TM-5-3825-230-14-and-P

TM 5-3825-230-14&P

TECHNICAL MANUAL

OPERATOR'S, UNIT, DIRECT SUPPORT AND GENERAL

SUPPORT MAINTENANCE MANUAL

(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)

SWEEPER, ROTARY TOWED

MODEL 53MH

NSN 3825-01-314-2926

Approved for public release; distribution is unlimited.

INTRODUCTION 1-1

OPERATING INSTRUCTIONS 2-1

OPERATOR MAINTENANCE

INSTRUCTIONS 3-1

UNIT MAINTENANCE

INSTRUCTIONS 4-1

DIRECT SUPPORT AND GENERAL

SUPPORT MAINTENANCE

INSTRUCTIONS 5-1

REFERENCES A-1

MAINTENANCE ALLOCATION

CHART B-1

EXPENDABLE SUPPLIES AND

MATERIALS LIST E-1

REPAIR PARTS AND SPECIAL

TOOLS LIST F-1

ILLUSTRATED LIST OF

MANUFACTURED ITEMS G-1

SCHEMATICS H-1

HEADQUARTERS, DEPARTMENT OF THE ARMY

20 APRIL 1992

TM 5-3825-230-14&P

C2

CHANGE HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 2 Washington D.C., 24 May 1993

OPERATOR, UNIT, DIRECT SUPPORT AND

GENERAL SUPPORT MAINTENANCE MANUAL

(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)

FOR

SWEEPER, ROTARY TOWED

53MH (3825-01-314-2926)

Current as of 16 February 1993

TM 5-3825-230-14&P, dated 20 April 1992, is changed as follows:

1. Remove old pages and insert new pages.

2. New or changed material is indicated by an asterisk or by a vertical bar in the margin of the page.

Remove Pages Insert Pages

1-1 and Figure 2 1-1 and Figure 2

6-1 through Figure 8 6-1 through Figure 8

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16-1 and Figure 17 16-1 and Figure 17

18-1 through Figure 20 18-1 through Figure 20

21-1 and Figure 22 21-1 and Figure 22

23-1 and Figure 24 23-1 and Figure 24

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29-1 and Figure 30 29-1 and Figure 30

31-1 and 31-2 31-1 and 31-2

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Bulk-1 and Figure 161 Bulk-1 and Figure 61

I-1 through I-49 I-1 through I-49

3. File this change sheet in front of the publication for reference purposes.

Approved for public release; distribution is unlimited.

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TM 5-3825-230-14&P

WARNING

CARBON MONOXIDE (EXHAUST GAS) CAN KILL YOU

Carbon monoxide is without color or odor, 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 engine of vehicle in a closed place without proper ventilation.

2.

DO NOT operate 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 and get medical attention.

FIRST AID. If symptoms of exhaust gas (CO) poisoning are present, remove affected personnel from vehicle, or confined area, and treat as follows:

1.

Expose to fresh air.

2.

Keep warm.

3.

Do not permit physical exercise.

4.

If not breathing, administer artificial respiration.

NOTE

The Army-approved Cardiopulmonary Resuscitation (CPR) method is contained in the Soldier's

Manual of First Aid, FM 21-11, which is available to all soldiers.

5.

Administer oxygen, if available.

6.

Seek prompt medical attention for possible delayed onset of lung congestion.

THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS GOOD VENTILATION.

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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

DO NOT use a dry brush or compressed air to clean brakeshoes. There may be asbestos dust on brakeshoes which can be dangerous to your health if you breath it. (Brakeshoes must be wet, and a soft bristle brush must be used.)

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid.

If contact with eyes is made, flush eyes with water and get medical aid immediately.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

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, gloves, etc).

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” (15.24 m) of vehicle.

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TM 5-3825-230-14&P

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.

WARNING

Hearing protection must be worn when performing adjustments in close proximity to the sweeper. Long term exposure may cause hearing damage.

WARNING

If NBC exposure is suspected, all air filter media should be handled by personnel wearing protective equipment.

Consult your unit NBC Officer or NBC NCO for appropriate handling or disposal procedures.

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TM 5-3825-230-14&P

TECHNICAL MANUAL

HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 5-3825-230-14&P Washington, D.C., 20 April 1992

OPERATOR, UNIT, DIRECT SUPPORT AND

GENERAL SUPPORT MAINTENANCE MANUAL

(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)

FOR

SWEEPER, ROTARY TOWED

53MH (3825-01-314-2926)

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, DA Form 2028 (Recommended Changes to

Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to:

Commander, U.S. Army Tank-Automotive Command, ATTN: AMSTA -MB, Warren, MI 48397-5000.

A reply will be furnished to you.

TABLE OF CONTENTS

Page

CHAPTER 1 INTRODUCTION ............................................................................................................. 1-1

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

Section II Equipment Description and Data ...................................................................................... 1-4

Section III Technical Principles of Operation..................................................................................... 1-8

CHAPTER 2 OPERATING INSTRUCTIONS ........................................................................................ 2-1

Section I Description and Use of Operator's Controls and Indicators ............................................... 2-1

Section II Operator Preventive Maintenance Checks and Services (PMCS)..................................... 2-7

Section III Operation Under Usual Conditions ................................................................................... 2-14

Section IV Operation Under Unusual Conditions ............................................................................... 2-28

CHAPTER 3 OPERATOR MAINTENANCE INSTRUCTIONS .............................................................. 3-1

Section I Lubrication Instructions .................................................................................................... 3-1

Section II Troubleshooting ............................................................................................................... 3-8

Section III Maintenance Procedures.................................................................................................. 3-14

CHAPTER 4 UNIT MAINTENANCE INSTRUCTIONS .......................................................................... 4-1

Section I Repair Parts, Special Tools, Test, Measurement and Diagnostic Equipment,

and Support Equipment.................................................................................................... 4-3

Section II Service Upon Receipt ...................................................................................................... 4-4

Section III Unit Preventive Maintenance Checks and Services (PMCS) ............................................ 4-5

Section IV Troubleshooting ............................................................................................................... 4-9

Section V Unit Maintenance Procedures .......................................................................................... 4-16

Section VI Preparation For Storage Or Shipment .............................................................................. 4-228

Approved for public release; distribution is unlimited.

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TABLE OF CONTENTS (CONT)

CHAPTER 5 DIRECT SUPPORT/GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS ................................................................................... 5-1

Section I Repair Parts, Special Tools, Test, Measurement and Diagnostic Equipment

and Support Equipment.................................................................................................... 5-2

Section II Troubleshooting ............................................................................................................... 5-2

Section III Maintenance Procedures.................................................................................................. 5-4

APPENDIX A REFERENCES ................................................................................................................ A-1

APPENDIX B MAINTENANCE ALLOCATION CHART ......................................................................... B-1

APPENDIX C COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST .................................... C-1

APPENDIX D ADDITIONAL AUTHORIZATION LIST ............................................................................. D-1

APPENDIX E EXPENDABLE SUPPLIES AND MATERIALS LIST........................................................ E-1

APPENDIX F UNIT, DIRECT, AND GENERAL SUPPORT MAINTENANCE

REPAIR PARTS AND SPECIAL TOOLS LIST ................................................................ F-1

Section I Introduction ...................................................................................................................... F-1

Section II Repair Parts List............................................................................................................... F-8

Group 01 Engine

0100 Engine Assembly..................................................................................................... 1-1

0101 Cylinder and Crankcase Assembly .......................................................................... 2-1

0101 Cylinder Head Assembly ......................................................................................... 3-1

0101 End Plate Assembly ................................................................................................ 4-1

0102 Crankshaft Assembly............................................................................................... 5-1

0103 Flywheel Assembly.................................................................................................. 6-1

0104 Piston and Connecting Rod Assembly ..................................................................... 7-1

0105 Rocker Cover Assembly .......................................................................................... 8-1

0105 Rocker Arm Assembly ............................................................................................. 9-1

0105 Camshaft Assembly................................................................................................. 10-1

10

0106 Oil Cap Assembly.................................................................................................... 11-1

11

0106 Oil Filter Assembly .................................................................................................. 12-1

12

0106 Oil Pump Assembly ................................................................................................. 13-1

13

8

9

6

7

3

4

5

1

2

0106 Oil Pan Assembly .................................................................................................... 14-1

14

0108 Intake Manifold Assembly........................................................................................ 15-1

15

0109 Hydraulic Pump Drive Assembly ............................................................................. 16-1

16

0109 Alternator Drive Pulley............................................................................................. 17-1

17

Group 03 Fuel System

0301 Injector Assembly .................................................................................................... 18-1

18

0302 Injector Pump Assembly.......................................................................................... 19-1

19

0302 Fuel Pump Assembly............................................................................................... 20-1

20

0304 Air Cleaner and Vapor Separator Assembly............................................................. 21-1

21

0306 Fuel Lines and Fittings ............................................................................................ 22-1

22

0306 Fuel Tank Assembly ................................................................................................ 23-1

23

0308 Governor and Governor Lever Assemblies .............................................................. 24-1

24

0308 Throttle Control Lever Assembly.............................................................................. 25-1

25

0309 Fuel Filter Assembly................................................................................................ 26-1

26

0311 Glow Plug Assembly................................................................................................ 27-1

27

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TM 5-3825-230-14&P

TABLE OF CONTENTS (CONT)

