.
Step 2. Check for truck batteries low on charge making alternator hard to drive.
a.
Start main engine to charge truck batteries.
b.
If main engine won't start, refer to Unit Maintenance.
3-12
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIRE PUMP
1
FIRE PUMP WILL NOT PRIME
Step 1. Check all discharge valves are closed.
Close all discharge valves.
Step 2. Check all suction caps fitted to suction ports not being used.
Replace all suction caps.
Step 3. Check fluid level in priming reservoir.
Refill priming reservoir.
Step 4. Check suction hose screen (if pumping from draft) is below water level.
Push screen well below surface.
Step 5. Check condition of suction hose and connection (if pumping from draft).
Tighten connections or replace hose as required. Refer to Unit Maintenance for repair.
Step 6. Check if TANK DISCHARGE valve open, if pumping from tank.
Open valve.
Step 7. Check water level in tank, if pumping from tank.
Refill tank as required.
2
FIRE PUMP WILL NOT ENGAGE
Step 1. Check correct switching sequence has been carried out.
Carry out correct switching sequence (see para 2-13 .).
Step 2. Check for MANUAL PUMP SHIFT control is in driving position.
Push control in for pumping position.
3-13
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
VALVES
1
AIR OPERATED VALVE FAILS TO OPEN OR CLOSE
Step 1. Check correct switching sequence.
Carry out correct switching sequence (see para 2-13 .).
Step 2. Check air leaking from switch or valve connections.
Tighten connection.
2
VALVES LEAKING WATER/AGENT
Check that ail valves are not closed.
Close valves.
WATER PIPING
1
WATER/AGENT REMAINS IN PIPING AFTER DRAIN OPENED
Check drain valve outlet.
Clean dirt/blockage from drain hole.
DISCHARGE HOSE
1
DISCHARGE HOSE WON'T DE-PRESSURIZE
Check drain valve.
Clean dirt/blockage from drain hole.
3-14
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FOAM DISCHARGE
1
NO FOAM DISCHARGE AT ANY NOZZLE
Step 1. Check if FOAM valve set open.
Set FOAM valve to open.
Step 2. Check it foam METERING VALVE closed.
Set foam METERING VALVE to required percentage (see para 2-13 .).
Step 3. Check if foam tank empty or contents diluted.
Drain tank and/or refill tank as required.
WATER TANK
1
FOAM ENTERING WATER TANK
Check if WATER valve is closed.
Close valve.
FOAM TANK
8
WATER ENTERING FOAM TANK
Check FOAM valve is closed.
Close valve.
3-15
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEM
1
AIR SYSTEM ALARM SOUNDING
Step 1. Check ail reservoir drain valves are closed.
Close drain valves.
Step 2. Check engine has been running for at least 5 minutes.
Check pressure after 5 minutes.
NOTE
If brakes have been operated excessively, allow pressure to
recover before proceeding.
LIGHTS
1
ANY LIGHT FAILS TO OPERATE
Step 1. Check if switch is ON.
Set switch to ON.
NOTE
Some lights require ignition switch ON, others require only
battery switch ON.
Step 2. Check that ignition switch in ON.
Some lights require ignition switch in ON, others require only battery switch ON.
3-16
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEERING
1
WHEEL STEERING HARD IN ONE OR BOTH DIRECTIONS
Check tire pressures.
Inflate tires to correct pressure.
2
ERRATIC STEERING OR NO STEERING AT ALL
Check steering system reservoir level.
Add power steering fluid as required.
TRANSMISSION
1
TRANSMISSION OVERHEATING
Step 1. Check if low fluid level.
Add transmission fluid as required.
Step 2. Check engine coolant level.
Add coolant as required.
Step 3. Check if gear range selected is too high.
Select lower gear.
ENGINE
1
STARTER WILL NOT CRANK MAIN ENGINE
Step 1. Check battery switch set to Position 1, 2 or BOTH.
Set battery switch to Position 1, 2 or BOTH.
Step 2. Check if ignition switch ON.
Set ignition switch to ON.
3-17
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
2
ENGINE CRANKS BUT WILL NOT START
Check fuel gauge for low fuel level.
Fill fuel tank as required.
3
ENGINE IS DIFFICULT TO START
Step 1. Check battery switch set to Position 1, 2 or BOTH.
Set battery switch to Position 1, 2 or BOTH.
Step 2. Check fuel grade.
Drain and refill tank with correct fuel.
Step 3. Check for water in fuel.
Change fuel filters.
4
ENGINE STARTS THEN STOPS
Step 1. Check fuel gauge for low fuel level.
Fill tank as required.
Step 2. Check fuel grade.
Drain fuel tank and refill with correct fuel.
Step 3. Check fuel lines for crimping or leaks.
Refer to Unit Maintenance for repair.
3-18
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
5
ENGINE RUNS UNEVENLY OR STALLS FREQUENTLY
Step 1. Check for low coolant temperature on WATER TEMP gauge in cab.
Allow engine to reach normal operating temperature.
Step 2. Check fuel level.
Refill fuel tank.
Step 3. Check fuel grade.
Drain fuel tank and refill with correct clean fuel.
6
ENGINE WILL NOT REACH WORKING TEMPERATURE
Check ENGINE COOLER valve on pump panel is OFF.
Close ENGINE COOLER control valve.
7
ENGINE IS OVERHEATING WHEN PUMPING
Step 1. Check if ENGINE COOLER valve is closed.
Open ENGINE COOLER valve to reduce engine coolant temperature'.
Step 2. Check engine coolant level in radiator.
Add coolant if level is low.
NOTE
If engine coolant is continually lost, refer to Unit Maintenance for
repair.
Step 3. With engine off, check for debris in front of radiator.
Remove debris.
3-19
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
8
ENGINE FOOT THROTTLE WILL NOT OPERATE
Check wires and plugs connecting foot throttle to engine.
If wiring is damaged refer to Unit Maintenance for repair.
9
EXCESSIVE BLACK OR GREY EXHAUST SMOKE
Step 1. Check fuel grade.
Drain fuel tank and refill with correct fuel.
Step 2. Check if engine is overloaded.
Reduce speed and select lower gear range.
TIRES
1
EXCESSIVE TIRE WEAR
Step 1. Check tire pressure.
Inflate to correct pressure.
Step 2. Check that differential lock is not engaged.
Be sure differential lock is engaged only when on slippery ground or operating off road.
BRAKES
CAUTION
Truck brakes that have been applied for a long period, applied
harshly due to hill descent, or for emergency stop, may
overheat. Change to lower gear range when possible.
1
BRAKE SHOES SMELL OF BURNING
Check if brake drums have foreign material inside, e.g., sand or mud.
Hose down brake drums when cool to touch. Be sure all material is removed.
3-20
TM 5-4210-233-14&P-1
Table 3-3. Operator Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
BRAKES - Continued
2
BRAKES GRAB OR TRUCK PULLS TO ONE SIDE
Step 1. Ride brakes for 100 yards to check if there is water in the hubs.
This will dry shoes and drums.
Step 2. Check tire pressures.
Inflate tires to correct pressure.
Step 3. Check that linings are clean.
Refer to Unit Maintenance if covered in oil or grease.
3
BRAKES OPERATE SLOWLY OR ERRATICALLY
Step 1. Check air system pressures.
Allow air system to recharge.
Step 2. Check air lines and brake valves for leaks.
Refer to Unit Maintenance.
Step 3. Check tire pressure.
Inflate tires to correct pressure.
PARKING
17
PARKING BRAKES WILL NOT RELEASE
Check if secondary air pressure is low.
Release parking brakes by pushing emergency release button and holding it in until secondary
air reaches 65 psi (450 kPa).
3-21
TM 5-4210-233-14&P-1
SECTION III. OPERATOR MAINTENANCE PROCEDURES
3-3. PRIMING TANK
This task covers:
a. Inspection
b. Service
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Oil, SAE 40 (Item 20, Appendix E)
Oil, SAE 5W (Item 59, Appendix E)
Oil, SAE 5W-20 (Item 60, Appendix E)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Inspection.
(1) Check that tank (4) is securely mounted and not corroded or
leaking.
CAUTION
Do not enlarge either hole referred to in step (2).
(2) Check that hole in filler cap (1) and hole in top of elbow (2)
in priming tank are not plugged. Open (clean) holes, if
plugged.
(3) Check that gasket (3) in filler cap (1) is in place and not
damaged or deteriorated.
b. Service.
NOTE
•
•
At temperatures above 40°F, use same weight and type of oil
(SAE 40) used in truck engine.
At 0°F or below, use 5W or SAE 5W-20 engine oil in primer
tank. Heavier oils are not suitable at low temperatures.
(1) Remove filler cap (1) and check oil level in tank (4).
(2) Add oil as necessary.
3-22
TM 5-4210-233-14&P-1
3-4. WINDSHIELD WIPER BLADES
This task covers:
Service
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Blade, Wiper (Fig. F-48, Appendix F)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Service.
(a)
(b)
(c)
(d)
(e)
(f)
Depress clip (1) to release blade.
Push blade up arm (2).
Pull blade off arm end.
Install new blade assembly.
Push hole in blade over arm end.
Pull blade until hook locks into position.
3-23
TM 5-4210-233-14&P-1
3-5. BATTERIES
This task covers:
a. Inspection
b. Service
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Distilled Water (Item 54, Appendix E)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
a. Inspection.
WARNING
Batteries contain sulfuric acid. They may also contain explosive
mixtures of hydrogen and oxygen gases in each cell at all times.
To avoid serious injury, always wear face shield, goggles,
safety shoes, gloves and protective clothing when working with
batteries. Keep sparks, flames, burning cigarettes or other
ignition sources away at all times.
(1) Visually inspect outside of battery for cracked or broken case cover, damaged or missing filler caps and
terminal damage.
(2) Check condition of battery cables. Inspect for corrosion on battery terminals and cable terminations.
Clean minor corrosion off terminals and cable terminations using scraper and terminal cleaning
brush.
(3) Make sure ground cable makes good connection at ground point, and check cable connections at starter
relay and solenoid. Tighten if necessary.
(4) Make sure holddown bar secures battery properly. Tighten
if necessary.
(5) If there is serious physical damage, refer to Unit
Maintenance.
b.
Service. Check Electrolyte Levels.
NOTE
Check electrolyte level weekly. Water loss occurring at above
normal rate indicates short circuit.
(1) Remove filler caps (1) from battery.
(2) Check electrolyte level in each cell. If electrolyte is below tops of plates in any cell, fill all cells with
water to just above tops of separators. Use distilled water (Item 54, Appendix E).
(3) Install filler caps (1).
3-24
TM 5-4210-233-14&P-1
3-6. RADIATOR/COOLING SYSTEM
This task covers:
Service
MATERIAL/PARTS REQUIRED
Antifreeze, Permanent, Item 29, Appendix E
EQUIPMENT CONDITION
Main Engine Shutdown (para 2-12 .)
APU Shutdown (para 2-16 .)
Batteries Disconnected (para 4-114 .)
Engine Enclosure Covers Open
Service.
CAUTION
Never put coolant in a hot engine. The engine block or cylinder
head can be cracked due to difference in temperature between
engine block or cylinder head and coolant.
Add coolant to radiator only when engine is stopped or idling.
NOTE
Clean cooling system every 2000 hours of operation or once
every year. in areas where water has a high mineral content,
clean cooling system more frequently.
(a)
Operate vehicle until engine is warm. Park vehicle on level surface, apply parking brake, and
shut down engine.
WARNING
To remove radiator cap when engine is hot,
turn radiator cap slowly with a glove or rag to
first stop position to relieve pressure before
removing cap. This will prevent painful bums.
(b)
Using a glove or rag to prevent burns, slowly
turn radiator cap (1)
counterclockwise to first
stop position to relieve system pressure, and
after system pressure
is safely relieved
remove radiator cap (1).
NOTE
Cooling system has a capacity of 13.8 gallons (52I)
(c)
Open radiator drain cock (2) and drain coolant
into
suitable
container.
3-25
TM 5-4210-233-14&P-1
3-6. RADIATOR/COOLING SYSTEM - Continued
(d) Open cylinder block drain cocks on each side of cylinder block at rear, below exhaust manifolds and at
front of engine.
(e) Open oil cooler housing drain cock at extreme bottom.
(f) Close radiator drain cock (2), cylinder block drain cocks, and oil cooler housing drain cock.
(g) Fill radiator with soft clean water and install radiator cap (1).
(h) Reconnect batteries (para 4-114). Start and run main engine for 15 minutes.
(i) Shut down main engine.
(j) Open radiator drain cock (2), engine block drain cocks, and oil cooler housing drain cock, and drain
water.
(k) Close radiator drain cock (2), engine block drain cocks, and oil cooler housing drain cock.
WARNING
Compressed air used for cleaning and drying purposes will not
exceed 30 psi. Use only with effective chip guarding and
personal protective equipment.
(I) Using compressed air, clean exterior of radiator and remove foreign matter obstructing passage of air.
(m) Remove radiator cap.
(n) Fill radiator with solution of 50 percent water and 50 percent permanent antifreeze (Item 29,
Appendix E).
NOTE
Radiator is full when coolant is visible through sight glass (3).
(o) Install radiator cap (1).
(p) Start and run main engine at 1/2 throttle for approximately 5 minutes. Check for coolant leak at drain
cock (2), and tighten if necessary.
(q) Stop main engine after 30 minutes and check coolant level through sight glass (3).
WARNING
To remove radiator cap when engine is hot, turn radiator cap
slowly with a glove or rag to first stop position to relieve pressure
before removing cap. This ill prevent painful burns.
(r) Add coolant as needed.
3-26
TM 5-4210-233-14&P-1
3-7. TIRES AND RIMS
This task covers:
Service
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Service.
(a) Check tire pressure.
NOTE
Proper tire pressure is 130 psi (175 kPa) (front) and 110 psi (148
kPa) (rear).
(b) Add or remove air from tires as needed.
(c) Check tire tread for rocks, nails, etc.
(d) Remove debris from tire tread.
(e) Clean rims with wire brush if scale is present.
3-27
TM 5-4210-233-14&P-1
3-8. POWER STEERING RESERVOIR
This task covers:
Service
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Automatic Transmission Fluid (Item 12, Appendix E)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Service.
(a) Start and run main engine until it reaches normal operating temperature.
(b) Shut down main engine and open streetside engine enclosure cover.
(c) Turn dipstick handle (1) counterclockwise until dipstick plug (2) an be removed.
(d) Remove dipstick (3) and check fluid level.
(e) Add power steering fluid (Item 12, Appendix E) to reservoir through dipstick port as needed.
(f) Wipe oil from dipstick plug and reinstall dipstick (3). Turn dipstick handle (1) clockwise until
secure.
3-28
TM 5-4210-233-14&P-1
3-9. APU AIR CLEANER
This task covers:
a. Service
b. Follow-on Maintenance
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Solvent (Item 3, Appendix E)
Oil (Item 14, Appendix E)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 ).
a. Service.
(1)
Remove two wing nuts (1) and air cleaner cover (2).
(2)
Remove foam filter (3) and mesh filter (4) from bracket (5).
(3)
Inspect filters for damage. Replace filters as needed.
(4)
Wash foam filter (3) in solvent (item 3, Appendix E) or diesel fuel.
(5)
Dip foam filter in clean oil (item 14, Appendix E) of same viscosity and grade as APU crankcase
oil.
6)
Squeeze dry foam filter.
(7)
Clean mesh filter by tapping it on hard surface. If excessive dirt still remains, replace mesh filter.
(8)
Assemble mesh filter (4), foam filter (3), and install on bracket (5).
(9)
Install air cleaner cover (2) and secure with two wing nuts (1).
b. Follow-on Maintenance
(1)
Connect batteries (see para 4-114).
3-29/(3-30 Blank)
TM 5-4210-233-14&P-1
CHAPTER 4
UNIT MAINTENANCE
Contents
Para
Page
COMMON TOOLS AND EQUIPMENT ................................................................ 4-1
SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT .................................... 4-2
REPAIR PARTS .................................................................................................. 4-3
INTRODUCTION ................................................................................................. 4-4
GENERAL (Section III) ........................................................................................ 4-5
GENERAL (Section IV)........................................................................................ 4-6
PROCEDURES ................................................................................................... 4-7
SYMPTOM INDEX .............................................................................................. 4-8
GENERAL MAINTENANCE PROCEDURES ....................................................... 4-9
HARD SUCTION HOSES .................................................................................... 4-10
SOFT SUCTION HOSES .................................................................................... 4-11
PUMP PANEL LIGHTS........................................................................................ 4-12
COMPARTMENT LIGHTS .................................................................................. 4-13
STEP LIGHTS ..................................................................................................... 4-14
CROSSLAY HOSE BIN DIVIDERS...................................................................... 4-15
CROSSLAY HOSE BIN ROLLERS...................................................................... 4-16
GAUGES-CROSSLAY, DISCHARGE, PUMP PRESSURE AND VACUUM ......... 4-17
GAUGES-ENGINE STATUS ............................................................................... 4-18
WATER TANK LEVEL GAUGE........................................................................... 4-19
TACHOMETER ................................................................................................... 4-20
PUMP PANEL INDICATOR LIGHTS ................................................................... 4-21
PUMP PANEL TOGGLE SWITCHES .................................................................. 4-22
ENGINE COOLER VALVE .................................................................................. 4-23
PRIMER CABLE.................................................................................................. 4-24
STREET SIDE OPERATOR'S PANEL ................................................................ 4-25
CURB SIDE OPERATOR'S PANEL..................................................................... 4-26
THROTTLE CONTROL ....................................................................................... 4-27
GAUGE PANEL ENCLOSURE............................................................................ 4-28
RUNNING BOARDS............................................................................................ 4-29
PULL-OUTTREAD PLATE .................................................................................. 4-30
FOAM METERING VALVE (PROPORTIONER) .................................................. 4-31
METERING VALVE DRAIN ................................................................................. 4-32
EDUCTOR........................................................................................................... 4-33
OPERATING RODS ............................................................................................ 4-34
RELIEF VALVE ................................................................................................... 4-35
RELIEF VALVE PILOT ASSEMBLY ................................................................... 4-36
Y-STRAINER AND 1-1/2" CHECK VALVE........................................................... 4-37
Y-STRAINER DRAIN VALVE............................................................................... 4-38
#1, #2 AND AERIAL DISCHARGE DRAIN VALVES............................................ 4-39
FLUSH VALVE .................................................................................................... 4-40
FOAM VALVE ..................................................................................................... 4-41
WATER VALVE................................................................................................... 4-42
#1 CROSSLAY VALVE........................................................................................ 4-43
#2 CROSSLAY VALVE........................................................................................ 4-44
#1, #2, #3 AND #4 DISCHARGE VALVES .......................................................... 4-45
TANK FILL AND RECIRCULATING VALVE ....................................................... 4-46
AERIAL DISCHARGE VALVE ............................................................................. 4-47
TANK DRAIN VALVE .......................................................................................... 4-48
4-1
4-5
4-5
4-5
4-5
4-10
4-18
4-18
4-18
4-146
4-160
4-161
4-162
4-164
4-166
4-167
4-168
4-169
4-170
4-173
4-175
4-177
4-179
4-180
4-181
4-182
4-190
4-192
4-193
4-194
4-195
4-196
4-198
4-200
4-202
4-203
4-204
4-206
4-208
4-210
4-212
4-216
4-220
4-224
4-229
4-234
4-238
4-242
4-246
TM 5-4210-233-14&P-1
Contents
Para
TANK DISCHARGE VALVE ................................................................................ 4-49
PUMP DRAIN VALVE ......................................................................................... 4-50
FRONT SUCTION VALVE................................................................................... 4-51
DRIVER'S SIDE AUXILIARY SUCTION VALVE .................................................. 4-52
#3 AND #4 DISCHARGE DRAIN VALVES........................................................... 4-53
SUCTION DRAIN VALVES ................................................................................. 4-54
FOAM TANK DRAIN VALVE ............................................................................... 4-55
DISCHARGE CONNECTIONS/CHROME ADAPTERS ....................................... 4-56
PRIMING PUMP .................................................................................................. 4-57
PRIMING PUMP MOTOR .................................................................................... 4-58
PRIMING PUMP TUBING .................................................................................. 4-59
PRIMING PUMP OIL TANK ................................................................................ 4-60
REAR STROBE LIGHT. ...................................................................................... 4-61
REAR STROBE LIGHT POWER SUPPLY .......................................................... 4-62
HOSE BED FLOODLIGHT .................................................................................. 4-63
BACK-UP LIGHTS............................................................................................... 4-64
STOP, TURN AND TAIL LIGHTS ....................................................................... 4-65
REAR SCENE LIGHT.......................................................................................... 4-66
BACK-UP ALARM ............................................................................................... 4-67
WARNING BUZZER PUSH BUTTONS .............................................................. 4-68
CLEARANCE MARKER LIGHTS ........................................................................ 4-69
HANDRAILS ....................................................................................................... 4-70
UPPER AND LOWER COMPARTMENT DOORS ............................................... 4-71
COMPARTMENT DOOR HOLD-OPEN SPRINGS ............................................. 4-72
REAR ROLL-UP DOOR ...................................................................................... 4-73
AIR BOTTLE RACK AND SLIDE TRAY .............................................................. 4-74
WATER TANK LEVEL SENDING UNIT............................................................... 4-75
CAB ROOF PANEL ............................................................................................ 4-76
CAB DOORS....................................................................................................... 4-77
DOOR GLASS..................................................................................................... 4-78
WINDSHIELD ..................................................................................................... 4-79
MIRRORS .......................................................................................................... 4-80
HEADLIGHTS .................................................................................................... 4-81
DIRECTIONAL MARKER LIGHTS....................................................................... 4-82
WARNING LIGHTS ............................................................................................ 4-83
CAB SPOTLIGHTS . ........................................................................................... 4-84
ROOF BEACON LIGHT ...................................................................................... 4-85
SIREN AND PA SYSTEM ................................................................................... 4-86
AIR HORNS ....................................................................................................... 4-87
CAB SUNROOFS ............................................................................................... 4-88
CAB ROOF VENT FAN ...................................................................................... 4-89
LADDER LOCK LIGHT........................................................................................ 4-90
MECHANICAL SIREN ........................................................................................ 4-91
CAB EXTERIOR TRIM ........................................................................................ 4-92
CAB INSTRUMENT PANEL GAUGES ................................................................ 4-93
CAB INSTRUMENT PANEL SWITCHES............................................................. 4-94
CAB INSTRUMENT PANEL INDICATOR LIGHTS ............................................. 4-95
WARNING BUZZER................................... ......................................................... 4-96
CAB DOME LIGHTS.................................. ......................................................... 4-97
DASHBOARD COMPARTMENT DOORS ........................................................... 4-98
CIRCUIT BREAKERS ......................................................................................... 4-99
TRANSMISSION SHIFTCONTROL ..................................................................... 4-100
BATTERY SELECTOR SWITCH ........................................................................ 4-101
4-2
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TM 5-4210-233-14&P-1
Contents
Para
HEATER CONTROL HEAD ASSEMBLY ............................................................ 4-102
HEATER VALVE ................................................................................................. 4-103
HEATER/DEFROSTER ...................................................................................... 4-104
DRIVER'S SEAT ................................................................................................. 4-105
PASSENGERR AND STATIONARY JUMP SEATS............................................. 4-106
FOLD-DOWN JUMP SEAT ................................................................................. 4-107
SEAT BELTS....................................................................................................... 4-108
WINDSHIELD WASHER PUMP .......................................................................... 4-109
WINDSHIELD WASHER RESERVOIR................................................................ 4-110
WINDSHIELD WIPER MOTOR ........................................................................... 4-111
WINDSHIELD WIPER ARMS ............................................................................. 4-112
BATTERY ISOLATOR ........................................................................................ 4-113
BATTERIES ....................................................................................................... 4-114
BATTERY BOX ASSEMBLY ............................................................................... 4-115
BATTERY CHARGE RECEPTACLE ................................................................... 4-116
110 VAC, 60 HZ RECEPTACLES........................................................................ 4-117
AERIAL CIRCUIT ON/OFF SWITCH ................................................................... 4-118
110 VAC, 60 HZ CIRCUIT BREAKERS ............................................................... 4-119
12 VDC/110 VAC RELAYS.................................................................................. 4-120
12 VDC IN-LINE FUSE ....................................................................................... 4-121
CURRENTTRANSFORMER ............................................................................... 4-122
AC AMMETERS AND VOLTMETERS ................................................................ 4-123
PORTABLE WORK LIGHTS (110 VAC).............................................................. 4-124
ENGINE ENCLOSURE INSULATION ................................................................. 4-125
ENGINE ENCLOSURE LATCHES ...................................................................... 4-126
ENGINE ENCLOSURE PANELS AND HINGES .................................................. 4-127
ENGINE AIR CLEANER ASSEMBLY ................................................................. 4-128
ENGINE ASSEMBLY........................................................................................... 4-129
FUEL FILTERS ................................................................................................... 4-130
FAN BELT ........................................................................................................... 4-131
FAN..................................................................................................................... 4-132
ALTERNATOR ................................................................................................... 4-133
ENGINE STARTING AID .................................................................................... 4-134
ALTERNATOR BELT........................................................................................... 4-135
THERMOSTATS ................................................................................................ 4-136
THERMOSTATHOUSINGS ................................................................................ 4-137
ENGINE SENDING UNITS ................................................................................. 4-138
ENGINE OIL DIPSTICK ASSEMBLY/FILLER TUBE............................................ 4-139
ROCKER ARM COVERS .................................................................................... 4-140
RADIATOR HOSES AND PIPING ....................................................................... 4-141
TRANSMISSION ................................................................................................ 4-142
TIRES AND RIMS ............................................................................................... 4-143
FRONT WHEEL HUBS, BEARINGS AND SEALS............................................... 4-144
PARKING BRAKE CONTROL VALVES............................................................... 4-145
SLACK ADJUSTER............................................................................................. 4-146
AIR LINES AND PIPING ..................................................................................... 4-147
IN-LINE SINGLE CHECK VALVES...................................................................... 4-148
DOUBLE CHECK VALVES.................................................................................. 4-149
QUICK RELEASE VALVES (QR-1) ..................................................................... 4-150
BRAKE PEDAL VALVE ..................................................................................... 4-151
SAFETY VALVE ................................................................................................. 4-152
PRESSURE PROTECTION VALVES ................................................................. 4-153
R-12 RELAY VALVES ........................................................................................ 4-154
4-3
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TM 5-4210-233-14&P-1
Contents
Para
D2 GOVERNOR.................................................................................................. 4-155
SR-1 SPRING BRAKE VALVE ........................................................................... 4-156
AIR TANKS.. ....................................................................................................... 4-157
STEERING WHEEL ............................................................................................ 4-158
STEERING COLUMN.......................................................................................... 4-159
STEERING SHAFT ............................................................................................. 4-160
POWER STEERING GEAR................................................................................. 4-161
POWER STEERING RESERVOIR...................................................................... 4-162
U-BOLTS............................................................................................................. 4-163
SHOCK ABSORBERS......................................................................................... 4-164
REAR AXLE ASSEMBLIES................................................................................. 4-165
EXHAUST PIPE CLAMPS AND HANGERS ........................................................ 4-166
FUEL LINES AND PIPING................................................................................... 4-167
FUEL TANK SENDING UNITS ............................................................................ 4-168
FUELTANKAND MOUNTING BRACKETS .......................................................... 4-169
FRONTBUMPER ................................................................................................ 4-170
TOW HOOKS...................................................................................................... 4-171
WHEEL CHOCK BRACKETS.............................................................................. 4-172
LADDER TREADS............................................................................................... 4-174
OUTRIGGER WARNING LIGHTS ....................................................................... 4-175
OUTRIGGER COMPARTMENT LIGHTS ............................................................ 4-176
AERIAL LADDER SPOT/FLOOD LIGHTS........................................................... 4-177
OUTRIGGER AND AERIAL CONTROL PANEL INDICATOR LIGHTS ............... 4-178
OUTRIGGER AND AERIAL CONTROL PANEL TOGGLE SWITCHES............... 4-179
LADDER LOAD GAUGE...................................................................................... 4-180
HYDRAULIC SYSTEM PRESSURE GAUGE (0-3000 PSI).................................. 4-181
WATER PRESSURE GAUGE (0-600 PSI) .......................................................... 4-182
FLOW MINDER .................................................................................................. 4-183
FLOW MINDER SENDING UNIT ......................................................................... 4-184
RUN/LOCK LEVER AND LINKAGE..................................................................... 4-185
RUN/LOCK SELECTOR VALVE.......................................................................... 4-186
PRESSURE SENSOR GAUGE ........................................................................... 4-187
TESTING HYDRAULIC SYSTEM ........................................................................ 4-188
HYDRAULIC TANK RETURN FILTER ................................................................ 4-189
OUTRIGGER CONTROL VALVES...................................................................... 4-190
PRESSURE RELIEF VALVE (PUMP DE-STROKE) ........................................... 4-191
PRESSURE REDUCING VALVE (OUTRIGGERS).............................................. 4-192
DIVERTER VALVE.............................................................................................. 4-193
OUTRIGGER EXTEND/RETRACT CYLINDERS ................................................. 4-194
OUTRIGGER JACK CYLINDERS AND CHECK VALVES.................................... 4-195
OUTRIGGER LIMIT SWITCHES ......................................................................... 4-196
AERIAL LADDER ANGLE LIMIT SWITCH .......................................................... 4-197
AERIAL LADDER INTERCOM............................................................................. 4-198
AIR OPERATED AERIAL DISCHARGE VALVE .................................................. 4-199
AERIAL DISCHARGE VALVE PNEUMATIC ACTUATOR.................................... 4-200
AERIAL LADDER WATER PIPE ASSEMBLY...................................................... 4-201
MONITOR AND NOZZLE .................................................................................... 4-202
MONITOR AND NOZZLE CONTROLS ............................................................... 4-203
COUNTERBALANCE VALVES............................................................................ 4-204
AERIAL LADDER TENSION CABLES................................................................. 4-205
AERIAL LADDER ELECTRICAL CABLES........................................................... 4-206
AUXILIARY POWER UNIT (APU)........................................................................ 4-207
4-4
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TM 5-4210-233-14&P-1
Contents
Para
APU BRUSHES .................................................................................................. 4-208
APU ANTI-FLICKER POINTS AND RESISTOR .................................................. 4-209
APU PRIMARY FUEL FILTER ............................................................................ 4-210
APU SECONDARY FUEL FILTER ...................................................................... 4-211
APU OIL FILTER ................................................................................................. 4-212
APU AIR CLEANER ............................................................................................ 4-213
APU GLOW PLUG AND AIR INTAKE HEATER .................................................. 4-214
APU EXHAUST SYSTEM.................................................................................... 4-215
APU FUEL TRANSFER PUMP............................................................................ 4-216
APU OIL PRESSURE SWITCH........................................................................... 4-217
APU CRANKCASE BREATHER.......................................................................... 4-218
MITER BOX ........................................................................................................ 4-219
PREPARATION FOR STORAGE OR SHIPMENT ............................................... 4-220
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4-541
SECTION I. REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
4-1. COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment refer to the
Modified Table of Organization and Equipment (MTOE) applicable to your unit.
4-2. SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT. There are no special tools, TMDE and support
equipment required for the fire truck.
4-3. REPAIR PARTS. Repair parts for this equipment are illustrated and listed in Appendix F of this manual.
SECTION II. SERVICE UPON RECEIPT
4-4. INTRODUCTION. This paragraph provides instructions for preparing a new, reconditioned, or recently
transported tuck for operation. Refer to Chapter 3, Lubrication Instructions and fluids.
CAUTION
Due to the critical nature of the service for which this vehicle is
intended, no vehicle should be placed in service if there is any
doubt or evidence of improper function of any of the
components or systems.
a. Pump Body, Hose Body.
(1)
(2)
(3)
Inspect body for shipping damage; minor damage (e.g., scratches, small dents) should not affect
truck function. Major damage should be repaired prior to use and all items adjacent to the damage
should be thoroughly checked for correct operation.
Check all doors, latches, and hinges operate correctly; replace any which are defective. Refer to
para 4-71 and para 4-77 .
Check all lamps and beacons for dirty or broken lenses. Clean or replace as required. Refer to
para 4-61 through 4-66 .
4-5
TM 5-4210-233-14&P-1
4-4. INTRODUCTION -Continued
b. Cab.
(1) Inspect cab body for shipping damage as described in para a. (1) above.
(2) Check all doors, latches, and hinges operate correctly; replace any which are defective. Refer to
para 4-71 and 4-77 .
(3) Check all windows for cracks and proper seating within weather stripping; replace or repair as
required. Refer to para 4-78 and 4-79 .
(4) Check all lamps and beacons for dirty or broken lenses. Clean or replace as required. Refer to para
4-81 through 4-85 .
(5) Check seats and belts are properly installed and are adjustable. Replace seats if fabric is damaged
or seat is not adjustable. Replace seat belt if belt fabric is damaged (cuts or abrasions greater than
1/4 in. (6 mm) long), belt is not adjustable, or fastener is broken. Refer to para 4-105 through 4-108 .
(6) Check level of solvent in windshield washer reservoirs. Refill as required.
(7) Check that all switches and controls are set to OFF or NEUTRAL, see Chapter 2.
c. Chassis, Axle, Wheels.
(1) Check tire pressure 90 psi (75 kPa) front, 110 psi (148 kPa) rear. Inflate as required.
(2) Inspect each tire for serious cuts, separated tread, or lumps. Remove all foreign objects lodged in
tread.
(3) Check axle vents to ensure freedom from obstruction.
(4) Check lubricant level in front and rear differentials. Add oil (Item 30, Appendix E) as required. Check
for any leaks.
(5) Check front and rear suspension for loose bolts, broken springs or damaged parts. Replaceas
required.
(6) Check all wheel mounting nuts for proper torque; 450 ft lb (612 Nm) (dry).
(7) Check steering reservoir for proper fluid level. Add automatic transmission fluid (Item 12,
Appendix E).
(8) Examine steering linkages and steering gear for shipping damage.
d. Fuel System.
(1) Check fuel tank level and fill as necessary.
(2) Inspect fuel line connections for evidence of leakage. Tighten or remake joints, as require Refer to
para 4-167 .
4-6
TM 5-4210-233-14&P-1
4-4. INTRODUCTION -Continued
e. Engine.
(1) Remove any seals, plugs, or tape used to seal any air inlets and ports during shipping.
(2) Check crankcase oil level and inspect oil on dipstick for cleanliness. Take an oil sample for
analysis. Top up, or drain and refill the crankcase with engine oil (Item 14, Appendix E) as required.
(3) Inspect engine and all piping connections for evidence of leakage. Repair as required.
(4) Check tension of fan, alternator and power steering drive belts. Belts should be tight enough to
allow 1/2 in. (12 mm) deflection midway between the pulleys. Adjust as required. Refer to
para 4-131 and 4-135 .
f. Cooling System.
(1) Clear away any debris blocking air flow to radiator.
(2) Check level of coolant in radiator; not more than 3 in. (76 mm) air space between coolant and top of
radiator.
(3) Sample the coolant and ensure there is sufficient antifreeze for the environment in which the truck is
to be operated.
(4) Check all cooling system hoses for evidence of leakage. Refit or tighten connections as required.
Refer to para 4-141 .
g. Transmission.
(1) Check transmission oil level. Take an oil sample for analysis. Top up, or drain and refill as
required.
(2) Check all external hydraulic lines for evidence of leakage. Tighten or replace all defective fittings.
Refer to para 4-9 .
h. Fire Pump.
(1) Check priming tank oil level. Take an oil sample for analysis. Top up, or drain and refill the tank as
required.
(2) Drain water and foam tanks. Inspect interior of both tanks for foreign objects.
(3) Close all drains.
(4) Fill water, foam, and priming tank via top mount fills. Check there are no leaks.
(5) Check all external suction and discharge connection caps are in place and secure. (Three on righthand side of truck, four on left-hand side and two at rear of truck).
(6) Pull out both crosslay hoses and inspect for damage and correct installation.
4-7
TM 5-4210-233-14&P-1
4-4. INTRODUCTION - Continued
i. Electrical System.
(1) Check engine, starter motor, and instrumentation wiring for proper connections and condition of
wiring insulation. Pay particular attention to the wiring harnesses as they pass through bulkheads or
holes in the frame. Ensure all grommets are in place.
(2) Check battery compartment and battery connection. Clean away any corrosion, neutralizing the acid
with baking soda solution. Paint any bare or rusty steel. Coat all battery connections with a
petroleum jelly. Check tightness of battery connections.
j. Auxiliary Power Unit.
(1) Inspect auxiliary power unit, removing any seals plugs or tape used to seal air inlets or ports during
shipping.
(2) Check crankcase oil level and inspect oil on dipstick for cleanliness.
analysis. Top up, or drain and refill crankcase as required.
Take an oil sample for
(3) Examine air cleaner element for dirty or restricted condition. Replace as required.
(4) Inspect engine and all piping connections for evidence of leakage. Repair asrequired.
(5) Inspect fuel line connections for evidence of leakage. Tighten, or remake joints as required.
k. Main Engine Test.
(1) Start main engine.
(2) When engine is running, check:
- oil pressure builds up to at least 20 psi (140 kPa); warning lamp
extinguishes
- air pressure warning lamps extinguish. (primary and secondary)
- engine air filter gauge remains in safety zone
- engine water temperature warning lamp extinguishes
- battery voltage and current (amps) remain in safety zone
- transmission oil temperature lamp extinguishes
(3) Check operation of all lamps and beacons:
- tail, park and head lights (high beam and low beam)
- marker lights
- spotlights
- panel lights
- dome lights
- rear beacon lights
- compartment lights
- hose pick-up lights
- engine compartment lights
- dash lights
(4) Check operation of rear buzzer, main siren, and PA system.
4-8
TM 5-4210-233-14&P-1
4-4.
I.
m.
n.
INTRODUCTION - Continued
(5)
Allow engine to warm up to 170-195 deg. F (77-90 deg. C).
(6)
Check receptacles on both sides of hose body (110 V, 60 Hz) and lower engine speed to low idle.
(7)
Visually inspect engine and transmission for signs of leakage (coolant, fuel, or oil).
(8)
Open drain valves on all air reservoirs and drain all condensate.
Truck Test.
(1)
Set transmission shift to D (drive), release parking brake and drive vehicle at low speed, checking
operation of brakes, steering, and throttle.
(2)
Check operation of differential lock selectors.
(3)
Check operation of all transmission gear ranges.
Fire Pump Test.
(1)
With transmission in drive, set electric pump shift to pump.
(2)
Move transmission shift lever to neutral.
(3)
Start fire pump and check pump discharge pressure exceeds 250 psi (336 kPa).
Structural Firefighting Test.
(1)
Engage pump.
(2)
Control discharge pressure of pump using hand throttle on the street side pump panel.
(3)
Check operation of both crosslay hoses.
(4)
Check operation of all structural hoses and other fire equipment.
(5)
Connect front or side suction to a hydrant.
(6)
With pump running, open hydrant valve and tank fill valve and check tank fills.
(7)
Ensure that with two crosslay hoses operational and nozzle operating, that pump maintains level of
tank at greater than 75%.
(8)
Close all hose and turret valves and refill tank to 100%. Close tank fill valve.
(9)
Disengage pump and remove suction hose from truck and hydrant.
(10)
Replace all hoses in their storage position.
4-9
TM 5-4210-233-14&P-1
4-4.
INTRODUCTION - Continued
o.
Vehicle Standby.
(1)
Allow main engine to run for 2 minutes in N (neutral) after coming to rest and applying parking
brake.
(2)
Switch off engine and all lights.
(3)
Top up fuel tank.
(4)
Top up foam tank.
(5)
Vehicle is now on standby and may be used in the event of an emergency.
SECTION III. UNIT PMCS
4-5.
GENERAL
a.
The purpose of scheduled preventive maintenance checks and services (PMCS) is to prevent
trouble, reduce down time, and ensure that the fire truck is ready for operation at all times.
b.
Records and reports of preventive maintenance checks and services must be made in accordance
with requirements set forth in DA PAM 738-750 the Army Maintenance Management System
(TAMMS).
c.
Explanation of Table.
(1)
Item Number Column. The Item Number Column of the PMCS table is used for numerical
sequencing of the procedures.
(2)
Interval Column. The Interval Column tells you when to do a particular check or service.
NOTE
Always keep in mind the CAUTIONS and WARNINGS when
performing PMCS.
The following coding is used:
W - Weekly Checks: These checks are carried out once a week.
M - Monthly Checks: These checks are carried out once a month.
S - Semi-Annual Checks: These checks are carried out twice per year.
A - Annual Checks: These checks are carried out once per year.
B - Bi-Annual Checks: These checks and services are carried out once every two years.
(3)
Explanation of ITEM TO BE INSPECTED/Procedures column. The ITEM TO BE INSPECTED/
Procedure column of the PMCS table tells you what item to inspect and tells you how to do the
required checks and services. Carefully follow these instructions. If you do not have the tools, or
if the procedure tells you to, have direct support maintenance do the work.
4-10
TM 5-4210-233-14&P-1
Table 4-1. Unit PMCS-Continued
Item
Interval
No. W M
S
1
A
B
ITEM TO BE INSPECTED/Procedures
PUMP, PIPING SYSTEM AND VALVES
Foam System Piping
*
With foam tank full, inspect foam system for leaks. Check attaching
hardware for tightness. Tighten as required. If piping is leaking, refer to
Direct Support for piping replacement.
Tank Assembly, Foam
*
With foam tank full, inspect for leaks. Check foam tank filler door latches
properly, door seals are in place. With foam tank empty, inspect tank interior
for corrosion or clogged screens; clean as required. Refer to Direct Support
for foam tank replacement.
2
WATER TANK ASSEMBLY
Water Piping, Tank to Pump
*
With water tank full, inspect for leaks. Check attaching hardware for tightness.
Tighten as required. Replace piping as required. Refer to para 4-31 through 4-55.
Tank
*
With water tank full, inspect for leaks. Check aftaching hardware for tightness.
Tighten as required. Report any tank leak to Direct Support for tank
repair/replacement.
Open hatch and inspect tank interior for debris, sand, algae, etc. Clean tank
as required.
3
CAB ASSEMBLY, LIGHTS AND CONTROLS
Cab Mounting Brackets
*
Check for tightness, missing attaching hardware. Tighten as required.
Check mounting bushings for cracks, missing. Refer to General Support for
bushing replacement.
Check mounting brackets for cracks, distortion. Refer to General Support for
mounting bracket replacement.
4
ENGINE AND ACCESSORIES
*
Starter
Check brushes for wear, replace as required. Remove oil caps and add 8
drops of engine oil (Item 14, Appendix E) to the oil wicks.
4-11
TM 5-4210-233-14&P-1
Table 4-1. Unit PMCS-Continued
Item
Interval
No. W M
S
4
A
B
ITEM TO BE INSPECTED/Procedures
ENGINE AND ACCESSORIES - Continued
Fuel Pump
*
Inspect visually for fuel leaks. Report any fuel leak to Direct Support for
repair/replacement.
Fan Belt, Fan
*
Inspect fan belts visually for signs of excessive wear or damage. Belts
should move less than 1/2 inch (1 2.7 mm) at midpoint between pulleys.
Adjust/replace as required (see para 4-131).
*
With main engine off, inspect fan for damage, loose blades.
Air Compressor
*
With main engine running, visually inspect air compressor for cooling water
or oil leaks.
Alternator and Belts
*
Visually inspect alternator for damage. Check cables are tight and free of
cracked or missing insulation.
*
Check belts are tight and free of excessive wear or damage. Belt should
move less than 1/2 inch (12.7 mm) at midpoint between pulleys.
Adjust/replace as required (see para 4-135).
*
With main engine running, listen for any squeals or rumbling in alternator
bearings. Replace as required. Refer to Direct Support for alternator repair.
Turbocharger
*
Check turbocharger attaching hardware for tightness/missing.
Tighten/replace as required. Check piping connections and clamps for
tightness. Tighten as required.
*
With main engine running, listen for excessive noise in turbocharger. Report
any bearing noise to Direct Support.
4-12
TM 5-4210-233-14&P-1
Table 4-1. Unit PMCS-Continued
Item
Interval
No. W M
S
A
B
ITEM TO BE INSPECTED/Procedures
ENGINE AND ACCESSORIES - Continued
Exhaust Manifold
WARNING
Severe Burns. Exhaust manifold surfaces may be hot. Avoid touching
surfaces; allow adequate cooling time before working on exhaust
system.
*
Inspect visually for any cracks. Check for loose attaching hardware, tighten
as required. Ensure connections to exhaust tubes are tight.
Thermostat Housing
*
Check for coolant leaks. Ensure attaching hardware is tight. Replace as
required (see para 4-137).
Engine Water Pump
*
Inspect visually for leaks. Ensure attaching hardware is tight. Refer to Direct
Support for replacement/repair.
Engine Oil Dipstick/Filler Tube
*
Inspect base of dipstick/filler tube for leaks. Ensure attaching hardware is
tight. Check crankcase oil level. Add proper engine oil as required.
Rocker Arm Covers
*
Inspect visually for leaks, check attaching hardware is tight. Replace gasket
biannually, or as required (see para 4-140).
Oil Pan
*
5
Inspect visually for leaks. Ensure attaching hardware is tight. Refer any
leaks to Direct Support.
WHEEL ASSEMBLY
Hubs, Bearing and Seals
*
Inspect visually for leaks. Ensure mounting hardware is in place and tight.
Check to see that front axle sight glass is intact and free of cracks.
*
Check oil level in front axle, fill as required. Change oil in front axle as
required; see lubrication instructions (para 3-1).
4-13
TM 5-4210-233-14&P-1
Table 4-1. Unit PMCS-Continued
Item
Interval
No. W M
S
6
A
B
ITEM TO BE INSPECTED/Procedures
BRAKE SYSTEM
Slack Adjuster
*
Inspect for visible damage, cracks, missing clevis pins, cotter keys.
Lubricate as required. Replace if necessary (see para 4-146).
Brake Chamber, Rear
*
Check chamber attaching hardware is in place/tight. Check for visible
damage. Check linkage to slack adjuster is tight. Check that clamp rings are
in place/tight. Check that stud and nut used for servicing are in storage
position on each chamber.
Service Brake, Front
*
Visually inspect for loose or missing attaching hardware, damage, loose
linkage, torn, cracked or chafed hoses.
Air Lines and Piping
*
Check for worn hoses, connectors. Listen for air leaks with main engine off.
With service brakes en!aaged and main engine off, leakage must not exceed
2 psi/minute (5.8 kg/cm min.). Replace/repair as required (see para 4-147).
In-Line Single Valves, Double Check Valves, Quick Release Valve
*
Visually inspect for cracks, looseness, damage. Replace as e
r quired. Check
lines for abrasion, cracks, visible damage. Replace as required (see para
4-148, 4-149 and 4-150).
Brake Pedal Valve
*
Inspect visually for damage, loose attaching hardware, cracks, damaged
lines.
*
With main engine off and adequate pressure in main reservoir, depress
service brake pedal. Listen for sound of service brakes engaging.
Replace/tighten as required (see para 4-151).
Safety Valve, Pressure Protection Valve
*
Check that valve is in place and free of cracks, damage or corrosion. Check
attaching hardware and hose connections for looseness. Replace/tighten as
required (see para 4-152 and 4-153).
4-14
TM 5-4210-233-14&P-1
Table 4-1. Unit PMCS-Continued
Item
Interval
No. W M
S
A
6
B
ITEM TO BE INSPECTED/Procedures
BRAKE SYSTEM - Continued
R-12 Relay Valves
*
Check that valve is in place and free of cracks, corrosion, or visible damage.
Check attaching hardware and hose connections for tightness.
Replace/tighten as required (see para 4-154).
Push-Pull Brake Control Valves
*
Check that valve is in place and free of visible damage. Check attaching
hardware is in place/tight. Check knob for cracks/looseness. Check hose
connections are tight. Replace/tighten as required (see para 4-145).
D2 Governor, SR-1 Spring Brake Valve
*
Check that attaching hardware is in place and tight. Check hose
connections/clamps on underside are tight.
Air Tanks
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. When working with compressed air always use eye
protection and other personal protective equipment.
*
Check that attaching hardware is in place/tight. Check all plugs/fittings are
in place/tight. Check hose connections are tight. Check drain cock is tight,
free of damage. Check drain cock operates smoothly, closes properly.
Air Dryer
*
Check attaching hardware, hose, wiring connections are tight. Check orifice
at bottom of dryer is free of obstruction.
7
STEERING ASSEMBLY
Steering Gear
*
Inspect steering gear for signs of wear, leakage, or other damage. Operate
gear and check relief valve in gear operates before wheels reach left or right
hand stops. Adjust gear as required.
4-15
TM 5-4210-233-14&P-1
Table 4-1. Unit PMCS-Continued
Item
Interval
No. W M
S
A
7
B
ITEM TO BE INSPECTED/Procedures
STEERING ASSEMBLY - Continued
Steering Arm Drag Link
*
8
Inspect steering arm and drag link for any scoring, corrosion, bends, or
other damage. Carry out operational test to ensure steering geometry.
SUSPENSION SYSTEM
U-Bolts, Leaf Springs
*
9
Inspect visually for major damage. Replace as required (see para 4-163).
FRONT AXLE ASSEMBLY
Front Axle Assembly
*
Inspect visually for major damage. Report any damage to Direct Support.
Tie Rod Ends
*
10
Inspect tie rod end seals for indication of damage and ensure seals are
properly seated. Inspect tie rod for bends or serious dents. When wheels
are turned, the tie rod should move smoothly. Report any deficiencies to
Direct Support.
REAR AXLE ASSEMBLY
Rear Axle Assembly
*
11
Check for signs of oil leakage. Check vent lines are firmly attached and vent
is open.
AERIAL LADDER/WATER TOWER ASSEMBLY
Hydraulic Oil Tank
*
Check for signs of hydraulic oil leakage. Report any leaks to Direct Support.
Outrigger Beams
*
Inspect visually for signs of damage, scoring, cracks, or broken welds.
Report any deficiencies to Direct Support.
Outrigger Extend/Retract Cylinders, Outrigger Jack Cylinders
*
Check for hydraulic oil leakage. Report any leaks to Direct Support.
4-16
TM 5-4210-233-14&P-1
Table 4-1. Unit PMCS-Continued
Item
Interval
No. W M
S
11
A
B
ITEM TO BE INSPECTED/Procedures
AERIAL LADDER/WATER TOWER ASSEMBLY - Continued
Ladder Assembly
*
Inspect carefully for signs of damage, cracks, broken welds. Inspect
extension mechanism for adequate lubrication.
Inspect hydraulic cylinders for leaks. Inspect cables and sheaves for
damage or improper operation. Report any deficiencies to Direct Support.
12
AUXILIARY POWER UNIT (APU)
Generator Brushes
*
Inspect for excessive wear. Replace as required.
APU Engine
*
Inspect primary and secondary fuel filter, oil filter, glow plug and crankcase
breather. Replace as required.
4-17
TM 5-4210-233-14&P-1
Section IV. UNIT TROUBLESHOOTING PROCEDURES
4-6.
GENERAL. Troubleshooting at the Unit Maintenance level requires you to locate any trouble as
quickly as possible. Once the trouble is located, repair or replace the part if you are authorized to do so, or
determine if a higher category of maintenance is required.
4-7.
PROCEDURES. Repair by Unit Maintenance is limited by tools, test equipment, and replacement
parts allocated to that level. Before using the troubleshooting table, check your work order and talk to the
operator, if possible, for a description of the symptoms if the trouble occurred while the equipment was in
operation.
4-8.
SYMPTOM INDEX. Refer to Table 4-2, Operator Troubleshooting, under the number against the
symptom in this index to determine the tests and corrective action required.
SYMPTOM
PAGE NO.
CAB
NO HEAT ........................................................................................................................
NO DEFROST .................................................................................................................
FAN INOPERATIVE ........................................................................................................
WASHER INOPERATIVE ................................................................................................
WIPER WON'T RUN .......................................................................................................
WIPER WON'T CLEAR WINDSHIELD ............................................................................
CAB DOOR WON'T OPEN ..............................................................................................
4-26
4-26
4-27
4-27
4-27
4-28
4-28
PUMP COMPARTMENT
WATER GAUGE INOPERATIVE .....................................................................................
PUMP GAUGE INOPERATIVE .......................................................................................
ENGINE GAUGE INOPERATIVE ....................................................................................
4-28
4-28
4-29
AUXILIARY POWER UNIT
WON'T CRANK ................................................................................................................
WON'T START.................................................................................................................
CRANKS SLOWLY...........................................................................................................
ERRATIC OPERATION ....................................................................................................
LOW POWER .................................................................................................................
4-29
4-29
4-30
4-30
4-31
WATER PUMP & PIPING
PUMP WON'T ENGAGE ..................................................................................................
INSUFFICIENT PRESSURE ...........................................................................................
WON'T PRIME ................................................................................................................
PUMP LEAKS .................................................................................................................
VALVE LEAKS ................................................................................................................
FOAM PERCENTAGE INCORRECT ...............................................................................
4-18
4-31
4-31
4-32
4-32
4-32
4-33
TM 5-4210-233-14&P-1
SYMPTOM
PAGE NO.
RADIATOR
COOLANTLOSS ..............................................................................................................
OIL IN COOLANT ............................................................................................................
4-33
4-33
AIR SYSTEM/BRAKES
INSUFFICIENT PRESSURE ...........................................................................................
COMPRESSOR NOISY ...................................................................................................
HIGH RESERVOIR PRESSURE .....................................................................................
EXCESS OIL IN PURGE .................................................................................................
EXCESS LOSS OF AIR ...................................................................................................
SERVICE BRAKES WON'T HOLD PRESSURE ..............................................................
BRAKES BURNING .........................................................................................................
BRAKES GRAB ...............................................................................................................
BRAKES SLOW TO OPERATE ......................................................................................
PARK BRAKE WON'T RELEASE ....................................................................................
RESERVOIR PRESSURE LOW ......................................................................................
4-34
4-34
4-34
4-35
4-35
4-35
4-36
4-36
4-37
4-37
4-38
STEERING SYSTEM
HARD ..............................................................................................................................
ERRATIC ........................................................................................................................
PUMP NOISY ..................................................................................................................
PUMP OIL LEAK .............................................................................................................
GEAR OIL LEAK, OUTPUT SHAFT ................................................................................
GEAR OIL LEAK, INPUT SHAFT ....................................................................................
EXCESSIVE BACKLASH ................................................................................................
WHEELS WON'T GO STRAIGHT AHEAD ......................................................................
TURNING RESTRICTED .................................................................................................
4-38
4-39
4-39
4-39
4-40
4-40
4-40
4-40
4-41
DRIVE LINE
TRUCK VIBRATION, NOISE ...........................................................................................
SQUEAL, CENTER BEARING .........................................................................................
4-41
4-41
TRANSMISSION
LOW STALL SPEED .......................................................................................................
OIL OUT OF FILLER TUBE .............................................................................................
OIL PRESSURE LOW .....................................................................................................
OVERHEATING . .............................................................................................................
ROUGH SHIFTS .............................................................................................................
NO SHIFTS .....................................................................................................................
TRUCK MOVES IN NEUTRAL ........................................................................................
HIGH STALL SPEED .......................................................................................................
4-19
4-41
4-41
4-42
4-42
4-42
4-43
4-43
4-43
TM 5-4210-233-14&P-1
SYMPTOM
PAGE NO.
ENGINE
WON'T CRANK . ..............................................................................................................
WON'T START ................................................................................................................
DIFFICULT TO START ...................................................................................................
ERRATIC OR STOPS ......................................................................................................
LOW POWER .................................................................................................................
LOW OIL PRESSURE......................................................................................................
FUMES FROM ROAD DRAFT TUBE ..............................................................................
EXHAUST BLACK ...........................................................................................................
HIGH OIL CONSUMPTION .............................................................................................
OVERHEATS ..................................................................................................................
4-43
4-44
4-44
4-44
4-45
4-46
4-46
4-47
4-47
4-48
AXLES
NOISY .............................................................................................................................
WHEELS WON'T DRIVE .................................................................................................
AXLE SHAFT LUBE LEAK ..............................................................................................
PINION SHAFT OIL LEAK ...............................................................................................
NO DIFFERENTIAL LOCK-UP .........................................................................................
4-48
4-48
4-49
4-49
4-50
FIREFIGHTING SYSTEM
PUMP FAILS TO PRIME OR LOSES PRIME ..................................................................
ENGINE AND PUMP SPEED TOO LOW AT FULL THROTTLE ......................................
ENGINE AND PUMP SPEED HIGHER THAN SPECIFIED FOR DESIRED PRESSURE .
AND VOLUME
ENGINE SPEED HIGHER THAN SPECIFIED FOR DESIRED PRESSURE AND VOLUME
INSUFFICIENT PRESSURE ...........................................................................................
PRESSURE NOT RELIEVED WHEN DISCHARGE VALVES ARE CLOSED ..................
PRESSURE WILL NOT RETURN TO ORIGINAL SETTING
AFTER DISCHARGE VALVES ARE RE-OPENED......................................................
"HUNTING" (FLUCTUATING PRESSURE) .....................................................................
SLOW RESPONSE .........................................................................................................
FIRE PUMP WILL NOT ENGAGE ...................................................................................
AIR OPERATED VALVE (FOR AERIAL DISCHARGE) FAILS TO OPEN OR CLOSE .....
VALVES LEAKING WATER/AGENT ...............................................................................
WATER/AGENT REMAINS IN PIPING AFTER DRAIN OPENED ....................................
DISCHARGE HOSE WON'T DE-PRESSURIZE ...............................................................
NO FOAM DISCHARGE AT ANY NOZZLE .....................................................................
EXCESS FOAM FROM NOZZLE ....................................................................................
FOAM ENTERING WATER TANK ...................................................................................
WATER ENTERING FOAM TANK ...................................................................................
4-50
4-53
4-53
4-53
4-54
4-54
4-54
4-55
4-55
4-55
4-56
4-56
4-56
4-57
4-57
4-57
4-57
4-57
HYDRAULIC SYSTEM
P.T.O. WILL NOT ENGAGE.............................................................................................
OUTRIGGERS WILL NOT OPERATE..............................................................................
AERIAL CONTROLS WILL NOT OPERATE ...................................................................
LADDER RAISES AND EXTENDS SLOWLY OR ERRATICALLY ...................................
ALL LADDER OPERATIONS ERRATIC OR SLOW .........................................................
LADDER DOES NOT OPERATE .....................................................................................
LADDER LOWERS AND RETRACTS SLOWLY .............................................................
LADDER WILL NOT LOWER OR RETRACT ..................................................................
4-20
4-58
4-58
4-59
4-60
4-60
4-61
4-62
4-62
TM 5-4210-233-14&P-1
SYMPTOM
PAGE NO.
HYDRAULIC SYSTEM - CONTINUED
LADDER WILL NOT LOWER ..........................................................................................
SWING OPERATION SLOW IN ONLY ONE DIRECTION ...............................................
SWING OPERATION ERRATIC IN ONE DIRECTION ONLY ..........................................
NO SWING OPERATION IN EITHER DIRECTION .........................................................
SWING OPERATION ERRATIC IN EITHER DIRECTION ...............................................
SWING OPERATION SLOW IN EITHER DIRECTION .....................................................
ERRATIC OPERATION IN ALL HYDRAULIC CIRCUITS .................................................
OUTRIGGER JACK CYLINDER EXTENDS WHILE MACHINE IS ROADING ..................
SLOW OR ERRATIC OPERATION OF OUTRIGGER EXTENSION CYLINDERS ...........
OUTRIGGER EXTENDS WHILE MACHINE IS ROADING ..............................................
OUTRIGGER JACK CYLINDER SLOW OR ERRATIC ....................................................
OUTRIGGER JACK CYLINDER RETRACTS UNDER LOAD ..........................................
PUMP NOISE DUE TO CAVITATION .............................................................................
FOAMING HYDRAULIC OIL ............................................................................................
CLOUDY HYDRAULIC OIL ..............................................................................................
OVERHEATING HYDRAULIC OIL ...................................................................................
EXCESSIVE PRESSURE BUILD-UP ...............................................................................
PUMP NOISE (ACCOMPANIED BY OIL FOAMING IN RESERVOIR) .............................
HYDRAULIC RESERVOIR OVERFLOWING....................................................................
4-62
4-63
4-63
4-63
4-64
4-64
4-65
4-65
4-66
4-66
4-67
4-67
4-67
4-68
4-68
4-68
4-68
4-69
4-69
ELECTRICAL SYSTEM - IGNITION CIRCUITS
"BATTERY ON" LIGHT DOES NOT ILLUMINATE ............................................................
4-69
IGNITION "ON" LIGHT DOES NOT ILLUMINATE ...........................................................
4-70
WARNING BUZZER DOES NOT SOUND WHEN IGNITION IS FIRST TURNED ON .....
4-70
ENGINE/TRANSMISSION BUZZER REMAINS ON ..........................................................
4-71
ENGINE/TRANSMISSION ALARM BUZZER DOES NOT SOUND DURING IGNITION TEST 4-71
DDEC ALARM (BEEPER) DOES NOT SOUND DURING IGNITION TEST .....................
4-72
STOP ENGINE LIGHT FAILS TO TURN OFF AFTER TEST ...........................................
4-72
CHECK ENGINE LIGHT FAILS TO TURN OFF AFTER TEST ........................................
4-73
STOP ENGINE LIGHT DOES NOT ILLUMINATE.............................................................
4-73
CHECK ENGINE LIGHT DOES NOT ILLUMINATE .........................................................
4-74
ENGINE STARTER MOTOR DOES NOT OPERATE ......................................................
4-74
ETHER STARTING AID DOES NOT OPERATE .............................................................
4-75
ALL CAB ELECTRIC INSTRUMENTS DO NOT OPERATE .............................................
4-75
NEUTRAL SAFETY CIRCUIT DOES NOT PROVIDE +12V SIGNAL TO CRY030 ...........
4-76
+12 VOLTS IS NOT PRESENT AT BATTERY ACCESSORY BUSS ...............................
4-76
+12 VOLTS IS NOT PRESENT AT IGNITION ACCESSORY BUSS ................................
4-76
ELECTRICAL SYSTEM - CAB CONTROLS AND INDICATORS
HEADLIGHTS (HIGH OR LOW BEAM) DO NOT ILLUMINATE .......................................
FRONT ID LIGHTS, ID BULLETS (FRONT AND REAR), TAIL LIGHTS,
SIDE ID LAMPS DO NOT ILLUMINATE ...........................................................................
STEP LIGHTS DO NOT ILLUMINATE ..............................................................................
CLEARANCE LIGHTS DO NOT ILLUMINATE .................................................................
TURN SIGNALS DO NOT FUNCTION PROPERLY ........................................................
BACKUP LIGHTS DO NOT ILLUMINATE, OR BACKUP ALARM DOES NOT SOUND ...
BRAKE LIGHTS DO NOT ILLUMINATE WITH FOOT PEDAL..........................................
MECHANICAL SIREN DOES NOT OPERATE ................................................................
MECHANICAL SIREN BRAKE DOES NOT OPERATE ...................................................
4-21
4-77
4-77
4-78
4-79
4-79
4-79
4-80
4-80
4-81
TM 5-4210-233-14&P-1
SYMPTOM
PAGE NO.
ELECTRICAL SYSTEM - CAB CONTROLS AND INDICATORS - Continued
ELECTRIC HORNS DO NOT SOUND..............................................................................
REAR SIGNAL BUZZER DOES NOT OPERATE ............................................................
ENGINE COMPARTMENT LIGHTS DO NOT ILLUMINATE ............................................
CAB OR CREW CAB DOME LIGHTS DO NOT ILLUMINATE .........................................
MAP LIGHTS DO NOT ILLUMINATE ..............................................................................
REMOTE CONTROL CAB SPOTLIGHTS DO NOT ILLUMINATE ...................................
REAR SCENE LIGHTS DO NOT ILLUMINATE WITH CAB SWITCH ...............................
CREW CAB EXHAUST FANS DO NOT OPERATE..........................................................
COMPARTMENT LIGHTS DO NOT ILLUMINATE ..........................................................
COMPARTMENT OPEN WARNING LIGHT DOES NOT ILLUMINATE OR FLASH .........
WINDSHIELD WIPERS DO NOT OPERATE ..................................................................
WINDSHIELD WASHERS DO NOT OPERATE ..............................................................
PARK BRAKE INDICATOR DOES NOT ILLUMINATE WHEN PARK BRAKE IS ENGAGED
INTER-AXLE LOCKOUT INDICATOR DOES NOT ILLUMINATE WHEN AXLES ARE.....
LOCKED
CAB HEATER FAN DOES NOT OPERATE ....................................................................
AIR DRYER DOES NOT DRY COMPRESSOR AIR ........................................................
"PUMP NOT IN GEAR" LIGHT DOES NOT ILLUMINATE ...............................................
PUMP SHIFT SWITCH DOES NOT ENGAGE PUMP .....................................................
"PUMP IN GEAR" LIGHT DOES NOT ILLUMINATE ........................................................
"PUMP IN GEAR" LIGHT ILLUMINATES, BUT PUMP DOES NOT ENGAGE .................
LOW FRONT AND REAR AIR LIGHTS DO NOT ILLUMINATE/FLASH WITH
LOW AIR PRESSURE INDICATED ON GAUGES ...........................................................
LOW VOLTAGE LIGHT STAYS ON ................................................................................
LOW VOLTAGE BUZZER DOES NOT SOUND DURING IGNITION "TEST ...................
LOW VOLTAGE BUZZER DOES NOT SOUND WHEN VOLTAGE IS LOW ...................
LOW VOLTAGE BUZZER CONTINUES TO SOUND WHEN VOLTAGE IS AT OR .........
ABOVE 12V
VOLTMETER (12V) DOES NOT OPERATE ....................................................................
CAB ENGINE OIL PRESSURE, ENGINE COOLANT TEMPERATURE GAUGES DO .....
NOT OPERATE
CAB PANEL TRANSMISSION OIL TEMPERATURE GAUGE DOES NOT OPERATE ....
CAB PANEL FUEL GAUGE DOES NOT OPERATE ........................................................
INSTRUMENT PANEL GAUGE AND BACKLIGHTING DOES NOT ILLUMINATE ..........
ENGINE HOUR METER DOES NOT OPERATE .............................................................
AERIAL HOUR METER DOES NOT OPERATE WITH AERIAL MASTER ON,
PARK BRAKE ON, AND SHIFT SELECTOR IN NEUTRAL .............................................
CAB TACHOMETER DOES NOT INDICATE ENGINE RPM ...........................................
CAB SPEEDOMETER DOES NOT INDICATE VEHICLE SPEED ...................................
4-82
4-82
4-83
4-83
4-84
4-84
4-85
4-85
4-86
4-86
4-87
4-87
4-88
4-89
4-89
4-90
4-90
4-91
4-91
4-92
4-92
4-92
4-93
4-93
4-94
4-94
4-95
4-95
4-96
4-96
4-97
4-97
4-98
4-99
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS
EMERGENCY MASTER SWITCH DOES NOT ENERGIZE EMERGENCY EQUIPMENT
ROTATING BEACONS (CAB ROOF) WILL NOT ROTATE .............................................
ROTATING BEACONS DO NOT ILLUMINATE ...............................................................
ROTATING BEACONS DO NOT OPERATE ...................................................................
FRONT WARNING (CROSSFIRE) LIGHTS DO NOT OSCILLATE .................................
FRONT WARNING (CROSSFIRE) LIGHTS DO NOT ILLUMINATE ................................
FRONT WARNING (CROSSFIRE) LIGHTS DO NOT OPERATE ....................................
4-22
4-99
4-100
4-100
4-100
4-101
4-101
4-101
TM 5-4210-233-14&P-1
SYMPTOM
PAGE NO.
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS - Continued
SIDE FLASHERS DO NOT ILLUMINATE/FLASH.............................................................
REAR WARNING STROBES DO NOT ILLUMINATE/FLASH...........................................
DECK SPOTLIGHTS DO NOT ILLUMINATE ...................................................................
ELECTRONIC SIREN DOES NOT SOUND .....................................................................
+12 VOLTS IS NOT PRESENT AT EMERGENCY MASTER BUSS ................................
4-102
4-102
4-103
4-103
4-104
ELECTRICAL SYSTEM -THROTTLE
THROTTLE DOES NOT ADVANCE WITH ELECTRONIC FOOT PEDAL .......................
PUMP PANEL VERNIER THROTTLE (SENSOR PTO CONTROL)
DOES NOT FUNCTION PROPERLY ..............................................................................
HYDRAULIC TRANSMISSION MODULATION CONTROL SOLENOID
NOT WORKING PROPERLY ..........................................................................................
HYDRAULIC TRANSMISSION MODULATION CONTROL VALVE DOES NOT OPERATE
4-104
4-105
4-106
4-106
ELECTRICAL SYSTEM - JACOBS ENGINE BRAKE
JACOBS ENGINE BRAKE DOES NOT ACTIVATE WITH CAB SWITCH ........................
JACOBS ENGINE BRAKE WORKS ONLY IN ONE SWITCH POSITION ........................
JACOBS BRAKE WORKS WHILE VEHICLE IS SHIFTED TO "PUMP" MODE ................
JACOBS BRAKE WORKS WHEN THROTTLE IS DEPRESSED .....................................
BRAKE LIGHTS DO NOT ILLUMINATE WHEN JACOBS BRAKE IS ENGAGED.............
4-107
4-108
4-108
4-108
4-109
ELECTRICAL SYSTEM - HI-IDLE CIRCUITS
HIGH IDLE SWITCH IN CAB WILL NOT ENGAGE HIGH IDLE .......................................
HIGH IDLE ENGAGES, BUT INDICATOR LIGHT DOES NOT ILLUMINATE ..................
REAR CONTROL PANEL HIGH IDLE SWITCH WILL NOT ENGAGE HIGH IDLE ..........
RUN/LOCK LEVER ON AERIAL PANEL WILL NOT ENGAGE HIGH IDLE WITH PARK
BRAKE ON, SHIFT SELECTOR IN NEUTRAL, AND AERIAL MASTER SWITCH ON ....
CAB SWITCH WILL NOT DISENGAGE HIGH IDLE ........................................................
REAR SWITCH WILL NOT DISENGAGE HIGH IDLE .....................................................
RUN/LOCK LEVER WILL NOT DISENGAGE HIGH IDLE WHEN IN "LOCK" POSITION
REAR PANEL "DO NOT ENGAGE HIGH IDLE UNLESS LIGHT IS ON" LIGHT WILL NOT
ILLUMINATE WITH PARK BRAKE ON AND SHIFT SELECTOR IN N (NEUTRAL) .........
4-109
4-110
4-111
4-112
4-113
4-113
4-114
4-114
ELECTRICAL SYSTEM - PTO
CAB SWITCH WILL NOT ENGAGE AERIAL PTO WITH PARK BRAKE ON,
SHIFT SELECTOR IN N (NEUTRAL), AND AERIAL MASTER CIRCUIT ON ..................
PTO ENGAGED LIGHT WILL NOT ILLUMINATE ...........................................................
4-23
4-115
4-115
TM 5-4210-233-14&P-1
SYMPTOM
PAGE NO.
ELECTRICAL SYSTEM -PUMP PANEL
PUMP PANEL ILLUMINATION LIGHTS DO NOT ILLUMINATE ......................................
PUMP COMPARTMENT LIGHT (CURB SIDE) DOES NOT ILLUMINATE .......................
WATER PRIMER PUMP DOES NOT OPERATE WITH SWITCH ...................................
PUMP PANEL TACHOMETER DOES NOT FUNCTION PROPERLY .............................
PUMP PANEL VOLTMETER (12V) DOES NOT FUNCTION PROPERLY .......................
PUMP PANEL FUEL GAUGE DOES NOT FUNCTION PROPERLY ...............................
WATER TANK LEVEL INDICATOR DOES NOT OPERATE ...........................................
RELIEF VALVE INDICATOR LIGHTS DO NOT ILLUMINATE ..........................................
4-116
4-117
4-117
4-118
4-118
4-118
4-119
4-120
ELECTRICAL SYSTEM - OUTRIGGER CONTROL PANEL
OUTRIGGER DOWN LIGHT DOES NOT ILLUMINATE WHEN OUTRIGGER IS DOWN
OUTRIGGER ALARM DOES NOT SOUND WHEN OUTRIGGERS STOWED AND
DIVERTER VALVE IS SWITCHED TO OUTRIGGER POSITION ....................................
OUTRIGGER ALARM DOES NOT SHUT OFF WHEN OUTRIGGERS ARE DEPLOYED
AND OUTRIGGER DOWN LIGHTS ARE LIT ...................................................................
REAR PANEL OUTRIGGER DOWN LIGHT WILL NOT ILLUMINATE .............................
OUTRIGGER ILLUMINATION LIGHTS WILL NOT LIGHT ..............................................
OUTRIGGER JACK FLASHER DOES NOT ILLUMINATE OR FLASH ............................
AERIAL POSITION OF DIVERTER CONTROL VALVE DOES NOT FUNCTION WITH
OUTRIGGERS PROPERLY DEPLOYED ........................................................................
OUTRIGGER POSITION OF AERIAL DIVERTER VALVE DOES NOT FUNCTION
WITH AERIAL LADDER NESTED ...................................................................................
AERIAL LADDER FUNCTIONS WITHOUT OUTRIGGER DEPLOYED ............................
OUTRIGGER FUNCTION WHILE AERIAL LADDER IS RAISED .....................................
PSI REDUCTION (PUMP DE-STROKE) VALVE DOES NOT ENGAGE WITH
DIVERTER SWITCH IN NEUTRAL POSITION AND AERIAL PANEL T-HANDLE IN "LOCK"
PSI REDUCTION VALVE WILL NOT DISENGAGE WITH DIVERTER VALVE SET TO
"OUTRIGGER" POSITION AND MANUAL OVERRIDE DISENGAGED ...........................
OVERRIDE ACTIVATED LIGHT WILL NOT ILLUMINATE WHEN OVERRIDE ACTIVATED
DIVERTER VALVE POSITION INDICATOR LIGHTS WILL NOT ILLUMINATE ................
OUTRIGGER CONTROL PANEL ILLUMINATION LIGHTS DO NOT LIGHT WITH
AERIAUMASTER SWITCH ON .......................................................................................
4-120
4-121
4-122
4-122
4-123
4-123
4-124
4-125
4-126
4-126
4-126
4-128
4-128
4-128
4-129
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL
AERIAL MASTER CIRCUIT DOES NOT ENERGIZE AERIAL CONTROLS .....................
TURNTABLE SWIVEL ASSEMBLY SLIP RING CONTACT INTERRUPTED....................
AERIAL PANEL LIGHT WILL NOT ILLUMINATE WITH AERIAL MASTER ON ................
TURNTABLE STEP LIGHTS DO NOT ILLUMINATE WITH AERIAL MASTER ON...........
LEFT OR RIGHT TRACKING LIGHT WILL NOT ILLUMINATE IN FLOOD OR
SPOT SWITCH POSITION ..............................................................................................
LEFT OR RIGHT TIP LIGHT WILL NOT ILLUMINATE IN FLOOD OR SPOT
SWITCH POSITION .........................................................................................................
RUNG ALIGNMENT LIGHT WILL NOT ILLUMINATE WHEN RUNGS ARE ALIGNED.....
EMERGENCY HYDRAULIC POWER LIGHT WILL NOT ILLUMINATE ON AERIAL PANEL
WHEN EMERGENCY PUMP IS ACTIVATED ..................................................................
EMERGENCY HYDRAULIC POWER DOES NOT ACTIVATE FROM
AERIAL PANEL SWITCH.................................................................................................
AERIAL DISCHARGE VALVE DOES NOT CLOSE WITH PANEL SWITCH.....................
AUDIO ALARM DOES NOT FUNCTION .........................................................................
4-24
4-129
4-130
4-130
4-131
4-131
4-132
4-132
4-133
4-133
4-133
4-134
TM 5-4210-233-14&P-1
SYMPTOM
PAGE NO.
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
LADDER INTERCOM DOES NOT FUNCTION PROPERLY ............................................
LADDER TIP SPEAKER DOES NOT FUNCTION PROPERLY ................... ....................
AERIAL LADDER HOIST CYLINDER LOCKING VALVES DO NOT RELEASE LADDER
WHEN RAISE/LOWER CONTROL IS PLACED IN "LOWER" POSITION .......................
ELEVATION SLOW-DOWN VALVE DOES NOT ENGAGE WHEN LADDER
REACHES 70' ELEVATION .............................................................................................
FLOW MINDER (GALLONS-PER-MINUTE) METER DOES NOT FUNCTION PROPERLY
OVERLOAD ALARM DOES NOTSOUND WHEN HYDRAULIC SYSTEM IS AT 1950 PSI
OVERLOAD ALARM SOUNDS CONTINUOUSLY WHILE HYDRAULIC SYSTEM
PRESSURE IS BELOW 1950 PSI....................................................................................
AERIAL MONITOR/NOZZLE DOES NOT RESPOND TO UPPER CONTROL BOX .........
AERIAL MONITOR/NOZZLE DOES NOT RESPOND TO LOWER CONTROL BOX
(ON AERIAL PANEL) .......................................................................................................
AERIAL MONITOR/NOZZLE DOES NOT RESPOND IN ONE DIRECTION ....................
AERIAL MONITOR/NOZZLE WILL NOT FUNCTION IN ONE MODE (I.E., RAISE/LOWER)
+12 VOLTS IS NOT PRESENT AT AERIAL MASTER BUSS ..........................................
4-134
4-135
4-135
4-136
4-137
4-137
4-138
4-138
4-139
4-139
4-140
4-140
ELECTRICAL SYSTEM - EMERGENCY HYDRAULIC SYSTEM
EMERGENCY HYDRAULIC MOTOR DOES NOT OPERATE .........................................
EMERGENCY HYDRAULIC POWER ACTIVATED LIGHT DOES NOT ILLUMINATE ......
4-141
4-141
ELECTRICAL SYSTEM - APU AND 1 1 O-VOLT CIRCUITS
AUXILIARY POWER UNIT (APU) DOES NOT START/RUN WITH CAB OR
PUMP PANEL CONTROLS .............................................................................................
AUXILIARY POWER UNIT (APU) RUNS, BUT NO POWER OUTPUT.............................
AUXILIARY POWER UNIT DOES NOT SHUT OFF .........................................................
AUXILIARY POWER UNIT PREHEAT CONTROL DOES NOT WORK ...........................
DRIVERS/PASSENGERS FLOODLIGHT (110V) DOES NOT ILLUMINATE WITH
CAB SWITCH AND AUXILIARY POWER UNIT RUNNING ....................... ......................
NO POWER AT ANY 11OV OUTLET (EXCEPT LADDER TIP) .......................................
NO POWER AT LADDER TIP OUTLET ...........................................................................
110V PORTABLE WORK LIGHT DOES NOT ILLUMINATE WITH CAB SWITCH ..........
4-25
4-142
4-142
4-143
4-143
4-143
4-144
4-145
4-145
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CAB
1
CAB HEATER FAILS TO HEAT
Step
Step
Step
1.
2.
3.
Heater valve closed.
a.
Open heater valve.
b.
Replace heater valve or heater valve operating cable (see para 4-103).
Engine not at working temperature.
a.
Wait until engine at temperature.
b.
Engine thermostat failed, replace thermostat (see para 4-136).
Core or fan blocked by dirt or litter.
Clean fan housing or heater.
Step
4.
Coolant lines blocked.
Replace damaged hose (see para 4-103 and 4-104).
Step
5.
Air lock in heater.
Loosen outlet connection and vent air.
Step
2
6.
Blower fan not working.
a.
Replace defective switch, wire or circuit breaker (see para 4-9).
b.
Replace fan motor, or tighten fan blower to motor shaft (see para 4-104).
CAB DEFROSTER LOUVERS NOT BLOWING
Step
1.
Defroster damper not opening.
Check cable and damper.
Step
2.
Blower motor not operating.
a.
Check blower motor.
b.
Notify Direct Support.
4-26
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CAB - Continued
3
CAB CIRCULATING FAN NOT OPERATING
See Electrical System troubleshooting section.
4
WINDSHIELD WASHER INOPERATIVE
Step
1.
Washer reservoir empty
Refill reservoir.
Step
2.
Failed switch, wires, or circuit breaker.
See Electrical System troubleshooting section.
Step
3.
Leaking water line.
Check and tighten water lines.
Step
4.
Plugged nozzles on wiper arm.
Clean or replace nozzles (see para 4-112).
Step
5.
Failed pump.
Replace pump (see para 4-109).
5
WINDSHIELD WIPERS WILL NOT RUN
Step
1.
Failed switch, wires, or circuit breaker.
See Electrical System troubleshooting section.
Step
2.
Motor failed.
Replace motor (see para 4-111).
Step
3.
Linkages tight, bent, or corroded.
Replace wiper arm, or free up as required (see para 4-112).
4-27
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
CAB - Continued
6
WIPERS NOT CLEARING WINDSHIELD EVENLY
Step
1.
Wiper blade worn out.
Replace wiper blade (see para 3-4).
Step
2.
Linages tight, or bent.
Replace wiper arm, or free up as required (see para 4-112).
7
CAB DOOR WILL NOT OPEN
Step
1.
Failed door latch.
Replace door latch (see para 4-77).
Step
1.
Failed door handle.
Replace door handle (see para 4-77).
PUMP COMPARTMENT
1
WATER LEVEL GAUGE NOT FUNCTIONING
Step
1.
Bulbs failed/missing
Replace bulbs (see para 4-19).
Step
2.
Failed wire, harness plug, or circuit breaker.
See Electrical System troubleshooting section.
2
PUMP SUCTION OR DISCHARGE GAUGE NOT OPERATING
Step
1.
Water pressure line blocked or disconnected either end.
Replace/tighten hose or connections as required (see para 4-17).
Step
2.
Gauge failed.
Replace gauge (see para 4-17).
4-28
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
PUMP COMPARTMENT - Continued
3
ENGINE MONITORING GAUGE NOT OPERATING
Step
1.
Replace gauge with known working gauge.
If gauge does not operate, refer to Step 2.
Step
2.
Test sending unit or replace with known working sending unit.
If gauge does not operate, refer to Step 2.
Step
3.
Refer to Electrical System troubleshooting.
AUXILIARY POWER UNIT
1
STARTER WILL NOT CRANK APU ENGINE
Step
1.
Battery switch set OFF.
Set battery switch to position 1 or 2.
Step
2.
Batteries low in charge.
Charge batteries.
Step
3.
Engine starter switch faulty.
Replace starter switch (see para 4-84).
2
APU ENGINE CRANKS NORMALLY BUT WILL NOT START
Step
1.
Check fuel level.
Add fuel and prime system.
Step
2.
Air in fuel system.
Remove connection to injector, turn start swdtch and prime until fuel appears out of
injector connection.
Step
3.
Broken fuel line or blocked fuel filter.
Check for leakage/blockage. Replace/repair as required (see para 4-210 and 4-211).
Step
4.
Failed fuel pump.
Replace fuel pump (see para 4-216).
4-29
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AUXILIARY POWER UNIT - Continued
3
APU ENGINE CRANKS SLOWLY
Step
1.
Sample lubricating oil.
Change lubricating oil to correct viscosity. Refer to Chapter 3.
Step
2.
Loose or corroded starter motor or battery terminals.
Tighten, clean, or replace starter terminals.
Step
3.
Batteries not fully charged.
Charge or replace batteries.
Step
4.
Low ambient temperature.
Operate generator preheating system (see para 2-16).
4
ERRATIC APU ENGINE OPERATION
Step
1.
Check fuel filter.
Replace filter if blocked (see para 4-210 and 4-211).
Step
2.
Check truck battery charge.
Recharge batteries if very low.
Step
3.
Notify Direct Support.
4-30
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AUXILIARY POWER UNIT - Continued
5
APU ENGINE LOW POWER
Step
1.
Check air cleaner.
Replace filter and clean housing (see para 4-213).
Step
2.
Check fuel filter and hoses.
Replace filter if dirty. Replace hoses if blocked or kinked (see para 4-210 and 4-211).
Step
3.
Notify Direct Support.
WATER PUMP & PIPING
1
PUMP WILL NOT ENGAGE
Step
1.
Check correct sequence of switching has been carried out (see para 2-13.).
Use proper switching sequence.
Step
2.
Check shift solenoid clicks when pump switch operated.
If no click, see Electrical System troubleshooting.
Step
2
3.
Notify Direct Support.
PUMP ENGAGES BUT WILL NOT ACHIEVE DESIRED WATER PRESSURE
Step
1.
Check relief valve setting.
Adjust or replace relief valve as required (see para 4-35 and 4-36).
Step
2.
Check pump speed.
a. Binding in pump (notify Direct Support).
4-31
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WATER PUMP & PIPING - Continued
3
PUMP WILL NOT PRIME.
Step
1.
Check hose connections between suction and priming pump for-air leaks.
Repair hoses/tighten connections as required (see para 4-3 through 4-60).
Step
2.
Priming pump failed.
Replace or repair priming pump (see para 4-57).
4
PUMP LEAKS WATER WHILE PUMPING
Check location of leak.
Refer to Direct Support for repair.
5
VALVES LEAKING WATER/AGENT
Step
1.
Check actuator linkage.
Adjust actuator linkage (see para 4-34).
Step
2.
Valve dirty or worn.
Replace or repair valve (see para 4-31 through 4-55).
4-32
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
WATER PUMP & PIPING - Continued
6
FOAM PERCENTAGE DOES NOT MEET SPECIFICATION
Step
1.
Check correct water flow used for calculation.
Repeat test with metering valve set according to new flow rate (see para 2-13).
Step
2.
Check foam metering valve for cleanliness and correct operation.
Replace metering valve (see para 4-31).
Step
3.
Check eductor for cleanliness.
Remove and clean eductor (see para 4-33).
Step
4.
Check foam concentrate for contamination (see para 2-13).
Drain tank and fill with proper solution.
RADIATOR
1
LOSS OF COOLANT FROM RADIATOR SYSTEM
Step
1.
Check all hoses with engine at working temperature.
Replace hoses/fittings if any are leaking (see para 4-141).
Step
2.
Check cab heater for leak.
Repair or replace cab heater or components (see para 4-104).
Step
3.
Check radiator for leakage.
Repair or replace radiator (notify Direct Support).
2
OIL IN RADIATOR COOLANT
Notify Direct Support.
4-33
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEM/BRAKES
1
AIR COMPRESSOR FAILS TO MAINTAIN PRESSURE OR ADEQUATE AIR SUPPLY
Step
1.
Check compressor air cleaner.
Replace compressor air cleaner if blocked.
Step
2.
Check hose between engine and compressor is not kinked or leaking.
Replace hose.
Step
3.
Check for excessive system leakage.
Close air drain valves.
Replace broken hose, leaking air tank, etc., or close air drain valve.
2
AIR COMPRESSOR NOISY
Step
Step
1.
2.
Check for restriction in discharge line to air drier.
a.
Remove restriction.
b.
Replace hose (see para 4-9).
Check oil flow to compressor.
Replace hose or fittings (see para 4-9).
Step
3
3.
Notify Direct Support.
AIR RESERVOIRS AT 110 PSI (760 kPa) OR GREATER
Step
1.
Check for restriction or leak in control hose between air drier and governor.
Replace hose or fittings (see para 4-9).
Step
2.
Notify Direct Support.
4-34
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEM/BRAKES - Continued
4
EXCESSIVE OIL IN PURGE WHEN COMPRESSOR UNLOADS OR OIL IN AIR RESERVOIR
Step
1.
Check compressor air cleaner.
Replace air cleaner.
Step
2.
Check hose between engine and compressor for kinks or other obstruction.
Remove obstruction.
Replace hose (see para 4-9).
Step
3.
Check oil return line from compressor to engine.
Replace hose if kinked or obstructed (see para 4-9).
Step
5
4.
Notify Direct Support.
RESERVOIR PRESSURE FALLS MORE THAN 2 PSI/MIN (14 kPa/MIN) WHEN ENGINE STOPPED
Step
1.
Check reservoir draincocks.
Close/repair draincocks (see para 4-157).
Step
2.
Check all valves for leaks.
Replace valves (see para 4-145 through 4-156).
Step
3.
Listen for loss of air on all air lines and fittings. Check with bubble test.
Tighten connections or replace hose (see para 4-9).
6
SERVICE BRAKES WILL NOT HOLD PRESSURE
Step
1.
Check all air lines and connections for leaks. Check with bubble test.
Repair as required (see para 4-147).
Step
2.
Check chambers for leakage.
Replace as required. Notify Direct Support.
4-35
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEMIBRAKES - Continued
7
BRAKE SHOES SMELL OF BURNING
Check if brake shoes are dragging.
Adjust slack adjusters (see para 4-146).
8
BRAKES GRAB OR PULL TO ONE SIDE
Step
1.
Check brake linings.
Replace if coated with oil or grease. Notify Direct Support.
Step
2.
Check brake slack adjuster adjustment.
Adjust (see para 4-146).
Step
3.
Check brake chamber diaphragms for leaks.
Notify Direct Support.
4-36
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEM/BRAKES - Continued
9
BRAKES ERRATIC OR SLOW TO OPERATE
Step
1.
Check air lines for leaks.
Repair or replace air lines (see para 4-147).
Step
2.
Check quick release, relay and spring brake valves for leaks.
Repair or replace valves (see para 4-145 through 4-156).
Step
3.
Check brake pedal valve for leaks.
Replace brake pedal valve (see para 4-151).
Step
4.
Check brake linings are clean.
Replace shoes if coated with oil or grease. Notify Direct Support.
Step
5.
Check brake adjustment.
Adjust slack adjusters (see para 4-146).
10
PARKING BRAKE-WILL NOT RELEASE
Step
1.
Check for leaks in secondary or emergency release circuits.
Replace hoses/fittings (see para 4-147).
Step
2.
Check quick release valves for leaks.
Repair brake quick release valves (see para 4-150).
Step
3.
Check parking brake chambers for leaks.
Notify Direct Support.
4-37
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEM/BRAKES - Continued
11
ANY AIR RESERVOIR PRESSURE LOW
Step
1.
Check reservoir drain valve closed.
Close drain valve.
Step
2.
Check for leaks from reservoir.
Repair hoses/connectors (see para 4-147).
Replace tank (see para 4-157).
Step
3.
heck pressure protection valves for correct operation.
Replace as required (see para 4-153).
STEERING SYSTEM
1
STEERING HARD IN ONE OR BOTH DIRECTIONS
Step
1.
Check ambient air temperature.
Run engine for few minutes. Steering will be stiff at very low temperatures.
Step
2.
Check oil level.
a.
Step
3.
Fill reservoir as required (see Chapter 3, Lubrication Instructions).
Check oil viscosity and/or oil cleanliness.
Drain system and refill with correct oil (see Chapter 3, Lubrication Instructions).
Step
4.
Check for binding in steering column or shaft.
Replace steering column or shaft U-joints (see para 4-160).
Step
5.
Notify Direct Support.
4-38
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEERING SYSTEM - Continued
2
STEERING ERRATIC
Step 1. Check tire pressure.
Inflate tires to correct pressure (see para 3-7).
Step 2. Check tread wear.
Change tire if tread is bulging or warped due to broken plies (see para 4-143).
Step 3. Check for air in oil circuit.
Bleed power steering oil system.
Step 4. Check suction hose and fittings for blockage.
Replace hoses or fittings (see para 4-9). +
Step 5. Check for worn universal joint in steering shafts.
Replace universal joint (see para 4-160).
3
STEERING PUMP NOISY
Step 1. Check oil level in reservoir.
Fill reservoir as required.
Step 2. Visually check hoses for leaks.
Replace hoses (see para 4-9).
Step 3. Check suction hose at pump for blockage.
Replace hose. (see para 4-9)
Step 4. Check pump for leaks.
Notify Direct Support.
4
OIL LEAKING AT STEERING PUMP DRIVE SHAFT
Notify Direct Support.
4-39
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEERING SYSTEM - Continued
5
OIL LEAKING AT OUTPUT SHAFT OF STEERING GEAR
Step 1. Check oil filter in power steering reservoir (high back pressure).
Replace filter if dirty (see para 4-162).
Step 2. Check oil return hose.
Replace hose if pinched or restricted (see para 4-9).
Step 3. Notify Direct Support.
6
OIL LEAKING AT INPUT SHAFT OF STEERING GEAR
Notify Direct Support.
7
STEERING WHEEL HAS EXCESSIVE BACKLASH
Step 1. Check steering shaft universal joints for wear.
Replace universal joints (see para 4-160).
Step 2. Check for loose steering shaft or worn splines.
Replace steering shaft (see para 4-160).
Step 3. Notify Direct Support.
8
WHEELS WILL NOT ATTEMPT TO RETURN TO STRAIGHT AHEAD POSITION FROM TURNS
Step 1. Check steering column and steering shafts for binding.