Illus/

Page Figure

Group 04 Exhaust System

0401 Muffler and Pipe Assembly...................................................................................... 28-1

28

Group 05 Cooling System

0502 Shrouds and Guards................................................................................................ 29-1

29

Group 06 Electrical System

0601 Alternator Installation............................................................................................... 30-1

30

0603 Starter Motor Assembly ........................................................................................... 31-1

31

0607 Instrument Panel Assembly ..................................................................................... 32-1

32

0608 Wire Harness Mounting Parts .................................................................................. 33-1

33

0608 Junction Box and Jumper Wire Assemblies ............................................................. 34-1

34

0609 Lights and Light Mounts........................................................................................... 35-1

35

0610 Sending Units and Warning Switches ...................................................................... 36-1

36

0612 Battery Installation................................................................................................... 37-1

37

0613 12V, 24V, Rear Tail Light, and Broom Head Wire Harnesses .................................. 38-1

38

0613 Starter Relay, Engine, and Fuel and Glow Plug Wire Harnesses ............................. 39-1

39

Group 12 Brakes

1201 Hand Brake Assembly ............................................................................................. 40-1

40

1201 Hand Brake Lever Assembly ................................................................................... 41-1

41

Group 13 Wheels and Tracks

1311 Wheel and Hub Assembly ....................................................................................... 42-1

42

1311 Wheel, Hub, and Drum Assembly............................................................................ 43-1

43

1313 Tires........................................................................................................................ 44-1

44

Group 15 Frame, Towing Attachments, and Drawbars

1501 Main Frame Assembly............................................................................................. 45-1

45

1503 Tow Pole and Strut Assembly.................................................................................. 46-1

46

Group 18 Body, Cab, Hood, and Hull

1801 Engine Enclosure .................................................................................................... 47-1

47

Group 22 Body, Chassis, or Hull and Accessory Items

2210 Decals ..................................................................................................................... 48-1

48

Group 24 Hydraulic Lift Components

2401 Hydraulic Pump Assembly....................................................................................... 49-1

49

2401 Hydraulic Motor Assembly ....................................................................................... 50-1

50

2402 Hydraulic Control Valve Assembly........................................................................... 51-1

51

2406 Hydraulic Pressure Lines and Fittings ...................................................................... 52-1

52

2406 Hydraulic Return Lines and Fittings ......................................................................... 53-1

53

Group 47 Gages (non-electrical) Weighing and Measuring Devices

4701 Tachometer and Tachometer Drive ......................................................................... 54-1

54

Group 71 Sweeping Equipment Components

7111 Dirt Deflector Assembly ........................................................................................... 55-1

55

7111 Brush Frame Assembly ........................................................................................... 56-1

56

7111 Hydraulic Core and Brush Kit Assembly................................................................... 57-1

57

7113 Hydraulic Cylinder Assembly ................................................................................... 58-1

58

7114 Spray Pump Assembly ............................................................................................ 59-1

59

7114 Spray System Installation ........................................................................................ 60-1

60

Group 94 9401 Repair Kits............................................................................................................... Kits-1

Group 95 9501 Bulk Materials.......................................................................................................... Bulk-1

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TABLE OF CONTENTS (CONT)

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Page Figure

Section III Special Tools List

Group 26 Tools and Test Equipment

2604 Engine Special Tools............................................................................................... 61-1

61

Section IV Cross-reference Indexes .................................................................................................. I-1

National Stock Number Index........................................................................................... I-1

Part Number Index ........................................................................................................... I-10

Figure and Item Number Index......................................................................................... I-30

APPENDIX G ILLUSTRATED LIST OF MANUFACTURED ITEMS ....................................................... G-1

APPENDIX H SCHEMATICS ................................................................................................................. H-1

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TM 5-3825-230-14&P

HOW TO USE THIS MANUAL

This manual is designed to help operate and maintain the 53MH Rotary Towed Sweeper, NSN 3825-01-314-2926. Listed below are some of the special features that have been included to help locate and use the needed information:

A front cover Table of Contents is provided for quick reference to chapters and sections that will be used often.

Warning, caution and note headings, subject headings, and certain other essential information are printed in bold type to make them easier to see.

The maintenance tasks describe what must be done to the sweeper before starting the task, and what must be done to return the sweeper to operating condition after the task is finished.

The appendixes are located at the end of the manual. They contain a reference guide to other manuals, guidelines to reading the Maintenance Allocation Chart (MAC), a list of expendable supplies and materials, and other material for maintaining the sweeper.

In addition to text, there are exploded-view illustrations showing you how to take the part off and put it on.

Cleaning and inspection procedures are also included, when required.

Chapters 1 and 2 of this manual are directed at the crew/operator of the sweeper. These chapters include an overall description of the sweeper and discuss the controls and indicators, their location and use, and the instructions for operation of the sweeper under different circumstances.

Chapter 3 of this manual covers crew/operator lubrication, preventive maintenance checks and services, and basic

troubleshooting. Crew/operator maintenance is also covered in this chapter.

Chapter 4 of this manual covers unit maintenance including troubleshooting and! maintenance procedures.

Chapter 5 of this manual covers direct support and general support maintenance including troubleshooting and

maintenance procedures.

FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:

The operator must read through this manual and become familiar with the contents before attempting to operate the sweeper.

Read all WARNINGS and CAUTIONS before performing any procedure.

The equipment conditions listed at the start of a maintenance procedure and any equipment conditions required for those equipment conditions should be performed before the primary maintenance task. The mechanic may be able to perform only certain steps within a procedure to accomplish the equipment condition.

The follow-on maintenance tasks listed at the end of a maintenance procedure, and any follow-on tasks listed at the end of those procedures should be performed to return the sweeper to an operational condition.

"Brush" and "broom" are interchangeable and indicate the same component on the sweeper.

v/(vi blank)

TM 5-3825-230-14&P

CHAPTER 1

INTRODUCTION

Para Contents Page

1-1

1-2

1-3

1-4

1-5

1-6

Scope ..................................................................................................................................................1-1

Maintenance Forms, Records, and Reports .........................................................................................1-1

Destruction of Army Materiel To Prevent Enemy Use ..........................................................................1-3

Reporting Equipment Improvement Recommendations (EIR) ..............................................................1-3

Warranty Information...........................................................................................................................1-3

Abbreviations.......................................................................................................................................1-3

1-7

1-8

1-9

Preparation For Storage Or Shipment..................................................................................................1-3

Quality Assurance/Quality Control (QA/QC).........................................................................................1-3

Safety, Care, and Handling..................................................................................................................1-3

1-10 Equipment Characteristics, Capabilities, and Features.........................................................................1-4

1-11 Location and Description of Major Components ...................................................................................1-4

1-12 Equipment Data...................................................................................................................................1-5

1-13 Mechanical System .............................................................................................................................1-8

1-14 Electrical System.................................................................................................................................1-9

1-15 Hydraulic System.................................................................................................................................1-10

1-16 Fuel System ........................................................................................................................................1-11

1-17 Sprinkler System .................................................................................................................................1-12

Section I. GENERAL INFORMATION

1-1. SCOPE.

a. Type of Manual Operator's, Unit, Direct Support and General Support Maintenance Manual including Repair

Parts and Special Tools List (RPSTL).

b. Model Number and Equipment Name. Rotary Towed Sweeper, Model 53MH, NSN 3825-01-314-2926,

produced by M-B Company, Inc. of Wisconsin. (See figures 1-1 and 1-2).

c. Purpose of Equipment The Rotary Towed Sweeper, from here on referred to as the sweeper, is used to clear dirt, snow, and debris from paved surfaces.

1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS.

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM

738-750, The Army Maintenance Management System (TAMMS).

1-1

ROTARY TOWED SWEEPER 53 MH - LEFT FRONT VIEW

TM 5-3825-230-14&P

Figure 1-1. Rotary Towed Sweeper 53MH - Left Front View

ROTARY TOWED SWEEPER 53MH - RIGHT REAR VIEW

Figure 1-2. Rotary Towed Sweeper 53MH - Right Rear View

1-2

TM 5-3825-230-14&P

1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE.

Command decision, according to the tactical situation, will determine when the destruction of the sweeper, will be accomplished. A destruction plan will be prepared by the using organization unless one has been prepared by a higher authority. For general destruction procedures for this equipment, refer to TM 750-244-6, Procedures for Destruction of

Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-Automotive Command).

1-4. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).

If your sweeper needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Put it on an SF 368 (Quality Deficiency Report). Mail it to us at Commander, U. S.

Army Tank-Automotive Command, ATTN: AMSTA-Q, Warren, Michigan 48397-5000. A reply will be furnished to you.

1-5. WARRANTY INFORMATION.

Reserved.

1-6. ABBREVIATIONS.

All abbreviations used in this manual conform to MIL STD-12 and it's amendments.

1-7. PREPARATION FOR STORAGE OR SHIPMENT.

Refer to Chapter 4, Section VI for preparation for storage or shipment.

1-8. QUALITY ASSURANCE/QUALITY CONTROL (QA/QC).

If there are any Quality Assurance/Quality Control problems with the sweeper, put the problem on a SF 368 Quality

Deficiency Report and mail it direct to: Commander, U. S. Army Tank-Automotive Command, ATTN: AMSTA-Q,

Warren, Michigan 48397-5000. A reply will be furnished to you.

1-9. SAFETY, CARE, AND HANDLING. The following are significant hazards and safety recommendations.

a. Refueling the Sweeper. This is a normal operating condition. Shut off engine and do not smoke when filling the tank.

b. Connecting/Disconnecting the Sweeper. This is a normal operating condition. Do not go between sweeper and vehicle until both are shut off and brakes are set.

1-3

TM 5-3825-230-14&P

Section II. EQUIPMENT DESCRIPTION AND DATA

1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

a. Purpose of the Sweeper. The sweeper is a model 53MH sweeper having three wheels, designed to follow a 1-

1/4 ton cargo truck. It is designed to sweep paved surfaces.

b. Capabilities and Features.

(1) Low maintenance.

(2) Easily transported.

(3) High maneuverability.

capability.

(4) Brush is hydraulically operated and has flotation and angle adjustments to provide maximum sweeping

(5) A sprayer system wets down surfaces to keep dust to a minimum.

(6) 12-volt and 24 volt electrical hook-ups to the tow vehicle.

1-11. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

Refer to figure 1-3 for location of the following items:

1. Tow Pole and Strut. Tow strut provides a simple way to pull and guide the sweeper.

2. Data Plates. Data plates provide information on operation and technical details of the sweeper.

3. Main Frame. The main frame serves as the hydraulic fluid reservoir and as a mounting point for the vehicle systems.

4. Hydraulic System. The hydraulic system consists of hydraulic controls, pump, motor, reservoir and filter.

5. Fuel Tank. The fuel tank provides an on-board source for fuel.

6. Engine. The engine provides power for the hydraulic pump and hydraulic motor.

7. Sprinkler System. The sprinkler system is made up of a water tank, hoses, pump, spray bar, and nozzles. As water is pumped from the tank it travels through the hoses to the spray nozzles.

8. Hand Brakes. The hand brakes hold the vehicle in place when parked.

9. Brush Frame Assembly. Brush assembly is made up of the brush and the hydraulic core. The brush hood covers the top of the brush to avoid splash back onto the engine and electrical components. The brush frame also serves as a mount for the hydraulic motor.

*U S GOVERNMENT PRINTING OFFICE 1993 -746 -017/80257

PIN: 069815-001

Change 1 1-4

Figure 1-3. Rotary Towed Sweeper Major Components

1-12. EQUIPMENT DATA.

Table 1-1 contains the equipment data that applies to the sweeper.

Table 1-1. Equipment Data

General Specifications:

Length .........................................................165 in. (4.19 m)

Height ..........................................................54 in. (1.37 m)

Width ...........................................................108 in. (2.74 m)

Weight .........................................................2950 lb (1,338.11 kg)

Fuel .............................................................Diesel

Tires:

Size .......................................................ST225/75R15

Pressure ................................................65 psi (4.57 Kg/cm2)

Maximum Towing Speed .............................25 mph (40 kph)

Maximum Sweeping Speed .........................8 mph (12 kph)

Type ............................................................Rotary Towed Sweeper

Model...........................................................53MH

1-5

TM 5-3825-230-14&P

TM 5-3825-230-14&P

Table 1-1. Equipment Data - CONT.

Engine Specifications:

Type .....................................................................................Diesel

Manufacturer ........................................................................Lombardini

Model....................................................................................12LD435-2

Horsepower...........................................................................15.50

Number of Cylinders .............................................................2

Total Displacement ...............................................................53 cu-in (871 cc)

Maximum Operating RPM.....................................................2850 RPM

Idle Speed ............................................................................1100-1150 RPM

Bore......................................................................................3.3858 in. (86 mm)

Stroke ...................................................................................2.9527 in. (75 mm)

Compression Ratio ...............................................................18.5:1

Air Cleaner............................................................................Dry paper element, replaceable

Number of Compression Rings .............................................2

Number of Oil Rings .............................................................1

Crankcase capacity with Filter Change..................................2.90 qt (2.75 L)

Cylinder Bore Limits..............................................................3.3858 to 3.3866 in. (86 to 86.02 mm)

Piston to Cylinder Bore Limits ...............................................0.0023 to 0.0039 in. (0.06 to 0.10 mm)

Valve Clearance (Adjustment) ..............................................0.0059 to 0.0078 in. (0.15 to 0.20 mm)

Crankshaft Endplay...............................................................0.0078 to 0.0118 in. (0.20 to 0.30 mm)

Injector Nozzle Depth............................................................0.1182 to 0.1379 in. (3.0 to 3.5 mm)

Injector Nozzle Diameter.......................................................0.0110 in. (0.28 mm)

Injector Nozzle Release Pressure .........................................2986 to 3129 psi (210 to 220 Kg/cm2)

Crankshaft End Dimension Limits.(Flywheel) ........................2.8338 to 2.8346 in. (71.98 to 72.00 mm)

Crankshaft End to Bearing Limits..........................................0.0027 to 0.0043 in. (0.07 to 0.11 mm)

Crankshaft End Dimension Limits (Pump side) .....................2.1625 to 2.1633 in. (54.93 to 54.95 mm)

Crankshaft End to Bearing Limits..........................................0.0019 to 0.0031 in. (0.05 to 0.08 mm)

Center Bearing Journal .........................................................2.1787 to 2.1791 in. (55.34 to 55.35 mm)

Crankcase Crankshaft Opening (rear) ...................................5.1181 to 5.1188 in. (130 to 130.02 mm)

Crankcase Crankshaft Opening (front) ..................................2.9921 to 2.9929 in. (76 to 76.02 mm)

Center Bearing Journal to Bearing ........................................0.0019 to 0.0035 in. (0.05 to 0.09 mm)

Connecting Rod Journal........................................................1.5748 to 1.5755 in. (40.0 to 40.02 mm)

Connecting Rod Bearing to Journal.......................................0.0013 to 0.0029 in. (0.035 to 0.076 mm)

Valve Stem Diameter............................................................0.3141 to 0.3149 in. (7.98 to 8.0 mm)

Valve Stem to Bore...............................................................0.00118 to 0.0031 in. (0.03 to 0.08 mm)

Valve Stem Guide Diameter .................................................0.5531 to 0.5535 in. (14.05 to 14.06 mm)

Valve Depth (In cylinder head) ..............................................0.0295 to 0.0492 in. (0.75 to 1.25 mm)

Connecting Rod Pin Diameter...............................................0.8659 to 0.8661 in. (21.995 to 22.000 mm)

Connecting Pin to Bearing Limits ..........................................0.0005 to 0.0011 in. (0.015 to 0.030 mm)

Connecting Pin Side Play......................................................0.0019 in (0.05 mm)

Piston Diameter ....................................................................3.3858 to 3.3866 in. (86.00 to 86.02 mm)

Oil Consumption ...................................................................0.036 qt (0.035 Kg/h)

Oil Sump Capacity ................................................................2.64 qt (2.51 1)

Oil Pressure..........................................................................14.22 psi (1.0 Kg/cm2)

Oil Pump ..............................................................................Internal, mechanical drive

Oil Filter................................................................................External, cartridge type

1-6

TM 5-3825-230-14&P

Table 1-1. Equipment Data - CONT.

Engine Specifications (cont):

Oil Filter capacity............................................................0.26 qt (0.251)

Camshaft End (flywheel side) .........................................1.6511 to 1.6519 in. (41.94 to 41.96 mm)

Camshaft End (pump side) .............................................1.0999 to 1.1007 in. (27.44 to 27.96 mm)

Injector Lobe...................................................................1.3307 to 1.3346 in. (33.95 to 34.05 mm)

Valve Spring Length .......................................................2.0472 in. (52 mm)

Fuel System:

Fuel Pump......................................................................Mechanical, external

Fuel Tank Capacity.........................................................8 gal (301)

Governor ........................................................................Mechanical, internal

Fuel Injectors..................................................................Mechanical, pressure activated

Fuel Injector Pump .........................................................Mechanical, internal

Fuel Consumption ..........................................................0.93 gal/per hour (3.52 1/per hour)

Hydraulic System:

Reservoir Capacity .........................................................7.5 gal (28.38 1)

Pump Capability .............................................................17.5 gpm (66.23 1pm)

Motor Capability .............................................................10.0 gpm (37.85 1pm)

Electrical:

Batteries .........................................................................Two 12-volt

Starter ............................................................................24 volt (solenoid attached)

Alternator........................................................................24 volt/50 amp

Lighting...........................................................................12 volt and 24 volt systems (Discrete)

Sprinkler System:

Capacity .........................................................................120 gal (4541)

Motor ..............................................................................12 volt

Brush:

Ground Clearance ..........................................................Variable

Brush Pattern..................................................................2 to 4 in (5.08 to 10.16 cm)

Brush Speed...................................................................Variable

1-7

1-13. MECHANICAL SYSTEM.

Section IIl. TECHNICAL PRINCIPLES OF OPERATION

TM 5-3825-230-14&P

Item

Tow Pole and Strut

Mainframe

Brush Frame

Engine

Rear Axles and Brakes

Description

Tow pole and strut provide a means to tow and steer the vehicle.

Mainframe provides a mounting place for the rest of the systems. It doubles as the hydraulic fluid reservoir.

Brush frame holds the rotating brush. The brush is able to be raised and lowered and moved from side to side. The brush frame also acts as a mount for the hydraulic motor. The brush is reversible.