Replace column or universal joints (see para 4-160).
Step 2. Notify Direct Support.
4-40
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEERING SYSTEM - Continued
9
WHEEL TURN ANGLE RESTRICTED
Notify Direct Support.
DRIVE LINE
1
EXCESSIVE TRUCK VIBRATION OR NOISE
Notify Direct Support.
2
HIGH PITCHED SQUEAL FROM CENTER BEARING AREA, OR GRINDING SOUND
Notify Direct Support.
TRANSMISSION
1
TRANSMISSION HAS LOW STALL SPEED
Step 1. Engine not performing efficiently
Refer to Engine troubleshooting section.
If engine performance is satisfactory refer to Direct Support.
2
OIL THROWN FROM FILLER TUBE
Step 1. Dipstick loose.
Install correctly.
Step 2. Dipstick gasket worn.
Replace gasket.
Step 3. Oil level too high.
Drain to proper level.
Step 4. Breather clogged.
Clean/replace breather (see para 4-142).
4-41
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION - Continued
3
TRANSMISSION OIL PRESSURE LOW
Step 1. Check oil level.
Add oil as required.
Step 2. Check transmission oil cooler hoses for restriction or kinks.
Replace hoses (see para 4-9).
4
TRANSMISSION OVERHEATING
Step 1. Check oil level.
Add oil as required. if overheating continues, drain and flush transmission. Fill with correctoil
and change filter (see Chapter 3, Lubrication Instructions. )
Step 2. Check oil cooler lines between transmission and radiator.
a. Replace kinked or restricted hose.
b. Notify Direct Support.
5
TRANSMISSION SHIFTS ROUGHLY
Check shift linkage adjustment.
Adjust as required (see para 4-100).
4-42
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION - Continued
6
NO RESPONSE TO SHIFT LEVER MOVEMENT
Step 1. Check shift linkage.
Reconnect and/or adjust as required (see para 4-100).
Step 2. Main pressure low.
Change oil and filter (see para 4-142).
7
TRUCK MOVES IN NEUTRAL
Check shift linkage adjustment.
Adjust as required (see para 4-1 00).
8
TRANSMISSION HAS HIGH STALL SPEED
Check for low oil level.
a. Add oil.
b. Notify Direct Support.
ENGINE
1
STARTER WILL NOT CRANK MAIN ENGINE
Step 1. Check all connections between battery and starter for tightness and corrosion.
Clean/tighten as required.
Step 2. Connect jumper between B and S terminal on motor.
a. If starter motor starts, fault is in ignition circuit (see Electrical troubleshooting section).
b. If starter motor will not start, Notify Direct Support.
Check ignition circuit.
4-43
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
2
ENGINE CRANKS BUT WILL NOT START
Step 1. Air in fuel system.
Prime the system by blocking or disconnecting the supply line from the fuel pump, the apply
fuel under pressure (60-80 psi) to the inlet of the secondary fuel filter. Purge the system of air
by allowing fuel to flow freely from the fuel return line until a solid stream without air bubbles is
observed.
Step 2. Check for choked fuel filter.
Replace fuel filter (see para 4-130).
Step 3. Check for blocked or broken fuel line.
Replace (see para 4-130 and 4-167).
Step 4. Remove fuel tank fill cap. If engine runs smoothly, tank vent is blocked.
Clean/replace vent.
3
ENGINE HAS DIFFICULTY IN STARTING
Step 1. Check battery and starting motor connections.
Clean and tighten connections.
Step 2. Check engine oil level.
Fill engine with correct lubricating oil (see Chapter 3, Lubrication Instructions).
Step 3. Check starter motor current draw.
Repair motor as required (notify Direct Support).
4
ENGINE STARTS BUT STOPS OR RUNS ERRATICALLY
Step 1. Check for fuel leaks.
a. Tighten/remake connections.
b. Replace fuel lines (see para 4-130 and 4-167).
Step 2. Check for crimped or blocked fuel lines.
Replace fuel lines (see para 4-130 and 4-167).
4-44
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
4
ENGINE STARTS BUT STOPS OR RUNS ERRATICALLY - Continued
Step 3. Check for dirty fuel filters.
Replace fuel filters (see para 4-130).
Step 4. Remove fuel tank fill cap. If engine runs smoothly, vent in tank is blocked.
Clean/replace vent.
Step 5. Check coolant temperature.
a. Replace thermostat if engine will not heat up (see para 4-136).
Step 6. Air in system due to foaming in fuel tank.
Replace fuel tank (see para 4-169. ).
5
ENGINE HAS LOW POWER
Step 1. Check engine oil.
Drain and refill if oil is very dirty.
Step 2. Check engine air cleaner.
Replace engine air cleaner if dirty (see para 4-128).
Step 3. Check engine fuel filter.
Replace fuel filters (see para 4-130).
Step 4. Check brakes are not dragging.
Check for slow air leak in brake system and adjust or repair brakes.
4-45
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
6
ENGINE LOW OIL PRESSURE AT WORKING TEMPERATURE
Step 1. Check oil level.
Fill as required.
Step 2. Wrong oil viscosity.
Drain and refill with correct oil (see Chapter 3, Lubrication Instructions).
Step 3. Oil bypassing oil cooler.
Clean or replace oil cooler. Notify Direct Support.
Step 4. Visually check gauge.
Replace as required (see para 4-93).
Step 5. Check sending unit.
Replace as required (see para 4-138).
7
OIL OR FUMES SEEN AT ROCKER COVER BREATHER TUBE
Step 1. Check engine breather filtering disc.
Clean or replace breather filtering disc.
Step 2. Visually check exhaust and muffler for dents or blockage.
Remove blockage or Notify Direct Support if damaged.
4-46
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
8
EXHAUST SMOKE - BLACK
Step 1. Recheck engine when operating.
Allow engine to reach operating temperature and check for black smoke.
Step 2. Check fuel.
Drain and refill tank with correct fuel.
Step 3. Check exhaust for restriction.
Remove restriction or notify Direct Support to replace exhaust.
Step 4. Check air cleaner.
Replace air cleaner if blocked (see para 4-128. ).
9
HIGH LUBRICATING OIL CONSUMPTION
Step 1. Check external oil lines or connections for leaks.
Tighten/remake connections, or replace hoses (air compressor, turbocharger)
(see para 4-9. ).
Step 2. Check crankcase oil level.
Drain oil from crankcase if overfilled.
Step 3. Check crankcase breathers.
Clean/replace as required (see para 4-140).
Step 4. Check air cleaner.
Replace air cleaner if blocked (see para 4-128. ).
4-47
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
10
ENGINE OVERHEATING
Step 1. Check radiator coolant level.
Fill as required (see Chapter 3).
Step 2. Check radiator and coolant hoses for leaks.
Replace radiator hoses (para 4-141) or notify General Support.
Step 3. Check radiator core.
Remove foreign material from radiator.
Step 4. Check for contaminants in cooling system.
Refer to Direct Support.
Step 5. Check fan belts for wear.
Replace fan belts (see para 4-131).
AXLES
1
CONSTANT NOISE FROM AXLES
Step 1. Check lubricant level.
Top up as required.
Step 2. Check lubricant.
Drain and refill with correct lubricant.
Step 3. Refer to Direct Support.
2
REAR WHEELS DO NOT DRIVE (DRIVE SHAFT ROTATING)
Notify Direct Support.
4-48
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AXLES - Continued
3
LUBRICANT LEAKS THROUGH AXLE SHAFTS
Step 1. Check axle housing vent system for restrictions.
Replace axle housing breather (see para 4-165)
Step 2. Check lubricant.
Drain and fill with correct lubricant.
Step 3. Check lubricant level.
Drain as required.
Step 4. Visually check for worn or incorrectly installed axle shaft oil seal.
Notify Direct Support.
4
LUBRICANT LEAKS AT AXLE PINION SHAFTS
Step 1. Check lubricant.
Drain and fill with correct lubricant.
Step 2. Check lubricant level.
Drain as required.
Step 3. Check axle vent system for restrictions.
Replace axle housing breather (see para 4-165).
Step 4. Check if drive yoke loose on pinion shaft.
Tighten yoke.
4-49
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AXLES - Continued
5
AXLE DOES NOT ENGAGE DIFFERENTIAL LOCK-UP
Step 1. Check for broken or pinched air line.
Check and replace air line (see para 4-9).
Step 2. Check if lock-up air chamber diaphragm is broken or chamber has internal damage.
Replace air chamber. Notify Direct Support.
Step 3. Air switch defective.
Replace switch. Notify Direct Support.
FIREFIGHTING SYSTEM
1
PUMP FAILS TO PRIME OR LOSES PRIME
NOTE
Some pump operators mistakenly assume that the main pump is
fully primed when they see the first discharge of water and oil
come out of the priming pump discharge pipe, or when they see
a slight pressure on pressure gauge. Operate pump until it
emits a solid stream of water through its discharge pipe.
NOTE
If desired, the pump may be running while priming. However,
priming may be more positive if the impellers are stationary.
NOTE
At temperatures of 0 deg. F (-18'C) or below, use SAE 5W or
5W-20 engine oil in priming tank. Heavier oils are not suitable
at low temperatures.
Step 1. Battery has low state of charge.
Make sure battery is properly charged. If battery is in low state of charge, it may be difficult
to operate the priming pump at proper speed.
4-50
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
1
PUMP FAILS TO PRIME OR LOSES PRIME - Continued
Step 2. No oil in priming tank.
NOTE
With rotary primer, oil is usually required to maintain a tight rotor
seal.
Step 3. Check priming tank oil supply and replenish, if necessary.
CAUTION
Speeds much higher than those recommended do not
accelerate priming, and may actually damage priming pump.
Step 4. Engine speed too low.
Refer to operating instructions for correct priming speeds.
Step 5. Check for air leaks.
Clean and tighten all suction connections. Make sure suction hoses and gaskets are in good
condition. .
Step 6. Check for dirt on suction strainer.
Remove all leaves, dirt, and other foreign material from suction strainer.
When drafting from shallow water source with mud, sand, or gravel bottom, protect suction
strainer in one of the following ways:
a.
Suspend suction strainer from a log or other floating object to keep it off bottom. Anchor
float to prevent it from drifting into shallow water.
b.
Remove top from a barrel. Sink barrel so open end is below water surface. Place suction
strainer inside barrel.
c.
Make a suction box, using fine-mesh screen. Suspend suction strainer inside box.
Step 7. Check for defective priming valve.
Refer to Direct support maintenance level.
4-51
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
1
PUMP FAILS TO PRIME OR LOSES PRIME - Continued
Step 7. Check for a clogged orifice in the oil line at the fitting of the priming pump head.
Refer to Direct support maintenance level to remove obstruction from orifice.
Step 8. Check vane primer pump.
After prolonged service, wear may increase primer vane clearance and reduce efficiency.
Refer to Direct support maintenance level to adjust.
Step 9. Check valve in by-pass line stuck open.
If a bypass line is installed between the pump discharge and water tank to prevent pump
from overheating with all discharge valves closed, look for a check valve in the line. If valve is
stuck open, clean it, replace it, or temporarily block off line until a new valve can be obtained.
Step 10. Estimate or measure vertical distance from water source to pump.
Do not attempt lifts exceeding 22 vertical feet (6. 7 m) except at iow altitudes and with
equipment in new condition.
Step 11. Check that end of suction hose is deep enough.
Although suction hose might be immersed enough for priming, pumping large volumes of
water may produce whirlpools, which will allow air to be drawn into suction hose. Whenever
possible, place end of suction hose at least two feet below water surface.
Step 12. Check that suction line is below pump.
If possible, avoid placing any part of suction hose higher than pump suction inlet. If high point
cannot be prevented, close discharge valve as soon as pressure drops, and reprime. This
procedure will usually eliminate air pockets in suction line, but it may have to be repeated
several times.
Step 13. Primer not operated long enough.
Refer to operating instructions for required priming time. Repeat priming procedure.
NOTE
The maximum time for priming should not exceed one-half
minute for lifts up to 10 feet (3. 05 m).
4-52
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
2
ENGINE AND PUMP SPEED TOO LOW AT FULL THROTTLE
Step 1. Check that relief valve is set correctly.
Refer to Direct Support maintenance level.
Step 2. Insufficient engine power.
Engine requires maintenance; refer to Direct Support maintenance level.
3
ENGINE AND PUMP SPEED HIGHER THAN SPECIFIED FOR DESIRED PRESSURE AND VOLUME
Step 1. Check suction strainer, suction screens, or impeller vanes for debris.
Remove suction strainer and hose, and clear away all debris. Pressure backwash (preferably
in parallel or "volume" position) will usually clear impeller vanes when pump is stopped.
Step 2. Check for defective suction hose.
On old suction hoses, the inner liner sometimes becomes so rough it causes enough friction
to prevent pump from drawing full capacity. Sometimes, the liner will separate from the outer
wall and collapse when drafting. It is usually impossible to detect liner collapse, even with a
light. Try drafting with a new suction hose; if pump then delivers capacity, it may be assumed
that previous hose was defective. Replace defective hose.
Step 3. Check that suction hose correct size.
When pumping at higher than normal lifts, or at high altitudes, use a larger suction hose.
Step 4. Pump impellers or wear rings badly worn.
Refer to Direct Support maintenance level.
4
ENGINE SPEED HIGHER THAN SPECIFIED FOR DESIRED PRESSURE AND VOLUME
Check gear selection of transmission.
Ensure transmission is in "drive".
4-53
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
5
INSUFFICIENT PRESSURE
Step 1. Follow procedures for engine and pump speed higher than specified for desired pressure
and volume.
Step 2. Check pump speed with tachometer at RPM COUNTER connection on pump operator's
panel. If pump speed is too low, adjust throttle. If proper engine speed cannot be maintained,
refer to engine troubleshooting.
CAUTION
Do not attempt to pump greater volume of water at the desired
pressure than the pump is designed to handle. Exceeding
pump capacity will reduce pressure in an inverse ratio.
Exceeding maximum recommended pump speed will produce
cavitation, and will seriously impair pump efficiency.
6
PRESSURE NOT RELIEVED WHEN DISCHARGE VALVES ARE CLOSED
Step 1. Check for sticky pilot valve.
Repair pilot valve (see para 4-36).
Step 2. Check for plugged lines.
Remove obstruction or replace line.
7
PRESSURE WILL NOT RETURN TO ORIGINAL SETTING AFTER DISCHARGE VALVES ARE REOPENED
Step 1. Check for sticky pilot valve.
Repair pilot valve (see para 4-36).
Step 2. Check for main relief valve sticking.
Repair relief valve (see para 4-35).
4-54
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
8
"HUNTING" (FLUCTUATING PRESSURE)
NOTE
Hunting can result from a combination of suction and discharge
conditions involving the pump, relief valve, and engine. When
the elasticity of the suction and discharge system and the
response rate (reaction time) of the engine, pilot valve, and
relief valve are such that the system never stabilizes, hunting
results. Changing one or more of these factors enough to
disrupt this timing should eliminate hunting.
Step 1. Inspect suction hoses and connections for worn seals or loose connections.
Tighten connections or replace seals in suction hoses (see para 4-1 0 and 4-1 1).
Step 2. Check for sticky pilot valve.
Repair pilot valve (see para 4-36).
Step 3. Check for sticking relief valve.
Repair relief valve (see para 4-35).
9
SLOW RESPONSE
Check for plugged filter or line.
Clean lines and filter.
10
FIRE PUMP WILL NOT ENGAGE
Step 1. Check correct switching sequence has been carried out.
Carry out correct switching sequence (see para 2-13).
Step 2. Check for electric shift disengaged.
Push in manual disengage handle (on left hand side of pump body).
4-55
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
11
AIR OPERATED VALVE (FOR AERIAL DISCHARGE) FAILS TO OPEN OR CLOSE
Step 1. Check position of battery switch.
Rotate battery selector switch to 1, 2 or BOTH.
Step 2. Check that air system is pressurized.
Start engine to pressurize system.
Step 3. Check for air leaking from valve or motor connections.
Tighten connections.
Step 4. Refer to electrical system troubleshooting.
If valve fails to operate, replace or repair air operated valve (para 4-199) or pneumatic
actuator (para 4-200).
12
VALVES LEAKING WATER/AGENT
Step 1. Check that valves are closed.
Close valve.
Step 2. Check for internal valve failure.
Refer to Direct support maintenance level.
13
WATER/AGENT REMAINS IN PIPING AFTER DRAIN OPENED
Step 1. Check for clogged drain valve outlet.
Clean dirt/blockage from drain hole.
Step 2. Check for water frozen in piping or drain valve.
Apply heat to piping and drain valve.
Step 3. Check for defective drain valve or linkage.
Refer to Direct support maintenance level.
4-56
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
14
DISCHARGE HOSE WON'T DE-PRESSURIZE
Check drain valve for blockage.
Clean dirt/blockage from drain hole.
15
NO FOAM DISCHARGE AT ANY NOZZLE
Step 1. Check if foam valve set OPEN.
Set foam valve to OPEN.
Step 2. Check if foam proportioning valve (in cab or on structural panel) closed.
Set foam proportioning valve to required percentage.
Step 3. Check if foam tank empty or content diluted.
Drain tank and/or refill tank as required.
16
EXCESS FOAM FROM NOZZLE
Check percentage setting on foam metering valve with chart.
Reset from metering valve. If condition continues, refer to Direct Support Maintenance.
17
FOAM ENTERING WATER TANK
Check if tank fill/recirculating valve is open or partially open.
Close valve.
18
WATER ENTERING FOAM TANK
Defective 1-1/2" check valve in foam system piping.
Replace 1-1/2" check valve (see para 4-37).
4-57
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM
1
P. T. O. WILL NOT ENGAGE
Step 1. Check that AERIAL MASTER switch is energized.
Engage AERIAL MASTER switch.
Step 2. Check that AERIAL P. T. O. switch is engaged.
Engage AERIAL P. T. O. switch.
Step 3. Check that transmission range selector is in N (neutral).
Engage N (neutral) with range selector.
Step 4. Check that parking brake is engaged.
Engage parking brake.
Step 5. Check engine speed on tachometer.
Ensure engine speed is below 1 000 RPM.
Step 6. Check for malfunctioning high idle interlock system (DDEC).
See electrical troubleshooting procedures. If problem cannot be corrected, refer to Direct
Support maintenance level.
2
OUTRIGGERS WILL NOT OPERATE
Step 1. Check that P. T. O. is engaged.
Engage P. T. O.
Step 2. Check position of DIVERTER VALVE OUTRIGGERIAERIAL switch.
Select OUTRIGGER position with DIVERTER VALVE OUTRIGGER/AERIAL switch.
Step 3. Check position of manual override.
Ensure maual override is in neutral position and handle moves freely.
4-58
TM 5-4210-233-14&P- 1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
2
OUTRIGGERS WILL NOT OPERATE - Continued
Step 4. Check operation of main hydraulic pump.
Use emergency pump to deploy outriggers and refer to Direct Support level to troubleshoot
the main hydraulic pump.
Step 5. Check for malfunctioning of outrigger/aerial interlock (Aerial interlock relay).
See outrigger electrical troubleshooting procedure.
Step 6. Check for malfunctioning of pressure reducer (de-stroking) valve.
Refer to electrical troubleshooting procedure.
Step 7. Check for malfunctioning of diverter valve.
Refer to Direct Support maintenance level to repair or replace diverter valve.
3
AERIAL CONTROLS WILL NOT OPERATE
Step 1. Check that P. T. O. is engaged.
Engage P. T. O.
Step 2. Check position of manual override.
Ensure manual override is in neutral position and handle moves freely.
Step 3. Check position of diverter valve.
Select AERIAL position with DIVERTER VALVE OUTRIGGER/AERIAL switch.
Step 4. Check that outriggers are extended beyond 18 inches and supporting the weight of the truck.
See para 2-14. for ladder set-up instructions.
Step 5. Check position of RUNILOCK lever.
Engage RUN position with RUNILOCK lever.
Step 6. Check for malfunction of outrigger/aerial interlock (outrigger downlimit switches)
See aerial P. T. O. electrical troubleshooting procedure.
4-59
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
3
AERIAL CONTROLS WILL NOT OPERATE - Continued
Step 7. Check for malfunction of diverter valve.
Replace diverter valve (see para 4-193).
4
LADDER RAISES AND EXTENDS SLOWLY OR ERRATICALLY
Step 1 hydraulic oil level.
Refill hydraulic oil to proper level.
Step 2. Check position of HIGH IDLE switch.
Engage HIGH IDLE switch (1250 RPM min. )
Step 3. Check for sufficient lubrication on ladder slides and water pipes.
Lubricate ladder slides and water pipes (see Chapter 3, Lubrication Instructions).
Step 4. Check for leaking cylinder piston seals.
Notify Direct Support.
5
ALL LADDER OPERATIONS ERRATIC OR SLOW
Step 1. Check engine RPM.
Increase to proper RPM (1250 RPM).
Step 2. Check SYSTEM PRESSURE at gauge on aerial control platform.
Ensure SYSTEM PRESSURE is 2100-2150 PSI, if pressure is not within limits, refer to Direct
Support maintenance level to test pressure reducing (de-stroking) valve for proper operation.
Step 3. Check for restriction in hydraulic tank return hose or filter.
Replace hydraulic filter (see para 4-189).
Replace return hose (see para 4-9).
4-60
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
6
LADDER DOES NOT OPERATE
Step 1. Check position of manual override.
Ensure manual override handle is in neutral position and moves freely.
Step 2. Check that aerial system has engaged.
Ensure DIVERTER VALVE AERIAL/OUTRIGGER switch is in AERIAL position.
Step 3. Check for possible aerial interlock malfunction.
Refer to electrical troubleshooting procedures to test aerial interlock system
.
Step 4. Check that diverter valve has not shifted to aerial position.
Refer to electricai troubleshooting procedures and test diverter valve solenoid, if solenoid
tests good refer to Direct Support maintenance to replace diverter valve.
Step 5. Check for malfunctioning ladder control valve.
Refer to Direct Support maintenance level to repair or replace control valve.
Step 6. Check for low hydraulic oil level.
Refill to proper level.
Step 7. Check for leaks in hydraulic swivel.
Refer to Direct Support maintenance level to replace hydraulic swivel.
Step 8. Check for defective swing motor thermal relief valve in port N of swing cross-over manifold
block.
Replace swing motor thermal relief valve if SYSTEM PRESSURE is not within 2400-2450
PSI when DIVERTER VALVE AERIAL/OUTRIGGER switch is in AERIAL position (see
para 6-74).
4-61
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
7
LADDER LOWERS AND RETRACTS SLOWLY
NOTE
Extremely cold hydraulic oil will affect operation of the ladder.
Operate unit to bring oil to operating temperature.
Check for restriction in hydraulic tank return hose or filter.
Replace hydraulic filter (see para 4-189).
Replace return hose (see para 4-9).
8
LADDER WILL NOT LOWER OR RETRACT
Step 1. Check position of manual override.
Ensure manual override handle is in neutral position and moves freely.
Step 2. Check that aerial system is engaged.
Ensure DIVERTER VALVE AERIAL/OUTRIGGER switch is in AERIAL position.
Step 3. Check for possible aerial interlock malfunction.
Refer to electrical troubleshooting procedures to test system.
Step 4. Check hydraulic oil level in tank.
Refill to proper level (Chapter 3, Lubrication Instructions).
8
LADDER WILL NOT LOWER
Step 1. Check that locking solenoids are released.
Refer to electrical troubleshooting procedures to test solenoid valves.
Step 2. Check operation of LOWER/RAISE ladder control valve.
Refer to Direct Support maintenance for repair or replacement.
Step 3. Check if excessive fluid flow has forced a hydraulic fuse in one or both hoist cylinders to
engage.
With the system pressurized, raise the ladder slightly then lower it.
4-62
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
9
SWING OPERATION SLOW IN ONLY ONE DIRECTION
Check for clogged or restricted directional control hose.
Disconnect the appropriate hose connecting the swing crossover relief manifold block to the
turntable control valve. Remove obstruction or replace hose (see para 4-9).
10
SWING OPERATION ERRATIC IN ONE DIRECTION ONLY
Step 1. Turntable bearing binding due to continuous duty and lack of lubrication.
Rotate machine in both directions several times.
Step 2. Check for clogged or restricted directional control hose.
Disconnect the appropriate hose connecting the swing crossover relief manifold block to the
turntable control valve. Remove obstruction or replace hose (see para 4-9).
11
NO SWING OPERATION IN EITHER DIRECTION
Step 1. Check for swing brake not releasing properly.
Refer to Direct Support maintenance.
Step 2. Check for defective swing motor.
Refer to Direct Support maintenance for replacement.
Step 3. Check for internal damage to planetary speed reducer.
Refer to Direct Support maintenance for replacement.
Step 4. Check operation of turntable control valve.
Refer to Direct Support maintenance.
Step 5. Check for defective swing motor thermal relief valve in port N of swing cross-over manifold
block.
Notify Direct Support.
4-63
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
12
SWING OPERATION ERRATIC IN EITHER DIRECTION
Step 1. Check hydraulic oil level.
Fill tank with hydraulic oil to proper level (see para 3-1).
Step 2. Check for defective gear or bearing in planetary speed reducer.
Refer to Direct Support maintenance.
Step 3. Check for insufficient turntable bearing lubrication.
Lubricate bearing (see para 3-1. ).
Step 4. Check for excessive overload on LADDER LOAD gauge.
Reduce load.
Step 5. Check for proper operation of swing motor.
Refer to Direct Support maintenance for replacement.
Step 6. Check for restricted or partly clogged hydraulic hoses or fittings.
Remove the hoses from the swing cross-over manifold block to the hydraulic motor and
inspect fittings and hoses for foreign objects or restrictions.
13
SWING OPERATION SLOW IN EITHER DIRECTION
Step 1. Check that swing brake is releasing.
Refer to Direct Support maintenance.
Step 2. Check for clogged or restricted hydraulic hoses or fittings.
Remove and inspect hoses and fittings from the diverter valve to the swing brake.
Step 3. Check for defective swing motor.
Refer to Direct Support maintenance.
Step 4. Check for defective swing motor relief valves.
Replace swing cross-over relief manifold relief cartridges in ports "N'", "O" or "R".
4-64
TM 5-4210-233-14&P-1
Table 4-2 Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
14
ERRATIC OPERATION IN ALL HYDRAULIC CIRCUITS
Step 1 heck for low hydraulic oil level.
Fill to proper level (see para 3-1. ).
Step 2. Check engine RPM.
Increase engine RPM to 1250 for smooth operation.
Step 3. Check for loose hose and/or fitting allowing air to enter system.
Re-tighten or replace fittings or hose (see para 4-9).
Step 4. Check operation of pressure reducing (de-stroking) valve.
Refer to Direct Support maintenance to test or replace valve.
Step 5. Check operation of hydraulic pump.
Refer to Direct Support maintenance to repair pump.
15
OUTRIGGER JACK CYLINDER EXTENDS WHILE MACHINE IS ROADING
Step 1. Air in system.
Purge system by extending and retracting, raising and lowering the outrigger to its full travel
limits several times.
Step 2. Check for defective jack cylinder check valve.
Refer to Direct Support maintenance for troubleshooting.
Step 3. Check for leaking jack cylinder piston seals or internal damage.
Refer to Direct Support maintenance, to replace seals.
4-65
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
16
SLOW OR ERRATIC OPERATION OF OUTRIGGER EXTENSION CYLINDERS
Step 1. Check for air in system.
Purge system by extending and retracting, raising and lowering the outrigger to its full travel
limits several times.
Step 2. Check for low hydraulic oil.
Fill oil to proper level (see para 3-1).
Step 3. Check for malfunctioning outrigger control valve.
Refer to Direct Support maintenance to replace control valve.
Step 4. Check for defective outrigger extension cylinder (internal parts).
Refer to Direct Support maintenance to repair outrigger extension cylinder.
Step 5. Check for defective main hydraulic pump.
Refer to Direct Support maintenance to repair pump.
17
OUTRIGGER EXTENDS WHILE MACHINE IS ROADING
Step 1. Check for air in extension cylinder.
Purge system by extending and retracting, raising and lowering the outrigger several times
to its full travel limits.
Step 2. Check for leaking piston seals or internal damage in outrigger extension cylinders.
Refer to Direct Support maintenance to replace seals.
4-66
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
18
OUTRIGGER JACK CYLINDER SLOW OR ERRATIC
Step 1. Check for air in system.
Purge system by extending and retracting, raising and lowering the outrigger several times
to its full travel limits.
Step 2. Check for defective jack cylinder check valves.
Replace check valves (see para 4-195).
Step 3. Jack cylinder piston seals worn or internal damage.
Refer to Direct Support maintenance to replace jack cylinder piston seals.
19
OUTRIGGER JACK CYLINDER RETRACTS UNDER LOAD
Step 1. Check for air in system.
Purge system by extending and retracting, raising and lowering outrigger to its full travel
limits several times.
Step 2. Check for defective jack cylinder check valves.
Replace jack cylinder check valve (see para 4-195).
Step 3. Check for leaking piston seals or internal damage in jack cylinders.
Refer to Direct Support maintenance to replace piston seals.
20
PUMP NOISE DUE TO CAVITATION
Step 1. Check hydraulic oil level.
Fill system to proper level (see para 3-1).
Step 2. Check for plugged hydraulic return line filter.
Replace filter (see para 4-189).
Step 3. Check for air leakage in hydraulic suction lines with shaving cream.
Tighten or remake leaking connections (see para 4-9).
4-67
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
21
FOAMING HYDRAULIC OIL
Step 1. Check hydraulic oil level.
Fill system to proper level (see para 3-1).
Step 2. Check for broken or loose supply line.
Tighten or replace line (see para 4-9).
Step 3. Check for water in hydraulic system as indicated by white or milky hydraulic oil.
Drain, flush, and refill system (see para 3-1).
Step 4. Check for Incorrect type of oil in system.
Drain and refill system (see para 3-1).
22
CLOUDY HYDRAULIC OIL
Excessive moisture in system.
Drain, flush, and refill system (see para 3-1).
23
OVERHEATING HYDRAULIC OIL
Step 1. Check hydraulic oil level.
Fill system to proper level (see para 3-1).
Step 2. Check for contaminated hydraulic oil.
Determine/correct cause of contamination; drain, flush and refill system (see para 3-1).
Step 3. Check for defective pressure reducing (de-stroking) valve.
Replace pressure reducing valve (see para 4-191).
24
EXCESSIVE PRESSURE BUILD-UP
Check for defective pump pressure compensating valve in main hydraulic pump.
Refer to Direct Support maintenance.
4-68
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM-Continued
25
PUMP NOISE (ACCOMPANIED BY OIL FOAMING IN RESERVOIR)
Air entering at suction manifold.
Check all lines for security, manifold for cracks and proper attachment. Tighten, repair, or
replace components as necessary (see para 4-9).
26
HYDRAULIC RESERVOIR OVERFLOWING
Aerial ladder was lowered without hydraulic pressure applied and air entered the lift cylinders
Raise and lower ladder several times to purge air from the lift cylinders and service hydraulic
reservoir
ELECTRICAL SYSTEM-IGNITION CIRCUITS
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2, 3, 5, and 6 of 16)
1
"BATTERY SWITCH" LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16).
Step 1. Check bulb.
Replace bulb.
Step 2. Check battery switch for proper operation.
Replace switch (see para 4-101).
Step 3.
Check for +12V at circuit breaker #9 on battery accessory buss.
Replace breaker.
(see para 4-99).
Step 4. Refer to "+12 volts not present at battery accessory buss" troubleshooting procedures.
Step 5. Check wiring for continuity.
Replace wire (see para 4-9).
4-69
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-IGNITION CIRCUITS-Continued
2
IGNITION "ON" LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check bulb.
Replace bulb.
Step 2. Check ignition switch.
Replace switch (see para 4-94).
Step 3. Check ignition solenoid for proper operation.
Replace solenoid.
Step 4. Check for +12V at circuit breaker #9 on battery accessory buss.
Replace breaker (see para 4-99).
Step 5. Refer to "+12 volts not present at battery accessory buss" troubleshooting procedures.
Step 6. Check wiring for continuity.
Replace wire(s)(see para 4-9).
3
WARNING BUZZER DOES NOT SOUND WHEN IGNITION IS FIRST TURNED ON
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check buzzer.
Replace buzzer (see para 4-96).
Step 2. Check ignition switch.
Replace ignition switch (see para 4-94).
Step 3. Check for +12V at circuit breaker #4 on ignition buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire(s) (see para 4-9).
4-70
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-IGNITION CIRCUITS-Continued
4
ENGINE/TRANSMISSION BUZZER REMAINS ON
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check low oil PSI switch.
Replace switch (see para 4-138).
Step 2. Check low air PSI switch.
Replace switch (see para 4-9.4).
Step 3. Check low rear air PSI switch.
Replace switch (see para 4-9.4).
Step 4. Check high transmission oil pressure switch.
Replace switch (see para 4-9.4).
Step 5. Check high/low voltage alarm.
Replace alarm. (see para 4-9.4).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
5
ENGINE/TRANSMISSION ALARM BUZZER DOES NOT SOUND DURING IGNITION TEST
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check for +12V on ignition accessory buss.
Refer to "+12 volts not present at battery accessory buss" troubleshooting procedure.
Step 2. Check for +12V at circuit breaker #4 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 3. Place a jumper from wire 1046 to a good ground.
If buzzer sounds, go on to step 4.
If buzzer does not sound, replace alarm buzzer unit (see para 4-96).
4-71
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-IGNITION CIRCUITS-Continued
5
ENGINE/TRANSMISSION ALARM BUZZER DOES NOT SOUND
DURING IGNITION TEST-Continued
Step 4. Check wire 1046 is grounded by ignition switch when switch is on.
Replace ignition switch (see para 4-94).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
6
DDEC ENG/TRANS ALARM (BEEPER) DOES NOT SOUND DURING IGNITION TEST
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16).
Step 1. Check DDEC ENG/TRANS ALARM for proper operation.
Replace DDEC ENG/TRANS ALARM (see para 4-9.4).
Step 2. Check DDEC alarm relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check stop engine relay for proper operation.
Replace relay (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Check DDEC Engine Control Module using ECM Diagnostic Data Reader (DDR).
Replace DDEC ECM.
7
Notify Direct Support.
STOP ENGINE LIGHT FAILS TO TURN OFF AFTER TEST
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check for mechanical failure/deficiency using DDR (Diagnostic Data Reader) and
instrument panel gauges.
Repair deficiency.
Step 2. Check stop engine relay for proper operation.
Replace relay (see para 4-9.4).
4-72
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-IGNITION CIRCUITS-Continued
7
STOP ENGINE LIGHT FAILS TO TURN OFF AFTER TEST-Continued
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
8
CHECK ENGINE LIGHT FAILS TO TURN OFF AFTER TEST
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check for mechanical failure/deficiency using DDR (Diagnostic Data Reader) and instrument
panel gauges.
Repair deficiency.
Step 2. Check engine light relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
9
STOP ENGINE LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check stop engine light relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check fuse.
Replace fuse (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Check DDEC Engine Control Module (ECM) using Diagnostic Data Reader (DDR).
Replace DDEC ECM.
Notify Direct Support.
4-73
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-IGNITION CIRCUITS-Continued
10
CHECK ENGINE LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Steet 6 of 16)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check engine light relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check fuse.
Replace fuse (see para 4-9.4).
Step 4. Check DDEC Engine Control Module (ECM) using Diagnostic Data Reader (DDR).
Replace DDEC ECM.
11
Notify Direct Support.
ENGINE STARTER MOTOR DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 5 of 16.)
Step 1. Check engine starter motor.
Replace starter motor. Notify Direct Support.
Step 2. Check A and B start solenoids.
Replace solenoid(s) (see para 4-9.4).
Step 3. Check A and B start switches.
Replace switch (see para 4-94).
Step 4. Check neutral start safety switch.
Replace switch (see para 4-9.4).
Step 5. Check for +12V at ignition accessory buss.
Refer to "+12 volts not present at ignition accessory buss" troubleshooting procedure.
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-74
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-IGNITION CIRCUITS-Continued
12
ETHER STARTING AID DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Ensure that starter motor is engaged while attempting to use ether starting aid.
Engage starter motor.
NOTE
If starter motor will not engage, refer to "engine starter
motor does not operate" troubleshooting procedure.
Step 2. Check solenoid valve.
Replace valve (see para 4-9.4).
Step 3. Check panel switch for proper operation.
Replace switch (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
13
ALL CAB ELECTRIC INSTRUMENTS DO NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 2. Refer to "+12 volts not present at ignition accessory buss" troubleshooting procedure.
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-75
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-IGNITION CIRCUITS-Continued
14
NEUTRAL SAFETY CIRCUIT DOES NOT PROVIDE +12V SIGNAL TO CRY030
(Refer to Electrical Wiring Diagram, Appendix H, Sheet 5 of 16.)
Step 1.
With ignition switch on, check for +12V at circuit breaker #5 on ignition accessory buss.
Replace circuit breaker (see para 4-99).
Step 2. With shift selector in neutral, check for +12V on both sides of neutral safety switch.
Replace neutral safety switch (see para 4-9.4).
Step 3. Check wiring for continuity
Replace wire (see para 4-9.4).
15
+12 VOLTS IS NOT PRESENT AT BATTERY ACCESSORY BUSS
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 5 of 16.)
Step 1. Check batteries for proper charge.
Charge or replace batteries (see para 4-114).
Step 2. Check battery selector switch.
Replace switch (see para 4-101).
Step 3. Check wiring for continuity.
Replace wires (see para 4-9.4).
16
+12 VOLTS IS NOT PRESENT AT IGNITION ACCESSORY BUSS
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check ignition solenoid.
Replace solenoid (see para 4-9.4).
Step 2. Check ignition switch.
Replace switch (see para 4-9.4).
Step 3. Check wiring for continuity.
Replace wires (see para 4-9.4).
4-76
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS
1
HEADLIGHTS (HIGH OR LOW BEAM) DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-81).
Step 2. Check dimmer switch on cab floor.
Replace switch (see para 4-9.4).
Step 3. Check headlight relay for proper operation.
Replace relay (see para 4-9.4).
Step 4. Check light switch for proper operation.
Replace switch (see para 4-9.4).
Step 5. Check for +12V at circuit breaker #16 on battery buss.
Replace circuit breaker (see para 4-99).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
2
FRONT ID LIGHTS, ID BULLETS (FRONT AND REAR), TAIL LIGHTS,
SIDE ID LAMPS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb.
Step 2. Check for +12V at circuit breaker #7 on headlight buss.
Replace breaker (see para 4-9.4).
Step 3. Check headlight switch for proper operation.
Replace switch (see para 4-9.4).
4-77
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
2
FRONT ID LIGHTS, ID BULLETS (FRONT AND REAR), TAIL LIGHTS,
SIDE ID LAMPS DO NOT ILLUMINATE-Continued
Step 4. Check for +12V at circuit breaker #16 on battery accessory buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
3
STEP LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-14).
Step 2. Check step light relay for proper operation.
Replace relay (see para 4-.94).
Step 3. Check for +12V at circuit breaker #1 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check for +12V at circuit breaker #7 on headlight buss.
Replace breaker (see para 4-99).
Step 5. Check for +12V at headlight buss.
Refer to headlight troubleshooting procedure.
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-78
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
4
CLEARANCE LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-69).
Step 2. Check for +12V at circuit breaker #7 on battery accessory buss.
Replace breaker (see para 4-99).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
5
TURN SIGNALS DO NOT FUNCTION PROPERLY
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-65).
Step 2. Check directional control switch for proper operation.
Replace flasher unit (see para 4-9.4).
Step 3. Check for +12V at circuit breaker #1 5 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
6
BACKUP LIGHTS DO NOT ILLUMINATE, OR BACKUP ALARM DOES NOT SOUND
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 8 of 16.)
Step 1. Check bulb or alarm.
Replace bulb/alarm (see para 4-64 and 4-67).
Step 2. Check transmission switch for proper operation.
Replace switch (see para 4-100).
4-79
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
6
BACKUP LIGHTS DO NOT ILLUMINATE, OR BACKUP ALARM DOES NOT SOUND-Continued
Step 3. Check for +12V at circuit breaker #14 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire.
7
(see para 4-9.4)
BRAKE LIGHTS DO NOT ILLUMINATE WITH FOOT PEDAL
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 8 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-65).
Step 2. Check PSI switch for proper operation.
Replace switch (see para 4-9.4).
Step 3. Check brake light relay for proper operation.
Replace relay (see para 4-9.4).
Step 4. Check for +12V at circuit breaker #1 3 on battery accessory buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
8
MECHANICAL SIREN DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check motor.
Replace motor (see para 4-91).
Step 2
Check solenoid.
Replace solenoid (see para 4-9.4).
4-80
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
8
MECHANICAL SIREN DOES NOT OPERATE-Continued
Step 3. Check footswitch for proper operation.
Replace switch (see para 4-9.4).
Step 4. Check for +12V at emergency master buss.
Refer to "+12 volts not present at emergency master buss" troubleshooting procedure.
Step 5. Check for +12V at emergency master circuit breaker #2.
Replace breaker (see para 4-99).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
9
MECHANICAL SIREN BRAKE DOES NOT OPERATE
(See Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check brake solenoid for proper operation.
Replace solenoid (see para 4-9.4).
Step 2. Check siren brake switch.
Replace switch (see para 4-9.4).
Step 3. Check for +12V at siren brake relay (wire 1633) when siren is off.
Replace relay (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4)
4-81
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
10
ELECTRIC HORNS DO NOT SOUND
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check horns for proper operation.
Replace horns (see para 4-9.4).
Step 2. Check horn relay.
Replace relay (see para 4-9.4).
Step 3. Check column switch for proper operation.
Replace switch (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
11
REAR SIGNAL BUZZER DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 4 of 16.)
Step 1. Check switch for proper operation.
Replace switch (see para 4-68).
Step 2. Check buzzer unit for proper operation.
Replace buzzer (see para 4-96).
Step 3. Check for +12V at circuit breaker #12 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-82
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
12
ENGINE COMPARTMENT LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-9.4).
Step 2. Check switch at fixture.
Replace switch (see para 4-9.4).
Step 3. Check for +12V at circuit breaker #12 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
13
CAB OR CREW CAB DOME LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-9.4 and 4-97).
Step 2. Check switch at fixture.
Replace switch (see para 4-9.4 and 4-97).
Step 3. Check door switch (step light may also fail to come on when door is opened).
Replace door switch (see para 4-9.4).
Step 4. Check for +12V at circuit breaker #10 on battery accessory buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-83
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
14
MAP LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-97).
Step 2. Check switch at fixture.
Replace switch (see para 4-97).
Step 3. Check for +12V at circuit breaker #10 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
15
REMOTE CONTROL CAB SPOTLIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb. (see para 4-84).
Step 2. Check switch at swivel control.
Replace switch (see para 4-84).
Step 3. Check for +12V at circuit breaker #7 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-84
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
16
REAR SCENE LIGHTS DO NOT ILLUMINATE WITH CAB SWITCH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 3 and 8 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-66).
Step 2. Check cab switch.
Replace switch (see para 4-94).
Step 3. Check for +12V at circuit breaker #6 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
17
CREW CAB EXHAUST FANS DO NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check motor.
Replace motor (see para 4-89).
Step 2. Check switch.
Replace switch (see para 4-9.4).
Step 3. Check for +12V at circuit breaker #12 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-85
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
18
COMPARTMENT LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 1 5 and 8 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-13).
Step 2. Check switch at fixture.
Replace switch (see para 4-13).
Step 3. Check for +12V at circuit breaker #5 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
19
COMPARTMENT OPEN WARNING LIGHT DOES NOT ILLUMINATE OR FLASH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-9.4).
Step 2. Check flasher unit for proper operation.
Replace flasher (see para 4-9.4).
Step 3. Check compartment light relay for proper operation.
Replace relay (see para 4-9.4).
Step 4. Check door switch(es).
Replace switch (see para 4-9.4).
4-86
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
19
COMPARTMENT OPEN WARNING LIGHT DOES NOT ILLUMINATE OR FLASH-Continued
Step 5. Check for +12V at circuit breaker #9 on battery accessory buss.
Replace breaker (see para 4-99).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
20
WINDSHIELD WIPERS DO NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check motor.
Replace motor (see para 4-111).
Step 2. Check switch.
Replace switch (see para 4-94).
Step 3. Check for +12V at circuit breaker #6 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check ignition solenoid for proper operation.
Replace solenoid (see para 4-9.4).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
21
WINDSHIELD WASHERS DO NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check washer pump motor.
Replace motor (see para 4-109).
Step 2. Check switch.
Replace switch (see para 4-94).
4-87
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
21
WINDSHIELD WASHERS DO NOT OPERATE-Continued
Step 3. Check for +12V at circuit breaker #6 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check ignition solenoid for proper operation.
Replace solenoid (see para 4-9.4).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
22
PARK BRAKE INDICATOR DOES NOT ILLUMINATE WHEN PARK BRAKE IS ENGAGED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check PSI switch for proper operation.
Replace switch (see para 4-145).
Step 3. Check for +12V at circuit breaker #4 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-88
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
23
INTER-AXLE LOCKOUT INDICATOR DOES NOT ILLUMINATE WHEN AXLES ARE LOCKED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check under dash PSI switch for proper operation.
Replace switch (see para 4-9.4).
Step 3. Check for +12V at circuit breaker #5 on ignition buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
24
CAB HEATER FAN DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check blower motor for proper ground.
Repair ground (see para 4-9.4).
Step 2. Check blower motor.
Replace blower motor (see para 4-9.4).
Step 3. Check switch.
Replace switch (see para 4-102).
Step 4. Check for +12V at circuit breaker #3 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-89
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
25
AIR DRYER DOES NOT DRY COMPRESSOR AIR
Step 1. Check dryer element for open.
Replace dryer element. Notify Direct Support.
Step 2. Check for +12V at circuit breaker #2 on ignition accessory buss.
Replace breaker #2 (see para 4-99).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9).
26
"PUMP NOT IN GEAR" LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check pump shift linkage switch for proper operation.
Adjust/replace switch (see para 4-9.4).
Step 3. Check cab pump shift switch for proper operation.
Replace switch (see para 4-94).
Step 4. Check pump shift circuit breaker for +12V on both sides.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-90
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
27
PUMP SHIFT SWITCH DOES NOT ENGAGE PUMP
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check switch.
Replace switch (see para 4-9.4).
Step 2. Check pump shift motor for proper operation.
Replace motor (see para 4-9.4).
Step 3. Check pump shift circuit breaker for +12V on both sides.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wiring (see para 4-9.4).
28
"PUMP IN GEAR" LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check pump shift linkage switch.
Replace switch (see para 4-9.4).
Step 3. Check pump shift switch for proper operation.
Replace switch (see para 4-9.4).
Step 4. Check pump shift circuit breaker for +12V on both sides.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-91
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
29
"PUMP IN GEAR" LIGHT ILLUMINATES, BUT PUMP DOES NOT ENGAGE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check solenoid actuated transmission locking valves for proper operation.
Replace valves (see para 4-9.4).
Step 2. Check wiring for continuity.
Replace wire (see para 4-9.4).
30
LOW FRONT AND REAR AIR LIGHTS DO NOT ILLUMINATE/FLASH WITH
LOW AIR PRESSURE INDICATED ON GAUGES
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check light.
Replace light (see para 4-9.4).
Step 2. Check flasher unit.
Replace flasher unit (see para 4-9.4).
Step 3. Check PSI switch for proper operation.
Replace switch (see para 4-9.4).
Step 4. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
31
LOW VOLTAGE LIGHT STAYS ON
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check batteries properly hold charge.
Replace batteries.
(see para 4-114).
Step 2. Check output of regulator/alternator.
Replace regulator/alternator (see para 4-133).
4-92
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
31
LOW VOLTAGE LIGHT STAYS ON-Continued
Step 3. Check battery isolator.
Replace isolator (see para 4-113).
Step 4. Check Nartron Voltron module for proper operation.
Replace module (see para 4-9.4).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
32
LOW VOLTAGE BUZZER DOES NOT SOUND DURING IGNITION "TEST"
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check alarm buzzer for proper operation.
Replace alarm buzzer (see para 4-9.4).
Step 2. Check ignition switch.
Replace switch (see para 4-94).
Step 3. Check fuse.
Replace fuse (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wiring (see para 4-9.4).
33
LOW VOLTAGE BUZZER DOES NOT SOUND WHEN VOLTAGE IS LOW
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check low voltage relay.
Replace relay (see para 4-9.4).
Step 2. Check 3A fuse on unswitched side of relay.
Replace fuse (see para 4-9.4).
4-93
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
33
LOW VOLTAGE BUZZER DOES NOT SOUND WHEN VOLTAGE IS LOW-Continued
Step 3. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
34
LOW VOLTAGE BUZZER CONTINUES TO SOUND WHEN VOLTAGE IS AT OR ABOVE 12V
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check low voltage relay.
Replace relay (see para 4-9.4).
35
VOLTMETER (12V) DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check meter.
Replace meter (see para 4-93).
Step 2. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 3. Refer to "+12 volts not present at ignition accessory buss" troubleshooting procedure.
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-94
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
36
CAB ENGINE OIL PRESSURE, ENGINE COOLANT TEMPERATURE GAUGES DO NOT
OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check sender.
Replace sender (see para 4-138).
Step 2. Check gauge.
Replace gauge (see para 4-93).
Step 3. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. "+12 volts not present at ignition accessory buss" troubleshooting procedure.
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
37
CAB PANEL TRANSMISSION OIL TEMPERATURE GAUGE DOES NOT OPERATE
Step 1. Check gauge.
Replace gauge (see para 4-93).
Step 2. Check sender.
Replace sender (see para 4-138).
Step 3. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Refer to "+12 volts not present at ignition accessory buss" troubleshooting procedure.
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 6. Check for +12V at ignition accessory buss.
Refer to "ignition accessory buss troubleshooting" procedure.
4-95
TM 5-4210-233-14&P-1
Table 4.2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
38
CAB PANEL FUEL GAUGE DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check sender.
Replace sender (see para 4-168).
Step 2. Check gauge.
Replace gauge (see para 4-93).
Step 3. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
39
INSTRUMENT PANEL GAUGE AND BACKLIGHTING DOES NOT ILLUMINATE
Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check dimmer control.
Replace dimmer control (see para 4-94).
Step 3. Check for +12V at headlight buss.
Refer to "headlights (high or low beam) do not illuminate" troubleshooting procedure.
Step 4. Check for +12V at circuit breaker #8 at headlight buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-96
TM 5-4210-233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
40
ENGINE HOUR METER DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check gauge.
Replace gauge (see para 4-93).
Step 2. Check engine hour PSI switch for proper operation.
Replace PSI switch (see para 4-9.4).
Step 3. Check for +12V at ignition accessory buss for +12V.
Refer to "+12 volts not present at ignition accessory buss" troubleshooting procedure.
Step 4. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
41
AERIAL HOUR METER DOES NOT OPERATE WITH AERIAL MASTER ON,
PARK BRAKE ON, AND SHIFT SELECTOR IN NEUTRAL
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check gauge.
Replace gauge (see para 4-93).
Step 2. Check PTO fuse.
Replace fuse (see para 4-9.4).
Step 3. Check aerial solenoid for proper operation.
Replace solenoid (see para 4-9.4).
Step 4. Check neutral safety relay (CRY032 in DDEC hi-idle interlock module) for +12V at wire 11 17.
Refer to "neutral safety circuit does not provide +12V signal to CRY030" troubleshooting
procedure.
4-97
TM 5-4210233-14&P-1
Table 4-2.
Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM-CAB CONTROLS AND INDICATORS-Continued
41
AERIAL HOUR METER DOES NOT OPERATE WITH AERIAL MASTER ON,
PARK BRAKE ON, AND SHIFT SELECTOR IN NEUTRAL-Continued
Step 5. Check PTO relay (CRY054 in DDEC hi-idle interlock module) for+12V at wire 1205.
Replace relay (see para 4-9.4).
Step 6. Check PTO switch.
Replace switch (see para 4-95).
42
CAB TACHOMETER DOES NOT INDICATE ENGINE RPM
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check for'+12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 2. Check for +12V at tachometer.
Replace wire (see para 4-9.4).
Step 3. Replace tachometer with a new unit to confirm proper operation of DDEC tachometer send.
If new tachometer functions properly, install new tachometer.
If tachometer fails to function properly, go on to step 4.
Step 4. Check wiring from DDEC tachometer send to tachometer for continuity.
Replace wire (see para 4-9.4).
Step 5. Check DDEC for fault using Diagnostic Data Reader according to manufacturer's instructions.
Replace DDEC Engine Control Module (ECM). Notify Direct Support.
4-98
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - CAB CONTROLS AND INDICATORS - Continued
43
CAB SPEEDOMETER DOES NOT INDICATE VEHICLE SPEED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 2 of 16.)
Step 1. Check gauge.
Replace gauge (see para 4-93).
Step 2. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 3. Check wiring from pulse generator to gauge for continuity.
Replace wire (see para 4-9.4).
Step 4. Check pulse generator (sender) for proper operation.
Replace pulse generator (see para 4-9.4).
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS
1.
EMERGENCY MASTER SWITCH DOES NOT ENERGIZE EMERGENCY EQUIPMENT
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check switch.
Replace switch (see para 4-94).
Step 2. Check emergency master solenoid for proper operation.
Replace solenoid (see para 4-9.4).
Step 3. Check for +12V at circuit breaker #9 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-99
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS - Continued
2
ROTATING BEACONS (CAB ROOF) WILL NOT ROTATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check motor.
Replace motor (see para 4-85).
Step 2. Check wiring to motor for continuity.
Replace wire (see para 4-9.4).
3
ROTATING BEACONS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-85).
Step 2. Check brush and collector ring assembly for good electrical contact.
Replace brush/collector assembly (see para 4-85).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
4
ROTATING BEACONS DO NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check switch.
Replace switch (see para 4-94).
Step 2. Check "roof light" solenoid for proper operation.
Replace solenoid (see para 4-9.4).
Step 3. Check for +12V at emergency master buss.
Refer to "+12 volts not present at emergency master buss" troubleshooting procedure.
Step 4. Check for +1 2V at circuit breaker #1 on emergency master buss.
Replace breaker (see para 4-99).
4-100
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS - Continued
4
ROTATING BEACONS DO NOT OPERATE - Continued
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
5
FRONT WARNING (CROSSFIRE) LIGHTS DO NOT OSCILLATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check motor for proper operation.
Replace motor (see para 4-83).
Step 2. Check wiring for continuity.
Replace wire (see para 4-9.4).
6
FRONT WARNING (CROSSFIRE) LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-83).
Step 2. Check wiring for continuity.
Replace wire (see para 4-9.4).
7
FRONT WARNING (CROSSFIRE) LIGHTS DO NOT OPERATE
(Refer to Electrical Diagrams, Appendix H, Sheet 1 of 16.)
Step 1. Check switch.
Replace switch (see para 4-94).
Step 2. Check for +12V at emergency master buss.
Refer to "+12 volts not present at emergency master buss" troubleshooting procedure.
Step 3. Check for +12V at circuit breaker #3 on emergency master buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-101
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS - Continued
8
SIDE FLASHERS DO NOT ILLUMINATE/FLASH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 7 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-175).
Step 2. Check flasher unit.
Replace flasher unit. (see para 4-9.4)
Step 3. Check switch.
Replace switch (see para 4-94).
Step 4. Check for +12V at emergency master buss.
Refer to "=12 volts not present at emergency master buss" troubleshooting procedure.
Step 5. Check for +12V at circuit breaker #4 on emergency master buss.
Replace breaker (see para 4-99).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
9
REAR WARNING STROBES DO NOT ILLUMINATE/FLASH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 8 of 16.)
Step 1. Check 10A fuse on trigger unit in left-rear storage compartment.
Replace fuse (see para 4-9.4).
Step 2. Check for +12V at emergency master buss.
Refer to "+12 volts not present at emergency master buss”troubleshooting procedure.
Step 3. Check sealed beam flash unit.
Replace sealed beam unit (see para 4-61).
4-102
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS - Continued
9
REAR WARNING STROBES DO NOT ILLUMINATE/FLASH - Continued
Step 4. Check trigger unit.
Replace trigger unit (see para 4-61).
Step 5. Check for +12V at circuit breaker #4 on emergency master buss.
Replace breaker (see para 4-99).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
10
DECK SPOTLIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 8 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-63).
Step 2. Check switch at fixture.
Replace switch (see para 4-63).
Step 3. Check for +12V at battery accessory buss.
Refer to "+12 volts not present at battery accessory buss" troubleshooting procedure.
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
11
ELECTRONIC SIREN DOES NOT SOUND
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check for +12V at emergency master buss.
Refer to "+12 volts not present at emergency master buss" troubleshooting procedure.
Step 2. Check speaker for proper operation.
Replace speaker (see para 4-86).
4-103
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - EMERGENCY MASTER CIRCUITS - Continued
11
ELECTRONIC SIREN DOES NOT SOUND - Continued
Step 3. Check for +12V on wire 1637 (terminal S5) at siren unit.
Replace broken wire (see para 4-9.4).
Step 4. Check internal fuse on siren unit.
Replace fuse (see para 4-86).
12
+12 VOLTS IS NOT PRESENT AT EMERGENCY MASTER BUSS
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 4 of 16.)
Step 1. Check emergency master solenoid.
Replace solenoid (see para 4-9.4).
Step 2. Check emergency master switch.
Replace switch (see para 4-94).
Step 3. Check wiring for continuity.
Replace wires (see para 4-9.4).
ELECTRICAL SYSTEM - THROTTLE
1
THROTTLE DOES NOT ADVANCE WITH ELECTRONIC FOOT PEDAL
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 13 of 16.)
Step 1. Check wiring from cab foot pedal to DDEC ECM for continuity.
Replace wire (see para 4-9.4).
Step 2. Check that throttle advances using vernier throttle on pump panel.
If throttle does not advance using pump panel control, replace ECM. Notify Direct Support.
If throttle advances using pump panel control, replace foot pedal sensor.
Notify Direct Support.
4-104
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - THROTTLE - Continued
2
PUMP PANEL VERNIER THROTTLE (SENSOR PTO CONTROL) DOES NOT FUNCTION
PROPERLY (Refer to Electrical Wiring Diagrams, Appendix H, Sheet 13 of 16.)
Step 1. Check that pump is engaged and green "Do not advance throttle unless light is on" light is
illuminated.
Engage pump, park brake on, shift selector in D (drive).
Step 2. Attempt to advance throttle using pump panel throttle control.
If throttle advances, control is operable.
If throttle fails to advance, go to Step 3.
Step 3. Engage hi-idle using dash HIGH IDLE switch.
If hi-idle engages, go onto Step 4.
If hi-idle fails to engage, refer to hi-idle circuit troubleshooting procedures.
Step 4. Check CRY054 contacts 4 and 7 for continuity (refer to Electrical Wiring Diagrams,
Appendix H, Sheet 4 of 15).
Replace CRY054 (see para 4-9.4).
Step 5. Check CRY031, contacts 1 and 7 for continuity (refer to Electrical Wiring Diagrams,
Appendix H, Sheet 4 of 15).
Replace CRY031 (see para 4-9.4).
Step 6. Check wire 1993 for continuity between CRY031 and vernier throttle "5" terminal B.
Replace wire (see para 4-9.4).
Step 7. Check wires D952 and D916 from vernier throttle connector DDEC ECM connector 1 for
continuity.
Replace wire (see para 4-9.4)
Step 8. Attempt to advance throttle using foot pedal.
If foot pedal advances throttle, replace vernier throttle control (see para 4-27).
If foot pedal does not advance throttle, replace DDEC electronic control module (ECM).
Notify Direct Support.
4-105
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - THROTTLE - Continued
3
HYDRAULIC TRANSMISSION MODULATION CONTROL SOLENOID NOT WORKING PROPERLY
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 13 of 16.)
Step 1. Check fuse (7.5A location in dash comp.)
Replace fuse (see para 4-9.4).
Step 2. Check relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check solenoid air valve for proper operation.
Replace valve. (see para 4-9.4)
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Refer to DDEC troubleshooting procedure.
4
HYDRAULIC TRANSMISSION MODULATION CONTROL VALVE DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 13 of 16.)
Step 1. Check Skinner air valve for proper operation.
Replace Skinner air valve (see para 4-9).
Step 2. Check control relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check fuse.
Replace fuse (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Check DDEC ECM using Diagnostic Data Reader (DDR).
Replace DDEC ECM. Notify Direct Support.
4-106
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - JACOBS ENGINE BRAKE
1
JACOBS ENGINE BRAKE DOES NOT ACTIVATE WITH CAB SWITCH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 14 of 16.)
Step 1. Check that pump shift switch is in ROAD position.
Shift pump to ROAD position.
Step 2. Check switch for proper operation.
Replace switch (see para 4-9.4).
Step 3. Condition of truck is not correct for Jacobs brake operation, torque converter must be
locked up, throttle off.
Lock up torque converter, place throttle off.
Step 4. Check wire D508 is ground for and for continuity to DDEC.
Replace wire (see para 4-9.4).
Step 5. Check torque converter lockup psi switch for proper operation. (Continuity between wires
1093 and 1162 when torque converter is locked).
Replace switch (see para 4-9.4).
Step 6. With wire 1657 disconnected from pump in gear auto disengage relay, check for
+12V at wire 1099.
Replace auto disengage relay (see para 4-9.4).
Step 7. With wire D508 removed and throttle control relay terminal 85 connected to ground,
check for +12Von wire 1093L.
Replace throttle control (disenable) relay (see para 4-9.4).
Step 8. Check for +12V at wire 1161 at circuit breaker.
Replace breaker (see para 4-99).
Step 8. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-107
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - JACOBS ENGINE BRAKE - Continued
2
JACOBS ENGINE BRAKE WORKS ONLY IN ONE SWITCH POSITION
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 14 of 16.)
Step 1. Check switch.
Replace switch (see para 4-9.4).
Step 2. Check wiring for continuity.
Replace wiring (see para 4-9.4).
Step 3. Check solenoid valve at engine brake for proper operation.
Replace solenoid valve (see para 4-9.4).
3
JACOBS BRAKE WORKS WHILE VEHICLE IS SHIFTED TO "PUMP" MODE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 14 of 16.)
Step 1. Check wire 1657 from pump shift switch to auto disengage relay for continuity.
Replace wire (see para 4-9.4).
Step 2. Check auto disengage relay for proper operation.
Replace relay (see para 4-9.4).
4
JACOBS BRAKE WORKS WHEN THROTTLE IS DEPRESSED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 14 of 16.)
Step 1. Check wire D508 from DDEC to throttle control relay for continuity.
Replace wire (see para 4-9.4).
Step 2. Check throttle control relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check DDEC for ground on pin A1 of connector 1 when throttle is released.
Replace ECM. Notify Direct Support.
4-108
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - JACOBS ENGINE BRAKE - Continued
5
BRAKE LIGHTS DO NOT ILLUMINATE WHEN JACOBS BRAKE IS ENGAGED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 14 of 16.)
Step 1. Confirm that Jacobs brake is functioning properly.
Refer to Jacobs brake troubleshooting procedure.
Step 2. Check Jacobs brake light relay for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 4. Refer to brake light troubleshooting procedure.
ELECTRICAL SYSTEM - HI-IDLE CIRCUITS
1
HIGH IDLE SWITCH IN CAB WILL NOT ENGAGE HIGH IDLE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check that parking brake is engaged.
Engage parking brake.
Step 2. Check that transmission selector is in N (neutral).
Place transmission selector in N (neutral).
Step 3. Check HIGH IDLE switch.
Replace switch (see para 4-9.4).
Step 4. Check for +12V signal at neutral safe relay (CRY030) coil.
Replace CRY030 (see para 4-9.4).
Step 5. Check CRY032 for 12V signal at coil.
Replace park brake PSI switch (see para 4-9.4).
4-109
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - HI-IDLE CIRCUITS - Continued
1
HIGH IDLE SWITCH IN CAB WILL NOT ENGAGE HIGH IDLE - Continued
Step 6. Check for +12V at terminal #9 of CRY032.
Replace pump linkage switch (see para 4-9.4).
Step 7. Check for +12V at terminal #6 of CRY032.
Replace CRY032 (see para 4-9.4).
Step 8. With PTO switch off, check for continuity between terminals 6, 9 and 7, 4 on CRY054.
Replace CRY054 (see para 4-9.4).
Step 9. Attempt to engage high idle using cab switch, then, with wires 1494 and 1495 disconnected,
check for continuity between terminals 4 and 7 of CRY031.
Replace CRY031 (see para 4-9.4).
2
HIGH IDLE ENGAGES, BUT INDICATOR LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-95).
Step 2. Check terminal #9 on CRY031 (wire 1427) for +12V.
Replace wiring/circuit breaker #2 on ignition accessory buss (see para 4-99).
Step 3. With high idle engaged, check for +12V on terminal #6 of CRY031 (wire 1510).
Replace CRY031 (see para 4-9.4).
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TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - HI-IDLE CIRCUITS - Continued
3
REAR CONTROL PANEL HIGH IDLE SWITCH WILL NOT ENGAGE HIGH IDLE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check that parking brake is engaged.
Engage parking brake.
Step 2. Check that transmission selector is in N (neutral).
Place transmission selector in N (neutral).
Step 3. Check that aerial master switch is ON.
Turn aerial master switch ON.
Step 4. Attempt to engage high idle with cab switch.
If high idle engages with cab switch, go to step 2.
If high idle does not engage with cab switch, refer to "cab switch will not engage high idle
with parking brake on and transmission shift selector in N (neutral)."
Step 5. Check rear control panel high idle switch.
Replace switch (see para 4-179).
Step 6. Check for +12V at aerial buss.
Refer to "+12 volts not present at aerial master buss" troubleshooting procedure.
Step 7. Check for +12V at circuit breaker #5 on aerial master buss.
Replace breaker (see para 4-99).
Step 8. Check for +12V at switch (wire 1222).
Replace wire from breaker to switch (see para 4-9.4).
Step 9. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-111
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - HI-IDLE CIRCUITS - Continued
4
RUN/LOCK LEVER ON AERIAL PANEL WILL NOT ENGAGE HIGH IDLE WITH PARK BRAKE
ON, SHIFT SELECTOR IN NEUTRAL, AND AERIAL MASTER SWITCH ON
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Attempt to engage high idle with cab switch.
If cab switch engages high idle, go to step 2.
If cab switch does not engage high idle, refer to "cab switch will not engage high idle with
parking brake on and transmission selector in N (neutral)."
Step 2. Attempt to engage high idle with rear panel switch.
If rear panel switch engages high idle, go to step 3.
If rear panel switch does not engage high idle, refer to "rear switch will not engage high idle
with parking brake on and transmission selector in N (neutral)."
Step 3. Check limit switch at RUN/LOCK for proper operation.
Replace limit switch (see para 4-185).
Step 4. Check "on" timer for proper operation (a +12V signal applied to wire 1207 should produce
a +12V signal on wire 1133 for 1/2 second).
Replace timer (see para 4-9.4).
Step 5. Check for +12V at circuit breaker #5 on the aerial master buss.
Replace breaker (see para 4-99).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-112
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - HI-IDLE CIRCUITS - Continued
5
CAB SWITCH WILL NOT DISENGAGE HIGH IDLE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check that aerial master is off and RUN/LOCK lever on aerial panel is in LOCK position.
Turn off aerial master, place RUN/LOCK lever in LOCK position.
Step 2. Check latching relay (CRY031) for proper operation. Relay should disengage when +12V is
applied to terminal #8 (Wire 1134).
Replace CRY031 (see para 4-9.4).
Step 3. Check for +12V at circuit breaker on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check high idle switch for proper operation.
Replace high idle switch (see para 4-94).
6
REAR SWITCH WILL NOT DISENGAGE HIGH IDLE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check that aerial master is on.
Turn on aerial master switch.
Step 2. Check that RUN/LOCK lever on aerial panel is in LOCK.
Step 3. Attempt to disengage high idle using cab switch.
Refer to "cab switch will not engage high idle with parking brake on and transmission
selector in N (neutral)."
Step 4. Check rear control panel high idle switch for proper operation.
Replace switch (see para 4-179).
Step. 5. Check wire 1134 for continuity between high idle switch and terminal #8 on CRY031.
Replace wire (see para 4-9.4).
4-113
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - HI-IDLE CIRCUITS - Continued
6
REAR SWITCH WILL NOT DISENGAGE HIGH IDLE - Continued
Step 6. Check aerial circuit breaker#5 for +12V.
Replace aerial circuit breaker #5 (see para 4-99).
Step 7. Check for +12V at high idle switch (wire #1222).
Replace wire 1222 between breather and switch (see para 4-9.4).
7
RUN/LOCK LEVER WILL NOT DISENGAGE HIGH IDLE WHEN IN "LOCK" POSITION
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check that aerial master switch is on.
Turn on aerial master switch.
Step 2. Attempt to disengage high idle with rear switch.
If high idle disengages with rear switch, go on to Step 3.
If high idle does not disengage with rear switch refer to "rear switch will not engage high idle
with parking brake on and transmission selector in N (neutral)."
Step 3. Check limit switch at run/lock lever for proper operation.
Replace run/lock lever limit switch (see para 4-185).
Step 4. Check "off " timer for proper operation (a +12V signal applied to wire 1304 should produce
a +12V signal on wire 1134 for 1/2 second).
Replace "off" timer (see para 4-9.4).
8
REAR PANEL "DO NOT ENGAGE HIGH IDLE UNLESS LIGHT IS ON" LIGHT WILL NOT
ILLUMINATE WITH PARK BRAKE ON AND SHIFT SELECTOR IN N (NEUTRAL)
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
Step 2. Check CRY032 (park brake relay) for proper operation.
Replace CRY032 (see para 4-9.4).
Step 3. Refer to high idle circuit troubleshooting procedures.
4-114
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PTO
5
CAB SWITCH WILL NOT ENGAGE AERIAL PTO WITH PARK BRAKE ON, SHIFT SELECTOR IN
N (NEUTRAL), AND AERIAL MASTER CIRCUIT ON
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check for +12V at aerial buss.
If +12V is present at aerial buss, go on to Step 2..
If +12V is not present at aerial buss, refer to "+12 volts not present at aerial master buss"
troubleshooting procedure.
Step 2. Check aerial master fuse for continuity.
Replace fuse (see para 4-9.4).
Step 3. Test aerial PTO switch for proper operation.
Replace aerial PTO switch (see para 4-94).
Step 4. Check CRY054 for continuity between terminals 6 and 9 while relay is energized.
(To be energized, parking brake must be on, transmission shift selector in N (neutral),
and battery switch on.)
Replace CRY054 (see para 4-9.4).
Step 5. Check wire 1206 for continuity between CRY054 and PTO solenoid valve.
Replace wire (see para 4-9.4).
Step 6. Check PTO solenoid valve for proper operation.
Replace PTO solenoid valve (see para 4-9.4).
2
PTO ENGAGED LIGHT WILL NOT ILLUMINATE
(Refer to Electrical Wiring Diagram, Appendix H, Sheet 3 of 16.)
Step 1. With diverter valve in outrigger position, operate outrigger control levers.
If outriggers function, go on to Step 2.
If outriggers do not function, refer to "cab switch will not engage aerial PTO with
park brake on, shift selector in N (neutral), and aerial master circuit on."
4-115
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PTO Continued
2
PTO ENGAGED LIGHT WILL NOT ILLUMINATE - Continued
Step 2. Check bulb.
Replace bulb (see para 4-95).
Step 3. Check aerial PTO switch for proper operation.
Replace switch (see para 4-94).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
ELECTRICAL SYSTEM - PUMP PANEL
1
PUMP PANEL ILLUMINATION LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-12).
Step 2. Check switch.
Replace switch (see para 4-22).
Step 3. Check for +12V at circuit breaker #8 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-116
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
2
PUMP COMPARTMENT LIGHT (CURB SIDE) DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 5 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-9.4).
Step 2. Check switch at fixture.
Replace switch (see para 4-9.4).
Step 3. Check for +12V at circuit breaker #8 on battery accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
3
WATER PRIMER PUMP DOES NOT OPERATE WITH SWITCH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 5 or 16.)
Step 1. Check switch.
Replace switch (see para 4-9.4).
Step 2. Check solenoid for proper operation.
Replace solenoid (see para 4-9.4).
Step 3. Check pump motor.
Replace motor (see para 4-58).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-117
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
4
PUMP PANEL TACHOMETER DOES NOT FUNCTION PROPERLY
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 6 of 16.)
Step 1. Check gauge.
Replace gauge (see para 4-20).
Step 2. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 3. Check pulse generator.
Replace pulse generator (see para 4-9.4).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9).
5
PUMP PANEL VOLTMETER (12V) DOES NOT FUNCTION PROPERLY
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 6 of 16.)
Step 1. Check fuse.
Replace fuse (see para 4-9.4).
Step 2. Check gauge.
Replace gauge (see para 4-18).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
6
PUMP PANEL FUEL GAUGE DOES NOT FUNCTION PROPERLY
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check sender.
Replace sender (see para 4-168).
Step 2. Check gauge.
Replace gauge (see para 4-18).
4-118
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
6
PUMP PANEL FUEL GAUGE DOES NOT FUNCTION PROPERLY - Continued
Step 3. Check for +12V at circuit breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
7
WATER TANK LEVEL INDICATOR DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check bulb(s).
Replace bulb (see para 4-19).
Step 2. Check sender.
Replace sender (see para 4-75).
Step 3. Check indicator unit.
Replace indicator unit (see para 4-19).
Step 4. Check for +12V at circuit breaker #8 on battery accessory buss.
Replace breaker (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-119
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
8
RELIEF VALVE INDICATOR LIGHTS DO NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 6 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-21).
Step 2. Check switch on valve.
Replace switch (see para 4-35).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 4. Check pump shift circuit for proper operation.
Refer to "pump shift switch does not engage pump" troubleshooting procedure.
ELECTRICAL SYSTEM - OUTRIGGER CONTROL PANEL
1
OUTRIGGER DOWN LIGHT DOES NOT ILLUMINATE WHEN OUTRIGGER IS DOWN
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 3 and 9 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
Step 2. Check outrigger down limit switches.
Replace switch (see para 4-196).
Step 3. Check for +12V at breaker #1 on ignition accessory buss.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
4-120
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
2
OUTRIGGER ALARM DOES NOT SOUND WHEN OUTRIGGERS STOWED AND DIVERTER
VALVE IS SWITCHED TO OUTRIGGER POSITION
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 7 of 16.)
Step 1. Check that "outrigger" light is illuminated.
If light is not illuminated, refer to diverter valve test procedure.
If light is illuminated, go on to Step 2.
Step 2. Check alarm for 12 volts across terminals.
If 12 volts is present at alarm, replace alarm.
If 12 volts is not present at alarm, go on to Step 3.
Step 3. With all power off, check contacts of outrigger and alarm interlock relays for continuity
(3, 9 left ply, 1, 7 right ply.)
Replace relay (see para 4-9.4).
Step 4. Check for +1 2V at aerial circuit breaker #2.
Replace breaker (see para 4-99).
Step 5. Check outrigger down limit switches by testing for +12V signal on wire #2389 when
engaged (outrigger down).
Replace limit switch (see para 4-196).
Step 6. Check front left outrigger down and front right outrigger down relays. Left - Continuity
between #1233 and wire #1249 when coil is energized. Right - continuity between wire
#1248 and #1228 when coil is energized.
Replace relay (see para 4-9.4).
4-121
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
3
OUTRIGGER ALARM DOES NOT SHUT OFF WHEN OUTRIGGERS ARE DEPLOYED AND
OUTRIGGER DOWN LIGHTS ARE LIT
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 7 of 16.)
Step 1. Check front left and front right outrigger down relays for +12V at wires 1249 (left)
and 1248 (right).
Replace outrigger down relay. (see para 4-9.4)
Step 2. Check left and right interlock and alarm relays for proper operation.
Replace relay (see para 4-9.4).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
4
REAR PANEL OUTRIGGER DOWN LIGHT WILL NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
Step 2. Place a jumper wire across the outrigger down limit switch terminals.
If light illuminates, replace outrigger down limit switch (see para 4-196).
If light fails to illuminate, go on to Step 3.
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 4. Check aerial circuit breaker #2 for +12V.
Replace breaker (see para 4-99).
4-122
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
5
OUTRIGGER ILLUMINATION LIGHTS WILL NOT LIGHT
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 7 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-176).
Step 2. Check jack flashers and outrigger control compartment illumination for proper operation.
If jack flashers and outrigger control compartment illuminations are not functioning properly
refer to "+12 volts not present at aerial master buss" troubleshooting procedure.
If jack flashers and aerial control compartment lights are functioning properly, go on
to Step 3.
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
6
OUTRIGGER JACK FLASHER DOES NOT ILLUMINATE OR FLASH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 7 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-175).
Step 2. Check flasher unit.
Replace flasher unit (see para 4-9.4).
Step 3. Check for +12V at aerial circuit breaker #1.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Check for +12V at aerial master buss.
Refer to "+12 volts not present at aerial master buss" troubleshooting procedure.
4-123
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
7
AERIAL POSITION OF DIVERTER CONTROL VALVE DOES NOT FUNCTION WITH
OUTRIGGERS PROPERLY DEPLOYED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check that diverter valve manual override engages aerial hydraulics.
Refer to hydraulic troubleshooting.
Step 2. Check that diverter valve manual override lever is disengaged. Control lever should move
freely and T-handle should be in the horizontal position.
If lever does not move freely, unlock lever by turning T-handle to the horizontal position
and try aerial position of diverter valve switch again.
If lever moves freely, go to Step 3.
Step 3. If aerial ladder is raised, check aerial nested switch for proper operation.
Replace switch (see para 4-9.4).
Step 4. If aerial ladder is nested, check left and right outrigger interlock relays for continuity between
wires 1224 and 1247 (left) and wires 1247 and 1242 (right).
Replace relay (see para 4-9.4).
Step 5. Check aerial solenoid for proper operation.
Replace aerial solenoid (see para 4-9.4).
Step 6. Check diverter switch for proper operation.
Replace switch (see para 4-179).
Step 7. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 8. Check for +12V at aerial circuit breaker #2.
Replace breaker (see para 4-99.)
4-124
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
8
OUTRIGGER POSITION OF AERIAL DIVERTER VALVE DOES NOT FUNCTION WITH AERIAL
LADDER NESTED (Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check that manual override engages outrigger hydraulics.
Refer to hydraulic troubleshooting.
Step 2. Check that diverter valve manual override lever is disengaged. Control lever should move
freely and T-handle should be in the horizontal position.
If lever does not move freely, unlock lever by turning T-handle to horizontal position and try
outrigger position of diverter valve switch again.
If lever moves freely, go on to Step 3.
Step 3. With ladder nested, check for continuity between wires 1241 and 1230 at aerial nested limit
switch. Be sure switch is functioning properly.
Adjust/replace aerial nested limited switch (see para 4-9.4).
Step 4. Check diverter valve switch for proper operation.
Replace diverter valve switch (see para 4-179).
Step 5. Check diverter valve "aerial" solenoid for +12 volt signal with switch in aerial position.
Replace solenoid (see para 4-9.4).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 7. Check circuit breaker #2 on aerial buss for +12V.
Replace circuit breaker #2 (see para 4-99).
If further troubleshooting is required, refer to "+12 volts not present at emergency master buss"
troubleshooting procedure.
4-125
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
9
AERIAL LADDER FUNCTIONS WITHOUT OUTRIGGER DEPLOYED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 5 and 9 of 16.)
Step 1. Check aerial nested switch for continuity between wires 1230 and 1241 when ladder is nested.
Adjust/replace aerial nested switch (see para 4-9.4).
Step 2. Check outrigger interlock relays for open with all power off between wires 1224 and 1247
(left relay) and 1247 and 1242 (right relay).
Replace interlock relay (see para 4-9.4).
Step 3. With all power off, check front left and front right down relays for open between 1233 and
1249 (left and 1228 and 1248 (right).
Replace down relay (see para 4-9.4).
Step 4. Check outrigger down limit switches for open when outriggers are up.
Adjust/replace outrigger limit switches (see para 4-196).
10
OUTRIGGER FUNCTION WHILE AERIAL LADDER IS RAISED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 5 of 16.)
Step 1. Check aerial nested switch for continuity between wires 1230 and 1241.
Adjust/replace aerial nested switch (see para 4-9.4).
11
PSI REDUCTION (PUMP DE-STROKE) VALVE DOES NOT ENGAGE WITH DIVERTER SWITCH
IN NEUTRAL POSITION AND AERIAL PANEL T-HANDLE IN "LOCK"
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 5 and 9 of 16.)
Step 1. Check for +12V at PSI reduction solenoid valve connector.
If 12V is present, repair/replace solenoid valve (see para 4-191).
If 12V is not present, go on to Step 3.
Step 2. Check for +12V at aerial circuit breaker #6.
Replace circuit breaker (see para 4-99).
Step 3. Check for +12V at wire 1304 at RUN/LOCK handle limit switch.
Replace RUN/LOCK limit switch (see para 4-185).
4-126
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
11
PSI REDUCTION (PUMP DE-STROKE) VALVE DOES NOT ENGAGE WITH DIVERTER SWITCH
IN NEUTRAL POSITION AND AERIAL PANEL T-HANDLE IN "LOCK" - Continued
Step 4. With all power off check for continuity between wires 1304 and 1305 at PSI reduction
manual diverter override relay.
Replace PSI reduction manual diverter override relay (see para 4-9.4).
Step 5. Check for 12V across coil at PSI reduction diverter valve override relay.
If 12V is present, go on to Step 6.
If 12V is not present, go to Step 9.
Step 6. With manual override T-handle in horizontal position, check diverter valve manual override
limit switch for open.
Replace limit switch (see para 4-9.4).
Step 7. With diverter valve switch in neutral position, check for open between wires 1238 and 1270.
Replace switch (see para 4-179).
Step 8. Check for open between wires 1223 and 1337 on PSI reduction diverter valve relay.
Replace relay (see para 4-9.4).
Step 9. Check wires for continuity.
Replace wire (see para 4-9.4).
4-127
TM 5-4210-233-14&P-1
Table 4-2. Unit Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
12
PSI REDUCTION VALVE WILL NOT DISENGAGE WITH DIVERTER VALVE SET TO
"OUTRIGGER" POSITION AND MANUAL OVERRIDE DISENGAGED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 5 and 9 of 16.)
Step 1. Check "outrigger" position of diverter valve switch for proper operation.
Replace diverter switch (see para 4-179).
Step 2. Check for +12V at wire 1337 at PSI reduction diverter valve relay.
Replace relay (see para 4-9.4).
Step 3. Check for 12V across coil of PSI reduction manual diverter override relay.
If 12V is present, go on to Step 4.
If 12V is not present, go to Step 5.
Step 4. Check for open between wires 1304 and 1305 at PSI reduction manual diverter overriderelay.
Replace relay (see para 4-9.4).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
13
OVERRIDE ACTIVATED LIGHT WILL NOT ILLUMINATE WHEN OVERRIDES ACTIVATED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
Step 2. Check wiring for continuity.
Replace wiring (see para 4-9.4).
14
DIVERTER VALVE POSITION INDICATOR LIGHTS WILL NOT ILLUMINATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet'9 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
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4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - PUMP PANEL - Continued
14 DIVERTER VALVE POSITION INDICATOR LIGHTS WILL NOT ILLUMINATE - Continued
Step 2. Check diverter valve switch for proper operation.
Replace switch (see para 4-179).
15 OUTRIGGER CONTROL PANEL ILLUMINATION LIGHTS DO NOT LIGHT WITH
AERIAL/MASTER SWITCH ON (Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-9.4).
Step 2. Check for +12V at aerial buss.
Refer to "+12 volts not present at aerial master buss" troubleshooting procedure.
Step 3. Check circuit breaker #1 for +12V.
Replace circuit breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL
1 AERIAL MASTER CIRCUIT DOES NOT ENERGIZE AERIAL CONTROLS
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 3 and 11 of 16.)
Step 1. Check switch.
Replace switch (see para 4-94).
Step 2. Check aerial solenoid.
Replace solenoid (see para 4-9.4).
Step 3. Check for +12V at circuit breaker #9 on battery accessory buss. Replace breaker (see para 4-99).
Replace breakers (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4)
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4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
2 TURNTABLE SWIVEL ASSEMBLY SLIP RING CONTACT INTERRUPTED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 0 of 16.)
Step 1. Disconnect +12V supply wire for malfunctioning item at terminal strip located under turntable and
attach one lead of continuity tester to wire leading to slip ring.
Step 2. Attach other lead of continuity tester to corresponding terminal on terminal strip at aerial console.
Step 3. Rotate turntable while checking for continuity.
If continuity is interrupted while rotating turntable, replace swivel assembly.
Notify Direct Support
If continuity is not interrupted while rotating turntable, see the appropriate troubleshooting
procedure for the malfunctioning circuit. (Fault does not exist in swivel assembly).
3 AERIAL PANEL LIGHT WILL NOT ILLUMINATE WITH AERIAL MASTER ON
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 3 and 11 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-9.4).
Step 2. Check switch.
Replace switch (see para 4-179).
Step 3. Confirm that turntable step lights illuminate.
If step lights illuminate go on to Step 4 .
If step lights do not illuminate, refer to "swivel assembly slip ring contact interrupted"
troubleshooting procedure.
Step 4. Check wiring from terminal block to light for continuity.
Replace wire (see para 4-9.4).
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4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
4 TURNTABLE STEP LIGHTS DO NOT ILLUMINATE WITH AERIAL MASTER ON
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 3 and 8 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-14).
Step 2. Confirm that aerial panel light illuminates.
If aerial panel light does not illuminate, refer to "swivel assembly slip ring contact interrupted"
troubleshooting procedure.
If aerial panel light illuminates, go on to Step 3.
Step 3. Check wiring from terminal block to lights for continuity.
Replace wire (see para 4-9.4).
5 LEFT OR RIGHT TRACKING LIGHT WILL NOT ILLUMINATE IN FLOOD OR SPOT SWITCH
POSITION (Refer to Electrical Wiring Diagrams, Appendix H, Sheet 10 of 16.)
Step 1. Check bulb(s).
Replace bulb(s) (see para 4-177).
Step 2. Check switch at light for proper operation in both spot (down) and flood (up) positions.
Replace switch (see para 4-177).
Step 3. Check "tracking lights" switch on aerial console for proper operation.
Replace switch (see para 4-179).
Step 4. Check wiring from terminal strip under aerial console to tracking light for continuity.
Replace wire (see para 4-9.4).
Step 6. Refer to "swivel assembly slip ring contact interrupted" troubleshooting procedure.
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4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
6 LEFT OR RIGHT TIP LIGHT WILL NOT ILLUMINATE IN FLOOD OR SPOT SWITCH POSITION
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 12 of 16.)
Step 1. Check bulb(s).
Replace bulb(s) (see para 4-177).
Step 2. Check switch at light for proper operation in both spot (down) and flood (up) positions.
Replace switch (see para 4-177).
Step 3. Check "tip lights" switch at aerial console for proper operation.
Replace switch (see para 4-179).
Step 4. Check wiring from terminal strip under console to tip light for continuity.
NOTE
Each tip light uses two wires in the left side front traveler to
supply +12V.
Replace wire (see para 4-9.4).
Step 5. Refer to "swivel assembly slip ring contact interrupted" troubleshooting procedure.
7 RUNG ALIGNMENT LIGHT WILL NOT ILLUMINATE WHEN RUNGS ARE ALIGNED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 11 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
Step 2. Check switch for proper operation.
Adjust/replace switch (see para 4-179).
Step 3. Check wiring from switch to light for continuity.
Replace wire (see para 4-9.4).
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4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
8
EMERGENCY HYDRAULIC POWER LIGHT WILL NOT ILLUMINATE ON AERIAL PANEL WHEN
EMERGENCY PUMP IS ACTIVATED
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 11 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
Step 2. Check wiring to switch for continuity.
Replace wire (see para 4-9.4).
9
EMERGENCY HYDRAULIC POWER DOES NOT ACTIVATE FROM AERIAL PANEL SWITCH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 11 of 16.)
Step 1. Check for proper operation of rear control panel emergency hydraulic power switch.
If pump does not function with rear switch, refer to rear switch troubleshooting procedure.
If pump functions with rear switch, go on to Step 2.
Step 2. Check switch for proper operation.
Replace switch (see para 4-179).
Step 3. Check wiring for continuity.
Replace wire (see 4-9.4).
Step 4. Refer to "swivel assembly slip ring contact interrupted" troubleshooting procedure.
10
AERIAL DISCHARGE VALVE DOES NOT CLOSE WITH PANEL SWITCH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet I 1 of 16.)
Step 1. Check panel switch for proper operation.
Replace switch (see para 4-179).
Step 2. Check pneumatic solenoid valve in ladder compartments for proper operation.
Replace pneumatic solenoid valve (see para 4-200).
Step 3. Check aerial circuit breaker #6 for +12V.
Replace circuit breaker (see para 4-99).
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4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
10
AERIAL DISCHARGE VALVE DOES NOT CLOSE WITH PANEL SWITCH - Continued
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Refer to "+12 volts not present at aerial master buss" troubleshooting procedure."
Step 6. Refer to "turntable swivel assembly slip ring contact interrupted" troubleshooting procedure.
11
AUDIO ALARM DOES NOT FUNCTION
(Refer to Electrical Wiring Diagrams, Appendix H, Sheets 11 and 12 of 16.)
Step 1. Check switch for proper operation.
Replace switch (see para 4-9.4).
Step 2. Check alarm sounds when 12V is applied across terminals.
Replace alarm (see para 4-9.4).
Step 3. Check aerial circuit breaker#4 for +12V.
Replace circuit breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Refer to "swivel assembly slip ring contact interrupted" troubleshooting procedure.
Step 6. Refer to "aerial circuit +12 volts not present at aerial master buss" troubleshooting procedure.
12
LADDER INTERCOM DOES NOT FUNCTION PROPERLY
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 11 of 16.)
Step 1 Check for +12V at circuit breaker #6 with aerial master circuit on.
Replace breaker (see para 4-99).
Step 2. Check for +12V at aerial panel intercom unit on wire #1237.
Replace wire from breaker (see para 4-9.4).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
12 LADDER INTERCOM DOES NOT FUNCTION PROPERLY - Continued
Step 3. Check continuity of audio wires 1291 and 1292 between intercom unit (on aerial panel)
and intercom speaker (at ladder tip).
Replace wire. (see para 4-9.4)
Step 4. Check internal fuse inside intercom unit for continuity.
Replace fuse. (see para 4-9.4)
Step 5. Check intercom for proper operation with 12V applied across terminals.
Replace intercom unit (see para 4-198).
13 LADDER TIP SPEAKER DOES NOT FUNCTION PROPERLY
Step 1. Bypass traveler cables using jumper wires and check remote speaker for proper operation.
If speaker operates properly, replace traveler cable (see para 4-206).
If speaker does not operate properly, replace ladder tip speaker or refer to "ladder intercom
does not function properly" troubleshooting procedure.
14 AERIAL LADDER HOIST CYLINDER LOCKING VALVES DO NOT RELEASE LADDER WHEN
RAISE/LOWER CONTROL IS PLACED IN "LOWER" POSITION
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1O of 16.)
Step 1. Check aerial elevation control limit switch (on manifold block raise/lower control) for proper
operation. Switch is normally activated when control lever is in neutral position. Should
disengage Immediately when control lever is moved to "lower" position.
Adjust/replace switch (see para 4-9.4).
Step 2. Check that valve releases properly when 12V is applied to solenoid coil.
Repair/replace valve (see para 4-9.4).
Step 3. Check for +12V at aerial circuit breaker #5.
Replace breaker (see para 4-99).
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4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
14 AERIAL LADDER HOIST CYLINDER LOCKING VALVES DO NOT RELEASE LADDER WHEN
RAISE/LOWER CONTROL IS PLACED IN "LOWER" POSITION - Continued
Step 4. Refer to "swivel assembly slip ring contact interrupted" troubleshooting procedure.
Step 5. Refer to "aerial +12 volts not present at aerial master buss" troubleshooting procedure.
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
15 ELEVATION SLOW-DOWN VALVE DOES NOT ENGAGE WHEN LADDER REACHES
700 ELEVATION (Refer to Electrical Wiring Diagrams, Appendix H, Sheet 1 0 of 16).
Step 1. Check slow-down valve limit switch for proper operation.
Adjust/replace slow-down valve limit switch (see para 4-197).
Step 2. Check solenoid valve for proper operation by applying 12V to coil.
Repair/Replace valve (see para 4-9.4).
Step 3. Check aerial circuit breaker #5 for +12V.
Replace breaker (see para 4-99).
Step 4. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 5. Refer to "swivel assembly slip ring contact interrupted" troubleshooting procedure.
Step 6. Refer to "+12 volts not present at aerial master buss" troubleshooting procedure.