Engine is a two cylinder diesel that provides power for the hydraulic system.

Rear axles are mounted separately in the mainframe. The two hand brakes are mounted on the mainframe and are manually operated mechanical brakes.

Transport and Safety Chains Safety chains on the tow pole attach to the tow vehicle and transport chains on the frame attach to the brush frame to stabilize the sweeper during transport.

1-8

1-14. ELECTRICAL SYSTEM.

TM 5-3825-230-14&P

Item

Power Hookups

Panel Gages/Switches

Starter

Alternator

Batteries

Lighting

Spray Pump Motor

Junction Box

Description

Vehicle has separate 12 and 24 volt vehicular light hookup capability. They are stored by wrapping around harness stowage pegs.

Switches and gages (12 volt) are used to start vehicle and monitor vehicle performance.

Starter is a 24 volt unit that starts the engine by engaging the flywheel with a gear.

Alternator is a 24 volt unit that maintains the battery charge.

Batteries consist of two 12 volt units located on each side of the sweeper.

Lighting provides rear, side, safety marking, stopping, and signaling capability.

Constant speed electric motor (12 volt) that pumps water forward to brush assembly.

Junction box provides a way of routing the electrical harnesses. 1

1-9

TM 5-3825-230-14&P

1-15. HYDRAULIC SYSTEM.

Item

Hydraulic Controls

Hydraulic Breather

Hydraulic Fluid Dipstick

Hydraulic Fluid Filter

Hydraulic Reservoir

Hydraulic Motor broom.

Hydraulic Pump

Description

Hydraulic controls regulate the hydraulic fluid flow, raise and lower the brush assembly, and start and stop the hydraulic motor.

Eliminates pressure or vacuum in the hydraulic reservoir.

Hydraulic fluid dipstick provides a means of checking hydraulic fluid level.

Hydraulic fluid filter separates particulates from hydraulic fluid.

Hydraulic reservoir is contained in the mainbeam of the mainframe.

Hydraulic motor uses hydraulic power from hydraulic pump to drive the

Hydraulic pump is driven by the engine to produce hydraulic pressure providing a capability to lift or lower the brush assembly.

1-10

TM 5-3825-230-14&P

1-16. FUEL SYSTEM.

Item

Fuel Tank

Fuel Filler Cap

Fuel Sending Unit

Fuel Pump

Fuel Filter

Fuel Injector Pump

Fuel Injectors

Fuel Shutoff Valve

Description

Fuel tank provides an on-board fuel capacity.

Fuel filler cap provides a safe way of sealing fuel tank and taking on fuel.

Fuel sending unit works with fuel gage to sense and indicate fuel level in fuel tank.

Fuel pump forces fuel through fuel filter to injection pump.

Fuel filter removes particulates from fuel.

Fuel injector pump provides pressurized fuel to fuel injectors.

Fuel injectors provide a measured amount of fuel to cylinders.

Fuel shutoff valve provides a way to safely shut off fuel at fuel tank by turning valve clockwise.

1-11

TM 5-3825-230-14&P

1-17. SPRINKLER SYSTEM.

Item

Water Tank

Saddle

Water Tank Shut Off Valve

Spray Pump

Spray Bar

Description

Water tank provides an on-board source of water for sprinkler system.

Saddle provides a secure support for water tank on the frame.

Water tank shut off valve provides a way to shut water off at the tank.

Spray pump provides pressurized water to spray bar.

Spray bar spreads water evenly over spray surface to prevent dust during sweeping operations.

1-12

TM 5-3825-230-14&P

CHAPTER 2

OPERATING INSTRUCTIONS

Para Contents Page

2-1

2-2

2-3

2-4

2-5

2-6

Controls and Indicators Introduction.....................................................................................................2-1

Location and Use of Controls and Indicators ........................................................................................2-1

PMCS Introduction ..............................................................................................................................2-7

Special Instructions..............................................................................................................................2-7

PMCS Column Entry Explanation ........................................................................................................2-8

PMCS Table ........................................................................................................................................2-9

2-7

2-8

2-9

Assembly and Preparation For Use......................................................................................................2-14

Operating Procedures..........................................................................................................................2-14

Transportation by Towing.....................................................................................................................2-24

2-10 Operating Instructions on Decals and Instruction Plates.......................................................................2-25

2-11 Operation Under Unusual Conditions ...................................................................................................2-28

2-12 Fording ................................................................................................................................................2-28

2-13 Emergency Procedures .......................................................................................................................2-28

Section I. DESCRIPTION AND USE OF OPERATOR'S CONTROLS AND INDICATORS

2-1. CONTROLS AND INDICATORS INTRODUCTION.

This section shows the location and describes the use of controls and indicators used to operate the sweeper.

2-2. LOCATION AND USE OF CONTROLS AND INDICATORS.

Know the location and proper use of every control and indicator before operating the sweeper. Use this section to learn how each control and indicator is to be used. Separate illustrations, with keys, are provided in this section.

2-1

TM 5-3825-230-14&P

4

5

2

3

6

7

1

Key

8

Control/Indicator

Throttle Handle

Fuel Shutoff Handle

Push Button (24V)

Toggle Switch

Ammeter Gage (24V)

Fuel Gage

Key Switch (12V)

Tachometer/Hourmeter

Figure 2-1. Panel Controls and Indicators

Function

Controls engine speed; is able to be locked in position by turning left or right to allow engine to maintain a constant speed. Pull out to increase engine speed.

Pulls out to shut off the fuel supply to the engine and shut the engine down.

Provides power to glow plug for cold weather starting. Push in to activate.

Turns on the spray pump motor; up for "on" down for "off”.

Indicates the voltage of the charging system.

Indicates the fuel level.

Turns on power; provides power to sprinkler switch and gage lights.

Starts the engine.

Indicates the engine RPM and records hours of operation.

2-2

TM 5-3825-230-14&P

1

Key

2

3

Control/Indicator

Hydraulic Fluid

Dipstick

Broom Motor

Control

Broom Lift Control

Figure 2-2. Hydraulic Controls and Indicators

Function

Indicates the level of hydraulic fluid in the reservoir.

Lifts up to turn hydraulic broom motor on, down to turn motor off.

Raises and lowers broom to the float position; push forward to raise the broom and pull back to lower the broom.

2-3

TM 5-3825-230-14&P

1

Key Control/Indicator

Hand Brake Controls

Figure 2-3. Hand Brake Controls

Function

Lift up to apply the hand brake, down to disengage. There are two hand brake levers, one on each side of the sweeper.

2-4

TM 5-3825-230-14&P

1

Key Control/Indicator

Broom Angle Lock

Figure 2-4. Broom System

Function

Locks the angle of the broom assembly in left or right position.

1

Key Control/Indicator

Shutoff Valve

Figure 2-5. Water Tank Shutoff Valve

Function

Turns water supply off and on by turning lever. Lever is shown in open position.

2-5

TM 5-3825-230-14&P

1

2

Key Control/Indicator

Decompression Levers

Engine Oil Dipstick

Figure 2-6. Engine Controls and Indicators

Function

Releases compression from the cylinder bores. Used only when engine is off.

Indicates the level of the engine oil. The dipstick is located on right side of engine.

2-6

TM 5-3825-230-14&P

Section II. OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

2-3. PMCS INTRODUCTION.

a. PMCS Procedures. To ensure that the sweeper is ready for operation at all times, it must be inspected

systematically so that defects may be discovered and corrected before they result in serious damage or failure. Table 2-1

contains a tabulated listing of preventive maintenance checks and services to be performed by the operator.

(1) Do the before (B) preventive maintenance just before operating the sweeper. Pay attention to the

CAUTIONS and WARNINGS.

(2) Do the during (D) preventive maintenance while the sweeper is in operation. Pay attention to the

CAUTIONS and WARNINGS.

(3) Do the after (A) preventive maintenance right after operating the sweeper.

(4) Do the (W) preventive maintenance on a weekly basis.

(5) Do the (M) preventive maintenance on a monthly basis.

(6)

If something does not work properly, troubleshoot using the instructions in Chapter 3. Report any

deficiencies using the proper forms.

(7) Always do preventive maintenance in the same order until it gets to be a habit. Once practiced, problems can be spotted in a hurry.

(8) When doing preventive maintenance, take along the tools needed and a rag or two to make all the checks.

(9) Report all deficiencies on DA Form 2404.

b. Equipment is not ready/available if: procedures. The terms ready/available and mission capable refer to the same status: equipment is on hand and is able to perform its combat mission (see AR 700-138).

2-4. SPECIAL INSTRUCTIONS.

a. Shortened Maintenance Instructions. Local conditions of extreme heat, dust, cold, or wetness dictate that service intervals may need to be shortened.

b. Additional Maintenance Inspections. Additional maintenance inspections may be required for the following reasons:

(1) Prolonged storage. Vehicles having been stored for a period of three months or more should be inspected.

(2) Initial preparation upon receipt.

(3) Preparation for storage.

c. Fluid Leakage. It is necessary to know that fluid leakage affects the status of fuel, oil, coolant, and the hydraulic systems. The following are definitions of the different types/classes of leakage that determine the status of the sweeper.

2-7

TM 5-3825-230-14&P

2-4. SPECIAL INSTRUCTIONS (CONT).

• Equipment operation is allowable with minor leakage (hydraulic or water, Class I or II).

Consideration must be given to, the fluid capacity in the item/system being checked/inspected. When in doubt, notify the supervisor.

• When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS. Class

III leaks should be reported to your supervisor or organizational maintenance.

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

(2) Class II. Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected.

(3) Class III. Leakage of fluid great enough to form drops that fall from the item being checked/inspected.

2-5. PMCS COLUMN ENTRY EXPLANATION.

a. Item Number Column. The checks and services are numbered in chronological order showing a logical sequence around the sweeper.

b. Interval Column. This column contains a dot (•) opposite the appropriate check. Thus, if a given check is performed before operation, a dot is opposite the check in the "B" column; if the dot is in the "D" column the check should be performed during operation; and if the check is made in two or more periods, a dot is placed in each applicable column.

c. Item to be Inspected Column. The items listed in this column are divided into groups indicating the portion of the equipment of which they are a part, i.e. brakes, fuel, engine. Under these groupings a few common words are used to identify the specific item being checked.

d. Procedures Column. This column contains a brief description of the procedure by which the check is performed.

e. Equipment is not Ready/Available if: Column. This column contains the criteria that causes the equipment to be classified as NOT READY/NOT AVAILABLE because of inability to perform its primary mission. An entry in this column will:

(1) Identify conditions that make the equipment not ready/available for readiness reporting purposes.

(2) Deny use of the equipment until corrective maintenance has been performed.

2-8

TM 5-3825-230-14&P

1

2

3

4

2-6. PMCS TABLE.

Refer to Table 2-1 for the preventive maintenance checks and services for the sweeper.

Table 2-1. Operator Preventive Maintenance Checks and Services

NOTE: Within designated interval, these checks are to be performed in the order listed.

B - BEFORE D-DURING A-AFTER W-WEEKLY M-MONTHLY

Item

No.

Equipment Is

Not Ready/

Available If:

Interval

B D A W M

Item To Be

Inspected

Procedure

Check for and have repaired or adjusted as necessary

Exterior

General Visually inspect for damage, loose or missing parts.

Fluid Leakage Look under sweeper for fluid leakage (hydraulic or water).

Lights and Check condition of lights or

Reflectorsreflectors (para 3-10).

Wheels and

Tires

a. Check wheels for cracks, broken, or bent surfaces.

b. Check that lugnuts are not damaged and are secure on the wheel.

c. Check tires for cuts, gouges, or cracks. Remove any sharp objects.

Any component is damaged that would impair sweeper mission.

Class III leakage is evident.

If lights are broken or do not work.

A wheel is cracked, broken, or bent.

One or more nuts or studs are missing, broken, or bent.

Tires have cuts, gouges, or cracks which would result in tire failure during operation.

One or more missing or unserviceable tires.

• d. Check tires for obviously low air pressure, front and rear. Correct as needed, by notifying unit maintenance.

2-9

5

6

Item

No.

TM 5-3825-230-14&P

Table 2-1. Operator Preventive Maintenance Checks and Services - CONT.

NOTE: Within designated interval, these checks are to be performed in the order listed.

B - BEFORE D-DURING A-AFTER W-WEEKLY M-MONTHLY

B

Interval

D A W M

Item To Be

Inspected

Procedure

Check for and have repaired or adjusted as necessary

Equipment Is

Not Ready/

Available If:

Hand Brake

Assembly

Batteries

Check hand brake levers. Adjust if

necessary (para 3-12).

Hand brake will not adjust, linkage has parts missing or bent. Hand brake will not hold the vehicle.

Do not wear watches, rings, or other jewelry which could short out battery terminals while servicing batteries. Do not smoke or use open flame around batteries.

Batteries may explode from a spark. Battery acid is harmful to skin and eyes.

NOTE

It may be necessary to use a flashlight to check fluid level.

a. Remove strap and cover of battery box. Remove battery caps and check electrolyte level of each cell. Electrolyte level should be up

to split ring (para 3-11).

b. Visually inspect battery for cracked or leaking casing, broken or burned terminal posts

(para 3-11).

c. Check electrical cables and

connectors for damage (para 3-11).

2-10

Missing battery or battery will not crank engine.

Battery is damaged, terminals are broken or burned.

Damage found to cables or connectors.

TM 5-3825-230-14&P

Item

No.

Table 2-1. Operator Preventive Maintenance Checks and Services - CONT.

NOTE: Within designated interval, these checks are to be performed in the order listed.

B - BEFORE D-DURING A-AFTER W-WEEKLY M-MONTHLY

B

Interval

D A W M

Item To Be

Inspected

Procedure

Check for and have repaired or adjusted as necessary

Equipment Is

Not Ready/

Available If:

7

8

Hydraulic

System

Fuel System

a. Check that hydraulic fluid reservoir is full.

(para 3-13).

b. Check condition of hydraulic fluid in reservoir.

c. Check hydraulic breather.

Fluid level is low.

Fill as needed

Fluid appears milky or foamy.

Breather is bent or missing.

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

(15.24 m) OF VEHICLE."

a. Check to see fuel tank is full.

Inspect filler screen for obstructions. Fill as necessary

(para 3-8).

b. Check fuel tank, hoses, and connections for leaks or damage.

Make sure all connections are secure.

2-11

Any fuel leakage is present or damage that would impair the mission of the sweeper.

TM 5-3825-230-14&P

Item

No.

Table 2-1. Operator Preventive Maintenance Checks and Services - CONT.

NOTE: Within designated interval, these checks are to be performed in the order listed.

B - BEFORE D-DURING A-AFTER W-WEEKLY M-MONTHLY

B

Interval

D A W M

Item To Be

Inspected

Procedure

Check for and have repaired or adjusted as necessary

Equipment Is

Not Ready/

Available If:

9

Engine NOTE

If engine has been running, wait about five minutes after engine shutdown before checking engine oil level.

a. Check engine oil level on dipstick. Oil level should be between low and full mark

(para 3-6).

Oil level is above full mark or below low mark.

10

Sprinkler

System

If NBC exposure is suspected, all air filter media should be handled by personnel wearing protective equipment. Consult your unit

NBC Officer or NBC NCO for appropriate handling or disposal procedures.

b. Check air filter. Clean before operation or replace as necessary

(para 3-7).

c. Check alternator belt for

looseness or fraying (para 3-9).

a. Check water tank, hoses, and connections for leaks or damage.

Inspect nozzles for damage.

b. Clean water system strainer

(para 3-14).

2-12

Air filter or gasket is missing or torn.

Belt missing.

Damage that would impair the mission of the sweeper.

Strainer missing.

Item

No.

TM 5-3825-230-14&P

Table 2-1. Operator Preventive Maintenance Checks and Services - CONT.

NOTE: Within designated interval, these checks are to be performed in the order listed.

B - BEFORE D-DURING A-AFTER W-WEEKLY M-MONTHLY

B

Interval

D A W M

Item To Be

Inspected

Procedure

Check for and have repaired or adjusted as necessary

Equipment Is

Not Ready/

Available If:

11

12

13

14

Brush

Assembly

Broom Head

Grease Fittings

Chains

Controls and

Gages

a. Check for loose, damaged, or missing nuts and screws.

b. Check hydraulic cylinder for leakage or damage.

c. Check dirt deflector assembly for damage.

d. Check brush pattern

(para 2-8h).

Refer to lubrication chart and

lubricate fittings (para 3-1).

Check for damaged or missing hardware or links.

Check gages for operation.

Connecting hardware damaged that would impair the mission of the sweeper.

Class III leakage or cylinder damage that would impair the mission of the sweeper.

Damage that would impair the mission of the sweeper.

Brush pattern is not 2 to 4 in.

(5 to 10 cm).

Fittings are broken off.

Hardware or links broken or missing.

Ammeter showing negative or gages missing.

2-13

TM 5-3825-230-14&P

Section III. OPERATION UNDER USUAL CONDITIONS

2-7. ASSEMBLY AND PREPARATION FOR USE.

The sweeper may be shipped with the motor guard and hydraulic motor temporarily attached to the main frame rather than the broom head. The mounting hardware is with these items. The hydraulic hoses are connected and bundled with the sprinkler hose. If a unit in this condition is received, notify unit maintenance.

2-8. OPERATING PROCEDURES.

Always set hand brakes before starting the sweeper, or injury to personnel may result.

a.

Starting Engine.

(1) Set hand brakes (1) by pulling handles up.

2-14

TM 5-3825-230-14&P

(2) Place broom lift control (2) in center position and broom motor control (3) in the OFF position.

(3) Open fuel shutoff valve (4) (para 3-15).

(4) To start engine:

(a) Turn key (5) to first position.

Do not crank engine for more than five seconds. Damage to starter may result.

(b) In cold weather, press glow plug button (6) located on panel for five seconds. If engine has been running and was shut down for a short period, or during warm weather, pressing button is not necessary.

(c) In cold weather only, continue to depress the glow plug button (6) and turn key (5) to second position to crank engine. When engine starts release both the glow plug button and the key.

(d) In warm weather or with a hot engine, turn key (5) to second position to crank engine. Release key when engine starts.

(e) If engine does not start, turn key (5) switch back to the left. Wait five seconds and repeat steps (a) through

(d) as applicable.

2-15

2-8. OPERATING PROCEDURES (CONT).

b. Shutdown Engine.