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
16 FLOW MINDER (GALLONS-PER-MINUTE) METER DOES NOT FUNCTION PROPERLY
Step 1. Check for +12V at aerial buss.
Refer to "+12 volts not present at aerial master buss" troubleshooting procedure."
Step 2. Check fuse between aerial panel terminal strip and flow minder unit.
Replace fuse (see para 4-9.4).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 4. Check sender wire for continuity.
Replace wire (see para 4-9.4).
Step 5. With water flowing through aerial nozzle, check for display on gallons-per-minute meter.
If no response, replace sender (see para 4-184).
17 OVERLOAD ALARM DOES NOT SOUND WHEN HYDRAULIC SYSTEM IS AT 1950 PSI
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 10 of 16.)
Step 1. Check that Murphy load sensor switch is set at 1950 psi.
Adjust load sensor switch (see para 4-187).
Step 2. Check electric horn relay for proper operation.
Replace relay (see para 4-187).
Step 3. Check contacts on Murphy load sensor switch make good contact.
Replace Murphy load sensor switch (see para 4-187).
Step 4. Check electric horn for proper operation.
Replace horn (see para 4-187).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
17 OVERLOAD ALARM DOES NOT SOUND WHEN HYDRAULIC SYSTEM IS AT 1950 PSI - Continued
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 6. Check aerial circuit breaker #6 for +12V.
Replace breaker (see para 4-99).
Step 7. Refer to "+12 volts not present at aerial master buss" troubleshooting procedure.
Step 8. Refer to "swivel assembly slip ring contact interrupted" troubleshooting procedure.
18 OVERLOAD ALARM SOUNDS CONTINUOUSLY WHILE HYDRAULIC SYSTEM PRESSURE
IS BELOW 1950 PSI
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 10 of 16.)
Step 1. Check relay for proper operation.
Replace relay (see para 4-9.4).
Step 2. Check Murphy load sensor switch for proper operation.
Replace switch (see para 4-187).
19 AERIAL MONITOR/NOZZLE DOES NOT RESPOND TO UPPER CONTROL BOX
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 12 of 16.)
Step 1. Check automotive override relay (R7) for proper operation.
Replace relay (see para 4-9.4).
Step 2 Check wires from relay box to control box for continuity.
Replace wire (see para 4-9.4).
Step 3. Check switches for proper operation.
Replace switch (see para 4-203).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
20 AERIAL MONITOR/NOZZLE DOES NOT RESPOND TO LOWER CONTROL BOX
(ON AERIAL PANEL)
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 11 of 16.)
Step 1. Check automotive override relay (R7) for proper operation.
Replace relay (see para 4-9.4).
Step 2. Check wires from control box to relay box for continuity.
Replace wire (see para 4-9.4).
Step 3. Check switches for proper operation.
Replace switch (see para 4-203).
Step 4. Check for +12V at aerial circuit breaker #5.
Replace breaker (see para 4-99).
Step 5. Check circuit breaker in relay box for +12V.
Replace breaker (see para 4-99).
Step 6 Refer to "+12 volts not present at aerial master buss" troubleshooting procedure.
21 AERIAL MONITOR/NOZZLE DOES NOT RESPOND IN ONE DIRECTION
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 11 of 16.)
Step 1. Check corresponding relay for proper operation.
Replace relay (see para 4-9.4).
Step 2. Check switch for proper operation.
Replace switch (see para 4-203).
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - AERIAL CONTROL PANEL - Continued
22 AERIAL MONITOR/NOZZLE WILL NOT FUNCTION IN ONE MODE (I.E., RAISE/LOWER)
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 12 of 16.)
Step 1. Check motor brushes for damage/excessive wear.
Replace brushes (see para 5-63).
Step 2. Check switch for proper operation.
Replace switch (see para 4-203).
Step 3. Check wiring for continuity.
Replace wire. (see para 4-9.4)
Step 4. Check both relays for proper operation.
Replace relay(s) (see para 4-9.4).
Step 5. Test motor.
Replace motor (see para 5-63).
23 +12 VOLTS IS NOT PRESENT AT AERIAL MASTER BUSS
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 3 of 16.)
Step 1. Check aerial master solenoid.
Replace solenoid (see para 4-9.4).
Step 2. Check aerial master switch.
Replace switch (see para 4-179).
Step 3. Check wiring for continuity.
Replace switch (see para 4-9.4).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - EMERGENCY HYDRAULIC SYSTEM
1 EMERGENCY HYDRAULIC MOTOR DOES NOT OPERATE
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 9 of 16.)
Step 1. Check switch.
Replace switch (see para 4-179).
Step 2. Check two solenoids for proper operation.
Replace solenoid (see para 4-9.4).
Step 3. Check motor.
Replace motor, Notify Direct Support.
Step 4. Check for +12V at circuit breaker #6 on aerial master buss.
Ensure aerial master is on. Replace breaker as required (see para 4-99).
Step 5. Check wiring for continuity.
Replace wire (see para 4-9.4).
2 EMERGENCY HYDRAULIC POWER ACTIVATED LIGHT DOES NOT ILLUMINATE
(Refer to Electrical Wiring Diagram, Appendix H, Sheet 9 of 16.)
Step 1. Check bulb.
Replace bulb (see para 4-178).
Step 2. Confirm pump is actually running when switch is actuated.
If pump is not running, refer to "emergency hydraulic motor does not operate"
troubleshooting procedure.
If pump is running, go on to step 3.
Step 3. Check wiring to light for continuity.
Replace wire (see para 4-9.4).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - APU AND 11O-VOLT CIRCUITS
1 AUXILIARY POWER UNIT (APU) DOES NOT START/RUN WITH CAB OR PUMP PANEL
CONTROLS (Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check switch.
Replace switch (see para 4-22 or 4-94).
Step 2. Check common/start wires for continuity.
Replace wire (see para 4-9.4).
Step 3. Check electric fuel pump for proper operation.
Replace fuel pump (see para 4-216).
Step 4. Check APU start solenoid for proper operation.
Replace solenoid, Notify Direct Support.
Step 5. Check APU cranking motor.
Replace motor, Notify Direct Support.
2 AUXILIARY POWER UNIT (APU) RUNS, BUT NO POWER OUTPUT
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check fuse on APU.
Replace fuse (see para 4-9.4).
Step 2. Check service panel circuit breakers are on.
Turn on service panel breaker.
Step 3. Check wiring for continuity.
Replace wire (see para 4-9.4).
Step 4. Check pump panel and cab panel volt and ammeters for output from APU.
Refer to APU troubleshooting procedures.
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - APU AND 110-VOLT CIRCUITS - Continued
3 AUXILIARY POWER UNIT DOES NOT SHUT OFF
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check switch.
Replace switch (see para 4-22 or 4-94).
Step 2. Check common/stop wire for continuity.
Replace wire (see para 4-9.4).
Step 3. Refer to APU troubleshooting procedure.
4 AUXILIARY POWER UNIT PREHEAT CONTROL DOES NOT WORK
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check switch.
Replace switch (see para 4-22 or 4-94).
Step 2. Check heater element.
Replace heater element (see para 4-9.4).
Step 3. Check wires for continuity.
Replace wire (see para 4-9.4).
5 DRIVERS/PASSENGERS FLOODLIGHT (11OV) DOES NOT ILLUMINATE WITH CAB SWITCH AND
AUXILIARY POWER UNIT RUNNING(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check output of APU with cab or pump panel gauge.
If gauge indicates no output, refer to "APU runs, but no power output"
troubleshooting procedure above.
Step 2. Check service panel breaker is on.
Turn on breaker.
Step 3. Check bulb.
Replace bulb. (see para 4-124).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - APU AND 110-VOLT CIRCUITS - Continued
5DRIVERS/PASSENGERS FLOODLIGHT (11 OV) DOES NOT ILLUMINATE WITH CAB SWITCH
AND AUXILIARY POWER UNIT RUNNING - Continued
Step 4. Check relay inside service panel for proper operation.
Replace relay (see para 4-9.4).
Step 5. Check for +12V at circuit breaker #14 at battery accessory buss.
Replace breaker (see para 4-99).
Step 6. Check wiring for continuity.
Replace wire (see para 4-9.4).
6 NO POWER AT ANY 11OV OUTLET (EXCEPT LADDER TIP)
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check outlet.
Replace outlet (see para 4-117).
Step 2. Check breaker.
Reset/replace breaker (see para 4-119).
Step 3. Check auxiliary power unit for proper operation.
Refer to auxiliary power unit test procedure (see Chapter 6).
Step 4. Check writing for continuity.
Replace wire (see para 4-9.4).
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TM 5-4210-233-14&P-1
4-2. Unit Troubleshooting-Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ELECTRICAL SYSTEM - APU AND 11O-VOLT CIRCUITS - Continued
7 NO POWER AT LADDER TIP OUTLET
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check aerial control panel switch for proper operation.
Replace switch (see para 4-179).
Step 2. Check turntable slip rings for continuity.
Replace swivel unit. Notify Direct Support.
Step 3. Refer to 1 OV outlet troubleshooting procedure.
8 11OV PORTABLE WORK LIGHT DOES NOT ILLUMINATE WITH CAB SWITCH
(Refer to Electrical Wiring Diagrams, Appendix H, Sheet 15 of 16.)
Step 1. Check floodlight bulb.
Replace bulb (see para 4-124).
Step 2. Check relay for proper operation.
Replace relay (see para 4-9.4)
Step 3. Check circuit breaker.
Reset/replace breaker (see para 4-119).
Step 4. Check dash panel switch for proper operation.
Replace switch (see para 4-94).
Step 5. Check breaker #14 on battery accessory buss for +12V.
Replace breaker (see para 4-99).
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TM 5-4210-233-14&P-1
SECTION V. UNIT MAINTENANCE PROCEDURES
4-9. GENERAL MAINTENANCE PROCEDURES. This section describes general procedures that apply to
all maintenance tasks detailed in this manual. To avoid repetition, these general procedures will not be
repeated elsewhere in the manual.
4-9.1. General Removal and Disassembly Instructions
a.
Troubleshooting. Before removing any item, refer to the troubleshooting table. This ensures that faults
are isolated to a particular component.
b.
Cleanliness. Work areas must be kept clean. This avoids contamination of internal parts. This is
especially true for areas where controls, valves, cylinders, or other hydraulic or air system parts are
disassembled.
c.
De-energize and De-pressurize. Before removing any part of electrical, hydraulic, pneumatic, or foam
systems ensure the system is not energized or pressurized (e.g. disconnect batteries or relieve all
pressure from air system by opening drain valves). Ensure that all controls are in the OFF position before
starting any removal procedure.
d.
Preparation. Study the task description before disassembling or removing any item. This reduces job time
as all tools and equipment will be available and procedures will have been noted.
e.
Work Space. Ensure there is sufficient clearance to remove or disassemble a particular part.
Disassemble adjacent parts as necessary to provide reasonable working clearance.
f.
Lifting. Use a hoist, jack, or other aid when lifting heavy parts. Lifting devices should be positioned and
attached to the part to remove all strain from mounting hardware before part is removed. Never work
under a part which is supported only by a lifting device. Always support that part on maintenance trestles
or other supports before starting work.
g.
Lifting Truck. In certain cases it will be necessary to raise the truck so that all tires clear the ground. The
following procedure describes a safe method of lifting the truck.
(1)
Drain water tank to reduce truck weight.
(2)
Park truck on level, hard surface. Position gear selector to N (neutral) and apply parking brakes.
(3)
Chock wheels of opposite axle.
(4)
Place 1O ton hydraulic jack beneath differential. Raise the jack until tires clear the ground.
(5)
Place maintenance trestles beneath axle, one on each side of differential. If truck is to be
supported by frame, and tires still need to clear the ground, raise the truck high enough to
compensate for leaf spring sag.
(6)
Carefully lower truck onto maintenance trestles. Be sure maintenance trestles are adjusted to the
same height and are of sufficient capacity to carry truck weight.
(7)
Repeat steps 4 through 6 to raise other axle.
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TM 5-4210-233-14&P-1
4-9. GENERAL MAINTENANCE PROCEDURES- Continued
h. Lowering the Truck.
(1) Place 10 ton hydraulic jack beneath differential. Raise the jack until all weight is off maintenance
trestles.
(2) Remove maintenance trestles from beneath axle (one on each side of differential).
(3) Carefully and slowly, lower jack until all weight is removed from jack. Immediately after truck is
grounded, chock the wheels.
(4) Repeat steps 1 through 3 to lower other axle as necessary.
(5) Ensure gear selector is positioned to N (neutral) and parking brakes are applied, then remove all
wheel chocks.
i. Identification. Identify all parts of similar shape with tags. This will make proper reassembly easier. Be
sure to identify ends of electric, hydraulic, and air lines as they are disconnected.
j. Salvage.
Some assemblies that are removed, even though defective, shall be treated as valuable
items. They may be rebuilt for future use.
k. Expendable Parts.
Whenever possible, all gaskets, packings, and seals shall be discarded during
removal or disassembly. Similarly, lock wire, lockwashers, cotter pins, and like items shall be discarded
during disassembly. All should be replaced during assembly. When removing seals, gaskets, or packings,
take care not to damage (e.g. scratch) the sealing surfaces. If surfaces are damaged they must be
repolished to give a good sealing surface.
I. Parts Protection. To prevent moisture and dirt from entering housings, lines, and other openings, apply
protective covers after disassembly. Wrap all parts in clean paper or dip parts in rust preventive oil.
4-9.2. General Cleaning Instructions
CAUTION
Do not use scrapers, wire brushes, abrasive wheels, or
compounds when cleaning parts unless called for in detailed
instructions. These procedures may alter size of machined
surface and may weaken a stressed part.
a. Dry Cleaning Solvent.
WARNING
Dry cleaning solvent P-D-680 (safety or Stoddard's solvent) is
potentially dangerous. Avoid repeated and prolonged breathing
of vapors and skin contact with the liquid. Do not use near open
flame, arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of P-D680 is 1 00 to 138 deg. F (38 to 59 deg. C).
Whenever dry cleaning solvent is recommended for cleaning, use item 3, Appendix E.
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4-9. GENERAL MAINTENANCE PROCEDURES - Continued
b. Mineral Spirits.
WARNING
Mineral spirits are toxic to skin, eyes, and lungs. Skin and eye
protection is required. Avoid prolonged or repeated contact.
Good, general ventilation is normally adequate.
c. Gasoline, Diesel Fuel.
WARNING
Never use gasoline or diesel fuel to clean parts.
d. Freon 113.
WARNING
All freons are asphyxiants and are toxic to skin and eyes. Skin
and eye protection is required. Use only in a well ventilated area.
Freons are used to clean any parts that normally come in direct
contact with hydraulic fluid.
e. Degreasing Machine.
WARNING
1,1,1 Trichloroethane is toxic to skin, eyes and lungs. Skin and
eye protection is required. Avoid prolonged or repeated contact.
Good, general ventilation is normally adequate.
Heavy oil and grease may be removed with a degreasing
machine filled with 1,1,1 Trichloroethane. All parts shall be
dipped in rust preventive oil after removal from
machine.
f. Baking Soda Solution. Truck battery exterior surfaces, terminals, and cable clamps should be cleaned
with a weak solution of baking soda (Item 5, Appendix E) and water. A bristle brush soaked in the solution
may be used to remove caked dirt or corrosion products.
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4-9. GENERAL MAINTENANCE PROCEDURES- Continued
g. Solvent Spray Gun.
WARNING
Spray gun must be used in a spray booth with filter and face
shield for personnel since dry cleaning solvent (Item 3,
Appendix E) is toxic to skin, eyes and lungs. Avoid prolonged or
repeated contact.
h. Hot Water/Steamer. Radiator cores should be cleaned with steam or hot water. If sediment with the core
cannot be completely removed in this way, core will have to be boiled in a chemical bath. This bath is a
strong solution of caustic soda and is available in a radiator repair shop.
i. Pressure Wash. Painted surfaces (e.g., truck body) shall be cleaned with a detergent solution and a
pressure washer. Always rinse surface with clean water.
Although the truck body paint is very durable, certain solvents may damage the paint. Keep solvents
away from painted surfaces. A pressure washer should be used to remove excessive road dirt, oil, and
grease from exterior parts prior to dismantling.
j. Steam Cleaning. Oil and fuel tanks should be flushed with steam for at least 24 hours before welding or
maintaining such tanks.
k. Ball and Roller Bearings. When cleaning ball or roller bearings, place them in a basket. Suspend the
basket in a dry-cleaning solvent, (Item 3, Appendix E) preferably overnight. if needed, use a brush to
remove caked grease or chips. Avoid rotating the bearings until all solid particles are removed. When
bearings are clean, spin them in a light lubricating oil (Item 10, Appendix E) to remove solvent.
I. Rubber Parts. Do not clean performed packings or other rubber parts in solvent. These parts should be
wiped with a clean, dry, lint-free cloth (Item 42, Appendix E).,
m. Electrical Components. Electrical components (e:g. coils, switches) which use insulating materials shall
not be soaked or sprayed with cleaning solutions. Remove dirt with a clean, dry, lint-free cloth (Item 42,
Appendix E). If necessary, moisten cloth with dry-cleaning solvent (Item 10, Appendix E).
n. Complex Components. Components that consist of a fabrication with passages and cavities should be
checked thoroughly after cleaning. A thin flexible wire should be run through all passages to ensure they
are not blocked. Individual passages may be cleaned using a pressure spray gun and dry-cleaning
solvent (Item 3, Appendix E).
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4-9.
GENERAL MAINTENANCE PROCEDURES - Continued
4-9.3.
General Inspection Instructions
a. Sealing Surfaces. Check all contact surfaces of gaskets, packings, or seals. Ensure there are no nicks,
burrs, or scratches. These might damage new seals during assembly. If any defect is found, correct it as
outlined in para 4-9.4 following.
b. Ball and Roller Bearings. Check bearings for pitted balls, races, or separator. Bearings shall be rejected
if any of the following are seen in the race load area.
c.
(1)
Cuts or grooves parallel to ball or roller rotation.
(2)
Fatigue pits (not minor machine marks or scratches).
(3)
Cracks found during magnetic particle inspection.
(4)
Serious abrasion of balls or rollers.
(5)
Serious discoloration of any part of the bearing.
Drain Plugs. When removing drain plugs from transmission, engine, or axles, inspect the plug. A buildup of grit and/or fine metal particles may indicate part failure. A few fine particles are normal.
d. Tubing and Hoses. Check all hose surfaces for broken or frayed fabric. Check for breaks or weak points
due to kinking or rubbing. Inspect metal tube lines for kinks or excessive corrosion. Inspect fitting threads
or clamps for damage. Replace any faulty part. After assembly, check all disturbed joints for leaks.
e. Splines. Inspect shaft splines for wear. This will include pitting, peening or fatigue cracks. Perform
magnetic particle inspection if needed.
f. Electrical Parts. Inspect all wiring for chaffed or burned insulation. Check all terminals for tightness.
Check all lamps for failure. Check for burns, or broken fittings or components.
g. Gears. The following steps should be used to make a general visual inspection of all gears. Specific
tests for particular gears, outlined in the text, should also be carried out. It any gear looks faulty, perform
a surface temper and/or magnetic particle inspection.
(1)
Normal Wear. Loss of metal from surface of teeth. Wear must not prevent gears from meshing
or performing properly.
(2)
Initial Pitting. This may occur when gears are first put into service. It may continue until high
spots have been reduced. It will not affect contact surfaces. This pitting is not necessarily serious.
(3)
Destructive Pitting. This pitting occurs after initial pitting, often at an increasing rate. This type
will destroy the contact area and reduce the load capacity of the gear. Rapid destruction will
occur with use.
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4-9. GENERAL MAINTENANCE PROCEDURES- Continued
(4) Abrasive Wear. This damage is caused by fine particles carried in the lubricant or embedded in gear
tooth. This material may come from:
Bearing or gear tooth material.
Abrasives not removed during assembly.
Sand or scale from castings.
Impurities from oil or the environment.
(5) Scoring. Slight scoring, galling or other surface damage is seen as tears or scratches in the direction of
sliding. It starts in areas of highest stress and speed. This is usually at tip of teeth.
(6) Burning. Burning is seen as discoloration, and causes loss of hardness of the metal. Burning is caused by
any of the following:
Gear Overload
Overspeed
Lack of Backlash
Too Little Lubrication
Wrong Lubricant
If discoloration can be wiped off, such marks can usually be traced to oil-burn stains which are not
serious.
(7) Rolling. This damage usually occurs only on plastic gears. Rolling is when material is pushed out of
shape but does not break off. It is usually caused by heavy, even loads and overheating.
h. Metal Parts. Visually inspect all castings and weldments for cracks. Parts that carry a great load should be
inspected by the magnetic particle method. Non-ferrous parts may be inspected by the fluorescent
penetrant method.
i.
Magnetic Particle Inspection. This type of inspection can only be carried out on metals that can be
magnetized. If in doubt check whether a magnet sticks to the surface. It should only be carried out it parts
are not easily replaceable (cost or special order), or parts have been reworked or reground, or parts are
subject to high stress. Magnetizing current depends on parts being magnetized. For solid section parts,
current shall be 1000 amps per diameter-inch. For variable diameter thickness, current shall be adjusted for
diameter inspected.
Parts shall be rejected if:
(1) Indications of non-metallic inclusions are present (foreign body-solid, liquid, or gaseous) and these are
longer than one inch, or indications are closer than 1/8 in. apart.
(2) Any evidence of cracks are seen.
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4-9. GENERAL MAINTENANCE PROCEDURES-Continued
(3) Scattered short sharp bursts are seen. Bursts are caused by metals working at temperatures that weaken
and break the material. Bursts are not usually seen until the metal is cut through to the burst area.
(4) Separate short wavy lines in the same general direction are seen. Flakes are caused by improper
cooling. They are not usually seen until the metal is cut through to the flake area.
(5) Fine, sharp, tightly packed lines are seen (grinding cracks). These are usually caused by a glazed
grinding wheel. The wheel, instead of cutting the material, rubs and overheats the material. The lines are
thermal cracks similar to heat treat and hardening cracks.
j. Fluorescent Penetrant Inspection. This type of inspection can be carried out on any metal but is usually
reserved for non-magnetic material (e.g. aluminum, stainless steel). The parts shall be warm prior to applying
penetrant. The penetrant may be applied by dipping, painting or spraying. All surfaces to be examined shall
be completely covered. Penetrant time for various metals is as follows:
Aluminum Alloy - no less than 20 minutes.
Magnesium Alloy - no less than 20 minutes.
Brass or Bronze - no less than 30 minutes.
Ferrous Alloys - no less than 30 minutes.
After applying penetrant, the surfaces will be cleaned with lukewarm water - less than 120 deg. F
(49°C). (Cool water may be used, but cleaning time will be longer.) Pressurized water spray may be
used to shorten the washing cycle. The following methods may be used to develop the parts.
(1) Wet Developer Method. Parts shall be completely covered in developer by spraying or dipping. Parts
shall be dried and developed in a recirculating hot air drier for one half the penetration time.
(2) Dry Developer Method. Parts must first be dried. The dry developer shall be spread on all surfaces by
dusting or by dipping the part. Parts shall be developed for one-half the penetration time.
(3) No Developer Method. When no developer is used, drying and developing time shall be at least equal to
penetration time to allow sufficient bleeding of penetrant from defects. If additional clarity is required
during inspection dry developer may be applied by a hand powder bulb.
Following development, the part shall be inspected under black light. Any evidence of cracks is cause for
rejection. After inspection the parts shall be cleaned with dry-cleaning solvent (item 3, Appendix E) and
covered with rust preventive oil.
k. Lapping Procedures.
(1) Clean the part with dry-cleaning solvent (item 3, Appendix E) and dry with compressed air. Clean the
lapping blocks with compressed air. Do not use a cloth or any other material for this purpose.
(2) Spread a good quality 600 grit dry lapping powder on one of the lapping blocks. Place the part to be
lapped flat on the block and, using a figure eight motion, move it back and forth across the block. Do not
press on the part, but use just enough pressure to keep the part flat on the block. It is important that the
part be kept flat on the block at all times.
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4-9. GENERAL MAINTENANCE PROCEDURES - Continued
(3) After each four or five passes, clean the lapping powder from the part by drawing it across a clean piece
of tissue placed on a flat surface and inspect the part. DO NOT LAP EXCESSIVELY.
(4) When the part is flat, wash it in dry-cleaning solvent (item 3, Appendix E) and dry it with compressed air.
(5) Place the dry part on the second block. After applying lapping powder, move the part lightly across the
block in a figure eight motion several times to give it a smooth finish. DO NOT LAP EXCESSIVELY.
Wash the part in dry-cleaning solvent (item 3, Appendix E) again, and dry it with compressed air.
(6) Place the dry part on the third block. Do not use lapping powder on this block. Keep the part flat and
move it across the block several times, using the figure eight motion. Lapping the dry part in this manner
gives it the "mirror, finish required for perfect sealing.
(7) Wash the lapped part in dry-cleaning solvent (item 3, Appendix E) and dry with compressed air.
4-9.4. General Repair/Assembly Instructions
a. Truck Body. Chassis and exterior painted parts may be resurfaced where paint is damaged or parts have
been repaired. Before resurfacing, scrape off loose and blistered paint. Clean area to be painted by sanding
or buffing. Remove dust. During repair operations, protect bare steel surfaces from rusting with protective
oil. Minor body dents may be removed by bumping with a soft-faced hammer while using a wooden block
backing.
b. Welding. Welding and brazing may be used to repair cracks in steel parts (e.g., brackets, panels and light
framework). Aluminum body panels may also be welded. They should only be welded when replacement
parts are not available. Do not weld or braze castings, moving parts, or parts under great stress, except in
emergencies. Refer to TM 9-237 for welding practices.
CAUTION
This vehicle is equipped with electronically controlled
equipment. When welding anywhere on the vehicle, all modules
for the electronically controlled devices must be disconnected.
c. Hoses. Replace all broken, frayed, crimped or soft flexible hoses. Replace stripped or damaged fittings.
When replacing hose clamps ensure hoses are not crimped.
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4-9. GENERAL MAINTENANCE PROCEDURES- Continued
d. Hydraulic Hoses Tubes and Fittings.
WARNING
Escaping fluid under pressure can penetrate the skin causing
serious injury. Relieve pressure before unhooking hydraulic or
other lines. Tighten all connections before applying pressure.
Keep hands and body away from pinholes and nozzles which
eject fluids under high pressure. Use a piece of cardboard to
check for leaks.
If any fluid is injected into the skin, it must be surgically
removed by a doctor familiar with this type of injury or gangrene
may result.
(1) Shut down engine before servicing hydraulic system. With engine off, operate hydraulic controls in all
modes to relieve any pressure trapped in lines.
(2) Clean any dirt or debris away from hydraulic line or fitting that is to be removed.
(3) Tag and disconnect hose or tube.
(4) Cap all openings to prevent the entry of dirt.
(5) Discard all seals or O-rings that have been removed and install new seals and O-rings.
CAUTION
Do not twist hoses during installation. Make sure hoses will not
rub against sharp objects that may cut them.
(6) Install hoses or tubes and tighten connections securely. Do not over-tighten.
(7) Install new plastic tie straps or protective sleeves over hoses to prevent rubbing or chafing during vehicle
operation.
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4-9. GENERAL MAINTENANCE PROCEDURES - Continued
e. Hose Assembly Replacement. There are two different styles of hose assemblies. Described below are
procedures for hose replacement.
NOTE
If original hose route cannot be followed at time of replacement,
find alternative route and measure for new hose length.
(1) General Purpose - High Temperature; Hydraulic, Air and Fuel Application.
(a)
Carefully examine both hose end fittings. Discard hose end fittings if any signs of damage are
evident. Proceed to steps (d thru j), following, to assemble new hose assembly using new hose
end fittings.
(b)
If hose end fittings are to be reused, remove from old hose. Clamp socket in a vise. Remove
nipple from hose and socket by unscrewing in a counterclockwise direction.
(c)
Once nipple is removed, invert hose and reclamp socket in vise. Unscrew hose from socket by
turning hose in a clockwise direction. If hose is excessively long, socket removal is possible by
clamping hose in vise and unscrewing socket from hose in clockwise direction.
(d)
Using a cut-off saw or a fine tooth hacksaw cut new hose square to length.
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air always use
chip guards, eye protection and other personal protective
equipment.
(e)
Using compressed air, blow out shavings from hose bore.
(f)
Clamp socket in vise. Thread new hose into socket in a counterclockwise direction until it
bottoms out. Then back out hose 1/4 turn.
(g)
Using hydraulic oil (item 28, Appendix E), liberally lubricate nipple threads and inside of hose.
(h)
Insert nipple into hose and socket and tighten in a clockwise direction. Leave 1/32 in. (.8 mm)
between nipple hex and socket.
(i) To prevent any contamination from new hose assembly, blow out hose assembly using compressed air.
Rinse inside of hose with hot water. Do not allow water temperature to exceed 180 deg. F (82 deg. C).
Using compressed air, blow out all water from hose assembly.
(j) If hose assembly is not going to be installed immediately after installing fittings, cap both ends to keep hose
clean.
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4-9. GENERAL MAINTENANCE PROCEDURES - Continued
(2) Teflon Hose - Medium Pressure (with Vacuum Service)
(a)
Carefully examine both hose end fittings. Discard hose end fittings if any sign of damage is
evident. Proceed to steps (c thru 1) following, to reassemble new hose assembly using new hose
end fittings.
(b)
If hose end fittings are to be reused, remove from old hose. Clamp socket in vise. Unscrew
nipple (in a counterclockwise direction) and remove. Slide the socket away from the hose end by
tapping on flat surface. Using pliers, pull the sleeve from hose.
NOTE
It is recommended that new sleeves be used when old fitting is reused.
(c)
Wrap tefIon hose with masking tape (item 52, Appendix E) at cut-off area. Using a cut-off saw or
a fine-tooth hacksaw, cut hose square to length. Remove all tape. Trim any extending wires flush
with hose end, then remove hose material burrs.
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air always use
chip guards, eye protection and other personal protective
equipment.
(d)
Using compressed air, blow out shavings from hose bore.
(e)
Slip two sockets onto new hose. Ensure the sockets are back to back.
(f)
Push a sleeve over the end of the tube and under the wire braid by hand. Position sleeve in hose
by pushing the hose against a flat surface. Ensure the tube stock butts against the inside
shoulder of the sleeve.
(g)
Set the sleeve barbs into the Teflon tube by installing the end of the sleeve andtube over the
nipple and then work the hose bore over the nipple.
(h)
Lubricate the nipple and socket threads with hydraulic oil (item 28, Appendix E).
(i)
Clamp the nipple hex in a vise. Push the hose over the nipple using a twisting action until seated
against nipple clamper. Push socket forward and thread onto nipple hand tight.
(j)
Invert hose assembly and clamp socket in vise. Tighten nipple in a clockwise direction until 1/32
in. (.8 mm) clearance between nipple and socket is achieved. Further tightening is acceptable if
socket and nipple hexes are to be aligned.
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4-9. GENERAL MAINTENANCE PROCEDURES -Continued
(k)
To prevent any contamination from new hose assembly, blow out hose assembly using
compressed air. Rinse inside of hose with hot water. Do not allow water temperature to exceed
180 deg. F (82 deg. C). Using compressed air, blow out all water from hose assembly.
(I)
If new hose assembly is not going to be installed immediately after installing fittings, cap both
ends to keep hose clean.
f. Locating Air Leaks in Water/Foam Piping. The following procedure describes a method of locating air leaks.
(1) Attach suction caps to all suction ports.
(2) Close all discharge and drain valves.
(3) Open priming valve and operate primer until vacuum gauge indicates 20 to 22 in (51 to 56 mm) Hg.
NOTE
If primer fails to draw specified vacuum, prime may be defective
or air leaks are too large for primer to handle.
(4) Close primer valve and shut off primer. If vacuum drops more than 10 in (25 mm) Hg in 10 minutes,
serious air leaks are indicated. With engine stopped air leaks are frequently loud enough to be heard.
(5) If leaks cannot be heard, apply engine oil to the suspected points and watch for break in oil film or oil
being drawn into pump or piping.
(6) Connect suction hose to hydrant or auxiliary pump.
CAUTION
When testing for leaks, 1 00 psi (689 kPa) water pressure is
sufficient. Do not exceed recommended pressures. Damage to
components may result.
(7)
Open one discharge valve and run in water until pump is completely filled and all air expelled.
Close discharge valves, apply pressure to system and watch for leaks.
(8)
If the pump has not been operated for several weeks, packings may be dried out. Close
discharge and drain valves and cap suction ports. Operate primer to build up a strong vacuum in
pump, run pump slowly, and apply engine oil to impeller shaft near packing gland. Also be sure
packing is adjusted properly.
g. Fasteners. Replace any bolt, screw, nut, or fitting that has damaged threads. Inspect tapped holes for
damage. If fitting cannot be retapped with next oversize screw or stud, chasing the threads with proper
size tap or die may cure the problem.
h. Gaskets. Never reuse old gaskets except in an absolute emergency. Always ensure correct gasket is
being used as replacement by fitting dry.
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4-9. GENERAL MAINTENANCE PROCEDURES - Continued
i. Oil Seals. Install oil seals with seal lip facing the source of oil. Install by carefully applying an even force on
the outer edge of the seal. If oil seals are to be installed over a keyed or splined shaft, use a guide.
This will prevent the sharp edges of the shaft damaging the lip seal. Make a guide by cutting and
shaping very thin gauge sheet metal over the splines. Make sure the edges are bent slightly inward
to prevent these damaging the seal.
j. Bearing Installation.
CAUTION
To prevent personal injury or premature bearing failure when
removing or installing bearing races, always exert force on the
tight ring of the bearing.
To assist in bearing installation procedures it is acceptable to heat or cool bearing races. Outer bearing
races can be cooled to reduce the race diameter. Place bearing in a deep freeze for about two hours
prior to assembly. It is acceptable to leave bearing in deep freeze for a longer period of time.
CAUTION
To avoid bearing failure, never heat a bearing using an open
flame. Inner bearing races can be heated to increase the race
diameter.
An electrically-heated-type oil bath is recommended. Do not
allow oil temperature to exceed 275 deg. F (135 deg. C). The
preceding procedure can also be used to help during installation
of gears on shafts. If accessible, shafts may be cooled to reduce
outer diameter, and gears may be heated to increase inner
diameter.
k. Lubrication. Lubricate bearings with the type of lubricant normally used before assembly (e.g., gear lube in
gear box bearing). This will provide lubrication during first run-in until system lubrication can reach bearings.
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4-9. GENERAL MAINTENANCE PROCEDURES -Continued
I. Electrical Components. This information pertains to the replacement of alarms, switches, relays, fuses,
solenoids, flasher units and sender units on the vehicle. Refer to the Electrical Wiring Diagrams,
Appendix H for locations of most of these components. Refer to para 4-95 and 4-96 for removal and
installation procedures for cab instrument panel switchs and lights.
CAUTION
To prevent damage to the electrical system components, always
disconnect the batteries before working on the electrical system.
NOTE
A wire number is stamped on each end of the wires. This
number pertains to the wire numbers on the electrical wiring
diagrams in Appendix H.
(1) Tag all wires before disconnecting.
(2) Inspect wires for cut, burned, cracked or broken wire insulation. Repair by wrapping insulation
tape around damaged area or replacing damaged wires. Use an ohmmeter to check continuity of
wires. Refer to Electrical Wiring Diagrams, Appendix H.
(3) Note the quantity, type, location and position of all mounting hardware before removal of
component.
(4) Refer to the illustrated Parts List in Appendix F for replacement parts.
(5) Always use the same wire size and type when replacing wires.
(6) If plastic cable ties or protective sleeves were removed to gain access to components or wires,
replace the ties or sleeves to protect wires from possible damage due to vehicle vibration or
heat.
m. Testing. Test operation of any system after installation or repair. Inspect for leaks, vibration, noise,
misalignment or other problems. Recheck after a few hours of normal operation.
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4-10. HARD SUCTION HOSES
This task covers:
a. Inspection
b. Testing
c. Repair
CAUTION
If there is even suspicion of damage to sleeve or couplings,
replace hose.
a. Inspection.
NOTE
Hard suction hoses are located in equipment storage rack at
rear of truck.
(1) Visually inspect hose (1) for deep cuts or holes.
(2) To inspect swivel gaskets (2) remove gaskets and pinch together between the thumb and index
fingers; check for cracks, creases, and general elastic deterioration.
(3) Install gaskets (2) in hose.
b. Testing.
(1) Cap hose end and connect to a vacuum source.
(2) Gradually increase vacuum to 23 inches of mercury for three minutes.
(3) Check hose for leaks and/or distortion of sleeve.
(4) To pressure test hose, cap hose end and connect to a water pressure source.
(5) Gradually increase pressure to 200 psi (1371 kPa) and hold for 5 minutes.
(6) Check hose for leaks and/or distortion of sleeve.
c. Repair.
(1) Install new gaskets (2) if found defective or damaged.
(2) Replace hose if found defective during inspection or testing.
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4-11. SOFT SUCTION HOSES
This task covers:
a. Inspection
b. Testing
c. Repair
CAUTION
If there is even suspicion of damage to sleeve or couplings,
replace hose.
a. Inspection.
(1) Visually inspect hose (1) for jacket damage, deep cuts, mildew, chemical damage or holes.
(2) To inspect swivel gaskets (2) remove gaskets and pinch together between the thumb and index
finger; check for cracks, creases, and general elastic deterioration.
(3) Install gaskets in hose.
b. Testing.
(1) To pressure test hose, cap hose end and connect to a water pressure source.
(2) Gradually increase pressure to 300 psi (2057 kPa) and hold for 5 minutes.
(3) Check hose for leaks and/or distortion of sleeve.
c. Repair.
(1) Replace hose if found defective during inspection or testing.
(2) Replace gaskets if damaged or defective.
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4-12. PUMP PANEL LIGHTS
This task covers:
a.
b.
Disassembly
Cleaning and Inspection
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
c.
d.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
a.
Disassembly.
NOTE
The pump panel lights are located above the
pump panel on the drivers side of the truck. (1)
Remove two screws (1) and lens (2).
(2) Remove four screws (3) and nuts (4) from tight base
assembly (5).
(3) Tag and disconnect wires.
(4) Remove light base assembly (5) from pump panel
shield (6).
b.
Installation
Follow-on Maintenance
Cleaning and Inspection.
(1) Clean lens and reflector.
(2) Inspect lens for cracks. If cracked, replace lens.
(3) Inspect for broken or cracked reflector. If damaged,
replace light base assembly.
(4) Inspect wiring for fraying or cracked insulation. If
wiring is damaged contact Direct Support
Maintenance.
(5) Inspect bulb socket, bulb contacts and wiring for
corrosion. Clean corrosion with emery cloth (Item 25,
Appendix E).
If corrosion cannot be removed,
replace light base assembly.
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TM 5-4210-233-14&P-1
4-12. PUMP PANEL LIGHTS - Continued
c.
Installation.
(1) Connect electrical leads and remove wire tags.
(2) Secure light base assembly (5) to pump panel shield (6) with screws (3) and nuts (4).
(3) Check that bulb illuminates.
(4) Replace bulb (7), if necessary.
(5) Install lens (2) and secure with two screws (1).
d.
Follow-on Maintenance.
(1) Reconnect Batteries (see para 4-114).
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TM 5-4210-233-14&P-1
4-13. COMPARTMENT LIGHTS
This task covers:
a.
b.
Disassembly
Cleaning and Inspection
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
c.
d.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice Connectors (Item 27, Appendix E)
a.
Assembly
Follow-on Maintenance
Disassembly.
NOTE
The compartment lights are located in each of
the storage compartments on the hose body.
(1) Remove nut (1) from switch (2).
(2) Remove four screws (3).
(3) Remove lens (4).
(4) Remove and replace bulb (5) if failed.
(5) To remove switch (2) tag and cut wires from splice.
Replace switch if detective.
(6) Remove four screws (6).
(7) Tag and disconnect electrical leads.
(8) Remove light base assembly (7).
4-164
TM 5-4210-233-14&P-1
4-13. COMPARTMENT LIGHTS - Continued
b.
Cleaning and Inspection.
(1) Clean lens (4) and light base assembly (7).
(2) Inspect lens for cracks. If cracked, replace lens.
(3) Inspect for broken or cracked reflector. If damaged, replace light base assembly (7).
(4) Inspect wiring for fraying or cracked insulation.
Maintenance.
If wiring is damaged contact Direct Support
(5) Inspect bulb socket, bulb contacts and wiring for corrosion. Clean corrosion with emery cloth (Item
25, Appendix E). If corrosion cannot be removed, replace light base assembly.
c.
Assembly.
(1) To install new switch, splice switch (2) to wiring harness.
(2) Install lens (4) and fasten in place with nut (1).
(3) Connect electrical leads with butt splice.
(4) Position light assembly (7) and secure with four screws (6).
(5) Secure lens (4) with four screws (3).
(6) Test light for proper operation.
d.
Follow-on Maintenance.
(1) Reconnect batteries (see para 4-114).
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TM 5-4210-233-14&P-1
4-14. STEP LIGHTS
This task covers:
a.
b.
Disassembly
Cleaning and Inspection
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
c.
d.
Assembly
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Tags (Item 32, Appendix E)
Butt Splice Connectors (Item 27, Appendix E)
a.
Disassembly.
(1) Remove cover (1) with lens (2) and gasket (3)
by removing two screws (4).
(2) Remove bulb (8) if defective and install new bulb.
(3) Remove two screws (5), gasket (6) and light base
assembly (7).
(4) Tag and disconnect electrical leads.
b.
Cleaning and Inspection.
(1) Clean lens (2) and light base assembly (7).
(2) Inspect lens for cracks. It cracked replace.
c.
(3) Inspect wiring for fraying or cracked insulation.
wiring is damaged contact Direct Support.
If
(4) Inspect bulb socket and wiring for corrosion.
corroded, replace light base assembly (7).
If
Assembly.
(1) Using a butt splice connect electrical leads of light
assembly. Remove tags.
(2) Install light base assembly (7) with gasket (6) and
secure with two screws.
(3) Install cover (1), with lens (2) and Gasket (3) and
secure with two screws (4)
d.
Follow-on Maintenance
(1) Connect batteries (see para 4-114).
4-166
TM 5-4210-233-14&P-1
4-15. CROSSLAY HOSE BIN DIVIDERS
This task covers:
a.
b.
Replace Front Divider
Replace Rear Divider
c.
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
a.
Replace Front Divider.
(1) Remove from top: two acorn nuts (1) with attached
rods (2), flatwashers (3), and tubing (4) with attached
plastic bearings (5).
(2) Remove five screws (6), with flatwashers (11),
lockwashers (12), and nuts (13) from bottom flange
and remove front divider (7).
(3) Install front divider (7), align bottom flange, and install
with five screws (6), with flatwasher (11),
lockwashers (12), and nuts (13).
(4) Install rods (2), with attached flatwashers (3) and nuts
(1), and tubing with plastic bearing (5).
(5) Install assembly in place with acorn nuts (1).
b.
Replace Rear Divider.
(1) Remove from top: two acorn nuts (1) with attached
rods (2), flatwashers (3), and tubing (4) with attached
plastic bearings (5).
(2) Remove two screws (8), with flatwashers (14),
lockwashers (15), and nuts (16) from each end of
bottom flange and remove rear divider (9).
(3) Install rear divider (9) and install with two screws (8),
with flatwashers (14), lockwashers (15), and nuts (16)
on each end of bottom flange.
(4) Install rods (2), with attached flatwashers (3) and nuts
(1), and tubing with plastic bearing (5).
c.
Replace Bed Floor.
(1) Remove front divider (see para a. above).
(2) Remove rear divider (see para b. above).
(3) Lift bed floor (10) from truck.
(4) Install bed floor (10) in location.
(5) Install rear divider (see para b. above).
(6) Install front divider (see para a. above).
4-167
Replace Bed Floor
TM 5-4210-233-14&P-1
4-16. CROSSLAY HOSE BIN ROLLERS
This task covers:
a.
Removal
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
a.
b.
Installation
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Removal.
(1) Remove from top of front roller: two acorn nuts (1) with attached rods (2) and flat washers (3).
Remove tubing (4) with attached plastic bearings (5).
(2) Remove rear and lower rollers by removing bolts (6), flatwashers (9), lockwashers (10), and nuts
(11), and two brackets (7). Remove tubing (4) and bearings (5) from rods (8).
b.
Installation.
(1) Install front tubing (4) with plastic bearings (5), and attach with rods (2), flat washers (3) and acorn
nuts (1).
(2) Assemble rear and lower tubing (4) and bearings (5) on rods (8).
(3) Install rollers in position.
(4) Install two brackets (7).
(5) Fasten brackets to truck with bolts (6), flatwashers (9) lockwashers (10), and nuts (11).
4-168
TM 5-4210-233- 14&P-1
4-17. GAUGES-CROSSLAY, DISCHARGE, PUMP PRESSURE AND VACUUM
This task covers:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Removal.
(1) Open panel access door at top of pump operators
panel.
(2) Close valve (1) connected to gauge (2)
turning knurled knob (3) fully clockwise.
by
(3) Disconnect tube (4) from valve (1).
(4) Remove two nuts (5), lockwashers (6) and
bracket(s) (7) or (8) and remove gauge (2) with
valve (1) attached.
(5) Remove valve (1) from gauge (2).
b.
Installation.
(1) Install valve (1) on new gauge (2).
(2) Install gauge (2) with valve (1) attached. Secure
gauge with two nuts (5), lockwashers (6) and
bracket(s) (7) or (8).
(3) Open valve (1) by turning knurled knob (3) fully
counter-clockwise.
(4) Check valves under operating conditions.
(5) Close pump panel access door.
c.
Follow-on Maintenance
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-169
TM 5-4210-233-14&P-1
4-18. GAUGES-ENGINE STATUS
This task covers:
a.
b.
c.
d.
e.
f.
g.
Removal of Gauge Panel
Installation of Gauge Panel
Removal of FUEL and VOLTS gauges.
Installation of FUEL and VOLTS gauges.
Removal of WATER TEMP, OIL TEMP and OIL PRESS gauges.
Installation of WATER TEMP, OIL TEMP and OIL PRESS gauges.
Follow-on Maintenance
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Removal of Gauge Panel.
(1) Remove four crown nuts (1), lockwashers (2), flat
washers (3) and screws (4).
(2) Remove light shield (5) and allow lights to hang
from wire harnesses.
(3) Remove five screws (6), trim (7) and corner (8).
(4) Remove eight screws (9) and trim (10).
(5) Remove six screws (11) and trim (12).
CAUTION
Do not use force when removing gauge
panel.
Wires and tubes connected to
instruments can be damaged.
(6) Remove panel (13).
b.
Installation of Gauge Panel.
(1) Put panel (13) in position. Loosely install one
screw in top of panel to hold it in position.
(2) Install trim (12) and secure with six screws (11).
(3) Install trim (10) and secure with eight screws (9).
(4) Install trim (7) and secure with top two screws (6).
(5) Install corner (8) and secure with two screws (6).
(6) Put light shield (5) in position and secure with four
screws (4), flat washers (3), lockwashers (2) and
crown nuts (1).
4-170
TM 5-4210-233-14&P-1
4-18. GAUGES - ENGINE STATUS - Continued
c.
Removal of FUEL and VOLTS gauges.
(1) Remove gauge panel (see para a. above).
(2) Tag and disconnect wires from back of gauge (1).
Remove nuts (2) and washers (3) as necessary to
remove wires.
(3) Carefully pull bulb socket (4) from back of gauge (1).
Replace bulb (5) in bulb socket (4) if necessary.
(4) Remove two nuts (6) and lockwashers (7) securing
bracket (8) to back of gauge (1). Remove gauge
through front of panel.
d.
Installation of FUEL and VOLTS gauges.
(1) Install gauge (1) through front of gauge panel.
(2) Install bracket (8) and secure with two lockwashers
(7) and nuts (6).
(3) Connect wires to back of gauge (1) and install
lockwashers (3) and nuts (2) as necessary to secure
wires.
(4) Install bulb socket (4) with bulb (5) in back of gauge
(1) by pressing it firmly into place.
(5) Install gauge panel (see para b. above).
(6) Start truck engine and check gauge operation. Turn
PANEL LIGHTS switch ON at gauge panel and check
that gauge illuminates.
e.
Removal of WATER TEMP, OIL TEMP and OIL PRESS
gauge.
(1) Remove gauge panel (see para a. above).
(2) Carefully pull bulb socket (2) from back of gauge (1).
Replace bulb (3) in bulb socket (2) if necessary.
(3) Disconnect pressure line (4) from back of gauge (1).
(4) Remove two nuts (5) and lockwashers (6) securing
bracket (7) to back of gauge. Remove gauge (1)
through front of gauge panel.
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TM 5-4210-233-14&P-1
4-18. GAUGES - ENGINE STATUS - Continued
f.
Installation of WATER TEMP, OIL TEMP and OIL PRESS gauges.
(1) Install gauge (1) through front of gauge panel.
(2) Install bracket (7) and secure with two lockwashers (6) and nuts (5).
(3) Connect pressure line (4) to back of gauge (1).
(4) Install bulb socket (2) with bulb (3) in back of gauge (1) by pressing firmly into place.
(5) Install gauge panel (see para b. above).
(6) Start truck engine and check gauge operation. Allow engine sufficient time to reach operating
temperature. Turn PANEL LIGHTS switch ON at gauge panel and check that gauge illuminates.
g.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114)
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TM 5-4210-233-14&P-1
4-19. WATER TANK LEVEL GAUGE
This task covers:
a.
b.
c.
Removal
Disassembly
Cleaning and Inspection
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
d.
e.
f.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Gasket (Figure 4, Appendix F)
a.
Removal.
(1) Remove gauge panel (see para 4-18 .).
(2) Disconnect wiring harness from plug (1) on assembly
gauge.
(3) Remove locknut (2), washer (3) and clamp (4).
(4) Remove gauge assembly.
b.
Assembly
Installation
Follow-on Maintenance
Disassembly.
(1) Remove screws (5).
(2) Remove lens (6) and gasket (7) from plate (8).
(3) Remove bulbs (9) from circuit board (12).
(4) Remove four screws (1 0) and spacers (11) to
remove circuit board (12) from housing (13).
(5) Remove four screws (14) to remove plug (1) from
housing (13).
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TM 5-4210-233-14&P-1
4-19. WATER TANK LEVEL GAUGE - Continued
c.
Cleaning and Inspection.
(1) Clean lens (6).
(2) Inspect lens for cracks. If cracked, replace lens.
(3) Inspect wiring for fraying or cracked insulation.
Maintenance.
If wiring is damaged, contact Direct Support
(4) Inspect bulb sockets, bulb contacts, and wiring for corrosion. Clean corrosion with emery cloth (Item
25, Appendix E). If corrosion cannot be cleaned, replace parts as required.
d.
Assembly.
(1) Install circuit board (12) in housing (13) with four screws (10) and spacers (11).
(2) Install plug (1) in housing (13) with four screws (14).
(3) Install bulbs (9) in circuit board (12).
(4) Install lens (6) and gasket (7) on plate (8). Secure in place with two screws (5).
e.
Installation.
(1) Position gauge in gauge panel.
(2) Secure gauge with clamp (4), washer (3) and locknut (2).
(3) Connect wiring harness to plug (1) on rear of gauge.
f.
Follow-on Maintenance.
(1) Install gauge panel (see para 4-18).
(2) Connect batteries (see para 4-114).
(3) Fill water tank and check operation of gauge with battery switch on.
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TM 5-4210-233-14&P-1
4-20. TACHOMETER
This task covers:
a.
b.
Removal
Installation
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
a.
c.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Gauge Panel Removed (see para 4-18 .)
Batteries Disconnected (see para 4-114 .)
Removal.
(1) Carefully pull bulb socket (1) from tachometer (2).
Remove bulb (3) from bulb socket (1).
(2) Disconnect wiring harness from cable connector (4)
on back of tachometer.
(3) Remove two wing nuts (5) and bracket (6) Remove
tachometer through front of gauge panel.
b.
Follow-on Maintenance
Installation.
(1) Install tachometer (2) through hole in gauge panel.
(2) Install bracket (6) and fasten to tachometer (2) with
two wing nuts (5).
(3) Connect wiring harness cable connector (4) on back
of tachometer.
(4) Install bulb (3) in bulb socket (1). Install bulb socket
(1) in back of tachometer (2) by pressing firmly.
(5) Run engine to make sure tachometer is operating
properly.
4-175
TM 5-4210-233-14&P-1
4-20. TACHOMETER - Continued
c.
Follow-on Maintenance.
(1) Install gauge panel (see para 4-18).
(2) Connect batteries (see para 4-114).
4-176
TM 5-4210-233-14&P-1
4-21. PUMP PANEL INDICATOR LIGHTS
This task covers:
a.
b.
c.
Removal
Disassembly
Cleaning and Inspection
TOOLS REQUIRED:
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
d.
e.
f.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Gauge Panel Removed (see para 4-18 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
O-Ring (Figure 4, Appendix F)
a.
Removal.
(1) Tag wires. Remove two screws (4) and
disconnect wiring harness.
(2) Remove nut (5) and lockwasher (6).
(3) Remove light base assembly (7) from
gauge panel.
b.
Disassembly.
(1) Unthread and remove lens (1) and O-ring
(2) from light assembly (7). Discard Oring (2).
(2) Remove bulb (3).
c.
Cleaning and Inspection.
(1) Clean lens (1).
(2) Inspect lens (1) for cracks.
replace lens.
Assembly
Installation
Follow-on Maintenance
If cracked,
(3) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(4) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion cannot be removed, replace
light assembly.
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TM 5-4210-233-14&P-1
4-21. PUMP PANEL INDICATOR LIGHTS- Continued
d.
Assembly.
(1) Install bulb (3).
(2) Install O-ring (2).
(3) Install lens (1).
e.
Installation.
(1) Install light base assembly (7).
(2) Fasten light base assembly (7) in place with lockwasher (6) and nut (5).
(3) Connect wiring harness to light assembly with two screws (4).
f.
Follow-on Maintenance.
(1) Install gauge panel (see para 4-18).
(2) Connect batteries (see para 4-114).
4-178
TM 5-4210-233-14&P-1
4-22. PUMP PANEL TOGGLE SWITCHES
This task covers:
a. Inspection
b. Replacement
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section III, Item 1)
MATERIALS/PARTS REQUIRED
Tags (Item 32, Appendix E)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Gauge Panel Removed (see para. 4-18.)
Batteries Disconnected (see para. 4-114.)
a. Removal.
(1 ) Tag wires and remove screws (3).
(2) Remove nut (1) and lock washer (2).
(3) Remove switch (4).
b. Installation.
(1 ) Connect wires to switch with screws (3).
(2) Secure switch to panel with nut (1) and lock
washer (2).
c.
Follow-on Maintenance.
(1) Install gauge panel (see para. 4-18).
(2) Connect batteries (see para. 4-114).
(3) Test operation of switch.
4-179
TM 5-4210-233-14&P-1
4-23. ENGINE COOLER VALVE
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section lIl, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Gauge Panel Removed (see para. 4-18.)
Batteries Disconnected (see para. 4-114.)
a. Removal.
(1) Remove set screw (1), and handle (2).
(2) Tag and remove two hoses (6) from valve (5).
NOTE
Before removal, note orientation of valve on panel
to ensure correct operation after replacement.
(3) Remove nut (at, lock washer (4) and valve {51
b. Installation.
(1) Install valve (5) on panel and secure with lock
washer (4) and nut (3).
(2) Install two hoses (6) on valve (5).
(3) Install handle (2) and set screw (1).
c.
Follow-on Maintenance.
(1) Install gauge panel (see para. 4-18).
(2) Connect batteries (see para. 4-114).
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TM 5-4210-233-14&P-1
4-24. PRIMER CABLE
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Batteries Disconnected (see para. 4-114.)
Gauge Panel Removed (see para. 4-18.)
Curbside Panel Removed (see para. 4-26.)
a. Removal.
(1) Unscrew handle (1 ) from cable (5).
(2) Remove nut (2), nut (3), and washer (4) from
cable (5).
(3) At primer pump, loosen screw (6) and washer (7)
and remove cable clamp (8) from cable (5).
(4) Remove two nuts (9), two washers (10) and two
screws (11 ).
(5) Remove cable clamps (12) from cable (5).
(6) Remove cable (5).
b. Installation.
(1) Install cable (5) through street side operators
panel.
(2) Install washer (4), nut (3), nut (2) and handle (1).
Tighten nut (2) against handle (1).
(3) Install cable clamps (12) on cable (5) and install
two screws (11), two washers (10) and two nuts
(9).
(4) Install cable clamp (8) on cable (5).
(5) At pump panel, push PRIMER handle (1 ) in as
far as possible
(6) Install washer (7) and screw (6).
(7) Check operation of primer valve. Adjust position
of cable clamp (8) as necessary.
c.
Follow-on Maintenance.
(1) Install gauge panel (see para. 4-18).
(2) Install curside panel (see para. 4-26).
(3) Connect batteries (see para. 4-114).
4-181
TM 5-4210-233-14&P-1
4-25. STREET SIDE OPERATOR'S PANEL
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section III, Item 1)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B. Section III, Item 4)
c. Follow-on Maintenance
PERSONNEL REQUIRED: 2
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Batteries Disconnected (see para. 4-114.)
Drivers Side Auxiliary Suction Valves Remove
(see para. 4-52.)
Discharge Connections/Chrome Adapters
Removed (see para. 4-56.)
a. Removal.
(1) Remove fourteen roll pins (1 ) and fourteen T-handles
(2) from operating rods (3).
(2) Remove roll pin (4) and remove front suction control
wheel (5) and washer (6) from shaft (7).
(3) Remove side suction cap.
(4) Remove snap ring (8) and pull plunger assembly (9)
from three drain valves (10).
(5) Remove six screws (11) from three drain valves (10).
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TM 5-4210-233-14&P-1
4-25. STREET SIDE OPERATOR'S PANEL - Continued
(6) Remove PRIMER handle (12), two nuts (13) and
washer (14) from primer control cable (15).
(7) Remove set screw (16) and remove handle (17)
from valve (18).
(8) Remove nut (19) and lock washer (20) from valve
(18).
(9) Remove manual pump shift handle (21), two nuts
(22) and (23) and washer (24) from manual pump
shift rod (25).
(10) Remove set screw (26) and handle (27) from rod
(28).
(11) Remove nut (29) from rod (28).
4-183
TM5 4210-233-14&P-1
4-25. STREET SIDE OPERATOR'S PANEL-Continued
(12) Remove pump drain handle (30), two nuts (31
and 32) and washer (33) from pump drain cable
(34).
(13) Disconnect RPM counter cable (35) from coupler
(36) at back of panel.
(14) Remove two screws (37) and metering valve
handle (38).
(15) Remove two screws (39) and metering valve
indicator ring (40).
4-184
TM 5-4210-233-14&P-1
4-25. STREET SIDE OPERATOR'S PANEL - Continued
(16) Tag and remove three 3/8 inch hoses (41) from pilot
valve (42).
NOTE
It is not necessary to remove two hoses
between relief valve and back of fittings on
test gauge panel.
(17) Tag and remove two hoses (43) from top of tees (44)
at test gauge panel (45).
4-185
TM5-4210-233 14&P-1
4-25. STREET SIDE OPERATOR'S PANEL - Continued
(18) Tag and remove two 3/8 hoses (46) from
ENGINE COOLER cooler valve (47).
(19) Tag and remove Y-strainer drain hose (48),
metering valve drain hose (49) and air supply
hose (50) from back of panel.
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TM 5 4210-233-14&P-1
4-25. STREET SIDE OPERATOR'S PANEL - Continued
(20) Tag and remove wires from back of relief valve indicator lights (51 and 52).
(21) Tag and remove wires from back of throttle light (53).
(22) Remove any remaining tie straps securing wires or hoses.
(23) Remove two pan head screws (54), two flat washers (55) and two nuts (56) from center of pump panel.
(24) Remove thirty screws (57) and six pieces of panel trim (58).
(25) Remove street side operator's panel.
4-187
TM 5-4210-233-14&P-1
4-25. STREET SIDE OPERATOR'S PANEL- Continued
b. Installation.
(1) Place street side operator's panel on running board.
(2) Secure wires to throttle light (53) and remove tags.
(3) Secure wires to relief valve indicator lights (51 and 52) and remove tags.
(4) Install two 3/8 hoses (46) on cooler valve (47).
(5) Install two hoses (43) on top of tees (44) at the test gauge panel.
(6) Install three 3/8 inch hoses (41) on pilot valve (42).
(7) Secure center of panel with two panhead screws (54), two flat washers (55), and two nuts (56).
(8) Secure panel with six pieces of panel trim (58) and thirty screws (57).
(9) Install metering valve drain hose (49).
(10) Install air supply hose (50).
(11) Install Y-strainer drain hose (48).
(12) Secure metering valve indicator ring (40) to panel with two screws (39).
(13) Secure metering valve handle (38) with two screws (37).
(14) Install RPM counter cable (35) in coupler (36).
(15) Install pump drain cable (34), washer (33), two nuts (31 and 32) and handle (30).
(16) Install manual pump shift cable (25), with washer (24), two nuts (22 and 23) and handle (21).
(17) Install nut (29) on rod (28) and install handle (27) with set screw (26).
(18) Install washer (20) and nut (19) on valve (18) and secure handle (17) with setscrew (16).
(19) Install primer control cable (15), washer (14), two nuts (13) and handle (12).
(20) Secure three drain valves (10) to panel with six screws (11).
(21) Install three plunger assemblies (9) in drain valves (10) and install snap rings (8).
(22) Secure front suction control wheel (5) and washer (6) with roll pin (4) on shaft (7).
(23) Install fourteen T-handles (2) on operating rods (3) and secure with fourteen roll pins (1).
(24) Replace any tie straps that were removed.
4-188
TM 5-4210-233-14&P-1
4-25. STREET SIDE OPERATOR'S PANEL- Continued
c.
Follow-on Maintenance.
(1) Install Drivers Side Auxiliary Suction Valves (see para. 4-52).
(2) Install Discharge Connections/Chrome Adapters (see para. 4-56).
(3) Connect Batteries (see para. 4-114).
4-189
TM 5-4210-233-14&P-1
4-26. CURB SIDE OPERATOR'S PANEL
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section Hi, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Batteries Disconnected (see para. 4-114.)
a . Removal
NOTE
Make provision for draining of water from suction and discharge lines.
(1) Close (push forward) all T-handles for valves on street-side panel.
(2) Remove 6-inch suction cap (1) and two 2-1/2 inch discharge caps (2).
(3) Remove two 45°elbows (3).
(4) Remove oil tank access door (4) by removing four screws (5), nuts (6), lock washers (7) and flat
washers (8).
4-190
TM -4210-233-14&P-1
4-26. CURB SIDE OPERATOR'S PANEL - Continued
(5) Remove NO. 3 and NO. 4 DISCHARGE drain valve (10), knobs and plungers (right-bottom corner) by
pulling knobs outward and removing retaining rings (9).
(6) Remove drain valves (10) from panel by removing screws (11).
(7) Disconnect tubing (12) from RELIEF VALVE DRAIN valve (13) on back of panel.
(8) Remove panel trim (14) and two corner pieces (15) by removing 32 screws.
(9) Remove screw (16), nut (17), lock washer (18), and flat washer(19) from center of panel.
(10) Remove panel.
b. Installation.
(1) Lubricate hinge pin and surfaces of moving parts connected to handle on oil primer tank access door.
(2) Remove screw (20) from swivels on elbows (3) and apply small amount of oil to bearings. Rotate swivel
and replace screw.
(3) Install operators panel using screw (16), nut (17), lockwasher (18) and flatwasher (19).
(4) Install panel trim (14) and two corner pieces (15) with 32 screws.
(5) Install DRAIN valves (10) with screws (11).
(6) Install NO. 3 and NO. 4 DISCHARGE drain valve (10), knobs and plungers with retaining rings (9).
(7) Connect tubing (12) to RELIEFVALVE DRAIN valve (13) on beck of panel.
(8) Install oil tank access door (4) with four screws (5), nuts (6), lockwashers (7) and flatwashers (8).
(9) Install two 45°elbows (3).
(10) Install 6 inch suction cap (1) and two 2-1/2 inch discharge caps (2).
c.
Follow-on Maintenance.
(1) Connect batteries (see para. 4-114).
4-191
TM 5-4210-233-14&P-1
4-27. THROTTLE CONTROL
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section lIl, Item 1 )
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Batteries Disconnected (see para. 4-114.)
a. Removal.
NOTE
Throttle control must be in idle position.
(1) Disconnect wiring harness (1) from end
of throttle control cable.
(2) Unscrew rear half of throttle control (2)
and remove connector (6) from ball on
end of from control rod (3).
(3) Remove nut (4).
(4) Remove front half of throttle control (5)
from panel.
b. Installation.
(1) Install front half of throttle control (5) in
panel.
(2) Install nut (4).
(3) Install control rod (3) in connector (6)
and thread rear half of throttle control
(2) onto front half of throttle control (5).
(4) Attach throttle control connector to
wiring harness.
c.
Follow-on Maintenance.
(1) Connect batteries (see para.
and test throttle control.
4-114)
4-192
TM 5-4210-233-14&P-1
4-28. GAUGE PANEL ENCLOSURE
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section III, Item 1),
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Batteries Disconnected (see para. 4-114.)
a. Removal.
(1) Remove seven screws (1) attaching hinge
(2) to panel (3).
(2) Remove door (4) and hinges (2).
(3) Remove six screws (5), lock washers (6)
and acorn nuts (7) securing hinge (2) to
door (4).
(4) Remove latch (8) from door (4).
b. Installation.
(1) Install latch (8) in door (4).
(2) Fasten hinge (2) to door (4) with six screws
(5), lock washers (6) and acorn nuts (7).
(3) Position hinge on panel (3) and secure with
seven screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para. 4-114).
4-193
TM 5-4210-233-14&P-1
4-29. RUNNING BOARDS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.1
Batteries Disconnected (see para. 4-114.)
a. Removal.
(1) Remove either running
removing 16 screws (2).
board
(1)
by
(2) Remove two identification plates (3) from
curb-side running board by removing four
nuts (4) and tapping on pins from back side
of plates.
b. Installation.
(1) Install two identification plates (3) and
secure with four nuts (4).
(2) Install new Dunning board(s) (1) and secure
with 16 screws (2).
c.
Follow-on Maintenance.
(1) Connect batteries (see para. 4-114).
4-194
TM 5-4210-233-14&P-1
4-30. PULL-OUT TREAD PLATE
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Batteries Disconnected (see para. 4-114.)
MATERIALS/PARTS REQUIRED
Lubricating Oil (Item 10, Appendix El
a. Removal.
NOTE
Position tread plate so that heads of bolts
are accessible through holes in stationary
slides.
(1) Remove four acorn nuts (1), four bolts (2),
and tread plate (3).
(2) Remove four bolts (4), four acorn nuts (5),
and two slide rails (6).
b. Installation.
(1) Install two side rails (6), four acorn nuts (5),
and four bolts (4).
(2) Align tread plate (3).
(3) Install four bolts (2) and acorn nuts (1).
(4) Lubricate tread plate parts with lubricating
oil (Item 10, Appendix E).
(5) Be sure tread plate operates without
binding.
c.
Follow-on Maintenance.
(1) Connect Batteries (see para. 4-114).
4-195
TM 5-4210-233-14&P-1
4-31. FOAM METERING VALVE (PROPORTIONER)
This task covers:
a. Removal
c.
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section lIl, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
Batteries Disconnected (see para. 4-114.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
a. Removal.
NOTE
For proper operation, dial and handle must be
positioned in the same orientation as shown at
installation.
(1) Remove two screws (1) and handle (2).
(2) Remove two screws (3) and dial (4).
(3) Loosen swivel hex (5) and remove upper hose (6).
(4) Loosen swivel hex (7) and remove lower hose (8).
(5) Loosen hex (9) and remove drain hose (10).
(6) Remove two swivels (11) and elbow (12) from valve (13).
4-196
TM 5-4210-233-14&P-1
4-31. FOAM METERING VALVE (PROPORTIONER) - Continued
b. Installation.
(1) Apply pipe sealant (Item 2, Appendix E) to all pipe threads.
(2) Install elbow (12) end two swivels (11) in valve (13).
(3) Secure drain hose (10) with hex (9).
(4) Secure lower hose (8) with swivel hex (7).
(5) Secure upper hose (6) with swivel hex (a).
(6) Position valve (13) on panel and install dial (4) and two screws (3).
(7) Install handle (2) and two screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para. 4-114).
(2) Test operation of foam system (See para. 2-13).
4-197
TM 5-4210-233-14&P-1
4-32. METERING VALVE DRAIN
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B. Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para. 2-12.)
APU Shutdown (see para. 2-16.)
All Piping Drained (see para. 2-17.)
Batteries Disconnected (see para. 4-114.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Grease (Item 17, Appendix E)
a. Removal.
(1) Tag and remove hoses (1).
(2) Turn nut (3) counterclockwise until free from housing (4).
(3) Turn knob (2) counterclockwise until needle (5) is free from housing (4).
(4) Remove knob (2), nut (3), and needle (5) from housing (4) as assembly.
(5) Remove nut (6), washer (7), internal tooth washer (8) and housing (4) from panel.
(6) Note position and remove fittings (9) from housing (4).
(7) Loosen set screw (10).
(8) Remove knob (2) and nut (3) from needle (5).
4-198
TM 5-4210-233-14&P-1
4-32. METERING VALVE DRAIN - Continued
b. Installation.
(1) Install nut (3) and knob (2) on needle (5).
(2) Tighten set screw (1 0).
(3) Apply pipe sealant (Item 2, Appendix E) to fittings (9).
(4) Install fittings (9).
(5) Position housing in panel and install internal tooth washer (8), washer (7) and nut (6) on housing
(4).
(6) Apply a light coat of grease (Item 17, Appendix E) to needle (5).
(7) Install needle (5), nut (3), and knob (2) as an assembly.
(8) Thread needle (5) into housing (4).
(9) Tighten nut (3).
(10) Install two hoses (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-199
TM 5-4210-233-14&P-1
4-33. EDUCTOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section Ill, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
All Piping Drained (see para 2-17 .)
Batteries Disconnected (see para 4-114 .)
Curbside Pump Panel Removed (see para 4-26 .)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
a. Removal.
NOTE
The eductor is located on the passenger side
suction inlet.
(1) Disconnect water hose (1) and foam hose (2)
by loosening two swivels (3 and 4).
(2) Remove check valve (5) nipple (6), reducer (7)
and elbow (8) from eductor (9).
(3) Remove eductor (9) from suction inlet.
b. Installation.
(1) Make sure threads on valve and removed parts
are clean and undamaged. Apply pipe sealant
(Item 2, Appendix E) to all threads.
(2) Install eductor valve (9) in suction inlet.
(3) Install elbow (8), reducer (7), nipple (6) and
check valve (5) on eductor.
(4) Install swivel (4) on hose (2).
(5) Install swivel (3) on hose (1).
(6) Connect water hose (1) and foam hose (2) and
tighten swivels (3) and (4).
4-200
TM 5-4210-233-14&P-1
4-33. EDUCTOR - Continued
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test foam system (see para 2-13) and check for leaks. Tighten/remake any leaking connections.
(3) Install curbside panel (see para 4-26).
4-201
TM 5-4210-233-14&P-1
4-34. OPERATING RODS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Remove roll pin (1) and remove T-handle (2).
(2) Remove valve rod guide (3).
(3) Remove cotter pin (4) and clevis pin (5)
from valve arm (6).
(4) Remove lock nut (7).
(5) Remove rods (8 and 9).
(6) Loosen allen head screw (1 0).
(7) Remove swivel block (11).
(8) Remove clevis (12) from rod (8).
b.
Installation.
(1) Install swivel block (11) on rod (9) and secure
with allen head screw (10).
(2) Thread clevis (12) onto rod (8).
(3) Position rod (9) through hole in panel.
(4) Secure rod (8) to swivel block (11) with
locknut (7).
(5) Align clevis (12) with valve arm ( 6) and secure
with clevis pin (5) and cotter pin (4).
(6) Install valve rod guide (3).
(7) Secure T-handle (2) to rod (8) with roll pin (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-202
TM 5-4210-233-14&P-1
4-35. RELIEF VALVE
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Piping Drained (see para 2-17 .)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Curbside Pump Panel Removed (see para 4-26 .)
MATERIALS/PARTS REQUIRED
O-rings (Fig 36, Appendix F)
a. Removal.
(1) Disconnect wires and remove micro switch
and bracket (1).
(2) Remove four bolts (2) and four washers (3).
(3) Remove two bolts (4).
(4) Remove relief valve (5) and pipe (7).
(5) Remove and discard three O-rings (6).
b. Installation.
(1) Install three new O-rings (6).
(2) Install pipe (7) and relief valve (5); secure
relief valve (5) with two bolts (4), four bolts (2)
and four washers (3).
(3) Install micro switch and bracket (1) and
reconnect wires.
c. Follow-on Maintenance.
(1) Install curbside panel (see para 4-26).
(2) Connect batteries (see para 4-114).
(3) Test relief valve operation (see para 2-13).
4-203
TM 5-4210-233-14&P-1
4-36. RELIEF VALVE PILOT ASSEMBLY
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Gauge Panel Removed (see para 4-18 .)
MATERIALS/PARTS REQUIRED
Pipe Sealing Compound (Item 2, Appendix E)
a. Removal.
(1) Tag and disconnect three hoses (1, 2 and 3).
(2) Remove pins (6 and 7) and remove valve
handles (8 and 9).
(3) Unscrew knob (1 0) and remove strainer.
(4) Remove two screws (11), nuts (12) and
lockwashers (13). Remove pilot assembly (14).
(5) If necessary, remove drain cock (15) from pilot
assembly (14).
b. Installation.
NOTE
Coat all threads with pipe sealing compound
(Item 2, Appendix E).
(1) If necessary, install drain cock (15) in pilot
assembly (14).
(2) Put pilot assembly (14) in position on pump
panel and secure with two screws (11),
lockwashers (13) and nuts (12).
(3) Install strainer (10) in pilot assembly (14).
(4) Install valve handles (8 and 9) and install pins (6
and 7).
(5) Connect hoses (1, 2 and 3) to pilot assembly
(14).
4-204
TM 5-4210-233-14&P-1
4-36. RELIEF VALVE PILOT ASSEMBLY- Continued
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine, operate pump and test operation of relief valve pilot. Check for leaks.
(3) Install gauge panel (see para 4-18).
4-205
TM 5-4210-233-14&P-1
4-37. Y-STRAINER AND 1-1/2" CHECK VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Curbside Pump Panel Removed (see para 4-26 .)
Foam Valve Removed (see para 4-41 .)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
a. Removal.
(1) Remove pipe (1) from Y-strainer (6).
(2) Remove drain hose (2) from Y-strainer (6).
(3) Remove two nuts (3) and lockwasher (4) and U-bolt (5).
(4) Remove Y-strainer (6) from nipple (7).
(5) Remove nipple (7), elbow (8), nipple (9), 1-1/2" check
valve (10), nipple (11) and elbow (12).
4-206
TM 5-4210-233-14&P-1
4-37. Y-STRAINER AND 1-1/2" CHECK VALVE - Continued
b. Disassembly.
(1) Remove elbow (13), reducer (14), cap (15) and
screen (16) from Y-strainer body (6).
c. Cleaning and Inspection.
(1) Clean any debris from y-strainer body (6), screen
(16) and fittings (13, 14, and 15).
(2) Inspect y-strainer body (6) for cracks. Replace
valve body if damaged.
(3) Inspect screen (1 6) for rust or corrosion. Replace
if required.
d. Assembly.
(1) Coat all pipe threads with pipe sealant (Item 2,
Appendix E).
(2) Install screen (16) in cap (15). Install cap (15) in
Y-strainer body (6).
(3) Install reducer (14) and elbow (13).
e. Installation.
(1) Coat all pipe threads with pipe sealant (Item 2,
Appendix E).
NOTE
Be sure 1-1/2" check valve (10) is installed with pipe cap
facing up and arrow pointing towards elbow (8).
(2) Install elbow (12), nipple (11), 1-1/2" check valve (10), nipple (9), elbow (8) and nipple (7).
(3) Install Y-strainer (6) on nipple (7).
(4) Install U-bolt (5), lockwasher (4) and nut (3).
(5) Install drain hose (2).
(6) Install pipe (1) in Y-strainer (6).
f. Follow-on Maintenance.
(1) Install foam valve (see para 4-41).
(2) Install curbside panel (see para 4-26).
(3) Connect batteries (see para 4-114).
4-207
TM 5-4210-233-14&P-1
4-38. Y-STRAINER DRAIN VALVE
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Piping Drained (see para 2-17 .)
MATERIALS/PARTS REOUIRED
Grease (Item 17, Appendix E)
Pipe Sealant (Item 2, Appendix E)
a. Removal.
(1) Tag and remove two hoses (1).
(2) Turn nut (3) counterclockwise until free from
housing (4).
(3) Turn knob (2) counterclockwise until needle
(5) is free from housing (4).
(4) Remove knob (2), nut (3), and needle (5)
from housing (4) as assembly.
(5) Remove nut (6), washer (7), internal tooth
washer (8) and housing (4) from panel.
(6) Note position and remove fittings (9) from
housing (4).
(7) Loosen set screw (10).
(8) Remove knob (2) and nut (3) from needle (5).
4-208
TM 5-4210-233-14&P-1
4-38. Y-STRAINER DRAIN VALVE - Continued
b. Installation.
(1) Install nut (3) and knob (2) on needle (5).
(2) Tighten set screw (10).
(3) Apply pipe sealant (Item 2, Appendix E) to fittings (9).
(4) Install fittings (9).
(5) Position housing in panel and install internal tooth washer (8), washer (7) and nut (6) on housing
(4).
(6) Apply a light coat of grease (Item 17, Appendix E) to needle (5).
(7) Install needle (5), nut (3), and knob (2) as assembly.
(8) Thread needle (5) into housing (4).
(9) Tighten nut (3).
(10) Install two hoses (1).
c. Follow-on Maintenance.
(1) Connect Batteries (see para 4-114).
4-209
TM 5-4210-233-14&P-1
4-39. #1, #2 AND AERIAL DISCHARGE DRAIN VALVES
This task covers:
a. Removal
c. Installation
b. Cleaning and Inspectione. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Grease, Item 1, Appendix E
Dry Cleaning Solvent, Item 3, Appendix E
O-rings (Figure 18, Appendix F)
a. Removal.
(1) Remove snap ring (1).
(2) Remove knob (2), rod (3), and plunger (4) with
O-rings (11) as assembly.
(3) Remove two screws (8) and remove valve body (7)
from panel.
(4) Loosen hose clamp (9) and remove drain hose (10).
(5) Turn valve body (7) until fitting(5) and hose (6)
with clamp (12) is free of valve body (7).
(6) Remove and discard two 0-rings (11).
b. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially
dangerous. Avoid repeated and prolonged
breathing of vapors and skin contact with the
liquid. Do not use near open flame, arcing
equipment or other ignition sources. Always
wear eye protection and protective clothing.
The flash point of P-D-680 is 100 to 138 deg.
F (38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
4-210
TM 5-4210-233-14&P-1
4-39. #1, #2 AND AERIAL DISCHARGE DRAIN VALVES- Continued
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (7) for cracks and damaged threads. Replace as necessary.
(4) Inspect plunger (4) for grooves or cracks. Replace as necessary.
c. Installation.
(1) Install two new O-rings (11) on plunger (4).
(2) Secure hose (6) with clamp (12) and fitting (5) to valve body (7).
(3) Install drain hose (1 0) and hose clamp (9).
(4) Secure valve body (7) to panel with two screws (8).
(5) Apply grease (Item 1, Appendix E) to O-rings (11).
(6) Install plunger (4) with O-ring (11), rod (3) and knob (2) in valve port.
(7) Install snap ring (1).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-211
TM 5-4210-233-14&P-1
4-40. FLUSH VALVE
This task covers:
a. Removal
b. Disassembly
c. Cleaning and Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Piping Drained (see para 2-17 .)
Curbside Pump Panel Removed (see para 4-26 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Cotter Pin (Figure 28, Appendix F)
Repair Kit (Figure 22, Appendix F)
a. Removal.
NOTE
Access to Flush Valve is gained
through access door on curb-side
pump panel
(1) Remove cotter pin (1) and retaining pin (2).
Discard cotter pin.
(2) Remove control rod (3) and nylon washer (4).
(3) Remove eight bolts (5).
(4) Remove valve (6) from between flanges (7).
(5) Remove and discard two O-rings (8).
4-212
TM 5-4210-233-14&P-1
4-40. FLUSH VALVE - Continued
b. Disassembly.
(1) Use spanner wrench to turn seat retainer (1) counterclockwise until free from valve body (2).
(2) Discard retainer (1) and O-ring (3).
(3) Remove and discard seat (4).
(4) Remove and discard seat O-ring (5).
(5) Remove capscrew (6) and handle washer (7).
(6) Mark position of handle (8).
(7) Remove handle (8) and handle O-ring (9). Discard O-ring (9).
(8) Mark position of stop plates (1 0).
(9) Remove two stop plates (10).
(10) Remove pivot bolt (11) and pivot bolt O-ring (12). Discard pivot bolt O-ring (12).
(11) Remove ball valve (13).
(12) Remove actuator shaft (14) and actuator shaft O-ring (15). Discard actuator shaft O-ring (15).
4-213
TM 5-4210-233-14&P-1
4-40.
FLUSH VALVE- Continued
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame,
arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of
P-D-680 is 100 to 138 deg. F (38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (2) for cracks and damaged threads. Replace as necessary.
(4) Inspect ball valve (1 3) for grooves or cracks. Replace as necessary.
d. Assembly.
(1) Install new actuator shaft O-ring (15) and actuator shaft (14). Apply a thin coat of silicone grease
(Item 11, Appendix E) to actuator shaft.
(2) Fit ball valve (13) to actuator shaft (14).
(3) Install new pivot bolt O-ring (12) and pivot bolt (11). Apply a thin coat of silicone grease (Item
11, Appendix E) to O-ring.
(4) Install new seat O-ring (5) and new seat (4) in new seat retainer (1). Apply a thin coat of silicone
grease (Item 11, Appendix E) to O-ring.
(5) Install new retainer O-ring (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to
inside edge of seat retainer.
(6) Use a spanner wrench to thread seat retainer (1) clockwise into valve body (2) until tight.
(7) Install two stop plates (10) to original position on actuator shaft (14).
(8) Install new handle O-ring (9). Apply a thin coat of silicone grease (Item 11, Appendix E) to Oring.
(9) Install handle (8) to original position.
4-214
TM 5-4210-233-14&P-1
4-40. FLUSH VALVE - Continued
(10) Install handle washer (7) and capscrew (6).
e. Installation.
(1) Carefully pull pipe (1) towards curbside and place valve (2) with two new O-rings (1 0) between
two flanges (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to O-rings.
(2) Secure valve (2) with eight bolts (4).
(3) Position control rod (5) and nylon washer (6) on valve handle (7).
(4) Install retaining pipe (8) and new cotter pin (9).
f. Follow-on Maintenance.
(1) Install curbside operator's panel (see para 4-25).
(2) Connect batteries (see para 4-114).
4-215
TM 5-4210-233-14&P-1
4-41. FOAM VALVE
This task covers:
a. Removal
b. Disassembly
c. Cleaning and Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Took Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Piping Drained (see para 2-17 .)
Curbside Operators Panel Removed
(see para 4-26 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Cotter Pin (Figure 28, Appendix F)
Repair Kit (Figure 22, Appendix F)
a. Removal.
(1) Remove cotter pin (1) and retaining pin (2).
Discard cotter pin.
(2) Remove control rod (3) and nylon washer (4)
(3) Remove eight bolts (5).
(4) Remove valve (6) from between flanges (7).
(5) Remove and discard two O-rings (8).
4-216
TM 5-4210-233-14&P-1
4-41. FOAM VALVE- Continued
b.
Disassembly.
(1) Use spanner wrench to turn seat retainer (1) counterclockwise until free from valve body (2).
Discard retainer.
(2) Remove and discard retainer O-ring (3).
(3) Remove and discard seat (4).
(4) Remove and discard seat O-ring (5).
(5) Remove capscrew (6) and handle washer (7).
(6) Mark position of handle (8).
(7) Remove handle (8) and handle O-ring (9). Discard O-ring (9).
(8) Mark position of stop plates (10).
(9) Remove two stop plates (10).
(10) Remove pivot bolt (11) and pivot bolt O-ring (12). Discard pivot bolt O-ring (12).
(11) Remove ball valve (13).
(12) Remove actuator shaft (14) and actuator shaft O-ring (15). Discard actuator shaft O-ring (15).
4-217
TM 5-4210-233-14&P-1
4-41.
FOAM VALVE - Continued
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (2) for cracks and damaged threads. Replace as necessary.
(4) Inspect ball valve (13) for grooves or cracks. Replace as necessary.
d. Assembly.
(1) Install new actuator shaft O-ring (15) and actuator shaft (14). Apply a thin coat of silicone grease
(Item 11, Appendix E) to actuator shaft.
(2) Fit ball valve (13) to actuator shaft (14).
(3) Install new pivot bolt O-ring (12) and pivot bolt (11). Apply a thin coat of silicone grease (Item
11, Appendix E) to 0-ring.
(4) Install new seat O-ring (5) and new seat (4) in new seat retainer (1). Apply a thin coat of silicone
grease (Item 11, Appendix E) to O-ring.
(5) Install new retainer O-ring (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to
inside edge of seat retainer.
(6) Use spanner wrench to thread seat retainer (1) clockwise into valve body (2) until tight.
(7) Install two stop plates (1 0) to original position on actuator shaft (14).
(8) Install new handle O-ring (9). Apply a thin coat of silicone grease (Item 11, Appendix E) to Oring.
(9) Install handle (8) to original position.
4-218
TM 5-4210-233-14&P-1
4-41. FOAM VALVE - Continued
(10) Install handle washer (7) and capscrew (6).
e. Installation.
(1) Carefully pull pipe (1) towards curbside and place valve (2) with two new O-rings (10) between
two flanges (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to O-rings.
(2) Secure valve (2) with eight bolts (4).
(3) Position control rod (5) and nylon washer (6) on valve handle (7).
(4) Install retaining pin (8) and new cotter pin (9).
f. Follow-on Maintenance.
(1) Install curbside operator's pump panel (see para 4-26).
(2) Connect batteries (see para 4-114).
4-219
TM 5-4210-233-14&P-1
4-42. WATER VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Took Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Piping Drained (see para 2-17.)
Curb Side Operators Panel Removed (see para
4-26 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Cotter Pin (Figure 28, Appendix F)
Repair Kit (Figure 22, Appendix F)
a. Removal
(1) Remove cotter pin (1) and retaining pin (2).
Discard cotter pin.
(2) Remove control rod (3) and nylon washer (4).
(3) Remove eight bolts (5).
(4) Remove valve (6) from between flanges (7).
(5) Remove and discard two O-rings (8).
4-220
TM 5-4210-233-14&P-1
4-42. WATER VALVE - Continued
b. Disassembly.
(1) Use spanner wrench to turn seat retainer (1) counterclockwise until free from valve body (2).
Discard retainer.
(2) Remove and discard retainer O-ring (3).
(3) Remove and discard seat (4).
(4) Remove and discard seat O-ring (5).
(5) Remove capscrew (6) and handle washer (7).
(6) Mark position of handle (8).
(7) Remove handle (8) and handle O-ring (9). Discard O-ring (9).
(8) Mark position of stop plates (10).
(9) Remove two stop plates (10).
(10) Remove pivot bolt (11) and pivot bolt O-ring (12). Discard pivot bolt O-ring (12).
(11) Remove ball valve (13).
(12) Remove actuator shaft (14) and actuator shaft O-ring (15). Discard actuator shaft O-ring (15).
4-221
TM 5-4210-233-14&P-1
4-42. WATER VALVE- Continued
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid repeated and
prolonged breathing of vapors and skin contact with the liquid. Do not use near
open flame, arcing equipment or other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D-680 is 100 to 138 deg. F
(38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed against the skin.
Do not use compressed air for cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working with compressed air,
always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (2) for cracks and damaged threads. Replace as necessary.
(4) Inspect ball valve (1 3) for grooves or cracks. Replace as necessary.
d. Assembly.
(1) Install new actuator shaft O-ring (15) and actuator shaft (14). Apply a thin coat of silicone grease
(Item 11, Appendix E) to actuator shaft.
(2) Fit ball valve (13) to actuator shaft (14).
(3) Install new pivot bolt O-ring (12) and pivot bolt (11). Apply a thin coat of silicone grease (Item
11, Appendix E) to O-ring.
(4) Install new seat O-ring (5) and new seat (4) in new seat retainer (1). Apply a thin coat of silicone
grease (Item 11, Appendix E) to O-ring.
(5) Install new retainer O-ring (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to
inside edge of seat retainer.
(6) Use spanner wrench to thread seat retainer (1) clockwise into valve body (2) until tight.
(7) Install two stop plates (10) to original position on actuator shaft (14).
(8) Install new handle O-ring (9). Apply a thin coat of silicone grease (Item 11, Appendix E) to Oring.
(9) Install handle (8) to original position.
(10) Install handle washer (7) and capscrew (6).
4-222
TM 5-4210-233-14&P-1
4-42. WATER VALVE - Continued
e. Installation.
(1) Carefully pull pipe (1) towards curbside and place valve (2) with two new O-rings (10) between
two flanges (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to O-rings.
(2) Secure valve (2) with eight bolts (4).
(3) Position control rod (5) and nylon washer (6) on valve handle (7).
(4) Install retaining pin (8) and new cotter pin (9).
f. Follow-On Maintenance.
(1) Install Curbside Operator's Pump Panel (see para 4-26).
(2) Connect batteries (see para 4-114).
4-223
TM 5-4210-233-14&P-1
4-43. #1 CROSSLAY VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Took Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Piping Drained (see para 2-17 .)
Curb Side Operators Panel Removed (see para
4-26 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Cotter Pin (Figure 10, Appendix F)
Repair Kit (Figure 12, Appendix F)
a. Removal
(1) Remove cotter pin (1) and retaining pin (2).
Discard cotter pin.
(2) Remove control rod (3) and nylon washer (4).
(3) Remove eight bolts (5).
(4) Remove valve (6) from between flanges (7).
(5) Remove and discard two O-rings (8).
4-224
TM 5-4210-233-14&P-1
4-43. #1 CROSSLAY VALVE - Continued
b. Disassembly.
(1) Move handle (13) so valve is in open position.
(2) Remove socket head screw (9), handle washer (10) and handle disc (11).
(3) Mark position of actuator clip (12) and handle assembly (13) and remove.
(4) Mark position of lock spring (14) and remove.
(5) Mark position of roll pin (15) and remove.
(6) Remove pivot bolt (16) and O-ring (17). Discard O-ring.
(7) Rotate valve ball (18) out of valve body (6).
NOTE
Valve must be in open position.
(8) Remove actuator shaft (19) and O-ring (20). Discard O-ring.
(9) Remove seat retainer (21) by turning counterclockwise with spanner wrench.
(10) Discard seat (23), O-ring (25), and seat retainer (21).
(11) Remove and discard O-ring (22).
4-225
TM 5-4210-233-14&P-1
4-43. #1 CROSSLAY VALVE -Continued
NOTE
The following step should be performed only as necessary.
(12) Remove four socket head screws (26) and two stop brackets (27). Note position of stop brackets
(27) for assembly.
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid repeated and
prolonged breathing of vapors and skin contact with the liquid. Do not use near
open flame, arcing equipment or other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D-680 is 100 to 138 deg. F
(38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed against the skin.
Do not use compressed air for cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working with compressed air,
always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (6) for cracks or damaged threads. Check mounting surfaces for deep
scratches. Replace as necessary.
(4) Inspect ball valve (18) for grooves or cracks. Replace as necessary.
(5) Replace any other parts determined to be defective.
4-226
TM 5-4210-233-14&P-1
4-43. #1 CROSSLAY VALVE - Continued
d.
Assembly.
(1) Install new O-ring (25) in new seat retainer (21). Apply a thin coat of silicone grease (Item 11,
Appendix E) to inside edge of seat retainer (21).
(2) Install new seat (23) in seat retainer (21).
(3) Install new O-ring (22) in groove on outside edge of seat retainer (21). Apply a thin coat of
silicone grease (Item 11, Appendix E) to new O-ring (22).
(4) Install new O-ring (20) on actuator shaft (19). Apply a thin coat of silicone grease (Item 11,
Appendix E) to actuator shaft (19).
(5) Install actuator shaft (19) in valve body (6).
(6) Install valve ball (18) in valve body (6).
(7) Install new O-ring (17) on pivot bolt (16). Apply a thin coat of silicone grease (item 11, Appendix
E) to O-ring (17).