TM 5-3825-230-14&P

(1) Allow engine to idle for five minutes.

(2) Pull out and hold engine fuel shutoff handle (1) until engine stops running.

(3) Turn key (2) fully left to the stop position.

2-16

TM 5-3825-230-14&P

c. Remove Transport Chains. Transport chains are connected to the sweeper head to support the sweeper head while the unit is being transported.

(1) With engine running at idle, use hydraulic control (1) to raise broom head (2).

(2) Disconnect transport chain (3) from broom head (2) by removing screw (4) from connecting clevis (5).

(3) Loop chain (3) through tiedown ring and secure by installing screw (4) in clevis (5).

2-17

TM 5-3825-230-14&P

2-8. OPERATING PROCEDURES (CONT).

d. Brush Angle Adjustment. Brush angle can be selected to windrow sweepings to either the right or left of the sweeper. Selection of brush angle is largely dependent upon width of surface to be swept and the pattern used to sweep the surface.

Always set hand brakes before performing this adjustment procedure or injury to personnel may result.

(1) Raise brush (1) and shut down engine.

(2) Remove angle securing pin (2) and swing brush (1) to desired angle.

(3) Replace pin (2) in hole on opposite side the brush (1) is pointing.

2-18

TM 5-3825-230-14&P

e. Sprinkler System Operation. The sprinkler system is used to aid in the sweeping process and to reduce creation of dust during sweeping. The sprinkler system should not be used in temperatures below 32°F (0°C).

(1) Remove water tank top (1).

(2) Fill tank (2) with water and install top (1).

(3) Open water tank shutoff valve (3) located beneath water tank.

(4) Turn key (4) right to first position.

Do not operate sprinkler system without water in tank or damage to equipment may result.

(5) Move sprinkler system toggle switch (5) on control panel to the ON position.

(6) Move sprinkler system toggle switch (5) to the

OFF position.

(7) Turn key (4) fully left to the stop position.

2-19

TM 5-3825-230-14&P

2-8. OPERATING PROCEDURES (CONT).

NOTE

The sweeper is configured to permit towing by a variety of vehicles with both 12V and 24V electrical systems.

f.

Connect Unit to Tow Vehicle

(1) Set hand brakes (1) by pulling handles up.

(2) Back tow vehicle into position to permit connection of pintle hitch (2).

(3) Couple tow vehicle and sweeper at pintle hitch

(2).

(4) Connect safety chains (3) to tow vehicle.

(5) Connect sweeper wiring harness (4) to tow vehicle. The red harness on the sweeper is for use with 12V vehicles and the black for 24V systems.

(6) Wind unused wiring harness around harness stowage pegs on frame.

(7) Release hand brakes (1) by moving handles to the down position.

2-20

TM 5-3825-230-14&P

g. Sweeping.

(1) Connect sweeper to tow vehicle (para 2-8f).

(2) Select brush angle (para 2-8d).

(3) Fill water tank and open water tank shutoff valve (para 2-8e), if sprinkler system is to be used.

• Failure to follow these instructions may result in injury to personnel.

• Keep body parts away from the space between broom hood and frame when raising the broom or injury to personnel may result. Operator may have to use control levers from right side of vehicle if brush angle is turned to the left side.

(4) Start engine (para 2-8a).

(5) Lower broom (1) to float position by moving broom control lever (2) fully down.

NOTE

For most conditions operation at full throttle is recommended. In light sweeping applications, throttle setting may be reduced. Reduced throttle setting may extend broom life.

(6) Pull throttle handle (3) fully out and lock it in position by turning it to either the left or right until it tightens.

(7) Start broom (1) by moving brush motor control lever (4) up.

2-21

2-8. OPERATING PROCEDURES (CONT).

TM 5-3825-230-14&P

(8) Move sprinkler toggle switch (5) to on position.

(9) Proceed with sweeping operation:

(a) When driving the tow vehicle, keep in mind the overall length of both the sweeper and tow vehicle.

(b) When turning allow adequate clearance for the sweeper to turn inside of the turning radius of the tow vehicle.

(c) When employing sweeping patterns requiring more than one pass, allow a minimum of six inches of overlap with the last pass.

(d) Avoid abrupt stops as the sweeper may swing to the left or right.

(e) Whenever possible, an assistant will act as a ground guide to direct the driver when backing.

• Maximum towing speed during sweeping operation is 8 mph (12 kph). Do not exceed this speed or damage to equipment may result.

• Do not run water pump when tank is empty. Damage to equipment may result.

(f) Do not exceed a towing speed of 8 mph (12 kph) during sweeping operations.

(g) Monitor water level in tank during operation.

2-22

TM 5-3825-230-14&P

(10) To discontinue sweeping operation:

(a) Move sprinkler system toggle switch (5) to the off position.

(b) Turn off broom (1) by moving brush motor control lever (4) down to the off position.

(c) Raise broom (1) by moving broom control lever (2) to up position.

(d)

Shutdown engine (para 2-8b).

NOTE

If temperature is expected to drop below 32°F (0°C), drain water tank (para 3-14).

(e)

Park unit for later use or prepare for transport (para 2-9).

(f) Wrap wiring harness around harness stowage pegs.

h. Brush Pattern Check. It is necessary to check brush pattern during operation. Improper brush pattern is caused by brush wear. If the sweeper does not have the proper brush pattern, notify unit maintenance. To check brush pattern:

(1) Raise brush (1) two inches above a smooth surface by moving broom lift control lever (2).

(2) Start broom rotation by lifting broom motor control lever (3).

(3) Lower brush to its lowest position by moving brush lift control lever (2) down.

(4) Raise brush (1) and stop broom rotation.

(5) Shut down engine (para 2-8b).

(6) Brush pattern should indicate 2 to 4 in. (5 to 10 cm) of contact. If it does not, notify unit maintenance for adjustment.

2-23

2-9. TRANSPORTATION BY TOWING.

(1) Set hand brakes (1) by placing levers in the up position.

(2) Start engine (para 2-8a).

TM 5-3825-230-14&P

(3) Raise broom head (2) by moving broom lift control (3) to the up position.

(4) Remove angle pin (4) and move brush to the straight position.

(5) Remove front pins (5) and clevis pins (6) from transport chains (7).

(6) Remove transport chains (7) from rear tiedowns (8) and connect to broom head (2) using pin (5) and clevis (6).

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TM 5-3825-230-14&P

(7) Lower broom head (2) by moving broom lift control (3) fully down to float position and shut down engine (para 2-

8b).

(8) Connect sweeper to tow vehicle (para 2-8f).

Maximum towing speed is 25 mph (38 kph). Do not exceed this speed or damage to equipment may result.

(9) Do not tow the sweeper at speeds in excess of 25 mph (38 kph).

2-10. OPERATING INSTRUCTIONS ON DECALS AND INSTRUCTION PLATES.

Refer to figure 2-7 for location of sweeper decals and data plates.

2-25

Figure 2-7. Decals and Data Plates (Sheet 1 of 2)

2-26

TM 5-3825-230-14&P

Figure 2-7. Decals and Data Plates (Sheet 2 of 2)

2-27

TM 5-3825-230-14&P

TM 5-3825-230-14&P

Section IV. OPERATION UNDER UNUSUAL CONDITIONS

2-11. OPERATION UNDER UNUSUAL CONDITIONS.

a. Operation in Hot Weather. During hot weather, operator should avoid allowing engine to idle for extended periods.

b. Operation in Wet, Mud, or Snow.

(1) Wet weather conditions require no special operating procedures.

(2) Excessively muddy conditions may require several passes or reduced vehicle speed to obtain desired results.

(3) The sweeper may remove up to six inches of light powdered snow.

(4) If the outside temperature falls below 32°F (0°C), the water tank must be drained.

c. Operation in Extreme Dust or Sand. Operation in extreme dust or sand conditions may require additional maintenance of the air cleaner, fuel filter, oil filter, and hydraulic filter as well as other lubricated parts. Severity of the local condition will dictate the level of additional maintenance.

2-12. FORDING.

Do not ford water exceeding 18 in. (45.7 cm) depth. Damage to equipment may result.

While the sweeper is not designed for fording, it may be exposed to high water conditions. If these conditions are encountered it may be necessary to repack the wheel bearings and lubricate all lube points. Do not exceed 18 in. (45.7

cm) fording depth.

2-13. EMERGENCY PROCEDURES.

In case of severe damage to the sweeper assembly, the entire brush assembly may be removed prior to transport. Notify unit maintenance to separate brush assembly from sweeper.

2-28

TM 5-3825-230-14&P

CHAPTER 3

OPERATOR MAINTENANCE INSTRUCTIONS

Para Contents Page

3-1 General Lubrication Instructions ..............................................................................................3-1

3-2 Troubleshooting Introduction ...................................................................................................3-8

3-3 Troubleshooting Symptoms.....................................................................................................3-8

3-4 Maintenance Introduction ........................................................................................................3-14

3-5 Left and Right Access Covers .................................................................................................3-14

3-6 Engine Oil Check ....................................................................................................................3-15

3-7 Air Filter Inspection .................................................................................................................3-16

3-8 Service Fuel Tank Screen/Fill Fuel Tank.................................................................................3-18

3-9 Alternator Belt Check ..............................................................................................................3-19

3-10 Lights ......................................................................................................................................3-20

3-11 Battery Service .......................................................................................................................3-21

3-12 Hand Brakes Adjustment/Inspection ........................................................................................3-22

3-13 Hydraulic Fluid Check/Bleed Hydraulic System .......................................................................3-23

3-14 Sprayer System Strainer Service/Water Draining ....................................................................3-24

3-15 Fuel Shutoff ............................................................................................................................3-25

Section I. LUBRICATION INSTRUCTIONS

3-1. GENERAL LUBRICATION INSTRUCTIONS.