(8) Install pivot bolt (1 6) in valve body (6).
(9) Install seat retainer (21) in valve body (6). Screw seat retainer (21) in until some resistance is felt
when turning valve ball (18).
(10) Install roll pin (15) and lock spring (14).
4-227
TM 5-4210-233-14&P-1
4-43. #1 CROSSLAY VALVE -Continued
NOTE
Perform step (11) only if handle assembly was disassembled.
(11) install stop brackets (27) onto handle (13) with socket head screws (26).
(12) Install handle assembly, actuator clip (12), handle disc (11), handle washer (10) and socket head
screw (9).
e. Installation.
(1) Apply a thin coat of silicone grease (Item 11, Appendix E) to two new O-rings(8). Install new
O-rings (8) in grooves on valve body.
(2) Install valve (6) between flanges (7).
(3) Install eight bolts (5).
(4) Position control rod (3) and nylon washer (4) on valve handle.
(5) Install retaining pin (2) and new cotter pin (1).
f. Follow-on Maintenance.
(1) Install curbside operator's panel (see para 4-26).
(2) Connect batteries (see para 4-114).
4-228
TM 5-4210-233-14&P-1
4-44. #2 CROSSLAY VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Took Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Piping Drained (see para 2-17 .)
Curb Side Operators Panel Removed (see para
4-26 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Cotter Pin (Figure 11, Appendix F)
Repair Kit (Figure 12, Appendix F)
a. Removal
(1) Remove cotter pin (1) and retaining pin (2).
Discard coffer pin.
(2) Remove control rod (3) and nylon washer (4).
(3) Remove eight bolts (5).
(4) Remove valve (6) from between flanges (7).
(5) Remove and discard two O-rings (8).
4-229
TM 5-4210-233-14&P-1
4-44. #2 CROSSLAY VALVE - Continued
b. Disassembly.
(1) Move handle (13) so valve is in open position.
(2) Remove socket head screw (9), handle washer (10) and handle disc (11).
(3) Mark position of actuator clip (12) and handle assembly (13) and remove.
(4) Mark position of lock spring (14) and remove.
(5) Mark position of roll pin (15) and remove.
(6) Remove pivot bolt (16) and O-ring (17). Discard O-ring.
(7) Rotate valve ball (18) out of valve body (6).
NOTE
Valve must be in open position.
(8) Remove actuator shaft (19) and O-ring (20). Discard O-ring.
(9) Remove seat retainer (21) by turning counterclockwise with spanner wrench.
(10) Discard seat (23), O-ring (25), and seat retainer (21).
(11) Remove and discard O-ring (22).
4-230
TM 5-4210-233-14&P-1
4-44. #2 CROSSLAY VALVE - Continued
NOTE
The following step should be performed only as necessary.
(12) Remove four socket head screws (26) and two stop brackets (27). Note position of stop brackets
(27) for assembly.
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid repeated and
prolonged breathing of vapors and skin contact with the liquid. Do not use near
open flame, arcing equipment or other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D-680 is 100 to 138 deg. F
(38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed against the skin.
Do not use compressed air for cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working with compressed air,
always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (6) for cracks and damaged threads. Check mounting surface for deep
scratches. Replace as necessary.
(4) Inspect ball valve (13) for grooves or cracks. Replace as necessary.
(5) Replace any other parts determined to be defective.
4-231
TM 5-4210-233-14&P-1
4-44. #2 CROSSLAY VALVE - Continued
d. Assembly.
(1) Install new O-ring (25) in new seat retainer (21). Apply a thin coat of silicone grease (Item 11,
Appendix E) to inside edge of seat retainer (21).
(2) Install new seat (23) in seat retainer (21).
(3) Install new O-ring (22) in groove on outside edge of seat retainer (21). Apply a thin coat of
silicone grease (Item 11, Appendix E) to new O-ring (22).
(4) Install new O-ring (20) on actuator shaft (19). Apply a thin coat of silicone grease (Item 11,
Appendix E) to actuator shaft (19).
(5) Install actuator shaft (19) in valve body (6).
(6) Install valve ball (18) in valve body (6).
(7) Install new O-ring (17) on pivot bolt (16). Apply a thin coat of silicone grease (Item 11, Appendix
E) to O-ring (17).
(8) Install pivot bolts (16) in valve body (6).
(9) Install seat retainer (21) in valve body (6). Screw seat retainer (21) in until some resistance is felt
when turning valve ball (18).
4-232
TM 5-4210-233-14&P-1
4-44. #2 CROSSLAY VALVE - Continued
(10) Install roll pin (15) and lock spring (14).
NOTE
Perform step (11) only if handle assembly was disassembled.
(11) Install stop brackets (27) with socket head screws (26).
(12) Install handle assembly, actuator clip (12), handle disc (11), handle washer (10) and socket head
screw (9).
e. Installation.
(1) Apply a thin coat of silicone grease (Item 11, Appendix E) to two new O-rings (8). Install O-rings
(8) in grooves on valve body.
(2) Carefully pull pipe (1) towards curbside and place valve (2) between two flanges (3).
(3) Secure valve (2) with eight bolts (4).
(4) Position control rod (5) and nylon washer(6) on valve handle (7).
(5) Install retaining pin (9) and new cotter pin (10).
f. Follow-On Maintenance.
(1) Install curbside operator's panel (see para 4-26).
(2) Connect batteries (see para 4-114).
4-233
TM 5-4210-233-14&P-1
4-45. #1, #2, #3 AND #4 DISCHARGE VALVES
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Took Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Curb Side Operators Panel Removed (see para 4-26 .)
MATERIALS/PARTS REQUIRED
Grease, Silicone (Item 11, Appendix E)
Pipe Sealant (Item 2, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
Repair Kit (Figures 14 and 15, Appendix F)
a. Removal
NOTE
To locate valve in question, one person
operates valve handle on pump panel while a
second person watches for valve actuation in
pump compartment to identify valve.
(1) Disconnect drain hose (1) and pressure hose
(2).
(2) Remove two hex nuts (3), two lockwashers
(4), bracket (5) and U-bolt (6).
(3) Mark position of sector (7) on shaft (8).
(4) Remove roll pin (9) and sector (7).
(5) Remove four capscrews (10) and remove
plate (11) from valve.
(6) Remove pipe nipple (12) and hose adapter
(13).
(7) Loosen four capscrews (14).
(8) Turn valve (15) until free of mounting flange
(16).
(9) Remove and discard O-ring (17).
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TM 5-4210-233-14&P-1
4-45. #1, #2, #3 and #4 DISCHARGE VALVES - Continued
b. Disassembly.
(1) Remove four socket head capscrews (18).
(2) Remove seal retainer (19).
(3) Remove and discard O-ring (20).
(4) Remove seal (21) and four springs (22). Discard seal and springs.
(5) Remove and discard O-ring (23).
(6) Apply pressure to bottom of ball (24), and push
out upper stem bushing (25).
(7) Remove and discard O-ring (26).
(8) Remove ball (24) from valve body (15).
(9) Remove and discard O-rings (27) and (28).
4-235
TM 5-4210-233-14&P-1
4-45. #1, #2, #3 and #4 DISCHARGE VALVES - Continued
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid repeated and
prolonged breathing of vapors and skin contact with the liquid. Do not use near
open flame, arcing equipment or other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D-680 is 100 to 138 deg. F
(38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed against the skin.
Do not use compressed air for cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working with compressed air,
always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect ball (24) for scratches and scoring. Replace as necessary.
(4) Inspect valve body (1 5) for scoring, cracks, and damaged threads. Replace as necessary.
(5) Inspect upper stem bushing (25) and lower stem bushing (29) for excessive wear. Replace as
necessary.
(6) Inspect seal retainer (19) for scoring, scratches, and cracking. Replace as necessary.
4-236
TM 5-4210-233-14&P-1
4-45. #1, #2, #3 and #4 DISCHARGE VALVES - Continued
d. Assembly.
CAUTION
Apply silicone grease (Item 11, Appendix E) to all O-rings before assembly.
Failure to do so could result in damage to O-rings.
(1) Install new O-rings (27) and (28).
(2) Install ball (24) in valve body (15).
(3) Install new O-ring (26) on upper stem bushing (25).
(4) Install upper stem bushing (25).
(5) Install new O-ring (23).
(6) Place four new springs (22) in holes of new seal (21).
(7) Install new O-ring (20) on seal retainer (19).
(8) Assemble seal (21) and seal retainer (19), and install on valve body (15).
(9) Install four socket head capscrews (18).
e. Installation.
(1) Install new O-ring (17).
(2) Install valve (15) in mounting flange (16) and rotate to secure in place.
(3) Tighten four capscrews (14).
(4) Apply pipe sealant (Item 2, Appendix E) to pipe nipple (12) and hose adapter (13) threads.
(5) Install pipe nipple (12) and hose adapter (13).
(6) Secure plate (11) to valve body (1 5) with four capscrews (10).
(7) Secure sector (7) in position marked when removed to shaft (8) with roll pin (9).
(8) Install U-bolt (6), bracket (5), two lockwashers (4), and two hex nuts (3).
(9) Install pressure hose (2) and drain hose (1).
f. Follow-on Maintenance.
(1) Install Curbside Pump Panel (see para 4-26).
(2) Connect Batteries (see para 4-114).
4-237
TM 5-4210-233-14&P-1
4-46. TANK FILL AND RECIRCULATING VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Piping Drained (see para 2-17 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Repair Kit (Figure 12, Appendix F)
a. Removal
(1) Remove 4 screws (1) from foam tank
compartment grate (2); remove grate.
(2) Locate tank fill and recirculating valve
by operating handle on streetside
operator's panel.
(3) Remove cotter pin (3) and retaining pin (4).
4-238
TM 5-4210-233-14&P-1
4-46. TANK FILL AND RECIRCULATING VALVE - Continued
(4) Remove control rod (5) and nylon washer (6).
(5) Remove eight bolts (7).
(6) Remove valve (8) from between flanges (9).
(7) Remove and discard two O-rings (10).
b. Disassembly.
(1) Use spanner wrench to turn seal retainer (1) counterclockwise until free from valve body (2).
(2) Remove and discard retainer and O-ring (3).
(3) Remove and discard seat (4).
(4) Remove and discard seat O-ring (5).
(5) Remove capscrew (6) and handle washer (7).
(6) Mark position of handle (8).
(7) Remove handle (8) and handle O-ring (9). Discard O-ring (9).
(8) Mark position of stop plates (10).
(9) Remove two stop plates (10).
(10) Remove pivot bolt (11) and pivot bolt O-ring (12). Discard pivot bolt O-ring (12).
(11) Remove ball valve (13).
(12) Remove actuator shaft (14) and O-ring (15). Discard O-ring.
4-239
TM 5-4210-233-14&P-1
4-46. TANK FILL AND RECIRCULATING VALVES - Continued
c. Cleaning and Inspection
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame,
arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of
P-D-680 is 100 to 138 deg. F (38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm 2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (2) for cracks and damaged threads. Replace as necessary.
(4) Inspect ball valve (13) for grooves or cracks. Replace as necessary.
d. Assembly.
(1) Install new actuator shaft O-ring (15) and actuator shaft (14). Apply a thin coat of silicone grease
(Item 11, Appendix E) to actuator shaft.
(2) Fit ball valve (13) to actuator shaft (14).
(3) Install new pivot bolt O-ring (12) and pivot bolt (11). Apply a thin coat of silicone grease (Item
11, Appendix E) to O-ring.
(4) Install new seat O-ring (5) and new seat (4) in new seat retainer (1). Apply a thin coat of silicone
grease (Item 11, Appendix E) to O-ring.
(5) Install new retainer O-ring (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to
inside edge of seat retainer.
(6) Use a spanner wrench to thread seat retainer (1) clockwise into valve body (2) until tight.
(7) Install two stop plates (10) to original position on actuator shaft (14).
(8) Install new handle O-ring (9). Apply a thin coat of silicone grease (item 11, Appendix E) to Oring.
(9) Install handle (8) to original position.
(10) Install handle washer (7) and capscrew (6).
4-240
TM 5-4210-233-14&P-1
4-46. TANK FILL AND RECIRCULATING VALVE - Continued
e. Installation.
(1) Carefully pull pipe (1) towards curbside and place valve (2) with two new O-rings (12) between
two flanges (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to O-rings.
(2) Secure valve (2) with eight bolts (4).
(3) Position control rod (5) and nylon washer (6) on valve handle (7).
(4) Install retaining pin (8) and cotter pin (9).
(5) Install Foam Tank compartment grate (10). Secure with four screws (11).
f. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-241
TM 5-4210-233-14&P-1
4-47. AERIAL DISCHARGE VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Silicone Grease (Item 11, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
Gasket (Figure 23, Appendix F)
Repair Kit (Figure 24, Appendix F)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Curb Side Operator's Panel Removed
(see para 4-26.)
a. Removal
(1) Remove hose (1) from elbow (1A).
(2) Loosen hose clamp (2) and remove drain hose (3)
from fitting (4).
4-242
TM 5-4210-233-14&P-1
4-47. AERIAL DISCHARGE VALVE - Continued
(3) Remove center roll pin from universal joint (5).
(4) Remove sixteen nuts (6) and sixteen screws (7).
(5) Lift and support aerial waterway (8). Remove valve (9) and gaskets (10). Discard gaskets.
b. Disassembly.
(1) Mark position of sector (12). Drive out roll pin (11) from hub of sector (12)
(2) Lift sector (12) off stem of ball (13).
(3) Remove rack (14) from bracket (15).
(4) Remove four screws (16).
(5) Lift bracket (15) off dowel pins (17).
(6) Remove four screws (18) attaching seal housing (19) to valve body (9).
(7) Remove seal housing (19) from valve body (9). Seal (20) should come out with housing (19).
(8) Remove seal (20), four springs (21) and O-rings (22 and 23) from housing (19). Discard seal,
springs and O-rings.
(9) Remove four screws (24) and cover (25).
(10) Use a spanner wrench to remove bearing retainers (26) from valve body (9); 1/4"-20 a
t pped
puller holes are provided. Ball bearings (27) will come off ball trunnions with the retainers (26).
(11) Ball (13) can be removed through large opening of body by lifting it upward and pulling the short
trunnion out first.
(12) Remove ball bearings (27) from retainers (26).
(13) Remove O-rings (28 and 29) from bearing retainers (26). Discard O-rings.
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame,
arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of
P-D-680 is 100 to 138 deg. F (38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
4-243
TM 5-4210-233-14&P-1
4-47. AERIAL DISCHARGE VALVE - Continued
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (9) and seal housing (19) for cracks. Check mounting surfaces for deep
scratches. Replace as necessary.
(4) Inspect ball (13) for grooves or cracks. Replace as necessary.
(5) Replace all parts determined to be defective.
d. Assembly.
NOTE
Whenever locking plate (30) is loosened or removed,
adjust it with a feeler gage during reassembly to provide
0.010 inch (.254 mm) clearance between plate and rack
(14) when unlocked.
4-244
TM 5-4210-233-14&P-1
4-47. AERIAL DISCHARGE VALVE - Continued
(1) Install new O-rings (28 and 29) in bearing retainers (26).
NOTE
Apply a light coat of silicone grease (Item 11, Appendix
E) to all O-rings, bearing bores, journals and ball (13) to
aid in assembly.
(2) Install ball (13) in valve body (9).
(3) Install ball bearings (27) in bearing retainers (26).
(4) Install bearing retainers (26) in valve body (9).
(5) Install cover (25) with four screws (24).
(6) Install new O-rings (22 and 23) on seal housing (19).
(7) Install four new springs (21) in holes of new seal (20). Slide seal (20) into seal housing (19).
Make sure springs (21) are working properly by pressing down on seal (20). It should spring back
when released.
(8) Install seal housing (19) into valve body (9) and attach with four screws (18).
(9) Install bracket (15) on dowel pins (17).
(10) Install four screws(16).
(11) Install rack (14) in bracket (15).
(12) Place sector (12) on stem of ball (13) in same position removed from, engage first tooth of sector
with first space of rack.
(13) Install roll pin (11).
e. Installation.
(1) Install valve (9) and two new gaskets (10) between aerial waterway (8) and pump.
(2) Lower aerial water way onto valve (9) and install sixteen screws (7) and sixteen nuts (6).
(3) Install roll pin in universal joint (5).
(4) Install drain hose (3) on fitting (4) and tighten hose clamp (2).
(5) Install hose (1) on elbow (1A).
f. Follow-on Maintenance.
(1) Install curbside operator's panel (see para 4-26).
(2) Connect batteries (see para 4-114).
4-245
TM 5-4210-233-14&P-1
4-48. TANK DRAIN VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Cotter Pin (Figure 18, Appendix F)
Repair Kit (Figure 22, Appendix F)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
All Piping Drained (see para 2-17.)
Curbside Operator's Panel Removed
(see para 4-26.)
a. Removal
(1) Remove cotter pin (1) and retaining pin (2).
(2) Remove control rod (3) and nylon washer (4).
(3) Remove eight bolts (5).
(4) Remove valve (6) from between flanges (7).
(5) Remove and discard two O-rings (8).
4-246
TM 5-4210-233-14&P-1
4-48. TANK DRAIN VALVE - Continued
b. Disassembly.
(1) Use spanner wrench turn seat retainer (1) counterclockwise until free from valve body (2).
Discard retainer.
(2) Remove and discard retainer O-ring (3).
(3) Remove and discard seat (4).
(4) Remove and discard seat O-ring (5).
(5) Remove capscrew (6) and handle washer (7).
(6) Mark position of handle (8).
(7) Remove handle (8) and handle O-ring (9). Discard O-ring (9).
(8) Mark position of stop plates (1 0).
(9) Remove two stop plates (1 0).
(10) Remove pivot bolt (11) and pivot bolt O-ring (12). Discard pivot bolt O-ring (12).
(11) Remove ball valve (13).
(12) Remove actuator shaft (14) and actuator shaft O-ring (15). Discard actuator shaft O-ring (15).
4-247
TM 5-4210-233-14&P-1
4-48. TANK DRAIN VALVE - Continued
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame,
arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of
P-D-680 is 100 to 138 deg. F (38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (2) for cracks and damaged threads. Replace as necessary.
(4) Inspect ball valve (13) for grooves or cracks. Replace as necessary.
d. Assembly.
(1) Install new actuator shaft O-ring (15) and actuator shaft (14). Apply a thin coat of silicone grease
(Item 11, Appendix E) to actuator shaft.
(2) Fit ball valve (13) to actuator shaft (14).
(3) Install new pivot bolt O-ring (12) and pivot bolt (11). Apply a thin coat of silicone grease (Item
11, Appendix E) to O-ring.
(4) Install new seat O-ring (5) and new seat (4) in new seat retainer (1). Apply a thin coat of silicone
grease (Item 11, Appendix E) to O-ring.
(5) Install new retainer O-ring (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to
inside edge of seat retainer.
(6) Use a spanner wrench to thread seat retainer (1) clockwise into valve body (2) until tight.
(7) Install two stop plates (10) to original position on actuator shaft (14).
(8) Install new handle O-ring (9). Apply a thin coat of silicone grease (Item 11, Appendix E) to Oring.
(9) Install handle (8) to original position.
(10) Install handle washer (7) and capscrew (6).
4-248
TM 5-4210-233-14&P-1
4-48. TANK DRAIN VALVE - Continued
e. Installation.
(1) Carefully pull pipe (1) towards curbside and place valve (2) with two new O-rings (10) between
two flanges (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to O-rings.
(2) Secure valve (2) with eight bolts (4).
(3) Position control rod (5) and nylon washer (6) on valve handle (7).
(4) Install retaining pin (8) and new cotter pin (9).
f. Follow-On Maintenance.
(1) Install curbside operator's panel (see para 4-26).
(2) Connect batteries (see para 4-114).
4-249
TM 5-4210-233-14&P-1
4-49. TANK DISCHARGE VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Cotter Pin (Figure 19, Appendix F)
Repair Kit (Figure 20, Appendix F)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
All Piping Drained (see para 2-17.)
a. Removal
NOTE
Access to Tank Discharge valve is gained
from beneath truck. Grating from water tank
compartment must be removed.
(1) Remove four screws (1) from foam tank
compartment grating (1A); remove grating.
(2) Locate task discharge valve by operating tank
discharge valve handle on streetside
operator's panel.
(3) Remove cotter pin (2) and retaining pin (3).
(4) Remove control rod (4) and nylon washer (5).
(5) Remove twelve bolts (6).
(6) Remove valve (7) from between flanges (8).
(7) Remove and discard two flange O-rings (9).
4-250
TM 5-4210-233-14&P-1
4-49. TANK DISCHARGE VALVE - Continued
b. Disassembly.
(1) Use spanner wrench to turn seal retainer (10) counterclockwise until free from valve body (7).
Discard retainer.
(2) Remove and discard retainer O-ring (11).
(3) Remove and discard seat (12).
(4) Remove and discard seat O-ring (13).
(5) Remove socket head screw (14), handle washer (15), and handle disc (16).
(6) Mark position of handle (17).
(7) Remove handle (17).
(8) Remove pivot bolt (18) and pivot bolt O-ring (19). Discard pivot bolt O-ring (19).
(9) Remove ball valve (20).
(10) Remove actuator shaft (21) and actuator shaft O-ring (22). Discard actuator shaft O-ring (22).
NOTE
The following step should be performed only as necessary.
(11) Remove four socket head screws (23) and two stop brackets (24). Note position of stop brackets
(24) for assembly.
4-251
TM 5-4210-233-14&P-1
4-49. TANK DISCHARGE VALVE - Continued
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame,
arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of
P-D-680 is 100 to 138 deg. F (38 to 59 deg. C).
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm 2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (7) for cracks and damaged threads. Replace as necessary.
(4) Inspect ball valve (20) for grooves or cracks. Replace as necessary.
d. Assembly.
(1) Install stop brackets (24) and four socket head screws (23) (if removed).
(2) Install new actuator shaft 0-ring (22) and actuator shaft (21). Apply a thin coat of silicone grease
(Item 11, Appendix E) to actuator shaft.
(3) Fit ball valve (20) to actuator shaft (21).
(4) Install new pivot bolt O-ring (19) and pivot bolt (18). Apply a thin coat of silicone grease (Item
11, Appendix E) to O-ring.
(5) Install new seat O-ring (13) and new seat (12) in new seat retainer (10). Apply a thin coat of
silicone grease (Item 11, Appendix E) to O-ring.
(6) Install new retainer O-ring (11). Apply a thin coat of silicone grease (Item 11, Appendix E) to
inside edge of seat retainer.
(7) Use spanner wrench to thread seat retainer (1 0) clockwise into valve body (7) until tight.
(8) Install handle (17) to original position.
(9) Install handle washer (15), handle disc (16), and socket head screw (14).
4-252
TM 5-4210-233-14&P-1
4-49. TANK DISCHARGE VALVE - Continued
e. Installation.
(1) Place valve (7) with two new O-rings (9) between two flanges (8). Apply a thin coat of silicone
grease (Item 11, Appendix E) to 0-rings.
(2) Secure valve (7) with twelve bolts (6).
(3) Position control rod (4) and nylon washer (5) on valve handle.
(4) Install retaining pin (3) and new cotter pin (2).
(5) Install water tank compartment grating (1A). Secure with four screws (1).
f. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-253
TM 5-4210-233-14&P-1
4-50. PUMP DRAIN VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Repair Kit (Figure 37, Appendix F)
a. Removal
NOTE
Access for pump drain valve is from beneath truck.
(1) Locate pump drain valve by operating handle for pump drain valve on street side operators
panel.
(2) Remove and discard cotter pin (1).
(3) Remove control cable (2) from valve stem (3).
(4) Remove capscrews (4) and lockwashers (5).
(5) Remove bolts securing bracket (6).
(6) Separate bracket (6) from valve body (7).
b. Disassembly
(1) Remove plunger (13) and end cap (8) as assembly.
Remove and discard plunger.
(2) Remove and discard O-ring (9), quad ring (10), and
groove pin (11).
(3) Remove and discard two u-cup packings (12).
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially
dangerous. Avoid repeated and prolonged
breathing of vapors and skin contact with the
liquid. Do not use near open flame, arcing
equipment or other ignition sources. Always
wear eye protection and protective clothing.
The flash point of P-D-680 is 100 to 138 deg.
F (38 to 59 deg. C).
4-254
TM 5-4210-233-14&P-1
4-50. PUMP DRAIN VALVE - Continued
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm 2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect bore of body (7) for nicks and scratches caused by sand and dirt in the water being
pumped. Use emery cloth (Item 25, Appendix E) to remove any raised metal near abrasions.
Replace body if required.
NOTE
Drain hoses must be removed to replace body.
Assembly.
(1) Coat new O-ring (9), new u-cup packings (12), and new quad ring (10) with silicone grease (Item
11, Appendix E).
(2) Assemble new plunger (13) and end cap (8).
(3) Install plunger (13) in body (7).
(4) Slide end cap (8) over stem (3) and seat in body.
(5) Install new groove pin (11).
e. Installation.
(1) Position bracket (6) over flange of body (7).
(2) Secure bracket (6) with bolts.
(3) Insert end of control cable eyelet (14) in slot of stem (3) and secure with new cotter pin (1).
(4) Adjust control cable (2) if necessary to be certain that the plunger (13) bottoms in body (7) with
valve closed.
f. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-255
TM 5-4210-233-14&P-1
4-51. FRONT SUCTION VALVE
This task covers:
a. Removal
e.
b. Disassembly-Gear Box f.
c. Cleaning and Inspectiong.
-Gear Box
h.
d. Assembly-Gear Box
i.
Disassembly-Valve
Cleaning and Inspection-Valve
Assembly
Installation
Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
1-1/2 Ton Hydraulic Floor Jack
MATERIALS/PARTS REQUIRED - Continued
Roll Pin (Figure 17, Appendix F)
Seals (Figure 17, Appendix F)
Gasket (Figure 17, Appendix F)
MATERIALS/PARTS REQUIRED
Multi-purpose Grease (Item 17, Appendix E)
Grease (Item 1, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
O-Rings (Figure 17, Appendix F)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
All Piping Drained (see para 2-17.)
a. Removal
(1) Locate front suction valve by operating pump
handle on street side operator's panel.
(2) Remove roll pin (1) from universal joint (2)
and separate universal joint (2).
(3) Position hydraulic floor jack under valve (3).
Raise jack until it just contacts valve (3).
WARNING
Front suction valve is heavy. Keep valve
centered over jack while removing couplings.
(4) Remove four nuts (4) and four bolts (5).
Remove couplings (6) and slide gaskets (7)
away from valve.
(5) Lower jack until valve (3) clears truck.
4-256
TM 5-4210-233-14&P-1
4-51. FRONT SUCTION VALVE - Continued
b. Disassembly - Gear Box.
(1) Remove four screws (1) and lift gear housing (16) off of valve body (32).
(2) Remove excess or loose paint, with wire brush, from top of gear housing.
(3) Remove two screws (2) and remove indicator (3).
(4) Remove two screws (4) and two screws (5) and remove gear housing cover (6) and gasket,(17).
Discard gasket.
(5) Remove segment gear (7), stem adapter (8), and two O-rings (9). Discard 0-rings.
CAUTION
To remove roll pin, drive pin out just past outer surface of
worm gear. Then grind pin off until it is flush with the
surface of the gear. Be careful not to damage gear while
grinding off pin. Repeat procedure until pin can be
removed.
(6) Remove roll pin (10).
(7) Remove shaft (11), worm gear (12), and two bearings (14).
(8) Remove and discard seal (15).
4-257
TM 5-4210-233-14&P-1
4-51. FRONT SUCTION VALVE - Continued
c. Cleaning and Inspection - Gear Box.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame,
arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of
P-D-680 is 100 to 138 deg. F (38 to 59 deg. C).
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working
with compressed air, always use chip guards, eye protection, and other personal protective equipment.
(1) Clean all parts using cleaning solvent P-D-680; dry using compressed air.
(2) Check housing (1 6) and gears (7 and 12) for cracks or breaks. Replace part if any of these
conditions are observed.
(3) Inspect bearing (1 4) for wear or damage. Replace if worn or damaged.
(4) Inspect shaft (11) for bends, deep grooves or scoring. Replace if damaged in any way.
Assembly - Gear Box.
(1) Install new seal (15).
(2) Install two bearings (14), gear (12) and shaft (11).
(3) Align hole in gear (12) and shaft (11). Install new roll pin (10).
(4) Install new O-rings (9) on segment gear (7). Apply a thin coat of grease (Item 1, Appendix E) to
O-rings (9).
(5) Install segment gear (7) and stem adapters (8) in housing (16) as shown.
(6) Pack housing (16) with grease (Item 1, Appendix E) and rotate shaft (11) back and forth several
times to distribute grease.
(7) Install cover (6) and new gasket (17) on housing (16). Install two screws (4) and two screws (5).
NOTE
The two shorter screws are used on the shaft end of the
housing.
(8) Install indicator (3) with two screws (2) as shown.
(9) Remove two limit stop locking screws (18) and unscrew two limit stop screws (19) several turns.
4-258
TM 5-4210-233-14&P-1
4-51. FRONT SUCTION VALVE-Continued
(10)
Turn shaft (11) until indicator (3) is at closed position.
(11)
Turn in limit stop screw (19), located on the shaft side of the housing, until it bottoms outs.
(12)
Turn shaft (11) until indicator (3) is at open position. Turn in other limit stop screw (19) until it
bottoms out.
(13)
Install two limit stop locking screws (18).
e. Disassembly - Valve.
(1)
Remove six screws (20), lockwashers (21) and nuts (22).
(2)
Remove inlet section (23) and outlet section (24).
(3)
Remove two screws (25) and 0-rings (26). Discard 0-rings.
(4)
Remove shaft (27), disk (28), bushing (29) and seal (30). Discard seal.
(5)
Remove seat (31) from housing (32).
f. Cleaning and Inspection - Valve.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
(1)
Clean all parts using cleaning solvent P-D-680; dry using compressed air.
(2)
Check housing (32) and disk (28) for cracks or breaks. Replace part if any of these conditions
are observed.
(3)
Inspect seat (3) for wear or damage. Replace if required.
(4)
Inspect bushing (29) for wear or damage. Replace if worn or damaged.
(5)
Inspect shaft (27) for bends, deep grooves or scoring. Replace if damaged in any way.
4-259
TM 5-4210-233-14&P-1
4-51. FRONT SUCTION VALVE-Continued
g. Assembly-Valve.
(1)
Install new seal (30) in bore of housing (32).
(2)
Apply a light coat of grease (Item 1, Appendix E) to bore in housing (32).
(3)
Install seat (31) in housing (32).
(4)
Install disk (28) in housing.
(5)
Apply a light coat of grease to shaft (27). Insert shaft (27) through housing (32) and into disk
(28). Shaft (27) must be turned so that recessed holes in shaft face out toward holes in disk (28).
(6)
Install two new O-rings (26) over two screws (25). Install two screws (25).
(7)
Slide bushing (29) over shaft and into bore in housing (32).
(8)
Install gear box (1 6) onto housing (32) with screws (1).
(9)
Check rotation of disk (28). Make sure disk (28) is sealed tightly when closed. Adjust limit stop
screws (19) if necessary.
h. Installation.
(1)
Remove gaskets (7) from inlet suction pipe. Inspect gaskets (7) for damage or wear. Replace if
necessary.
(2)
Clean ends of inlet suction pipe and check for any damage.
(3)
Install one gasket (7) on each end of inlet suction pipe. Coat the inside of the gasket with multipurpose grease (Item 17, Appendix E).
(4)
Place valve (3) on hydraulic floor jack and raise valve (3) into position between ends of inlet
suction pipe.
(5)
Slide each gasket (7) over valve and pipe. Center gaskets (7) between grooves on suction pipe
and valve.
(6)
Install couplings (6) with four bolts (5) and four nuts (4). Remove jack.
(7)
Install roll pin (1) in universal joint (2).
i. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
4-260
TM 5-4210-233-14&P-1
4-52. DRIVER’S SIDE AUXILIARY SUCTION VALVE
This task covers:
a. Removal
d. Assemble
b. Disassembly
e. Installation
c. Cleaning and
Inspection
f. Follow-on
Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Batteries Disconnected (see para 4-114 .)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (item 3, Appendix E)
Grease, Silicone (Item 11, Appendix E)
Repair Kit (Figure 27, Appendix F)
a. Removal
(1) Remove eight bolts (1 and 4) securing valve body (2) to end caps (36 and 37).
(2) Remove valve body (2) and 0-rings (3, 6 and 19). Discard O-rings.
4-261
TM 5-4210-233-14&P-1
4-52. DRIVER’S SIDE AUXILIARY SUCTION VALVE-Continued
b. Disassembly.
(1)
Remove seat retainer (18) by using spanner wrench to turn counterclockwise. Remove O-ring
(3). Discard seal retainer along with seat (20) and O-ring (21).
(2)
Move handle so valve is in open position.
(3)
Remove socket head screw (7), handle washer (8) and handle disc (9).
(4)
Mark position of actuator clip (1 0) and handle assembly and remove.
(5)
Mark position of stop washers (11) and lock spring (1 2) and remove.
(6)
Remove pivot bolt (13) and 0-ring (14). Discard O-ring.
(7)
Rotate valve ball (1 5) out of valve body (2).
NOTE
Valve must be in open position.
(8)
Remove actuator shaft (16) and O-ring (17). Discard O-ring.
NOTE
The following step should be performed only as necessary.
(9)
Remove four socket head screws (23) and two stop brackets (24). Note position of stop brackets
(24) for assembly.
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
(1)
Clean all parts in dry cleaning solvent (Item 3, Appendix E).
4-262
TM 5-4210-233-14&P-1
4-52. DRIVER’S SIDE AUXILIARY SUCTION VALVE-Continued
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
(2)
Dry all parts with compressed air.
(3)
Inspect valve body (2) for cracks. Check mounting surfaces for deep scratches. Replace as
necessary.
(4)
Inspect ball valve (1 5) for grooves or cracks. Replace as necessary.
(5)
Replace any other parts determined to be defective.
NOTE
Perform step 6 only if stop brackets were disassembled.
(6)
Install stop brackets (24) with socket head screws (23).
4-263
TM 5-4210-233-14&P-1
4-52. DRIVER’S SIDE AUXILIARY SUCTION VALVE-Continued
d. Assembly.
(1)
Install new O-ring (21) in new seat retainer (1 8). Apply a thin coat of silicone grease (Item 11,
Appendix E) to inside edge of seat retainer (18).
(2)
Install new seat (20) in seat retainer (18). Apply a thin coat of silicone grease (Item 11,
Appendix E) to new O-ring (21).
(3)
Install new O-ring (3) in groove on outside edge of seat retainer (18).
(4)
Install new O-ring (17) on actuator shaft (1 6). Apply a thin coat of silicone grease (Item 11,
Appendix E) to actuator shaft (16).
(5)
Install actuator shaft (16) in valve body (2).
(6)
Install valve ball (15) in valve body (2).
(7)
Install new O-ring (14) on pivot bolt (13). Apply a thin coat of silicone grease (Item 11, Appendix
E) to O-ring (14).
(8)
Install pivot bolt (13) in valve body (2).
(9)
Install seat retainer (18) in valve body (2) using spanner wrench. Screw seat retainer (18) in until
some resistance is felt when turning valve ball (15).
NOTE
When valve is in open position the narrow part of the valve ball
(15) should face up.
(10)
Install lock spring (12) and stop washers (11).
(11)
Install handle assembly (25, 26, 27 and 38), actuator clip (10), handle disc (9), handle washer (8)
and socket head screw (7).
Apply a thin coat of silicone grease (Item 11, Appendix E) to new O-rings (6 and 19). Install new
O-ring in grooves on valve body (2).
(12)
e. Installation.
(1)
Install valve (2) in end caps (36 and 37) with eight bolts (1 and 4).
f. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
4-264
TM 5-4210-233-14&P-1
4-53. #3 and #4 DISCHARGE DRAIN VALVES
This task covers:
a. Removal
b. Cleaning and Inspection
c. Installation
d. Follow-on
Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Grease (Item 1, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
O-Rings (Figure 18, Appendix F)
a. Removal.
(1)
Remove snap ring (1).
(2)
Remove knob (2), rod (3), and
plunger (4) as assembly.
(3)
Remove two screws (8) and
remove valve body (7) from panel.
(4)
Loosen hose clamp (9) and
remove drain hose (10).
(5)
Turn valve, (7) until fitting (5)
and hose (6) are free of valve (7).
(6)
Remove and discard two O-rings (11).
b. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is
potentially dangerous. Avoid repeated
and prolonged breathing of vapors and
skin contact with the liquid. Do not use
near open flame, arcing equipment or
other ignition sources. Always wear eye
protection and protective clothing. The
flash point of P-D-680 is 100 to 138 deg.
F (38 to 59 deg. C).
(1)
Clean all parts in dry cleaning
solvent (Item 3, Appendix E).
4-265
TM 5-4210-233-14&P-1
4-53. #3 AND #4 DISCHARGE DRAIN VALVES-Continued
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
(2)
Dry all parts with compressed air.
(3)
Inspect valve body (7) for cracks and damaged threads. Replace as necessary.
(4)
Inspect plunger (4) for grooves or cracks. Replace as necessary.
c. Installation.
(1)
Install two O-rings (11) on plunger (4).
(2)
Secure hose (6) to valve (7) with fitting (5).
(3)
Install drain hose (1 0) and hose clamp (9).
(4)
Secure valve body (7) to panel with two screws (8).
(5)
Apply grease (Item 1, Appendix E) to O-rings (11).
(6)
Install plunger (4), rod (3) and knob (2) in valve port.
(7)
Install snap ring (1).
d. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
4-266
TM 5-4210-233-14&P-1
4-54. SUCTION DRAIN VALVES
This task covers:
a. Removal
b. Disassembly
c. Cleaning and Inspection
d. Assembly
e. Installation
f. Follow-on
Maintenance
MATERIAL/PARTS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease (Item 1, Appendix E)
Pipe Sealant (Item 2, Appendix E)
O-Rings (Figure 18, Appendix F)
a. Removal.
(1)
Turn turnbuckle (1) clockwise to separate
outer rod (2) from inner rod (3).
(2)
Remove elbows (5 and 9) and pipe nipple
(4) from valve body (6).
b. Disassembly.
c.
(1)
Remove snap ring (7).
(2)
Remove inner rod (3) and plunger (8) as
assembly.
(3)
Remove and discard two O-rings (10).
(4)
Remove knob (11) from rod (2).
Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially
dangerous.
Avoid repeated and prolonged
breathing of vapors and skin contact with the liquid.
Do not use near open flame, arcing equipment or
other ignition sources. Always wear eye protection
and protective clothing. The flash point of P-D-680
is 1 00 to 138 deg. F (38 to 59 deg. C).
(1)
Clean all parts in dry cleaning solvent
(Item 3, Appendix E).
4-267
TM 5-4210-233-14&P-1
4-54. SUCTION DRAIN VALVES-Continued
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless th2e pressure is/has been reduced to 30 psi (2.11
kg/cm ) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
d.
e.
f.
(2)
Dry all parts with compressed air.
(3)
Inspect valve body (6) for cracks and damaged threads. Replace as necessary.
(4)
Inspect plunger (8) for damage and replace as necessary.
Assembly.
(1)
Install two new O-rings (10) on plunger (8).
(2)
Install plunger (8) and rod (3) as an assembly.
(3)
Install snap ring (7).
Installation.
(1)
Apply pipe sealant (Item 2, Appendix E) and install nipple (4) and elbows (5 and 9) on valve body
(6).
(2)
Secure outer rod (2) to inner rod (3) with turnbuckle (1).
(3)
Install knob (11).
Follow-on Maintenance.
(1)Connect batteries (see para 4-114).
4-268
TM 5-4210-233-14&P-1
4-55. FOAM TANK DRAIN VALVE
This task covers:
a. Removal
b. Disassembly
c. Cleaning and Inspection
d. Assembly
e. Installation
f. Follow-on
Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Foam Tank Drained (see para 2-17 .)
Curb Side Operator's Panel Removed
(see para 4-26 .)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Repair Kit (Figure 13, Appendix F)
Grease Silicone (Item 11, Appendix E)
a. Removal.
(1)
Remove four bolts (1).
(2)
Remove valve (2) from brackets (3).
(3)
Remove four bolts (4) and valve (2) from flanges (6).
(4)
Remove and discard two flange O-rings (5).
4-269
TM 5-4210-233-14&P-1
4-55. FOAM TANK DRAIN VALVE-Continued
b.
Disassembly.
(1)
Use spanner wrench to turn seat retainer (1) counterclockwise until free from valve body (2).
(2)
Discard retainer (1) and O-ring (3).
(3)
Remove and discard seat (4).
(4)
Remove and discard seat O-ring (5).
(5)
Remove capscrew (6) and handle washer (7).
(6)
Mark position of handle (8).
(7)
Remove handle (8) and handle O-ring (9). Discard O-ring (9).
(8)
Mark position of stop plates (10).
(9)
Remove two stop plates (10).
(10)
Remove pivot bolt (11) and pivot bolt O-ring (12). Discard pivot bolt O-ring (12).
(11)
Remove ball valve (13).
(12)
Remove actuator shaft (14) and actuator shaft 0-ring (15). Discard actuator shaft O-ring (15).
4-270
TM 5-4210-233-14&P-1
4-55. FOAM TANK DRAIN VALVE-Continued
c.
Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
(1)
Clean all parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
d.
(2)
Dry all parts with compressed air.
(3)
Inspect valve body (2) for cracks and damaged threads. Replace as necessary.
(4)
Inspect ball valve (13) for grooves or cracks. Replace as necessary.
Assembly.
(1)
Install new actuator shaft O-ring (15) and actuator shaft (14). Apply a thin coat of silicone grease
(Item 11, Appendix E) to actuator shaft.
(2)
Fit ball valve (13) to actuator shaft (14).
(3)
Install new pivot bolt O-ring (1 2) and pivot bolt (11). Apply a thin coat of silicone grease (Item
11, Appendix E) to O-ring.
(4)
Install new seat O-ring (5) and new seat (4) in new seat retainer (1). Apply a thin coat of silicone
grease (Item 11, Appendix E) to O-ring.
(5)
Install new retainer O-ring (3). Apply a thin coat of silicone grease (Item 11, Appendix E) to
inside edge of seat retainer.
(6)
Use a spanner wrench to thread seat retainer (1) clockwise into valve body (2) until tight.
(7)
Install two stop plates (10) to original position on actuator shaft (14).
(8)
Install new handle O-ring (9). Apply a thin coat of silicone grease (Item 11, Appendix E) to Oring.
(9)
Install handle (8) to original position.
(10)
Install handle washer (7) and capscrew (6).
4-271
TM 5-4210-233-14&P-1
4-55. FOAM TANK DRAIN VALVE-Continued
e.
f.
Installation.
(1)
Coat two O-rings (6) with silicone grease (Item 11, Appendix E) and install on valve (1).
(2)
Position valve (1) between flanges (2).
(3)
Install and tighten four short bolts (3) and four long bolts (4).
(4)
Remove four long bolts (4).
(5)
Position valve (1) in brackets (5).
(6)
Install and tighten four long bolts (4).
Follow-on Maintenance.
(1)
Install curbside operator's panel (see para 4-26).
(2)
Connect batteries (see para 4-114).
4-272
TM 5-4210-233-14&P-1
4-56. DISCHARGE CONNECTIONS/CHROME ADAPTERS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
a. Removal.
(1)
Remove cap and chain (1).
(2)
Remove chrome discharge piping (2) using spanner wrench from truck.
b. Installation.
(1)
Install replacement chrome discharge piping (2).
(2)
Tighten using spanner wrench.
(3)
Attach cap and chain (1).
4-273
TM 5-4210-233-14&P-1
4-57. PRIMING PUMP
This task covers:
a. Removal
b. Disassembly
c. Cleaning and Inspection
d. Assembly
e. Installation
f. Follow-on
Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Priming Pump Motor Removed (see para 4-58 .)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
Oil, SAE 40 (Item 20, Appendix E)
Cloth, Cleaning (Item 42, Appendix E)
Repair Kit (Figure 34, Appendix F)
a. Removal.
(1)
Remove priming tank hose (1) and priming valve hose (2).
(2)
Remove four bolts (3) and lockwashers (4).
(3)
Remove priming pump.
4-274
TM 5-4210-233-14&P-1
4-57. PRIMING PUMP-Continued
b.
Disassembly.
NOTE
Before disassembling pump for repairs, be sure to clean its
exterior. Make sure the working space, benches, and tools are
clean. Use only clean, lint free cloths to wipe off components.
(1)
Remove two bolts (5).
(2)
Remove front head (6).
(3)
Remove and discard O-ring (7) and shaft bearing (8).
(4)
Remove rotor with shaft assembly (9) and vanes (10). Discard vanes.
(5)
Remove and discard shaft bearing (11).
(6)
Remove cylinder (12) and shims (13) from rear head (14). Discard shims.
NOTE
Repair kit includes O-ring (7), shaft bearing (8), vanes (10),
shaft bearing (11), and shims (13).
c.
Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protective clothing.
The flash point of P-D-680 is 1 00 to 138 deg. F (38 to 59 deg.
C).
(1)
Clean all parts with dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
(2)
Dry all parts with compressed air.
(3)
Examine parts for cracks, severe corrosion, or other damage. Replace defective parts.
4-275
TM 5-4210-233-14&P-1
4-57. PRIMING PUMP-Continued
d.
e.
f.
Assembly.
(1)
Install new bearing (11) in rear head (14).
(2)
Align new shims (13) and cylinder (12).
(3)
Install new vanes (10) in rotor and shaft assembly (9).
(4)
Install rotor and shaft assembly (9) and install in cylinder (12).
(5)
Install new bearing (8) and new O-ring (7).
(6)
Align and install front head (6) and fasten with two bolts (5).
Installation.
(1)
Secure priming pump with four bolts (3) and lockwashers (4).
(2)
Apply pipe sealant (item 2, Appendix E) to fitting threads.
(3)
Connect priming tank hose (1) and priming valve hose (2) to priming pump.
Follow-on Maintenance.
(1)
Install priming pump motor (see para 4-58).
(2)
Connect batteries (see para 4-114).
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TM 5-4210-233-14&P-1
4-58. PRIMING PUMP MOTOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Tag, Identification (Item 32, Appendix E)
a. Removal.
(1)
Tag and disconnect electrical leads from solenoid (1).
(2)
Remove two bolts (2) and two lockwashers (3).
(3)
Remove motor (4).
(4)
Remove solenoid (1) from motor by removing two nuts (6).
b. Installation.
c.
(1)
Install solenoid (1) and secure with two nuts (6).
(2)
Install motor (4), making sure groove in motor shaft coupling engages pump shaft (5).
(3)
Secure motor to mounting with two lockwashers (3) and two bolts (2).
(4)
Connect electrical leads to solenoid (1).
Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
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TM 5-4210-233-14&P-1
4-59. PRIMING PUMP TUBING
This task covers:
a. Replace
b. Follow-on Maintenance
TOOLS REQUIRED
PERSONNEL REQUIRED: 2
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Curbside Panel Removed (see para 4-26 .)
MATERIALS/PARTS REQUIRED
Tie, cable plastic (Item 33, Appendix E)
a. Replace.
NOTE
Priming pump tank is located behind access
panel on curbside operators panel.
(1) Disconnect tubing (1) from check valve (2)
and drain oil from tubing.
NOTE
In step 1, note orientation of orifice and take
care to avoid loss of orifice and reducer.
(2) Disconnect tubing (1) from elbow (3).
(3) Position loosely attached, new tubing ties
next to old ties. Cut and remove old tubing
ties.
(4) Connect tubing (1) to elbow (3). Route tubing
(1) through new ties. Tighten ties one at a
time.
(5) Connect tubing (1) to check valve (2).
b. Follow-on Maintenance.
(1) Install curbside operator's panel (see para
4-26).
(2) Connect batteries (see para 4-114).
(3 Operate priming pump and check for leaks
(see para 2-13).
4-278
TM 5-4210-233-14&P-1
4-60. PRIMING PUMP OIL TANK
This task covers:
a. Removal
b. Installation
TOOLS REOUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Sealing Compound (Item, 2, Appendix E)
Oil (Item 20, Appendix E)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Curbside Operator's Panel Removed
(see para 4-26 .)
a. Removal.
(1) Disconnect tubing (5) from top of tank.
(2) Remove tank (1) by removing two screws
(3), nuts (4), and straps (2).
(3) Drain priming pump oil tank into suitable
container.
b. Installation.
(1) Position new tank (1) in mounting
brackets. Secure with two straps (2),
screws (3), and nuts (4).
(2) Apply pipe sealant (Item 2, Appendix E) to
fitting threads.
(3) Connect tubing (5) to tank.
(4) Fill priming tank with oil (Item 20,
Appendix E).
c.
Follow-on Maintenance.
(1) Install curbside operator's panel
(see para 4-26).
(2) Connect batteries (see para 4-114).
(3) Operate priming motor and check for leaks.
4-279
TM 5-4210-233-14&P-1
4-61. REAR STROBE LIGHT
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Remove screw (1).
(2) Remove ring (2) and gasket (4).
(3) Disconnect wiring harness and remove light
(3)
b. Installation.
(1) Connect wiring harness.
(2) Install light (3).
(3) Install ring (2) and gasket (4).
(4) Fasten screw (1) to secure light.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test rear strobe light.
4-280
TM 5-4210-233-14&P-1
4-62. REAR STROBE LIGHT POWER SUPPLY
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Tag all wires and remove wiring harness
(1).
(2) Remove four screws (2).
(3) Remove power supply (3).
(4) Remove and replace fuse (4) as necessary.
b. Installation.
(1) Secure power supply (3) to panel with four
screws (2).
(2) Attach wiring harness (1) to power supply
(3).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test rear strobe lights.
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TM 5-4210-233-14&P-1
4-63. HOSE BED FLOODLIGHT
This task covers:
a. Disassembly
b. Cleaning and Inspection
c. Assembly
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
d. Removal
e. Installation
f. Follow-on
Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
a. Disassembly.
(1) Remove ring mounting screw (1).
(2) Pull ring (2) forward. Sealed beam (3) is held in ring with springs (4).
(3) Pull wire connectors (4A) from back of sealed beam (3).
(4) Remove sealed beam (3) from housing assembly (8).
(5) Remove nut (5) from switch (6).
(6) Tag and disconnect wiring harness. Remove switch (6).
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TM 5-4210-233-14&P-1
4-63. HOSE BED FLOODLIGHT-Continued
b. Cleaning and Inspection.
(1)
Clean light assembly.
(2)
Inspect for broken or cracked housing assembly. If damaged, replace light assembly.
(3)
Inspect wiring for fraying or cracked insulation. If wiring is damaged, contact Direct Support
Maintenance.
(4)
Inspect bulb socket, bulb contacts, and wiring for corrosion. Clean corrosion with emery cloth
(Item 25, Appendix E). If corrosion cannot be removed, replace light assembly.
(5)
Inspect switch and switch contacts for corrosion and proper operation. If damaged, replace
switch.
c. Assembly.
(1)
Install switch (6) and fasten to housing assembly with nut (5).
(2)
Attach wiring harness to switch (6).
(3)
Install springs (4) and secure sealed beam to ring (2).
(4)
Attach wire connectors to terminals of sealed beam (3).
(5)
Push ring (2) onto lamp head. Ensure lower lip on ring aligns with lamp housing indent.
(6)
Secure ring (2) with screw (1).
d. Removal.
(1)
Remove four screws (7) securing lamp assembly (8) to hose body.
(2)
Cut wire (9) adjacent to butt connector. Cut butt connector from harness.
(3)
Remove lamp assembly (8) from hose body.
e. Installation.
(1)
Attach wire (9) of new lamp assembly to wiring harness using new butt connector (Item 27,
Appendix E).
(2)
Align new lamp assembly (8) on hose body, and install with four screws (7).
f. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
(2)
Test operation of floodlights.
4-283
TM 5-4210-233-14&P-1
4-64. BACK-UP LIGHTS
This task covers:
a. Disassembly
d. Follow-on Maintenance
b. Cleaning and Inspection
c. Assembly
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
a. Disassembly.
(1) Remove two screws (1), ring (2), and lens
(3).
(2) Remove gasket (4).
(3) Remove and replace failed bulb (5) as
needed.
(4) Remove two screws (6).
(5) Remove wiring harness by cutting butt
splice.
(6) Remove reflector assembly (7).
(7) Remove gasket (8).
b. Cleaning and Inspection.
(1) Clean lens (3) and reflector (7).
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect for broken or cracked reflector. If
damaged, replace reflector.
(4) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(5) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion cannot be removed, replace light
assembly.
4-284
TM 5-4210-233-14&P-1
4-64. BACK-UP LIGHTS-Continued
c. Assembly.
(1)
Thread wires through hole in gasket (8).
(2)
Attach wiring harness to wire of new lamp assembly (7) using new butt connector (item 27,
Appendix E).
(3)
Install reflector assembly (7) with two screws (6).
(4)
Install gasket (4) and lens (3). Fasten ring (2) with two screws (1).
d. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
(2)
Start engine, place truck transmission in reverse and test operation of back-up lights.
4-285
TM 5-4210-233-14&P-1
4-65. STOP, TURN AND TAIL LIGHTS
This task covers:
a. Disassembly
d. Follow-on Maintenance
b. Cleaning and Inspection
c. Assembly
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
a. Disassembly.
(1) Remove four screws (1).
(2) Remove ring (2) with lens (3). Remove
gasket (4). Turn tabs on inside of ring (2)
to separate lens (3) from ring.
(3) Remove three bulbs (5) as needed.
(4) Remove four screws (6).
(5) Disconnect wiring harness from reflector
assembly (7).
(6) Remove reflector assembly (7).
b. Cleaning and Inspection.
(1) Clean lens (3) and reflector (7).
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect for broken or cracked reflector. If
damaged, replace reflector.
(4) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(5) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion is excessive, replace light
assembly.
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TM 5-4210-233-14&P-1
4-65. STOP, TURN AND TAIL LIGHTS-Continued
c. Assembly.
(1)
Attach wiring harness to reflector assembly (7).
(2)
Install reflector assembly with four screws (6).
(3)
Install three bulbs (5).
(4)
Install lens (3) in ring (2) and secure by turning two tabs inside ring (2).
(5)
Test stop, turn and tail lights as follows:
(a) Turn battery switch on.
(b) Turn headlights on. One taillight bulb should illuminate.
(c) Step on brake pedal. Second bulb should illuminate.
(d) Actuate turn signal switch in both directions. Turn signal lights should flash.
(6)
Install gasket (4) and ring (2) and secure with four screws (1).
d. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
4-287
TM 5-4210-233-14&P-1
4-66. REAR SCENE LIGHT
This task covers:
a. Removal
d. Follow-on Maintenance
b. Cleaning and Inspection
c. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
a. Removal.
(1) Remove four screws (1), lens (2) and
gasket (3).
(2) Remove bulb (4).
(3) Remove four screws (5) from reflector (6).
(4) Remove wiring harness by cutting butt
splice.
(5) Remove reflector (6).
b. Cleaning and Inspection.
(1) Clean lens (1) and reflector (6).
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect for broken or cracked reflector. If
reflector is damaged, replace reflector.
(4) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(5) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion cannot be removed, replace
reflector.
4-288
TM 5-4210-233-14&P-1
4-66. REAR SCENE LIGHT-Continued
c. Installation.
(1)
Attach wiring harness to wire of new reflector using new butt splice (Item 27, Appendix E).
(2)
Align reflector (6), and fasten in place with four screws (5).
(3)
Install bulb (4).
(4)
Align gasket (3) and Iens (2), and install on reflector (6) with four screws (1).
d. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
(2)
Test operation of rear scene light.
4-289
TM 5-4210-233-14&P-1
4-67. REAR SCENE LIGHT
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Unplug electrical lead (1).
(2) Remove four nuts (2), four lockwashers (3),
four bolts (4) and ground lead (5).
(3) Remove back-up alarm (4) from bracket
(7).
b. Installation.
(1) Position back-up alarm (6) on bracket (7).
(2) Install four bolts (4), four lockwashers (3),
four nuts (2) and ground lead (5).
(3) Attach electrical plug (1) to wiring harness.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine and depress brake pedal. Put
truck transmission in reverse. Back-up
alarm should sound.
4-290
TM 5-4210-233-14&P-1
4-68. WARNING BUZZER PUSH BUTTONS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Stop, Turn and Tail Lights removed
(see para 4-65 .)
a. Removal.
(1) Unscrew switch cap (1).
(2) Remove switch (2) through tail light
opening.
(3) Remove two screws (3) and wires (4).
b. Installation.
(1) Install wires (4) with two screws (3).
(2) Adjust nut (5) so that it is in the middle of
the threaded area of the switch.
(3) Install switch (2) and thread on switch cap
(1).
c.
Follow-on Maintenance.
(1) Install stop, turn & tail lights (see para 465 .).
(2) Connect batteries (see para 4-114).
(3) Turn battery switch on and test both
warning buzzer push buttons. Buzzer
should be heard in cab when pressed.
4-291
TM 5-4210-233-14&P-1
4-69. CLEARANCE MARKER LIGHTS
This task covers:
a. Disassembly
d. Follow-on Maintenance
b. Cleaning and Inspection
c. Assembly
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
a. Disassembly.
(1) Pry lens (1) loose from light body (2).
(2) Remove bulb (3).
(3) Pry reflector (4) from light body (2).
(4) Remove bulb socket assembly (5) from
reflector (4).
(5) Remove two screws (6).
(6) Tag and disconnect wires.
(7) Remove bulb socket assembly (5) from
light body (2).
(8) Remove light body (2) and gasket (7).
(9) Remove and replace O-ring (8) if
damaged.
b. Cleaning and Inspection.
(1) Clean lens and reflector.
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect for broken or cracked reflector. If
damaged, replace light assembly.
(4) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(5) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion cannot be removed, replace light
assembly.
4-292
TM 5-4210-233-14&P-1
4-69. CLEARANCE MARKER LIGHTS-Continued
c. Assembly.
d.
(1)
Install wires from bulb socket assembly (5) through light body (2).
(2)
Connect wires using butt splice connector (Item 27, Appendix E).
(3)
Align light body (2) and gasket (7),on to truck.
(4)
Fasten light body (2) to truck with two screws (6).
(5)
Install bulb socket assembly (5) into reflector (4).
(6)
Press reflector (4) into light body (2).
(7)
Install bulb (3).
(8)
Press lens (1) into light body (2).
Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
(2)
Turn battery switch on. Turn headlight switch on and check operation of clearance marker lights.
4-293
TM 5-4210-233-14&P-1
4-70. HANDRAILS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
MATERIALS/PARTS REQUIRED
Gaskets (Figure 48, Appendix F)
a. Removal.
(1) Remove four screws (1).
(2) Remove stanchion (2) and two gaskets (3).
(3) Remove two screws (4) and tubing (5).
b. Installation.
(1) Secure tubing (5) to stanchion (2) with two
screws (4).
(2) Install two gaskets (3) and stanchion (2).
(3) Secure stanchion with four screws (1).
4-294
TM 5-4210-233-14&P-1
4-71. UPPER AND LOWER COMPARTMENT DOORS
This task covers:
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
I.
m.
n.
Removal of Door (Inside Handle)
Replace Hinge (Inside Handle)
Installation of Door (Inside Handle)
Removal of Inside Handle
Installation of Inside Handle
Removal of Latch (Inside Handle)
Installation of Latch (Inside Handle)
Removal of Door (Outside Handle)
Replace Hinge (Outside Handle)
Installation of Door (Outside Handle)
Removal of Outside Handle/Lock
Replace Hinge (Outside Handle)
Installation of Outside Handle/Lock
Replace Door Seals
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
MATERIALS/PARTS REQUIRED
Grease, Silicone (Item 11, Appendix E)
Sealant (Item 35, Appendix E)
a. Removal of Door (Inside Handle).
(1) Support compartment door (1) and remove
spring clip (2) and clevis pin (3) from clevis
(4).
(2) Remove screws (5) securing hinge (6) to
body.
(3) Remove compartment door (1) from truck.
b. Replace Hinge (Inside Handle).
(1) Inspect hinge for cracks, oversized
mounting holes and excessive hinge pin
movement. Replace hinge if damaged.
(2) To remove hinge, remove screws (7).
(3) Position hinge (6) on compartment door
and align holes. Install and tighten screws
(7).
(4) Lubricate hinge with silicone grease (Item
11, Appendix E).
4-295
TM 5-4210-233-14&P-1
4-71. UPPER AND LOWER COMPARTMENT DOORS-Continued
c. Installation of Door (Inside Handle).
(1)
Lift compartment door (1) into position. Align holes in hinge (6) with holes in body.
(2)
Install and tighten screws (5).
(3)
Align clevis (4) and install pin (3) and spring clip (2).
d. Removal of Inside Handle.
(1)
Open compartment doors (1).
(2)
Remove socket set screw (2) and remove inside handle (3) and washer (4).
e. Installation of Inside Handle.
(1)
Open compartment door (1).
(2)
Position handle (3) and washer (4) as shown and install with socket set screw (2).
f. Removal of Latch (Inside Handle).
(1)
Remove button (13) from inside of door.
(2)
Remove two screws (6), nuts (7) and lockwashers (8) and remove latch (9).
g. Installation of Latch (Inside Handle).
(1)
Apply sealant (Item 35, Appendix E) to mating surface of new latch.
(2)
Position latch (9) as shown and secure with screws (6), washers (8) and nuts (7).
(3)
Lubricate latch jaws with silicone grease (Item 11, Appendix E).
4-296
TM 5-4210-233-14&P-1
4-71. UPPER AND LOWER COMPARTMENT DOORS-Continued
h. Removal of Door (Outside Handle).
(1)
Support compartment door (1) and
remove spring clip (2) and clevis pin
(3) from clevis (4).
(2)
Remove screws (5) securing hinge
(6) to body.
(3)
Remove compartment door (1) from
truck.
i. Replace Hinge (Outside Handle).
(1)
(2)
Inspect hinge for cracks, oversized
mounting holes and excessive hinge
pin movement. Replace hinge if
damaged.
To remove hinge, remove screws (7).
(3)
Position hinge (6) on compartment
door and align holes. Install and
tighten screws (7).
(4)
Lubricate hinge with silicone grease
(Item 11, Appendix E).
j. Installation of Door (Outside Handle).
(1)
Lift compartment door (1) into
position. Align holes in hinges (6)
with holes in body.
(2)
Install and tighten screws (5).
(3)
Align clevis (4) and install clevis pin
(3) and spring clip (2).
4-297
TM 5-4210-233-14&P-1
4-71. UPPER AND LOWER COMPARTMENT DOORS-Continued
k. Removal of Outside Handle/Lock.
NOTE
The handle cannot be repaired; replace if
damaged.
(1)
Open compartment door (1).
(2)
To remove handle, remove screw (2)
and flatwasher (3).
NOTE
If binder holder (4) is installed over screw
(2) remove storage area (4) by removing
four screws (5) and washers (6).
(3)
Remove handle (7) and gasket (8).
NOTE
Sealant has been applied to both sides of
gasket (8); force may be required to break
this seal during removal of outside handle.
(4)
To remove latch (9), complete above
and remove four screws (10),
washers (11) and nuts (12).
(5)
Pull latch (9) from door (1).
l. Replace Hinge (Outside Handle).
(1)
Inspect hinge for cracks, oversized
mounting holes and excessive hinge
pin movement. Replace hinge if
damaged.
(2)
To remove
screws (14).
(3)
Position hinge (13) on compartment
door and align holes. Install and
tighten screws (14).
(4)
Lubricate hinge with silicone grease
(Item 11, Appendix E).
hinge
(13),
remove
4-298
TM 5-4210-233-14&P-1
4-71. UPPER AND LOWER COMPARTMENT DOORS-Continued
m.
Installation of Outside Handle/Lock.
(1)
If latch (9) has been removed, install in door (1).
(2)
Secure latch (9) to door (1) with four screws (10), washers (11) and nuts (12).
NOTE
If blinder holder (4) blocks way, remove it by removing four
screws (5) and washers (6).
(3)
To install handle, apply sealant (Item 35, Appendix E) to both sides of gasket (8).
NOTE
Center handle (7) and gasket (8) on outside of door and secure
with screw (2) and flatwasher (3) from inside of door.
n.
Replace Door Seals.
(1)
To remove damaged door seals (15), pull damaged seals from door (1).
(2)
Remove all remaining glue and damaged seal.
(3)
To install new seals, remove backing from glue strip on seals.
(4)
Align seals (15) on door and press on door (1).
4-299
TM 5-4210-233-14&P-1
4-72. COMPARTMENT DOOR HOLD-OPEN SPRINGS
This task covers:
a. Removal
b. Installation
c. Follow-on-Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section III, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Remove two spring clips (1) and two clevis
pins (2) to remove door arm (2A).
(2) Remove one bolt (3), one lockwasher (4),
and one flat washer (5) from both ends of
rod (6).
(3) Remove rod (6) with spring (7), slide (9)
and spring (8).
b. Installation.
NOTE
Short spring should be installed closest to
door.
(1) Position long spring (7), short spring (8)
and door slide (9) as shown.
(2) Install rod (6) with bolt and secure with one
flat washer (5), one lockwasher (4) and bolt
(3) at each end.
(3) Secure door arm (2A) to door slide (9) and
to body with two clevis pins (2) and spring
clips (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-300
TM 5-4210-233-14&P-1
4-73. REAR ROLL-UP DOOR
This task covers:
a. Removal
b. Installation
c. Latch Replacement
d. Follow-on Maintenance
TOOLS RECOVERED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section IlI, Item 1)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Stop, Turn and Tail Signal Light Removed
Tag (Figure 42, Appendix F)
(see para 4-65 .)
Warning Buzzer Pushbutton Removed
(see para 4-68 .)
Rear Strobe Light Removed (see para 4-61 .)
Rear Step Lights Removed (see para 4-14 .)
a.
Removal.
(1)
(2)
(3)
(4)
(5)
(6)
b.
Remove eleven screws (1) securing
right-hand panel (2) to frame.
Remove tag (3) from warning buzzer
bezel (4).
Remove two screws (5) from bezel
(4), and remove bezel from panel (2).
Remove fifteen screws (6) securing
panel (7) to frame and remove panel
(7).
Remove
screws
(8)
securing
passenger side track (9) to frame.
Slide door (10) from driver's side
door track (11).
Installation.
(1)
(2)
(3)
(4)
(5)
(6)
Install new door (10) in driver's side
door track (11).
Install passenger side door track (9)
over door (10).
Secure door track (9) with screws (8).
Install panel (7) and fasten in place
with fifteen screws (6).
Install bezel (4) and secure with two
screws (5).
Install new tag (3) to bezel (4).
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TM 5-4210-233-14&P-1
4-73. REAR ROLL-UP DOOR-Continued
(7)
c.
d.
Install panel (2) and secure to frame.
Latch Replacement.
(1)
With door open, support door to
prevent door from failing when latch
(1) is removed.
(2)
Remove two screws (2) and remove
latch (1).
(3)
Put new latch (1) in position and
secure with two screws (2).
Follow-on Maintenance.
(1)
Install warning buzzer pushbutton
(see para 4-68).
(2)
Install rear step light (see para 4-14).
(3)
Install rear strobe light (see para 461).
(4)
Install stop, turn and tail lights (see
para 4-65).
(5)
Connect batteries (see para 4-114).
4-302
TM 5-4210-233-14&P-1
4-74. AIR BOTTLE RACK AND SLIDE TRAY
This task covers:
a. Removal
c. Follow-on Maintenance
b. Installation
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-2 .)
(Appendix B, Section lIl, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Connect batteries (see para 4-114 .)
(1) Remove two screws (1), two flatwashers
(2), two lockwashers (3) and two nuts (4)
from bottle box (5).
(2) Remove bottle box (5).
(3) Remove the six screws (6), twelve flat
washers (7), six lockwashers (8) and six
hex nuts (9).
(4) Remove slide tray (10) and rails (11).
(5) Remove six screws (12), flatwashers
(13), lockwashers (14), six hex nuts (15),
and slide tray (10) from rails (11).
b. Installation.
(1) Secure rails (11) to compartment floor
with six screws (6), twelve flatwashers
(7), six lockwashers (8) and hex nuts (9).
NOTE
Do not install the center screw on each side at this
time. The bottle box must be in position when
these screws are installed.
(2) Secure slide tray (10) to rails (11) with
six screws (12), flatwashers (13),
lockwashers (14), and hex nuts (15).
c.
(3) Secure bottle box (5) to slide tray (10)
with two screws (1), two flat washers (2),
two lockwashers (3) and two hex nuts (4).
Follow-on Maintenance.
4-303
TM 5-4210-233-14&P-1
4-75. WATER TANK LEVEL SENDING UNIT
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section III, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS PARTS
Gasket (Fig. 44, Appendix F)
a. Removal.
(1) Remove four screws (1) and access panel (2)
from hose bed floor.
(2) Disconnect wiring harness (3).
(3) Remove six screws (4).
(4) Remove sending unit (5) and gasket (6) from
water tank.
(5) Clean water tank gasket surface.
b. Installation.
(1) Install new gasket (6) and sending unit (5).
(2) Secure sending unit with six screws (4).
(3) Connect wiring harness (3).
(4) Install access panel (2) to hose bed floor with
four screws (1).
c.
Follow-on Maintenance.
(1)
Connect batteries (see para 4-
114).
4-304
TM 5-4210-233-14&P-1
4-76. CAB ROOF PANEL
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
PERSONNEL REQUIRED: 2
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1) EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
MATERIALS/PARTS REQUIRED
APU Shutdown (see para 2-16 .)
Silicone Sealant (Item 35, Appendix E) Batteries Disconnected (see para 4-114 .)
Loctite (Item 7, Appendix E)
Ladder Raised and Moved to Side of Truck
(see para 2-14 .)
a. Removal.
(1) From inside of crew cab, remove thirteen
pan head screws (1) and nylon washers (2).
Remove center panel headliner (3).
(2) From outside of truck, remove
twenty-eight pan head screws (4) and
washers (5) from roof panel (6).
(3) Lift roof panel (6) from truck.
(4) Clean silicone sealant from roof panel
edges and opening.
b. Installation.
(1) Apply a continuous bead of silicone
sealant (Item 35, Appendix E) to roof
panel opening on cab roof.
(2) Install roof panel (6).
(3) Secure roof panel with twenty-eight pan
head screws (4) and twenty-eight
washers (5).
(4) Install center headliner panel (3), thirteen
nylon washers (2), and thirteen pan head
screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Ladder bedded (see para 2-14).
4-305
TM 5-4210-233-14&P-1
4-77. CAB DOORS
This task covers:
a. Removal
b. Disassembly
c. Cleaning and Inspection
d. Follow-on Maintenance
e. Installation
TOOLS REQUIRED: EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section III, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Silicone Grease (Item 11, Appendix E)
a. Removal.
(1) Remove three screws (1) attaching strap (2) to door (3).
(2) Support door (3).
(3) Remove eight screws (4) and internal tooth lockwashers (4A) attaching hinge (5) to truck.
(4) Remove door from truck.
b. Disassembly.
NOTE
Grip handles (20 and 24) should remain in place when
removing panel (11).
(1) Press inner ring (6) on window crank toward door and drive pin (7) from handle (8).
(2) Remove handle (8).
(3) Remove nine screws (9) and washers (10) from door panel (11).
(4) Remove nut (12) and release cable (13).
(5) Remove door panel (11).
(6) To remove inside door release handle (14), remove two screws (15) and nuts (16).
(7) Remove nut (17), bolt (18), and spring (19) from door handle (14).
(8) Remove inside grab handle (20) and spacers (20A) by removing screws (21), washers (22) and
nuts (23).
(9) Remove grab handle (24) and spacers (24A) by removing screws (25), washers (26) and nuts (27).
4-306
TM 5-4210-233-14&P-1
4-77. CAB DOORS-Continued
4-307
TM 5-4210-233-14&P-1
4-77. CAB DOORS-Continued
c.
(10)
To remove window regulator (28), remove nut (29) and bolt (30) from horizontal slide track (31).
(11)
Remove two screws (32), lockwashers (33) and nuts (34) securing regulator (28) to bracket (28A)
inside door.
(12)
Remove three screws (35), nuts (36) and washers (37) securing regulator mounting bracket to
edge of door.
(13)
To remove paddle lock (45), remove cotter pin (38), clevis pin (39), two washers (40) and
cable (41).
(14)
Remove nut (42) from striker (43). Remove bracket (44) and paddle lock (45).
(15)
To remove rotary lock (47), remove cotter pin (48), washers (49), clevis pin (50) and two cables
(41 and 13).
(16)
Remove four nuts (51) and screws (52).
(17)
Remove rotary lock (47).
Cleaning and Inspection.
(1)
Clean all internal door parts.
(2)
Inspect window for cracks or damage. If damaged, replace window (see para 4-78).
(3)
Inspect for broken, cracked or corroded parts. If damaged, replace.
(4)
Inspect cables for cuts or fraying. If damaged, replace.
(5)
Apply a light coat of silicone grease (Item 11 Appendix E) to all internal moving parts and the door
latch.
d. Assembly.
(1)
Align rotary lock (47) in door and secure with four nuts (51) and screws (52).
(2)
Attach two cables (41 and 13) to door latch (47) with clevis pin (50), two washers (49) and cotter
pin (48).
(3)
Install paddle lock (45) in door. Install bracket (44) and install nut (42) on striker (43).
(4)
Install cable (41) with clevis pin (39), washers (40), and cotter pin (38).
(5)
To install window regulator bracket (28A), align in door and fasten to door frame edge with three
screws (35), washers (37) and nuts (36).
4-308
TM 5-4210-233-14&P-1
4-77. CAB DOORS-Continued
(6)
Install two screws (32), lockwashers (33) and nuts (34) to secure window crank assembly (28) to
bracket (28A).
(7)
Install bolt (30) and nut (29) to secure arm of window regulator (28) to horizontal slide track (31).
(8)
To install inside door handle (14) on door panel (11), attach spring (19) to handle with bolt (18) and
nut (17).
(9)
Attach handle (14) to door panel (11) with two screws (15) and nuts (16).
(10)
To install door panel (11) to door, attach cable (13) to inside door handle (14) and fasten with nut
(12).
Remove three screws (35), nuts (36) and washers (37) securing regulator mounting bracket to edge
of door.
(11)
Align door panel (1 6) on door and fasten with nine screws (9) and washers (10).
(12)
Install grab handles (20 and 24) and spacers (20A and 24A) with screws (21 and 25), washers (22
and 26) and nuts (23 and 27).
(13)
Install ring (6) and window handle (8) on stud of crank assembly.
(14)
Press inner ring (6) on window crank (8) toward door and install pin (7) into handle to fasten to
assembly.
e. Installation.
(1)
Align door (3) on truck and support.
(2)
Secure door hinge (5) to truck with eight screws (4) and internal tooth lockwashers (4A).
(3)
Attach strap (2) to door (3) with three screws (1).
4-309
TM 5-4210-233-14&P-1
4-78. DOOR GLASS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section III, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Door Panel Removed (see para 4-77 .)
a. Removal.
(1) Loosen four screws (1) and remove glass
from channel (2).
(2) Slide glass from track (3).
(3) Remove glass.
b. Installation.
(1) Install glass in track (3).
(2) Position new glass in door and tighten four
screws (1) to tighten channel (2).
(3) Raise and lower window to check tracking.
Loosen screws (1) to adjust glass if needed
Be sure to re-tighten screws (1) when
adjustment is complete.
c.
Follow-on Maintenance.
(1) Install door panel (see para 4-77).
(2) Connect batteries (4-114).
4-310
TM 5-4210-233-14&P-1
4-79. WINDSHIELD
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section III, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Window Installation Tool
Windshield Wiper Arms Removed
(Appendix B, Section III, Item 17)
(see para 4-112 .)
MATERIALS/PARTS REQUIRED
Sealant (Item 35, Appendix E)
a. Removal.
(1) Remove chrome locking strips (1) from
center of rubber gasket (2).
(2) Remove glass (3) from gasket (2).
(3) Remove gasket (2) from window frame.
b. Installation.
(1) Clean surfaces of window frame and
edge of new glass.
(2) Apply sealant (Item 35, Appendix E) to
inner and outer groove of gasket (2).
(3) Install gasket (2) in frame of window.
(4) Install glass (3) in gasket (2).
(5) Install locking strip (1) in gasket (2) with
window installing tool (Appendix B,
Section III, Item 17).
(6) Remove any excess sealant on glass or
window frame.
c.
Follow-on Maintenance.
(1) Install windshield wiper arms
(see para 4-112).
(2) Connect batteries (see para 4-114).
4-311
TM 5-4210-233-14&P-1
4-80. MIRRORS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section lll, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
NOTE
Removal and installation of the left hand
mirror is detailed.
The procedure for
removal and installation of the right hand
mirror is similar.
a. Removal.
(1) Remove two screws (1), lockwashers (2)
and flatwashers (3). Remove mirrors (4)
and (5) from brackets (6).
(2) Remove screw (7), washer (8), nut (9),
flatwasher (10), plastic washer (11) and
rubber grommet (12) from upper mirror
bracket (13).
(3) Remove screw (14), cap (15), rubber
grommet (16), spacer (17), toothed washer
(18), flatwasher (19) and nut (20) from
lower mirror bracket (21).
(4) Remove two screws (22), lockwashers (23)
and flatwashers (24). Remove upper
mirror
bracket (13) from top of cab door.
(5) Remove two screws (25), lockwashers (26)
and flatwashers (27). Remove lower mirror
bracket (21) from cab door.
4-312
TM 5-4210-233-14&P-1
4-80. MIRRORS - Continued
b. Installation.
(1) Install lower mirror bracket (21) on cab door with two screws (25), lockwashers (26), and
flatwashers (27).
(2) Install upper mirror bracket (13) on top of cab door with two screws (22), lockwashers (23) and
flatwashers (24).
(3) Install screw (14), cap (15), rubber grommet (16), spacer (17), toothed washer (18), flatwasher (19) and
nut (20) on lower mirror bracket (21).
(4) Install screw (7), washer (8), nut (9), flatwasher (10), plastic washer (11) and rubber grommet (12)
on upper mirror bracket (13).
(5) Install mirrors (4 and 5) on brackets (6) with two screws (1), lockwashers (2) and flatwashers (3).
c.
Follow-on Maintenance.
(1) Connected batteries (see para 4-114).
4-313
TM 5-4210-233-14&P-1
4-81. HEADLIGHTS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REOUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section IlI, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1)
(2)
(3)
(4)
(5)
Remove six screws (1).
Remove cover (2).
Remove four screws (3) and retainer (4).
Remove head lamp (5).
Disconnect wiring harness from headlamp.
b. Installation.
(1) Connect wiring harness to back of
headlamp (5
(2) Install headlamp (5).
(3) Install retainer (4) and four screws (3).
(4) Install cover (2) and six screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of headlights.
(3) Adjust headlights (see para d. below).
d. Adjustment.
(1) Locate vehicle on level surface with lamps
25 ft. (7.6 m) from garage door or
headlamp adjusting screen.
(
(2) Align centerline of vehicle with centerline of
screen (1).
(3) Locate a horizontal line on screen at height
of
lamp centers (2).
(4) Light head lamps and adjust lamp by
turning adjusting screws until the height
intensity zone is located on adjusting
screen as indicated (3).
4-314
TM 5-4210-233-14&P-1
4-82. DIRECTIONAL MARKER LIGHTS
This task covers:
a. Disassembly
b. Cleaning and Inspection
c. Assembly
d. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12 .)
(Appendix B, Section III, Item 1) APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice Connectors (Item 27, Appendix E)
a. Disassembly.
(1) Remove two screws (1).
(2) Remove lens retaining ring (2), lens (3) and
gasket (4).
(3) Remove bulb (5) from reflector (7).
(4) Remove two screws (6).
(5) Remove reflector (7) and gasket (8).
(6) Tag and disconnect wiring from truck.
b. Cleaning and Inspection.
(1) Clean lens and reflector.
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect for broken or cracked reflector. If
damaged, replace light assembly.
(4) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(5) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion cannot be removed, replace light
assembly.
4-315
TM 5-4210-233-14&P-1
4-82. DIRECTIONAL MARKER LIGHTS-Continued
c.
Assembly.
(1) Install gasket (8) over wires and connect wiring to truck with butt splice connector (Item 27,
Appendix E). Remove wire tags.
(2) Install reflector (7) with two screws (6).
(3) Install bulb (5).
NOTE
When assembling light make sure drain hole in lens is facing
down.
(4) Install gasket (4), lens (3) and retaining ring (2).
(5) Install two screws (1).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of lights.
4-316
TM 5-4210-233-14&P-1
4-83. WARNING LIGHTS
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12.)
(Appendix B, Section III, Item 1) APU Shutdown (see para 2-16.)
Disconnect Batteries (see para 4-114.)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
Gaskets (Figure 50, Appendix F)
a. Removal.
(1) Remove six screws (8) and washers (9) from
light assembly.
(2) Remove light assembly and gasket (11).
(3) Disconnect wiring harness from light
assembly.
b. Disassembly.
(1) Remove four screws (1) and frame (2).
4-317
TM 5-4210-233-14&P-1
4-83. WARNING LIGHTS-Continued
(2) Remove six hex screws (4) and six lens clips (5).
(3) Remove lens (6) and gasket (7) from frame (2).
(4) Remove and replace failed bulbs (3) as needed.
c. Cleaning and Inspection.
(1) Clean lens (6) and reflector (12) of light assembly.
(2) Inspect lens for cracks. If cracked, replace lens.
(3) Inspect for broken or cracked reflector. If damaged, replace reflector.
(4) Inspect wiring for fraying or cracked insulation. If wiring is damaged, contact Direct Support
Maintenance.
(5) Inspect bulb socket and bulb contacts for corrosion. Clean corrosion with emery cloth
(Item 25, Appendix E). If corrosion is excessive, replace base (13).
(6) Apply 12 VDC to test two motors. Replace if defective.
d. Assembly.
(1) Install lens (6) and new gasket (7) in frame (2).
(2) Fasten lens (6) in place with six hex screws (4) and lens clips (5).
(3) Fasten frame (2) in place with four screws (1).
e. Installation.
(1) Attach wiring harness to wire of lamp assembly using new butt connector (Appendix E,
Item 27).
(2) Install light assembly and new gasket (11) on truck.
(3) Fasten in place with six screws (8) and washers (9).
f.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of front warning lights.
4-318
TM 5-4210-233-14&P-1
4-84. CAB SPOTLIGHTS
This task covers:
a. Disassembly
b. Cleaning and Inspection
TOOLS REOUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Assembly
d. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REOUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
Silicone Grease (Item 11, Appendix E)
NOTE
Driver's side spotlight is illustrated.
Passenger's side spotlight is identical except
components are reversed.
a. Disassembly.
(1) To replace spotlight bulb, remove
screw (1) and ring (2). Unscrew spotlight
bulb (3) from shell assembly (24).
(2) Remove retaining springs (4)
attaching bulb (3) to ring (2) and
remove bulb (3).
(3) Cutout splice (11) and discard.
NOTE
Be sure to cut as close as possible to splice
on both sides. If splice is not accessible, cut
wire at least 2 in. (50 mm) away from
spotlight.
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TM 5-4210-233-14&P-1
4-84. CAB SPOTLIGHTS-Continued
(4)
Remove screw (6) and wedge (7). Pull handle assembly (8) free of shaft assembly (21).
(5)
Loosen set screw (9) and remove collar (10).
(6)
Loosen screw (14) and pull shaft assembly out of clamp (12). Be sure to retain bushing (13).
(7)
Remove two screws (15) and remove switch cap (16) from handle assembly (8).
(8)
Remove screw (17) and toggle assembly (18) from handle assembly (8).
(9)
Remove screw (19) and switch (20) from handle assembly (8).
(10)
Remove plug (22), screw (23), and shell assembly (24) from shaft assembly (21).
b. Cleaning and Inspection.
c.
(1)
Clean bulb (3) and shell assembly (24).
(2)
Inspect wiring for fraying or cracked insulation. If wiring is damaged, contact Direct Support
Maintenance.
(3)
Inspect bulb socket in shell assembly, bulb contacts, and wiring for corrosion. Clean corrosion with
emery cloth (item 25, Appendix E). If corrosion cannot be removed, replace shell assembly (24),
wiring (5), and bulb (3) as required.
(4)
Inspect all remaining parts for wear and corrosion. Clean corrosion with emery cloth (Item 24,
Appendix E). If corrosion cannot be removed replace part(s) as required.
(5)
Inspect internal gear in handle assembly (8) and external gear on shaft assembly (21) for
excessive wear or damaged teeth. Replace complete handle assembly and shaft assembly if
damaged.
(6)
Check continuity of switch (20). Replace if defective.
Assembly.
(1)
Lubricate internal gear in handle assembly (8) using Silicone Grease (Item 11, Appendix E).
(2)
Install switch (20) with screw (19).
(3)
Install toggle assembly (18) with screw (17).
(4)
Be sure gear is properly located in handle assembly (8)and install switch cap (16). Secure cap to
handle assembly with two screws (15).
(5)
Be sure bushing (13) is placed on shaft assembly (21) and push shaft assembly through clamp (12)
until bushing is seated and shaft assembly stop butts against clamp. Tighten screws (14). Install
sleeve (10) and tighten set screw (9).
(6)
While holding shaft assembly (21) and pushing handle assembly (8) onto shaft, rotate handle until
internal gear in handle and external gear on shaft slip together.
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TM 5-4210-233-14&P-1
4-84. CAB SPOTLIGHTS-Continued
(7)
Be sure notch in shaft aligns with wedge mounting hole in handle and install wedge (7) and screw
(6).
(8)
Connect spotlight wiring by installing new butt splice (11) (Item 27, Appendix E).
(9)
Replace shell assembly (24) on shaft assembly (8) with screws (23), and replace plug (22) in end
of shaft assembly.
(10)
Assemble ring (2) and bulb (3) using springs (4). Attach two wires (5) to shell assembly (24).
(11)
Install assembled ring (2) and bulb (3) in shell assembly (24) and secure with screw (1).
d. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
(2)
Test operation of cab spotlights.
4-321
TM 5-4210-233-14&P-1
4-85. ROOF BEACON LIGHT
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IIl, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
a. Removal.
(1) Open clip and remove ring (1).
(2) Remove dome (2).
(3) Remove three nuts (3) and lift light
assembly for access to connecting wires.
(4) Tag and disconnect wires.
(5) Remove light assembly.
b. Disassembly.
(1) Open clip (4).
(2) Remove and replace lamp (5).
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TM 5-4210-233-14&P-1
4-85. ROOF BEACON LIGHT-Continued
c.
Cleaning and Inspection.
(1) Clean dome (2) and lamps (5).
(2) Inspect dome for cracks; if cracked, replace.
(3) Inspect for lamp holders (4A); replace if damaged.
(4) Inspect wiring for fraying or cracked insulation. If wiring is damaged, contact Direct Support
Maintenance.
(5) Inspect sockets in lamp holders (4A), lamp contacts, and wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If corrosion cannot be removed, replace lamp holder(s) (4A),
lamp(s) and wiring as required.
(6) Inspect shaft (10) and replace if burned or damaged.
(7) Check fit of shaft (10) in upper and lower bearings (13 and 19) and replace bearings if shaft isn't a
snug fit.
(8) Inspect two brushes (8) and brush springs (7). Replace as required.
(9) Inspect worm gear and clutch assembly (18). Replace as required.
(10) Inspect collector ring (14). Replace as required.
(11) Apply 12 VDC to test motor (22). Replace if required.
d. Assembly.
(1) Install globe (2).
(2) Install ring (1).
e. Installation.
(1) Secure wires to light assembly.
(2) Hold gasket (6) in place with tape.
(3) Align base with mounting bolts and install three nuts (3).
(4) Install dome (2) and ring (1).
f.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
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TM 5-4210-233-14&P-1
4-86. SIREN AND PA SYSTEM
This task covers:
a. Removal
b. Cleaning and Inspection
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Installation
d. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown'(see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIAL/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
a. Removal.
.
(1) To remove PA speaker (1), tag and
disconnect wiring harness under
dashboard.
(2) Remove two mounting bolts (2) and
lockwashers (3) from bracket (4).
(3) Remove PA speaker (1) through front of
cab.
(4) Tag and disconnect wiring harness from
siren control box (5).
(5) Remove two bolts (6) and washers (7) from
bracket (8) and remove siren control box
(5).
b. Cleaning and Inspection.
(1) Inspect wiring for fraying or cracked
insulation. If wiring is damaged,
contact Direct Support Maintenance.
(2) Inspect wire contacts and wiring for
corrosion. Clean corrosion with emery
cloth (Item 25, Appendix E). If corrosion
cannot be removed, replace
assembly
4-324
TM 5-4210-233-14&P-1
4-86. SIREN AND PA SYSTEM-Continued
c.
Installation.
(1) To install PA Speaker (1), install speaker through front of truck.
(2) Connect wiring harness to PA speaker with butt splice connector (Item 27, Appendix E).
(3) Align speaker and fasten to bracket (4) with two bolts (2) and lockwashers (3).
(4) Connect wiring harness to control box (4).
(5) Align control box (5) to bracket (8) and fasten in place with two bolts (6) and washers (7).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of siren and PA system.
4-325
TM 5-4210-233-14&P-1
4-87. AIR HORNS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove screw (1) and disconnect end of
air horn cord (2) from cab roof.
(2) Remove twelve screws (3) and headliner
(4) from cab-roof.
(3) Remove air hose (5) from fitting (6).
(4) Remove two fittings (6 and 7).
(5) Remove three capscrews (8), nuts (9),
lockwashers (10) and flatwashers (11).
(6) Remove horn (12) and gaskets (13 and
14).
b. Installation.
(1) Install air horn (12) and gaskets (13 and 14)
and secure with three screw (8), nuts (9),
lockwashers (10) and flatwashers (11).
(2) Install two fittings (6 and 7).
(3) Attach air hose (5) to fitting (6).
(4) Install cab head liner (4) and secure with
twelve screws (3).
(5) Secure end of air horn cord (2) to cab roof
with screw (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-326
TM 5-4210-233-14&P-1
4-88. CAB SUNROOFS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Disconnect Batteries (see para 4-114.)
MATERIALS/PARTS REQUIRED
Window Installation Tool (Appendix B, Section III, Item 17)
Sealant (Item 35, Appendix E)
a. Removal.
(1) Remove chrome locking strip (1) from
center of rubber gasket (2).
(2) Remove glass (3) from gasket (2).
(3) Remove gasket (2) from cab roof.
b. Installation.
(1) Clean surfaces of cap roof opening and
edge of new glass.
(2) Apply sealant (Item 35, Appendix E) to
inner and outer groove of gasket (2).
(3) Install gasket (2) in cap roof opening.
(4) Install glass (3) in gasket (2).
(5) Install locking strip (1) in gasket (2) with
window installation tool (Appendix B,
Section IIl, Item 17).
(6) Remove any excess sealant on glass or
cab roof.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-327
TM 5-4210-233-14&P-1
4-89. CAB ROOF VENT FAN
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Silicon Sealant (Item 35, Appendix E)
a. Removal.
(1) Remove three screws (1) and roof unit (2)
from roof of cab.
(2) Tag and disconnect wire (3).
(3) Remove twelve screws (4) and fan
assembly (5) from cab roof.
b. Installation.
(1) Apply silicon sealant (Item 35,
Appendix E).
(2) Install fan assembly (5) and secure with
twelve screws (4).
(3) Connect wire (3) and remove tags.
(4) Install roof unit (2) and secure with three
screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-328
TM 5-4210-233-14&P-1
4-90. LADDER LOCK LIGHT
This task covers:
a. Removal
c.
b. Cleaning and Inspection d.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Installation
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Loctite (Item 7, Appendix E)
Butt Splice Connector (Item 27, Appendix E)
Emery Cloth (Item 25, Appendix E)
a. Removal.
(1) Remove two screws (1) and lens (2).
(2) Remove bulb (3).
(3) Remove four screws (4), reflector (5) and
four nuts (6).
(4) Pull back protective covering and cut wire
at butt splice connector.
b. Cleaning and Inspection.
(1) Clean lens and reflector.
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect for broken or cracked reflector. If
damaged, replace light assembly.
(4) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(5) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion cannot be removed, replace light
assembly.
c.
Installation.
(1) Connect wire with butt splice connector
(Item 27, Appendix E).
4-329
TM 5-4210-233-14&P-1
4-90. LADDER LOCK LIGHT-Continued
NOTE
Nuts (6) are used as spacers only. Screws (4) should not thread
into nuts, but must slide through without interference.
Coat screws (4) with Loctite (Item 7, Appendix E).
(2) Put nuts (6) in position over holes in ladder support. Put reflector in position and install four screws
(4).