Do not start engine or move sweeper when anyone is under sweeper. Severe injury or death could result.

NOTE

These instructions are mandatory.

a. Intervals. Intervals (on-condition or hard time) and the related man-hour times are based on normal operation.

The man-hour time specified is the time needed to do all the services prescribed for a particular interval. Change the hard time interval if lubricants are contaminated or if operating the equipment under adverse operating conditions, including longer-than-usual operating hours. The calendar interval may be extended during periods of low activity. If extended, adequate preservation precautions must be taken. Hard time intervals must be applied during the warranty period. Intervals shown in this lubrication section are based on calendar and hourly times or calendar times and mileage.

An example of a calendar and hourly lubrication is: M/60 HR, in which M stands for monthly and 60 HR stands for 60 hours of vehicle operation. The lubrication is to be performed, at whichever interval occurs first for the sweeper. Special lubrication intervals and services are shown by the use of an asterisk (*) symbol.

3-1

TM 5-3825-230-14&P

3-1. GENERAL LUBRICATION INSTRUCTIONS (CONT).

b. Determination of Operating Hours. The reading on the hourmeter is the basis of all lubrication intervals that are based on hours of operation.

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medial aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

c. Clean Fitting Before Lubricating. Clean parts with dry cleaning solvent, item 31, Appendix E, or equivalent.

Dry before lubricating. Dotted arrow points indicate lubrication on both sides of the sweeper.

d. Lubrication After Fording. If fording occurs, lubricate all fittings below fording depth. Fording is not recommended.

e. Lubrication after High-Pressure Washing. After washing, lubricate all grease fittings and oil can points outside and underneath sweeper.

f. Level of Maintenance. The lowest level of maintenance authorized to lubricate a point is indicated by either

Operator/Crew (C) or Unit Maintenance (O). Operator can lubricate points authorized for unit maintenance when authorized by unit maintenance.

g. Localized Views. A reference to the appropriate localized view is given after most lubrication entries.

h. Oil Filter Statement. Oil filters shall be changed as applicable, when:

(1) They are known to be contaminated or clogged.

(2) At prescribed hard time intervals.

i. Warranty Hard Time Statement. For equipment under manufacturers' warranty, hard time oil service intervals shall be followed. Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions (such as longer-than-usual operating hours, extended idling periods, extreme dust).

j. Lubrication Interval Symbols. The following lubrication interval symbols are used. Refer to figure 3-1 and

figure 3-2 for lubrication instructions for the sweeper.

D - daily

W - weekly

M - monthly

Q - quarterly

A - annually

B - biannually

H - hours (operated)

S - semiannually

3-2

TM 5-3825-230-14&P

A. Fig 3-2

B. Fig 3-2

C. Fig 3-2

D. Fig 3-2

E. Fig 3-2

F. Fig 3-2

Figure 3-1. Lubrication Chart (Sheet 1 of 3)

I. Fig 3-2

I. Fig 3-2

I. Fig 3-2

I. Fig 3-2

J. Fig 3-2

L. Fig. 3-2

K. Fig. 3-2

K. Fig 3-2

M. Fig 3-2

G. Fig 3-2

G. Fig 3-2

H. Fig 3-2

Figure 3-1. Lubrication Chart (Sheet 2 of 3)

3-4

TM 5-3825-230-14&P

G. Fig 3-2

G. Fig 3-2

G. Fig 3-2

H. Fig 3-2

Figure 3-1. Lubrication Chart (Sheet 3 of 3)

3-5

TM 5-3825-230-14&P

Figure 3-2. Localized Lubrication Points (Sheet 1 of 2)

3-6

TM 5-3825-230-14&P

Figure 3-2. Localized Lubrication Points (Sheet 2 of 2)

3-7

TM 5-3825-230-14&P

TM 5-3825-230-14&P

Section II. TROUBLESHOOTING

3-2. TROUBLESHOOTING INTRODUCTION.

This section contains step by step procedures for identifying, locating, and isolating equipment malfunctions.

3-3. TROUBLESHOOTING SYMPTOMS.

Refer to table 3-1 for a list of common malfunctions. Table 3-2 lists the most common malfunctions found during

operation or maintenance of the sweeper or its components. Tests or inspections and corrective actions should be performed in the order listed. If a malfunction is not listed, or is not corrected by listed corrective actions, notify the supervisor.

Table 3-1. System Symptom Index

Troubleshooting

Procedure Page

ENGINE

1

2

3

4

5

Fails to crank when engine start switch is engaged .................................................................................3-9

Cranks but fails to start...........................................................................................................................3-9

Engine does not develop full power ........................................................................................................3-10

Excessive engine oil consumption ..........................................................................................................3-10

Engine will not stop running ....................................................................................................................3-10

WHEELS, TIRES, AND HUBS

1

2

Wheel wobbles .......................................................................................................................................3-10

Tire pressure low . ..................................................................................................................................3-11

ELECTRICAL SYSTEM

1

2

Lighting does not operate .......................................................................................................................3-11

Gages do not operate .............................................................................................................................3-11

HYDRAULIC SYSTEM

Brush operates too fast, too slow, or jerky ........................................................................................................3-12

BRAKE SYSTEM

1

2

Hand brake will not apply........................................................................................................................3-12

Hand brakes will not hold........................................................................................................................3-12

FUEL SYSTEM

Engine starts and stops....................................................................................................................................3-12

SPRINKLER SYSTEM

Fails to spray when switch is engaged .............................................................................................................3-13

3-8

TM 5-3825-230-14&P

Table 3-2. Troubleshooting

Malfunction

Test or Inspection

Corrective Action

ENGINE

1. FAILS TO CRANK WHEN ENGINE START SWITCH IS ENGAGED.

Remove straps and open battery boxes. Check for dirty connections and loose or broken battery cables

(para 3-11).

If battery connections are dirty, or cables are loose or damaged, notify unit maintenance.

If battery has been serviced and engine fails to start, notify unit maintenance.

2. CRANKS BUT FAILS TO START.

Step 1. Check indication on fuel gage.

If fuel gage shows there is enough fuel but engine still will not start, go to step 2.

If fuel gage reads empty, fill tank (para 3-8).

Step 2. Check that the fuel shutoff valve is open (para 3-15).

If valve is open, go to step 3.

Step 3. Visually check fuel level in fuel tank.

If tank is empty, fill (para 3-8) and notify unit maintenance that fuel gage does not work.

If tank is not empty, go to step 4.

WARNING

If NBC exposure is suspected, all air filter media should be handled by personnel wearing protective equipment. Consult your unit NBC Officer or

NBC NCO for appropriate handling or disposal procedures.

Step 4. Check air filter (para 3-7).

If air filter is clogged, notify unit maintenance.

If engine still does not start, notify unit maintenance.

3-9

Table 3-2. Troubleshooting

Malfunction

Test or Inspection

Corrective Action

3. ENGINE DOES NOT DEVELOP FULL POWER.

ENGINE (CONT)

Step 1. Check that the fuel shutoff valve is completely open (para 3-15).

If the valve is open, go to step 2.

Step 2. Check that the air cleaner is not clogged (para 3-7).

If the air cleaner is not clogged, notify the supervisor.

4. EXCESSIVE ENGINE OIL CONSUMPTION.

Check engine for oil leaks or loose lines.

If any leaks or loose lines are found, notify unit maintenance.

Also notify unit maintenance about the oil consumption.

5. ENGINE WILL NOT STOP RUNNING.

Make sure key switch is turned off and the engine cutoff has been pulled (para 2-8b).

Shut off fuel shutoff valve (para 3-15) and notify unit maintenance.

WHEELS, TIRES, AND HUBS

1. WHEEL WOBBLES.

Step 1. Check wheel for loose, missing, or broken lug nuts.

Notify unit maintenance to have lug nuts tightened to torque requirements.

Step 2. Check to see if wheel is bent.

If wheel is bent, notify unit maintenance.

TM 5-3825-230-14&P

3-10

TM 5-3825-230-14&P

Table 3-2. Troubleshooting

Malfunction

Test or Inspection

Corrective Action

WHEELS, TIRES, AND HUBS (CONT)

2. TIRE PRESSURE LOW.

Step 1. Check for cuts, gouges, or damage to tire.

Notify unit maintenance to change tire.

Step 2. Check tire valve stem for damage.

Notify unit maintenance to change valve stem. E

ELECTRICAL SYSTEM

NOTE

Refer to Appendix H for electrical schematics, to aid in troubleshooting the electrical system.

1. LIGHTING DOES NOT OPERATE.

Step 1. For panel lights, check to ensure that the key switch is in the on position (para 2-8a).

If lights do not go on, go to step 2.

Step 2. Check to see if sweeper wire harness is properly connected to towing vehicle (para 2-8f).

If wire harness is connected properly, notify unit maintenance.

2. GAGES DO NOT OPERATE.

Check battery connections (para 3-11).