(3) Install bulb (3).
(4) Install lens (2) with four screws (1).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-330
TM 5-4210-233-14&P-1
4-91. MECHANICAL SIREN
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Butt Splice Connector (Item 27, Appendix E)
a. Removal.
(1) Remove three screws (1) and remove
cover (2) from siren assembly (3).
(2) Remove nut (4), lockwasher (5) and
remove cable (6).
(3) Disconnect wire (7) of butt splice
connector.
(4) Remove three screws (8), nuts (9),
lockwashers (10) and flatwashers (11).
Remove siren assembly (3) from bumper.
b. Installation.
(1) Position siren assembly (3) on bumper and
secure with three screws (8), flatwashers
(11), lockwashers (10) and nuts (9).
(2) Connect wire (7) with new butt splice
connector (Item 27, Appendix E).
(3) Install cable (6) and secure with lockwasher
(5) and nut (4). Install cover (2) and secure
with three screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) With battery switch on, depress
MECHANICAL SIREN button on either side
of cab floor to test siren.
(3) Depress red SIREN BRAKE switch on
dashboard. Siren operation should stop.
4-331
TM 5-4210-233-14&P-1
4-92. CAB EXTERIOR TRIM
This task covers:
a.
b.
c.
d.
Removal-Cab Trim
e. Removal-Scuff Plates
Installation-Cab Trim
f. Installation-Scuff Plates
Removal-Wheel Trim
g. Follow-on Maintenance
Installation-Wheel Trim
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal-Cab Trim.
(1) Gently pry damaged chrome strip (1) from
cab.
b. Installation-Cab Trim.
(1) Install replacement chrome strip (1).
(2) Gently tap new chrome strip until strip is
locked in place.
c.
Removal-Wheel Trim.
(1) Remove eleven screws (2) and eleven
washers (3).
(2) Remove chrome strip (4) and rubber strip
(5).
d. Installation-Wheel Trim.
(1) Install rubber strip (5) and chrome strip (4).
(2) Install eleven washers (3) and eleven
screws (2).
e. Removal-Scuff Plates.
(1) Remove six screws (6) fastening scuff
plate (7) to truck.
(2) Remove scuff plate.
f.
Installation-Scuff Plates.
(1) Align Scuff plate (7).
(2) Secure scuff plate with six screws (6).
g. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-332
TM 5-4210-233-14&P-1
4-93. CAB INSTRUMENT PANEL GAUGES
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix b, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove three screws (3) and tilt dash panel (4) forward to access wiring.
(2) Remove two screws (1) and bezel (2) from gauge.
(3) Tag and disconnect wiring from back of gauge.
(4) Remove nuts (5) from bracket (6).
(5) Remove gauge (7).
b. Installation.
(1) Install gauge (7), bracket (6) and nuts (5).
(2) Secure wiring to gauge.
(3) Close dash panel (4) and secure with three screws
(3).
(4) Install bezel (2) on gauge with two screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine and check operation of gauge.
4-333
TM 5-4210-233-14&P-1
4-94. CAB INSTRUMENT PANEL SWITCHES
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Tags, Identification (Item 32, Appendix E)
a. Removal.
(1) Locate applicable switch using following diagram.
4-334
TM 5-4210-233-14&P-1
4-94. CAB INSTRUMENT PANEL SWITCHES-Continued
(2) Remove screws (1) from appropriate panel.
(3) Pull panel forward to access wiring.
(4) Tag and disconnect wiring from back of switch.
(Rock Switch Removal)
(5) Depress clips (2) on switch (3) and push through panel.
(Ignition Switch Removal)
(6) Remove screw (4) and lever (5).
(7) Remove locking nut (6) from switch (7) and push switch (7) through panel.
(Engine Start Switch, Dimmer Switch, Headlight Switch and Wiper Switch Removal)
NOTE
Knob on engine start switch does not need to be removed.
(8) Remove knob (8) from switch (9).
(9) Remove locking nut (10) from switch (9) and push switch (9) through panel.
b. Installation.
(Engine Start Switch, Dimmer Switch, Headlight Switch and Wiper Switch Installation)
(1) Install switch (9) through panel and secure with locking nut (10).
(2) Install knob (8) on switch (9).
(Ignition Switch Installation)
(3) Install switch (7) through panel and secure with locking nut (6).
(4) Install lever (5) and secure with screw (4).
(Rock Switch Installation)
(5) Install switch (3) through front of panel.
(6) Connect wiring to switch as shown in wiring diagram (Appendix H).
(7) Close panel.
(8) Secure panel with screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-335
TM 5-4210-233-14&P-1
4-95. CAB INSTRUMENT PANEL INDICATOR LIGHTS
This task covers:
a. Disassembly
b. Cleaning and Inspection
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
a. Disassembly
(1) Tag and disconnect wires.
(2) Remove bulb socket (1) from bulb
housing (2). Remove bulb (3).
(3) Remove rubber guard (4) and lens
(5) from bulb housing (2).i
(4) Remove nut (6) and washer (7) and bulb
housing (2).
b. Cleaning and Inspection.
(1) Clean lens.
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(4) Inspect bulb socket, bulb contacts, and
wiring for corrosion. Clean corrosion with
emery cloth (Item 25, Appendix E). If
corrosion is excessive, replace light
assembly.
c.
Assembly.
(1) Install bulb housing (2), washer (7) and nut (6).
(2) Install lens (5) and rubber guard (4).
(3) Install bulb (3) in bulb socket (2).
(4) Install bulb socket (1) in bulb housing (2).
(5) Connect wires. Remove wire tags.
d. Follow-up Maintenance.
(1) Connect batteries (see para 4-114).
4-336
c. Assembly
d. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
TM 5-4210-233-14&P-1
4-96. WARNING BUZZER
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
NOTE
Warning buzzer is located in electrical compartment.
(1) Tag and remove two wires (1) from
buzzer (2).
(2) Remove two hex nuts (3), two
lockwashers (4), two flatwashers (5)
and two screws (6).
(3) Remove buzzer (2).
b. Installation.
(1) Install buzzer (2).
(2) Install two screws (6), flatwashers (5),
lockwashers (4) and hex nuts (3).
(3) Attach two wires (1) to buzzer (2).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of warning buzzer.
4-337
TM 5-4210-233-14&P-1
4-97. CAB DOME LIGHTS
This task covers:
a. Removal/Disassembly
b. Cleaning and Inspection
c. Installation/Assembly
d. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice Connectors (Item 27, Appendix E)
a. Removal/Disassembly
(1) Pull two cones (1) free of assembly to remove.
(2) Remove two bulb (2).
(3) To remove lens (3), squeeze sides of lens and remove.
(4) Remove bulbs (4).
4-338
TM 5-4210-233-14&P-1
4-97. CAB DOME LIGHTS-Continued
(5) Remove four screws (5) from dome light assembly (6).
(6) Tag and disconnect wires. Remove dome light assembly (6).
(7) Replace switch (7) as follows:
(a)
(b)
from light housing.
Tag and disconnect wires.
Press clips on both ends of switch and push switch
(8) Remove ground wires (8).
(9) Cut wire (9) at butt splice.
(10)
Remove light assembly from truck.
4-339
TM 5-4210-233-14&P-1
4-97. CAB DOME LIGHTS-Continued
b. Cleaning and Inspection.
(1) Clean lens and reflector.
(2) Inspect lens for cracks. If cracked, replace lens.
(3) Inspect for broken or cracked reflector. If damaged, replace light assembly.
(4) Inspect wiring for fraying or cracked insulation. If wiring is damaged, contact Direct Support
Maintenance.
(5) Inspect bulb socket, bulb contacts, and wiring for corrosion. Clean corrosion with emery cloth (Item
25, Appendix E). If corrosion is excessive, replace light assembly.
c.
Installation/Assembly.
(1) Install three switches (7), and attach wires.
(2) Attach wires to light assembly (6).
(3) Install new butt splice on wire (9) and connect ground wires (8).
(4) Align light assembly to cab roof and secure in place with four screws (5).
(5) Install two bulbs (2).
(6) Press two cones (1) on to light assembly to install.
(7) Install two bulbs (4).
(8) Press lens (3) into place.
d. Follow-up Maintenance.
(1) Connect batteries (see para 4-114).
4-340
TM 5-4210-233-14&P-1
4-98. DASHBOARD COMPARTMENT DOORS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnect (see para 4-114 .)
a. Removal.
(1) Remove six screws (1) washers (2) and nuts (3) from door side of hinge (4).
(2) Remove and replace door (5 or 6).
(3) Remove screws (7), washers (8) and nuts (9) and remove hinge (4).
b.
Installation.
(1) Install hinge (4)with screws (7), washers (8) and nuts (9).
(2) Install new door (5 or 6).
(3) Secure compartment door to hinge (4) with six screws (1), lockwashers 2
( ) and nuts (3).
c.
Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
4-341
TM 5-4210-233-14&P-1
4-99. CIRCUIT BREAKERS
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Tie Straps (Item 33, Appendix E)
a. Removal.
.
NOTE
Be sure that malfunction which caused the circuit
breaker to trip has been corrected before replacing
circuit breaker.
Access to circuit breaker can be gained through electric
compartment door in center of dash. Cut tie straps as
necessary.
(2) Tag and remove wires from faulty circuit breaker
(3).
(3) Remove faulty circuit breaker (3).
b. Installation.
(1) Install new circuit breaker (3).
(2) Attach and fasten wires with nuts.
(3) Install ground bar (2) and secure with nuts (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114)
4-342
TM 5-4210-233-14&P-1
4-100. TRANSMISSION SHIFT CONTROL
This task covers:
a.
b.
c.
d.
e.
f.
Removal, Transmission Shift Control
Removal, transmission Control Cable
Cleaning and Inspection
Installation, Transmission Control Cable
Installation, Transmission Shift Control
Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Tie Straps (Item 33, Appendix E)
a. Removal, Transmission Shift Control.
(1) Remove four screws (1) and remove
cover (2) and rubber gasket (3).
(2) Remove four screws (4) and four flat
washers (5) from plate (6).
(3) Remove four screws (7) and
washers (8) from plate (9).
(4) Remove four screws (10), and
washers (11). Remove plate (9)
from plate (6).
(5) Pull transmission shift control up to
access transmission cable (12).
(6) Mark location of end fitting (14) on
transmission shift control.
(7) Remove spring clip (13) and end
fitting (14).
(8) Remove two nuts (15), lockwasher (16)
and screws (17) and clamp (18).
(9) Remove cable (12) from transmission
shift control (19).
(10) Remove transmission shift control (19)
from truck.
4-343
TM 5-4210-233-14&P-1
4-100. TRANSMISSION SHIFT CONTROL-Continued
b. Removal, Transmission Control Cable.
(1) Remove cable (12) from transmission shift control (19) as described in para a. above.
(2) To remove cable from transmission, remove spring clip (20).
(3) Mark location of and remove end fitting (21) from bracket (22).
(4) Remove two nuts (23) and lockwashers (24) from U-bolt (25), and remove cable from bracket (26).
(5) Cut tie straps holding cable (12) to truck.
(6) Remove cable (12) from truck.
c.
Cleaning and Inspection.
(1) Inspect cable for fraying or cracked insulation. If cable is damaged, replace.
(2) Inspect cable for corrosion. Clean corrosion with emery cloth (Item 25, Appendix E). If corrosion
cannot be removed, replace cable assembly.
d. Installation, Transmission Control Cable.
(1) Install end fitting (14) of cable (12) to transmission shift control (19).
(2) Install spring clip (13) in end fitting (14).
(3) Attach cable (12) body to transmission shift control using two nuts (15), lockwashers (16) and
screws (17) and clamp (18).
(4) Feed cable through cab console and route to transmission hookup.
(5) Attach cable end fitting (21) to bracket (22) and install spring clip (20).
(6) Install cable (12) to bracket (26) with U-bolt (25) and two nuts (23) and lockwashers (24).
(7) Secure cable to truck with tie straps (Item 33, Appendix E).
4-344
TM 5-4210-233-14&P-1
4-100. TRANSMISSION SHIFT CONTROL-Continued
e. Installation, Transmission Shift Control.
(1) Install end fitting (14) of cable (12) to transmission shift control (19).
(2) Install spring clip (13) in end fitting.
(3) Attach cable (12) to transmission shift control (19) using two nuts (15), lockwashers (16), screws
(17) and clamp (18).
(4) Install plate (9) on transmission shift control (1 9) with four screws (1 0) and washers (11).
(5) Insert transmission shift control (19) in console.
(6) Secure transmission shift control (19) and plate (9) to plate (6) with four screws (7) and
washers (8).
(7) Secure plate (6) to console with four screws (4) and washers (5).
(8) Secure cover (2) and gasket (3) with four screws (1).
f.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Drive vehicle and test operation of transmission shift control.
4-345
TM 5-4210-233-14&P-1
4-101. BATTERY SELECTOR SWITCH
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section ll, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Place wheel chocks under wheels to
prevent vehicle movement when parking
(2) Remove four screws (1) and washers (2).
(3) Loosen set screw in knob (3) and remove
knob (3).
(4) Remove nut (4) from parking brake valve
(5).
(5) Remove four screws (6), four washers (7),
four lockwashers (8) and four nuts (9).
(6) Remove panel (10).
(7) Tag and remove wires from switch (11).
b. Installation.
(1) Install wires on switch (11).
(2) Install switch (11) in panel (10) with four
screws (6), four washers (7), four
lockwashers (8) and four nuts (9).
(3) Install parking brake valve (5) in panel (1 0)
with nut (4).
(4) Install knob (3) and tighten set screw.
(5) Install four screws (1) and washer (2).
(6) Remove wheel chocks.
c.
Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
4-346
TM 5-4210-233-14&P-1
4-102. HEATER CONTROL HEAD ASSEMBLY
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Remove two screws (1) and washers (2). Tilt plate (3) forward.
(2) Remove two screws (4), and two screws (5) with two flat washers (6), two lockwashers (7), and
two hex nuts (8).
4-347
TM 5-4210-233-14&P-1
4-102. HEATER CONTROL HEAD ASSEMBLY-Continued
(3) Tag and disconnect electrical leads from heater control.
(4) Tag two cables on heater control (9).
(5) Loosen nuts (1 0) and remove cables (11)from heater control.
b. Installation.
(1) Install cables (11) through slots in heater control and secure cables with nuts (10).
(2) Connect electrical leads to heater control. Remove wire tags.
(3) Secure heater control (9) to panel (3) with two screws (4) and two screws (5), two flat washers (6),
two lockwashers (7), and two hex nuts (8).
(4) Tilt plate (3) upwards and secure to dashboard with two screws (1) and washers (2).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-348
TM 5-4210-233-14&P-1
4-103. HEATER VALVE
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
Batteries Disconnected (see para 4-114.)
c. Follow-on Maintenance
EOUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
MATERIALSIPARTS REQUIRED
Coolant (Item 29, Appendix E)
a. Removal.
(1)
Close two valves (1)
4-349
TM 5-4210-233-14&P-1
4-103. HEATER VALVE-Continued
(2) Remove four screws (2) and shield (3) under cab at right front corner of truck.
(3) Loosen two hose clamps (4).
(4) Remove hoses (5) from valve (6) and drain fluid from hoses and heater core into suitable container.
(5) Remove cable (7) from valve (6).
b. Installation.
(1) Install cable (7) on valve (6).
(2) Install hoses (5) and hose clamps (4) on valve (6).
(3) Tighten hose clamps (4).
(4) Install shield (3) with four screws (2).
(5) Check coolant level in radiator. Add coolant
(Item 29, Appendix E) if necessary (see para 3-6).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-350
TM 5-4210-233-14&P-1
4-104. HEATER/DEFROSTER
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
a.
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Removal.
(1 ) Loosen two nose clamps (1) and disconnect two hoses (2).
(2) Open vent (3) on driver's side of heater and disconnect
defroster cable (4) from screw on flap (5) inside of heater.
(3) Remove four screws (6) and heater hose cover (7).
(4) Loosen two clamps (8). Tag and disconnect two hoses (9).
4-351
TM 5-4210-233-14&P-1
4-104. HEATER/DEFROSTER-Continued
(5) Remove eight bolts (10), eight lockwashers (11) and eight flat washers (1 2).
(6) Remove heater (13) from truck.
b. Installation.
(1) Position heater (13) on cab floor and secure with eight bolts (10), eight lockwashers (11) and eight flat
washers (12).
(2) Connect hoses (9) to heater and secure with clamps (8).
(3) Secure heater hose cover (7) to cab floor with four screws (6).
(4) Connect heater/defroster cable (4) with screw to flap (5).
(5) Connect two heater output hoses (2) to heater and secure with two clamps (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-352
TM 5-4210-233-14&P-1
4-105. DRIVER’S SEAT
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal.
(1) Disconnect seat adjustment air line (1).
(2) Remove two screws (2), washers (3), nuts (4) and seat belts (5) and tether belts (6) from frame of
seat assembly (7).
(3) Remove four socket head screws (8), lockwasher (9) and flatwasher (1 0).
(4) Remove seat assembly (7).
b. Installation.
(1) Replace seat (7).
(2) Install four socket head screws (8), lockwashers (9) and flatwashers (10).
(3) Attach seat belts (5) and tether belts (6) to seat frame with two screws (2), washer (3), and nuts (4).
(4) Connect seat adjustment air line(1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
4-353
TM 5-4210-233-14&P-1
4-106. PASSENGER AND STATIONARY JUMP SEATS
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal
(1) To remove seat back remove two screws (1) from air tank bracket (2).
(2) Remove air tank bracket (2).
(3) Remove four screws (3) and washers (4) and seat back (5).
(4) Remove four screws (6) and washers (7) and two seat back pads (8).
(5) To remove seat (9), lift seat from mounting posts.
b. Installation.
(1) Align seat (9) over posts and press in place.
(2) Install two seat back pads (8) on seat back (5) with four screws (6) and washers (7).
(3) Align seat back (5), and fasten in place with four screws (3) and washers (4).
(4) Install air tank bracket (2), and fasten to seat back (5) with two screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-354
TM 5-4210-233-14&P-1
4-107. FOLD-DOWN JUMP SEAT
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Disconnect Batteries (see para 4-114 .)
(1) Remove four screws (1), lockwashers (2)
and washers (3). Remove seat bracket (4) with
seat pad attached.
(2) Remove six screws (5) from bracket (4)
and remove seat pad (6).
(3) Remove two screws (7) and remove plate
(8) from pad (9).
(4) To remove back pad (1 0), remove two
screws (11) and bracket (12).
(5) Remove two screws (13) from cab exterior.
b. Installation.
(1) Align back pad (10) and install two screws
(13) through cab wall.
(2) Install bracket (12) with two screws (11).
(3) Attach plate (8) to pad (9) with two screws
(7).
(4) Install seat pad (6) to bracket (4) with six
screws (5).
(5) Align bracket (4) and fasten in place with
four screws (1), lockwashers (2) and
washers (3).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-355
TM 5-4210-233-14&P-1
4-108. SEAT BELTS
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lII, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
NOTE
This procedure covers removal and installation of all passenger
seat belts.
a. Removal.
(1) To remove shoulder belt remove cap (1)
and screw (2).
(2) Remove bolt (3) lockwasher (4) and
washer (5) from bracket (6).
4-356
TM 5-4210-233-14&P-1
4-108. SEAT BELTS-Continued
(3) Remove nut (7) and bracket (6).
(4) Remove bolt (8), lockwasher (9), and nut (10).
(5) Remove shoulder belt assembly (11) and end of tether belt (12).
(6) Remove bolt (13), lockwasher (14) and flat washer (15). Remove tetherbelt (12).
(7) To remove lap belt, remove nut ('16), washer (17), bolt (18).
(8) Remove lap belt (19) and end of tether belt (20).
(9) Remove bolt (21), lockwasher (22) and flatwasher (23). Remove tether belt (20).
b. Installation.
(1) Install bottom end of shoulder belt assembly (11) and end of tether belt (12) on seat frame and install
bolt (8), lockwasher (9), and nut (10).
(2) Install end of tether belt (12) on cab floor with bolt (13), lockwasher (14) and flatwasher (15).
(3) Install bracket (6) and nut (7) on seat belt (11).
(4) Position bracket (6) on cab wall and install bolt (3), lockwasher (4) and washer (5).
(5) Install screw (2) through end of belt (11). Install cap (1).
(6) Install lap belt (19) and tether belt (20) on seat frame with nut (16), washer (17) and bolt (18).
(7) Install tether belt (20) to cab floor with bolt (21), lockwasher (22) and flatwasher (23).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-357
TM 5-4210-233-14&P-1
4-109. WINDSHIELD WIPER PUMP
This task covers:
a. Removal
b Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section llI, Item 1)
c. Follow-on Maintenance
EOUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Washer Fluid (Item 26, Appendix E)
a. Removal.
(1) Disconnect wire (1).
(2) Remove four screws (5) and flatwashers
(6) and turn reservoir (2) so pump (3) faces
(3) Remove windshield washer pump (3).
b. Installation.
(1) Install windshield washer pump (3).
(2) Install hose (4) and wire (1).
(3) Install four screws (5) and flatwashers (6).
(4) Fill reservoir with washer fluid (Item 26,
Appendix E).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
(2) Test operation of windshield washer pump.
4-358
up and disconnect h
TM 5-4210-233-14&P-1
4-110. WINDSHEILD WASHER RESERVOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS REQUIRED
Washer Fluid (Item 26, Appendix E)
a. Removal.
(1) Remove wire (1).
(2) Remove four screws (2) and flatwashers (3).
(3) Turn reservoir (4) so pump (5) faces up and
disconnect hose (6).
(4) Drain washer fluid into suitable container.
(5) Remove screws (6), washers (7) and bracket (8) from
truck (if necessary).
b. Installation.
(1) Install bracket (8) with screws (6) and washers (7).
(2) Install pump (5) in new reservoir (4).
(3) Secure pump reservoir (4) to bracket (8) with four
screws (2) and four flatwashers (3).
(4) Connect hose (6) and wire (1).
(5) Fill reservoir with washer fluid (Item 26, Appendix E).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114)
4-359
TM 5-4210-233-14&P-1
4-111. WINDSHEILD WIPER MOTOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 11I, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Lift cover (1) to access nut.
(2) Remove nut (2) and washer (3).
(3) Remove wiper arm (4).
(4) Remove cover (5), nut (6), washer (7),and
spacer (8).
(5) Remove screw (9) and washer (10).
(6) Disconnect washer tube (12) from fitting on
front of truck.
(7) Disconnect electrical harness from motor
assembly (11) under dashboard.
(8) Remove windshield wiper motor assembly
(11) from truck.
b. Installation.
(1) Connect wiring harness to wiper motor
assembly (11).
(2) Align wiper motor in truck and install screw
(9), and washer (10).
(3) Install nylon spacer (8), washer (7), nut (6),
and cover (5
(4) Install wiper arm (4).
(5) Fasten arm in place with nut (2) and
washer (3) and close cover (1).
(6) Connect washer tube (12) to fitting on front
of truck.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
(2) Test operation of windshield wiper motor.
4-360
TM 5-4210-233-14&P-1
4-112. WINDSHIELD WIPER ARMS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal
(1) Disconnect washer hose (1).
(2) Lift cover (2).
NOTE
Mark position of blade on windshield before
removing wiper arm (5). This will help to insure
proper installation.
(3) Remove nut (3) and flat washer (4).
(4) Remove wiper arm (5) from shaft (6).
b. Installation.
(1) Install wiper arm (5) on shaft (6).
(2) Install flat washer (4) and nut (3).
(3) Close cover (2).
(4) Connect washer hose (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
(2) Test operation of windshield wiper.
4-361
TM 5-4210-233-14&P-1
4-113. BATTERY ISOLATOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove eight screws (1), washers (2) and
remove storage box (3), and remove seat
cushion (3A).
(2) Remove twelve screws (4) and remove plate
(5).
NOTE
Battery isolator is bolted to driver's side of compartment under communication box support plate.
4-362
TM 5-4210-233-14&P-1
4-113. BATTERY ISOLATOR - Continued
(3) Tag two green-labeled leads (6 and 7). Remove nut (8) and disconnect leads (6 and 7) from terminal 2
of isolator(15).
(4) Tag one red-labeled lead (9). Remove nut (10) and disconnect lead (9) from terminal A of isolator (15).
(5) Tag two yellow-labeled leads (11 and 12). Remove nut (13) and disconnect leads (11 and 12) from
terminal 1 of isolator.
(6) Remove eight screws (14) and remove isolator (15).
b. Installation
(1) Position isolator (15) and secure with eight screws (14).
(2) Secure two yellow-labeled leads (11 and 12) to terminal 1 of isolator (15) with nut (13).
(3) Secure one red-labeled lead (9) to terminal A of isolator (15) with nut (10).
(4) Secure two green-labeled leads (6 and 7) to terminal 2 of isolator (15) with nut (8).
(5) Install plate (5) and secure with twelve screws (4).
(6) Install storage box (3) and secure with eight screws (1) and washers (2).
(7) Replace seat cushion (3A).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
4-363
TM 5-4210-233-14&P-1
4-114. BATTERIES
This task covers:
a. Test
b. Removal
TOOLS REQUIRED:
c. Installation
PERSONNEL REQUIRED: 2
Tool Kit, General Mechanics, Automotive
(Appendix B, Section Ill, Item 1)
Hydrometer (Appendix B, Section Ill, Item 7)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
a. Test.
WARNING
Batteries contain sulfuric acid. They may also
contain explosive mixtures of hydrogen and oxygen
gases in each cell at all times. To avoid serious
injury, always wear face shield, goggles, safety
shoes, gloves and protective clothing when working
with batteries.
Keep sparks, flames, burning
cigarettes or other ignition sources away at all
times.
Do the following steps for each cell:
NOTE
Never take hydrometer reading immediately after
water is added to cell. Water must be mixed completely with electrolyte, by charging, before
hydrometer readings are reliable.
Make sure hydrometer barrel and float are not
cracked and that float is clean. Draw in and expel
electrolyte in hydrometer several times to bring
hydrometer float and barrel to same temperature as
electrolyte.
(1) Remove filler caps from battery.
(2) Draw electrolyte into hydrometer until bulb
is fully expanded and float Iifts free. Float
shouId not touch side, top or bottom
stopper of barrel.
(3) Hold hydrometer with surface of liquid in
barrel at eye level. Disregard curvature of
liquid at float stem and barrel. Read
specific gravity on float scale.
(4) Compare reading to following table. Fully
charged specific gravity of 1.265 corrected
to 80°F (26.7°C) is assumed.
4-364
TM 5-4210-233-14&P-1
4-114. BATTERIES - Continued
TYPICAL OPEN CIRCUIT VOLTAGE AND SPECIFIC GRAVITY VALUES
CHARGE LEVEL
SPECIFIC GRAVITY
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
DISCHARGED
1.120
11.89
VOLTAGE
Adjust readings as follows for temperature correction:
(5) Using thermometer, measure temperature of each cell.
(6) If temperature is ABOVE 80°F (26.7°C), ADD .004 for every 10°F (5.5°C) increment above 80°F.
(7) If temperature is BELOW 80°F (26.7°C), SUBTRACT .004 for every 10°F (5.5°C) increment below
80°F.
If specific gravity is less than 1.225 in all cells and/or cells vary more than 50 points, charge battery
and retest. If charging does not restore specific gravity to 1.225 or higher, replace battery.
(8) Make sure battery is fully charged.
(9) Remove cables from battery terminals as described below.
CAUTION
To avoid damage to battery terminals, do not use alligator
clamps to connect load to battery. Connect leads to battery with
bolted cable ends and use switch to connect and disconnect
load.
(10) Connect 290 amp load (0.041 W 4 kW rated resistor or carbon pile) in series with a switch across
battery terminals as shown (a load tester that incorporates the lead and a voltmeter with it may be
used). Turn on switch and wait 15 seconds to remove surface charge. Turn off switch.
(11) Wait 15 minutes after above test. Connect voltmeter across battery terminals as shown. Turn on
switch. After 15 seconds, read voltage and disconnect load.
(12) Compare voltage readings to following table:
LOAD TEST BATTERY VOLTAGES
Ambient
Temperature
70°F
21°C
60°F
16°C
50°F
10°C
40°F
4°C
30°F
-1°C
20°F
-7°C
10°F
-12°C
0°F
-18°C
Battery
Voltage
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
4-365
TM 5-4210-233-14&P-1
4-114. BATTERIES - Continued
(13) If battery fails load test, replace battery.
b. Removal.
NOTE
Steps 1 through 4 show battery disconnection procedure. Use
this procedure whenever disconnecting batteries for truck
maintenance.
WARNING
To avoid serious injury, use proper lifting procedures or use a
suitable lifting device or dolly. Do not drop or tilt batteries.
Batteries contain sulturic acid. Splashing acid can cause
blindness and severe skin burns. Always wear gloves and
protective clothing when working with batteries. If acid contacts
eyes or skin, wash affected area with large amounts of water.
Consult a doctor if splashed in eye or taken internally.
(1) Turn battery switch in cab to OFF.
(2) Unlatch and open battery box cover.
NOTE
Battery box is inside each floor step cab rear
compartment.
Battery A (or Battery 1) is on
passenger side and Battery B (or Battery 2) is on
driver's side.
(3) Loosen nut (1) and remove negative (-) cable
(2) from battery terminal (3).
4-366
TM 5-4210-233-14&P-1
4-114. BATTERIES - Continued
(4) Loosen nut (4) and remove positive (4) cable (5) from battery terminal (6).
(5) Remove nuts (7) and washers (8) securing holddown bar (9) on holddown rods (9A) and remove
holddown bar.
(6) Using two people, grasp handles (10) on each side of battery (11). Lift battery (12) straight up and out
of battery box (13) and truck.
c.
Installation.
(1) Using two people, install new battery in battery box. Do not trap battery leads.
(2) Install holddown bar (9) on holddown rods (9A). Fasten bar with nuts (7) and washers (8).
(3) Install red positive (+) cable (5) to POS (+) terminal (6) and tighten nut (4).
(4) Install black negative (-) cable (2) to NEG (-) terminal (3) and tighten nut (1).
(5) Tighten terminal post nuts (1 and 4) to 30 ft lb (41 N·m).
(6) Close and latch battery box cover.
4-367
TM 5-4210-233-14&P-1
4-115. BATTERY BOX ASSEMBLY
This task covers:
a. Disassembly
c. Assembly
b. Cleaning and Inspectiond. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIAL/PARTS REQUIRED:
Emery Cloth, Item 25, Appendix E
Baking Soda (Item 5, Appendix E)
WARNING
Never operate welding equipment near storage batteries
Batteries contain explosive mixtures of hydrogen and oxygen
gases in each cell at all times. To avoid serious injury, always
wear face shield, goggles, safety shoes, gloves and protective
clothing when working with batteries. Keep sparks, flames,
burning cigarettes or other ignition sources away at all times.
a. Disassembly.
(1) Remove eight screws (1), lockwashers (2), and nuts (3) from hinge (4).
(2) Remove hinge from panel (5) and truck body.
(3) Remove eight screws (6), washer (7), and nut (8).
(4) Remove hinge (9) from panels (5 and 10).
(5) Remove four screws (11), lockwasher(12), and nut (13).
(6) Remove latch (14).
(7) Remove three screws (15), lockwasher (16), and nut (17).
(8) Remove clip (18).
4-368
TM 5-4210-233-14&P-1
4-115. BATTERY BOX ASSEMBLY - Continued
b. Cleaning and Inspection.
(1) Clean box with water and baking soda (Item 5, Appendix E) solution.
(2) Inspect box doors for cracks. If cracked, replace.
(3) Inspect box panels for corrosion. Clean corrosion with emery cloth (Item 25, Appendix E). If corrosion
cannot be removed, replace battery box components as necessary.
c.
Assembly.
(1) Install clip(18), and fasten in place with three screws (15), washers (16), and nuts (17).
(2) Install latch (14), and fasten in place with three screws (11), washers (12), and nuts (13).
(3) Align hinge (9) on panels (5 and 10) and install eight screws (6), washers (7), and nuts (8).
(4) Align hinge (4) on panel (5) and truck body and install eight screws (1), washers (2), and nuts (3).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-369
TM 5-4210-233-14&P-1
4-116. BATTERY CHARGE RECEPTACLE
This task covers:
a. Removal
c. Installation
b. Cleaning and Inspectiond. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REOUIRED
Emery Cloth (Item 25, Appendix E)
a. Removal.
(1) Remove two bolts (1), washers (2), and
lockwashers (3).
(2) Tag and disconnect wiring harness.
(3) Remove receptacle (4) and gasket (5).
b. Cleaning and Inspection.
(1) Inspect for broken or cracked receptacle. If
damaged, replace.
(2) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(3) Inspect socket, contacts, and wiring for
corrosion. Clean corrosion with emery
cloth (Item 25, Appendix E). If corrosion
cannot be removed, replace receptacle
and/or wiring.
c.
Installation.
(1) install gasket (5).
(2) Connect wiring harness to receptacle with
butt splice (Item 27, Appendix E).
(3) Install receptacle (4) and fasten with two
bolts (1), washers (2), and lockwashers (3).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
4-370
TM 5-4210-233-14&P-1
4-117. 110 VAC, 60 HZ RECEPTACLES
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
a. Removal.
NOTE
There are five receptacles, two on each side of hose
body, and one at the ladder tip.
(1) Remove screws (1), face plate (2) and face
plate gasket (3).
(2) Remove screws (4) and carefully remove
receptacle (5) from panel (6).
(3) Loosen screws (7) on back of receptacle (5) and
tag and disconnect three wires (8).
b. Installation.
(1) Connect new receptacle (5) to wires (8) as
tagged. Secure with screws (7) on back of
receptacle (5).
(2) Install receptacle (5) on panel (6) using screws
(4).
(3)
Install gasket (3) and face plate (2) on
receptacle (5) using screws (1). Make sure face
plate gasket (3) is flat and pulled tight against
panel.
(4) Start APU (see para 2-16) and test 110V
receptacles.
4-371
TM 5-4210-233-14&P-1
4-118. AERIAL CIRCUIT ON/OFF SWITCH
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1lI, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
a. Removal.
(1) Remove two screws (1), cover (2) and gasket (3).
(2) Remove two screws (4) and pull switch (5) out of box to access wires.
(3) Tag and remove black wire (6), white wire (7) and green wire (8) from switch (5).
b. Installation.
(1) Connect black wire (6), white wire (7) and green wire (8) to switch (5).
(2) Install switch (5) with two screws (4).
(3) Install gasket (3), cover (2) and two screws (1).
(4) Start APU (see para 2-16). Turn switch on and check for 110 volts at ladder tip receptacle.
4-372
TM 5-4210-233-14&P-1
4-119. 110 VAC, 60 HZ RECEPTACLES
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
a. Removal.
(1) Remove two screws (1) and remove breaker box cover (2).
(2) Loosen screw (3) on circuit breaker (4). Tag and remove wire (5) from circuit breaker (4).
(3) Unhook tab (6) from under bar (7) and pull out on switch end of circuit breaker to remove.
4-373
TM 5-4210-233-14&P-1
4-119. 110 VAC, 60 HZ RECEPTACLES- Continued
b. Installation.
(1) Hook tab (6) of circuit breaker (4) under bar (7) in box and press breaker into place.
(2) Connect wire (5) to circuit breaker (4) and tighten screw (3).
(3) Install breaker box cover (2) and secure with two screws (1).
4-374
TM 5-4210-233-14&P-1
4-120. 12 VDC/110 VAC RELAYS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove two screws (1) and cover (2) from the circuit breaker box.
(2) Tag and remove wires connected to relay (3).
(3) Remove two screws (4) and remove relay (3).
b. Installation.
(1) Install relay (3) with two screws (4).
(2) Connect wires to relay (3).
(3) Install cover (2) with two screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-375
TM 5-4210-233-14&P-1
4-121.12 VDC IN-LINE FUSE
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Disconnect Batteries (see para 4-114.)
a. Removal.
(1) Remove two screws (1) and cover (2) from circuit breaker box.
(2) Twist and separate fuse holder (3).
(3) Remove fuse (4) from fuse holder (3).
b. Installation.
(1) Install fuse (4) in fuse holder (3) and connect fuse holder.
(2) Install cover (2) with two screws (1).
c.
Follow-on Maintenance.
(1) Disconnect batteries (see para 4-114).
4-376
TM 5-4210-233-14&P-1
4-122. CURRENT TRANSFORMER
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Butt Splices (Item 27, Appendix E)
a
Removal.
(1) Remove two screws (1) and cover (2) from circuit breaker box.
(2) Tag wire (3), that is looped through transformer (4). Remove screw and disconnect wire (3) at terminal
(5).
4-377
TM 5-4210-233-14&P-1
4-122. CURRENT TRANSFORMER -Continued.
(3) Tag and cut wires to transformer (4).
(4) Remove two screws (6), four washers (7), two lockwashers (8), two nuts (9), to remove transformer (4).
b. Installation.
(1) Install transformer (4) with two screws (6), four washers (7), two lockwashers (8) and two nuts (9).
(2) Install new butt splices (Item 27, Appendix E) and connect wires to transformer (2).
(3) Loop wire (3) through transformer (4) one turn and connect wire (3) to circuit breaker terminal with
screw (5).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-378
TM 5-4210-233-14&P-1
4-123. AC AMMETERS AND VOLTMETERS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove four screws (1) and remove plate (2) from box (3).
(2) Remove nuts (4) and lockwasher (5). Tag and disconnect wiring harness.
(3) Remove three nuts (6) and lockwashers (7) and remove meter (8) from plate (2).
4-379
TM 5-4210-233-14&P-1
4-123. AC AMMETERS AND VOLTMETERS - Continued
b
Installation.
(1) Install meter (8) to plate (2) with three lockwashers (7) and nuts (6).
(2) Install wiring harness to meter (8) with lockwasher (5) and nuts (4).
(3) Install plate (2) to box (3) with four screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start APU and check operation of meters (see para 2-16).
4-380
TM 5-4210-233-14&P-1
4-124. PORTABLE WORK LIGHTS (110 VAC)
This task covers:
a. Disassembly
c. Assembly
b. Cleaning and Inspection
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
a. Disassembly.
NOTE
Procedure to replace plug is same for plugs at each
end of cord.
(1) Remove screw (1) and remove cage (2)
from lamp housing (3).
(2) Remove bulb (4) and O-ring (5).
(3) To service electrical cord (6) push rubber
skirt (7) along cord until clear of plug.
(4) Loosen and remove three screws (8) on
plug (9).
(5) Loosen two screws (10) and separate base
(11) from plug (9).
(6) Tag wires and loosen three screws (12) and
remove wires from plug (9).
4-381
TM 5-4210-233-14&P-1
4-124. PORTABLE WORK LIGHTS (110 VAC) - Continued
b. Cleaning and Inspection.
(1) Clean cage and lamp body.
(2) Inspect cage for cracks. If cracked, replace.
(3) Inspect for broken or cracked housing. If damaged, replace.
(4) Inspect wiring and cord for fraying or cracked insulation. If damaged, replace.
(5) Inspect bulb socket, bulb contracts, and wiring for corrosion. Clean corrosion with emery cloth (item
25, Appendix E). If corrosion cannot be removed, replace light assembly.
(6) Inspect O-ring for cracks or deterioration. If damaged replace.
c.
Assembly.
(1) Install bulb (4), and O-ring (5) in housing (3).
(2) Install cage (2), and fasten in place with screw (1).
(3) Install wires and tighten screws (12). Remove wire tags.
(4) Install base (11), and tighten screws (10).
(5) Tighten screws (8).
(6) Install boot (7) over plug.
(7) Connect plug (9) to lamp and turn clockwise to lock in place.
4-382
TM 5-4210-233-14&P-1
4-125. ENGINE ENCLOSURE INSULATION
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section llI., Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Flame Resistant Tape (Item 36, Appendix E)
a. Removal.
(1) Remove tape from compartment door (1) and insulation (2).
(2) Remove clips (3) from pins (4).
(3) Remove insulation (2) and cover from compartment door.
b. Installation.
(1) Align insulation (2) on compartment door (1), and press on pins (4).
(2) Install clips (3).
(3) Using flame resistant tape (Item 36, Appendix E), tape edges of insulation to engine compartment door.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
4-383
TM 5-4210-233-14&P-1
4-126. ENGINE ENCLOSURE LATCHES
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove screw (1), bracket (2) and latch
assembly (3).
(2) Remove nut (4) and lockwasher (5).
(3) Remove arm (6), lockwasher (7) and nut
(8).
(4) Remove nut (9), special nut (10) and spring
(11).
b. Installation.
(1) Install spring (11), special nut (10) and nut
(9).
(2) Install nut (8), lockwasher (7) and arm (6).
(3) Install lockwasher (5) and nut (4).
(4) Align latch assembly (3) in door.
(5) Fasten latch assembly (3) to door with
bracket (2) and screw (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-384
TM 5-4210-233-14&P-1
4-127. ENGINE ENCLOSURE PANELS AND HINGES
This task covers:
a. Removal
c. Follow-on Maintenance
b. Installation
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-1 14.)
Engine Enclosure Insulation Removed
(see para 4-125.)
a. Removal.
(1) Remove thirty-four screws (1), lockwashers
(2) and nuts (3) from hinges (4) and panels
(5 and 6).
(2) Remove hinges (4) and panels (5) from
truck.
(3) Remove screws (7), flatwashers (8),
lockwashers (9) and nuts (10), and remove
panel (6).
b. Installation.
(1) Position center panel (6) and attach with
screws (7), flatwashers (8), lockwashers (9)
and nuts (10).
(2) Align hinges (4) and panels (5) and install
thirty-four screws (1), washers (2) and nuts
(3).
c.
Follow-on Maintenance.
(1) Install engine enclosure insulation (see
para 4-125).
(2) Connect batteries (see para. 4-114)
4-385
TM 5-4210-233-14&P-1
4-128. ENGINE AIR CLEANER ASSEMBLY
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers Open
a. Removal.
(1) Loosen clamp (1) and remove elbow (6)
from air cleaner (5).
(2) Open clamp (2) on air intake adapter (3).
(3) Open air cleaner mounting bands (4).
(4) Slide air cleaner (5) from bands and
adapter.
b. Installation.
(1) Slide new air cleaner (5) into mounting
bands (4) and air intake adapter (3).
(2) Rotate air cleaner until opening is
positioned as shown.
(3) Position air intake adapter (3) over opening
and secure with clamp (2).
(4) Secure elbow (6) to air cleaner with clamp
(1).
(5) Close air cleaner mounting bands (4).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Close engine compartment covers.
4-386
TM 5-4210-233-14&P-1
4-129. ENGINE ASSEMBLY
This task covers:
a. Service
b. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown-(see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers Open
MATERIALS/PARTS REQUIRED
Engine Oil (Item 20, Appendix E)
Oil Filter (Fig. 81, Appendix F)
a. Removal.
(1) Allow main engine to run for approximately five minutes and turn if off.
NOTE
Engine has an oil capacity of 25 quarts (23.7 I).
(2) Remove oil drain plug (1) and drain oil into suitable container (5 gal. (19 I) capacity).
(3) When oil has drained completely, install drain plug (1).
(4) Unscrew oil filter with filter removal tool. Place drain container under filter.
(5) Discard oil filter (2) in a combustible waste area.
(6) Coat seal gasket of new oil filter with clean engine oil (Item 20, Appendix E).
(7) Install oil filter (2) and tighten it one-half turn beyond gasket contact.
(8) Remove engine oil fill cap (3) from driver's side rocker cover of engine.
(9) Add 25 quarts (23.7 I) of engine oil (Item 20, Appendix E) through oil fill opening.
(10) Install engine oil fill cap (3).
(11) Turn two knurled screws (4) counter-clockwise and remove dipstick access door (5) from passenger
side of engine enclosure.
(12) Remove engine dipstick (6) and wipe off oil with rag.
(13) Reinstall engine dipstick (6).
(14) Remove engine dipstick (6) and check oil level (7).
(15) Reinstall engine dipstick (6).
(16) Add engine oil (Item 20, appendix E) as needed (1 quart (.95 I) at a time) and recheck oil level.
(17) Start main engine and check for leaks at oil filter and drain plug.
4-387
TM 5-4210-233-14&P-1
4-129. ENGINE ASSEMBLY Continued.
(18) Tighten oil filter (2) and drain plug (1) slightly if necessary to stop leakage.
(19) Replace dipstick access door (5) in passenger side engine enclosure and turn two knurled screws (4)
clockwise to secure it.
b. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Close engine compartment covers.
4-388
TM 5-4210-233-14&P-1
4-130. FUEL FILTERS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Fuel Oil (Item 41, Appendix E)
a. Removal.
WARNING
JP is approved as an alternate fuel for this vehicle
in emergency situations. JP-4 is a highly volatile
fuel. Extraordinary care must be taken when servicing components that use this fuel. The truck
shall be grounded to an approved grounding point it
contains JP-4 fuel.
WARNING
Fuel is very flammable and can explode easily. To
avoid serious injury or death, keep fuel away from
open fire and keep fire extinguisher within easy
reach when working with fuel. Do not work on fuel
system when engine is hot. Fuel can be ignited by
hot engine. When working with fuel, post signs that
read NO SMOKING WITHIN 50 FEET of vehicle.
NOTE
The primary and secondary engine fuel filters are
mounted along with the transmission filter, to
bracket on the front right-hand side of the truck
frame next to the transmission.
(1) Unscrew the filter cartridges (1) using a
filter removal tool. Place suitable drain
container under filters.
(2) Remove filter cartridges from the engine
and discard in a combustible waste area.
4-389
TM 5-4210-233-14&P-1
4-130. FUEL FILTERS - Continued
b. Installation.
(1) Fill replacement filter cartridges (1) about two-thirds full with clean fuel oil (Item 41, Appendix E).
(2) Coat the cartridge sea[ gaskets (2) lightly with clean fuel oil.
(3) Install the cartridges (1) and tighten them one-half turn beyond gasket contact.
(4) Start the engine and check for leaks. Tighten the filter cartridges slightly as required.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-390
TM 5-4210-233-14&P-1
4-131. FAN BELT
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers Open
a. Removal.
WARNING
Engine coolant can cause severe burns. Allow
engine to cool before attempting to maintain the
fan belts.
CAUTION
Damage to truck could occur in the event belts are
not equally tensioned. Always replace the belts as
a set.
(1) Remove locking bolts (1) from fan belt
pulley (2).
(2) Rotate bolt (3) counterclockwise until belts
(4) are loose enough to be pulled over fan
belt pulley (2).
(3) Pull belts (4) over fan and discard.
b. Installation.
(1) Check that new belts are a matched set
and are in good condition.
(2) Push belts (4) over the fan and loop them
over the top and bottom fan belt pulleys
(2). Ensure they are not crossed.
(3) Rotate bolt (3) clockwise until belts are
tight. There should be 1/2 in. (13 mm)
movement of belts (4) midway between the
pulleys (2).
(4) Install four locking bolts (1) on for belt
pulley (2) and tighten. Torque to 68 ft lb
(92 N.m).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Close engine compartment covers.
4-391
TM 5-4210-233-14&P-1
4-132. FAN
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Upper Radiator Hose Removed on Driver's Side
(see para 4-141.)
Engine Compartment Covers Open
a. Removal.
(1) Remove six bolts (1) and six lockwashers
(2).
(2) Remove fan (3) and two spacers (4) from
engine.
b. Installation.
(1) Install two spacers (4) and fan (3) and
secure with six bolts (1) and six
lockwashers (2).
(2) Tighten six bolts (1) to 75 ft lb (100 N·m).
c.
Follow-on Maintenance.
(1) Install upper radiator hose on driver's side
(see para 4-141).
(2) Connect batteries (see para 4-114).
(3) Close engine compartment covers.
4-392
TM 5-4210-233-14&P-1
4-133. ALTERNATOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers Open
Alternator Belt Removed (see para 4-135.)
a. Removal.
(1) Tag and disconnect engine harness and wires from alternator.
(2) Remove two nuts (1) and washer (2) from rod (3).
(3) Remove nut (4) and washer (5) and remove screw (6) and washer (7) to remove bracket (8) from
alternator (9).
4-393
TM 5-4210-233-14&P-1
4-133. ALTERNATOR - Continued
(4) Support alternator (9) and remove nut (10) and washer (11) and screw (12) securing alternator (9) to
bracket (13) on engine.
(5) Lift alternator (9) up and away from engine.
(6) Remove nut (14), washer (15) and screw (16). Remove rod (3) from bracket (8).
(7) Remove nuts (17), rod end (18) and washer(19).
b. Installation.
(1) Assemble rod (3), rod end (18), nuts (17) and washer(19).
(2) Install rod end (18) on bracket (21) and secure with screw (16), washer (15) and nut (14).
(3) Install alternator (9) in position on mounting bracket (13) and install screw (12) through alternator (9)
and mounting bracket (13). Install nut (10) and washer (11) on screw (12). Do not tighten.
(4) Hold alternator in position and install bracket (8) in position on alternator mounting lug. Install screw
(6), washer (7), nut (4) and washer (5).
(5) Install washer (2) and two nuts (1) on rod (3).
(6) Connect engine wiring harness and wires to alternator.
c.
Follow-on Maintenance.
(1) Install alternator belt (see para 4-135.).
(2) Connect batteries (see para 4-114.).
(3) Close engine compartment covers.
4-394
TM 5-4210-233-14&P-1
4-134. ENGINE STARTING AID
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Left Side Engine Compartment Door Open
a. Removal.
(1) Loosen clamp (1).
(2) Unscrew fuel cylinder (2) from fitting (3)
and discard cylinder if empty. Install cap
(4) on fitting (3) to keep dirt out.
(3) To remove bracket (5), remove four screws
(6), flatwashers (7) lockwashers (8) and
nuts (9).
(4) Disconnect tube (10).
(5) Tag and disconnect wires (11).
b.
Installation.
(1) Connect wires (11).
(2) Connect tube (10).
(3) Install bracket (5) to truck with four screws
(6), flatwashers (7), lockwashers (8) and
nuts (9).
(4) Remove cap (4) from fitting (3). Thread
cylinder (2) into fitting (3) until tight.
(5) Tighten clamp (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114.).
(2) Close left side engine compartment door.
4-395
TM 5-4210-233-14&P-1
4-135. ALTERNATOR BELT
This task covers:
a. Adjustment
b. Removal
c. Installation
d. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IIl, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers Open
a. Adjustment
(1) Depress belt midway between pulleys.
When properly adjusted belt should
depress 1/2 to 3/4 inch (12.7 to 19.0 mm).
Adjust tension as follows:
(2) Loosen nut (1) to loosen alternator (4) in its
mounting.
(3) Loosen nut (5) away from nut (3).
(4) To increase belt tension, turn nuts (2 and 3)
counter-clockwise.
(5) To decrease belt tension, turn nuts (2 and
3) clockwise.
(6) When proper belt tension is achieved,
tighten nut (5) against nut (3).
(7) Tighten nut (1) to hold alternator (4) in
position.
4-396
TM 5-4210-233-14&P-1
4-135. ALTERNATOR BELT - Continued
b. Removal.
(1) Loosen nuts (2 and 3) and nut (1).
(2) Move alternator (4) away from bracket (8) to loosen belt (7). Remove belt (7) from alternator pulley (6).
c.
Installation.
(1) With nuts (2 and 3) and nut (1) loosened, move alternator (4) towards bracket (8).
(2) Install new belt (7) in groove of alternator pulley (6).
(3) Refer to para a. above and adjust belt tension.
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Close engine compartment covers.
4-397
TM 5-4210-233-14&P-1
4-136. THERMOSTATS
This task covers:
a. Removal
b. Test
c. Installation
d. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 111, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Cooling System Drained (see para 3-6.)
Upper Radiator Hoses Removed (see para 4-141.)
Engine Compartment Covers Open
Thermometer (Appendix B, Section III, Item 10)
Thermostat Seal Installer
(Appendix B, Section III, Item 86)
Thermostat Seal Driver Handle
(Appendix B, Section III, Item 87)
MATERIALS/PARTS REQUIRED
Gaskets (Figure 98, Appendix F)
Seals (Figure 98, Appendix F)
4-398
TM 5-4210-233-14&P-1
4-136. THERMOSTATS-Continued
(2) Loosen two hose clamps (4) and disconnect hose (5) from water pump.
(3) Remove bolts (6) and lockwashers (7) securing covers (8) and (8A) to thermostat housings (9) and
(9A).
(4) Remove gaskets (1 0) and scrape any gasket residue from thermostat housings (9) and (9A) and
covers (8) and (8A).
(5) Remove seals (1 1) from thermostat covers (8) and (8A) and discard.
(6) Remove thermostats (12) from thermostat housings (9) and (9A).
(7) Clean the thermostat sealing surfaces in the thermostat housings (9) and (9A) and covers (8) and (8A).
b. Test.
(1) Immerse thermostats (1) in a container of heating water.
(2) Place thermostats (2) in container.
CAUTION
Keep thermometer (2) from touching bottom
of container. Failure to do so will result in
inaccurate readings.
(3) Stir water to maintain even temperature.
(4) When thermostats (1) start to open, and again
when it's fully open, observe water temperature
as indicated on thermometer.
(5) Water temperature observed in step (4) should
match temperature range stamped on
thermostats (1). Opening temperature is
approximately 180-F (82'C), and fully open
temperature is 197-F (92'C), allow at least 1 0
minutes for thermostat to react.
(6) If thermostats do not operate at specified temperatures,
replace thermostat(s).
4-399
TM 5-4210-233-14&P-1
4-136. THERMOSTATS-Continued
c.
Installation.
(1) Position new seals (1 1) so lips of seals
face up (away from thermostats) when installed.
Use thermostat seal installer (Appendix B,
Section l1, Item 87) to install seals in covers (8) and (8A)
NOTE
The seal installer tool assures that the seal is
positioned the correct distance from the bottom
face of the cover and is parallel with the
coverface.
(2) Place gasket (10) on thermostat
housings (9) and (9A).
(3) Place thermostats (1 2) in thermostat
housings (9)and (9A).
(4) Attach covers (8) to thermostat housings \par(9)
and (9A) with bolts (6) and washers (7). Tighten
bolts (6) to 33 ft lb (45 N.m).
(5) Slide hose (5) with clamps (4) between 11
water pump and right hand housing (9); tighten
clamps (4).
(6) Install bypass tube (3), hoses (2), and clamps
between both covers (8) and tightenclamps
(1).
(7) Refill cooling system (see para 3-6).
(8) Start main engine, run at 1/2 throttle for five
minutes, and check for leaks. Stop engine when
engine cools, recheck radiator level. Add
coolant as required.
d. Follow-on Maintenance.
(1) Install upper radiator hoses (see para 4-141).
(2) Connect batteries (see para 4-114).
(3) Close engine compartment covers.
4-400
TM 5-4210-233-14&P-1
4-137. THERMOSTAT HOUSINGS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Thermostats Removed (see para 4-136.)
Water Temperature Sending Units Removed
(see para 4-138.)
Engine Compartment Covers Open
MATERIALS/PARTS REQUIRED
Gaskets (Fig 98, Appendix F)
a. Removal.
(1) Right-hand side:
(a) Remove four screws (1, 2, 3 and 4), four lockwashers (5) and one flat washer (6).
(b) Remove thermostat housing (7) and gasket (8).
4-401
TM 5-4210-233-14&P-1
4-137. THERMOSTAT HOUSING-Continued
(2) Left-hand side:
(a) Remove three screws (9, 10 and 1 1), three lockwashers (12) and one flat washer (13).
(b) Remove thermostat housing (14) and gasket (15).
(3) Clean gasket material from thermostat housings (7 and 14) and from engine block.
b. Installation.
(1) Right-hand side:
(a) Put new gasket (8) and thermostat housing (7) in position on engine block and secure with four
screws (1, 2, 3 and 4), four lockwashers (5) and one flat washer (6). Install flat washer (6)
on bolt (3).
(2) Left-hand side:
(a) Put new gasket (15) and thermostat housing (14) in position on engine block and secure with three
screws (9, 10 and 1 1), three lockwashers (12) and one flat washer (13). Install flatwasher (13)
on bolt (10).
c.
Follow-on Maintenance.
(1) Install water temperature sending units in left side thermostat housing (14) (see para 4-138).
(2) Install thermostats (see para 4-136).
(3) Connect batteries (see para 4-114).
(4) Close engine compartment covers.
4-402
TM 5-4210-233-14&P-1
4-138. ENGINE SENDING UNITS
THIS TASK COVERS: a.
b.
Oil Pressure Sending Unit
Water Temperature Sending Unit
TOOLS REQUIRED
Too[ Kit, General Mechanics, Automotive
(Appendix B, Section iii, Item 1)
c.
d.
Hour Meter Sending Unit
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers Open
a. Oil Pressure Sending Unit.
(1) Testing.
(a) Run main engine and monitor oil pressure
gauge on pump panel and in cab. Each
gauge is supplied from a different sender.
(b) If no pressure is recorded on pump panel
gauge, replace gauge assembly on pump
panel (see para 4-18).
(c) If no pressure is recorded on gauge in cab,
ground the S terminal on gauge. If gauge
does not register, replace gauge.
(d) If gauge registers, either sending unit or
wire is at fault.
(e) To check wires for continuity (see Wiring
Diagrams, Appendix H). To replace
sending unit, see para (2) and (3) below.
(2) Removal.
(a) Tag and disconnect wires (1) from
sending unit (2).
(b) Remove sending unit (2) from fitting (3).
(3) Installation.
(a) Install new sending unit (2) in fitting (3).
(b) Connect wires (1) to sending unit (2).
4-403
TM 5-4210-233-14&P-1
4-138. ENGNE SENDING UNITS - Continued
b. Water Temperature Sending Unit.
(1) Testing.
(a) Run main engine and monitor water temperature
gauge on pump panel and in cab. Each gauge is
supplied from a different sender.
(b) If no temperature is recorded on pump panel
gauge, replace gauge assembly on pump panel
(see para 4-18.).
(c) If no temperature is recorded on gauge in cab,
ground the S terminal on gauge. If gauge does
not register, replace gauge.
(d) If gauge registers, either sending unit or wire is at f
(e) To check wire for continuity, see Wiring Diagrams
(Appendix H), to replace sending unit,
see para (a) below.
(2) Removal.
(a) Tag and disconnect wires (1) from sending unit (2).
(b) Remove sending unit (2) from thermostat housing (3)
(3) Installation.
(a) Install new sending unit (2) in thermostat housing (3).
(b) Connect wires (1) to sending unit (2).
4-404
TM 5-4210-233-14&P-1
4-138. ENGINE SENDING UNITS - Continued
c.
Hour Meter Sending Unit.
(1) Testing.
(a) Disconnect wire from hour meter sending unit.
(b) Connect continuity checker between terminal on
sending unit and truck ground.
(c) Run main engine and check for continuity
through hour meter sending unit. If no continuity
is found, replace sending unit. (See para (2) below).
(d) If continuity is found at sending unit; check wiring
to hour meter and hour check meter. (See Wiring
Diagrams, Appendix H).
(2) Removal.
(a) Tag and disconnect wire (1) from hour meter
sending unit (2).
(b) Remove hour meter sending unit (2) from fitting (3).
(3) Installation.
(a) Install hour meter sending unit (2) on fitting (3).
(b) Connect wire (1) to hour meter sending unit (2).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Close engine compartment covers.
4-405
TM 5-4210-233-14&P-1
4-139. ENGINE OIL DIPSTICK ASSEMBLYIFILLER TUBE
THIS TASK COVERS:
a.
Removal
b.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Installation
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Turn two knurled screws (1) counterclockwise and
remove dipstick access door (2) from passenger
side of engine enclosure.
(2) Remove dipstick (3) from dipstick (4).
(3) Loosen nut (5) at end of dipstick guide (4).
(4) Remove nut (6), washer (7), bolt (8) and clamp (9).
(5) Remove dipstick guide (4).
4-406
TM 5-4210-233-14&P-1
4-139. ENGINE OIL DIPSTICK ASSEMBLY/FILLER TUBE - Continued
b. Installation.
(1) Install dipstick guide (4) and secure with nut (5).
(2) Install clamp (9). Secure with bolt (8), washer (7), and nut (6).
(3) Install dipstick (3).
(4) Replace dipstick access cover.
4-407
TM 5-4210-233-14&P-1
4-140. ROCKER ARM COVERS
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers Open
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
a. Removal.
(1) Loosen clamp (1) and remove hose (2) from
breather shell assembly (3).
(2) Remove two bolts (4), two washers (5) and
two mounts (6).
(3) Remove rocker arm cover (7) and gasket (8).
(4) Remove three screws (9), breather retainer (10),
breather element (11), breather element retainer
(12), seal (13) and breather shell assembly (3).
4-408
TM 5-4210-233-14&P-1
4-140. ROCKER ARM COVERS - Continued
(5) Remove three screws (14), strainer (15), seal (16), tube (17), two S hooks (18), chain (19)
and cap (20) from left side rocker cover.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment or
other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138 deg.
F (38 to 59 deg. C).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with com- pressed air, always
use chipguards, eye protection, adn other personal protective
equipment.
(6) Clean strainer (15) and filtering disk (11) with solvent (Item 3, Appendix E) and air dry.
b. Installation.
(1) Install cap (20), chain (19), two S hooks (18), tube (17), seal (16), strainer (15) and three screws (14) in
left side rocker cover.
(2) Install breather retainer (3), seal (13), retainer (12), filtering disk (1 1), retainer (10) and three screws
(9).
(3) Install gasket (8) and cover (7).
(4) Secure cover with two mounts (6), two washers (5) and two bolts (4).
(5) Install hose (2) on breather retainer (3) and tighten clamp (1).
C. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Close engine compartment covers.
4-409
TM 5-4210-233-14&P-1
4-141. RADIATOR HOSES AND PIPING
THIS TASK COVERS:
a.
Replacement
TOOLS REOUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IIl, Item 1)
b.
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Compartment Covers
Removed (see para 4-127.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Tie Straps (Item 33, Appendix E)
Coolant (Item 29, Appendix E)
a. Replacement.
WARNING
Engine coolant can cause severe burns. Allow engine to cool
before attempting to remove any hose or pipe.
(1) Drain cooling system to level required prior to replacing any component (see para 3-6).
(2) Loosen clamps (6) and remove hoses (I thru 5) as necessary. Remove plastic tie straps as required.
(3) Prior to replacement of any fitting, coat pipe threads with pipe sealant (Item 2, Appendix E).
1.
2.
3.
4.
5.
6.
UPPER RADIATOR HOSE
OIL COOLER HOSE
HEATER HOSE
HEATER HOSE
LOWER RADIATOR HOSE
CLAMPS
4-410
TM 5-4210-233-14&p-1
4-141. RADIATOR HOSES AND PIPING - Continued
(4) Install hoses (1 through 5) as necessary. Secure with damps (6).
(5) After installation always ensure there is at least 1 in. (25 mm) clearance between any hose or pipe
and any moving part (eg: fan belt). Replace any plastic tie straps (Item 33, Appendix E) removed in
Step (2).
(6) Fill radiator with coolant (Item 29, Appendix E). Make sure all drain cocks are closed.
(7) Install radiator cap and start engine. Check for leaks as engine warms up.
(8) Stop main engine, and when cool, check radiator level. Add coolant as required.
b. Follow-on Maintenance.
(1) Install engine compartment covers (see para 4-127).
(2) Connect batteries (see para 4-114).
4-411
TM 5-4210-233-14&P-1
4-142. TRANSMISSION
THIS TASK COVERS:
a.
Service
b.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section fi1, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Tie Straps (Item 33, Appendix E)
Transmission Fluid (Item 12, Appendix E)
Filter (Figure 133, Appendix F)
Gasket (Figure 133, Appendix F)
Lint-Free Cloth (Item 42, Appendix E)
a. Service.
(1) Operate vehicle until transmission is warm.
Park vehicle on level surface, apply parking
brake, and shut down engine.
NOTE
Transmission has a capacity of 33 quarts (31.2 1)
(2) Remove drain plug (1) and drain transmission
fluid into suitable container.
NOTE
The transmission filter is located on the passenger
side of the transmission, mounted to a bracket
attached to the passenger side truck frame. It is
the large filter directly behind the two smaller fuel
filters.
(3) Remove transmission filter (2) with filter
wrench. Place a suitable container under filter
for transmission fluid.
4-412
TM 5-4210-233-14&P-1
4-142. TRANSMISSION - Continued
(4) Discard filter (2) in a combustible waste area.
(5) Coat gasket of new filter with clean transmission fluid (Item 12, Appendix E).
(6) Install filter (2) and tighten it to one-half turn beyond gasket contact.
(7) Install drain plug (1) in transmission.
(8) Loosen two knurled screws (3) and remove dipstick access door (4) from passenger side engine
enclosure. Remove transmission dipstick.
(9) Add 33 quarts (31.2 1) of transmission fluid (Item 12, Appendix E) through transmission dipstick tube.
(10)
Install transmission dipstick.
(11)
Place transmission in neutral. Start main engine and allow it to idle.
(12)
Remove transmission dipstick and wipe fluid off with a clean lint-free cloth (Item 42, Appendix E).
(13)
Remove transmission dipstick and check fluid level.
(14)
Reinstall transmission dipstick.
(15)
Add transmission fluid (Item 12, Appendix E) as needed and recheck fluid level.
(16)
Check for leaks. Tighten filter (2) slightly and drain plug (1) as needed.
b. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-413
TM 5-4210-233-14&P-1
4-143. TIRES AND RIMS
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Ladder in Transport Position (see para 2-12.)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B, Section 1II, Item 4)
1 0 Ton Hydraulic Jack
Jack Stands
a. Removal.
WARNING
Wheel and tire are heavy; 257 lb (1 17 kg). To avoid personal
injury, use care when removing.
NOTE
Left-side wheels have left-hand nuts, right-side wheels have
right-hand nuts. Correct nuts must be reinstalled.
(1) Locate 10 ton hydraulic jack beneath axle just inboard of the wheel that is to be removed.
(2) Apply truck parking brake and chock both wheels of other axle.
(3) Raise jack until tire clears ground.
(4) Adjust for proper height and place jack stand beneath axle. Lower jack until jack stand takes weight of
truck. Tire must be clear of ground when axle rests on jack stand. (If not, repeat steps 3 and 4 raising
jack stand by one notch until it is properly adjusted).
(5) Using wheel brace or air operated wrench, remove wheel nuts completely and pull wheel off axle studs.
Take care not to damage stud threads. If necessary to remove inner sheel, remove inner wheel nuts.
(6) Place wheel lift truck beneath wheel and attach safety chain.
b. Installation.
(1) Check all parts for damage. Insure that
studs, nuts and mounting faces of hub
and wheels are sound, clean and free
from grease. Clean hub surface with
wire brush if scale is present. Replace
any damaged parts.
4-414
TM 5-4210-233-14&P-1
4-143. TIRES AND RIMS - Continued
(2) Mount wheel or inner dual wheel over studs.
Adjust height of wheel lift truck, so damage
does not occur to threads on studs.
(3) Snug up nuts alternately in sequence shown.
DO NOT tighten them fully until they have
been seated.
CAUTION
Insufficient mounting torque can allow wheel
movement and breakage at low mileage. Excessive mounting torque can cause stud breakage,
bolt hole chamfer burns and disc cracks in the bolt
hole area.
(4) Tighten nuts fully, using the same alternating
sequence. Torque nuts to 450-500 ft-lbs
(612-680 N.m).
(5) Repeat steps 2-4 for outer dual wheel.
IMPORTANT
After the first 50 to 100 miles (80 to 160 km) of service, recheck
torque on wheel nuts, including inner cap nuts on duals. When
inner cap nuts are retighten, be sure to first loosen outer cap
nuts several turns, tighten inner cap nuts and retighten outer cap
nuts. Reset to recommended torque levels.
(6) Raise truck with hydraulic jack and remove jack stands.
(7) Lower jack until truck is supported on its tires. Remove jack and chocks.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-415
TM 5-4210-233-14&P-1
4-144. FRONT WHEEL HUBS, BEARINGS AND SEALS
THIS TASK COVERS:
a.
Serviceb.
Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Oil, Hypoid 75W/140 (Item 30, Appendix E)
a. Service.
(1) Check the oil level on the clear plastic cap. If oil level is not up to lowest portion of OIL LEVEL line on
the cap, add oil as follows.
(2) Rotate wheel until fill plug (1) is at top of hub.
(3) Remove fill plug (1) and add oil (Item 30, Appendix E) until oil is up to lowest portion of OIL LEVEL line
in plastic cap.
(4) Install plug (1).
b. Follow-on Maintenance.
(1) Connect batteries (see para 4-114.)
4-416
TM 5-4210-233-14&P-1
4-145. PARKING BRAKE CONTROL VALVES
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
All Air Tanks Drained
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
a. Removal.
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Always drain air tanks via the draincocks prior
to maintaining the parking brake valves.
NOTE
The following procedure covers replacement of the PARKING
BRAKE control, the EMERGENCY PARKING BRAKE
RELEASE, and the FRONT WHEEL LOCK control. Remove
and replace components as necessary.
(1) Remove eight screws (1) with washers (1 A) to loosen two panels.
(2) Remove six nuts (2) and six washers (3) and three U-bolts (4) and remove six washers (5) and six nuts
(6) from U-bolts (4).
(3) Remove set screws (7) and control knobs (8).
(4) Tag and disconnect air hoses from brake valves (10).
(5) Remove retaining nuts (9) to remove control valves (10).
(6) Remove all pipe fittings (11) and (12).
(7) Remove parking brake switch (13) and retain.
b. Installation.
(1) Coat all threads with sealant (Item 2, Appendix E). Install fittings (11 and 12) and switch (13)
on valves (10).
(2) Install three control valves (10) to control panels (1 B and 1 C).
(3) Connect air hoses to brake valves (10).
(4) Secure brake valves (10) with retaining nuts (9).
4-417
TM 5-4210-233-14&P-1
4-145. PARKING BRAKE CONTROL VALVES - Continued
4-418
TM 5-4210-233-14&P-1
4-145. PARKING BRAKE CONTROL VALVES - Continued
(5) Install control knobs (8) and secure with setscrews (7).
(6) Install three U-bolts (4) with nuts (6) and washers (5). Secure U-bolts (4) with washers (3) and nuts (2).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine. Allow air tanks to reach full pressure. Use soap solution to check for leaks. No leaks are
allowed. Tighten/remake joints as required.
(3) Refer to Operating Instructions in Chapter 2 and check operation of PARKING BRAKE control,
EMERGENCY PARKING BRAKE RELEASE, and FRONT WHEEL LOCK control.
4-419
TM 5-4210-233-14&P-1
4-146. SLACK ADJUSTER
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
d.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Air Tanks Drained
MATERIALS/PARTS REQUIRED
Cotter Pin (Figure 154, Appendix F)
a. Removal.
(1) Remove cotter pin (1) from clevis pin (2) and
remove pin.
(2) Remove snap-ring (3) and remove slack adjuster
(4) from camshaft (5).
b. Installation.
(1) Install slack adjuster (4) to camshaft (5) and
secure with snap ring (3).
(2) Install clevis pin (2) through slack adjuster (4) and
secure with cotter pin (1).
c.
Adjust
Follow-on Maintenance
Adjust.
(1) Raise wheel off ground.
(2) Depress collar (7) for access to adjusting bolt (6).
(3) Rotate wheel while turning adjusting bolt (6)
clockwise.
(4) Turn adjusting bolt (6) until brake shoes make
contact with brake drum.
(5) Back-off adjusting bolt (6) three clicks.
(6) Seat collar (7) over bolt (6).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine and charge air system.
4-420
TM 5-4210-233-14&P-1
4-147. AIR LINES AND PIPING
THIS TASK COVERS:
a.
b.
Inspectc.
Removal
Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
a. Inspect.
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Always drain the air tank via the drain cocks prior to
maintaining the service brake valve.
NOTE
Refer to locator illustration on following page and air system
schematic in Appendix G for additional information.
(1) Check all fittings for tightness.
(2) Check for leaks with soap and water solution applied to all lines, fittings and components with air
system pressurized. No leakage is allowed.
b. Removal.
(1) Open drain cocks on six air tanks and drain air system.
(2) Loosen nuts on hose fittings as required.
(3) Remove hoses as required.
c.
Installation.
(1) Install hoses.
(2) Tighten fittings.
(3) Start engine and charge air system.
(4) Check for air leaks (see para a.(2) above).
4-421
TM 5-4210-233-14&P-1
4-147. AIR LINES AND PIPING - Continued
4-422
TM 5-4210-233-14&P-1
4-148. IN-LINE SINGLE CHECK VALVES
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section Ill, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
Batteries Disconnected (see para 4-114 .)
All Air Tanks Drained (see para 4-157 .)
a. Removal.
NOTE
There are four in-line check valves located in the brake system.
Refer to air schematics in Appendix G. One check valve is
located on the lower tank on the passenger side of the vehicle
(front service). The valve is in-line on the forward line. Another
check valve is located in-line on the air tank located in the rear
of the truck above the fuel tank (isolated emergency spring
brake release tank) fed by a black pressure line. The other two
are located on the top tank on the driver's side (rear service).
There is one valve in-line on each end of the tank.
NOTE
Refer to the locator view in para 4-147 and the air schematics in
Appendix G.
(1) Note direction of arrow on check valve body to
ensure correct installation.
(2) Tag and disconnect air line at check valve.
(3) Remove check valve.
b. Installation.
(1) Install check valve making certain that it is installed
correctly with respect to the desired air flow. An
arrow indicating the direction of air flow is cast into
the body of the valve.
(2) Install air line.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for leaks as described in para 4-147 .
4-423
TM 5-4210-233-14&P-1
4-149. DOUBLE CHECK VALVES
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
Batteries Disconnected (see para 4-114 .)
All Air tanks Drained (see para 4-157 .)
a. Removal.
NOTE
One double check valve (DC-4) is mounted on the center of the
first crossmember ahead of the front rear tandem. One doublecheck valve (DC-4) is located on the relay valve (R-12) between
the axles on the left-hand side of the truck.
NOTE
Refer to locator view in para 4-147 and air schematics in
Appendix G for additional information.
(1) Block vehicle wheels or hold by means other than vehicle service brakes.
(2) Tag and disconnect air lines. Remove mounting bolt and remove the double check valve.
b. Installation.
(1) Install double check valve with mounting bolt.
(2) Connect air lines to double check valve.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for air leaks (see para 4-147).
4-424
TM 5-4210-233-14&P-1
4-150. QUICK RELEASE VALVES (QR-1)
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
All Air Tanks Drained (see para 4-157 .)
a. Removal.
NOTE
There are three quick release valves in the brake system. One is
located in-line on the passenger side above the differential of the
forward tandem axle. Another is located in-line on the driver's
side above the differential of the rear tandem axle. The third is
mounted in the center of the first frame crossmem- ber ahead of
the front axle.
NOTE
Refer to locator view in para 4-147 and air schematics in
Appendix G for additional information.
(1) Tag and disconnect air lines from quick release valve.
(2) Remove two mounting bolts and remove valve.
b. Installation.
(1) Mount quick release valve with exhaust port pointing down.
(2) Install mounting bolts.
(3) Reconnect air lines as identified during removal.
c
Follow-on Maintenance.
(1) Connect batteries
(see para 4-114).
(2) Check for leakage as
described in para 4-147).
4-425
TM 5-4210-233-14&P-1
4-151. BRAKE PEDAL VALVE
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lll, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Truck Wheels Blocked
All Air Tanks Drained
a. Removal.
NOTE
The brake pedal valve is located under the dash panel and next
to the steering column. Refer to air system schematic in
Appendix G for additional information.
(1) Remove four nuts (1), four lockwashers (2), eight washers (3) and four screws (4).
(2) Tag and disconnect air lines and wiring
on brake pedal valve.
(3) Note location and position of fittings
and pressure switches on brake pedal
valve and remove.
(4) Remove three screws (5), intemal
tooth lockwashers (6) and washers (7).
Remove mounting plate (8).
4-426
TM 5-4210-233-14&P-1
4-151. BRAKE PEDAL VALVE - Continued
b. Installation.
(1) Install mounting plate (8) on brake pedal valve and secure with three washers (7), internal tooth
lockwashers (6) and screws(5).
(2) Install fittings and pressure switches on brake pedal valve.
(3) Connect air lines and wiring to brake pedal valve.
(4) Secure brake pedal valve and mounting bracket (8) with four screws (4), eight washers (3), four
lockwashers (2) and four nuts (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Charge air system and check for air leaks.
4-427
TM 5-4210-233-14&P-1
4-152. SAFETY VALVE
THIS TASK COVERS:
a.
b.
Removal and Replacement
Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section ll, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
Batteries Disconnected (see para 4-114 .)
All Air Tanks Drained (see para 4-157 .)
a. Removal and Replacement.
NOTE
Safety valve is located in the top passenger side air tank. Refer
to locator view in para 4-147 and air system schematic in
Appendix G for additional information.
(1) Unscrew safety valve from tank and install new safety valve. Tighten securely.
b. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for air leaks as described in para 4-147 .
4-428
TM 5-4210-233-14&P-1
4-153. PRESSURE PROTECTION VALVES
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section Ill, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
Batteries Disconnected (see para 4-114 .)
All Air Tanks Drained (see para 4-157 .)
a. Removal.
NOTE
There are five pressure protection valves located within the air
brake system. Three are located on the top passenger side
tank. One valve is located on the bottom air tank on the
driver's side. The fifth valve is located on the air tank located
on the rear of the truck above the fuel tank.
NOTE
Refer to locator view in para 4-147 and the air schematics in
Appendix G for additional information.
(1) Tag and disconnect the air lines leading to
and from the pressure protection valve.
(2) Remove the mounting bolts, that secure the
valve.
b. Installation.
NOTE
Check psi rating of valve being replaced. Replace
valve with new valve of equal psi rating only.
(1) Reinstall the mounting bolts and secure the
replacement valve to the vehicle.
(2) Reconnect the air lines to the pressure
protection valves.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for air leaks as described in para 4-147).
4-429
TM 5-4210-233-14&P-1
4-154. R-12 RELAY VALVES
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Too[ Kit, General Mechanics, Automotive
(Appendix B, Section IIl, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
Batteries Disconnected (see para 4-114 .)
All Air Tanks Drained (see para 4-157 .)
a. Removal.
NOTE
There are two R-12 relay valves. They are located
on the inside of each frame rail between the tandem axles.
Refer to the locator view in para 4-147 and the air
schematics in Appendix G for additional information.
(1) Tag and disconnect air lines from relay valve.
(2) Remove two mounting bolts and remove valve.
b. Installation.
(1) Install valve and install two bolts.
(2) Connect air lines to valve.
c.
Follow-on Maintenance
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for leaks as described in para 4-147 .
4-430
TM 5-4210-233-14&P-1
4-155. D2 GOVERNOR
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
Batteries Disconnected (see para 4-114 .)
Truck Wheels Blocked
All Air Tanks Drained (see para 4-157 .)
Engine Compartment Doors Open
MATERIALS/PARTS REOUIRED
Gasket (Figure 87, Appendix F)
a. Removal.
NOTE
The D-2 Governor is located on the air compressor on the engine.
(1) Tag and disconnect reservoir air line.
(2) Remove governor mounting bolts and
remove governor and gasket. Discard gasket.
(3) Clean the mounting surfaces on both the
compressor and governor.
(4) Clean connecting line or lines. Be certain the
unloading port is clear and clean.
b. Installation.
(1) Install governor and new gasket and secure
with mounting bolts.
(2) Connect air line to governor.
c.
Follow-on Maintenance
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for leaks as described in 4-147 .
4-431
TM 5-4210-233-14&P-1
4-156. SR-1 SPRING BRAKE VALVE
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
Batteries Disconnected (see para 4-114 .)
All Air Tanks Drained (see para 4-157 .)
a. Removal.
NOTE
The SR-1 spring brake valve is located on the passenger side
on the frame in front of and above the forward tandem
differential. Refer to locator view in para 4-147 air system
schematic in Appendix G for additional information.
(1) Prior to removing the spring brake valve, apply
the parking brakes and drain all the vehicle
air tanks.
(2) Identify all air lines before disconnecting.
(3) Remove the two mounting bolts from the
spring brake valve and remove the valve.
b. Installation.
(1) Install the spring brake valve and fasten with
two mounting bolts.
(2) Install air lines.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for leaks as described in para 4-147 .
4-432
TM 5-4210-233-14&P-1
4-157. AIR TANKS
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lII, Item 1)
Pipe Sealant (Item 2, Appendix E)
Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Air Tanks Drained
a. Removal.
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Always drain the air tanks via the draincocks
prior to removal.
NOTE
Refer to locator view in para 4-147 and air, schematics in
Appendix G for additional information.
This is a generalized procedure for removal of any (of six)
air tanks.
(1) Tag and remove all hoses connected to the
air tank being removed. Do not remove any
fittings or valves while tank is installed on
the truck.
(2) Remove two capscrews (1), washers (5),
and nuts (6).
(3) Remove capscrews (2) and nuts (4) and remove
support clamps (3) at each end of the tank.
(4) Slide the tank from and remove tank from
the truck.
(5) Note location and position of all fittings and
valves and remove from tank.
4-433
TM 5-4210-233-14&P-1
4-157. AIR TANKS - Continued
b. Installation.
(1) Coat all pipe threads with pipe sealant (Item 2, Appendix E) and n
i stall valves and fittings as noted
during removal procedure.
(2) Slide air tank into position. Be sure air tank draincock is at the lowest point.
(3) Install clamps (3) on frame and secure with capscrews (2) and nuts (4).
(4) Install capscrews (1), washers (5), and nuts (6). Tighten securely.
(5) Coat all pipe threads with pipe sealant (Item 2, Appendix E) and install air lines.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check for leaks as described in para 4-147.
4-434
TM 5-4210-233-14&P-1
4-158. STEERING WHEEL
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS REQUIRED
Threadlock Liquid (Item 7, Appendix E)
a. Removal.
(1) Place a piece of tape on the steering wheel
ring and on instrument panel to serve as
alignment marks at installation.
(2) Remove horn button (1).
(3) Remove steering wheel nut (2).
(4) Using a suitable puller, remove steering
wheel (3) from shaft (4).
b. Installation.
(1) Position steering wheel (3) on shaft (4)
making sure the wheel is properly aligned.
(2) Apply Threadlock liquid (Item 7, Appendix E)
to steering wheel nut (2). Install nut and
torque to 70 ft lb (95 N.m).
(3) Install horn button (1).
c.
Follow-on Maintenance
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-435
TM 5-4210-233-14&P-1
4-159. STEERING COLUMN
TASK COVERS:
a.
b.
Removal
Installation
c
Follow-on Maintenance
TOOLS REOUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Steering Wheel Removed (see para 4-158 .)
MATERIALS REQUIRED
Threadlock Liquid (Item 7, Appendix E)
a. Removal.
(1) Tag and disconnect steering column wiring
harness under dash.
(2) Remove bolt (1), washer (2), and nut (3) from
bottom of steering column (4).
(3) Remove four bolts (5), four washers (6), and
four nuts (7) from steering column clamp (8).
(4) Remove clamp (8) steering column (4) and spacer (9).
(5) Slide steering column boot (10) from steering
column (4).
b. Installation.
(1) Slide steering column boot (10) onto steering
column (4).
(2) Install steering column (4) on spline shaft
beneath floor.
(3) Secure column with bolt (1), washer (2) and
nut (3). Torque bolt (1) to 35 ft lb (48 N.m).
(4) Secure column (4) to dash with steering column
spacer (9), steering column clamp (8), four
bolts (5), four washers (6) and four nuts (7).
(5) Slide boot (10) over tube on cab floor.
(6) Connect steering column wiring harness under dash.
c.
Follow-on Maintenance.
(1) Install steering wheel (see para 4-158.).
(2) Connect batteries (see para 4-114).
4-436
TM 5-4210-233-14&P-1
4-160. STEERING SHAFT
THIS TASK COVERS:
a.
b.
Removal
Installation
c.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS REQUIRED
Antiseize Compound (Item 4, Appendix E)
a. Removal.
(1) Loosen two nuts (1) on bolts (1A) in steering
shaft U-joints (2).
(2) Slide steering shaft (3) toward steering gear
(4) until disengaged from miter box shaft (5).
(3) Pull steering shaft (3) from steering gear shaft (6).
b. Installation.
(1) Coat miter box shaft (5) and steering gear
shaft (6) with antiseize compound (Item 4,
Appendix E).
(2) Slide steering shaft (3) onto steering gear
shaft (6). Tighten nut (1) on U-joint (2) at
steering gear to a torque of 35 ft lb (48 N.m).
(3) Slide steering shaft U joint (2) onto miter box shaft (5).
(4) Torque nut (1) to 35 ft lb (48 N.m).
c.
Follow-on Maintenance
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-437
TM 5-4210-233-14&P-1
4-161. POWER STEERING GEAR
THIS TASK COVERS:
a.
b.
Removal
installation
c.
TOOLS REOUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Follow-on Maintenance
EOUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS
Tag, Identification (Item 32, Appendix E)
a. Removal.
WARNING
To prevent fire hazards collect residual fluid and
clean up spills immediately when disassembling
power steering components.
CAUTION
Pump or steering gear failure due to contamination
may occur unless strict cleanliness and protective
measures are taken when disassembling and assembling power steering components.
(1) Tag and disconnect two hoses (1) and (2) from
fittings (3) and (4).
(2) Drain steering fluid into suitable container.
(3) Cap hoses (1) and (2) and steering gear
fittings (3) and (4) to protect components from
contamination.
4-438
TM 5-4210-233-14&P-1
4-161. POWER STEERING GEAR - Continued
(4) Remove pitman arm nut (5) and bolt (6).
(5) Make timing marks on pitman arm (7) and sector shaft (8).
NOTE
A chisel will help you loosen the pitman arm. Use only a puller if you cannot
remove the pitman arm with your hands.
(6) Remove pitman arm (7).
(7) Loosen nut (9) on bolt (9A) and disconnect steering shaft (10) from steering gear (11).
(8) Remove six bolts (12) and six washers (13) securing steering gear to frame and remove
steering gear (11).
b. Installation.
(1) Secure steering gear (l1) to frame with six washers (13) and six bolts (12).
(2) Connect steering shaft (10) to steering gear (11) and tighten nut (9) to 35 ft lb (48 N•m).
(3) Install pitman arm (7) on sector shaft (8) making sure timing marks are aligned.
(4) Install bolt (6) and pitman arm nut (5).
(5) Torque bolt (6) to 300-320 ft. Ibs. (407-434 N•m).
(6) Connect hoses (1 and 2) to proper fittings (3 and 4) on steering gear (11).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Bleed air from steering system (see para 4-162).
4-439
TM 5-4210-233-14&P-1
4-162. POWER STEERING RESERVOIR
THIS TASK COVERS:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
O-ring (Figure 156, Appendix F)
Pipe Sealant (Item 2, Appendix E)
Fluid, Power Steering (Item 21, Appendix E)
a.
Removal.
WARNING
To prevent five hazards, collect residual fluid and clean up any spills immediately
when disassembling power steering components.
CAUTION
Pump or steering gear failure due to contamination may occur unless strict
cleanliness and protective measures are taken when disassembling and
assembling power steering components.
(1) Tag and disconnect hoses (1) and (2). Drain
steering fluid into a suitable container.
Reservoir contains about 6 quarts (5.7 1) of oil.
(2) Remove four bolts (3), four flatwashers (4),
lockwashers (5), and nuts (6) from two
brackets (7).
(3) Remove two screws (8) and two nuts (9)
from brackets (7). Remove reservoir(10).
(4) Remove fittings (1 1 and 12) and O-ring (13)
from reservoir (1 1). Discard O-ring (13).
4-440
TM 5-4210233-14&P-1
4-162. POWER STEERING RESERVOIR - Continued
b.
Installation.
(1) Install new O-ring (13) onfitting (12).
(2) Apply pipe sealant (Item 2, Appendix E) to fitting (11) threads and install fitting in reservoir (10).
(3) Position reservoir (10) and two brackets (7) as shown.
(4) Install brackets (7) on reservoir (10). Secure with two screws (8) and nuts (9).
(5) Install reservoir (10) and brackets (7). Secure with four bolts (3), four flatwashers (4), four lockwashers
(5) and four nuts (6).
(6) Install hoses (1 and 2).
(7) Add fluid (Item 21, Appendix E) to reservoir (see para 3-8.).
c.
Follow-on Maintenance.
(1) Connect Batteries (see para 4-114).
(2) Start engine and check hose connections for leaks. Tighten fittings as necessary.
(3) Turn steering wheel fully right and fully left to bleed air from steering system. After a couple of turns
the steering motion should become smooth.
(4) Stop the engine and check the reservoir dipstick. Top off the reservoir as required.
4-441
TM 5-4210-233-14&P-1
4-163. U-BOLTS
THIS TASK COVERS:
a. Replacement
b. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Truck wheel Removed (see para 4-143.)
Shock Absorber Removed (see para 4-164.)
Replacement.
NOTE
U-bolts are located on the front axle leaf springs.
(1) Support front axle on jack. Raise jack until it
just touches the axle.
(2) Remove four nuts (1) and four washers (2).
(3) Remove two U-bolts (3) from spring (4) and
frame stop (5).
(4) Install new U-bolts (3) on frame stop (5) and
spring (4).
(5) Secure U-bolts with four nuts (1) and four
washers (2).
(6) Remove jack from axle.
b.
Follow-on Maintenance.
(1) Install shock absorber (see para 4-164).
(2) Install wheel (see para 4-143).
(3) Connect banteries (see para 4-114).
4-442
TM 5-4210-233-14&P-1
4-164.SHOCK ABSORBERS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Removal.
(1) Remove two nuts (1) and washers (2 and 3)
from ends of shock absorber (4).
(2) Remove shock absorber (4).
b.
Installation.
(1) Install new shock absorber (4).
(2) Secure shock absorber (4) with two washers
(2 and 3) and two nuts (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-443
TM 5-4210-233-14&P-1
4-165.REAR AXLE ASSEMBLIES
THIS TASK COVERS:
a. Service
b. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Batteries Disconnected (see para 4-114.)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
MATERIALS/PARTS REQUIRED
Hypoid Gear Oil GL-5 SAE 75 W/140,
Item 30, Appendix E
Breather (Figure 164, Appendix F)
a.
Service.
(1) Remove carrier fill plug (1).
NOTE
Rear axle has a capacity of 29 pints (13.7 1).
(2) Remove drain plug (2) and drain gear oil into
suitable container.
(3) Remove and discard breather (3).
(4) Install drain plug (2).
(5) Fill axle with hypoid gear oil GL-5 S.A.E.
75W/140 (Item 30, Appendix E) until it flows
from fill hole.
(6) Install carrier fill plug (1).
(7) Install new breather (3).
b.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-444
TM 5-4210-233-14&P-1
4-166. EXHAUST PIPE CLAMPS AND HANGERS
THIS TASK COVERS:
a.
b.
c.
d.
Replacement of Clamps A and Hanger A
Replacement of Clamp B
Replacement of Clamps and Hangers C
Cleaning and Inspection
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
e. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS
Dry Cleaning Solvent (Item 3, Appendix E)
WARNING
The exhaust pipe and muffler can become very hot during vehicle operation. Be
careful not to touch these parts with bare hands, or allow body to come in contact
with pipe or muffler. Exhaust system parts can become hot enough to cause
serious burns.
a.
Replacement of Clamps A and Hanger A
(1) Support exhaust system while replacing clamps and hangers.
(2) Remove two nuts (1) and washers (2) from U-bolt (3), and remove U-bolt (3) from clamp (4).
(3) Remove nut (5), four washers (6) and two springs (7) from stud of clamp (4) andremove clamp (4)
from bracket (8).
(4) Refer to para d. below for cleaning and inspection instructions.
(5) Install two washers (6) and one spring (7) on stud of clamp (4). Insert stud of clamp (4) through bracket
(8) on truck frame.
(6) Install two washers (6), one spring (7) and nut (5) on stud of clamp (4). Tighten nut (5) until
approximately 1/2" of threads are showing above nut (5).
(7) Place U-bolt (3) in clamp (4) and secure with two nuts (1) and washers (2).
4-445
TM 5-4210-233-14&P-1
4-166. EXHAUST PIPE CLAMPS AND HANGERS - Continued
4-446
TM 5-4210-233-14&P-1
4-166. EXHAUST PIPE CLAMPS AND HANGERS - Continued
b.
Replacement of clamp "B"
(1) Support exhaust system while replacing clamps and hangers.
(2) Remove two nuts (9), washers (10), U-bolt (11) and clamp (12).
(3) Refer to para d. below for cleaning and inspection instructions.
(4) Install clamp (12) and U-bolt (11) and secure with two nuts (9) and washers (10).
c.
Replacement of clamps and hangers "C".
(1) Support exhaust system while replacing clamps and hangers.
(2) Remove nut (13), lockwasher (14), flatwasher (15) and screw (16). Remove band (17) from bracket
(18).
(3) Remove nut (19), four washers (20), two springs (21) and bracket (18) from bracket (22).
(4) Remove two nuts (23), lockwashers (24), flatwashers (25) and screws (26). Remove bracket (18) from
truck frame.
(5) Refer to para d. below for cleaning and inspection instructions.
(6) Position bracket (22) on truck frame and secure with two screws (26), flatwashers (25), lockwashers
(24) and nuts (23).
(7) Install two washers (20) and spring (21) on stud of bracket (18). Insert stud of bracket (18) through
bracket (22) and install two washers (20), spring (21) and nut (19). Tighten nut (19) until approximately
1/2" of threads is showing above nut (19).
(8) Install band (17) on muffler and align band (17) with bracket (18). Secure band (17) to bracket (18)
with screw (16), flatwasher (15), lockwasher (14) and nut (13).
4-447
TM 5-4210-233-14&P-1
4-166. EXHAUST PIPE CLAMPS AND HANGERS - Continued
d.
Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid repeated and
prolonged breathing of vapors and skin contact with liquid. Do not use near open
flame, arcing equipment or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 1 00 to 138 deg. F (38 to 59 deg.
C).
(1) Clean all items in dry cleaning solvent (Item 3, Appendix E).
(2) Inspect brackets and clamps for bent or cracked condition. Replace any damaged brackets or clamps.
(3) Inspect all screws, U-bolts and threaded studs for bent condition or damaged threads. Replace
damaged screws, U-bolts or studs.
(4) Inspect springs for cracked, broken or bent condition. Replace damaged springs.
e.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-448
TM 5-4210-233-14&P-1
4-167. FUEL LINES AND PIPING
THIS TASK COVERS:
a. Removal
b. Inspection
c. Installation
d. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Teflon Tape (Item 58, Appendix E)
WARNING
Fuel is very flammable and can explode easily. To avoid serious injury or death,
keep fuel away from open fire and keep fire extinguisher within easy reach when
working with fuel. Do not work on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel, post signs that read NO SMOKING
WITHIN 50 FEET OF VEHICLE.
a.
Removal.
NOTE
When disconnecting fuel lines, always place a pan beneath the disconnection point.
Be sure to catch all fuel.
(1) If leakage is detected, tighten connections and check for leaks when engine is running anduel
f
system is pressurized. No leaks are allowed.
(2) Tag all fuel lines before disconnecting. Note location and position of all fittings and elbows before
removal.
(3) Disconnect or remove fittings (1, 6, 7, 8 and 9), hoses (3 and 11), and elbows (4, 5, 12 and 13).
(4) Remove hose ends (2 and 10) from hoses (3 and 11) if needed.
b.
Inspection.
(1) Inspect all fittings, elbows and hose ends for stripped threads or damaged condition. Replace as
required.
(2) Inspect all hoses for leaks, cuts or damaged condition.
c.
Installation.
(1) Install hose ends (2 and 10) in hoses (3 and 11).
(2) Use teflon tape (Item 58, Appendix E) on all fuel system connections.
(3) install fittings (1, 6, 7,8 and 9), elbows (4, 5, 12 and 13) and hoses (3 and 11) as required.
4-449
TM 5-4210-233-14&P-1
4-167. FUEL LINES AND PIPING - Continued
d.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-450
TM 5-4210-233-14&P-1
4-168. FUEL TANK SENDING UNITS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Fuel Tank Removed (see para 4-169.)
MATERIALSIPARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Gasket (Figure 167, Appendix F)
Tags, Identification (Item 32, Appendix E)
a. Removal.
WARNING
Fuel is very flammable and can explode
easily. To avoid serious injury or death,
keep fuel away from open fire and keep
fire extinguisher within easy reach when
working with fuel. Do not work on fuel
system when engine is hot. Fuel can be
ignited by hot engine. When working
with fuel, post signs that read NO
SMOKING WITHIN 50 FEET of vehicle.
(1) Tag and disconnect leads from sending unit (2).
(2) Remove five screws (1) from fuel tank sending
unit (2).
NOTE
Two fuel tank sending units are identical
and use same procedure.
(3) Remove fuel tank sending unit (2) and gasket (3).
b.
Installation.
(1) Install new gasket (3) on fuel tank sending unit (2).
(2) Install fuel tank sending unit (2) and gasket (3)
and secure with five screws (1).
(3) Connect leads to sending unit (2).
c.
Follow-on Maintenance.
(1) Install fuel tank (see para 4-169.).
(2) Connect batteries (see para 4-114).
4-451
TM 5-4210-233-14&P-1
4-169. FUEL TANK AND MOUNTING BRACKETS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REOUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Tags, Identification (Item 32, Appendix E)
Fuel Oil (Item 41, Appendix E)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Removal.
WARNING
JP-4 is an alternate fuel for this truck. JP-4 is a
highly volatile fuel. Extraordinary care must be
taken when servicing components that use this
fuel. The truck must be grounded to an approved
grounding point if it contains JP-4 fuel.
WARNING
Fuel is very flammable and can explode easily.
To avoid serious injury or death, keep fuel away
from open fire and keep fire extinguisher within
easy reach when working with fuel. Do not work
on fuel system when engine is hot. Fuel can be
ignited by hot engine. When working with fuel,
post signs that read NO SMOKING WITHIN 50
FEET of vehicle.
(1) Place suitable container underneath fuel
tank drain.
(2) Remove fuel tank drain plug (1) and filler
cap (2) and drain all fuel from tank into a
suitable container. Fuel tank capacity is
65 gal. (246 1).
(3) Loosen clamp (3) and disconnect fuel inlet
hose (4).
(4) Place suitable support device under fuel tank.
(5) Remove four hex nuts (5) and remove fuel tan
mounting straps (6) with rubber pads (6A).
(6) Lower fuel tank (7) from truck. Tag and
disconnect leads from two fuel level senders (8).
(7) Tag and disconnect hoses (9, 10, 11 and 12).
4-452
TM 5-4210-233-14&P-1
4-169. FUEL TANK AND MOUNTING BRACKETS - Continued
b.
Installation.
(1) Connect fuel level sender leads to two fuel level senders (8) and remove tags.
(2) Connect hoses (9, 10, 11 and 12) to fuel tank and remove tags..
(3) Position fuel tank (7) and fuel tank mounting straps (6) with rubber pads (6A).
(4) Secure fuel tank mounting straps (6) with four hex nuts (5).
(5) Connect fuel inlet hose (4) to fuel tank (7).
(6) Secure inlet hose with clamp (3).
(7) Install filter caps (2) and fuel tank drain plug (1).
c.
Follow-on Maintenance.
(1) Fill Tank.
(2) Connect batteries (see para 4-114).
4-453
TM 5-4210-233-14&P-1
4-170. FRONT BUMPER
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALSIPARTS REQUIRED
Penetrating Oil, Item 8, Appendix E
a.
Removal.
WARNING
Serious injury could occur if heavy equipment is moved/lifted without sufficient
personnel to do the job. Use proper physical lifting procedures or use a suitable
lifting device or dolly. Wear safety shoes, gloves and other suitable protective
clothing. Area should be clear of other personnel. Serious injury or death can
result from falling objects.
NOTE
If the bumper fasteners are excessively corroded, apply penetrating oil (Item 8,
Appendix E) to ease disassembly.
(1) Remove four screws (1), four flat washers (2), four lockwashers (3) and four hex nuts (4).
(2) Remove eight bolts (5), eight nylon washers (6), eight flatwashers (6A), eight lockwashers (6B) and
eight hex nuts (7) from bumper (8).
(3) Remove bumper (8).
4-454
TM 5-4210-233-14&P-1
4-170. FRONT BUMPER - Continued
b.
Installation.
(1) Align bumper (8) with bumper extension (9).
(2) Secure bumper with eight bolts (5), eight nylon washers (6), eight flatwashers (6A), eight
lockwashers (6B) and eight hex nuts (7).
(3) Torque bolts (5) to 400 lb ft (542 N•m).
(4) Install four screws (1), four flat washers (2) four lockwashers (3) and four hex nuts (4).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-455
TM 5-4210-233-14&P-1
4-171.TOW HOOKS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Removal.
(1) Remove bolt (1), lockwasher (2) and
flatwasher (3).
(2) Remove bolt (4), lockwasher (5), and
flatwasher (6).
(3) Remove tow hook (7) from bumper.
b.
Installation.
(1) Position tow hook (7) on bumper.
(2) Install flatwasher (6) lockwasher (5),
and bolt (4).
(3) Install flatwasher (3), lockwasher (2),
and bolt (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-456
TM 5-4210-233-14&P-1
4-172. WHEEL CHOCK BRACKETS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Removal.
(1) Remove wheel chock (1) from bracket (2).
(2) Remove six capscrews (3), six
flatwashers (4), six lockwashers (5), and
six nuts (6).
(3) Remove brackets (2).
(4) Repeat procedure for three remaining
brackets.
b.
Installation.
(1) Secure bracket (2) to truck with six
capscrews (3), six flatwashers (4), six
lockwashers (4), and six nuts (5).
(2) Install wheel chock (1) in bracket (2).
(3) Repeat procedure for three remaining
brackets.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-457
TM 5-4210-233-14&P-1
4-173. LADDER TREADS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
a.
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Removal.
(1) Remove 2 screws (1).
(2) Remove fastener (2).
(3) Remove treads (3).
b.
Installation.
(1) Install new treads (3).
(2) Install fastener (2).
(3) Install and tighten two screws (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-458
TM 5-4210-233-14&P-1
4-174. SAFETY RAILINGS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 111, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Penetrating Oil (Item 8, Appendix E)
NOTE
All three railings are attached with the same attaching parts and same
removal and installation procedures are used for each.
a. Removal.
(1) Unclip safety chain snap (1) to remove
safety chain (2) from eyebolt (14) in
platform handrail (3) being removed.
(2) Loosen two nuts (4) which attach
handrail (3) to platform. Unscrew nuts
until they are flush with ends of handrail studs.
4-459
TM 5-4210-233-14&P-1
4-174. SAFETY RAILINGS - Continued
(3) Apply penetrating oil (Item 8, Appendix E) to handrail ends where they enter handrail base plates
(5) to ease removal.
(4) Strike nuts (4) at ends of handrail studs firmly with a lead hammer to dislodge handrail (3) from
platform. Shake and twist handrail (3) to loosen it from platform. Remove two nuts (4) and
flatwasher (6). Pull handrail (3) up and out of platform.
(5) Remove two each capscrews (8), flatwashers (9), hex nuts (10) and lockwashers (11) to remove
handrail base plates (5) from platforms.
(6) Remove locknut (12) and flatwasher (13) to withdraw eyebolt (14) from handrail (3).
b. Installation.
(1) Slide two handrail base plates (5) onto ends of handrail (3).
(2) Lubricate ends of handrail (3) to ease installation into platform.
(3) Shake and twist handrail (3) to insert it into platform until it seats.
(4) Attach handrail (3) to platform with two hex nuts (4), and flatwashers (6). Torque two nuts (4) to
150 ft Ibs (204 N·m).
(5) Position two handrail base plates (5) and attach to platform with two each screws (8), flatwashers
(9) lockwashers (1 1), and nuts (10). Torque to eight ft Ibs (11 N·m).
(6) Attach eye bolt (14) to handrail with flat washer (13) and locknut (12).
(7) Clip safety chain clip (1) of safety chain (2) to eyebolt (14) in handrail (3).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-460
TM 5-4210-233-14&P-1
4-175. OUTRIGGER WARNING LIGHTS
THIS TASK COVERS:
a.
b.
c.
d.
e.
Removal/Disassembly Outside Light
Installation/Assembly Outside Light
Removal/Disassembly Inside Light
Installation/Assembly Inside Light
Follow-on Maintenance.
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Outriggers Extended (see para 2-14.)
MATERIALS/PARTS REQUIRED
Butt Splice (Item 27, Appendix E)
a. Removal/Disassembly Outside Light
(1) Remove three screws (1) to remove
lens (2) and gasket (3) to gain access to
bulb (4). Remove bulb.
(2) To remove fixture (5) remove three
screws (6) and cut wires (7). Tag wires.
b. Installation/Assembly Outside Light
(1) Install fixture (5) (if removed) by connecting wires (7) with butt splice (Item 27, Appendix E) and
securing fixture (5) with three screws (6).
(2) Install bulb (4).
(3) Install lens (2) and gasket (3) with three screws (1).
c.
Removal/Disassembly Inside Light
(1) Remove three screws (1) on either side of fixture (2) to remove lens (3) and gaskets (4) to gain
access to bulbs (5). Remove bulbs.
(2) To remove fixture (2) remove nut (6) and cut wires (7). Tag wires for assembly.
4-461
TM 5-4210-233-14&P-1
4-175. OUTRIGGER WARNING LIGHTS - Continued
d. Installation/Assembly Inside Light
(1) Install fixture (2) (if removed) by connecting wires (7) with butt splice (Item 27, Appendix E) and
securing fixture (2) with nut (6).
(2) Install bulb (5).
(3) Install lens (3) and gasket (4) on either side with 3 screws (1).
e. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of lights.
(3) Retract outriggers (see para 2-14).
4-462
TM 5-4210-233-14&P-1
4-176. OUTRIGGER COMPARTMENT LIGHTS
THIS TASK COVERS:
a. Removal
b. Cleaning and Inspection
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
c. Installation
e. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown 2-16.)
Batteries Disconnected (see para 4-114.)
Outriggers Extended (see para 2-14.)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
Butt Splice (Item 27, Appendix E)
Gasket (Fig. 193, Appendix F)
a. Removal.
(1) Remove lens retainer (1), lens (2) and gasket
(3).
(2) Remove bulb (4).
(3) Remove three screws (5) and remove
reflector (6) from bracket (7).
(4) Tag and disconnect wiring harness by cutting
near butt splice (8).
(5) Remove reflector (6).
b. Cleaning and Inspection.
(1) Clean lens (2) and reflector (6).
(2) Inspect lens for cracks. If cracked, replace
lens.
(3) Inspect for broken or cracked reflector. If
reflector is damaged, replace light assembly.
(4) Inspect wiring for fraying or cracked
insulation. If wiring is damaged, contact
Direct Support Maintenance.
(5) Inspect bulb socket, bulb contacts, and wiring
for corrosion. Clean corrosion with emery
cloth (Item 25, Appendix E). If corrosion
cannot be removed, replace light assembly.
4-463
TM 5-4210-233-14&P-1
4-176. OUTRIGGER COMPARTMENT LIGHTS - Continued
c.
Installation.
(1) Connect wiring with new butt splice connector (Item 27, Appendix E).
(2) Install reflector (6) on bracket (7) and secure with three screws (5).
(3) Install bulb (4).
(4) Install gasket (3) and lens (2) and secure with retainer (1).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of light.
(3) Retract outriggers (see para 2-14).
4-464
TM 5-4210-233-14&P-1
4-177. AERIAL LADDER SPOT/FLOOD LIGHTS
THIS TASK COVERS:
a. Repair
b. Replacement
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IIl, Item 1)
EOUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Repair.
(1) Remove retaining ring (1) to remove end
cap with spring and O-ring.
(2) Remove lens ring (2) and lens (3).
(3) Remove bulb(s).
(4) Remove bulb mounts and reflector.
(5) Remove switch (4).
(6) Replace damaged or defective parts.
(7) Install switch (4).
(8) Install reflector and bulb mounts.
(9) Install bulbs.
(10)Install lens (3) and lens ring (2).
(11)Install end cap with spring and O-ring
and retain with retaining ring (1).
b. Replacement.
(1) Disconnect wiring harness.
(2) Remove four screws (5), four nuts (6) and spotflood light (7) from mounting bracket (8).
(3) Remove gasket (9) from mounting bracket (8).
(4) Install gasket (9) and spot/flood light (7).
(5) Secure spot/flood light with four screws (5) and four nuts (6).
(6) Connect wiring harness.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114.)
(2) Test lights.
4-465
TM 5-4210-233-14&P-1
4-178. OUTRIGGER AND AERIAL CONTROL PANEL INDICATOR LIGHTS
THIS TASK COVERS:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Emery Cloth (Item 25, Appendix E)
O-ring (Figure 199, Appendix F)
a. Removal.
(1) Tag and disconnect wires.
(2) Remove nut (1) and lockwasher (2).
(3) Remove light assembly.
b. Disassembly.
(1) Unthread and remove lens (3) and O-ring (4).
Discard O-ring (4).
(2) Remove bulb (5).
c.
Cleaning and Inspection.
(1) Clean lens (3).
(2) Inspect lens (3) for cracks. If cracked, replace lens.
(3) Inspect wiring for fraying or cracked insulation.
If wiring is damaged, contact Direct Support
Maintenance.
(4) Inspect bulb socket (6), bulb contacts, and wiring
for corrosion. Clean corrosion with emery cloth
(Item 25, Appendix E). If corrosion cannot be
removed, replace light assembly.
d. Assembly.
(1) Install bulb (5).
(2) Install O-ring (4).
(3) Install lens (3).
4-466
TM 5-4210-233-14&P-1
4-178. OUTRIGGER AND AERIAL CONTROL PANEL INDICATOR LIGHTS - Continued
e. Installation.
(1) Install light assembly.
(2) Fasten light assembly in place with lockwasher (2) and nut (1).
(3) Connect wires and remove tags.
f.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-467
TM 5-4210-233-14&P-1
4-179. OUTRIGGER AND AERIAL CONTROL PANEL TOGGLE SWITCHES
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Tags, Identification (Item 32, Appendix E)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove boot (1), nut (2) and lockwasher(3).
(2) Tag wires and remove from screws (4).
(3) Remove switch (5).
b. Installation.
(1) Install wiring harness to switch with screws (4).
(2) Secure switch (5) to panel with nut (2) and
lockwasher (3). Install boot (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of switch.
4-468
TM 5-4210-233-14&P-1
4-180. LADDER LOAD GAUGE
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Ladder Bedded (see para 2-14.)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Nylon Nuts (Figure 199, Appendix F)
a. Removal.
(1) With engine off, operate ladder control
levers in both directions to relieve
hydraulic pressure in system.
(2) Open front door of control console.
NOTE
Tag all hose and tube assemblies before
disconnecting. Cap or plug all hose, tube, and
fitting openings to prevent entry of foreign
material.
(3) Remove hydraulic hose (1). Cap hose
end.
(4) Remove two nylon nuts (2), two
lockwashers (3), two clamps (4), and
gauge (5).
(5) Remove fitting (6) from gauge (5).
b. Installation.
(1) Install fitting (6) on gauge (5).
(2) Install gauge (5), two clamps (4), two
lockwashers (3) and two nylon nuts (2).
(3) Apply pipe sealant (Item 2, Appendix E)
to fitting (6).
(4) Install hydraulic hose (1).
(5) Close front door of control console.
4-469
TM 5-4210-233-14&P-1
4-180. LADDER LOAD GAUGE - Continued
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Raise ladder (see para 2-14) and check operation of ladder load gauge.
4-470
TM 5-4210-233-14&P-1
4-181. HYDRAULIC SYSTEM PRESSURE GAUGE (0-3000 PSI)
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Ladder Bedded (see para 2-14.)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Nylon Nuts (Fig. 199, Appendix F)
a. Removal.
(1) With engine off, operate ladder control levers in
both directions to relieve pressure in hydraulic system.
(2) Open front door of control cabinet.
NOTE
Tag all hose and tube assemblies before
disconnecting. Cap or plug all hose, tube, and
fitting openings to prevent entry of foreign
material.
(3) Remove hydraulic hose (1). and cap hose end.
(4) Remove two nylon nuts (2), two lockwashers (3),
two clamps (4) and gauge (5).
(5) Remove fitting (6) from gauge (5).
b. Installation.
(1) Install fitting (6) on gauge (5).
(2) Install gauge (5), two clamps (4), two
lockwashers (3) and two nylon nuts (2).
(3) Apply pipe sealant (Item 2, Appendix E) to fitting (6).
(4) Install hydraulic hose (1).
(5) Close front door of control cabinet.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine, engage PTO (see para 2-14) and
check operation of system PRESSURE gauge
4-471
TM 5-4210-233-14&P-1
4-182. WATER PRESSURE GAUGE (0-600 PSI)
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown 2-16.)
Batteries Disconnected (see para 4-1 14.)
a. Removal.
(1) Without disconnecting hydraulic hoses,
remove ladder control valve (see para 5-56)
for access to water pressure gauge.
(2) Remove hose (1) and fitting (2).
(3) Remove two hex nuts (3), two star washers
(4) and two clamps (5).
(4) Remove gauge (6).
b. Installation.
(1) Install gauge (6).
(2) Install two clamps (5), two star washers (4),
and two hex nuts (3).
(3) Install hose (1) and fitting (2).
(4) Install ladder control valve (see para 5-56).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Operate aerial discharge (see para 2-13) an
test operation of WATER PRESSURE
GAUGE.
4-472
TM 5-4210-233-14&P-1
4-183. FLOW MINDER
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove four screws (1) and one locknut (2).
NOTE
Locknut (2) retains AUDIO ALERT buzzer ground wire.
(2) Tag wires.
(3) Loosen knurled ring (3) and remove yellow wire (4)
(4) Loosen knurled ring (5) and remove orange wire (6).
(5) Remove flow minder (7).
b. Installation.
(1) Install orange wire (6) and tighten knurled ring
(5).
(2) Install yellow wire (4) and tighten knurled ring
(3).
(3) Install flow minder (7) in panel.
NOTE
Locknut (2) retains AUDIO ALERT buzzer ground
wire.
(4) Install four screws (1).
(5) Connect AUDIO ALERT ground wire to screw (1)
and secure with locknut (2).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Operate aerial discharge and check operation
of flow minder (see para 2-13).
4-473
TM 5-4210-233-14&P-1
4-184. FLOW MINDER SENDING UNIT
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Aerial Waterway Drained (see para 2-3.)
MATERIALS/PARTS REQUIRED
Lubricating Oil, Item 10, Appendix E
O-ring (Fig. 23, Appendix F)
Gasket (Fig. 23, Appendix F)
a. Removal.
(1) Loosen knurled ring (1) and remove wire (2).
(2) Remove two square nuts (3), clamp (4), and mount (5).
(3) Remove and discard gasket (6).
(4) Remove four screws (7) and four lockwashers (8).
(5) Remove sending unit (9) from mount (5).
(6) Remove and discard two O-rings (10).
b. Installation.
(1) Install two new O-rings (10).
(2) Apply lubricating oil (Item 10, Appendix E) to
sending unit (9).
(3) Install sending unit (9) in mount (5).
(4) Install four lockwashers (8) and four screws (7).
(5) Install new gasket (6) on mount (5).
(6) Install mount (5) on water pipe with arrow or
decal (1 1) pointing toward water pipe nozzle.
(7) Install clamp (4) and two square nuts (3).
(8) Install wire (2) and tighten knurled ring (1).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Operate aerial discharge and check operation of flow minder sending unit (see para 2-13).
4-474
TM 5-4210-233-14&P-1
4-185. RUN/LOCK LEVER AND LINKAGE
THIS TASK COVERS:
a.
b.
c.
d.
Removal - Light Bulb
Installation - Light Bulb
Removal - Switch
Installation - Switch
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IiI, Item 1)
Removal Run/Lock Lever
Installation - Run/Lock Lever
Adjustment
Follow-on Maintenance
EQUIPMENT CONDITION
Ladder in Transport Position (see para 2-14.)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal - Light Bulb.
(1) Remove four screws (1) and lift cover
assembly (2).
(2) Remove two screws (3).
(3) Remove light bulb (4).
b. Installation - Light Bulb.
(1) Install new light bulb (4).
(2) Install two screws (3).
(3) Install cover assembly (2) and install four
screws (1).
c.
e.
f.
g.
h.
Removal - Switch.
(1) Tag and disconnect wires from switch (6).
(2) Remove two screws (7) and nuts (8).
(3) Remove switch (6).
d. Installation - Switch.
(1) Install switch (6) and secure with screws (7)
and nuts (8).
(2) Install wires on switch (6).
(3) Listen for the switch to click when the lever
is moved to the run position. Adjust tab on
switch if necessary.
4-475
TM 5-4210-233-14&P-1
4-185. RUN/LOCK LEVER AND LINKAGE - Continued
f.
Removal - Run/Lock Lever.
(1) Tag and remove wires from switch (6).
(2) Remove lock nut (10) from screw (15). Tag and remove two ground wires.
(3) Tag and remove remaining wire for light bulb socket (9) from panel light switch.
(4) Remove nut (11), lockwasher (12) and washer (13). Remove rod (14) from lever assembly (5).
(5) Remove four screws (15).
(6) Remove lever assembly (5).
g. Installation - Run/Lock Lever.
(1) Install lever assembly (5) in panel.
(2) Install four screws (15).
(3) Install rod (14) and secure with washer(13), lockwasher(12) and nut (11). See para. g below to
adjust rod (14).
(4) Attach wire from light bulb socket (9) to panel light switch.
(5) Attach two ground wires to screw (15) with locknut (1 0).
(6) Attach wires to switch (6).
g. Adjustment.
(1) Remove nut (16), lockwasher(17) and washer(18).
(2) Remove rod (14) from linkage (19).
(3) Move runtlock lever (5) to lock position.
(4) Lift up on linkage (19). Adjust length of rod (14) so that stud on rod (14) lines up with hole in linkage
(19).
(5) Install rod (14) in linkage (19) and secure with washer (18), lockwasher (17) and nut (16).
(6) Check motion of run/lock lever (5). Lever should have full movement from one position to the other
without resistance. Readjust length of rod (14) if necessary.
h. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Perform aerial ladder operation procedures (see para 2-14).
(3) Engine must shift into high idle when lever is in RUN position.
4-476
TM 5-4210-233-14&P-1
4-186. RUN/LOCK SELECTOR VALVE
THIS TASK COVERS:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlIl, Item 1)
MATERIALS/PARTS REQUIRED
Cleaning Solvent (Item 3, Appendix E)
Cotter Pin (Fig. 177, Appendix F)
Seals (Fig. 177, Appendix F)
Hydraulic Oil (Item 28, Appendix E)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B, Section III, Item 4)
EQUIPMENT CONDITION
Ladder in Transport Position (see para 2-14.)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal
(1) Remove cotter pin (1) and clevis pin (2).
Discard cotter pin.
(2) Tag and remove hoses (3).
NOTE
Tag all hose and tube assemblies before disconnecting. Cap or plug
all hose, tube, and fitting openings to prevent entry of foreign matter.
(3) Remove screws (4), washers (5), nuts (6) and horn (7)
(4) Remove selector valve (8) from cabinet.
4-477
TM 5-4210-233-14&P-1
4-186. RUN/LOCK SELECTOR VALVE - Continued
b. Disassembly.
(1) Remove fittings (9) from valve (8).
CAUTION
Use care when removing adapter (10) not to damage spool (12).
(2) Unscrew adapter(10) and remove washer(11) from spool (12).
(3) Remove two snap rings (13).
(4) Remove spool (12) from valve (8).
(5) Remove spool seals (14) from spool (12) and discard.
c.
Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame, arcing equipment or other ignition sources. Always
wear eye protection and protective clothing. The flash point of P-D-680 is 100 to 138 deg. F (38 to 59 deg. C).
Death or serious injury could occur if compressed air is directed against the skin. Do not use compressed air
for cleaning or drying unless the pressure is/has been reduced to 30 psi (2.11 kg/cm2) or less. When working
with compressed air, always use chip guards, eye protection and other personal protective equipment.
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E); dry using compressed air.
(2) Inspect valve housing (8) and spool (12) for deep grooves or score marks. Replace if defective.
NOTE
Spool and housing are not available as separate items. If either part is damaged, the entire valve assembly
must be replaced.
4-478
TM 5-4210-233-14&P-1
4-186. RUN/LOCK SELECTOR VALVE - Continued
d. Assembly.
(1) Install new spool seals (14) on spool (12).
(2) Lubricate the spool (12) with clean hydraulic oil (Item 28, Appendix E).
(3) Install spool (12) in valve housing (8).
(4) Install snap rings (13).
CAUTION
Use care when installing adapter (1 0) not to damage spool (12).
(5) Install adapter (10) and washer (11) in spool (12).
(6) Install fittings (9) in valve housing (8).
e. Installation.
(1) Install selector valve (8) and horn (7) with screws (4), washers (5) and nuts (6).
(2) Install hoses (3).
(3) Install clevis pin (2) and a new cotter pin (1).
f.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Operate aerial ladder (see para 2-14).
(3) Check level of hydraulic oil in tank and refill as necessary (see para 3-1).
4-479
TM 5-4210-233-14&P-1
4-187. PRESSURE SENSOR GAUGE
THIS TASK COVERS:
a. Removal
c. Installation
b. Cleaning and Inspection
TOOLS REOUIRED
Too[ Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Batteries Disconnected (see para 4-114.)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
MATERIALSIPARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Pipe Sealant (Item 2, Appendix E)
a. Removal.
(1) Remove screw (1) and nut (2) disconnecting white
ground wire (3) from central stand bracket.
(2) Disconnect gauge black wire (4) from Bosch relay (5).
(3) Use open end wrench to unscrew 1/2" coupler (6) and
remove coupler (6) and gauge (7) as an assembly from
control stand bracket.
b. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and skin
contact with the liquid. Do not use near open flame, arcing
equipment or other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D680 is 100 to 138 deg F (30 to 50 deg. C).
(1) Clean gauge with a shop cloth dampened in dry
cleaning solvent (Item 3, Appendix E)
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been reduced
to 30 psi (2.11 kg/cm2) or less. When working with
compressed air, always use chip guards, eye protection and
other personal protective equipment.
(2) Dry gauge with compressed air.
4-480
TM 5-4210-233-14&P-1
4-187. PRESSURE SENSOR GAUGE - Continued
(3) Compare gauge pressure setting to that of a calibrated master gauge. Replace gauge if accuracy
isn't ± 3% compared to calibrated master gauge.
(4) Check for continuity from black wire terminal through gauge to white wire terminal when pressure
reading equals gauge set point. Replace gauge if no continuity.
c.
Installation.
(1) Apply pipe sealant (Item 2, Appendix E) to threads of 1/2" coupler (6) and use open end wrench to
screw assembled 1/2" coupler (6) and gauge (7) into control stand bracket.
(2) Connect gauge black wire (4) to terminal B6 of Bosch relay (5).
(3) Connect gauge white ground wire (3) to control stand bracket with screw (1) and nut (2).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-481
TM 5-4210-233-14&P-1
4-188. TESTING HYDRAULIC SYSTEM
THIS TASK COVERS:
a. Testing Hydraulic Pressure
b. Testing Aerial Performance Times
EQUIPMENT CONDITION
Engine Running and warmed up to
normal operating temperature
a. Testing Hydraulic Pressure.
(1) To test hydraulic system pressure, move the RUN/LOCK lever on the aerial control platform to the
RUN position.
(2) With all hydraulic controls in the neutral position (no hydraulic circuits actuated) the pressure indication
on the SYSTEM PRESSURE gauge should be 2150 psi (14814 kPa). Pressures higher or lower than
2150 psi (14814 kPa) indicate component failure. Troubleshoot system (refer to Table 4-2) to identify
fault. Replace or repair components as required.
b. Testing Aerial Performance Times.
(1) With all outriggers fully extended and supporting the weight of the truck (see para 2-14.) perform the
following tests. Check the aerial performance times against the times listed below.
Raise ladder from 0°to 750............................
35 to 45 seconds
Lower ladder from 750 to 0°............................
35 to 45 seconds
Full left rotation (3600)....................................
130 to 140 seconds
Full right rotation (3600)..................................
130 to 140 seconds
Full extension .................................................
35 to 45 seconds
Full retraction .................................................
28 to 35 seconds
(2) Perform "three-function test". Push or pull all three aerial control levers simultaneously. Test the time
required to achieve 900 rotation, full elevation and full extension. Time required should be 1 05
seconds.
4-482
TM 5-4210-233-14&P-1
4-189. HYDRAULIC TANK RETURN FILTER
THIS TASK COVERS:
a.
Service
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1iI, Item 1)
Batteries Disconnected (see para 4-114.)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
MATERIALS/PARTS REQUIRED
Hydraulic Oil (Item 28, Appendix E)
O-ring (Figure 197, Appendix F)
a. Service.
(1) Remove filter (1) from filter head assembly (2).
Remove and discard O-ring (3).
(2) Apply a thin coat of hydraulic oil (Item 28,
Appendix E) to new O-ring (3).
(3) Install new filter (1) and O-ring (3) on filter head
assembly (2). Hand tighten filter 1/2 turn after
seal contacts filter head.
(4) Operate aerial ladder hydraulic system (see
para 2-14) and check for filter leakage. Tighten
filter slightly if leakage until it ceases.
4-483
TM 5-4210-233-14&P-1
4-190. OUTRIGGER CONTROL VALVES
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IiI, Item 1)
Disconnect Batteries (see para 4-114.)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
a. Removal.
(1) Tag and disconnect seven hoses (1) from valve (2).
(2) Cap all hoses (1) and ports in valve (2).
(3) Remove three screws, nuts, and washers attaching
valve to mounting plate..
(4) Remove valve (2).
b. Installation.
(1) Install valve (2) and attach to plate with three
screws, nuts, and washers.
(2) Connect seven hoses (1) on valve (2) Remove tags.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Operate outriggers and check for leaks (see para 2-14).
4-484
TM 5-4210-233-14&P-1
4-191. PRESSURE RELIEF VALVE (PUMP DE-STROKE)
THIS TASK COVERS:
a. Valve Cartridge Replacement d. Follow-on Maintenance
b. Solenoid Replacement
c. Valve Block Replacement
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1IJ, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Pull-out Treadplate Pulled Out (Driver's Side)
MATERIALS/PARTS REQUIRED
Tags (Item 32, Appendix E)
Hydraulic Oil (Item 28, Appendix E)
Caps, Shipping and Sealing (Item 39, Appendix E)
O-ring (Figure 198, Appendix F)
a. Valve Cartridge Replacement. To replace valve
cartridge (1), unscrew cartridge from valve block
(2). Remove and discard O-ring. Install new O-ring
on valve cartridge and install cartridge in valve
block. Tighten securely.
b. Solenoid Replacement.
(1) Loosen screw (3) and remove plug (4) from
solenoid (5).
(2) Remove nut (6) and remove solenoid (5) from
valve block (2).
(3) Install new solenoid (5) on valve block (2) as
shown and install nut (6).
(4) Connect plug (4) to solenoid (5) and tighten
screw (3).
c.
Valve Block Replacement.
(1) Loosen screws (3) and remove plug (4) from
solenoid (5).
(2) Tag and disconnect three hoses (7, 8 and 9)
and tube (1O) from valve block (2). Plug ends
of hoses and tube and parts in block to prevent
entry of dirt.
(3) Connect hydraulic tube (1 0) to new valve block (2
(4) Connect three hydraulic hoses (7, 8 and 9) to
valve block (2).
(5) Connect plug (4) to solenoid (5) and tighten
screw (3).
4-485
TM 5-4210-233-14&P-1
4-191. PRESSURE RELIEF VALVE (PUMP DE-STROKE) - Continued
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine, operate aerial ladder hydraulic system (see para 2-14), and check for leaks.
4-486
TM 5-4210-233-14&P-1
4-192. PRESSURE REDUCING VALVE (OUTRIGGERS)
THIS TASK COVERS:
a. Valve Cartridge Replacement c. Follow-on Maintenance
b. Valve Block Replacement
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section IlI, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Tags (Item 32, Appendix E)
Hydraulic Oil (Item 28, Appendix E)
Caps, Shipping and Sealing (Item 39, Appendix E)
O-ring (Figure 198, Appendix E)
a. Valve Cartridge Replacement.
(1) To remove valve cartridge (1), unscrew
cartridge from valve block (2). Remove and
discard O-ring from valve cartridge.
(2) Install new O-ring on valve cartridge (1) and
install cartridge in valve block (2).
(3) Start engine and check for leaks. Check
outrigger operation.
b. Valve Block Replacement.
(1) Tag and disconnect hydraulic hoses (3, 4 5
and 6). Cap hose ends and parts in block to
prevent entry of dirt.
(2) Remove two screws (7) and washers (8).
Remove valve block (2) from bracket (9).
(3) Put new valve block (2) in position on bracket
(9) and install two screws (7) with washers (8).
(4) Connect four hydraulic hoses (3, 4, 5 and 6)
to valve block (2).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operate pressure reducing valve.
(3) Start engine, operate outrigger hydraulic
system (see para 2-14), and check for leaks
and proper operation.
4-487
TM 5-4210-233-14&P-1
4-193. DIVERTER VALVE
THIS TASK COVERS:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Disconnect Batteries (see para 4-114.)
Ladder Bedded (see para 2-14.)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
a. Removal.
(1) Tag and disconnect eight hoses (1) from valve (2).
(2) Cap all hoses (1) and ports in valve (2).
(3) Remove three nuts (3), washers (4) and screws (5).
(4) Tag and disconnect wires at solenoid on top of valve (2).
(5) Remove valve (2).
4-488
TM 5-4210-233-14&P-1
4-193. DIVERTER VALVE - Continued
b. Installation.
(1) Attach wires to solenoid to top of valve. Remove tags.
(2) Secure valve (2) with three screws (5), washers (4) and nuts (3).
(3) Connect eight hoses (1) to valve (2). Remove tags.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Check operation of valve and inspect hose connections for leaks (see para 2-14).
4-489
TM 5-4210-233-14&P-1
4-194. OUTRIGGER EXTEND/RETRACT CYLINDERS
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Too[ Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Outriggers Extended (see para 2-14.)
PERSONNEL REQUIRED: 2
a. Removal.
(1) Remove one bolt (2), one star washer (3) and pin (4) from outrigger (1).
(2) Remove nine screws (5) and outrigger panel (6).
(3) Tag and disconnect wires from side warning light (7).
(4) On opposite side remove two capscrews (8), two star washers (9), flatwashers (10) and cylinder cover
(11).
(5) Tag all hose and tube assemblies before disconnecting. Cap or plug all hose, tube, and fitting openings
to prevent entry of foreign matter.
(6) Remove tie wraps (12) from hydraulic hoses (13 and 14).
(7) Disconnect one hydraulic hose (13).
(8) Lift cylinder (15) from mount (16) and pull cylinder (15) out until remaining hydraulic hose (14) is
visible.
(9) Disconnect remaining hydraulic hose (14) and remove cylinder (15).
b. Installation.
(1) Fully extend cylinder ram (15) and install hydraulic hose (14).
(2) Secure extended cylinder ram (1 5) to outrigger beam with pin (4), star washer (3), and bolt (2).
(3) Place cylinder (15) in rnount (16).
(4) Install hydraulic hose (13).
(5) Install tie wraps (12).
(6) Install cylinder cover (11), two star washers (9), flatwashers (10) and two capscrews (8).
(7) Connect warning light (7) wires tagged during removal.
(8) Install outrigger panel (6), nine screws (5).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-490
TM 5-4210-233-14&P-1
4-194. OUTRIGGER EXTEND/RETRACT CYLINDERS Continued
(2) Operate outriggers (see para 2-14) and check for leaks.
4-491
TM 5-4210-233-14&P-1
4-195. OUTRIGGER JACK CYLINDERS AND CHECK VALVES
THIS TASK COVERS:
a. Removal
b. Installation
c. Repair
d. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
O-ring (Figure 194, Appendix F)
a. Removal.
(1) Extend outrigger (1).
(2) Lower outrigger jack stand (2) until it just
touches the ground.
(3) Remove three screws (3), and cover (4).
(4) Remove snap ring (5), and pad pin (6).
(5) Tag all hose and tube assemblies before
disconnecting. Cap or plug all hose, tube,
and fitting openings to prevent entry of
foreign matter.
(6) Disconnect two hydraulic hoses (7).
(7) Cap hydraulic hoses and plug valve fittings.
(8) Support cylinder (12) with suitable lifting device.
(9) Remove bolt (8), star washer (9),
flatwasher (10), and pin (11).
(10)Lift cylinder (1 2) from outrigger jack tube (13).
(11)Remove hydraulic line (14).
(12)Remove two screws (15), check valve (16),
and O-ring (17). Discard O-ring.
4-492
TM 5-4210-233-14&P-1
4-195. OUTRIGGER JACK CYLINDERS AND CHECK VALVES - Continued
b. Installation.
(1) Install new O-ring (17), check valve (16), and two screws (15).
(2) Install hydraulic line (14).
(3) Using a suitable lifting device, lower cylinder (12) into outrigger jack tube (13).
(4) Install pad pin (6) through cylinder (12), jack stand (2) and pad (18).
(5) Install snap ring (5).
(6) Install pin (1 1), flat washer (1 0), star washer (9), and bolt (8).
(7) Connect two hydraulic hoses (7).
(8) Install cover (4) and three screws (3).
c.
Repair.
Repair of he jack cylinder check valve is limited to replacement.
(1) Remove cover (4), see para a. above.
(2) Disconnect hydraulic line (14) from check valve (16).
(3) Remove two screws (15), check valve (16), and O-ring (17).
(4) Discard O-ring (17).
(5) Install new O-ring (17) and check valve (16) and secure with two screws (15).
(6) Connect hydraulic line (14) to check valve (16).
(7) Install cover (4), see para a. above.
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operate outrigger jack cylinders (see para 2-14) and check for leaks.
(3) Retract outriggers.
4-493
TM 5-4210-233-14&P-1
4-196. OUTRIGGER LIMIT SWITCHES
THIS TASK COVERS:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section lII, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Outriggers Extended (see para 2-14.)
Disconnect Batteries (see para 4-114.)
a. Removal.
(1) Remove two nuts (1), two lockwashers (2), two washers (3) and two screws (4).
(2) Remove three screws (5), three lockwashers (6), cover (7) and gasket (8).
4-494
TM 5-4210-233-14&P-1
4-196. OUTRIGGER LIMIT SWITCHES - Continued
(3) Tag and disconnect wires from switch (9).
(4) Remove nut (10) from sleeve (11).
(5) Remove wiring harness (12) with nut (10), washer (13) and seal (14) from switch housing (15).
(6) Remove screws (1 6) and washers (1 7).
(7) Remove switch (9) from switch housing (15).
(8) Remove switch actuator (18) and seal (19).
b. Installation.
(1) Install switch actuator (18) and seal (19).
(2) Install switch (9) in switch housing (15) and secure with washers (17) and screws (16).
(3) Install wiring harness (12) with nut (10), washer (13) and seal (14). Thread nut (10) onto sleeve (1 1).
(4) Attach wiring harness (1 2) to switch (9).
(5) Install gasket (8), cover (7), lockwashers (6) and screws (5).
(6) Install switch housing (15) with screws (4), washers (3), lockwashers (2) andnuts (1).
c.
Follow-on Maintenance.
(1) Retract outriggers (see para 2-14).
(2) Connect batteries (see para 4-114).
4-495
TM 5-4210-233-14&P-1
4-197. AERIAL LADDER ANGLE LIMIT SWITCH
THIS TASK COVERS:
a. Adjustment
b. Removal
c. Installation
d. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
a. Adjustment.
(1) Raise ladder to approximately 65 deg. position (see para 2-14).
(2) Loosen nut (1).
(3) Move arm (2) so that it just touches base of ladder.
(4) Tighten nut (1).
b. Removal.
(1) Remove nuts (3) and screws (4).
(2) Remove screws (5), cover (6) and gasket (7).
(3) Tag and disconnect wires from switch (8).
(4) Remove switch (8) from switch housing (9).
(5) Remove wires and seal (10) from switch housing (9).
c.
Installation.
(1) Install seal (10) and wires in switch housing (9).
(2) Install switch (8) in switch housing (9).
(3) Attach wires to switch (8).
(4) Install gasket (7), cover (6) and screws (5).
(5) Attach switch housing (9) with screws (4) and nuts (3).
d. Follow-on Maintenance.
(1) Bed ladder (see para 2-14).
4-496
TM 5-4210-233-14&P-1
4-198. AERIAL LADDER INTERCOM
THIS TASK COVERS:
a.
b.
c.
d.
e.
Removal of Base Unit
Installation of Base Unit
Removal of Laddertip Speaker
Installation of Laddertip Speaker
Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Butt Splice Connectors (Item 27, Appendix E)
a. Removal of Base Unit.
(1) Remove two crown nuts (1) and remove two
screws and plastic washers (not shown) that
secure intercom assembly to control panel cover.
(2) Remove six capscrews (2) with lockwashers
and remove cover (3) and gasket (4) from
intercom.
4-497
TM 5-4210-233-14&P-1
4-198. AERIAL LADDER INTERCOM - Continued
(3) Tag and disconnect all wires (5).
(4) Loosen two cable connectors (6). Tag and
remove two cables (7) from intercom.
b. Installation of Base Unit.
(1) Install two cables (7) in intercom and install two
cable connectors (6).
(2) Using tags for identification, splice ail wires (5) with
butt splice connectors (Item 27, Appendix E).
(3) Position cover (3) with gasket (4) on intercom
and install six screws (2) with lockwashers.
c.
(4) Position intercom in control panel cover. Install
two screws with plastic washers from exterior side
of cover. Install two crown nuts (1) and tighten
securely.
Removal of Laddertip Speaker.
(1) Tag two wires (1) and cut wires of butt
splice connectors.
(2) Remove crown nuts (2), hex nuts (3), bolts (4),
lockwashers (5) and bracket (6). Remove
intercom speaker (7) from ladder.
d. Installation of Laddertip Speaker.
(1) Position speaker (7) on ladder and install
bracket (6) across ladder brace with two bolts (4),
lockwashers (5) and hex nuts (3). Tighten
nuts (3) securely.
(2) Install two crown nuts (2) and tighten snugly
against hex nuts (3). Use two wrenches to
lock crown nuts (2) against hex nuts (3).
Turn crown nuts (3) in a clockwise direction
while turning hex nut (2) in a counter-clockwise
direction.
(3) Connect two wires (1) with butt splice
connectors (Item 27, Appendix E).
e. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-498
TM 5-4210-233-14&P-1
4-199. AIR OPERATED AERIAL DISCHARGE VALVE
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Gaskets (Figure 23, Appendix F)
Gaskets (Figure 25, Appendix F)
PERSONNEL REQUIRED: 2
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Drain Aerial Waterway (see para 2-17 .)
a. Removal
(1) Remove four nuts (1) and washers (2). Remove actuator (3) from valve (4).
(2) Remove two nuts (5), two bolts (6) and two clamps
(7). Slide seal (8) onto pipe (9).
(3) Remove eight nuts (10), lockwashers (10A) and
eight bolts (11). Remove elbow (12), gaskets (13)
and valve (4). Discard gaskets.
b. Disassembly.
(1) Remove four screws (14), four lockwashers
(15), cover (16), gasket (17) and thrust washer
(18). Discard gasket.
4-499
TM 5-4210-233-14&P-1
4-199. AIR OPERATED AERIAL DISCHARGE VALVE - Continued
(2) Remove four screws (19), two locating plates (20), retaining ring (21), gasket (22) and seat (23).
Discard gasket.
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
(1) Clean all metal parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been reduced
to 30 psi (2.11 kg/cm2) or less. When working with compressed air, always use chip guards, eye protection, and other
personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect valve body (4), seat (23) and thrust washer (18) for damage. Replace parts or entire
valve as necessary.
d. Assembly.
(1) Install seat (23), new gasket (22), and retaining ring (21). Install two locating plates (20) and
secure with four screws (19).
(2) Install thrust washer (18), new gasket (17), cover (16) and secure with four lockwashers (15) and
four screws (14).
e. Installation.
(1) Install valve (4), new gaskets (13), and elbow (12), and secure with eight bolts (11), eight nuts
(10), and eight lockwashers (10A).
(2) Slide seal (8) on pipe (9) and position between grooves in pipe (9) and elbow (12). Use new seal
if necessary.
(3) Install two clamps (7) and secure with two bolts (6) and two nuts (5).
(4) Install actuator (3) on valve (4) and secure with four washers (2) and nuts (1).
f. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-500
TM 5-4210-233-14&P-1
4-200. AERIAL DISCHARGE VALVE PNEUMATIC ACTUATOR
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Grease (Item 17, Appendix E)
O-rings (Figure 21, Appendix F)
PERSONNEL REQUIRED: 2
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal
(1) Operate valve to the closed position. Check
that the actuator indicator is in the fully
closed position.
(2) Tag and remove two air lines (1 and 2) from
actuator (3).
(3) Remove four nuts (4) and four washers (5).
Remove actuator (3).
4-501
TM 5-4210-233-14&P-1
4-200. AERIAL DISCHARGE VALVE PNEUMATIC ACTUATOR - Continued
b. Disassembly.
(1) Remove arrow indicator (1) by prying off with a small screwdriver.
(2) Loosen socket head cap screw (2), but do not remove. Tap the head of the socket head cap
screw (2) to break seal created by tapered adapter piece (3).
(3) Remove position indicator (4).
(4) Remove eight socket head cap screws (5), eightwashers (6) and end caps (7).
(5) Remove and discard four O-rings (8 and 9).
(6) Rotate drive-shaft (10) in a counter-clockwise direction to drive pistons (11) apart and remove
pistons (11).
(7) Remove and discard O-rings (12) from pistons (11).
4-502
TM 5-4210-233-14&P-1
4-200. AERIAL DISCHARGE VALVE PNEUMATIC ACTUATOR - Continued
(8) Remove center split spacer (13).
(9) Remove spring clip (14) and retaining washer (15).
(10) Tap shaft downward and remove. Take care to protect actuator bore from possible damage from
lower pinion gear teeth. As drive shaft (1 0) is being withdrawn, the internal components can be
removed in sequence. Upper spacer (16), upper pinion gear (17), lower pinion gear (18), lower
spacer (19) and keys (20).
(11) Remove spring clip (21) and retaining washer (22) from drive shaft (10).
(12) Remove two bearings (23) from actuator body (24). Remove and discard four O-rings (25 and
26).
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
(1) Clean all metal parts in dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been reduced
to 30 psi (2.11 kg/cm2) or less. When working with compressed air, always use chip guards, eye protection, and other
personal protective equipment.
(2) Dry all parts with compressed air.
(3) Inspect pistons (11) for scoring. Inspect teeth on pistons (11) for damage. Replace pistons as
necessary.
(4) Inspect pinion gears (17 and 18) for damage. Replace as necessary.
(5) Inspect piston bores and drive shaft bore in actuatorbody (24) for scoring.
(6) Inspect all other parts for damage. Replace parts as necessary.
4-503
TM 5-4210-233-14&P-1
4-200. AERIAL DISCHARGE VALVE PNEUMATIC ACTUATOR - Continued
d. Assembly.
(1) Coat actuator bore, pistons, pinion assembly and all new O-rings with grease (Item 17, Appendix
E).
(2) Press bottom bearing assembly (23, 25, 26) on to drive shaft (10). Bearing assembly should be
installed so that outer O-ring (25) is closer to the piston bore.
(3) Install retaining washer (22) and spring clip (21).
(4) Install bottom spacer (19).
(5) Install keys (20) on drive shaft (10).
(6) Insert drive shaft (10) into actuator body (24) from bottom. Install bottom pinion gear (18) and
upper pinion gear (17) as the drive shaft is inserted.
(7) Install top spacer (16).
(8) Install top bearing assembly (23, 25, 26). Bearing assembly should be installed so that outer Oring (25) is closer to the piston bore.
(9) Install retaining washer (15) and spring clip (14).
(10) Install center split spacer (13) between pinion gears (17 and 18).
(11) Install piston O-rings (12) onto pistons (11).
(12) Insert pistons (11) until rack engages pinion gears. At moment of engagement, drive shaft
should be positioned as shown. Rotate drive shaft in a clockwise direction until pistons bottom
out. In this position, the double "D" flats or the actuator bore keyway will be perpendicular to the
body axis.
(13) Install O-rings (9) in end caps (7).
(14) Install air passage O-rings (8) into the recess on the end face of the actuator body.
(15) Install end caps (7) and secure with washers (6) and socket head cap screws (5). Alternately
tighten screws (5) until secure.
(16) Install tapered adapter piece (3), position indicator (4), socket head capscrew (2), and indicator
arrow (1).
e. Installation.
(1) Install actuator (3) on valve and secure with four washers (5) and nuts (4).
(2) Connect two air lines (1 and 2) to actuator (3).
f. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-504
TM 5-4210-233-14&P-1
4-201. AERIAL LADDER WATER PIPE ASSEMBLY
This task covers:
a. Disassembly
c. Assembly
b. Cleaning and Inspection d. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
PERSONNEL REQUIRED: 2
EQUIPMENT CONDITION
Aerial Waterway Drained (see para 2-3 .)
MATERIALS/PARTS REQUIRED
O-Rings (Figure 23, Appendix F)
Wear Pad Cup Seal (Figure 23, Appendix F)
Grease (Item 48, Appendix E)
a. Removal
(1) Fully extend ladder in a horizontal position at the
rear of the truck (see para 2-14).
(2) Support section of pipe (1) that pipe (2) is being
removed from with cable or chain as shown. Allow
several inches of slack in cable so pipe can drop
slightly.
4-505
TM 5-4210-233-14&P-1
4-201. AERIAL LADDER WATER PIPE ASSEMBLY - Continued
(3) Remove four nuts (3), lockwashers (4) and bolts (5).
(4) Remove O-ring (6) from end of pipe (2).
(5) Remove eight bolts (7), eight washers, and
eight locknuts (8).
(6) Remove pipe (2) from pipe (1).
(7) Remove nut (12) and Bronze wear pad (13).
(8) Remove Ryertex wear pad (9) from pipe (2). Remove O-ring (10).
(9) Remove cup seal (11) from Ryertex wear pad (9).
(10) Repeat procedure for each section of pipe tobe removed.
4-506
TM 5-4210-233-14&P-1
4-201. AERIAL LADDER WATER PIPE ASSEMBLY - Continued
b. Cleaning and Inspection.
(1) Inspect water pipe sections for dents or deep scoring.
(2) Inspect Ryertex wear pad (9) for damage or excessive wear.
(3) Inspect bronze wear pad (1 3) for damage or excessive wear.
(4) Discard O-rings (6 and 10) and cup seal (11).
(5) Replace all damaged or excessively worn parts.
c. Assembly.
(1) Install new cup seal (11) in Ryertex wear pad (9).
(2) Coat cup seal with lithium grease (Item 48, Appendix E).
(3) Install Ryertex wear pad (9) on pipe (2).
(4) Install bronze wear pad (13) and nut (12) in pipe (2).
(5) Install new O-ring (10) in groove on flange of pipe (1). Coat O-ring (10) with lithium grease (Item
48, Appendix E).
(6) Install pipe (2) in pipe (1). Bronze wear pad (13) must face down so it rides on bottom of pipe
(1).
(7) Install screws (7), washers (7A) and nuts (8).
(8) Install O-ring (6) in groove in flange of pipe (2). Coat O-ring (6) with lithium grease (Item 48,
Appendix E).
(9) Install bolts (5), lockwashers (4) and nuts (3).
(10) Remove support cable.
d. Follow-on Maintenance.
(1) Charge aerial waterway (see para 2-13) and check for leaks.
(2) Bed ladder (see para 2-14).
4-507
TM 5-4210-233-14&P-1
4-202. MONITOR AND NOZZLE
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
Aerial Waterway Drained (see para 2-17 .)
MATERIALS/PARTS REQUIRED
Butt Connectors (Item 27, Appendix E)
Tags, Identification (Item 32, Appendix E)
Silicone Sealant (Item 35, Appendix E)
a. Removal
WARNING
Serious injury could occur if heavy equipment is
moved/lifted without sufficient personnel to do the
job. Use proper physical lifting procedures or use
a suitable lifting device or dolly. Wear safety
shoes, gloves and other suitable protective clothing. Area should be clear of other personnel.
Serious injury or death can result from falling
objects.
(1) Attach a suitable lifting device to the monitor
and nozzle assembly.
(2) Loosen four screws (1) and remove cover (2)
from electrical box on end of ladder.
4-508
TM 5-4210-233-14&P-1
4-202. MONITOR AND NOZZLE - Continued
(3) Tag and disconnect six wires from terminals #2 thru #7 from lower terminal block (TB1).
(4) Unscrew connector (strain relief) (3) and
remove cable (4) from electrical box.
(5) Be sure monitor and nozzle assembly is
supported by lifting device. Remove four bolts (5),
nuts (6) and lockwashers (7) and remove
monitor and nozzle assembly from ladder.
(6) Clean all traces of sealant from the mating
surfaces of the monitor and the ladder mounting
plate.
4-509
TM 5-4210-233-14&P-1
4-202. MONITOR AND NOZZLE - Continued
b. Installation.
(1) Before installation, apply a generous bead of silicone sealant (Item 35, Appendix E) to the mating
surface of the monitor. The sealant must seal around the full diameter of the waterway opening,
and should also be applied around the four mounting holes.
WARNING
Serious injury could occur if heavy equipment is moved/lifted
without sufficient personnel to do the job. Use proper physical
lifting procedures or use a suitable lifting device of dolly. Wear
safety shoes, gloves and other suitable protective clothing.
Area should be clear of other personnel. Serious injury or
death can result from falling objects.
(2) Attach a suitable lifting device to monitor and nozzle assembly and lift into position.
(3) Install four bolts (5), lockwashers (7) and nuts (6).
pattern.
Tighten nuts (6) evenly in a criss-cross
(4) Feed individual wires of cable (4) into electrical box until cable can be pulled into box. Tighten
connector (3) securely.
(5) Connect six wires of cable (4) to lower terminal block (TB1) terminals #2 thru #7, as shown in
wiring diagram (Appendix H).
(6) Install cover (2) on electrical box and tighten four screws (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test monitor and nozzle operation using the STREAM/SHAPE, LEFT/RIGHT and
RAISE/LOWER toggle switches located on the aerial control panel and at the ladder tip (see para
2-13).
4-510
TM 5-4210-233-14&P-1
4-203. MONITOR AND NOZZLE CONTROLS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Removal
(1) Remove four screws (1) and cover (2).
(2) Tag and disconnect wires from switch to be replaced.
(3) Remove hex nut with boot (3), lockwasher (4) and switch (5).
b. Installation.
(1) Put switch (5) in position and install lockwasher (4) and hex nut with boot (3).
(2) Connect wires to switch (5) and remove tags.
(3) Install cover (2) with four screws (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Test operation of switch.
4-511
TM 5-4210-233-14&P-1
4-204. COUNTERBALANCE VALVES
This task covers:
a. Replacement of Valve Cartridge
b. Removal of Valve Block
c. Installation of Valve Block
d. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Ladder Fully Retracted and Elevated (see para 2-14 .)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Emergency hydraulic system deactivated
(see para 2-15 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Grease, Automotive (Item 1, Appendix E
Tags (Item 32, Appendix E)
Hydraulic Oil (Item 28, Appendix E)
Caps, Shipping and Sealing (Item 39, Appendix E)
O-ring (Figure 188, Appendix F)
a. Replacement of Valve Cartridge.
(1) With engine off, actuate three ladder control
levers in each direction to relieve pressure in
hydraulic system.
CAUTION
Do not loosen or tighten hex fitting on end of valve
cartridge. Do not attempt to adjust or change the
setting of the valve cartridge.
(2) Remove valve cartridge (1) by unscrewing large
hex nut (2) closest to valve block.
(3) Install new valve cartridge (1) and tighten large hex
nut (2) closest to valve block only.
b. Removal of Valve Block.
(1) Tag and disconnect two hydraulic hoses (3) and
two tubes (4). Cap hose and tube ends to prevent
entry of dirt.
(2) Remove two capscrews (5) and remove valve
block (6) from end of cylinder. Remove and discard
two O-rings (7) between valve block and cylinder.
4-512
TM 5-4210-233-14&P-1
4-204. COUNTERBALANCE VALVES - Continued
c. Installation of Valve Block.
(1) Coat two new O-rings (7) with grease (Item 1, Appendix E) to hold them in position on valve
block (6). Install valve block (6) on cylinder and install two capscrews (5).
(2) Connect two hydraulic tubes (4) and two hydraulic hoses (3) to valve block.
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start engine and actuate ladder extend and retract control lever (see para 2-14). Check for
leaks.
4-513
TM 5-4210-233-14&P-1
4-205. AERIAL LADDER TENSION CABLES
This task covers:
a. Adjustment
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Outriggers Extended (see para 2-14 .)
a. Adjustment.
WARNING
When tightening the cables do not allow the cable take-up to
rotate as this will cause the cable to unwrap and damage the
cable and may cause serious personal injury or death.
CAUTION
Do not overtighten cables. Overtightening of the cables will
cause excessive wear on the cable, sheaves, bushings, and
pins.
NOTE
The ladder must be adequately lubricated before any cable
adjustments are made.
To check cable alignment, extend the ladder, raise it to 60
degrees elevation, and fully retract it, then lower it back down
to 0 degrees elevation. There should be 114" to 3/4" (6.35 to
19 mm) gap between the front of the base section front
crossmember and the back of the lower mid section water
pipe flange mounting bracket. This gap should be maintained
for all the ladder sections and should not be any larger or
smaller than recommended.
Any adjusting or retensioning of the extension cables should
start on the base section extension cables.
If the ladder is retracted too far back, the front cables on the
base section should be tightened as this will draw all the
above sections outward.
(1) Extend, elevate, the ladder, then retract and lower to see if an alignment problem still exists.
(2) If the ladder is still misaligned the cables should again be adjusted accordingly and the test
redone to check alignment.
(3) Once all adjustments are made to the base section the rear cables should have any excess slack
taken out of them with care not to overtighten the cables
4-514
TM 5-4210-233-14&P-1
4-205. AERIAL LADDER TENSION CABLES - Continued
(4) Correct tension on extension and retraction cables is checked by placing the ladder at 0 degrees
elevation, extending the ladder approximately two feet (610 mm), and then retracting ladder
approximately one foot (305 mm). Upon inspection of the cables, all cables should be selfsupporting with no portion of the cables coming in contact with any part of the ladder. Should
cables come in contact with the ladder or sag unevenly, tighten cables appropriately. Front
extension cables should be tightened first unless the ladder sections are not retracting far
enough. In this case the rear retraction cables should be tightened first. This will pull the ladder
sections inward, while tightening the front extension cables will draw the sections outward. Care
must be taken to maintain the required 1/4" to 3/4" (6.35 to 19 mm) gap between the water pipe
mounting brackets and the front crossmembers of the sections below.
(5) Once the base section and the lower mid section are aligned properly, the upper mid section
should be checked for proper alignment in relation to the lower mid section and adjustments
made to front cables of the lower mid section in the same manner as was done on the base
section. (6)
Once the lower and upper mid sections are aligned properly, alignment of the
fly and upper mid sections should be checked in the same manner as the other sections.
(7) After all adjustments are completed on the extension and retraction cables, the electrical cables
should be adjusted.
4-515
TM 5-4210-233-14&P-1
4-206. AERIAL LADDER ELECTRICAL CABLES
This task covers:
a. Adjustment
b. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
a. Adjustment.
CAUTION
Proper spring tension on electrical cables must be checked
and inspected after the extension/retraction cables are
checked. Failure to maintain proper tension can result in
damage to cables.
(1) Measure the distance (A) between the strut and spring stop washer.
(2) The measurement should be 4-1/8 inches (105 mm).
(3) Adjust nut to increase or decrease spring tension.
b. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-516
TM 5-4210-233-14&P-1
4-207. AUXILIARY POWER UNIT (APU)
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDMON
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
APU Air Cleaner Removed (see para 4-213 .)
a. Removal.
(1) Disconnect exhaust pipe (1).
(2) Remove four screws (2) and control box cover (3).
NOTE
Tag all wires before disconnecting them.
(3) Remove wire nut (4) securing black cable to white
wires #1 and #3.
(4) Remove one white and one green cable from mounting
nut (5).
(5) Remove wire #1674 from terminal #2 of decompression solenoid relay (6).
(6) Tag and remove the following wires from the remote control terminal block (7):
#1670M from #1 Terminal
#1671 from #2 Terminal
#1672 from #3 Terminal
#1673 from H Terminal
4-517
TM 5-4210-233-14&P-1
4-207. AUXILIARY POWER UNIT - Continued
(7) Tag and disconnect two fuel hoses.
(8) Loosen hose clamp (9) on oil drain hose (10).
Remove oil drain hose (10) and clamp (9) from
drain cock (8).
(9) Remove four nuts (11), lockwashers (12),
washers (13), bushing (14) and snubber(15).
WARNING
Serious injury could occur if heavy equipment is
moved/lifted without sufficient personnel to do the
job. Use proper physical lifting procedures or use
a suitable lifting device of dolly. Wear safety
shoes, gloves and other suitable protective clothing. Area should be clear of other personnel.
Serious injury or death can result from falling
objects.
(10) Secure suitable lifting device to lifting eye (16)
and lift APU from truck.
b. Installation.
WARNING
Serious injury could occur if heavy equipment is
moved/lifted without sufficient personnel to do the
job. Use proper physical lifting procedures or use
a suitable lifting device of dolly. Wear safety
shoes, gloves and other suitable protective clothing. Area should be clear of other personnel.
Serious injury or death can result from falling
objects.
(1) Using a suitable lifting device, lower APU onto mount assemblies (17).
(2) Install four snubbers (15), bushings (14), washers (13), lockwashers (12) and nuts (11).
(3) Secure oil drain hose (10) to drain cock (8) with hose clamp (9).
(4) Connect two fuel hoses to APU.
(5) Connect the following wires to the remote control terminal block (7):
#1670M to #1 Terminal
#1671 to #2 Terminal
#1672 to #3 Terminal
#1673 to H Terminal
4-518
TM 5-4210-233-14&P-1
4-207. AUXILIARY POWER UNIT - Continued
(6) Connect wire #1 674 to terminal #2 of decompression solenoid relay (6).
(7) Secure one yellow and one green cable with mounting nut (5).
(8) Secure black cable to white wires #1 and #3 with wire nut (4).
(9) Install control box cover (3) and four screws (2).
(10) Connect exhaust pipe (1).
c. Follow-on Maintenance.
(1) Install APU air cleaner (see para 4-213).
(2) Connect batteries (see para 4-114).
4-519
TM 5-4210-233-14&P-1
4-208. APU BRUSHES
This task covers:
a. Inspection
b. Service
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove two screws (1) and endbell cover (2).
(2) Loosen two screws (3) and remove generator band (4).
(3) Remove brush (5) from spring holder (6) by pressing
spring holder (6) down and out as shown in broken
lines.
NOTE
If there is less than 5/8 in. (16 mm) of brush
remaining, it must be replaced.
(4) Tag brush lead (7) Remove nut (8) and disconnect
brush lead (7).
4-520
TM 5-4210-233-14&P-1
4-208. APU BRUSHES - Continued
b. Installation.
(1) Connect brush lead (7) and secure with nut (8).
NOTE
Install brushes with beveled top slanting down toward spring
holder.
(2) Position brush (5) and secure with spring holder (6).
(3) Install generator band (4) and secure with two screws (3).
(4) Install end bell cover (2) and secure with two screws (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-521
TM 5-4210-233-14&P-1
4-209. APU ANTI-FLICKER POINTS AND RESISTOR
This task covers:
a. Inspection
b. Service
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Adjust.
(1) Remove screw (1), lockwasher (2), anti-flicker
cover (3), and wire (4).
NOTE
Slightly burned points can be smoothed with a tile
or fine stone. Heavily damaged points must be
replaced.
(2) Rotate crankshaft to maximum point opening
and check point gap with feeler gauge.
NOTE
Correct point gap is .025" (.64 mm).
(3) Loosen and adjust stationary contact (5) to
correct gap of .025" (.64 mm).
4-522
TM 5-4210-233-14&P-1
4-209. APU ANTI-FLICKER POINTS AND RESISTOR - Continued
b. Removal.
(1) Remove plunger diaphragm (6), plunger guide (7) and plunger (8).
(2) Remove point set (9).
(3) Replace O-ring seal (1 0).
c. Installation.
(1) Install point set (9), plunger (8), plunger guide (7)
and plunger diaphragm (6).
(2) Adjust point gap to .025" (.64 mm). See para a. above.
(3) Install wire (4), anti-flicker cover (3), lockwasher (2)
and screw (1).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-523
TM 5-4210-233-14&P-1
4-210. APU PRIMARY FUEL FILTER
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Diesel Fuel (Item 41, Appendix E)
Primary Fuel Filter (Figure 212, Appendix F)
a. Removal.
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important the fuel
be kept clean. Dirt or water in the system can
cause severe damage to both the injection
pump and the injection nozzle.
CAUTION
When removing or installing drain plug on fuel
filter, use two wrenches in combination for
breaking plug loose and for final tightening.
(1) Remove drain plug (1) and drain primary filter (2).
(2) Remove bolt (3) and washer (4).
(3) Remove primary fuel filter (2).
b. Installation.
(1) Clean filter mounting area and moisten filter
gasket with diesel fuel (Item 41, Appendix E).
(2) Install new primary fuel filter until gasket touches
mounting base then tighten 1/4 to 1/2 turn.
(3) Install bolt (3) and washer (4).
(4) Install drain plug (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Prime fuel system and start and operate APU (see
para 2-16) and check for leaking. Tighten filter
in small increments till leaking ceases.
4-524
TM 5-4210-233-14&P-1
4-211. APU SECONDARY FUEL FILTER
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Diesel Fuel (Item 41, Appendix E)
Secondary Fuel Filter (Figure 212, Appendix E)
a. Removal.
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important the fuel
be kept clean. Dirt or water in the system can
cause severe damage to both the injection
pump and the injection nozzle.
CAUTION
When removing or installing drain plug on fuel
filter, use two wrenches in combination for
breaking plug loose and for final tightening.
(1) Remove drain plug (1) and drain secondary fuel filter (2).
(2) Remove bolt (3) and washer (4).
(3) Remove secondary fuel filter (2).
b. Installation.
(1) Clean filter mounting area and moisten filter
gasket with diesel fuel (Item 41, Appendix E).
(2) Install new secondary fuel filter until gasket touches
mounting base then tighten 1/4 to 1/2 turn.
(3) Install bolt (3) and washer (4).
(4) Install drain plug (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Prime fuel system and start and operate APU (see para
2-1 6) and check for leaking. Tighten filter
in small increments till leaking ceases.
4-525
TM 5-4210-233-14&P-1
4-212. APU OIL FILTER
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Oil, SAE 40 (Item 20, Appendix E)
Oil Filter (Figure 205, Appendix F)
a. Removal.
(1) Drain oil from oil filter (1) in a suitable
container.
(2) Remove oil filter (1) by turning counterclockwise
and discard.
(3) Clean filter mounting base (2).
b. Installation.
(1) Moisten filter gasket with oil (Item 20, Appendix E)
and install new oil filter (1). Turn on clockwise until
gasket touches mounting base (2).
(2) Tighten 1/4 to 1/2 additional turn.
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start and operate APU (see para 2-16) and
check for leaking. Tighten filter in small increments
till leaking ceases.
4-526
TM 5-4210-233-14&P-1
4-213. APU AIR CLEANER
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Oil, SAE 40 (Item 20, Appendix E)
Solvent, Dry Cleaning (Item 3, Appendix E)
a. Removal.
(1) Remove two wing nuts (1) and air
cleaner cover (2).
(2) Remove foam filter (3) and mesh filter (4)
from bracket (5).
(3) Inspect filters for damage. Replace filters
as needed.
b. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially
dangerous. Avoid repeated and prolonged
breathing of vapors and skin contact with the
liquid. Do not use near open flame, arcing
equipment or other ignition sources. Always
wear eye protection and protective clothing.
The flash point of P-D-680 is 100 to 138 deg.
F (38 to 59 deg. C).
Compressed air used for cleaning purposes
will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.)
(1) Clean filters in dry cleaning solvent (Item
3, Appendix E) and dry with compressed
air.
(2) Dip foam filter in clean oil (Item 20,
Appendix E).
(3) Squeeze dry foam filter.
4-527
TM 5-4210233-14&P-1
4-213. APU AIR CLEANER - Continued
c. Installation.
(1) Assemble mesh filter (4), foam filter (3), and install on bracket (5).
(2) Install air cleaner cover (2) and secure with two wing nuts (1).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-528
TM 5-4210-233-14&P-1
4-214. APU GLOW PLUG AND AIR INTAKE HEATER
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Gasket (Figure 214, Appendix F)
a. Removal.
(1) Loosen door screw (1) and remove air
housing door (2).
(2) Remove glow plug wire (3)..
(3) Remove glow plug (4) and glow plug
gasket (5).
(4) Remove air intake heater wires (6 and 7)
(5) Remove air intake heater (8) from air cleaner
adapter (9).
b. Installation.
(1) Install new glow plug gasket (5) and glow
plug (4). Torque glow plug to 10 to 15 ft Ibs
(14 to 20 N•m).
(2) Install glow plug wire (3).
(3) Install air intake heater (8) in air cleaner adapter
(9). Torgue heaterto 10 to 15 ft Ibs (14 to 20 N•m).
(4) Install air intake heater wires (6 and 7).
(5) Install air housing door (2) and secure with
door screws (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-529
TM 5-4210-233-14&P-1
4-215. APU EXHAUST SYSTEM
This task covers:
a. Inspection
b. Repair
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12 .)
APU Shutdown (see para 2-16 .)
Batteries Disconnected (see para 4-114 .)
MATERIALS/PARTS REQUIRED
Wire Brush (Item 62, Appendix E)
Penetrating Oil (Item 8, Appendix E)
a. Inspection.
WARNING
Exhaust parts can be hot enough to cause
severe burns if touched. Allow exhaust system
to cool before inspection or repair.
(1) Use a wire brush to remove loosen rust
and dirt from exhaust system.
(2) Check entire exhaust system for holes,
loose connections, and broken welds.
(3) Make sure exhaust clamps are tight and
undamaged.
(4) Make sure exhaust gasket is undamaged
and exhaust nuts are tight.
(5) Make sure exhaust lock tab is properly
secured.
4-530
TM 5-4210-233-14&P-1
4-215. APU EXHAUST SYSTEM - Continued
b. Repair.
NOTE
If components are excessively. corroded, apply
penetrating oil (Item 20, Appendix E) to ease disassembly.
(1) Disconnect exhaust tube (1) from elbow (2) at union (3).
(2) Remove four nuts (4), four lockwashers (5) and four washers (6) from u-bolts (7).
(3) Remove muffler (8) and exhaust tube (1) from truck.
(4) Remove muffler (8) from fitting (9).
(5) Remove fitting (10) from muffler (8).
(6) Replace any damaged parts.
(7) Install fitting (10) on muffler (8).
(8) Install muffler (8) in fitting (9).
(9) Install muffler (8) and exhaust tube (1) in truck. Secure muffler (8) with u-bolts (7), washers (6),
lockwashers (5) and nuts (4).
(10) Connect exhaust tube (1) to elbow (2) with union (3).
c. Follow-on Maintenance.
Connect Batteries (see para 4-114).
4-531
TM 5-4210-233-14&P-1
4-216. APU FUEL TRANSFER PUMP
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Butt Splice Connectors (Item 27, Appendix E)
a. Removal.
(1) Tag and disconnect two wires (1) from fuel
transfer pump (2).
(2) Tag two hoses (3 and 4) to ensure correct
connections at reassembly. Make note of
directional arrow on pump body.
(3) Loosen two hose clamps (5 and 6) and remove
hoses (3 and 4) from fuel transfer pump (2).
(4) Remove capscrew (7) and remove fuel transfer
pump (2).
b. Installation.
NOTE
Be sure directional arrow on fuel transfer
pump is facing in proper direction.
(1) Position fuel transfer pump (2) on chassis and
install capscrew (7).
(2) Install two hoses (3 and 4) on fuel transfer
pump (2) and tighten two hose clamps (5 and 6).
(3) Connect two wires (1) with butt splice connectors
(Item 27, Appendix E).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Start APU (see para 2-16) and check for leaks.
4-532
TM 5-4210-233-14&P-1
4-217. APU OIL PRESSURE SWITCH
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Remove screw (1). Tag and disconnect wire
(2) from oil pressure switch (3).
(2) Remove oil pressure switch (3) from elbow (4).
b. Installation.
(1) Install oil pressure switch (3) on elbow (4).
(2) Secure wire (2) to oil pressure switch (3) with
screw (1).
c. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-533
TM 5-4210-233-14&P-1
4-218. APU CRANKCASE BREATHER
This task covers:
a. Removal
c. Installation
b. Cleaning and Inspectiond. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
O-ring (Figure 203, Appendix F)
Solvent, Dry Cleaning (Item 3, Appendix E)
a. Removal.
(1) Loosen screw (1) and remove air housing door (2).
(2) Remove hose clamp (3) and hose (4).
(3) Loosen screw (5) and remove clamp (6).
(4) Remove two insulator halves (7).
(5) Remove breather cover (8), O-ring (10), and
breather (9). Discard O-ring.
b. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially
dangerous. Avoid repeated and prolonged
breathing of vapors and skin contact with the
liquid. Do not use near open flame, arcing
equipment or other ignition sources. Always
wear eye protection and protective clothing.
The flash point of P-D-680 is 100 to 138 deg.
F (38 to 59 deg. C).
Compressed air used for cleaning purposes
will not exceed 30 psi (207 kPa). Use only with
effective chip guarding and personal protective equipment (goggles/shield, gloves, etc.)
(1) Clean breather with dry cleaning solvent
(Item 3, Appendix E) and dry with compressed air.
c. Installation.
(1) Install new breather cover O-ring (1 0).
(2) Install breather (9) and breather cover (8).
4-534
TM 5-4210-233-14&P-1
4-218. APU CRANKCASE BREATHER - Continued
(3) Install two insulator halves (7) and clamp (6).
(4) Tighten screw (5).
(5) Install hose (4) and clamp (3).
(6) Install air housing door (2) and secure with screw (1).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
4-535
TM 5-4210-233-14&P-1
4-219. MITER BOX
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Follow-on Maintenance
TOOLS REQUIRED
MATERIALS/PARTS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Cleaning Solvent (Item 3, Appendix E)
Grade 2 Grease (Item 18, Appendix E)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B. Section III, Item 4)
Batteries Disconnected (see para 4-114.)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
a. Removal.
(1) Loosen two nuts (1 and 2).
(2) Remove shafts (3 and 4) from
miter box (5).
(3) Remove four screws (6) to remove miter box
(5) from bracket (7).
4-536
TM 5-4210-233-14&P-1
4-219. MITER BOX - Continued
b. Disassembly.
(1) Remove four screws (1) and lock washers (2) to separate 900 housing assemblies (3).
CAUTION
Keep shims (4) together as a shim pack and use same
ones for assembly to maintain correct backlash of miter
gears if shaft and gear assemblies are reused.
(2) Remove shims (4).
(3) Use a 5/64" (2 mm) drift pin and hammer to drive out two locking pins (5).
(4) Remove two oil seals (6) by center punching to cock in bore and lifting out with a pliers. Discard
them.
(5) Use a spanner wrench to remove two bearing retaining nuts (7).
(6) Unscrew relief fitting (8) and grease fitting (9) from 900 miter housings (3).
4-537
TM 5-4210-233-14&P-1
4-219. MITER BOX - Continued
(7) Rotate bevel gears (1 1) to align spring pins (1 0) with grease fitting and relief fitting holes.
(8) Use a drift pin through grease fitting and relief fitting holes to drive spring pins (1 0) out of bevel
gears (11).
(9) Press shafts (12) with ball bearings (13) out of bevel gears (1 1) and out of 900 miter housings
(3).
CAUTION
Support inner races of ball bearings (13) when pressing
shafts (1 2) out of them to prevent damaging bearings.
(10) Press shafts (12) from ball bearings (13).
c. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and
skin contact with the liquid. Do not use near open flame,
arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of
P-D-680 is 1 00 to 138 deg. F (38 to 59 deg. C).
(1) Wash all components using dry cleaning solvent (item 3, Appendix E).
(2) Clean and inspect ball bearings (1 3) as detailed in paragraph 4-9.
WARNING
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been
reduced to 30 psi (2.11 kg/cm2) or less. When working
with compressed air always use chip guards, eye protection and other personal protective equipment.
(3) After washing, dry all components (except ball bearings) using compressed air.
(4) Visually inspect threads of four screws (1), relief fitting (8), and grease fitting (9) for damage,
replace those with damaged threads.
(5) Visually inspect tapped holes in both 900 miter housings (3) for damage. Chase threads of those
which are damaged; if this doesn't produce satisfactory results, replace housing(s).
(6) Inspect splines of shafts (12) as detailed in paragraph 4-9.
(7) Inspect bevel gears (11) as detailed in paragraph 4-9.
4-538
TM 5-4210-233-14&P-1
4-219. MITER BOX - Continued
d. Assembly.
CAUTION
Support inner races of ball bearings (13) when
pressing shafts (12) into them to prevent
damaging bearings.
(1) Press shafts (12) into ball bearings (13).
(2) Insert shafts (12) and bearings (13) into
housings (3) and press bevel gears (11)
onto shafts, aligning timing marks on shafts
and gears. Press gears on until spring pin
holes in shaft and gear are aligned.
(3) Rotate bevel gears (11) to align spring pin
holes with grease fitting and relief fitting holes.
(4) Insert spring pins (10) into miter gears (11) and use pin punch to drive pins in until flush with gear
hubs.
(5) Use a spanner wrench to install two bearing retaining nuts (7), tighten till snug.
CAUTION
If same shaft (1 2) and bevel gear (11) assemblies are
reused, use same shims (4) as were removed to maintain
correct backlash of bevel gears.
(6) Press in two new oil seals (6) until they seat against bearing retaining nuts (7).
(7) Use a drift pin and hammer to drive locking pins (5) into housings (3) to secure bearing retaining
nuts (7) and seals (6).
(8) Install shims (4) between two 900 miter housings (3). Thickness of shim pack must be adjusted to
maintain .948" to .988" (25.09 to 24.08 mm) between housings (see illustration).
(9) Install four screws (1) and lock washers (2) to assemble 900 miter boxes (3) together. Torque
screws to 35 ft Ibs (47.5 N.m).
(10) With one shaft restrained, total backlash measured at the other shaft to be less than or equal to
0.010 inches (.254 mm) when measured with a dial indicator at a point 2.00 inches (50.8 mm)
from center of the shaft. This equates to 0.10 inches (2.54 mm) movement on a 20 inch (508
mm) steering wheel.
(11) Install relief fitting (8) and grease fitting (9) in housings (3).
4-539
TM 5-4210-233-14&P-1
4-219. MITER BOX - Continued
e. Installation.
(1) Attach miter box (5) to bracket (7) with four screws (6).
(2) Install shafts (3 and 4) on miter box (5).
(3) Torque nuts (1 and 2) to 35 ft lb (48 N.m).
f. Follow-on Maintenance.
(1) Apply grade 2 grease through grease fitting (9) until it is relieved by relief fitting (8).
(2) Connect batteries (see para 4-114).
4-540
TM 5-4210-233-14&P-1
4-220. PREPARATION FOR STORAGE OR SHIPMENT
This task covers:
a. Introduction
c. Storage Site Selection
b. Maintenance and Repair
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Cleaning Solvent (Item 3, Appendix E)
a. Introduction. Placement of equipment in administrative storage should be for short periods of
time when a shortage of maintenance effort exists. Items should be in mission readiness within
24 hours or within the time factors as determined by the directing authority. During the storage
period appropriate maintenance records will be kept.
b. Maintenance and Repair.
Before placing equipment in administrative storage, current
maintenance services and Equipment Serviceable Criteria (ESC) evaluations should be
completed, shortcomings and deficiencies should be corrected, and all Modification Work Orders
(MWO-s) should be applied.
c. Storage Site Selection. Inside storage is preferred for items selected for administrative storage.
4-541/(4-542 Blank)
TM 5-4210-233-14&P-1
CHAPTER 5
DIRECT SUPPORT MAINTENANCE
Contents
COMMON TOOLS AND EQUIPMENT ........................................................................
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT ...........................................
REPAIR PART ............................................................................................................
SERVICE UPON RECEIPT .........................................................................................
INTRODUCTION .........................................................................................................
TROUBLESHOOTING INSTRUCTIONS .....................................................................
DRIVE SHAFTS, UNIVERSAL JOINTS AND YOKES..................................................
FOAM TANK ASSEMBLY ...........................................................................................
FRONT SUCTION ASSEMBLY ...................................................................................
WATER TANK ASSEMBLY.........................................................................................
ENGINE ASSEMBLY...................................................................................................
STARTER MOTOR .....................................................................................................
STARTER SOLENOID ................................................................................................
STARTER REPAIR AND TESTING .............................................................................
OIL COOLER ..............................................................................................................
FUEL PUMP................................................................................................................
AIR COMPRESSOR....................................................................................................
ALTERNATOR ............................................................................................................
TACHOMETER DRIVE................................................................................................
AIR INLET ADAPTER..................................................................................................
BLOWER ....................................................................................................................
BLOWER REPAIR ......................................................................................................
TURBOCHARGER ......................................................................................................
EXHAUST MANIFOLD ................................................................................................
WATER PUMP ............................................................................................................
POWER STEERING PUMP ........................................................................................
OIL PAN ......................................................................................................................
DDEC ELECTRONIC CONTROL MODULE AND SENSORS......................................
TRANSMISSION GOVERNOR....................................................................................
SPEEDOMETER CABLE ASSEMBLY.........................................................................
RADIATOR..................................................................................................................
WHEEL LUGS.............................................................................................................
HUBS, BEARINGS, AND SEALS ................................................................................
REAR BRAKE AIR CHAMBER ....................................................................................
FRONT BRAKE AIR CHAMBER..................................................................................
BRAKE SHOES...........................................................................................................
BRAKE DRUMS ..........................................................................................................
AIR DRYER.................................................................................................................
STEERING GEAR .......................................................................................................
FRONT STEERING AXLE...........................................................................................
LEAF SPRINGS ..........................................................................................................
REAR TANDEM AXLE AND DIFFERENTIAL ..............................................................
FORWARD TANDEM AXLE AND DRIVE UNIT...........................................................
EXHAUST PIPE AND EXHAUST OUTLET PIPE.........................................................
MUFFLER ...................................................................................................................
SPARK ARRESTOR AND TAIL PIPE..........................................................................
FRONT FRAME EXTENSION .....................................................................................
HYDRAULIC OIL TANK...............................................................................................
5-1
Para
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
5-15
5-16
5-17
5-18
5-19
5-20
5-21
5-22
5-23
5-24
5-25
5-26
5-27
5-28
5-29
5-30
5-31
5-32
5-33
5-34
5-35
5-36
5-37
5-38
5-39
5-40
5-41
5-42
5-43
5-44
5-45
5-46
5-47
5-48
Page
5-3
5-3
5-3
5-3
5-3
5-3
5-28
5-34
5-35
5-38
5-41
5-62
5-64
5-68
5-87
5-90
5-96
5-97
5-109
5-111
5-114
5-123
5-144
5-163
5-165
5-174
5-180
5-182
5-189
5-190
5-191
5-195
5-196
5-199
5-201
5-203
5-207
5-208
5-216
5-236
5-247
5-255
5-286
5-323
5-325
5-326
5-327
5-329
TM 5-4210-233-14&P-1
Contents
POWER TAKE-OFF UNIT ...........................................................................................
HYDRAULIC SYSTEM COMPONENT TESTING ........................................................
HOIST CYLINDERS ....................................................................................................
HOIST MANIFOLD BLOCK .........................................................................................
PLANETARY SPEED REDUCER................................................................................
SWING BRAKE...........................................................................................................
SWING CROSSOVER RELIEF MANIFOLD BLOCK ...................................................
LADDER CONTROL VALVE .......................................................................................
OUTRIGGER BEAMS .................................................................................................
OUTRIGGER EXTEND/RETRACT CYLINDERS .........................................................
OUTRIGGER JACK CYLINDERS................................................................................
EMERGENCY HYDRAULIC PUMP AND MOTOR .......................................................
MAIN HYDRAULIC PUMP ...........................................................................................
SWING MOTOR..........................................................................................................
MONITOR AND NOZZLE ............................................................................................
FRONT EXTENSION/RETRACTION CYLINDER ........................................................
REAR EXTENSION/RETRACTION CYLINDER...........................................................
APU GENERATOR .....................................................................................................
APU FLYWHEEL.........................................................................................................
APU GEAR COVER ....................................................................................................
APU GOVERNOR CUP...............................................................................................
APU CAMSHAFT, GEAR AND BEARINGS .................................................................
APU CRANKSHAFT, BEARINGS AND SEALS ...........................................................
APU CYLINDER HEAD ...............................................................................................
DECOMPRESSION RELEASE....................................................................................
APU PISTONS, RINGS, AND CONNECTING RODS ..................................................
APU FUEL TRANSFER PUMP....................................................................................
APU ENGINE OIL PUMP AND OIL BASE ...................................................................
APU INJECTOR NOZZLE ...........................................................................................
APU INJECTION PUMP ..............................................................................................
APU GOVERNOR .......................................................................................................
APU VALVES..............................................................................................................
5-2
Para
5-49
5-50
5-51
5-52
5-53
5-54
5-55
5-56
5-57
5-58
5-59
5-60
5-61
5-62
5-63
5-64
5-65
5-66
5-67
5-68
5-69
5-70
5-71
5-72
5-73
5-74
5-75
5-76
5-77
5-78
5-79
5-80
Page
5-331
5-332
5-335
5-337
5-338
5-339
5-340
5-341
5-343
5-345
5-347
5-350
5-352
5-354
5-355
5-360
5-362
5-364
5-370
5-371
5-374
5-376
5-379
5-384
5-389
5-391
5-395
5-397
5-400
5-402
5-404
5-406
TM 5-4210-233-14&P-1
SECTION I. REPAIR PARTS, SPECIAL TOOLS,
TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE)
AND SUPPORT EQUIPMENT
5-1.
COMMON TOOLS AND EQUIPMENT. For authorized common tools and equipment, refer to the
Modified Table or Organization and Equipment (MTOE) applicable to your unit.
5-2.
SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT. No special tools, TMDE, or support
equipment are required by Direct Support Maintenance for the maintenance of the firetruck.
5-3.
REPAIR PARTS. Repair parts are listed and illustrated in Appendix F of this manual.
SECTION II. SERVICE UPON RECEIPT
5-4.
SERVICE UPON RECEIPT. See para 4-4.
SECTION III. TROUBLESHOOTING
5-5.
INTRODUCTION. This section contains step-by-step procedures for identifying, locating, isolating,
and repairing equipment malfunctions.
5-6.
TROUBLESHOOTING INSTRUCTIONS. The System Symptom Index, table 5-1, lists common
malfunctions which could be found during maintenance of the firetruck or its components.
a. Table 5-2 lists malfunctions which can occur during operation or maintenance of the firetruck or its
components. Each malfunction is followed by a list of tests or inspections which will help to determine
corrective action to be taken. Perform these tests, inspections, and corrective actions in the order
listed. Operation of a vehicle without a preliminary examination can cause further damage to a
disabled component and possible injury to personnel. By careful inspection and troubleshooting, such
damage and injury can be avoided. In addition, cause of faulty operation of a vehicle or component
can often be determined without extensive disassembly.
b. This manual can not list all malfunctions that may occur, nor all tests or inspections and corrective
actions. If a malfunction is not listed or is not corrected by listed correctable actions, notify your
supervisor.
5-3
TM 5-4210-233-14&P-1
Table 5-1. System Symptom Index
AUXILIARY POWER UNIT
Page
APU ENGINE LOW POWER..........................................................................................................
5-6
WATER PUMP AND PIPING
PUMP WILL NOT ENGAGE ...........................................................................................................
PUMP CASING LEAKS WATER WHILE PUMPING.......................................................................
5-6
5-6
RADIATOR
OIL IN RADIATOR COOLANT........................................................................................................
5-6
AIR SYSTEM/BRAKES
AIR COMPRESSOR FAILS TO MAINTAIN PRESSURE OR ADEQUATE AIR SUPPLY ................
AIR COMPRESSOR NOISY ...........................................................................................................
AIR RESERVOIRS AT 110 PSI OR GREATER..............................................................................
EXCESSIVE OIL IN PURGE WHEN COMPRESSOR UNLOADS, OR OIL IN AIR RESERVOIR....
5-7
5-7
5-7
5-7
STEERING SYSTEM
STEERING HARD IN ONE OR BOTH DIRECTIONS .....................................................................
STEERING EXTREMELY LIGHT IN ONE OR BOTH DIRECTIONS ...............................................
DARTING, WANDERING (OVER)STEERING ................................................................................
OIL LEAKING AT STEERING PUMP DRIVE SHAFT .....................................................................
OIL LEAKING AT OUTPUT SHAFT OF STEERING GEAR ............................................................
OIL LEAKING AT INPUT SHAFT OF STEERING GEAR ................................................................
STEERING WHEEL HAS EXCESSIVE BACKLASH.......................................................................
WHEELS WILL NOT ATTEMPT TO RETURN TO STRAIGHT-AHEAD POSITION ........................
WHEEL TURN ANGLE RESTRICTED ...........................................................................................
5-7
5-8
5-8
5-8
5-8
5-8
5-9
5-9
5-9
DRIVE LINE
HIGH PITCHED SQUEAL OR GRINDING SOUND FROM CENTER BEARING AREA ..................
5-10
ENGINE
FAILS TO CRANK ..........................................................................................................................
CRANKS-WILL NOT START..........................................................................................................
HARD TO START/STALLS AT IDLE SPEED/DOES NOT RUN SMOOTHLY.................................
FAILS TO DEVELOP FULL POWER..............................................................................................
OVERHEATS .................................................................................................................................
LOW OIL PRESSURE....................................................................................................................
HIGH OIL CONSUMPTION ............................................................................................................
5-4
5-10
5-10
5-10
5-11
5-12
5-12
5-13
TM 5-4210-233-14&P-1
Table 5-1. System Symptom Index - Continued
TRANSMISSION
Page
TRANSMISSION OVERHEATS IN ALL RANGES ..........................................................................
TRANSMISSION NOISY NOISE OCCURING INTERMITTENTLY (BUZZING) ...............................
TRANSMISSION WILL NOT SHIFT INTO GEAR, SLIPS OUT OF GEAR,
OR OPERATES ERRATICALLY.....................................................................................................
OIL LEAKING AT CONVERTER HOUSING ...................................................................................
EXCESSIVE CREEP IN FIRST AND REVERSE ............................................................................
AUTOMATIC SHIFTS OCCUR AT TOO HIGH A SPEED ...............................................................
AUTOMATIC SHIFTS OCCUR AT TOO LOW A SPEED - FULL THROTTLE ................................
ROUGH SHIFTS ............................................................................................................................
VEHICLE MOVES IN NEUTRAL ....................................................................................................
TRANSMISSION SLIPS IN ALL FORWARD GEARS .....................................................................
HIGH STALL SPEED......................................................................................................................
LOW STALL SPEED......................................................................................................................
5-15
5-16
5-16
5-17
5-17
5-17
5-18
5-18
5-19
5-19
5-20
5-20
FIREFIGHTING SYSTEM'
PUMP FAILS TO PRIME OR LOSES PRIME .................................................................................
ENGINE AND/OR PUMP SPEED TOO LOW AT FULL THROTTLE...............................................
ENGINE AND PUMP SPEED HIGHER THAN SPECIFIED FOR DESIRED PRESSURE
AND VOLUME................................................................................................................................
PRESSURE NOT RELIEVED WHEN DISCHARGE VALVES ARE CLOSED.................................
PRESSURE WILL NOT RETURN TO ORIGINAL SETTING AFTER DISCHARGE VALVES
ARE RE-OPENED..........................................................................................................................
HUNTING (FLUCTUATING PRESSURE) .......................................................................................
AIR OPERATED VALVE (FOR AERIAL DISCHARGE) FAILS TO OPEN OR CLOSE....................
5-21
5-22
5-22
5-22
5-23
5-23
5-23
HYDRAULIC SYSTEM
OUTRIGGERS WILL NOT OPERATE............................................................................................
AERIAL CONTROLS ARE INOPERATIVE .....................................................................................
LADDER RAISES OR EXTENDS SLOWLY OR ERRATICALLY ....................................................
ALL LADDER OPERATIONS ERRATIC OR SLOW .......................................................................
LADDER DOES NOT OPERATE....................................................................................................
LADDER WILL NOT LOWER.........................................................................................................
NO SWING OPERATION IN EITHER DIRECTION ........................................................................
SWING OPERATION ERRATIC IN EITHER DIRECTION ..............................................................
SWING OPERATION SLOW IN EITHER DIRECTION ...................................................................
ERRATIC OPERATION IN ALL HYDRAULIC CIRCUITS................................................................
JACK OUTRIGGER CYLINDER EXTENDS WHILE MACHINE IS ROADING.................................
SLOW OR ERRATIC OPERATION OF OUTRIGGER EXTENSION CYLINDERS ..........................
OUTRIGGER EXTENDS WHILE MACHINE IS ROADING .............................................................
OUTRIGGER VERTICAL STABILIZING CYLINDER SLOW OR ERRATIC ....................................
VERTICAL OUTRIGGER CYLINDER RETRACTS UNDER LOAD .................................................
EXCESSIVE PRESSURE BUILD-UP..............................................................................................
PUMP NOISE (ACCOMPANIED BY OIL FOAMING IN RESERVOIR) ............................................
5-5
5-23
5-24
5-24
5-24
5-24
5-24
5-24
5-25
5-25
5-25
5-26
5-26
5-26
5-26
5-27
5-27
5-27
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AUXILIARY POWER UNIT
1
APU ENGINE LOW POWER
Step 1. Check governor adjustment and linkage.
Adjust governor and/or replace linkage (see para 5-79).
Step 2. Check engine adjustments.
Check valve adjustment (see para 5-80), decompression release adjustment (see
para 5-73), injector opening pressure adjustment (see para 5-77), and injection pump
adjustment (see para 5-78).
Step 3. Test compression with gauge.
If compression is below 350 - 400 psi (2415 - 2760 kPa) at 1800 rpm, refinish or replace
valves and seats (see para 5-72), and/or replace piston rings (see para 5-74).
Step 4. Governor worn or damaged:
Repair governor (see para 5-79).
WATER PUMP AND PIPING
1
PUMP WILL NOT ENGAGE
Step 1. Check pump switch and shift linkage.
Step 2. Check power and ground connections at transmission lock up solenoids.
2
PUMP CASING LEAKS WATER WHILE PUMPING
Step 1. Check location of leak.
Repair pump as required (see para 6-6).
RADIATOR
1
OIL IN RADIATOR COOLANT
Sample radiator coolant and determine whether oil is from engine or transmission.
Overhaul engine or transmission as required (see Chapter 6).
5-6
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
AIR SYSTEM/BRAKES
1
AIR COMPRESSOR FAILS TO MAINTAIN PRESSURE OR ADEQUATE AIR SUPPLY
Check governor/governor setting.
Adjust or repair as required (see para 5-17).
2
AIR COMPRESSOR NOISY
Check bearings, shaft and housing for wear or damage.
Replace air compressor (see para 5-17).
3
AIR RESERVOIRS AT 110 PSI OR GREATER
Check governor/governor setting.
Replace air compressor (see para 5-17).
4
EXCESSIVE OIL IN PURGE WHEN COMPRESSOR UNLOADS, OR OIL IN AIR RESERVOIR
Check operation of compressor.
Replace air compressor (see para 5-17).
STEERING SYSTEM
1
STEERING HARD IN ONE OR BOTH DIRECTIONS
Step 1. Check wheel alignment.
Adjust tie rod ends (see para 5-40).
Step 2. Check axle king pins.
Replace king pins (see para 5-40 and 5-42).
Step 3. Check steering gear actuating valve.
Replace actuating valve and piston (see para 5-39).
Step 4. Check steering gear reversing springs.
Replace reversing springs (see para 5-39).
5-7
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEERING SYSTEM - Continued
1
STEERING HARD IN ONE OR BOTH DIRECTIONS - Continued
Step 5. Check for contamination in steering pump relief valve.
Clean or replace relief valve (see para 5-26).
2
STEERING EXTREMELY LIGHT IN ONE OR BOTH DIRECTIONS
Check steering gear reversing springs.
Replace reversing springs (see para 5-39).
3
DARTING, WANDERING (OVER)STEERING
Step 1. Check wheel alignment.
Adjust tie rod ends (see para 5-40).
Step 2. Check for looseness or worn axle steer joints.
Tighten or replace joints (see para 5-40).
Step 3. Check for worn or damaged steering gear.
Replace or repair steering gear (see para 4-161 or 5-39).
4
OIL LEAKING AT STEERING PUMP DRIVE SHAFT
Oil seal or shaft worn.
Repair or replace steering pump (see para 5-26).
5
OIL LEAKING AT OUTPUT SHAFT OF STEERING GEAR
Check quad ring seal and bronze bearings in steering gear.
Replace or repair steering gear (see para 4-161 and 5-39).
6
OIL LEAKING AT INPUT SHAFT OF STEERING GEAR
Check oil seals and actuating shaft.
Replace oil seals. Polish or replace actuating shaft (see para 5-39).
5-8
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
STEERING SYSTEM- Continued
7
STEERING WHEEL HAS EXCESSIVE BACKLASH
Step 1. Check pitman arm and tie rod ends.
Replace pitman arm and tie rod ends (see para 5-40).
Step 2. Check adjustment of drag link.
Adjust as required (see para 5-40).
Step 3. Check tightness of component mounting hardware.
Tighten mounting hardware as required.
Step 4. Check steering gear.
Replace or repair steering gear (see para 4-161 or 5-39).
8
WHEELS WILL NOT ATTEMPT TO RETURN TO STRAIGHT-AHEAD POSITION
Step 1. Check backlash in miter box.
Replace or repair miter box (see para 4-219).
Step 2. Check for looseness in tie rod ends.
Replace tie rod ends (see para 5-40).
Step 3. Check for loose steering shaft or worn splines.
Replace steering shaft (see para 4-160).
Step 4. Check axle king pins.
Replace axle king pins (see para 5-40).
Step 5. Check steering pump oil flow.
Replace or repair steering pump (see para 5-26).
9
WHEEL TURN ANGLE RESTRICTED
Check steering gear relief plungers.
Adjust as required (see para 5-39).
5-9
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
DRIVE LINE
1
HIGH PITCHED SQUEAL OR GRINDING SOUND FROM CENTER BEARING AREA
Check center bearing wear.
Replace drive shaft center bearing (see para 5-7).
ENGINE
1
FAILS TO CRANK
Step 1. Check battery charge and starter. Charge battery or repair or replace starter (para 5-12
and 5-14).
Step 2. Check if engine is internally seized. Try to rotate crankshaft by turning crankshaft pulley
clockwise. If engine does not turn, engine is seized.
Remove and repair engine (see para 5-11 and Chapter 6).
2
CRANKS - WILL NOT START
Step 1. Check fuel pump operation. Disconnect fuel line at inlet side of secondary fuel filter and crank
engine.
If no fuel flows from fuel line, replace or repair fuel pump (see para 5-16).
Step 2. Check injectors for free fuel flow. Remove fuel pipe between return manifold connector and
injector. Crank engine to pump fuel through injector. If fuel does not flow freely, tag injector,
replace fuel pipe, and check each injector same way.
Replace or repair tagged injectors (see para 6-43).
Step 3. Check for damaged or broken compression rings. Remove air box covers (see para 6-11).
Inspect three compression rings through ports in cylinder liners.
Replace damaged or broken compression rings (see para 6-33).
3
HARD TO START/STALLS AT IDLE SPEED/DOES NOT RUN SMOOTHLY
Step 1. Check exhaust valve and exhaust valve bridge clearance (see para 6-20 and 6-24).
Adjust exhaust valve and exhaust valve bridge clearances (see para6-20 and 6-24).
5-10
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
3
HARD TO START/STALLS AT IDLE SPEED/DOES NOT RUN SMOOTHLY - Continued
Step 2. Check for misfiring cylinders. Start engine. Hold injector follower down with a screwdriver to
prevent operation of injector. If cylinder has been firing properly, cylinder will miss with a
noticeable change in sound and engine operation. If cylinder has been misfiring, there will be
no noticeable change. Check all cylinders and tag misfiring injectors.
Remove tagged injectors (see para 6-43).
Test and repair injectors (see para 6-43).
Step 3. Repeat check for misfiring cylinder(s).
If cylinder(s) still misfire, perform engine tune-up.
Step 4. Check engine compression. lf minimum compression is not 450 psi (3101 kPa) at 600 rpm,
500 ft above sea level, remove air box covers (see para 6-11.). Variation between cylinders
must not exceed 25 psi (172 kPa). Inspect compression rings through ports of cylinder liners.
Replace damaged or broken compression rings (see para 6-33).
4
FAILS TO DEVELOP FULL POWER
Step 1. Perform engine tune-up.
Step 2. Check exhaust manifold for leaks.
Tighten loose connections (see para 5-24).
Replace damaged exhaust manifold gaskets (see para 5-24).
Replace damaged exhaust manifolds (see para 5-24).
Step 3. Check if cylinder liner ports are clogged. Remove air box covers (see para 6-11).
Check and clean cylinder ports if clogged (see para 6-32).
Step 4. Inspect turbocharger for free movement.
Replace or repair defective turbocharger (see para 5-23).
Step 5. Check operation of electronic engine control.
Repair or replace electronic engine control (see para 5-28 and 6-28).
5-11
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
5
OVERHEATS
Step 1. Check radiator fluid level.
Fill if necessary (see para 4-141).
Step 2. Check fan belts.
Replace defective fan belts (see para 4-131).
Step 3. Check the thermostat and seals.
Repair or replace as necessary (see para 4-136).
Step 4. Check radiator core for obstructions.
Remove obstructions.
Step 1. Check freeze plugs (four on each side of engine) for coolant leaks.
Replace defective freeze plugs (cup plugs) (see para 6-8).
Step 2. Check water pump impeller for looseness. Drain coolant below level of waterpump, remove
retaining ring, pump cover and preformed packing. Try to move impeller in and out to detect
play indicating worn bearings, gears, or seal.
Remove damaged water pump (see para 5-25).
Replace or repair water pump (see para 5-25).
6
LOW OIL PRESSURE
Step 1. Check for clogging of oil pump inlet screens. Remove oil pan (see 5-27).
Remove and clean oil pump inlet screens (see para 6-44).
Replace damaged screens (see para 6-44).
5-12
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
6
LOW OIL PRESSURE - Continued
Step 2. Inspect oil pressure regulator valve for clogging or damage.
Remove and clean oil pressure regulator valve (see para 6-45).
Inspect valve, valve seat, and valve spring for damage (see para 6-45).
Replace damaged parts (see para 6-45).
Step 3. Inspect oil pressure relief valve for clogging or damage.
Remove and clean oil pressure relief valve (see para 6-45).
Inspect valve, valve seat, and valve spring for damage (see para 6-45).
Replace damaged parts (see para 6-45).
Step 4. Inspect oil pump for damaged parts.
Remove and clean oil pump (see para 6-46).
Inspect oil pump for worn, scored, or damaged parts (see para 6-46).
Replace worn or damaged parts (see para 6-46).
7
HIGH OIL CONSUMPTION
Step 1. Check if oil breather tube assemblies are clogged or damaged.
Remove and clean breather tube assembly (see para 4-140).
Step 2. Check for low air box pressure. Air box pressure, with zero exhaust back pressure, should
be 1.1 in. (27.9 mm) mercury at 1200 rpm, 3.8 in. (96.5 mm) mercury at 1800 rpm, and 5.0 in.
(127 mm) mercury at 2100 rpm.
If pressure is low, do Steps 3 and 4.
Step 3. Check if blower-to-block gasket is damaged (see para 5-21).
Replace damaged gasket (see para 5-21).
5-13
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
ENGINE - Continued
7
HIGH OIL CONSUMPTION - Continued
Step 4. Check if front end plate gasket is leaking (see para 6-9).
Replace leaking front end plate gasket (see para 6-9).
Step 5. Check for head gasket leaks by performing engine compression check, minimum of 450 psi
(3101 kPa) at 600 rpm, 500 ft above sea level. Variation between cylinders must not exceed
25 psi (172 kPa).
Replace leaking gaskets (see para 6-13).
Step 6. Check turbocharger oil seals for wear or damage (see para 5-23).
Replace defective seals (see para 5-23).
Step 7. Start engine and check if blower oil seal leaks.
Repair blower (see para 5-22).
Step 8. Check for damaged or broken piston rings and pistons or liners (see para 6-32 and 6-33).
Replace damaged or broken piston rings, pistons, or liners (see para 6-32 and 6-33).
5-14
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION
Perform transmission stall test when power package (engine and transmission) is not performing
satisfactorily. Purpose of test is to find out if transmission or engine is defective.
WARNING
Apply both parking and service brakes when performing
transmission stall test. Block wheels to prevent forward
or reverse movement. In the event of brake failure and/or
improper blocking of wheels, vehicle can suddenly move
forward or backward and may cause personal injury or
death.
Chock wheels to prevent forward or reverse movement.
Set parking brake.
Start engine and set service brakes.
Set transmission to 2 position.
CAUTION
Do not maintain stall condition longer than 30 seconds.
Transmission oil can become overheated and damage to
transmission may occur. Do not allow temperature to
exceed 300°F (149°C). Keep close check to prevent
engine cooling system from overheating. If engine overheating occurs, place transmission in N (neutral) and run
engine at 1500 to 1800 RPM to cool engine.
Accelerate engine to full throttle. Write down maximum rpm engine will run (torque converter stall speed).
Stall speed should be 2100 rpm (+ 150 rpm).
If high engine speed is noted, go to MALFUNCTION 9.
If engine speed is low, go to MALFUNCTION 10.
1
TRANSMISSION OVERHEATS IN ALL RANGES
Step 1. Oil cooler lines are restricted (can cause excessive fuel consumption). Remove
restrictions; clean or replace lines. (Refer to vehicle service manual).
5-15
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION - Continued
1
TRANSMISSION OVERHEATS IN ALL RANGES - Continued
Step 2. Broken parts in converter (can cause excessive fuel consumption). Replace or overhaul
converter assembly.
Step 3. Aerated oil. Adjust oil to proper level; check for defective seal ring at suction tube; check
for defective pump.
Step 4. Cooler flow loss due to internal leakage. Overhaul transmission.
2
NOISE OCCURRING INTERMITTENTLY (BUZZING)
Step 1. Oil level is low. Add oil to proper level. Be sure dipstick calibration is correct.
Step 2. Seal ring on oil pickup tube is damaged or missing. Replace pickup tube seal ring
and filter.
Step 3. Filter is clogged. Replace filter.
Step 4. Aerated oil. Check for improper oil level.
Step 5. Hole in filter. Replace filter.
3
TRANSMISSION WILL NOT SHIFT INTO GEAR, SLIPS OUT OF GEAR,
OR OPERATES ERRATICALLY
Step 1. Check for low main pressure. Remove line from main pressure port on transmission and
install tee and 0 to 300 psi (O to 2070 kPa) gauge. Start engine and allow to run at idle
speed. With parking brake applied, shift transmission into D (Drive). Check for 90 psi
(621 kPa) main system pressure.
Step 2. Check for clogged internal filter element. Remove oil pan (see para 6-53).
If internal filter element is clogged, replace internal filter element (see para 6-54).
Step 3. Check for damaged or missing preformed packing on internal filter pickup tube.
If preformed packing is damaged or missing, replace preformed packing and gasket
(see para 6-54).
If preformed packing is not damaged or missing, disassemble transmission and inspect oil
pump, main pressure regulator valve, control valve body for leakage or sticking valves
(see para 6-50, 6-51 and 6-62).
5-16
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION - Continued
3
TRANSMISSION WILL NOT SHIFT INTO GEAR, SLIPS OUT OF GEAR,
OR OPERATES ERRATICALLY - Continued
Step 4. Remove oil pan (see para 6-53). Manually shift transmission and see if manual shaft and
detent lever engage selector valve and that actuator pin is attached to detent lever.
If selector valve does not engage detent lever, repair or replace defective parts
(see para 6-62).
If selector valve engages detent lever, disassemble transmission and valve body to check
for worn clutch packs in transmission, loose valve body screws, and sticking valves invalve
body (see para 6-52, 6-57, 6-59, 6-60 and 6-61).
4
OIL LEAKING AT CONVERTER HOUSING
Step 1. Remove cover from top of converter housing. Check for signs of oil.
If engine oil is inside housing, replace rear engine crankshaft oil seal (see para 6-31).
If transmission oil is inside housing, inspect inner converter housing mounting screws,
converter pump to converter housing seal ring, converter housing gasket, torque converter
cover seal ring, oil pump seal, pilot attachment screws, pump hub seal rings and converter
pump hub (see para 6-51).
5
EXCESSIVE CREEP IN FIRST AND REVERSE
Step 1. Check for too high engine idle speed.
If idle speed is more than 750 rpm, adjust engine idle speed.
If there is any lockup pressure, inspect lockup clutch valve for sticking pistons (para 6-64).
6
AUTOMATIC SHIFTS OCCUR AT TOO HIGH A SPEED
Step 1. Governor valve malfunctioning (stuck). Clean or replace governor screen and/or governor.
Step 2. Vacuum modulator vacuum hose to engine kinked or leaking - light throttle shifting delayed.
Step 3. Modulation delayed (vacuum). Replace vacuum modulator. Be sure that O-ring is installed.
Step 4. Mechanical actuator cable is kinked, broken, or not properly adjusted. Replace, adjust,
or repair cable. Full modulator travel must correspond with full throttle.
Step 5. Mechanical actuator malfunctioning. Replace actuator.
Step 6. Shift signal valve adjustment is too high. Adjust shift speeds.
5-17
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION - Continued
6
AUTOMATIC SHIFTS OCCUR AT TOO HIGH A SPEED - Continued
Step 7. Valve is sticking. Back off spring adjustment ring to specification.
Step 8. Improper modulator. Check modulator valve and modulator body.
7
AUTOMATIC SHIFTS OCCUR AT TOO LOW A SPEED - FULL THROTTLE
Step 1. Governor spring weak or missing. Replace governor.
Step 2. Mechanical actuator kinked, broken, or not properly adjusted. Replace, adjust, or repair
cable. Full modulator travel must correspond with full throttle.
Step 3. Shift signal valve spring adjustment too loose. Tighten spring adjusting ring to specification.
Step 4. Modulator valve stuck open. Check spring adjustment clean or replace modulator valve.
8
ROUGH SHIFTS
Step 1. Governor valve malfunctioning. Clean or replace governor screen and/or governor.
Step 2. Vacuum modulator valve hose kinked or leaking. Replace hose, check spring adjustment.
Step 3. Mechanical actuator cable kinked, broken, or not properly adjusted. Replace, adjust,
or repair cable. Full modulator travel must correspond with full throttle.
Step 4. Mechanical actuator malfunctioning. Replace actuator.
Step 5. Vacuum modulator failed. Replace vacuum modulator. Be sure that O-ring is installed.
Step 6. Trimmer valve sticking (broken spring). Replace or rebuild control valve body assembly.
Step 7. Control valves sticking. Replace or rebuild control valve body assembly.
Step 8. Modulator valve sticking. Clean valve. Check vacuum modulator, adjust spring.
Step 9. Engine idle speed too fast (N to D). Adjust engine idle screw.
Step 10. Selector linkage out of adjustment. Adjust linkage.
Step 11. Vacuum modulator valve spring not adjusted properly. Adjust spring.
5-18
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION - Continued
9
VEHICLE MOVES IN NEUTRAL
Step 1. Remove oil pan (see para 6-53). Manually shift transmission and see if the manual shaft
and detent lever are engaging with selector valve and that actuator pin is attached to detent
lever.
If selector valve does not engage replace defective parts (see para 6-62).
If selector valve engages, disassemble transmission and valve body to check for applied
clutch packs or leaking or sticking valves in valve body (see para 6-57, 6-58, 6-59, 6-60,
6-61 and 6-62).
10
TRANSMISSION SLIPS IN ALL FORWARD GEARS
Step 1. Check for low main pressure. Remove line from main pressure port on transmission and
install a tee and a 0 to 300 psi (O to 2070 kPa) gauge. Start engine and allow to run at idle
speed. With parking brake applied, shift transmission into D (drive) check for 90 psi
(621 kPa) main system pressure.
Step 2 If pressure is less than 90 psi (621 kPa).
- Check for low oil level, add oil to proper level.
- Oil filter element is clogged, replace oil filter.
- Seal ring on oil pickup tube damaged or missing, install new seal ring.
- Main pressure regulator valve spring is weak, replace spring.
- Control valve body leaking, replace or overhaul valve body assembly.
- Valves sticking (trimmer relays and main pressure regulator), overhaul valve body
assembly.
- Oil pump worn or damaged, replace or overhaul oil pump.
- Priority valve is missing, replace valve.
Step 3. If pressure is less than 90 psi (621 kPa).
- Forward clutch is defective, overhaul forward clutch.
5-19
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
TRANSMISSION - Continued
11
HIGH STALL SPEED
Step 1. Check for low main pressure. Remove line from main pressure port on transmission and
install a tee and a 0 to 300 psi (0 to 2070 kPa) gauge. Start engine and allow to run at idle
speed. With parking brake applied, shift transmission into D (drive) and accelerate engine
to approximately 1200 rpm. Check for 140 to 175 psi (965 to 1206 kPa) main system
pressure.
Step 2. If pressure is less than 140 psi (965 kPa). Refer to Part 9, Step 2.
Step 3. If pressure is less than 140 psi (965 kPa).
- Forward clutch is slipping, overhaul forward clutch.
- First clutch is slipping, overhaul first clutch.
- Fourth clutch is slipping (reverse), overhaul fourth clutch.
- Low clutch is slipping, overhaul low clutch.
12
LOW STALL SPEED
NOTE
Do Step 1, then run stall check. If problem remains, go to
Step 2.
Step 1. Go to Engine troubleshooting, ENGINE FAILS TO DEVELOP FULL POWER.
Step 2. Check for damaged torque converter. Disassemble torque converter stator, pump, and
housing (see para 6-49, 6-50 and 6-51).
Replace damaged torque converter parts (see para 6-49, 6-50 and 6-51).
5-20
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM
1
PUMP FAILS TO PRIME OR LOSES PRIME
Step 1. Air Leaks.
Use the following procedure to locate air leaks:
a.
Connect suction hose to pump and attach suction cap to intake end of hose.
b.
Close all pump openings.
c.
Open priming valve and operate primer until vacuum gauge indicates 20 to 22 in. Hg
(508 to 559 mm). (If primer fails to draw specified vacuum, it may be defective, or
leaks are too large for primer to handle.)
d.
Close priming valve and shut off primer. If vacuum drops more than 1 0 in. Hg (254
mm) in 1 0 minutes, serious air leaks are indicated. With engine stopped, air leaks are
frequently audible.
e.
If leaks cannot be heard, apply engine oil to suspected points and watch for break in
film or oil being drawn into pump.
f.
Connect suction hose to hydrant or auxiliary pump. Open one discharge valve and run
in water until pump is completely filled and all air expelled. Close discharge valve,
apply pressure to system and watch for leaks. A pressure of 100 psi (690 kPa) is
sufficient. DO NOT EXCEED RECOMMENDED PRESSURES.
g.
If pump has not been operated for several weeks, packing may be dried out. Close
discharge and drain valves and cap suction openings. Operate primer to build up a
strong vacuum in pump; run pump slowly, and apply oil to impeller shaft near packing
gland. Also, make sure packing is adjusted properly.
Step 2. Faulty wiring.
Check all wiring to the priming pump and valve for loose terminals, damaged insulation, or
broken wire strands, especially near terminals.
Step 3. Mechanical failure.
If priming pump does not operate, remove priming motor and manually turn rotor shaft. It
should turn freely without binding. Unless the priming pump is properly maintained, sediment
in the water being pumped may cause it to stick.
5-21
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
1
PUMP FAILS TO PRIME OR LOSES PRIME - Continued
NOTE
Oil the priming pump after each operation in accordance
with the lubrication instructions.
Step 4. Defective priming motor solenoid.
Refer to electrical troubleshooting procedures (see Chapter 4).
2
ENGINE AND/OR PUMP SPEED TOO LOW AT FULL THROTTLE
Step 1. Insufficient power.
Engine requires maintenance (see Chapter 6).
Step 2. Relief valve set improperly.
Adjust relief valve (see para 2-13).
NOTE
If relief valve is set to relieve below desired operating
pressure, water will bypass and reduce capacity.
3
ENGINE AND PUMP SPEED HIGHER THAN SPECIFIED FOR DESIRED PRESSURE AND
VOLUME
Pump impellers or wear rings badly worn.
Install undersize wear rings if impeller to wear ring clearance is within limits indicated in
MAINTENANCE INSTRUCTIONS. If not, install new impellers and wear rings (see para 6-6).
4
PRESSURE NOT RELIEVED WHEN DISCHARGE VALVES ARE CLOSED
Step 1. Pilot valve sticking.
Disassemble and clean (see para 4-36). Replace noticeably worn parts.
Step 2. Incorrect assembly or plugged tube lines.
Disconnect lines and inspect. Check to be sure the drain valve is sealing correctly and
not bypassing water.
5-22
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
FIREFIGHTING SYSTEM - Continued
5
PRESSURE WILL NOT RETURN TO ORIGINAL SETTING AFTER DISCHARGE VALVES
ARE RE-OPENED
Pilot valve sticking.
Disassemble and clean (see para 4-36). Replace noticeably worn parts.
6
HUNTING (FLUCTUATING PRESSURE)
Sticky pilot valve or faulty relief valve.
Disassemble and clean (see para 4-35 and 4-36). Replace worn parts.
7
AIR OPERATED VALVE (FOR AERIAL DISCHARGE) FAILS TO OPEN OR CLOSE
Step 1. Aerial discharge valve failed in open or closed position.
Remove pneumatic actuator and use a wrench on the valve shaft to open or close the valve
manually. If the valve does not move freely, replace the valve (see para 4-199).
Step 2. Pneumatic actuator defective.
Replace actuator (see para 4-200).
Step 3. Pneumatic actuator switch defective.
Replace pneumatic actuator switch (see para 4-179).
HYDRAULIC SYSTEM
1
OUTRIGGERS WILL NOT OPERATE
Step 1. Check power take-off operation.
Refer to hydraulic component testing (see para 5-50).
Step 2. Main hydraulic pump not operating.
Refer to hydraulic system component testing (see para 5-50).
Step 3. Pressure reducing (de-stroking) valve malfunctioning.
Refer to hydraulic system component testing (see para 5-50).
Step 4. Diverter valve malfunctioning.
Replace diverter valve (see para 4-193).
5-23
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
2
AERIAL CONTROLS ARE INOPERATIVE
Diverter valve malfunctioning.
Replace diverter valve (see para 4-193).
3
LADDER RAISES OR EXTENDS SLOWLY OR ERRATICALLY
Cylinder piston seals leaking.
Remove hoist and/or extension cylinders and replace piston seals, (see para 6-70 and 6-77).
4
ALL LADDER OPERATIONS ERRATIC OR SLOW
Refer to hydraulic system component testing (see para 5-50) to test pressure reducing (de-stroking)
valve.
5
LADDER DOES NOT OPERATE
Step 1. Diverter valve has not shifted to aerial position.
Replace diverter valve (see para 4-193).
Step 2. Ladder control valve malfunctioning.
Replace control valve (see para 5-56).
6
LADDER WILL NOT LOWER
Ladder control valve has failed (raise or lower).
Replace ladder control valve (see para 5-56).
7
NO SWING OPERATION IN EITHER DIRECTION
Step 1. Swing brake not releasing properly.
Replace or repair as necessary (see para 5-54 and 6-73).
Step 2. Worn or defective swing motor.
Replace or repair as necessary (see para 5-62 and 6-76).
Step 3. Internal damage to planetary speed reducer.
Repair or replace as necessary (see para 5-53 or 6-72).
5-24
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
7
NO SWING OPERATION IN EITHER DIRECTION - Continued
Step 1. Defective turntable control valve.
Replace turntable control valve (see para 5-56).
Step 2. Defective swing motor thermal relief valve.
Replace swing motor thermal relief valve in port N of swing cross-over manifold block
(see para 6-74).
8
SWING OPERATION ERRATIC IN EITHER DIRECTION
Step 1. Defective gear or bearing in planetary speed reducer.
Repair or replace planetary speed reducer as necessary (see para 5-53 or 6-72).
Step 2. Defective swing motor.
Repair or replace swing motor as necessary (see para 5-62 and 6-76).
9
SWING OPERATION SLOW IN EITHER DIRECTION
Step 1. Swing brake not releasing.
Repair as necessary (see para 5-54 and 6-73).
Step 2. Worn or defective swing motor.
Repair or replace swing motor as necessary (see para 5-62 or 6-76).
10
ERRATIC OPERATION IN ALL HYDRAULIC CIRCUITS
Step 1. Pressure reducing (de-stroking) valve defective.
Refer to hydraulic system component testing (see para 5-50) before replacing valve.
Step 2. Worn or defective hydraulic pump.
Refer to hydraulic system component testing (see para 5-50.) and repair or replace as
necessary (see para 5-61 or 6-75).
5-25
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
11
JACK OUTRIGGER CYLINDER EXTENDS WHILE MACHINE IS ROADING
Step 1. Defective double pilot operated check valve.
Refer to hydraulic system component testing (see para 5-50).
Step 2. Leaking piston seals or internal damage.
Replace seals (see para 5-59).
12
SLOW OR ERRATIC OPERATION OF OUTRIGGER EXTENSION CYLINDERS
Step 1. Scored valve spool in outrigger control valve.
Replace (see para 4-190).
Step 2. Defective extension cylinder (internal parts).
Remove extension cylinder and repair as necessary (see para 4-194 and 5-58).
Step 3. Worn or defective main hydraulic pump.
Repair or replace pump (see para 5-61 and 6-75).
13
OUTRIGGER EXTENDS WHILE MACHINE IS ROADING
Step 1. Air in system.
Purge system by extending and retracting, lowering and raising outrigger to its full travel
limits several times.
Step 2. Leaking piston seals or internal damage.
Replace required seals (see para 4-194 and 5-58).
14
OUTRIGGER VERTICAL STABILIZING CYLINDER SLOW OR ERRATIC
Step 1. Air in system.
Purge system by extending and retracting, lowering and raising outrigger to its ull
f travel
limits several times.
Step 2. Leaking piston seals or internal damage.
Replace seals (see para 4-195 and 5-59).
5-26
TM 5-4210-233-14&P-1
Table 5-2. Direct Support Troubleshooting - Continued
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
HYDRAULIC SYSTEM - Continued
14
OUTRIGGER VERTICAL STABILIZING CYLINDER SLOW OR ERRATIC - Continued
Step 3. Binding outrigger housing.
Repair or replace outrigger housing.
Step 4. Worn or defective main hydraulic pump.
Repair or replace pump (see para 5-61 or 6-75).
15
VERTICAL OUTRIGGER CYLINDER RETRACTS UNDER LOAD
Step 1. Defective double pilot operated check valve.
Replace pilot check valve (see para 4-195).
Step 2. Leaking piston seals or internal damage.
Replace piston seals (see para 4-195 and 5-59).
16
EXCESSIVE PRESSURE BUILD-UP
Defective pump pressure compensating valve.
Clean, repair, or replace as necessary (see para 6-75).
17
PUMP NOISE (ACCOMPANIED BY OIL FOAMING IN RESERVOIR)
Air entering at suction manifold.
Check all lines for security, manifold for cracks and proper attachment. Tighten, repair, or
replace components as necessary.
5-27
TM 5-4210-233-14&P-1
5-7. DRIVE SHAFTS, UNIVERSAL JOINTS AND YOKES
This task covers:
a. Removal of Drive Shafts
e. Cleaning and Inspection
b. Inspection of Drive Shafts
f. Installation of Universal Joints
c. Installation of Drive Shafts
g. Follow-on Maintenance
d. Removal of Universal Joints
TOOLS REQUIRED
MATERIALS/PARTS REQUIRED
Tool Kit, General Mechanics, Automotive
Penetrating Oil (Item 8, Appendix E)
(Appendix B, Section III, Item 1)
High Temperature Grease (Item 15, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
Shop Equipment, Automotive
Lint Free Cloth (Item 42, Appendix E)
Maintenance and Repair
(Appendix B, Section III, Item 4)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal of Drive Shafts.
(1) If the drive shaft universal joint locking
screws and straps are corroded, apply
penetrating oil (Item 8, Appendix E) to ease
disassembly.
(2) Mark all yokes and slip joints before
removal. This will ensure alignment of
components during installation.
(3) Using a hammer and chisel bend down the
ears on the two lockstraps (2) attached to
the yoke opposite the drive shaft to be
removed.
(4) Remove capscrews (1) and lockstraps (2).
(5) Turn the yoke until the bearing plates (3) are
vertically aligned. If necessary, raise the
front or rear axle.
(6) Using a floor jack and a block of wood, jack
the wooden block up until it contacts the
drive shaft end yoke (4) as shown.
(7) Continue to jack the block up until it forces
the upper bearing plate (3) out of the yoke.
(8) Once the upper bearing plate has been
removed, lower the jack and rotate the shaft
a half turn. Remove the second bearing
plate similar to steps 5, 6, and 7.
5-28
TM 5-4210-233-14&P-1
5-7. DRIVE SHAFTS, UNIVERSAL JOINTS AND YOKES - Continued
(9)
Support removed end of drive shaft using mechanics wire.
(10) Remove the bearing plates from the opposite end of the drive shaft similar to steps (3) through (9)
preceding.
(11) Carefully maneuver universal joint cross (5) out of the end yokes(4 or 7). Do not use force as this
can damage the bearing surfaces.
b. Inspection of Drive Shafts.
(1)
Using a clean, dry, lint free cloth (Item 42,
Appendix E) wipe exposed universal joint cross
journals.
(2)
Visually inspect exposed universal joint cross
journals and needle bearings in bearing plates.
Look for defects caused by lack of lubrication
and physical damage. If corrosion, pitting,
unusual wear or missing bearing needles is
evident, the universal joint must be replaced.
(3)
Check the remaining two universal joint
bearings. Grasp the universal joint cross as
shown, and oscillate the cross. Binding or
looseness indicates a defective bearing. If
damage is evident, the universal joint must be
replaced.
(4)
Apply a small amount of grease (Item 15,
Appendix E) to needle bearings of removed
bearing plates.
(5)
Install the bearing plates (3) to the universal
joint cross (5).
(6)
Turn and test each bearing plate on the cross
journals as shown. The movement must be
smooth and resistance free.
(7)
Install universal joint in a vise so the loose
bearing plates are clamped to the cross. Using
a grease gun, lubricate the universal joint until
grease (Item 15, Appendix E) is expelled from
all four bearing plates. If grease nipple is
blocked, remove and replace.
(8)
Remove universal joint from vise and temporarily tape or wire bearing plates to cross.
(9)
Visually inspect drive shafts for dents,
excessive corrosion, cracked welds, or missing
balance weights.
(10) If a drive shaft is damaged it should be replaced
along with the universal joints.
5-29
TM 5-4210-233-14&P-1
5-7. DRIVE SHAFTS, UNIVERSAL JOINTS AND YOKES - Continued
c.
Installation of Drive Shafts.
CAUTION
Ensure that the universal joint bearings stay clean. Contamination induced in bearings will severely cut the service life of the
universal joints.
During installation, damage to universal joint may occur if cross
binds on needle bearings. When tightening the bearing plates,
oscillate the universal joint cross and stop tightening capscrews
at the first sign of resistance.
(1)
Remove tape or wire retaining bearing plates and remove these from cross that is to be installed.
(2)
Support end of the drive shaft being installed
using mechanics wire.
(3)
Maneuver the universal joint cross (5) into yoke
so that cross journals are positioned in yoke
lugs (6).
(4)
Install bearing plate (3). Push journal of cross
(5) through the yoke lugs (6) and into needle
bearing in bearing plate.
(5)
While supporting the cross, to prevent
separation of cross and bearing, use a
hammer, and with the cross aligned, lightly tap
bearing plate (3) until it is completely installed.
(6)
Install lockstrap (2) and finger tighten both capscrews (1).
(7)
Rotate drive shaft and yoke one half turn to facilitate installation of the second bearing plate.
(8)
Carefully install bearing plate onto the opposite arm of the cross.
(9)
Install lockstrap and finger tighten both capscrews.
(10) Repeat step 1 at other end of drive shaft.
(11) Install the second universal joint. Repeat procedure detailed in steps 3 through 9.
(12) Torque all capscrews (1) to 40 ft lb (54 Nm).
(13) Secure capscrews by bending up lockstrap tabs.
5-30
TM 5-4210-233-14&P-1
5-7. DRIVE SHAFTS, UNIVERSAL JOINTS AND YOKES - Continued
d. Removal of Universal Joints.
NOTE
The universal joints used in the truck drive line are all the same.
The steps below describing removal and installation procedures
are common to all joints.
If the drive shaft fasteners are corroded, apply penetrating oil
(Item 8, Appendix E) to ease disassembly.
(1)
Support the drive shaft (1) in a vise.
(2)
Using a hammer and chisel, bend down
the ears on lockstrap (4).
(3)
Remove capscrews (3) and remove the
lockstrap (4).
(4)
Rotate bearing plate (5) about 1/4 turn
and, using a hammer and chisel, partially
separate bearing plate (5) from yoke (2) as
shown.
(5)
Using a pry bar on each side of the
bearing plate (5) pry on the plate until it is
removed from the yoke (2).
(6)
Repeat steps 2, 3, 4, and 5 on the
opposite bearing plate. If the bearing
cannot be removed by this method, use a
puller to pull the bearing plate.
(7)
Carefully maneuver the cross out of the
yoke.
5-31
TM 5-4210-233-14&P-1
5-7. DRIVE SHAFTS, UNIVERSAL JOINTS AND YOKES - Continued
e. Cleaning and Inspection.
(1)
Visually inspect exposed universal joint cross journals and needle bearings in bearing plates. Look
for defects caused by lack of lubrication and physical damage. If corrosion, pitting, universal wear or
missing bearing needles are evident, the universal joint must be replaced.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
(2)
Using dry cleaning solvent (Item 3, Appendix E) and a brush, wash universal joint crosses and yokes.
Do not attempt to disassemble or wash bearing plates.
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection and other personal protective
equipment.
(3)
After washing, dry the components using compressed air.
(4)
Apply a small amount of high temperature grease (Item 15, Appendix E) to each bearing plate needle
bearing.
(5)
Install and test needle bearings on cross journals as shown. The movement must be smooth and
resistance free.
(6)
If any component is failing, the complete universal joint must be replaced.
5-32
f.
Installation of Universal Joints.
(1)
Install the cross yoke so that cross journals
are positioned in yoke lugs. Grease fitting
in cross must be toward shaft.
(2)
Install the bearing plate (5). Push journal of
cross (6) through the yoke lugs and into
needle bearing in bearing plate.
(3)
While supporting the cross to prevent
separation of cross and bearing, use a
hammer to lightly tap bearing plate (5) into
place in the yoke (2).
(4)
Install lockstrap (4) and capscrews (3).
Finger tighten capscrews.
(5)
Rotate drive shaft yoke to facilitate
installation of the second bearing plate.
(6)
Carefully install bearing plate onto opposite
side of the cross (repeat procedure in steps
2 through 4).
(7)
Torque capscrews to 40 ft lb (54 Nm).
While tightening, move cross back and forth
to ensure that it does not bind in the needle
bearings.
(8)
Using a hammer and chisel, bend up the
lockstrap ears to secure capscrews.
(9)
Install drive shaft.
(10) When all bearing plates are installed and
drive shaft is in place, lubricate the
universal joints until high temperature
grease (Item 15, Appendix E) is expelled
from all four bearing plate seals.
g. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
5-33
TM 5-4210-233-14&P-1
5-8. FOAM TANK ASSEMBLY
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Raise Aerial Ladder (see para 2-14.)
Foam System Drained (see para 2-17.)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Curb Side Panel Removed (see para 4-26.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
a. Removal.
(1)
Loosen two hose clamps (1) and remove
two hoses (2).
(2)
Remove cargo floor grating by removing
four screws. Set grating aside.
(3)
Remove four bolts (3) and four washers (4).
(4)
Remove foam tank (6)j
(5)
If replacing tank, remove pipe fittings from
bottom of tank.
b. Installation.
c.
(1)
Install two hoses (2) and secure with two
clamps (1).
(2)
If necessary, apply pipe sealant (Item 2,
Appendix E) to pipe threads and install pipe
fittings (7) on new foam tank.
(3)
Position foam tank (6) and secure with four bolts (3) and washers (4).
(4)
Position floor grating and secure with four screws.
Follow-On Maintenance.
(1)
Fill foam system (see para 2-17).
(2)
Install curbside panel (see para 4-26).
(3)
Connect batteries (see para 4-114).
(4)
Aerial ladder bedded (see para 2-14).
5-34
TM 5-4210-233-14&P-1
5-9. FRONT SUCTION ASSEMBLY
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
Multipurpose grease (Item 17, Appendix E)
Tie Straps (Item 33, Appendix E)
c. Follow-on Maintenance
EQUIPMENT CONDITION
All Piping Drained (see para 2-17.)
Main Engine Shutdown (see
para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Curb Side Panel Removed (see para 4-26.)
a. Removal.
(1)
See paragraph 4-51 to remove and repair front suction valve. See paragraph 4-54 for removal and
installation of front suction drain valves.
(2)
To remove piping sections remove bolts (1), nuts (2), clamp halves (3) and seals (4) as necessary.
(3)
To remove elbow (5), support piping at front suction valve and remove eight bolts (6).
(4)
To remove long pipe (7) support pipe with suitable blocking and remove clamps (3) as described
above. Remove bolts (8), nuts (9) and flat washers (10 and 11). Remove rubber grommets (12) if
necessary.
(5)
To remove front pipe (13), disconnect tube (14) and remove elbow (15). Remove screws (1 6) and
garnish ring (17). Unscrew strainer (18). Remove nuts (19), washers (20 and 21) and U-bolt (22).
5-35
TM 5-4210-233-14&P-1
5-9. FRONT SUCTION ASSEMBLY - Continued
5-36
TM 5-4210-233-14&P-1
5-9. FRONT SUCTION ASSEMBLY - Continued
b. Installation.
(1)
Install elbow (5) and secure with bolts (6).
(2)
To install seals between pipe sections, coat the inside diameter of the seal with multi-purpose grease
(Item 17, Appendix E). Slide the seal over the end of the pipe, but not attempt to seat the seal in
groove on the pipe. When the two pipe ends are butted together, the seal should be centered
between the grooves. Install the clamp halves (3) over the pipe ends and install bolts (1) and nuts
(2).
(3)
Install front suction valve (see para 4-51).
(4)
Install rear suction drain valve on elbow (5) (see para 4-54).
(5)
Install pipe (23) with seal (4) and clamp (3).
(6)
Slide seal (4) over end of pipe (23). Place pipe (7) in position under frame support with suitable
blocking, and install grommets (12), bolts (8), washers (10 and 11) and nuts (9) at two locations.
(7)
Install clamp (3) with bolts (1) and nuts (2) over pipes (23 and 7).
(8)
Install front suction drain valve in pipe (7) (see para 4-54).
(9)
Install elbow (15) in pipe (13). Be sure elbow will point toward back of truck when pipe (13) is
installed.
(10) Place pipe (13) in position and install seal (4) and clamp (3) with bolts (1) and nuts (2).
(11) Install U-bolt (22) with washers (21 and 20) and nuts (19).
(12) Connect hose (14) to elbow (15), lay hose (14) along top of suction piping and secure with plastic tie
straps (Item 33, Appendix E).
(13) Install garnish ring (17) with screws (16). Thread strainer(18) on end of pipe (13).
c.
Follow-on Maintenance.
(1)
Install curbside pump panel (see para 4-26).
(2)
Connect batteries (see para 4-114).
(3)
Connect front suction to water source, run fire pump and check for leaks. Correct leaks that occur as
required.
5-37
TM 5-4210-233-14&P-1
5-10. WATER TANK ASSEMBLY
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
PERSONNEL REQUIRED - 2
EQUIPMENT CONDITION
Aerial Ladder Swung Aside to Provide Clearance
(see para 2-14)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Water Tank Drained (see para 2-17)
MATERIALS/PARTS REQUIRED
Tie Straps (Item 33, Appendix E)
a. Removal.
(1)
Remove screws (1), two strips (2 and 3) and grating (4).
(2)
Remove screws (5) and grating (6 and 7).
(3)
Remove divider panel (8) between water tank and hydraulic tank. Mounting screws (9) are accessed
through upper front storage compartments on each side of hosebody. Nut (10) and washers (11 and
12) are located inside water tank mounting area.
(4)
Cut all plastic tie-straps securing flex-tubing (13) to chassis.
(5)
Disconnect wiring harness from water level sending unit connector (14).
(6)
Remove two clamps (15) and hose (16) from water tank connection.
(7)
Disconnect hose (17) from tank fitting.
(8)
Remove bolts (18), nuts (19), washer (20) and springs (21) securing water tank to hosebody.
WARNING
Serious injury could occur if heavy equipment if moved/lifted
without sufficient personnel to do the job. Use proper physical
lifting procedures or use a suitable lifting device or dolly. Wear
safety shoes, gloves and other suitable protective clothing. Area
should be clear of other personnel. Serious injury or death can
result from falling objects.
CAUTION
When removing tank, lift slowly and be sure that the flex-hose is
not secured or caught on anything. Damage to the hose may
result.
(9)
Attach lifting slings to the water tank and remove tank (21A) from truck with hoist.
5-38
TM 5-4210-233-14&P-1
5-10. WATER TANK ASSEMBLY - Continued
5-39
TM 5-4210-233-14&P-1
5-10. WATER TANK ASSEMBLY - Continued
(10) Loosen clamp (22) and remove flex-hose (13) from bottom of tank.
(11) If necessary, remove filler strips (23) from under tank.
b. Installation.
(1)
Install flex-hose (13) on bottom of tank with clamp (22).
(2)
Place filler strips (23) in position on hosebody. Use tape to hold them in position while installing tank.
WARNING
Serious injury could occur if heavy equipment if moved/lifted
without sufficient personnel to do the job. Use proper physical
lifting procedures or use a suitable lifting device or dolly. Wear
safety shoes, gloves and other suitable protective clothing. Area
should be clear of other personnel. Serious injury or death can
result from falling objects.
(3)
Carefully lower tank into position. Be careful not to pinch or crush flex-hose (13).
(4)
Install bolts (18), springs (21), washers (20) and nuts (19). Tighten nuts (19) until approximately 1/2"
(12.7 mm) of bolt thread extends beyond the face of the nut.
(5)
Connect wiring harness to water level sending unit connector (14).
(6)
Connect hose (17) to tank fitting.
(7)
Connect hose (16) to tank and install clamps (15).
(8)
Install divider panel (8) between water tank and hydraulic tank. Mounting screws (9) are installed
through back wall of upper front storage compartments on each side of hosebody. Nut (10) and
washers (11 and 1 2) are located inside water tank mounting area.
(9)
Place grating (4) in position on top of tank and install strips (2 and 3) with screws (1).
(10) Install grates (6 and 7) with screws (5).
(11) Flex-hose (13) should be secured to bottom of truck with open end of hose facing to the rear. Us
e
plastic tie-straps (Item 33, Appendix E) to secure flex-hose to frame components.
c.
Follow-on Maintenance.
(1)
Fill water tank (see para 2-17).
(2)
Connect batteries (see para 4-114).
(3)
Aerial ladder bedded (see para 2-14).
5-40
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B, Section III, Item 4)
MATERIALSIPARTS REQUIRED
Plastic Tie Straps (Item 33, Appendix E)
Butt Splices (Item 27, Appendix E)
Tags, Identification (Item 32, Appendix E)
c. Follow-on Maintenance
PERSONNEL REQUIRED - 2
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Cab Roof Panel Removed (see para 4-76.)
Engine Enclosure Removed (see para 4-127.)
Radiator Removed (see para 5-31.)
Curb Side Operator's Panel Removed
(see para 4-26.)
Starter Motor Removed (see para 5-12.)
a. Removal.
(1)
Remove air cleaner indicator hose (1) from air intake tube (2).
(2)
Loosen two hose clamps (3) and remove air intake tube (2) with elbows (4) and clamps (5).
(3)
Cover turbocharger opening securely with duct tape to prevent entry of dirt.
(4)
Loosen two clamps (6) and remove flex hose (7).
(5)
Loosen air intake adapter (8) open two air cleaner clamps (9) and remove air cleaner (10).
(6)
Remove four hex head screws (11), flatwashers (12), lockwashers (13) andnuts (13A)
(7)
Remove air cleaner clamps (9).
5-41
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(8)
Remove bolt (14) securing ether start heat sensor (15) to the thermostat housing at the front of the
engine on the driver's side. Cut plastic tie straps as necessary and roll heat sensor and wiring back
to ether starting aid.
(9)
Tag and disconnect line (16) from ether start assembly.
5-42
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(10) Remove four hex head screws (17), eight flatwashers (18), four lockwashers (19) and nuts (20).
(11) Remove power steering reservoir (21) from bracket (22).
(12) Tag and disconnect two steering system hoses (23) from reservoir and drain oil from reservoir into
suitable container.
(13) Tag and disconnect four steering system hoses (24) from power steering pump at rear of engine.
5-43
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(14) Tag and disconnect two wires (25) from
water temperature sender. (Wire ID nos.
1010M and 1011M.)
(15) Remove sending unit (26) from thermostat
housing.
(16) Tag and disconnect two DDEC wiring
harnesses (27 and 28) from the top-center
and lower right-hand connectors of the
electronic control module on the top front of
the engine.
(17) Locate the Jacobs engine brake wire that
enters the inside of each cylinder head near
the rear of the blower (wire ID numbers
1095L and 1096L). Follow these wires to
the butt splices at the wiring harness on the
driver's side of the engine. Tag and cut the
wires at each butt splice.
(18) Tag and disconnect positive (29) and
negative cables (30) from alternator.
(19) Remove two wire plug (31) from top of
alternator.
5-44
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(20) Tag and disconnect wire (32) from engine
hour meter sending unit at left rear of
engine.
(21) Tag and disconnect two wires (33) from oil
pressure sending unit.
(22) Tag and disconnect all wires from starter
ground terminal (34).
(23) Tag and disconnect all wires from starter
BAT terminal (35).
(24) Loosen two clamps (36) and disconnect two
heater hoses (37) at right front side of engine.
5-45
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(25) Tag and disconnect fuel hose (38) from
front center of engine behind fan drive.
(26) Tag and disconnect four fuel hoses (39)
from passenger side front of engine.
(27) Tag and disconnect two hoses from fittings
(40) on oil cooler manifold.
5-46
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(28) Loosen exhaust clamp (41) at turbocharger.
(29) Remove band clamp (42) at rear of engine.
(30) Remove exhaust outlet (43).
(31) Disconnect copper discharge line (44) from top of compressor.
(32) Remove hex bolts (45) and remove governor (46).
5-47
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(33) Remove bolt (47) securing ladder lock solenoid to driver's side rear of engine and remove ladder lock
solenoid (47A).
5-48
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(34) Remove access plug (48) from drivers side of engine.
(35) Observe through in access hole while second person turns lower pulley nut (49) clockwise until head
of screw is centered in hole. Remove screw and repeat process until 12 screws have been removed.
(36) Connect suitable lifting device with a minimum capacity of 2 tons to engine lift points. Remove slack
from chain.
5-49
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(37) Remove two nuts (50), plates (51), washers (52) and bolts (53). Remove and discard two rubber
biscuits (54) from frame cross member.
(38) Remove twenty-four bolts (55) and lockwashers (56) securing transmission to engine.
WARNING
Keep out from under engine when removing from vehicle. If
engine slips, sways, or falls, serious injury or death may result.
CAUTION
•
Make sure loose hoses and wires are secure and moved out
of way so they do not snag and cause damage when engine
is lifted.
•
Before lifting engine completely out of vehicle, test by lifting
slightly to see if balanced. If engine starts to tilt, lower and
adjust chain lengths. Unbalanced engine may swing causing
damage.
(39) Carefully lift engine up and out of truck through roof panel opening.
(40) Mount engine on overhaul stand.
5-50
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
b. Installation.
WARNING
Keep out from under engine when installing in vehicle. If engine
slips, sways or falls, serious injury or death may result.
CAUTION
Before lifting engine completely off supports, test by lifting
slightly to see if balanced. If engine starts to tilt, lower engine
and adjust chain lengths. An unbalanced engine may swing
causing damage.
Make sure loose hoses and wires are secured and moved out of
way so they do not snag and cause damage when engine is
lifted.
(1)
Install two new rubber biscuits (1) in frame cross member.
(2) Connecting a suitable lifting device with a minimum capacity of 2 tons to the engine lift points. Lower
engine into truck through roof panel opening. Rest front mounting feet on frame cross-member. Leave
engine suspended until 24 transmission mounting bolts are installed.
5-51
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(3)
Install twenty-four screws (6) and lockwashers (7) that secure transmission
housing to engine.
(4)
Install two bolts (2), washers (3), plates (4) and nuts (5).
(5)
Remove lifting chains from engine.
5-52
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(6)
Remove access plug (8) from driver's side of engine. Remove access plug (10) in bottom of flywheel
housing (11).
(7)
Turn lower pulley nut (12) clockwise while other person looks in access hole in engine. Stop turning
when bolt hole in engine flex plate is centered in access hole.
(8)
Reach through access hole in bottom to turn flywheel while other person looks in access hole in
engine. Stop turning when bolt hole in flywheel aligns with bolt hole in engine flex plate.
(9)
Install access plug (10) in bell housing (11).
(10) Install bolt to secure engine flex plate to flywheel through access hole in engine. Do not tighten bolt
fully at this time.
(11) Turn nut on lower pulley clockwise while other person looks in access hole in engine. Stop turning
when next bolt hole in engine flex plate is centered in access hole. Install bolt. Repeat process until all
twelve bolts are installed in flex plate.
(12) Torque twelve bolts to 95to 115 Ib-ft (130to 156 Nm). Install access plug (8) in engine.
5-53
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(13) Put ladder lock solenoid (13) in position at driver's side rear of engine and install mounting bolt (13A).
(14) Attach governor (14) to compressor with
bolts (15).
(15) Connect copper discharge line (16) to top of
air compressor.
(16) Install exhaust outlet (17) between turbocharger and exhaust pipe and install band
clamp (18). Do not tighten band clamp at
this time.
5-54
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(17) Install exhaust clamp (19) at turbocharger. Tighten exhaust clamps (18 and 19).
(18) Connect hoses to two fittings (20) on oil cooler manifold and tighten clamps securely.
(19) Connect four fuel hoses (21) to manifold on passenger side of engine.
5-55
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(20) Connect fuel hose (22) at front center of engine behind fan drive.
(21) Connect two heater hoses (23) to fittings at right front side of engine and tighten clamps (24).
5-56
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(22) Connect wires to ground terminal (25) and BAT terminal (26) of starter motor.
(23) At left rear of engine, install two wires (27) on oil pressure sending unit. Connect wire (28) to hour
meter sending unit.
(24) Connect positive (29) and negative (30)
to alternator.
cables
(25) Connect two-wire plug (31) to top of
alternator.
(26) Install new butt splice connectors on wires 1095L
and 1096L for Jacobs engine brake which enter
inside of each cylinder head near rear of blower.
They connect to engine wiring harness on driver's
side of engine.
5-57
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(27) Connect two DDEC wiring harnesses (32 and 33) to the electronic control module on the top front of
the engine.
(28) Install sending unit (34) in thermostat housing.
(29) Connect two wires (35) to water temperature sending unit (wire ID no's. 101OM and 1011M).
(30) Connect four steering system gear hoses (36) to power steering pump at rear of engine.
5-58
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(31) Put power steering reservoir (37) in position on bracket (38) and install four screws (39), lockwashers
(40), flat washers (41) and nuts (42).
(32) Connect two hoses (43) to power steering reservoir.
(33) Connect line (44) to ether start assembly.
5-59
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
(34) Install ether start heat sensor (45) in thermostat housing at left front top of engine with bolt (46).
(35) Put air cleaner clamps (47) in position and install hex head screws (48), flat washers (49) lock washers
(50) and nuts (51). (36) Install air cleaner (52) and tighten clamps (47)
(37) Install flex hose (53) and tighten two clamps (54).
(38) Install elbows (55) and air intake hose (56) between air cleaner and turbocharger. Install lcamps (57
and 58).
(39) Connect air cleaner indicator hose (59) to air intake tube (56).
NOTE
Plastic tie-straps should be used as needed to secure loose
hoses, tubes and wiring. This should be done to prevent looses
items from being caught by moving parts, and also to prevent
chafing of parts due to vibration.
5-60
TM 5-4210-233-14&P-1
5-11. ENGINE ASSEMBLY - Continued
c.
Follow-on Maintenance.
(1)
Install starter motor (see para 5-12).
(2)
Install radiator (see para 5-31).
(3)
Fill power steering reservoir (see para 3-8).
(4)
Install engine enclosure (see para 4-127).
(5)
Install cab roof panel (see para 4-76).
(6)
Install curbside operator's panel (see para 4-26).
(7)
Connect batteries (see para 4-114).
(8)
Start engine and test operation.
5-61
TM 5-4210-233-14&P-1
5-12. STARTER MOTOR
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
Batteries Disconnected (see para 4-114.)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
MATERIALS/PARTS REQUIRED
Gasket (Figure 78, Appendix F)
a. Removal.
(1)
Tag and disconnect wires from starter ground terminal (14) and starter solenoid BAT terminal (15).
(2)
Support starter motor with a floor jack.
(3)
Remove two nuts (7), lockwashers (5), screws (1), flat washers (12) and spacers (3).
(4)
Remove three screws (11) and lockwashers (10) and lift starter (8) from flywheel housing.
(5)
Remove and discard gasket (9).
(6) If necessary, remove three screws (13) and remove bracket (2) from starter motor.
5-62
TM 5-4210-233-14&P-1
5-12. STARTER MOTOR - Continued
b. Installation.
c.
(1)
If necessary, remove three screws (13) from back of starter motor and install bracket (2) with screws
(1 3). Use holes "A", "B" and "C" when mounting bracket (2) to starter motor. Hole "C" should align
with brush cap "F" on starter motor.
(2)
Install new gasket (9) on face of starter (8).
(3)
Slide starter (8) into flywheel housing to engage starter drive with flywheel ring gear.
(4)
Hold starter in position and install three lockwashers (1O) and screws (11) to secure starter. Torque
screws to 137-147 ft lb (186-200 Nm).
(5)
Install two screws (1) and flat washers (12) through holes "D" and "E" of bracket 2. Install spacers (3),
lockwashers (5) and nuts (7).
(6)
Using tags for identification, connect engine harness wires to starter motor ground terminal (1 4) and
solenoid BATTERMINAL (15).
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
5-63
TM 5-4210-233-14&P-1
5-13. STARTER SOLENOID
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
EQUIPMENT CONDITION
Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Starter Removed (see para 45-12.)
a. Removal.
(1)
Remove nut (1) and lockwasher (2).
(2)
Disconnect ground lead (3) from terminal (4).
(3)
Remove nut (5) from motor terminal (6).
(4)
Remove nut (7) from field terminal (8).
(5)
Remove nut (9) and ground lead (3).
5-64
TM 5-4210-233-14&P-1
5-13. STARTER SOLENOID - Continued
(6)
Remove four screws (10) from solenoid (I1) and starter (12).
(7)
Loosen clip (13).
(8)
Remove solenoid (11) and clip (13) from plunger (14) and starter (12).
(9) Remove connector (15) from solenoid (11).
5-65
TM 5-4210-233-14&P-1
5-13. STARTER SOLENOID - Continued
b. Installation.
(1)
Install connector (1) on motor terminal (2).
(2) Position solenoid (3) on starter (4) and plunger (5)
(3)
Install connector (1) on field terminal (6).
(4) Install clip (7) over seal (8) on plunger (5).
5-66
TM 5-4210-233-14&P-1
5-13. STARTER SOLENOID - Continued
c.
(5)
Install four screws (9) into starter (4).
(6)
Install ground lead (10) and nut (11).
(7)
Install nut (12) on motor terminal (2). /
(8)
Install nut (13) on field terminal (6).
(9)
Connect ground lead (10) to terminal (14) on starter (4) with lockwasher (15) and nut (16).
Follow-on Maintenance.
(1)
Install starter (see para 5-12).
(2)
Connect batteries (see para 4-114).
5-67
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING
This task covers:
a. Disassembly
b. Cleaning and Inspection
c. Testing
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Engine Oil (OE) (Item 20, Appendix E)
Lint Free Cloth (Item 42, Appendix E)
Epoxy Adhesive (Item 35, Appendix E)
d. Assembly
e. Follow-on
Maintenance
EOUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Starter Removed (see para 5-12.)
a. Disassembly.
(1)
Matchmark end cap (1), field frame (2), lever housing (3), and drive housing (4).
(2)
Remove inspection plug (5) and gasket (6) from field frame (2).
(3)
Remove inspection plug (5) and gasket (6) from [ever housing (3).
5-68
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(4)
Remove three screws (7) to disconnect three field leads (8) from brush holder (9).
(5)
Remove six screws (10), end cap (1), and brush holder (9).
NOTE
Armature may stay with end cap or in field frame.
(6)
Remove armature (11).
(7)
Remove preformed packing (12) from end cap (1).
(8)
Remove washer (13) and thrust washer (14) from armature (11).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards eye protection and other personal protective
equipment.
569
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING-Continued
(9)
mm)
Cut commutator (1 5) as required on lathe. When cutting commutator, cut no more than 0.005 in.
(0.13 mm) at a time to remove scoring, pits, burrs, or to return commutator to round. Then make
final cut of 0.002 in. (0.051 mm). Undercut mica (16) 1/32-in. (0.8 mm) deep and 1/32-in. (0.8
wide. Blow off all loose copper and mica particles with compressed air.
(10)
Polish commutator (15) with abrasive paper.
(11)
Remove seven screws (17), lever housing (3), and drive housing (4).
(12)
Remove five long screws (18), one
short screw (19), and drive housing (4)
from lever housing (3).
(13)
Remove starter drive (20) and
preformed packing (21).
(14)
Remove retaining ring (22) and shift
lever shaft (23) from lever housing (3).
(15)
Remove large preformed packing (24)
and small preformed packing (25) from
shift lever shaft (23).
5-70
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(16)
Remove self-locking nut (26) and note number of turns.
(17)
Remove plunger assembly (27) and shift lever (28
(18)
Remove preformed packing (29) and oil seal (30).
(19)
Remove retaining ring (31) from plunger (27).
(20)
Remove retainer (32), spring (33), retainer (34), and boot (35) from plunger (27).
(21)
Remove washer (36) from boot (35).
(22)
Remove non-metallic washer (37).
(23)
Remove bushing (38) from lever housing (3).
(24)
Remove cup plug (39) and felt wick (40).
5-71
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(25)
Remove cup plug (41) and felt wick
(42) from drive housing (4).
(26)
Mark holes and remove six rubber balls
(43).
(27)
Remove bushing (44).
(28)
Remove six screws (45) and brushes
(46) from brush holder (9).
(29)
Remove nut (47), lockwasher (48), and
washer (49) from ground terminal (50).
5-72
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(30)
Remove three screws (51) from brush
holder (9) and end cap (1).
(31)
Remove insulator (52) from end cap
(1).
(32)
Remove end cap (1) from brush holder
(9).
(33)
Remove rubber bushing (53), two
insulating , washers (54), and paper
gasket (55) from ground terminal (50).
(34)
Remove cup plug (56) and felt wick
(57) from end cap (1).
(35)
Remove bushing (58) from end cap (1).
(36)
Remove six screws (59), three brush
holders (60), and three plates (61).
5-73
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(37)
Remove six screws (62), three brush holders (63), three plates (64), three plate insulators (65), and
six insulators (66).
(38)
Remove six spring (67) from brush holders (63).
(39)
Disassemble support plate (68), disc insulator (69), and plate assembly (70).
(40)
Remove nut (71), washer (72), and two insulators (73).
(41)
Remove 12 assembled screws (74).
(42)
Remove six pole shoes (75).
(43)
Remove field coil (76) and plate insulator (77) from field frame (2).
5-74
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING-Continued
(44)
Remove insulator bushing (78) from terminal stud (79).
b. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
(1)
Clean all metal parts in dry cleaning solvent (Item 3, Appendix E) except armature, field coil, and
starter drive.
(2)
Clean starter drive with clean, dry, lint free cloth (Item 42, Appendix E).
(3)
Inspect field frame for cracks, breaks, or other obvious damage.
(4)
Inspect armature shaft for rough surfaces or damaged splines.
(5)
Inspect commutator contact surface for rough surface, pits, scoring, burns, hard carbon, oil coat,
and out-of-round. Commutator diameter, when new, is approximately 2.3125 to 2.3250 in. (58.74
59.06 mm). Commutator diameter may not be less than 2.000 in. (50.8 mm) when returned to
service. Commutator may not be more than 0.0020 in. (.051 mm) out-of-round.
(6)
Check length of brushes. If length is less than 0.50 in. (12.7 mm), replace brushes.
(7)
Inspect brush springs for distortion.
(8)
Inspect splines and gear teeth on starter drive for damage.
(9)
Check bushings for damage or wear. If inside diameter of bushings is more than 0.005 in. (0.127
mm) larger than shaft diameter, replace bushings.
(10)
Replace unserviceable parts.
to
5-75
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING- Continued
c.
Testing.
NOTE
Start testing with brush holder located directly over ground
terminal.
(1)
Test brush holders (1, 2, and 3) one at
a time. Place red (+) lead on ground
terminal (4) and black (-) lead on
ground terminal (4) and black (-) lead
on each brush holder. Multimeter
needle must move.
(2)
Test brush holders (5, 6, and 7) one at
a time. Place red (+) lead on ground
terminal (4) and black (-) lead on each
brush holder. Multimeter needle must
not move.
(3)
Test armature (8). Place red (+) lead
on end of shaft (9). Place black (-)
lead on each metal strip (10) around
large part of armature. Multimeter
needle must move to zero.
(4)
Place red (+) lead on end of shaft (9).
Place black (-) lead on each
commutator strip (11). Multimeter
needle must not move.
5-76
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(5)
Test field coil. Place red (+) lead on field terminal stud (12). Place black (-) lead on field frame
(13). Multimeter needle must not move.
(6)
Place red (+) lead on field terminal stud (12). Place black (-) lead on one of field leads (1 4).
Multimeter needle must move.
(7)
Move black (-) lead to other field leads (14). Multimeter needed must move.
(8)
Place red (+) lead on one field lead (14). Put black (-) lead on another field lead. Multimeter
needle must move. Repeat for all leads.
(9)
Replace any defective parts as necessary.
d. Assembly.
(1)
Install insulator bushing (1) on terminal stud (2).
(2)
Install field coil (3) in field frame (4) and put terminal stud (2) through hole (5).
(3)
Align holes in plate insulator (6) with holes in field frame (4) and install around top of field coil (3).
5-77
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING-Continued
(4)
Install six pole shoes (7) with 12 assembled screws (8).
(5)
Install two insulators (9), washer (10), and nut (11).
(6)
Install six springs (12) on six brush holders (13 and 14).
(7)
Assemble support plate (15), disc insulator (16), and plate assembly (17).
5-78
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING-Continued
(8)
Install two screws (18), two insulators
(19), plate insulator (20), plate (21),
and brush holder (14).
(9)
Repeat step (8) for two remaining
brush holders (14).
(10)
Install two screws (22), plate (23), and
brush holder(13).
(11)
Repeat step (1 0) for remaining two
brush holders (13).
(12)
Press bushing (24) into end cap (25)
flush with top of bore.
(13)
Install preformed packing (26) on end
cap (25).
5-79
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(14)
Install felt wick (27) in end cap (25) and
fill with oil.
(15)
Install cup plug (28).
(16)
Install paper gasket (29), two insulating
washers (30), and rubber bushing (31)
on ground terminal (32) of brush holder
(33).
(17)
Install brush holder (33) on end cap
(25) with three screws (34).
(18)
Install insulator (35), washer (36),
lockwasher (37), and nut (38) on
ground terminal (32).
5-80
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING-Continued
(19)
Install washer (39) on armature shaft
(40).
(20)
Install armature (41) into end cap (25).
(21)
Hold six springs (12) and install six
brushes (42) with six screws (43).
(22)
Align hole in bushing (44) with hole in
bushing boss and press bushing into
lever housing (45).
(23)
Put four drops of epoxy adhesive (Item
35, Appendix E) on back of nonmetallic washer (46) and
install in lever housing (45).
5-81
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(24)
Press oil seal (47) into lever housing
(45).
(25)
Install preformed packing (48).
(26)
Install felt wick (49) in lever housing
(45) and fill with oil.
(27)
Install cup plug (50).
(28)
Install small preformed packing (51)
and large preformed packing (52) on
shift lever shaft (53).
(29)
Install shift lever (54) in lever housing
(45).
(30)
Install shift lever shaft (53) through
shift lever (54).
(31)
Install retaining ring (55).
5-82
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(32)
Install washer (56) in boot (57).
(33)
Install boot (57) on plunger (58). Push boot down so collar (59) on boot fits in groove (60).
(34)
Install retainer (61), spring (62), retainer (63), and retaining ring (64).
(35)
Install plunger (58) through shift lever (54). Install self-locking nut (65) with same number of turns
noted in removal.
(36)
Install gasket (66) and inspection plug (67).
5-83
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(37)
Install preformed packing (68) in lever
housing (45).
(38)
Press bushing (69) into drive housing
(70).
(39)
Install six rubber balls (71) into drive
housing
(40)
Soak felt wick (72) with oil and install.
(41)
Install cup plug (73).
(42)
Install starter drive (74) in shift lever
(54) in lever housing (45).
(43)
Align match marks and install drive
housing (70) on lever housing (45) with
five long screws (75) and one short
screw (76). Torque screws to 15 lb ft
(20 N.m).
5-84
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING-Continued
(44)
Align match marks and install lever
housing (45 on field frame (4) with
seven screws (77).
(45)
Coat splines (78) of armature (41) with
light film of lubricating oil (Item 20,
Appendix E).
(46)
Install thrust washer (79) on long end of
armature shaft (40).
(47)
Install armature (41) and end cap (25)
into field frame (4) with six screws (80).
Align match marks on end cap (25) and
field frame (4).
5-85
TM 5-4210-233-14&P-1
5-14. STARTER REPAIR AND TESTING - Continued
(48)
Connect three field leads (81) to bush holders (14) with three screws (82).
(49)
Install gaskets (83) and inspection plugs (84).
e. Follow-on Maintenance.
(1) Install starter (see para 5-12).
(2) Connect batteries (see para 4-114).
5-86
TM 5-4210-233-14&P-1
5-15. OIL COOLER
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B, Section III, Item 4)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Spring Shackle and Pivot Removed
(see para 5-41.)
MATERIALS/PARTS REQUIRED
Gaskets and Seal (Figure 82, Appendix F)
a. Removal
(1)
Drain engine cooling system by opening draincock at bottom of oil cooler housing.
(2)
Loosen clamps (1) and slide hose (2) down on the water inlet elbow. Remove two clamps (3) and
hoses (4).
5-87
TM 5-4210-233-14&P-1
5-15. OIL COOLER-Continued
(3)
Remove capscrews (5), and lockwashers (6). Remove elbow (7) and gasket (8). Discard gasket.
(4)
Loosen seal clamp (9), remove bolts (10), nuts (11), and lockwashers (12). Remove water outlet
elbow (13), seal (14) and gasket (15). Discard seal (14) and gasket (15).
(5)
Remove bolts (16) and lockwashers (17).
(6)
Remove oil cooler housing (18), inner oil cooler core gasket (19), oil cooler core (20) and outer oil
cooler core gasket (21). Discard gaskets.
(7)
Remove screws (22) and lockwashers (23). Remove screws (24)and lockwashers (25). Remove
oil cooler cover (26) and gasket (27). Discard gasket (27).
(8)
Remove screws (28) and lockwashers (29).
(9)
Remove screws (30) and lockwashers (31). Remove adapter assembly (32), spacers (33 and 34)
and gaskets (35). Discard gaskets (35).
(10)
Remove plug (36), gasket (37), spring (38) and valve disk (39). Discard gasket (37).
b. Installation.
5-88
TM 5-4210-233-14&P-1
5-15. OIL COOLER-Continued
(1)
Remove old gasket material from gasket surfaces.
(2)
Install valve disk (39), spring (38), new gasket (37) and plug (36).
(3)
Install adapter assembly (32), spacers (33 and 34) and new gaskets (35) and secure with screws
(28 and 30) and lockwashers (29 and 31).
(4)
Install new gasket (27) and oil cooler cover (26) and secure with screws (22 and 24) and
lockwashers (23 and 25).
(5)
Affix new inner core gasket (I 9) and outer core gasket (21) to core(20).
CAUTION
The inlet and outlet opening in the oil cooler core are marked
“IN”and “OUT”. Make sure the oil cooler core is reinstalled in its
original position.
c.
(6)
Install oil cooler core (20) in oil cooler housing (18).
(7)
Install housing (18).
(8)
Install bolts (16) and lockwashers (17).
(9)
Install water outlet elbow (13), new seal (14) and new gasket (15).
(10)
Install bolts (10), nuts (11) and lockwashers (12).
(11)
Tighten seal clamp (9).
(12)
Install new water inlet gasket (8).
(13)
Secure water inlet elbow (7) to housing with capscrews (5) and lockwashers (6).
(14)
Install hoses (4) and secure with clamps (3).
(15)
Slide water inlet elbow hose (2) in position and tighten clamps (1).
Follow-on Maintenance.
(1)
Close drain cock and fill cooling system to proper level.
(2)
Add oil to crankcase until oil level is at proper level on dipstick.
(3)
Spring shackle and pivot installed (see para 5-41).
(4)
Connect batteries (see para 4-114.).
(5)
Start and run engine for a short period and check for oil and water leaks. After any leaks have
been corrected and the engine has been stopped long enough (approximately twenty minutes) for
the oil from various parts of the engine to drain back to the crankcase, bring the oil level up to the
proper level on the dipstick.
5-89
TM 5-4210-233-14&P-1
5-16. FUEL PUMP
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection
d. Assembly
e. Installation
f. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Tool set, fuel pump (Appendix B, Section III, Item 12)
MATERIALS/PARTS REQUIRED
Solvent, dry cleaning (Item 3, Appendix E)
Grease, automotive and artillery (Item 1, Appendix E)
Adhesive-sealant, silicone (Item, Appendix E)
Oil, lubricating (Item 10, Appendix E)
Crocus cloth (Item 34, Appendix E)
Compound, pipe thread sealing (Item 2, Appendix E)
Tags, identification (Item 32, Appendix E)
Seals (Figure 84, Appendix F)
Gaskets (Figure 84, Appendix F)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
DDEC Electronic Control Module removed
(see para 5-28.
Thermostat crossover tube removed
(see para 4-137.)
a. Removal
(1)
Remove two fuel hoses (1).
(2)
Remove three screws (2).
5-90
TM 5-4210-233-14&P-1
5-16. FUEL PUMP-Continued
(3)
Remove fuel pump (3) and gasket (4)
from governor housing (5). Discard
gasket.
WARNING
Dry cleaning solvent P-D-680 is potentially
dangerous.
Avoid repeated and prolonged
breathing of vapors and skin contact with the liquid.
Do not use near open flame, arcing equipment or
other ignition sources. Always wear eye protection
and protective clothing. The flash point of P-D-680
is 100 to 138 deg. F (38 to 59 deg. C).
(4)
Clean fuel pump (3) with dry cleaning
solvent (Item 3, Appendix E).
b. Disassembly.
(1)
Remove fork (1) from fuel pump (2).
(2)
Mount fuel pump holder in vise and
install fuel pump.
(3)
Mark and remove elbow (3), elbow (4),
coupling (5), and nipple (6).
5-91
TM 5-4210-233-14&P-1
5-16. FUEL PUMP-Continued
(4)
Remove eight screws (7), lockwashers
(8), and cover (9) from housing (10).
(5)
Remove drive shaft and gear assembly
(11). Do not remove gear from shaft.
(6)
Remove drive shaft and gear assembly
(12). Do not remove gear from shaft.
(7)
Remove plug (13), gasket (14), spring
(15), pin (16), and valve (17) from
housing (10). Discard gasket.
(8)
Remove fuel pump holder from vise.
Install housing (10) in vise.
NOTE
Tag and mark how oil seals are installed. Install new seals with
lips pointing in same direction.
c.
(9)
Remove two oil seals (18 and 19) from housing (10). Discard oil seals.
(10)
Mark location and remove two pipe plugs (20) from housing (10).
Cleaning/lnspection.
WARNING
Dry cleaning solvent P-D-680 is potentially dangerous. Avoid
repeated and prolonged breathing of vapors and skin contact
with the liquid. Do not use near open flame, arcing equipment
or other ignition sources. Always wear eye protection and
protective clothing. The flash point of P-D-680 is 100 to 138
deg. F (38 to 59 deg. C).
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the. pressure is/has been reduced to 30 psi (2.11
kg/cm²) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
(1) Clean all parts in dry cleaning solvent (Item 3, Appendix E) and dry with compressed air. Inspect
all parts for damage. Replace damaged parts.
(2) Inspect mating surfaces of housing and cover. Mating surfaces mustbe flat and smooth and fit
together tightly.
5-92
TM 5-4210-233-14&P-1
5-16. FUEL PUMP-Continued
(3)
Inspect valve (17). If valve is lightly scored, use crocus cloth to remove marks. If marks cannot
be removed with crocus cloth, replace valve.
d. Assembly.
WARNING
Adhesives, solvents, and sealing compounds can burn easily,
can give off harmful vapors, and are harmful to skin and
clothing. To avoid injury or death, keep away from open fire and
use in well-ventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash immediately with soap
and water.
(1)
Coat threads of two pipe plugs (1) with
pipe thread sealing compound (Item 2,
Appendix E) and install in fuel pump
housing (2).
(2)
Mount fuel pump holder in vise and
install fuel pump housing (2) on holder.
(3)
Lubricate valve (3) with lubricating oil
(Item 10, Appendix E) and install
valve, pin (4), spring (5), new gasket
(6), and plug (7) in housing (2). Torque
plug to 20 lb ft (27 N·m).
(4)
Lubricate two new oil seals (8 and 9)
with lubricating oil (Item 10, Appendix
E).
(5)
Set fuel pump housing (2) on top of two
wooden blocks.
NOTE
Install new seals with lips pointing in same direction.
(6)
Install inner oil seal (8) on pilot (pin) of oil seal installer. Install inner oil seal (8) in housing (2). Tap
seal until seated.
(7)
Install adapter on tool.
(8)
Install outer oil seal (9) on pilot of oil seal installer. Install outer oil seal in housing (2). Tap seal
until seated.
(9)
Lubricate two shaft and gear assemblies (10 and 11) with lubricating oil (Item 10, Appendix E).
Install assemblies in housing (2).
CAUTION
When applying adhesive-sealant (Item 35,
Appendix E) to pump cover, insure no sealant gets
into gear compartment.
Sealant in gear
compartment can damage equipment.
5-93
TM 5-4210-233-14&P-1
5-16. FUEL PUMP-Continued
(10)
Apply coating of adhesive-sealant
(Item 35, Appendix E) to mating
surface of cover (1 2). Install cover on
housing (2).
(11)
Install eight lockwashers (13) and
screws (14). Tighten screws evenly.
(12)
Coat threads of nipple (15), coupling
(16), elbow (17), and elbow (18) with
pipe thread sealing compound (Item 2,
Appendix E) and install on pump (19).
(13)
Remove pump (19) from fuel pump
holder.
(14)
Install fork (20) in pump (19).
e. Installation.
(1)
Apply grease (Item 1, Appendix E) to
new gasket (1).
(2)
Install gasket (1) to governor housing
(2).
(3)
Aline fork (3) with blower shaft (4) and
install fuel pump (5).
5-94
TM 5-4210-233-14&P-1
5-16. FUEL PUMP-Continued
WARNING
Adhesives, solvents, and sealing compounds can
burn easily, can give off harmful vapors, and are
harmful to skin and clothing. To avoid injury or
death, keep away from open fire and use in wellventilated area. If adhesive, solvent, or sealing
compound gets on skin or clothing, wash
immediately with soap and water.
(4)
Apply adhesive-sealant (Item 35,
Appendix E) to three screws (6).
(5)
Install three screws (6).
(6)
Install two fuel hoses (7).
Follow-on Maintenance.
(1)
Install thermostat crossover tube (see
para 4-137).
(2)
Install DDEC Electronic Control Module
(see para 5-28).
(3)
Connect batteries (see para 4-114.)
5-95
TM 5-4210-233-14&P-1
5-17. AIR COMPRESSOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Coolant Drained (see para 3-6.)
Air Tanks Drained (2-17.)
Main Engine Shutdown (2-12.)
Air Cleaner Removed (see para 4-128.)
Exhaust Pipe Removed (see para 5-44.)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
a. Removal.
(1)
Tag and disconnect hoses (1, 2, 3 and 4).
(2)
Remove sending unit (5) from elbow (5A). This will prevent possible damage to sending unit when
removing air compressor.
(3)
Remove four bolts (6) and lockwashers (7) and remove air compressor.
b. Installation.
c.
(1)
Put compressor in position and install four bolts (6) with lockwashers (7).
(2)
Install sending unit (5) in elbow (5A).
(3)
Connect four hoses (1, 2, 3 and 4) to air compressor.
Follow-on Maintenance.
(1)
Install air cleaner (see para 4-1
(2)
Install exhaust pipe (see para 5-44.).
(3)
Refill coolant (see para 3-6.).
5-96
TM 5-4210-233-14&P-1
5-18. ALTERNATOR
This task covers:
a. Disassembly
c. Assembly
b. Cleaning and Inspection d. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Alternator Removed (see para 4-133.)
MATERIALS/PARTS REQUIRED
Multimeter (Item 6, Section III, Appendix B)
Ammeter (Item 94, Section III, Appendix B)
Brush Pin (Item 93, Section III, Appendix B)
Polishing Cloth (Item 63, Appendix E)
Lint Free Cloth (Item 42, Appendix E)
a. Disassembly.
(1)
Place a match mark on drive end frame (3),
stator (2) and stator frame (1) to aid in
assembly.
5-97
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
(2)
Remove four thru bolts (11). Separate drive end frame (20) from alternator. If necessary, carefully
pry drive end frame to remove.
(3)
Remove three rectifier bridge nuts (24). Lift stator (1) from frame (9). If necessary, pry stator away
from the frame.
5-98
TM 5-4210-233-14&P-1
5-18. ALTERNATOR -Continued
(4)
Remove screw (2) and remove diode
trio (25).
(5)
Remove nuts (6) and remove
connectors and 30). Remove three
screws (26, 28 28A). Remove
capacitor (29) and rectifier bridge (31).
(6)
Hold brushes (4) in retracted position
and insert brush pin (A) (Item 93,
Section III, Appendix B) to hold
brushes in position. Remove two
screws (32) and remove stud connector
(33).
(7)
Remove screw (3). Lift brush holder
assembly from frame.
(8)
Remove brush pin (A). Remove
brushes (4) and spacers (34), one at a
time. Keep fingers around springs (35)
to avoid losing springs. It may be
necessary to spread brush 3 lead clips
(36) to disengage tabs. Remove brush
holder (5).
(9)
Remove remaining regulator screw (7)
and remove regulator (8).
5-99
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
(10)
Check bushing (13) in housing (9). If
bushing is worn or damaged, replace
bushing. Use a tube or sleeve with a
diameter slightly less than bore of
frame. Drive bushing (13) through
inside of housing (9), using a hammer
on the sleeve.
(11)
Hold frame (20) and spin rotor (16) by
hand to see that rotor spins freely.
Check slip rings (37) for wear and
damage.
(12)
Remove shaft nut (23) by placing a
5/16 inch (8 mm) hex wrench (A) in
end of shaft to hold shaft while
removing nut with wrench (B).
5-100
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
(13)
Remove nut (23), washer (22), pulley (38) and fan (21).
(14)
Pull or press rotor (16) from drive end frame (20).
(15)
Remove three screws (17) and remove retaining plate (18) from frame.
(16)
Inspect drive end bearing (19) for wear and damage. If worn or damaged e
r move drive end
bearing.
b. Cleaning and Inspection.
(1)
Clean all components by wiping with a
clean, dry, lint free cloth (Item 42,
Appendix E).
(2)
Test stator. Use a multimeter to check
for continuity. There should be no
continuity between stator leads (1) and
stator laminations (2). If there is no
continuity, stator is good. If continuity
is present, replace stator.
(3)
Check diode trio (2). Place negative
lead on regulator strap (3) and positive
lead to each of the three rectifier bridge
straps (4). All three readings should
indicate continuity. Reverse the
multimeter leads and perform check
again. Readings should all indicate
open circuits. If all readings are
proper, diode trio is good. If any
reading is wrong, replace diode trio.
5-101
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
(4)
Check rectifier bridge with a
multimeter.
(a) Place negative lead on grounded heat
sink (1).
(b) Touch positive lead firmly to metal
diode clips (2) that surround the studs.
All three readings should be the same
and indicate open circuits. Switch
leads and repeat test. All three
readings should indicate continuity.
(c) If all readings are correct the rectifier
bridge is good. If any reading is
incorrect an open or shorted diode is
indicated and bridge should be
replaced.
(5)
Inspect bearing and bushing for wear
and damage.
(6)
Check connectors for bent, cracked
and damaged condition.
(7)
Use a multimeter to check rotor field
resistance.
(a) Place leads on the two slip rings (3).
Meter should read 2.2 to 3.1 ohms. If
reading is not within specifications,
replace rotor.
(b) Check for a grounded field by touching
one lead to slip ring (3) and one lead to
rotor frame (2) or rotor shaft (4).
(c) Reading should be infinite (open) to
show that field is not grounded. If field
is grounded, replace rotor.
(8)
Replace all damaged or unserviceable
parts.
5-102
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
c.
Assembly.
(1)
Install drive end bearing (19) in bore of
frame (20). Install retaining plate (18)
and secure with three screws (17).
Tighten screws to a torque of 26 lb in.
(3.0 N·m).
(2)
Install shaft of rotor (16) through
bearing (19).
(3)
Install fan (21) and pulley (38) on rotor
shaft. Secure pulley with washer (22)
and nut (23). Hold shaft with a hex
Allen wrench (A) and tighten nut to a
torque of 75 lb ft (1 00 N·m).
(4)
Install bushing (13) in bore of stator
frame (9). Use a tube or suitable driver
(A) slightly less in diameter than bore
of the frame. Drive bushing from
outside of frame until end of bearing is
flush with outside lip of frame. Cover
opening for bushing with a piece of
tape to prevent dirt from entering
during remainder of assembly
procedure.
(5)
Install rectifier bridge (31) in stator
frame (9). Install one screw (28) and
tighten finger tight.
5-103
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
(6)
Install terminal (14) through rear of
frame (9). Place washer (39) and
connector (27) in position on frame and
rectifier bridge. Secure terminal with
nut (40). Tighten nut to 22 lb in. (2.5
N·m).
(7)
Install output battery terminal (1 2)
through frame (9) and rectifier bridge.
Seat square insulator flange in hole in
frame. Install nut (41) on terminal and
tighten finger tight.
(8)
Install screw (26) through capacitor
(29), grounded heat sink, and frame
(9). Tighten screw finger tight.
(9)
Install screw (27) through capacitor,
insulated heat sink and frame (9).
Tighten screw finger tight.
(10)
Install regulator (8) in frame (9). Install
one regulator screw (7) and tighten
finger tight.
5-104
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
(11)
Install brushes (4) with springs (35) and
spacers (34) on post of brush holder
(5). Install pin (A) to hold brushes in a
retracted position.
(12)
Install assembled brush holder (5) in
frame (9). Install brush holder pivot
screw (3) and insulated regulator screw
(2). Tighten screws finger tight.
(13)
Install diode trio (25) on three studs on
rectifier bridge. Install long connector
on diode over closest mounting hole in
brush holder.
(14)
Install connector (33) on stud (2).
Mount other end over brush holder
mounting hole (3). Install nut (4) on
stud (2) and tighten finger tight.
(15)
Install regulator screw (7) through
diode trio connector (6). Tighten finger
tight.
5-105
TM 5-4210-233-14&P-1
5-18. ALTERNATOR-Continued
(16)
Torque screws and nuts as follows.
(a) Outside terminal nut (1) -50 lb in. (5.5
N·m).
(b) Rectifier bridge screws (2)-25 lb in.
(2.8 N·m).
(c) Capacitor screw (3)-22 lb in. (2.5
N·m).
(d) Relay and inside terminal nuts (4) -22
lb in. (2.5 N·m). It may be necessary
to hold terminal on outside while
tightening.
(e) Regulator mounting screw (grounding)
(5)-20 lb in. (2.2 N·m).
(f) Regulator attaching screws (6)-20 lb
in. (2.2 N·m).
(g) Regulator nut (7)-22 lb in. (2.5 N·m).
(h) Brush holder pivot screw (8)-20 lb in.
(2.2 N·m).
(17)
Install outside washer, lock washer and
nut on outside stud.
(18)
Install stator (1) in frame (9) with phase
leads (2) over studs (4) on rectifier
bridge.
(19)
Install nuts (24) on studs to secure
stator leads. Tighten nuts to a torque
of 22 lb in. (2.5 N·m).
(20)
Clean slip rings by holding 400 grain
polishing cloth (A) (Item 63, Appendix
E) and spinning rotor (16). Place
frame (20) and rotor in a vise (B).
5-106
TM 5-4210-233-14&P-1
5-18. ALTERNATOR - Continued
(21)
Install drive end frame (9), with
rotor shaft through bearing in
stator frame (20). Align matchmarks when installing stator
frame. Remove tape from stator
frame bearing.
(22)
Brushes must be pinned in
retracted position to allow slip
rings to enter frame. Brush pin (A)
(Item 93, Section III, Appendix B)
must extend through rotor housing
to allow removal.
(23)
Install thru bolts (11) in frames. Tighten thru bolts
to a torque of 50 lb in. (5.5 N.m).
(24)
Remove brush pin (A) from assembled atemator.
(25)
Mount alternator in a suitable test stand. A 12 volt fully charged battery should be available. Install
alternator in a test installation and make electrical connections as shown below with carbon pile
turned off.
5-107
TM 5-4210233-14&P-1
5-18.
(26)
volt.
ALTERNATOR -Continued
Check battery voltage and ground polarity. They must be the same as truck. The system is 12
(27)
Engage switch and start test stand, and slowly increase alternator speed to 5000 rpm. Check
multimeter for voltage.
(28)
If voltage does not increase and remains at or below l2 volts, there is no alternator output. Check
as follows:
(a) Insert a screwdriver (3) in "D" shaped hole (1) in frame. Do not
insert screwdriver more than 3/4 inch (19 mm) into hole.
(b) Screwdriver should contact tab (2) on grounding brush. Tilt
screwdriver slightly to ground tab to frame.
(c) Again adjust carbon pile to obtain maximum output on ammeter
(item 94, Section III, Appendix B) without allowing voltage to fail
below 13 volts.
(d) Record voltage reading, turn off carbon pile and stop test stand.
(e) If there is still no output, disassemble alternator and check rotor
and brushes for an open circuit.
(f) Check internal electrical connections to be sure grounding and
insulated mounting screws are installed in proper locations.
(29)
If voltage increases above 15 volts the voltage is uncontrolled.
(a) Check to see alternator has been assembled properly.
(b) Check to see that test tab in "D" hole is not grounded.
(c) If alternator has been assembled properly and tab is not grounded, replace regulator.
(30)
With alternator installed in test stand, run alternator at about 6500 rpm. Turn on carbon pile load
and adjust to obtain maximum alternator output on ammeter without allowing multimeter reading to
fall below 13 volts. If output is now up to 30 amps alternator is good. Turn off carbon pile and stop
test stand.
(31)
If ammeter reading is below 28 to 30 amps, proceed as described in (28) above.
d. Follow-on Maintenance.
(1) Install Alternator (see para (4-133).
5-108
TM 5-4210-233-14&P-1
5-19. TACHOMETER DRIVE
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine cover open
a. Removal
(1) Loosen jamnut (1).
(2) Loosen screw (2) and remove clamp (3).
(3) Remove tachometer drive housing (4) and gasket (5).
(4) Remove tachometer drive (6).
5-109
TM 5-4210-233-14&P-1
5-19. TACHOMETER DRIVE - Continued
b. Installation
(1) Install tachometer drive (1) in tachometer drive housing (2).
(2) Install gasket (3) on housing (2).
(3) Install housing (2).
(4) Install clamp (4) and tighten screw (5).
(5) Tighten jamnut (6).
c.
Follow-on Maintenance
(1) Connect batteries
5-110
TM 5-4210-233-14&P-1
5-20. AIR INLET ADAPTER
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Turbocharger Removed (see para 5-23.)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B, Section III, Item 4)
MATERIALUPARTS REQUIRED
Gasket (Figure 93, Appendix F)
Preformed Packings (Figure 93, Appendix F)
a. Removal
(1) Remove ether starting aid line (1) and fitting (2) from air inlet adapter (3).
(2) Disconnect turbo boost sensor hose (4).
5-111
TM 5210-233-14&P-1
5-20. AIR INLET ADAPTER - Continued
CAUTION
Keep dirt and debris out of blower. Foreign material will
damage blower.
(3) Remove ten screws (5) and lockwashers (6) from inlet adapter.
(4) Remove air inlet adapter (3), gasket (7), and two preformed packings (8) from top of blower (9).
Discard gasket and preformed packings.
b. Installation.
(1) Install new gasket (1) and two new preformed packings (4) on blower (3).
(2) Install air inlet adapter (2) on blower (3).
(3) Install 1 0 screws (5) and lockwashers (6) in air inlet adapter (2). Torque to 45 lb ft (61 N.m).
5-112
TM 5-4210-233-14&P-1
5-20. AIR INLET ADAPTER - Continued
(4) Install fitting (7) and ether starting aid line (8) to air inlet adapter (2).
(5) Connect turbo boost sensor hose (9).
c.
Follow-on-Maintenance.
(1) Install turbocharger (see para 5-23).
5-113
TM 5-4210-233-14&P-1
5-21. BLOWER
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
PERSONNEL REQUIRED: 2
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
EQUIPMENT CONDITION
Coolant level lowered
Shop Equipment, Automotive
Air inlet adapter removed (see para 5-20.)
Maintenance and Repair
Alternator Removed (see para 4-133.)
(Appendix B, Section III, Item 4)
Fuel pump removed (see para 5-16.)
Tool, blower shaft alignment
(Appendix B, Section III, Item 13)
MATERIAL/IPARTS REQUIRED
Grease, automotive and artillery (Item 1, Appendix E)
Compound, seal retaining (Item 6, Appendix E)
Gaskets (Figure 95, Appendix F)
Seal (Figure 95, Appendix F)
a. Removal.
(1) Disconnect blower lube line (1).
(2) Disconnect tachometer sender wire (2).
(3) Loosen clamp (3) on blower drive support seal (4).
5-114
TM 5210-233-14&P-1
5-21. BLOWER - Continued
(4) Remove nut (5), copper washer (6), and screw (7).
(5) Remove three screws (8) and lockwashers (9).
(6) Remove two screws (10), Iockwashers (11), cover (12), and gasket (13). Discard gasket.
(7) Remove retaining ring (14) from blower drive shaft (15).
5-115
TM 5-4210-233-14&P-1
5-21.
BLOWER - Continued
(8) Remove four screws (16) and washers (17) from each end plate of the blower (18).
(
9) Remove the six screws (19) and retainers (20).
5-116
TM 5-4210-233-14&P-1
5-21. BLOWER -Continued
(10)
Remove blower (21) and gasket (22) from engine block (23). Discard gasket.
(11)
Remove tachometer drive (para 5-19.).
(12)
Remove clamp (24) and seal (25) from drive end of cover (26). Discard seal.
5-117
TM 5-4210-233-14&P-1
5-21. BLOWER - Continued
b. Installation.
(1) Apply seal retaining compound (Item 6, Appendix E) to bottom side of gasket (1) to prevent shifting
when the blower is lowered in position.
(2) Position gasket (1) on engine block (2).
(3) Position new seal (3) and clamp (4) over drive end of cover (5).
(4) Install tachometer drive (see para 5-19).
5-118
TM 5-4210-233-14&P-1
5-21. BLOWER - Continued
(5) Position blower assembly (6)
on gasket (1).
(6) Install four screws (7) and
washers (8) finger tight.
(7) Install six screws (9) and
retainers (10) finger tight.
NOTE
The lip at the bevelled end of the bolt retaining
washer goes in the small recess in the blower
housing just above the bolt slot.
(8) Using blower shaft alignment
tool, (Item 13, Section III,
Appendix B) install blower
drive shaft (11) and spring
(12).
5-119
TM 5-4210-233-14&P-1
5-21. BLOWER - Continued
(9)
Slip the snap ring (13) over the notched end of the alignment tool (Item 13, Section III,
Appendix B) and thread the blower drive shaft onto the end. Install the alignment tool and
position the blower so that the shaft can be removed and reinstalled easily without drag.
(10)
Remove the shaft with the tool and rotate the lobes of the blower in 900 increments, reinserting
the alignment tool and repositioning the blower as necessary. Check the alignment at 900
increments through the full 3600 of blower rotation.
(11)
If it is not possible to position the blower so that the tool can be removed and reinstalled
without drag in ail positions, repeat Step 10. However, this time try to achieve a condition in
which the shaft can be removed with minimum drag in the two worst positions.
(12)
Tighten four screws (7) to 40 to 45 lb-ft (54 to 61 N.m).
(13)
Tighten six screws (9) in 5 Ib-ft (7 N.m) increments uniformly until tightened to 30 to 35 Ib-ft (41
to 47 N.m).
(14)
Retighten four screws (7) to 40 to 45 Ib-t (54 to 61 N.m).
(15)
Install the snap ring (13). The notch in the tool provides sufficient clearance for the installation
of the snap ring with a needle-nose pliers. Installing the snap ring with the alignment tool in
place will prevent it from being inadvertently dropped into the engine gear train.
(16)
Remove blower alignment tool.
(17)
Position blower cover seal (14) on blower drive support (15).
(18)
Position clamp (16) in groove of seal (14). Tighten clamp until the spring in the clamp is
completely compressed.
5-120
TM 5-4210-233-14&P-1
5-21. BLOWER -Continued
(19)
Position cover (17) with new gasket (18) on blower drive support (19).
(20)
Install three screws (20) and lockwashers (21).
(21)
Install screw (22), copper washer (23), and nut (24).
(22)
Install two screws (25) and lockwashers (26).
(23)
Connect and tighten blower lube line fitting (22).
5-121
TM 5-4210-233-14&P-1
5-21. BLOWER - Continued
c.
Follow-on Maintenance.
(1) Install air inlet adapter (see para 5-20.).
(2) Install valve rocker covers (see para 4-140).
(3) Install fuel pump 5-16.).
(4) Install DDEC Electronic Control Module (see para 5-28).
(5) Install alternator (see para 4-133).
(6) Add coolant to engine.
5-122
TM 5-4210-233-14&P-1
5-22. BLOWER REPAIR
This task covers:
a. Disassembly
b. Cleaning/inspection
c. Assembly
d. Follow-on Maintenance
TEST EQUIPMENT
None
MATERIALS/PARTS REQUIRED
Oil, lubricating (Item 10, Appendix E)
Adhesive-sealant, silicone (Item 35, Appendix E)
TOOLS REQUIRED
Solvent, dry cleaning (Item 3, Appendix E)
Tool Kit, General Mechanics, Automotive
Tags, identification (Item 32, Appendix E)
(Appendix B, Section III, Item 1)
Cloth, crocus (Item 34, Appendix E)
Grease, automotive and artillery (Item 1, Appendix E)
Shop Equipment, Automotive
Emery Cloth (Item 25, Appendix E)
Maintenance and Repair
Gaskets (Figure 95, Appendix F)
(Appendix B, Section III, Item 4)
Oil Seal (Figure 95, Appendix F)
Seal Rings (Figure 95, Appendix F)
Tool set, blower service (Appendix B, Section III, Item 14)
Gage set, piston (Appendix B, Section IIII, Item 15)
EQUIPMENT CONDITION
Blower Removed (see para 5-21.)
a. Disassembly.
NOTE
To keep gears from turning, place clean folded shop towel
between blower rotors.
(1) Remove ten screws (1), lockwashers (2), rear end plate cover (3), and gasket (4). Discard gasket.
5-123
TM 5-4210-233-14&P-1
522. BLOWER REPAIR - Continued
(2) Remove three bolts (5), coupling assembly (6), and
spacers (7).
(3) Remove three bolts (8) and two spring plates (9) from
coupling (6).
(4) Remove two screws (10 and
11) and washers (12).
5-124
TM 5-4210-233-14&P-1
5-22. BLOWER REPAIR - Continued
NOTE
Use five screws with puller tools on timing gears. Use 5/16 in.24 x 1-1/2 in. (38 mm) screws and align with tapped holes in
gears.
(5) Install puller tool on ieft timing gear (13) with two screws.
(6) Install puller tool on right timing gear (14). REAR END
CAUTION
If puller screws are not tightened evenly
during removal of timing gears damage
may result to gears.
(7) Tighten screws (15) evenly to remove
gears (13 and 14).
(8) Remove pullers from gears (13 and 14).
(9) Mark rear end plate to indicate top.
(10) Remove, tag and mark shims (16) and
two spacers (17) from each rotor shaft
(18).
(11) Remove front end plate cover (19)
and gasket (20) by removing nine
bolts (21).
5-125
TM 5-4210-233-14&P-1
5-22. BLOWER REPAIR - Continued
(12)
Bend tangs of lockwasher (22) flat.
(13)
Remove screw (23), lockwasher (22), fuel pump
disk (24), and oil slinger (25) from front end plate
(26).
NOTE
Remove shop cloth.
(14)
Remove six screws (27) and two flanged bearing
retainers (28) from front end plate (26).
(15)
Loosen two screws (29) three turns.
(16)
Remove six screws (30) and two flat bearing
retainers (31) from rear end plate (32).
(17)
Remove two screws (33) from rear end plate (32).
NOTE
Six puller screws must be 1/4 in.-20 x 1-1/4 in.
(32 mm) or longer.
5-126
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
NOTE
Six puller screws must be 1/4 in.-20 x 1 -1/4 in. (32
mm) or longer.
(18)
Install three screws and align two puller tools
to rear end plate (32).
(19)
Turn both puller screws (15) evenly and
remove rear end plate (32).
(20)
Remove puller tool from rear end plate (32).
(21)
Remove two screws (29) from front end
plate (26).
(22)
Tag front end plate (26) and indicate top.
(23)
Tag front end of blower housing (34) and
indicate top.
(24)
Remove front end plate (26) by tapping with
mallet.
CAUTION
Handle rotors with care to avoid scratching surfaces.
NOTE
Tag rotors before removal.
(25)
Remove right rotor (35) and left rotor (36).
5-127
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(26)
Remove oil seal ring (37) from ring carrier (38)
on each end of rotors (35 and 36).
NOTE
All carriers are removed the same. Tighten vise
just enough to hold rotor in place.
(27)
Clamp lobe of right rotor (35) in vise with soft jaws.
(28)
Install adapter on right rotor (35).
(29)
Install puller tool to adapter with two screws. Turn puller screw (15)to remove ring carrier (38)
and inner bearing race (39) from rotors (35 and 36).
5-128
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
NOTE
Repeat steps (30) through (33) for
front and rear end plates.
(30)
Position rear end plate (32) on
wood blocks.
(31)
Place long end of remover and
installer tool through seal ring
collar (40) into ball bearing (41).
(32)
Press out ball bearing (41) and
seal ring collar (40).
(33)
Inspect dowel pins (42) for
breakage or damage. Replace if
broken or damaged.
b. Cleaning/Inspection.
WARNING
•
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and skin
contact with the liquid. Do not use near open flame, arcing
equipment or other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 59 deg. C).
•
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been reduced
to 30 psi (2.11 kg/cm2) or less. When working with
compressed air, always use chip guards, eye protection, and
other personal protective equipment.
CAUTION
Do not use compressed air on bearings. Allow bearings to air dry. Compressed air
may cause damage to bearings.
(1) Clean metal parts in dry cleaning solvent (Item 3, Appendix E). Dry parts other than bearings with
compressed air.
(2) Examine the bearings for any indications of corrosion or pitting. Lubricate each ball bearing with light
engine oil (Item 10, Appendix E). Then, while holding the bearing inner race from turning, revolve the
outer race slowly by hand and check for rough spots. The double-row ball bearings are pre-loaded and
have no end play. A new bearing will seem to have considerable resistance to motion when revolved
by hand.
5-129
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(3) Check the oil seal rings, carriers and collar for wear or scoring. If worn excessively, they must be
replaced. The current oil seal rings are chrome flashed and the carriers are liquid nitrided. When
replacement of an oil seal ring or carrier is neccessary, both parts must be replaced together.
(4) Inspect the inside surface of the blower housing for burrs or scoring. The inside surface must be
smooth for efficient operation of the blower. If the inside surface of the housing is slightly scored or
burred, it may be cleaned up with emery cloth (Item 25, Appendix E).
(5) Examine the rotor shaft serrations for wear, burrs or peening. Also inspect the bearing and oil seal
contact surfaces of the shafts for wear or scoring.
(6) Inspect the inside surface of the blower housing for burrs or scoring. The inside surface must be
smooth for efficient operation of the blower. If the inside surface of the housing is slightly scored or
burred, it may be cleaned up with emery cloth (Item 25, Appendix E).
(7) Check the finished ends of the blower housing for flatness or burrs. The end plates must set flat
against the blower housing. The finished inside face of each end plate must be smooth and flat. If
the finished face is slightly scored or burred, it may be cleaned up with emery cloth (Item 25,
Appendix E).
NOTE
Be careful not to remove metal at the joint face
between the end plates and the housing. Air or oil
leaks could develop after assembly.
(8) Inspect both timing gears at teeth and at bore splines for
chips or nicks.
(9) Inspect oil holes. If clogged, clean with dry cleaning
solvent (Item 3, Appendix E).
c.
Assembly.
NOTE
Do steps (1) through (4) for all four ring carriers.
(1) Support rotor (1) on blocks.
(2) Apply lubricating oil (Item 10, Appendix E) inside ring
carrier (2).
(3) Install ring carrier (2) tight to rotor (1) with large side
facing rotor using remover and installer tool.
CAUTION
Do not spread oil seal rings too much when installing or rings will break.
5-130
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(4) Install oil seal ring (3) in ring carrier (2) on all four rotor shafts (4).
NOTE
Do steps (5) and (6) for front and rear plates.
(5) Apply lubricating oil to outside of seal ring collar (5).
(6) Press seal ring collar (5) into end plate bore, beveled side up, until removal and installer tool contacts
front end plate (6). Seal ring collar will seat 0.005-in. (0.127 mm) below inside facing.
5-131
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
NOTE
Do steps (7) and (8) for right and left rotors.
(7) Support front end plate (6) 4 in. (102 mm) off bench
with blocks.
NOTE
Gap between splines on rotor shaft must face
upward and align to one another.
(8) Tilt right hand rotor (1) and install into right hand side
of front end plate (6).
(9) Repeat step (8) for left-hand rotor (1).
(10) Apply light coat of grease (Item 1, Appendix E) to
front end plate side of blower housing (7).
(11) Align top of blower housing (7) with top edge of
front end plate (6).
(12) Align dowel pins (8) and install in front end plate
(6).
(13) Install and tighten two screws (9) to 10 Ib-ft
(14 N•m).
(14) Apply lubricating oil (item 10, Appendix E) to oil seal
rings (3).
(15) Apply light coat of grease (Item 1, Appendix E) to rear
end plate surfaces of blower housing (7).
5-132
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(16)
Turn seal rings (3) so gaps face top of blower housing (7).
(17)
Tilt rear end plate (10) back so that back side of seal rings (3) insert into seal ring collars first.
(18)
Position rear end plate (10) and align dowel pins (11) to holes in blower housing (7).
(19)
Tap rear end plate (10) onto blower housing (7).
(20)
Install and tighten two screws (12) to 10 Ib-ft
(14 N•m).
(21)
Apply lubricating oil (Item 10, Appendix E) to two
ball bearings (13).
(22)
Install two ball bearings (13), numbered end up,
in rear end plate (10) with bearing installer.
5-133
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(23)
Position two flat bearing retainers (14) on rear end ptate (10)
and install six screws (15) in retainers. Tighten six screws to
10 Ib-ft (14 N•m).
(24)
Install two roller bearing collars (16) to both shafts (4)
at front end plate (6) with bearing installer tool.
(25)
Apply lubricating oil (Item 10, Appendix E) to two
roller bearings (17).
(26)
Install roller bearings (17), over rotor shafts (4)
with bearing installer tool.
NOTE
Flanges on bearing retainers face front end plate.
(27)
Install two flanged bearing retainers (18) with six
screws (19) on front end plate (6). Tighten screws
to 10 Ib-ft (14 N•m).
5-134
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
WARNING
Do not place fingers betwen rotors. If rotors turn,
they can cause serious injury.
(28)
Set rotor shafts (4) at rear end plate (10) so that
each gap in splines align with one another.
(29)
Install spacer (20) and shim (21) on each rotor
shaft (4).
(30)
Apply lubricating oil (Item 10, Appendix E) to
splines on rotor shafts (4).
NOTE
Place folded shop towel between rotor lobes.
(31)
Install both timing gears (22 and 23) at same time so gap in splines on gears mate with gaps in
splines on rotor shafts (4).
(32)
Install two timing gear screws (24 and 25) with washers (26).
(33)
Tighten both timing gear screws (24 and 25) evenly to draw both timing gears (22 and 23) tight.
(34)
Apply lubricating oil (Item 10, Appendix E) to both timing gear screws (24 and 25).
(35)
Tighten timing gear screws (24 and 25) to 110 Ib-ft (1 49 N•m).
5-135
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
NOTE
Remove shop cloth before timing rotors and setting clearances.
(36)
Install four screws each (27) and washers (28) in front end plate (6) and rear end plate (10).
(37)
Tighten screws (27) to 15 Ib-ft (20 N•m).
NOTE
•
Correct rotor operating range is 0.004 to 0.006 in (0.102 to
0.152 mm). If rotor does not meet specification, do
steps (42) through (45).
•
Clearances between rotor lobes must be measured 1 in.
(25.4 mm) from end plate.
5-136
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(38)
Place 0.004-in. (0.102 mm) feeler gage between
rotor lobes (29 and 30). Rotate rotors while gage
is installed.
(39)
Remove feeler gage.
(40)
Turn blower (7) upside down and place 0.004-in.
(0.1 02 mm) feeler gage between rotor loves (29
and 30). Rotate rotors while gage is installed.
(41)
Remove feeler gage.
NOTE
To increase or decrease gap between trailing edge of right rotor
lobes and leading edge of left rotor lobes, do steps (42) through
(45).
(42)
Install puller tool on left timing gear (23) with two screws.
(43)
Install puller tool on right timing gear (22) with three screws.
NOTE
Place clean, folded shop towel between blower rotors to keep
gears from turning.
(44)
Tighten puller screws evenly to remove gears (22 and 23).
5-137
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
NOTE
To change gap between rotor lobes by
0.001-in. (0.025 mm), add or remove a
0.003-in. (0.076 mm) shim.
(45)
Add or remove shims (21) to left rotor
shaft (4) as necessary.
(46)
Install blower timing gears according
to steps (31) through (35).
(47)
Check rotor lobe clearance according
to steps (38) through (41).
NOTE
Correct rotor operating is 0.009 to 0.011 in. (0.23
to 0.28 mm). If rotors do not meet this specification, do steps (52) through (57).
(48)
Place 0.010-in. (0.254 mm) feeler gage
between rotor lobes (29 and 30). Rotate
rotors while gage is installed.
(49)
Remove feeler gage.
5-138
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(50)
Turn blower (7) right side up and
place 0.010-in. (0.254 mm) feeler
gage between rotor lobes (29 and
30). Rotate rotors while gage is
installed.
(51)
Remove feeler gage.
NOTE
To increase or decrease gap between leading edge of right rotor lobe and trailing
edge of left rotor lobe (30), do steps (52) through (55).
(52)
Install puller tool on left timing gear (23) with two screws.
(53)
lnstall puller tool on right timing gear (22) with three screws.
(54)
Tighten puller screws evenly to remove timing gears (22 and 23).
5-139
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
NOTE
To change gap between rotor lobes by
0.001-in. (0.025 mm), add or remove a
0.003-in. (0.076 mm) shim.
(55)
Add or remove shims (21) to right rotor
shaft (4) as necessary.
(56)
If rotor lobe clearances cannot be
corrected with shims, replace rotors.
(57)
Install blower timing gears, following
steps (31) through (35).
(58)
Check clearance of rotor lobes, following
steps (48) through (51).
NOTE
There are six measurements between
rear end plate and rotor lobes, one for
each lobe of each rotor.
(59)
Using 0.007-in. (0.178 mm) feeler gage
check clearance between rear end
plate (10) and both rotor lobes
(29 and 30). If clearance is not
correct, replace rear end plate.
(60)
Using 0.012-in. (0.305 mm) feeler
gage, check clearance between front
end plate (6) and both rotor lobes (29
and 30). If clearance is not correct,
replace front end plate.
5-140
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
NOTE
There are six measurements between rotors and
housing made through top of blower.
(61)
Using 0.015-in. (0.381 mm) feeler gage, check
clearance between rotor lobes (29 and 30) and
housing (7) while rotating rotors. If clearance is
not correct, replace housing.
NOTE
There are six measurements between
rotors and housing made through bottom
of blower.
(62)
Using 0.004-in. (0.102 mm) feeler
gauge, check clearance between
rotor lobes (29 and 30) and blower
housing (7) while rotating rotors.
If clearance is not correct, replace
housing.
5-141
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(63)
Remove four screws each (27) and washers (28) from
front end plate (6) and rear end plate (10).
(64)
Install oil slinger (31) on rotor shaft (4) at front end
plate (6).
(65)
Install fuel pump disk (32), lockwasher (33), and screw
(34).
(66)
Tighten screw (34) to 65 lb-ft (88 Nm).
(67)
Bend two lockwasher tangs around head of screw (34).
(68)
Install front end plate cover (35), new gasket (36) with
nine bolts (37)
5-142
TM 5-4210-233-14&P-1
5-22.
BLOWER REPAIR - Continued
(69)
Install three screws (38) and two spring plates (39)
onto coupling (40).
(70)
Tighten three screws (38) to 30 Ib-ft (40 N•m).
NOTE
Install clean shop cloth between gears.
(71)
Install coupling assembly (40) with three screws (41).
(72)
Tighten three screws (38) to 30 Ib-ft (40 N•m)
(73)
Install rear end plate cover (42) with new gasket (43).
(74)
Install 10 screws (44) and lockwashers (45).
(75)
Tighten screws (44) evenly to 15 lb-ft (20 N•m).
d. Follow-on Maintenance.
(1) Install blower (see para 5-21).
5-143
TM 5-4210-233-14&P-1
5-23. TURBOCHARGER
This task covers:
a. Removal
b. Disassembly
c. Cleaning and Inspection
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
d.
e.
f.
Assembly
Installation
Follow-on Maintenance
PERSONNEL: 2
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B, Section 111, Item 4)
MATERIALS/PARTS REQUIRED
Solvent, Dry Cleaning, (Item 3, Appendix E)
Grease, Automotive and Artillery (Item 1, Appendix E)
Compound, Antiseize (Item 4, Appendix E)
Oil, Lubricating (Item 10, Appendix E)
Compound, Sealing, Pipe Thread (Item 2, Appendix E)
Brush, Paint, Oval (Item 44, Appendix E)
Grease, Silicone (Item 1 1, Appendix E)
Piston Rings (Figure 94, Appendix F)
Retaining Rings (Figure 94, Appendix F)
Thrust Bearings (Figure 94, Appendix F)
Wear Washers (Figure 94, Appendix F)
Seal Ring (Figure 94, Appendix F)
Inlet Screen Seal (Figure 94, Appendix F)
Journal Bearings (Figure 94, Appendix F)
Gasket (Figure 94, Appendix F)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Parking Brake On (see para 2-12.)
Engine Enclosure Removed (see para 4-127.)
Exhaust Outlet Pipes Removed from Turbocharger
(see para 5-44.)
Air Inlet Elbow Disconnected from Turbocharger
(see para 4-128.)
a. Removal.
(1) Loosen four nuts (1) and clamps (2).
(2) Remove two exhaust tubes (3) from two exhaust
manifolds (4) and tee (5).
5-144
TM 5-4210-233-14&P-1
5-23.
TURBOCHARGER- Continued
(3) Disconnect oil hose (7) from elbow (6}.
(4) Remove four nuts (9), Iockwashers (10),
gasket (11), and tee (5) from turbocharger (8).
5-145
TM 5-4210-233-14&P-1
5-23.
TURBOCHARGER - Continued
(5) Loosen clamps (22) on hose (23).
(6) Remove two screws (24) and lockwashers
(25) from turbocharger (8).
NOTE
Hose should be pried loose if it sticks to
turbocharger.
(7) Remove turbocharger (8).
(8) Remove hose (23) and clamps (22).
(9) Inspect air inlet adapter (26) for breaks and
cracks. Replace if damaged (para 5-20).
(10) Remove seal (27) from air inlet adapter (26).
Discard seal.
(11) Cover openings in air inlet adapter (26) with
clean cloth.
5-146
TM 5-4210-233-14&P-1
5-23. TURBOCHARGER-Continued
b. Disassembly.
CAUTION
Be careful when removing turbine housing and compressor
housing in order to prevent damaging housings and/or turbine
and compressor wheels.
(1) Matchmark related positions of compressor housing (1), turbine housing (4), and center housing (6)
with a punch or scribe prior to disassembly to assure reassembly in the same relative positions.
(2) Remove inlet screen (6A) and seal (6B) from compressor housing (1).
(3) Loosen coupling (2) and remove compressor housing (1) and coupling.
(4) Loosen coupling (5) and
remove center housing (6)
and coupling from turbine
housing (4).
(5) Install turbine wheel (7) in
holding fixture. Remove
locknut (8).
CAUTION
To prevent the possibility of bending the turbine wheel shaft,
remove the compressor wheel
nut from the shaft with a double
universal socket and tee handle
wrench.
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TM 5-4210-233-14&P-1
5-23. TURBOCHARGER-Continued
(6) Tap shaft (9) with soft hammer while holding turbine
wheel (7) up to loosen compressor wheel (10).
CAUTION
Do not pry off compressor wheel. Damage will occur.
(7) Remove compressor wheel (10) from shaft (9).
(8) Remove center housing (6) from shaft (9).
(9) Remove turbine shroud wheel (11) from center
housing (6).
(10) Remove and discard turbine piston ring (12) from
shaft (9).
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5-23. TURBOCHARGER-Continued
(11) Remove four screws (15).
(12) Remove backplate (3) from center housing (6).
(13) Remove and discard seal ring (16) from center
housing (6).
(14) Remove elbow (16A) and adapter (17) from entire
housing (6).
(15) Remove thrust spacer (18), with two piston rings (19)
from backplate (3).
(16) Remove two piston rings (19) from thrust spacer (18).
Discard piston ring.
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5-23. TURBOCHARGER-Continued
(17) Remove thrust collar (20), three thrust bearing screws
(20A), and thrust bearing (21) from center housing (6).
(18) Remove and discard journal bearing (22) and wear
washer (23) from center housing (6).
(19) Remove and discard retaining ring (24) from center
housing (6).
(20) Remove retaining ring (25), wear
washer (26) and journal bearing (27).
Discard all three.
(21) Using retaining ring pliers, remove
and discard retaining ring (28).
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5-23. TURBOCHARGER-Continued
c.
Cleaning and Inspection.
WARNING
•
Adhesives, solvents, and sealing compounds can burn
easily, can give off harmful vapors, and are harmful to skin
and clothing. To avoid injury or death, keep away from
open fire and use in well-ventilated area. If adhesive,
solvent, or sealing compound gets on skin or clothing, wash
immediately with soap and water.
•
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and skin
contact with the liquid. Do not use near open flame, arcing
equipment or other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 59 deg. C).
NOTE
Do not use a caustic cleaning solution. It can damage parts.
(1) Soak metal parts in dry cleaning solvent (Item 3, Appendix E) for 25 minutes.
CAUTION
Do not clean with steel bristle brush. Turbocharger parts can be
damaged by steel bristles.
(2) Clean parts with stiff bristle brush after soaking in dry cleaning solvent (Item 3, Appendix E).
(3) Clean oil passages (1, 2, and 3) in center housing (4) and oil passages (5 and 6) in backplate (7).
(4) Clean oil inlet hose inside and out. If oil hose is damaged or deteriorated, replace it.
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5-23. TURBOCHARGER-Continued
WARNING
Compressed air used for cleaning purposes shall not exceed 30
psi (207 kPa). Use only with effective chip guarding and
personal protective equipment (goggles/shield, gloves, etc.).
(5)
Dry turbocharger parts with compressed air.
(6)
Inspect turbocharger parts for nicks, cuts, scratches, scoring or other damage.
(7)
Inspect screw threads for stripping or cross-threading.
NOTE
Measurements given in this section are for used parts.
(8) Check diameters of turbine wheel shaft journals (8 and 9) on
shaft (10) Journal diameters must be between 0.6250 and
0.6254-in (15.875 and 15.885 mm).
(9) Inside diameter of compressor wheel (11) must not be greater than
0.3749-in (9.522 mm).
(10) Inside diameter of center housing (12) must not be greater
than 0.9842-in (24.998 mm).
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5-23. TURBOCHARGER-Continued
(11) Seal bore (13) must not be greater than 0.6895-in
(17.513 mm).
(12) Thrust collar (15) thickness must not be less than 0.2970-in. (7.543
mm) Thrust collar bore inside diameter must not be greater than
0.3778-in. (9.596 mm).
(13) Thrust spacer (16) ring grove width will not be greater than 0.0715-in
(1.816 mm) Outside diameter must not be less than 0.6705-in.
(17.030 mm).
(14) Replace damaged parts or parts worn beyond specifications.
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5-23. TURBOCHARGER-Continued
d. Assembly.
CAUTION
Lubricate all rotating bearing surfaces
with oil (Item 10, Appendix E).
(1) Using retaining ring pliers, install a
new retaining ring (1).
(2) Install new bearing (2), new wear washer (3), and new
retaining ring (4) in turbine side of center housing (5).
(3) Install a new retaining ring (6), new wear washer (7), and
new bearing (8) in compressor side of center housing (5).
(4) Install thrust washer (10) and attach with three thrust
bearing screws (10A).
(5) Install thrust collar (12) and new seal ring (13).
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5-23. TURBOCHARGER-Continued
NOTE
Flat surface of thrust spacer faces up.
(6) Install two new piston rings (14) on thrust spacer (I5).
(7) Install thrust spacer (15) in compressor backplate (16).
(8) Align oil lubrication holes (17) in backplate (16) and center
housing (5) and install backplate on center housing.
CAUTION
Used backplates must not be
reused. Screws can come loose
and destroy turbocharger.
(9) Install four screws (19) in backplate (16).
(10) Tighten screws (19) to 80 to 100 lb in (9 to 11 Nm).
NOTE
If a new backplate with a warning
plate is inadvertently installed, the
warning plate must be removed and
the three drive screw holes plugged
to prevent air leakage.
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5-23. TURBOCHARGER-Continued
(11) Install turbine shroud wheel (20) on
center housing (5).
(12) Fill piston ring groove with Dow
Corning High Vacuum Silicon grease
or equivalent (Item 11, Appendix E)
and install piston ring (22) in groove.
(13) Install turbine wheel shaft (21)
through the shroud wheel and into
center housing (5) Lubricate the
wheel shaft bearing surfaces with oil
(Item 10, Appendix E) prior to
assembly.
(14) Install compressor wheel (23) on shaft (21).
(15) Lubricate shaft threads and wheel face
surface that will be under the nut with oil
(Item 10, Appendix E), and install locknut
(24) on shaft (21).
(16) Place turbine wheel (7) in holding fixture.
CAUTION
Do not put a bending load on shaft
while tightening locknut use a
double universal socket and tee
handle wrench.
(17) Tighten locknut (24) to 125-150 lb in
(14 to 17 Nm).
(18) Loosen locknut (24).
(19) Inspect faces of locknut (24) and
compressor wheel (23) Make sure
both surfaces are clean and smooth.
(20) Apply lubricating oil to threads of shaft
(21) and base of locknut (24).
(21) Retighten locknut (24) to 35 to 55 lb in
(4 to 6 Nm).
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5-23. TURBOCHARGER-Continued
(22) Continue to tighten until the shaft increases in
length by .009-.010 of an inch. If measuring
equipment is not available, turn the nut an
additional 120°-130°(90°= 1/4 turn).
(23) Place backplate (16) in vise with soft jaws.
(24) Check thrust float with dial indicator. Move shaft
(21) back and forth in center housing (5).
Indicator reading (thrust float) must be
0.003 to 0.010-in. (0.08 to 0.25 mm).
(25) Align matchmarks on center housing (5) and turbine housing (25).
(26) Install turbine wheel assembly (26) in turbine housing (25) and coupling (27).
(27) Apply high temperature antiseize compound (Item 4, Appendix 4) to threads of screw (28).
CAUTION
Do not tighten turbine housing clamp until center housing is
aligned with turbine housing. If parts are not aligned, turbocharger will be damaged.
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5-23. TURBOCHARGER-Continued
(28) Tighten locknut (29) to 160 lb in (18 Nm).
(29) Loosen locknut (29) to approximately 50 lb in (6
Nm).
(30) Retighten locknut (29) to 152-168 lb in (17 to 19
Nm).
(31) Align matchmarks on compressor housing (30)
and center housing (5).
(32) Install compressor housing (30) and coupling (31)
on backplate (16).
(33) Apply lubricating oil to threads of coupling screw (32).
CAUTION
Do not tighten compressor housing
clamp until center housing is
aligned with compressor housing.
If
parts
are
not
aligned,
turbocharger will be damaged.
(34) Tighten locknut (33) to 110 to 130 lb in.
(12 to 15 Nm).
(35) Coat threads of brass fitting (34) with pipe thread
sealing compound and install. Tighten to 240 lb in.
(27.1 Nm).
(36) Coat threads with pipe thread sealing compound
and install elbow (34A).
(37) Position magnetic base, equipped with swivel
adapter, dial indicator, and extension rod, on flat
surface of center housing oil outlet flange (35).
NOTE
Do not allow extension rod to touch sides of center housing.
Inaccurate readings can result in poor fit and damage.
(38) Insert extension rod into oil drain hole so that rod is against turbine wheel shaft.
(39) Grasp turbine and compressor wheels and move turbine wheel shaft up and down. Turbine wheel
shaft must not move more than 0.010-in (0.254 mm) or less than 0.003-in (0.076 mm).
(40) Disassemble and inspect turbocharger (36) if radial clearance of turbine wheel shaft is not within
limits.
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TM 5-4210-233-14&P-1
5-23. TURBOCHARGER-Continued
e. Installation.
(1) Remove clean cloth from openings in air
inlet adapter (2).
(2) Install hose (1) on air inlet adapter (2).
(3) Slide clamps (3) over hose (1).
(4) Install seal (4) in air inlet adapter (2).
(5) Slide air outlet end of turbocharger (5)
into hose (1).
(6) Install turbocharger (5) on air inlet
adapter (2) using a new gasket.
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5-23. TURBOCHARGER-Continued
(7) Install two screws (6) with lock
washers just enough to hold the
turbocharger tight against the
bracket.
(8) Position two clamps (3), one over air
inlet adapter (2) and one over
turbocharger (5).
(9) Tighten clamps (3).
NOTE
Secure the clamps with the "T"
section positioned away from the
parting line on the air inlet housing.
CAUTION
When installing the left bank exhaust manifold to turbocharger
tube on a blower mounted turbocharger, it is very important that
the tube is installed correctly. If the tube in installed incorrectly,
it can crack in the flange area and adversely affect performance.
(10)
The solid left bank tube is almost symmetrical, thus it is difficult to identify which end goes where.
Therefore, position the tube between the exhaust manifold and the turbocharger and check to
determine that the conical seat at each end of the tube is a flush fit with the openings. If not,
reverse the position of the tube and recheck to be sure each end of the tube is a flush fit with the
openings.
(11)
To help in the installation of the tube, loosen the exhaust manifold mounting bolts and then tighten
them alternately while tightening the tube clamps.
NOTE
Be sure the exhaust manifold remains seated on the locating
pads on the cylinder head.
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5-23. TURBOCHARGER-Continued
(12) Slide four clamps (6) over two exhaust tubes (7).
(13) Install two exhaust tubes (7) on tee (8) and two
exhaust manifolds (9).
(14) Tighten four clamp nuts (10).
(15) Install tee (8), gasket (11), four nuts (12), and
lockwashers (1 3) on turbocharger (5).
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5-23. TURBOCHARGER-Continued
(16)
Fill center housing (20) with clean engine oil through fitting (21).
NOTE
Be sure the exhaust manifold remains seated on the locating
pads on the cylinder head.
(17)
f.
Connect oil hose (22) to elbow (21) and tighten hose nut. Tighten the turbo to exhaust
manifold adapter bolts to 30-35 lb-ft.
Follow-on Maintenance.
(1) Connect air inlet elbow to turbocharger (see para 4-128).
(2) Connect exhaust outlet pipe to turbocharger (see para 5-44).
(3) Connect batteries (see para 4-114).
NOTE
The lube oil supply connector formerly installed in the plate is
now assembled directly to the turbocharger center housing. The
oil inlet of current TV turbochargers is being threaded by the
manufacturer.
(4) Start engine and run at idle for ten minutes. Engine oil pressure should register at 10 PSIG on the
gauge in the cab.
CAUTION
Do not hold the compressor wheel, for any reason, while the
engine is running. This could result in personal injury.
(5) Check turbocharger gaskets and ducts for leaks.
CAUTION
If any such noise is apparent, stop the engine immediately and
determine the cause.
(6) Operate the engine at rated output and listen for sounds of metallic contact from the turbocharger.
CAUTION
After the turbocharger has been operating long enough to permit
the unit and the oil to warm up, the rotating assembly should
coast freely to a stop after the engine is stopped. If the rotating
assembly jerks to a sudden stop, the cause should be
immediately determined and eliminated.
(7) Shut off engine.
(8) Install engine enclosure (see para 4-127).
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5-24. EXHAUST MANIFOLD
This task covers:
a. Removal
b. Inspection
c. Installation
d. Follow-on Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 1II, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Enclosure Removed (see para 4-127.)
MATERIALS/PARTS REQUIRED:
Penetrating Oil (Item 8, Appendix E)
Gaskets (Fig. 97, Appendix F)
a. Removal.
WARNING
Exhaust parts can be hot enough to cause severe burns if
touched. Allow exhaust system to cool before servicing.
NOTE
If exhaust manifold attaching parts are corroded, apply
penetrating oil (Item 8, Appendix E) to ease disassembly.
(1) Remove the right exhaust manifold to turbocharger pipe (1) by loosening and removing the two sea
clamps (2).
(2) Loosen dipstick bracket screw.
(3) While supporting the right exhaust manifold (3) remove the five nuts (4). Remove the two holddown crabs (5) and three bevel washers (6)from the exhaust manifold studs (7).
(4) Slide the right exhaust manifold from the studs and lift from engine compartment.
(5) Remove and discard the two exhaust manifold gaskets (8).
(6) Follow steps 1 and 3 through 5 to remove left exhaust manifold.
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5-24. EXHAUST MANIFOLD-Continued
b. Inspection.
(1) Remove all loose scale and carbon that may have accumulated on the internal walls of the exhaust
manifold. This is especially important on turbocharger engines becauseloose scale or carbon
could enter and damage the turbocharger.
(2) Examine the exhaust manifold studs for damage, and replace as necessary. Torque new studs to
25-40 lb-ft (34-54 Nm).
(3) Make sure all gasket material is removed from cylinder head and exhaust manifold mating surface.
(4) Inspect manifold for cracks, damage or warpage.
c.
Installation.
CAUTION
Ensure manifold interior is free from scale and carbon. This will
eliminate the possibility of turbocharger damage.
(1)
Place two new gaskets (8) over studs and up against the cylinder head.
NOTE
When installing the two metal clad exhaust manifold gaskets be
sure the crimped sides of the gaskets face the cylinder head.
(2) Lift right exhaust manifold (3) into engine compartment. Position the manifold over the studs (7)
and up against the exhaust manifold gaskets (8).
NOTE
Be sure the locating pads on the exhaust manifold rest on the
cylinder block locating pads.
(3) Install the two hold-down crabs (5), three bevel washers (6),and five nuts (4) on the studs (7), and
draw the exhaust manifold up against the gaskets. Set the bevel washers in position so that outer
diameter will rest on the manifold and the crown at the center is next to the nut. Tighten the
exhaust manifold stud nuts (4) from the center of the exhaust manifold outward, alternating toward
either end. Torque the nuts to 30-35 ft lb (41-47 Nm).
(4) Install the right exhaust manifold to turbocharger pipe (1) into position, and secure using two seal
clamps (2) Do not allow exhaust piping to impose excessive loads on turbocharger. Tighten seal
clamps firmly.
(5) Tighten dipstick bracket screw.
(6) Repeat steps 1 through 4 to install left exhaust manifold.
d. Follow-on Maintenance.
(1) Install engine enclosure (see para 4-127).
(2) Connect batteries (see para 4-114).
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TM 5-4210-233-14&P-1
5-25. WATER PUMP
This task covers:
a.
b.
c.
d.
Removal
Inspection
Repair
Disassembly
e. Assembly
f. Installation
g. Follow-on Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Enclosure Covers Removed (see para 4-127.)
Engine Coolant Drained (see para 3-6.)
Shop Equipment, Automotive
Maintenance and Repair
(Appendix B, Section III, Item 4)
MATERIALS/PARTS REQUIRED:
Pipe Sealant (Item 2, Appendix E)
Grease (Item 1, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
Motor Oil (Item 20, Appendix E)
Seal Retainer (Item 6, Appendix E)
Anti-Seize Compound (Item 4, Appendix E)
Seal Ring and Seals (Fig. 99, Appendix F)
a. Removal.
(1) Loosen hose clamps and loosen hose (1) between
thermostat cover (2) and water pump housing (3).
(2) Loosen hose clamps and loosen hose (4) between
radiator pipe and water pump housing (3).
(3) Loosen hose clamps and remove hose (5) between
oil cooler pipe and water pump housing (3).
(4) Remove capscrew (8), lockwasher (9), and flat
washer (10) from the rear side of the water pump
housing.
(5) Remove two bolts (11) and pull fuel line bracket (12)
away from pump. Remove tie wraps as necessary.
(6) Remove the two front capscrews (13) and
Iockwashers (14) Use extreme care to prevent
damage to the gear teeth when disengaging the pump
gear from the water pump drive.
(7) Remove seal ring (15) and discard.
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TM 5-4210-233-14&P-1
5-25. WATER PUMP-Continued
b. Inspection.
(1) Mount pump drive gear in a soft jawed vise.
(2) Using snap ring pliers, remove snap ring (16).
(3) Lift off pump cover (17). Do not remove seal
ring (18).
(4) Remove water pump from vise and rotate
impeller by hand. Check for any looseness
in the bearing. Repair as required. See repair
and disassembly procedures following.
(5) If required, check impeller for build up of
contaminants or foreign material. Remove impeller
and repair as detailed in repair and disassembly
procedures following.
c.
Repair.
NOTE
Water pump must be removed from truck. See Removal
preceding. Water pump can be repaired using one of three
methods.
(1) Replacing seals and individual components as required, and repairing impeller.
(2) Replacing impeller assembly, which has new insert installed, and replacing seals and individual
components as required.
(3) Replacing all internal pump parts.
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5-25. WATER PUMP - Continued
d. Disassembly
(1) Clean water pump, if necessary, with pressure hose to remove both internal and external dirt and
grime.
(2) Position water pump drive gear in soft jawed vise.
(3) Using snap ring pliers, remove snap ring (1) retaining pump cover (2) to water pump housing (3).
(4) Remove impeller Locknut (5) and washer (6).
(5) Using puller, remove impeller (7) from shaft assembly (8).
(6) Place pump assembly on workbench with drive gear upwards. Turn pump drive gear (14) so one of
the slots in the drive gear is over the ends of bearing retaining ring (13).
(7) Insert snap ring pliers into slot and remove ring (13) from groove.
(8) Press shaft bearings and pump gear assembly out of pump body.
(9) Place gear (14) on bed of press with the shaft extending downward. Using a suitable sized arbor
shaft, press shaft (8) out of gear.
(10) Support shaft assembly on the inner race of the larger bearing (12) with threaded end down. Place
flat stock between hydraulic ram and shaft. Press pump shaft out of large bearing.
(11) Invert shaft and support it on the inner race of the small bearing (11). Press shaft (8) from bearing.
(12) Use channel lock pliers to grasp the metal flange around the upper portion of seal (9), and twist it to
break the seal and boot away from the outside case of the water seal.
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5-25. WATER PUMP - Continued
(13) Remove and discard the cover seal ring (4).
(14) Push the oil seal (10) out of pump body (3).
NOTE
New seals and a new ceramic impeller insert must be used each
time a water pump is repaired.
WARNING
Dry cleaning solvent P-D-680 (safety or Stoddard's solvent) is
potentially dangerous Avoid repeated and prolonged breathing
of vapors and skin contact with the liquid. Do not use near open
flame, arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 59 deg. C)
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced 2) to 30 psi (2.11
kg/cm ) or less. When working with compressed air, always use
chip guards eye protection and other personal protective
equipment.
(15) Wash all parts in dry cleaning solvent (Item 3, Appendix E) and dry with compressed air. Inspect
and replace damaged or worn parts..
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5-25. WATER PUMP - Continued
(16)
Make sure "Y" drain passage in housing is clear of any obstructions.
(17) Examine bearings for corrosion, pitting and freedom of movement. Replace bearings if any found
faulty. Always replace both bearings.
e. Assembly.
(1)
Lubricate bearing bores and shaft bearing surfaces with motor oil (Item 20, Appendix E).
(2)
Press bearings (11 and 12) on shaft (8) using gear and bearing installer. Press only on the inner
races during installation.
(3)
Support pump body (3) on press bed with cover side down. Press shaft andbearing assembly in
place by applying pressure on the outer race of the large bearing (12).
(4)
Install bearing retaining ring (13).
(5)
Inspect water pump driven gear for damaged teeth. Replace as required.
(6)
Inspect water pump drive gear on engine for possible related failure. Refer to General Support
Level if necessary to replace drive gear.
(7)
Position gear installer on impeller end of shaft (8). Press gear (14) on shaft so it is flush with end of
shaft.
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5-25. WATER PUMP - Continued
(8)
Apply film of engine oil (Item 20, Appendix E) to sealing areas of oil seal (10) and shaft (8). Install
seal with spring loaded tip towards bearing in pump housing (3). Press or tap seal flush with water
seal counterbore using suitable installing sleeve.
(9)
Apply a light coat of seal retainer (Item 6, Appendix E) on outside diameter of water seal (9). Install
seal in the pump body housing (3) with a sleeve large enough to fit around the seal case and resting
on the brass lip. Press seal into position.
(10) Inspect water pump impeller (7) for erosion and excessive wear.
(11) If impeller is reused, the ceramic impeller insert must be replaced. If new impeller is to be installed
proceed to step 19.
(12) Bake impeller assembly at 500 deg. F (260 deg. C) for one hour. Remove insert while adhesive is
hot. Allow impeller to cool. Clean the insert area with buffing wheel to remove old adhesive and
oxide build up.
WARNING
Dry cleaning solvent P-D-680 (safety or Stoddard's solvent) is
potentially dangerous. Avoid repeated and prolonged breathing
of vapors and skin contact with the liquid. Do no use near open
flame, arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 59 deg. C).
(13) Clean with dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm 2) or less. When working with compressed air, always
use chip guards eye protection and other personal protection
equipment.
(14)
Clean parts with compressed air.
(15)
Place the new adhesive washer in the impeller bond area with the new ceramic insert on top.
(16)
Clamp ceramic insert and impeller together with 3/8"-24 in. bolt, nut and two flat washers. Torque
to 10 ft Ibs (14 Nm).
(17)
Place impeller assembly in level position, insert upwards, in an oven preheated to 350 deg. F (177
deg. C) for one hour to cure adhesive.
(18)
Cool impeller to room temperature and remove bolt, nut, and two flat washers.
(19)
Make sure mating surfaces of water seal (9) and the ceramic insert in impeller (7) are free of dirt
or oil film.
(20)
Apply small amount of antiseize compound (Item 4, Appendix E) to the threads of the pump shaft
(8).
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5-25. WATER PUMP - Continued
(21) Place impeller (7), washer (6), and new locknut (5)on shaft.
(22) Hold the pump gear securely in a brass jawed vise. Draw impeller down on tapered shaft with locknut.
Torque nut to 40 ft lb (54 Nm).
(23) Scribe a line across impeller, nut and shaft.
(24) Scribe a line across water pump gear, and shaft.
(25) Insert adaptor into impeller puller holes, apply a torque of 80 ft lb (108 Nm) to the impeller.
(26) Slippage of impeller or gear should not occur at this torque.
(27) If slippage is felt, remove pump assembly from vise and examine the scribe marks. Determine whether
the gear or impeller turned on shaft. In either case, the shaft must be replaced along with the component
that turned.
(28) After replacing necessary parts, retest the water pump shaft assembly for slippage.
(29) Insert a feeler gauge into the water outlet opening of the pump. The clearance between the impeller and
the bump body must be a minimum of 0.015 in. (0.38 mm). Repair or replace pump assembly to obtain
desired clearance.
(30) Install new cover seal ring (4)using grease (Item 1, Appendix E) in groove and on seal ring.
(31) Install cover (2) securely in place with snap ring (1).
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5-25. WATER PUMP - Continued
f.
Installation.
(1)
Install new seal ring (13) on pump body. Use
grease (Item 1, Appendix E) to hold in
position.
(2)
Mount pump on the engine. Be sure pump
meshes with front right-hand camshaft gear
and dowel pin (14) engages in front engine
plate hole.
(3)
Install and tighten two mounting bolts (2) and
washers (5).
(4)
Install and tighten mounting bolt (8), washer
(10), and lockwasher (9).
(5)
Install a bolt in the impeller puller holes (B)
and measure the backlash with a dial
indicator. Gear backlash should be 0.001 0.006 in. (0.025-0.15 mm).
(6)
Adjust backlash to these limits by loosening
bolts (2 and 8) and pivoting pump either
clockwise or counterclockwise.
(7)
Torque mounting bolts to 50 ft lb (68 Nm).
(8)
Install pump cover (15) on water pump
housing. Be careful not to damage front seal
ring (16) in housing.
(9)
While pushing on pump cover (1 5), install
snap ring (14). Be sure it seats in the groove.
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TM 5-4210-233-14&P-1
5-25. WATER PUMP - Continued
(10) Install hose (6) between oil cooler pipe and water pump housing (3). Tighten hose clamps
securely.
(11) Install hose (4) between radiator pipe, and water pump housing (3). Tighten hose clamps
securely.
(12) Install hose (1) between thermostat cover and water pump housing (3). Tighten hose clamps
securely.
(13) Install fuel line bracket (12) with two bolts (11). Replace tie straps as necessary.
g. Follow-on Maintenance.
(1)
Connect batteries (see para 4-114).
(2)
Refill radiator (see para 3-6), start main engine and check for leaks. Tighten/remake connections
as required.
(3)
Stop engine after 2 minutes and top up radiator again.
(4)
Restart engine and allow it to reach full working temperature. Watch for leaks as pressure builds.
Stop engine if leak is detected and repair.
(5)
When engine has run at full operating temperature for 5 minutes shutdown and allow to cool.
Recheck radiator level.
5-173
TM 5-4210-233-14&P-1
5-26. POWER STEERING PUMP
This task covers:
a. Removal
b. Inspection
c. Repair
d. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 111, Item 1)
e. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Remove Curb Side Operator's Panel
(see para 4-26.)
Power Steering Fluid Drained (see para 4-162.)
MATERIALS/PARTS REQUIRED
Lubricating Oil (Item 10, Appendix E)
Pipe Sealant (Item 2, Appendix E)
Retaining Compound (Item 7, Appendix E)
Dexron II (Item 12, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
Gasket (Figure 156, Appendix F)
Seal Kit (Figure 157, Appendix F)
WARNING
To prevent fire hazards, collect residual fluid and clean any
spills immediately when disassembling power steering
components.
CAUTION
Pump or steering gear failure due to contamination may occur
unless strict cleanliness and protective measures are taken
when disassembling and assembling power steering
components. Power steering fluid is Dexron II (Item 12,
Appendix E)
a. Removal.
(1) Tag and remove hoses (1, 2, 3 and 4) from
power steering pump (5). Plug or cover hose
ends immediately.
(2) Remove two cap screws (6), two lockwashers
(7), power steering pump (5) and gasket (8).
Discard gasket.
(3) Remove coupling (9).
(4) Remove elbows (10, 11, and 12), tee (13) and
fitting (14) from pump (if new pump is to be
installed). Plug or cover the ports to prevent
contamination of the pump.
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5-26. POWER STEERING PUMP - Continued
b. Inspection.
(1) Inspect hoses and pump body. Damaged or deteriorating parts must be replaced.
(2) Inspect reusable hardware. Items with stripped or damaged threads must be replaced.
(3) Clean pump fittings thoroughly and inspect for damage including stripped threads. Replace as
required.
c.
Repair.
(1) Control Valve Repair.
CAUTION
Do not repair control valve (4). If faulty, the control valve must
be replaced. Valve malfunction and potential pump destruction
may occur if disassembly is attempted.
NOTE
Control valve may be replaced without removing steering pump
from truck.
(a) Remove two plugs (2) and spring (3).
(b) Insert a suitable tool through the bore where plugs (2) are removed and push control valve (5) out of
valve cover.
NOTE
Retaining ring (6) can remain in flow control cover unless it is
damaged. If removed, be careful not to scratch valve bore.
(c) Inspect flow control cover (5) bore. If scratched or otherwise damaged, replace the cover. Do not
attempt to repair.
NOTE
During handling and shipping of new control valve, burrs may be
raised on sharp edges. Be sure to remove these burrs before
installing valve.
(d) Coat the new control valve (4) with lubricating oil (item 10, Appendix E) and install it in the cover, small
land first.
(e) Check that valve slides smoothly in the valve bore and install spring (3).
(f) Apply pipe sealant (Item 2, Appendix E) to plugs (2) and install plugs in flow control cover.
5-175
TM 5-4210-233-14&P-1
5-26. POWER STEERING PUMP - Continued
5-176
TM 5-4210-233-14&P-1
5-26. POWER STEERING PUMP - Continued
(2) Pump Cartridge Repair.
NOTE
Pump must be removed from truck (see para a.).
(a) Draw or scribe match marks across cover (5), ring (11) and body (17).
(b) Remove cover screws (1). Note position of cover ports with respect to body port and lift off cover (5)
and O-ring (10). Discard O-ring.
(c) Remove pressure plate (8) and spring (7).
(d) Note position of ring (11) with respect to body (17). Also note the direction of the arrow on the ring. Lift
ring (11) free of pump body (17). Remove O-ring (11A). Discard O-ring.
(e) Remove vanes (16) from rotor (15) and slide rotor off pump shaft (13).
(f) Remove pressure relief valve from valve cover (see para c.).
WARNING
Dry cleaning solvent P-D-680 (safety or Stoddard's solvent) is
potentially dangerous. Avoid repeated and prolonged breathing
of vapors and skin contact with the liquid. Do not use near open
flame, arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 59 deg. C).
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection, and other personal protective
equipment.
(g) Using dry cleaning solvent (Item 3, Appendix E), wash all parts thoroughly and blow dry using
compressed air.
(h) Inspect rotor (15) and vanes (16). Replace both along with ring (11) (repair kit) if excessive play is
noticed between vane and slots in rotor.
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TM 5-4210-233-14&P-1
5-26. POWER STEERING PUMP - Continued
(i) Check wearing surfaces of body (17), pressure plate (8), ring (11), and rotor (15) for scoring and
excessive wear. Light scoring marks may be removed by lapping. Deeply scored or worn parts
warrant replacement of the pump.
(j) Spin shaft and rock shaft end to and fro. Replace pump if bearing is noisy or excessive play is noted
when shaft is rocked.
(k) Push cover (5) onto pump shaft. Rock cover on shaft. If excessive play is noted between shaft
journal and cover, replace pump.
NOTE
During handling and shipping of new cartridge parts, burrs may
be raised on sharp edges. Be sure to remove these burrs before
installing new parts in pump.
(I) Install new O-rings (10 and 11A) in the body and cover. Install ring (11) so that the arrow on the
perimeter points in direction of rotation as noted in step (d).
(m) Install rotor (15) on shaft and insert vanes (16) in rotor slots. Be sure the rounded vane edges are
toward the cover ring.
(n) Place pressure plate (8) on locating pins (21) and flat against ring (11). Position spring (7) on
pressure plate and install cover (5). Be sure cover ports are orientated as noted in step (b).
(o) Install and torque cover screws (1) to 75-85 ft. Ib. (100-1 15 Nm).
(p) Rotate the shaft by hand to ensure that there is no internal binding in the pump. Install shaft key
(14).
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TM 5-4210-233-14&P-1
5-26. POWER STEERING PUMP - Continued
c.
Installation.
(1) Apply pipe sealant (Item 2, Appendix E) to all fittings.
(2) Remove protective plugs from pump ports and install fittings (10 thru 14).
(3) Install new gasket (8) and pump (5) making sure key in shaft engages drive slot.
(4) Secure pump (5) with two lockwashers (7) and two capscrews (6).
(5) Connect hoses (1, 2, 3 and 4) to pump.
e. Follow-on Maintenance.
CAUTION
To prevent damage to pump vanes, be sure power steering
reservoir is refilled before starting engine.
(1) Refill power steering reservoir with Dexron II, (Item 12, Appendix E).
(2) Connect batteries (see para 4-114.).
(3) Start main engine and check hose connections for leaks and, if necessary, tighten fittings.
(4) Turn the steering wheel fully left and fully right and make sure the response to turning is smooth and
easy.
(5) Install curbside operator panel (see para 4-26).
5-179
TM 5-4210-233-14&P-1
5-27. OIL PAN
This task covers:
a. Removal
b. Cleaning
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 111, Item 1)
c. Installation
d. Follow-on Maintenance
EQUIPMENT CONDITION,
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Dry Cleaning Solvent (Item 3, Appendix E)
Engine Oil (Item 20, Appendix E)
Retaining Compound (Item 7, Appendix E)
Gasket (Fig. 115, Appendix F)
a. Removal.
(1) Remove the drain plug (1), and drain the engine oil into a suitable container.
(2) Remove the dipstick (2) from dipstick tube (3).
(3) Remove eighteen capscrews (4) and eighteen washers (5).
(4) Support the oil pan (6) and using a soft faced hammer, tap the oil pan to loosen it from the cylinder
block, being careful not to damage the oil pump piping and inlet screen. Remove oil pan.
(5) Remove gasket (7) and discard. Ensure all gasket material is removed from cylinder block.
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5-26. OIL PAN - Continued
b. Cleaning.
WARNING
Dry cleaning solvent P-D-680 (safety or Stoddard's solvent) is
potentially dangerous. Avoid repeated and prolonged breathing
of vapors and skin contact with the liquid. Do not use near open
flame, arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 59 deg. C).
(1) Wash the oil pan and fasteners using dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm2) or less. When working with compressed air, always use
chip guards, eye protection and other personal protective
equipment.
c.
Installation.
(1) Place gasket (7) on pan (6).
CAUTION
Tighten bolts in a crossing pattern working from the center of
pan to ends. Support oil pan while installing.
(2) Install pan (6) and secure with eighteen bolts (4) and eighteen washers (5). Torque bolts to 10-20
Ibs. ft. (14-17 Nm).
(3) Install dipstick (2) in dipstick tube (3).
d. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Fill pan with engine oil (Item 20, Appendix E). See para 3-1.
(3) Start and run main engine to check for leaks. Tighten pan bolts as, necessary.
5-181
TM 5-4210-233-14&P-1
5-28. DDEC ELECTRONIC CONTROL MODULE AND SENSORS
This task covers:
a. Electronic Control
c. Turboboost Pressure Sensor
Wiring Harnesses
b. DDEC Electronic
d. Synchronous Reference Sensor
Control Module
(TRS)
e. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Lint Free Cloth (Item 42, Appendix E)
Seals (Fig. 128, Appendix F)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Engine Cover Removed (see para 4-127.)
Driver Side Turbo Pipe Removed (see para 5-23.)
Driver Side Air Intake Removed (see para 5-1 1).
a. Electronic Control Wiring Harnesses.
(1) Removal.
(a) Remove screws (1, 5 and 7),
lockwashers (2) and nut (3) to disengage
clamps.
(b) Remove any tie wraps as necessary to
free the harnesses.
(c) Disconnect wiring harness (6) from
control module and from sensors on
engine. Remove harness from engine.
(d) Disconnect harness (4) from control
module and from right bank of cylinder
head. Tag and disconnect harness wires
from engine brake retarder and injectors.
(e) Disconnect wiring harness (8) from
control module and from wiring harness
(11) at cab wail. Disconnect wiring
harness (11) from electronic unit in cab.
(f) Disconnect wiring harness (9) from
control module and from wiring harness
(10) at cab wall. Disconnect wiring
harness (I0) from electronic unit in cab.
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5-28. DDEC ELECTRONIC CONTROL MODULE AND SENSORS - Continued
(2)
Cleaning and inspection.
(a) Wipe all harnesses with a clean, dry, lint free cloth (Item 42, Appendix E).
(b) Inspect plugs and connectors on ends of harnesses for damage.
(c) Inspect harnesses for damage to insulation, fraying and cracks.
(d) Replace all damaged harnesses.
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TM 5-4210-233-14&P-1
5-28. DDEC ELECTRONIC CONTROL MODULE AND SENSORS - Continued
(3)
Installation.
(a) Connect wiring harness (10) to electronic control unit in cab. Install rear end of harness at rear of
cab. Connect wiring harness (9) to wiring harness (1 0) at cab wall and to control module on engine.
(b) Connect wiring harness (11) to electronic control unit in cab and install rear end of harness at rear of
cab. Connect wiring harness (8) to wiring harness (11) at rear of cab and to control module on
engine.
(c) Connect wiring harness (4) to control
module on top of engine. Connect other
end of harness to right bank cylinder
head. Feed harness wires through
opening in cylinder head. Check tags on
harness wires and connect wires to
engine brake retarder and to fuel
injectors.
(d) Connect wiring harness (6) to sensors on
engine. Position wiring harness (6) on
engine as shown. Connect connector on
wiring harness (6) to control module on
top of engine.
(e) Secure clamps on harness to engine
with screws (1, 5 and 7), lockwashers (2)
and nut (3).
(f) Install clamps and tie wraps to secure
wiring harnesses.
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TM 5-4210-233-14&P-1
5-28. DDEC ELECTRONIC CONTROL MODULE AND SENSORS - Continued
b. DDEC Electronic Control Module.
(1)
Removal.
(a) Refer to step a. above and
disconnect wiring harnesses
from control module (13).
(b) Disconnect two fuel hoses
from fitting block (7).
(c) Remove four screws (6) and
lockwashers (5).
Remove
eight isolator mounts (4).
(d) Remove control module (13)
with attached parts from
engine.
(e) Remove two screws (9) and
remove fitting block (7) and
seals (8) from plate (10).
Discard seals.
(f) Remove eight screws (11)
and remove heat shield (12)
and plate (10) from control
module (13).
(g) Remove screws (3, 15, 16
and 17), lockwashers (2 and
5) and flat washers (1) and
remove bracket (14) from
engine.
(2)
Cleaning and Inspection.
(a) Wipe all parts clean with a dry, clean, lint free cloth (Item 42, Appendix E).
(b) Inspect control module (1 3) for damage to electronic receptacles.
(c) Inspect fitting block (7) for damage.
(d) Replace ail damaged components.
5-185
'
TM 5-4210-233-14&P-1
5-28. DDEC ELECTRONIC CONTROL MODULE AND SENSORS - Continued
(3)
Installation.
(a) Install bracket (14) in position on engine and secure with two screws (15) and lockwashers (5).
Install screws (3, 16 and 17), three lockwashers (2) and three flat washers (1).
(b) Install plate (10) and shield (12) on control module (13) and secure with eight screws (11).
(c) Install fitting block (7) on end of plate (10). Install new seals (8) and secure fitting block to plate
with two screws (9).
(d) Install eight isolator mounts (4) on control module (13) and install module in position on bracket
(14) and secure with four screws (6) and lockwashers (5).
(e) Connect two fuel hoses to fitting block (7).
(f) Refer to a. above and connect wiring harnesses to control module.
c.
Turbo Boost Air Pressure Sensor.
(1) Removal.
(a) Disconnect wiring harness (1) from
air pressure sensor (2).
(b) Loosen clamp (3) and disconnect
hose (4) from hose fitting (5).
(c) Remove two screws (6) and lift
turbo boost pressure sensor (2)
from bracket (7).
(2)
Cleaning and Inspection.
(a) Wipe sensor and hose clean with a
dry, clean, lint free cloth (Item 42,
Appendix E).
(b) Inspect hose for cracks, damage
and evidence of leakage.
(c) Inspect hose fitting for damaged
threads.
(d) Replace any damaged components.
5-186
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5-28. DDEC ELECTRONIC CONTROL MODULE AND SENSORS - Continued
(3) Installation.
(4) (a) Install turbo boost sensor (2) on
bracket (7). Secure sensor with two
screws (6).
(b) Slide hose clamp (3) on hose (4) and
connect hose (4) to fitting (5). Tighten
clamp (3) to secure hose.
(c) Connect wiring harness (1) to Turbo
Boost sensor (2).
d. Synchronous Reference Sensor (SRS) And Timing Reference Sensor (TRS).
(1) Removal
(a) Disengage the locking tangs on the SRS connector (1). Grasp the connector bodies and
gently pull them apart. Repeat this procedure for the TRS connector (2).
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TM 5-4210-233-14&P-1
5-28. DDEC ELECTRONIC CONTROL MODULE AND SENORS - Continued
(b) Remove the SRS/TRS retaining screw (3) and clip (4).
(c) If removal of bracket (5) is required remove two screws (6) and washers (7 and 7A).
(2) Installation.
(a) Install the sensors assembly using retaining clip (4) and screw (3).
(b) Connect the locking tangs on the SRS connector (1) and on the TRS connector (2).
(3) Adjustment.
Refer to SRS/TRS Adjustment Procedures in para 6-28.
e. Follow-on Maintenance.
(1) Install driver side air intake (see para 5-1 1).
(2) Install driver side turbo pipe (see para 5-23).
(3) Install engine cover (see para 4-127).
(4) Connect batteries (see para 4-114).
5-188
TM 5-4210-233-14&P-1
5-29. TRANSMISSION GOVERNOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool kit, General Mechanics, Automotive
(Appendix B, Section
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Gasket (Figure 143, Appendix F)
a
Removal.
(1) Place suitable container under governor cover to catch oil.
(2) Remove four bolts (1) that retain governor cover (2) and gasket (3).
(3) Remove the cover and gasket. Discard gasket.
(4) Remove the governor (4) by rotating it clockwise.
b. Installation.
(1) Install governor (4) by rotating it counterclockwise.
(2) Install new gasket (3), cover (2) and four bolts (1).
(3) Torque bolts (l) to 13-16ft. Ib. (18-22 N.m).
c.
Follow-on Maintenance
(1) Connect batteries (see para 4-114)
5-189
TM 5-4210-233-14&P-1
5-30. SPEEDOMETER CABLE ASSEMBLY
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
a. Removal.
(1) Disconnect sender (1).
(2) Unthread sleeve (2) and remove cable (3).
b. Installation.
(1) Thread sleeve (2) into mounting until tight.
(2) Connect sender (1) to receptacle.
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
5-190
TM 5-4210-233-14&P-1
5-31. RADIATOR
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Antifreeze, Permanent, Glycol (Item 29, Appendix E)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Cab Roof Panel Removed (see para 4-76.)
Engine Enclosure Removed (see para 4-127.)
Fan Removed (see para 4-132.)
a. Removal.
NOTE
Do not remove screws securing velcro strips
to radiator shroud.
(1) Remove six panhead screws (1), six lockwashers (2), and six flatwashers (3) from
front edge of radiator shroud.
(2) Remove two hex head screws (4), lockwashers (5), and flatwashers (6) from inside
of radiator shroud.
(3) Remove nine panhead screws (7), nine
nylon 1 washers (8), and upper panel (9).
(4) Remove two hex head screws (10), two flatwashers (11), two lockwashers (12) and two
hex nuts (13) from driver side of radiator
shroud.
(5) Remove two hex head screws (1 4), two
flatwashers (15), and two lockwashers (16)
from passenger side of radiator shroud.
(6) Use a suitable lifting device to lift radiator
shroud (1 7) out through cab roof.
(7) Open radiator drain cock located on bottom
of radiator and drain coolant into suitable
container.
NOTE
Radiator coolant capacity is 14.5 gallons (55 liters).
5-191
TM 5-4210-233-14&P-1
5-31. RADIATOR - Continued
(8)
Tag and remove two wires (18) from low
water sensor (19).
(9)
Loosen two radiator clamps (20) and
remove two 2-1/2 inch upper radiator
hoses (21) from radiator.
(10) Loosen clamp (22) and remove 3/8 inch
by-pass hose (23) from radiator.
(11)
Loosen clamp (24) and remove 1 inch
by-pass hose (25) from radiator.
(12)
Remove two hex head screws (26) and
lock-washers
(27)
to
disconnect
stabilizer rod upper ends (28) from sides
of radiator.
(13)
Loosen two stabilizer rod lower ends to
pivot stabilizer rods clear of radiator.
WARNING
Serious injury could occur if heavy equipment is moved/lifted
without sufficient personnel to do the job. Use proper physical
lifting procedures or use a suitable lifting device or dolly. Wear
safety shoes, gloves and other suitable protective clothing. Area
should be clear of other personnel. Serious injury or death can
result from falling objects.
(14)
Attach suitable lifting device to top of radiator.
(15)
Loosen clamp (32) and disconnect 3-inch lower hose (33) from radiator.
(16)
Tag and remove two transmission coolant hoses (34) and drain fluid into suitable container.
(17)
Remove eight hex head screws (35), and eight lockwashers (36).
5-192
TM 5-4210-233-14&P-1
5-31. RADIATOR - Continued
(18)
Lift radiator from truck.
b. Installation.
(1) Connect a suitable lifting device to the
radiator top and carefully lower the radiator
into the truck.
(2) Install eight hex head screws (1) with lockwashers (2) to secure radiator in place.
(3) Connect two transmission coolant hoses (3)
to bottom of radiator.
(4) Install 3-inch lower hose (4) to bottom of
radiator and tighten clamp (5).
(5)
Close radiator drain cock on bottom of radiator by turning in a clockwise direction.
(6)
Attach stabilizer brackets (6) with screws (7) and washers (8).
(7)
Put radiator stabilizer rod assembly (9) in position (with spring (10) at top). Install lock-washers (11)
and nuts (12) on bottom end stabilizer rods.
(8)
Install 3/8-inch by-pass hose (14) on radiator and tighten clamp (13).
(9)
Install 1 -inch by-pass hose (1 5) on radiator and tighten clamp (1 6).
(10) Install two 2-1/2 inch hoses (17) and tighten clamps (18).
(11) Connect two wires (19) to low water sensor (20).
5-193
TM 5-4210-233-14&P-1
5-31. RADIATOR - Continued
(12) Be sure radiator drain cock is closed.
Fill radiator with approximately 14.5
gallons (55 liters) of coolant. Use a
50/50 mix of water and ethyleneglycol (Item 29, Appendix E). Install
radiator cap.
(13) Carefully lower radiator shroud into
truck.
(14) Install two hex head capscrews (21)
with lockwashers (22) and flat
washers (23) on passenger side of
radiator shroud.
(15) Install two hex head screws (24) with
flat washers (25), lockwashers (26)
and nuts (27) on driver's side of
radiator shroud.
(16) Install upper panel (28) with nine
panhead screws (29) and nylon
washers (30).
(17) Install two hex head screws (31) with
lock- washers (32) and flat washers
(33) from inside of radiator shroud.
(18) Install six panhead screws (34) with
lock- washers (35) and flatwashers
(36) at front edge of radiator shroud.
c.
Follow-on Maintenance.
(1)
Install fan (see para 4-132).
(2)
Install cab roof panel (see para 4-76).
(3)
Connect batteries (see para 4-114).
(4)
Start engine and check for leaks. Correct as required.
(5)
Install engine enclosure (see para 4-127).
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TM 5-4210-233-14&P-1
5-32. WHEEL LUGS
This task covers:
a. Replace
b. Follow-on Maintenance
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section ill, Item 1)
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Wheel Removed (see para 4-143.)
a. Replace.
CAUTION
Use a press to remove lugs if lugs are seized and difficult to
remove. This will avoid damage to bearing.
(1) Drive damaged lug (1) out through back of
hub assembly (2).
(2) Drive new lug (1) into hub assembly (2) as shown.
NOTE
Lugs are marked RH and LH. When replacing lug(s), make sure
the new lugs match those they are replacing.
b. Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
(2) Replace wheel (see para 4-143).
5-195
TM 5-4210-233-14&P-1
5-33. HUBS, BEARINGS, AND SEALS
This task covers:
a. Removal
b. Cleaning and Inspection
c. Installation
d. Follow-on Maintenance
TOOLS REQUIRED
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
Main Engine Shutdown (see para 2-12.)
(Appendix B, Section 111, Item 1)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED
Wheel Removed (see para 4-143.)
Dry Cleaning Solvent (Item 3, Appendix E)
Brake Shoes Removed (see para 5-36.)
Oil, Gear (Item 19, Appendix E)
Gaskets and Seals (Figure 150, Appendix F)
a. Removal.
(1) Remove plug (1) from hub cap (2) and drain oil into suitable container.
(2) Remove six capscrews (3) and six washers (4).
(3) Remove hub cap (2) and hub cap gasket (5). Discard gasket.
(4) Remove cotter (6), adjusting nut (7) and D-washer (8).
(5) Remove outer bearing (9) from hub (10).
(6) Remove hub (10).
(7) Remove wheel bearing seal (11) and inner bearing (12). Discard seal.
(8) Using appropriate tool, drive out inner (13) and outer (14) bearing cups from hub (10).
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5-33. HUBS, BEARINGS, AND SEALS - Continued
b. Cleaning and Inspection.
WARNING
Dry cleaning solvent P-D-680 (safety or Stoddard's solvent) is
potentially dangerous. Avoid repeated and prolonged breathing
of vapors and skin contact with the liquid. Do not use near open
flame, arcing equipment or other ignition sources. Always wear
eye protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 59 deg. C).
(1)
Wash all components using dry cleaning solvent (Item 3, Appendix E).
WARNING
Death or serious injury could occur if compressed air is directed
against the skin. Do not use compressed air for cleaning or
drying unless the pressure is/has been reduced to 30 psi (2.11
kg/cm ) or less. When working with compressed air always use
chip guards, eye protection and other personal protective
equipment.
(2) After washing, dry all components using compressed air. Do not allow bearings to spin while drying
with compressed air.
(3) Inspect bearing cups for cracks, or warped mating surfaces.
(4) Inspect bearings for pitting, scoring or other defects.
(5) Replace all gaskets and seals.
(6) Inspect hub assembly for cracks.
(7) Evidence of damage of any kind is cause for rejection. Replace components or assembly as
required.
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5-33. HUBS, BEARINGS, AND SEALS - Continued
c.
Installation.
(1)
Press in outer (1 4) and inner (1 3) bearing cups.
(2)
Install inner bearing (1 2) and new bearing seal (11).
(3)
Install hub (10) on spindle.
(4)
Install outer bearing (9).
(5)
Install D-washer (8) and adjusting nut (7).
(6)
Torque adjusting nut (7) to 100 Ibt t (136 N.m) while rotating hub (10) in both directions. Loosen
adjusting nut (7) completely and then torque adjusting nut (7) to 20 lb tt (27 N-m) while rotating
hub (1 0).
(7)
Install cotter pin (6).
(8)
Install hub cap gasket (5) and hub cap (2) and secure with six washers (4) and capscrews (3).
(9)
Fill hub assembly (2) with gear oil (Item 19, Appendix E). Install plug (1).
d. Follow-on Maintenance.
(1)
Install brake shoes (see para 5-36).
(2)
Install wheels (see para 4-143).
(3)
Connect batteries (see para 4-114).
'
6-198
TM 5-4210-233-14&P-1
5-34. REAR BRAKE AIR CHAMBER
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 111, Item 1)
MATERIALS/PARTS REQUIRED
Tag, Identification (Item 32, Appendix E)
Pipe Sealant (Item 2, Appendix E)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Parking Brake Set (see para 2-12.)
a. Removal.
(1)
Remove cotter pin (1) and clevis pin (2) from air chamber push rod clevis (2A).
(2)
Tag and disconnect brake air chamber air lines (3).
(3)
Remove nuts (4) and washers (5) attaching brake air chamber (6) to bracket (7).
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TM 5-4210-233-14&P-1
5-34. REAR BRAKE AIR CHAMBER - Continued
b. Installation.
(1) Attach brake air chamber (6) to brake air
chamber bracket (7) using washers (5)
and nuts (4). Be sure hose ports in
brake air chamber face away from
bracket. Tighten nuts (4) to 170 ft lb (230
N•m).
(2) Apply a light coat of pipe sealant (Item 2,
Appendix E) to thread of fittings and
install brake air chamber air lines (3) to
brake air chamber.
Tighten fittings
firmly to provide leak-proof connections.
(3) Attach slack adjuster (8) to brake air
chamber clevis using clevis pin (2) and
cotter pin (1).
(4) Adjust clevis position and push rod so
that distance F from bottom of brake air
chamber to center of clevis pin holes
equals 2-5/8 ± 1/16 in. (66.7+ 1.59 mm)
(see para 4-146).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
5-200
TM 5-4210-233-14&P-1
5-35 FRONT BRAKE AIR CHAMBER
This task covers:
a. Removal
b. Installation
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
MATERIALS/PARTS REQUIRED
Pipe Sealant (Item 2, Appendix E)
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Parking Brake Set (see para 2-12.)
a. Removal.
(1)
Remove cotter pin (1) and clevis pin (2) from air chamber push rod clevis (3).
(2)
Disconnect brake air chamber air line (4).
(3)
Remove nuts (5) and washers (6) attaching brake air chamber (7) to bracket (8).
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TM 5-4210-233-14&P-1
5-35. FRONT BRAKE AIR CHAMBER - Continued
b. Installation.
(1) Assemble brake air chamber (7) to brake
air chamber bracket (8) using washers
(6) and nuts (5). Be sure hose ports in
brake air chamber (6) face away from
bracket. Torque nuts (5) to 170 ft lb (230
N.m).
(2) Apply a light coat of pipe sealant (Item 2,
Appendix E) to thread of fitting and
install brake air chamber air line (4) to
brake air chamber (6). Tighten fitting
firmly to provide leak-proof connection.
(3) Attach slack adjuster (9) to brake
chamber clevis (3) using clevis pin (2)
and cotter pin (1).
(4) Adjust clevis position and push rod so
that distance F from bottom of brake air
chamber to center of clevis pin holes
equals 2-5t8 ± 1116 in. (66.7 ± 1.59 mm)
(see para 4-146).
c.
Follow-on Maintenance.
(1) Connect batteries (see para 4-114).
5-202
TM 5-4210-233-14&P-1
5-36. BRAKE SHOES
This task covers:
a. Removal
b. Service
TOOLS REQUIRED
Tool Kit, General Mechanics, Automotive
(Appendix B, Section 111, Item 1)
a.
c. Follow-on Maintenance
EQUIPMENT CONDITION
Main Engine Shutdown (see para 2-12.)
APU Engine Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Wheels and Drums Removed from
Axle to be Serviced (see para 4-143 and 5-37.)
Removal.
(1) Turn manual adjusting nut (1) until brake
shoes (2 and 3) are fully retracted.
(2) Push down on bottom brake shoe (3)
and pull on roller retaining clip (4) to
remove bottom cam roller (5).
(3) Lift top brake shoe (2) and pull on roller
retaining clip (6) to remove top cam
roller (7).
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TM 5-4210-233-14&P-1
5-36. BRAKE SHOES - Continued
(4) Lift bottom shoe (3) to release tension on
brake return spring (8) and remove
brake return spring (8).
(5) Rotate bottom shoe (3) to release
tension on two retaining springs (9).
Remove retaining springs (9) and brake
shoes (2 and 3).
5-204
TM 5-4210-233-14&P-1
5-36. BRAKE SHOES - Continued
b. Installation.
(1) Position upper brake shoe (2) on top
anchor pin (10).
(2) Hold lower brake shoe (3) on bottom
anchor pin (11) and install two new brake
shoe retaining springs (9).
(3) Rotate lower brake shoe (3) forward and
install new brake shoe return spring (8).
5-205
TM 5-4210-233-14&P-1
5-36. BRAKE SHOES - Continued
(4) Pull each brake shoe away from cam
(12) and install cam rollers (5 and 7) and
retainer clips (4 and 6).
(5) Push retainer clips (4 and 6) into brake
shoe until ears lock in shoe web holes
(13).
c.
Follow-on Maintenance.
(1) Install wheels and drums (see para and
4-143 and 5-37).
(2) Adjust slack adjusters (see para 4-146).
(3) Connect batteries (see para 4-114).
5-206
TM 5-4210-233-14&P-1
5-37. BRAKE DRUMS
This task covers:
a. Removal
b. Installation
c. Follow-on Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
Brake Chamber caged (see para 5-34.)
Slack adjusters released (see para 4-146.)
Wheels removed (see para 4-143.)
a. Removal.
(1) Remove six screws (1) from drum (2).
(2) Remove drum (2) from axle.
b. Installation.
(1) Install drum (2) on axle.
(2) Install six screws (1) in drum (2).
c.
Follow-on Maintenance.
(1) Install wheels (see para 4-143).
(2) Uncage brake chambers (see para 5-34).
(3) Adjust slack adjusters (see para 4-146).
(4) Connect batteries (see page 4-114).
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TM 5-4210-233-14&P-1
5-38. AIR DRYER
This task covers:
a. Removal
d. Assembly
b. Disassembly
e. Installation
c. Cleaning and Inspection f. Testing
g. Follow-on
Maintenance
TOOLS REQUIRED:
EQUIPMENT CONDITION
Tool Kit, General Mechanics, Automotive
(Appendix B, Section III, Item 1)
Engine Shutdown (see para 2-12.)
APU Shutdown (see para 2-16.)
Batteries Disconnected (see para 4-114.)
MATERIALS/PARTS REQUIRED:
Grease, Barium Based (Item 51, Appendix E)
Dry Cleaning Solvent (Item 3, Appendix E)
Tags, Identification (Item 32, Appendix E)
Pipe Sealant (Item 2, Appendix E)
O-rings (Fig. 153, Appendix E)
a. Removal.
NOTE
The air dryer is located near the front axle on the passenger
side.
(1) Park the vehicle on a level surface and prevent movement by means other than the brakes.
WARNING
Compressed air directed against the skin can cause death or
serious injury. Always drain the air tanks via the drain cocks
prior to removal.
(2) Drain ALL reservoirs to 0 psi (0 kPa).
CAUTION
Compressor discharge line may still contain residual pressure.
(3) Tag and disconnect the three air lines from the end cover and note the position of end cover ports
relative to the vehicle.
(4) Unplug the vehicle wiring harness (1) from the heater and thermostat assembly connector on the
purge valve housing assembly (31).
(5) Loosen the hex bolt (2) securing the upper mounting strap (30).
(6) Remove, retain and MARK the two end cover cap screws (3), lock nuts (4) and four special
washers (5) that retain the lower mounting bracket (6) to the end cover. Also mark the two holes of
the end cover. (These bolts are longer that the other six bolts.)
(7) Remove the air dryer from its mounting brackets (6 and 35) on the vehicle.
5-208
TM 5-4210-233-14&P-1
5-38. AIR DRYER-Continued
5-209
TM 5-4210-233-14&P-1
5-38. AIR DRYER-Continued
b. Disassembly.
NOTE
The following disassembly and assembly procedure is presented
for reference purposes and presupposes that a major rebuild of
the air dryer is being undertaken. Several replacement parts
and maintenance kits are available which do not require full
disassembly.
CAUTION
While performing service on the air dryer, it is not recommended
that a clamping device (vise, C-clamp, etc.) be used to hold any
die cast aluminum component as damage may result. To hold
the end cover, install a pipe nipple in the supply port and clamp
the nipple into a vise.
(1) Remove the check valve assembly (7) and O-ring (8). Remove the O-ring from the check valve
assembly.
(2) Remove the three self-tapping screws (9) that secure the purge valve housing assembly (31) to the
end cover assembly (13). Pull the purge valve housing assembly out of the end cover assembly.
Remove the three O-rings (10, 11 and 12) from the exterior of the purge valve housing assembly.
NOTE
O-rings (10 and 11) may be lodged in the end cover bores. If
so, they must be removed.
(3) Purge valve housing assembly disassembly.
NOTE
Exhaust cover (13) should be left intact while servicing the
purge valve housing assembly. To remove the piston (12) from
the purge valve housing assembly (31) requires twelve point
1/4" socket to hold the head of the purge valve bolt (14).
(a) Remove the nut (15) from the bottom of the purge valve housing assembly using a Torx head
socket to hold the head to the bolt. Remove the diaphragm washer (16), and the diaphragm (17),
and the purge valve (18) from the purge valve housing (31).
(b) Remove the Torx head bolt (14) from the opposite end, then the purge piston (19), the return spring
(36) and the two O-rings (20 and 21); one on the outside diameter and the other in the inside of the
purge piston.
5-210
TM 5-4210-233-14&P-1
5-38. AIR DRYER-Continued
CAUTION
Do not attempt to remove the heater and thermostat assembly,
as it will be damaged during the removal process and is NOT
AVAILABLE AS A SERVICE PART.
If the heater and
thermostat are defective, replace the entire purge valve housing
assembly (31) which includes these items.
(4) Remove the remaining six cap screws (22), lock nuts (23) and twelve special washers (24) that secure
the end cover (32) to the housing (25). Separate the end cover (32) and desiccant cartridge (26) from
the housing (25).
(5) Remove the end cover to outer housing O-ring (27).
(6) Do not remove the safety valve (28) from the end cover unless it has been proven defective. If
replacement is required, apply pipe sealant (Item 2, Appendix E) on the threads of the replacement valve and
torque to 120-400 in lbs (14-45 Nm), making sure the drain hole (slot) is facing down.
(7) Place a strap or chain wrench around the desiccant cartridge (26) so that it is approximately 2-3 inches
(51-76 mm) away from the end cover. Rotate the cartridge counterclockwise until it completely
separates from the end cover.
NOTE
A substantial torque (up to 50 lb ft (68 Nm)) may be required to
perform this disassembly.
(8) Remove the desiccant cartridge O-ring (29) from the end cover.
c.
Cleaning and Inspection.
WARNING
(1)
•
Dry cleaning solvent P-D-680 is potentially dangerous.
Avoid repeated and prolonged breathing of vapors and skin
contact with the liquid. Do not use near open flame, arcing
equipment of other ignition sources. Always wear eye
protection and protective clothing. The flash point of P-D680 is 100 to 138 deg. F (38 to 50 deg. C).
•
Death or serious injury could occur if compressed air is
directed against the skin. Do not use compressed air for
cleaning or drying unless the pressure is/has been reduced
2
to 30 psi (2.11 kg/cm ) or less. When working with
compressed air, always use chip guards, eye protection, and
other personal protective equipment.
Using dry cleaning solvent (Item 3, Appendix E), clean and dry all metal parts with compressed air.
5-211
TM 5-4210-233-14&P-1
5-38. AIR DRYER-Continued
5-212
TM 5-4210-233-14&P-1
5-38. AIR DRYER-Continued
(2) Inspect the interior and exterior of ail metal parts that will be reused for severe corrosion, pitting and
cracks. Superficial corrosion and/or pitting on the exterior portion of the upper and lower body halves is
acceptable.
(3) Inspect the bores of both the end cover (32) and the purge valve housing (31) for deep scuffing or
gouges.
(4) Make certain that all purge valve housing and end cover passages are open and free of obstructions.
(5) Inspect the pipe threads in the end cover (32). Make certain they are clean and free of thread sealant.
(6) Inspect the purge valve housing (31) bore and seats for excessive wear and scuffing.
(7) Inspect the purge valve piston seat for excessive wear.
(8) Inspect all air line fittings for c6rrosion. Clean all old thread sealant from the pipe threads.
(9) All O-rings removed should be discarded and replaced with new O-rings provided in appropriate kit(s).
NOTE
Any component exhibiting a condition described in steps (1
through 9) should be replaced.
d. Assembly.
(1) Prior to assembly, coat all O-rings, O-ring grooves, and bores with a generous amount of barium base
lubricant (Item 51; Appendix E).
(2) Purge valve housing assembly.
(a) Install the O-ring (21) in its groove on the outside diameter of the purge piston. Place the return
spring (36) in the bore of the purge valve housing (31). Install the Torx head bolt (14) into the I.D.
of the purge piston. Insert the purge piston (19) into the I.D. of the spring (20). Using a Torx head
wrench engaged on head of Torx head bolt (14), push the piston into the purge valve housing until
it bottoms.
(b) While depressing the purge piston with the 12 point socket, install the following parts over the
purge valve bolt (14) from the opposite end of the purge valve housing: the purge valve (18) with
its rubber side first, followed by the diaphragm (17) and the diaphragm washer (16) and finally the
hex nut (15). Torque the purge valve nut (15) and bolt (14) to between 60-80 in lbs (7-9 Nm).
(c) Install the three O-rings (10, 11 and 12) on the purge