If battery connections are good, notify unit maintenance.

3-11

TM 5-3825-230-14&P

Table 3-2. Troubleshooting

Malfunction

Test or Inspection

Corrective Action

HYDRAULIC SYSTEM

BRUSH OPERATES TOO FAST, TOO SLOW, OR JERKY.

Step 1. Check for low hydraulic fluid level (para 3-13).

If low, notify unit maintenance.

Step 2. Check to see if hydraulic connections and hoses are loose, damaged, or leaking.

If hydraulic connections and hoses are loose, damaged or leaking, notify unit maintenance.

BRAKE SYSTEM

1. HAND BRAKE WILL NOT APPLY.

If brake lever will not operate, notify unit maintenance.

2. HAND BRAKES WILL NOT HOLD.

Adjust hand brakes (para 3-12).

If hand brakes will not hold, notify unit maintenance.

FUEL SYSTEM

ENGINE STARTS AND STOPS.

Step 1. Check for kinks in fuel line.

If line is kinked or clogged, notify unit maintenance.

Step 2. Check to see if the fuel shutoff valve is fully open (para 3-15).

Notify unit maintenance to change filter.

3-12

TM 5-3825-230-14&P

Table 3-2. Troubleshooting

Malfunction

Test or Inspection

Corrective Action

SPRINKLER SYSTEM

FAILS TO SPRAY WHEN SWITCH IS ENGAGED.

Step 1. Check water level.

If tank is empty fill the tank (para 2-8e).

Step 2. Check water strainer.

If strainer is clogged, clean it (para 3-14) and fill tank (para 2-8e). If filter is not clogged

go to step 3.

Step 3. Check for loose connections or kinks at spray bar.

If loose or kinked, notify unit maintenance.

3-13

TM 5-3825-230-14&P

Section III. MAINTENANCE PROCEDURES

3-4. MAINTENANCE INTRODUCTION.

This section covers maintenance tasks authorized at the operator/crew level of maintenance. The tasks provided in this section include maintenance tasks done on a scheduled basis (PMCS).

3-5. LEFT AND RIGHT ACCESS COVERS.

a. Opening. Turn key (1) counterclockwise to release latch and open access cover (2).

b. Removing. Slide access cover (2) off hinges (3).

c. Installing. Slide access cover (2) on hinges (3).

d. Closing. Close cover (2) and turn key clockwise to secure.

3-14

TM 5-3825-230-14&P

3-6. ENGINE OIL CHECK.

NOTE

To obtain a proper oil level reading, shut off engine and allow to sit for five minutes on level ground so oil can settle in oil pan.

a. Open right side access cover (para 3-5).

b. Remove dipstick (1) and check oil level.

c. Install dipstick (1).

d. Close access cover (para 3-5).

e. Notify unit maintenance if oil level is low.

3-15

TM 5-3825-230-14&P

3-7. AIR FILTER INSPECTION.

WARNING

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

a.Removal.

(1)

Shut off engine (para 2-8b) and open left

side access cover (para 3-5).

(2) Remove wingstud (1) and air cleaner assembly (2).

(3) Remove cover (3).

(4) Remove air filter element (4) from air cleaner base (5).

b. Inspection.

(1) Inspect air filter element (4) for tears, damage, or excessive dust build-up.

3-16

3-7. AIR FILTER INSPECTION (CONT).

(2) Visually inspect gasket (6) on bracket (7) for tears or damage.

(3) Notify unit maintenance if any of the above conditions exist.

c. Installation.

(1) Install air filter element (4) in air cleaner base (5).

(2) Install cover (3) on base (5).

(3) Install air cleaner assembly (2) using wingstud (1).

(4)

Close access cover (para 3-5).

3-17

TM 5-3825-230-14&P

3-8. SERVICE FUEL TANK SCREEN/FILL FUEL TANK.

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 (15.24 m) of vehicle.

a. Inspect Fuel Tank Screen.

(1)

Shut off engine (para 2-8b).

(2) Remove filler cap (1) from fuel tank (2).

(3) Inspect fuel tank screen (3) for debris.

b. Clean Fuel Tank Screen.

(1) Remove any debris that can be reached using fingers.

(2) If screen (3) is clogged or debris cannot be reached, install cap (1) and notify unit maintenance.

c. Fill Fuel Tank.

(1)

Shut off engine (para 2-8b).

(2) Remove filler cap (1).

(3) Fill tank. Capacity is 8 gal. (30 1).

(4) Install filler cap (1).

3-18

TM 5-3825-230-14&P

3-9. ALTERNATOR BELT CHECK.

(1)

Stop engine (para 2-8b).

(2)

Open right side access cover (para 3-5)

and inspect belt (1)

(3) Check belt (1) for obvious looseness, cracks, or fraying.

(4) If loose, cracked, or frayed, notify unit maintenance.

(5)

Close right side access cover (para 3-5).

3-19

TM 5-3825-230-14&P

TM 5-3825-230-14&P

3-10. LIGHTS.

Check for obvious signs of damage to lights. Connect power hookups to tow vehicle and test lights while an assistant visually observes to make sure lights are operable. Notify unit maintenance if lights do not work.

3-20

TM 5-3825-230-14&P

3-11. BATTERY SERVICE.

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.

Wear eye protection when performing this procedure.

• Remove rings, bracelets, wristwatches, neck chains, and any other jewelry before working on batteries. Jewelry can catch on equipment and cause injury, or may short across an electrical circuit and cause severe burns or electrical shock.

a. Access to Batteries. Remove holddown strap

(1) and open battery box cover (2).

b. Inspect Battery Terminals. Inspect battery terminals (3). Clean battery with water and a clean cloth. Make certain battery terminal clamps are tight.

c. Cleaning Top of Battery. Clean top of battery and around cell filler holes (4) with water and a clean cloth.

d. Filling Battery Cells.

(1) Remove filler caps (5), and clean vent holes in caps as needed.

(2) Fill battery cell with distilled water to a level of 3/8 in. (9.5 mm) above plates.

Install filler caps (5).

e. Close battery box cover (2) and install holddown strap (1).

3-21

3-12. HAND BRAKES ADJUSTMENT/INSPECTION.

NOTE

• There are two hand brakes, one on each side of the sweeper.

• When applied, hand brakes should hold sweeper in place.

a. Operation. Lift up on hand brake levers (1).

Hand brakes should require firm pressure to lift into "on" (up) position.

b. Adjustment.

(1) Turn adjusting knob (2) clockwise to increase breaking resistance, counterclockwise to decrease breaking resistance.

(2) If hand brakes will not raise to "on" position, or will not stay in "on" position after adjustment, report condition to unit maintenance.

c. Inspection. Inspect hand brakes for loose and missing parts, if found, report condition to unit maintenance.

3-22

TM 5-3825-230-14&P

3-13. HYDRAULIC FLUID CHECK/BLEED HYDRAULIC SYSTEM.

TM 5-3825-230-14&P

a. Fluid Check.

(1) Place vehicle on level ground.

(2)

Bleed hydraulic system (para 3-13b).

(3) Remove dipstick (1) and check the fluid level.

(4) If fluid level is low, notify unit maintenance.

b. Bleed Hydraulic System. Shut off engine and work both control levers (2) for approximately 30 seconds. Bleed the hydraulic system before checking fluid or performing any hydraulic system maintenance.

3-23

3-14. SPRAYER SYSTEM STRAINER SERVICE/WATER DRAINING.

TM 5-3825-230-14&P

a. Prepare Sweeper.

(1)

Set hand brakes (para 2-8a).

(2)

Shut engine off (para 2-8b).

b. Removal.

(1) Remove clear cup (1) and strainer (2).

(2) Open water tank shut off valve (3) and allow water in tank and lines to drain.

c. Cleaning. Clean strainer (2) as required.

d. Installation.

(1) Install strainer (2) and clear cup (1).

(2) Close water tank shut off valve (3).

(3)

Fill water tank (para 2-8e).

(4) Inspect system for leaks, missing parts, and kinked lines.

3-24

TM 5-3825-230-14&P

3-15. FUEL SHUTOFF.

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 (15.24 m) of vehicle.

To safely shutoff the fuel at fuel tank, turn fuel shutoff valve (1) clockwise. Open fuel shut off valve by turning counterclockwise.

3-25/(3-26 blank)

TM 5-3825-230-14&P

CHAPTER 4

UNIT MAINTENANCE INSTRUCTIONS

Para Contents Page

4-1

4-2

4-3

4-4

4-5

Common Tools And Equipment .................................................................................................................4-3

Special Tools, TMDE And Support Equipment...........................................................................................4-3

Repair Parts ..............................................................................................................................................4-3

Service Upon Receipt ................................................................................................................................4-4

Service Upon Receipt From Storage .........................................................................................................4-5

4-6

4-7

4-8

Introduction................................................................................................................................................4-5

PMCS Table ..............................................................................................................................................4-6

Troubleshooting Introduction......................................................................................................................4-9

4-9 Troubleshooting Instructions ......................................................................................................................4-9

4-10 Unit Maintenance Introduction ...................................................................................................................4-16

4-11 Servicing Equipment .................................................................................................................................4-16

4-12 Ground Handling .......................................................................................................................................4-16

4-13 Operational Checks ...................................................................................................................................4-16

4-14 Inspection Of Components ........................................................................................................................4-16

4-15 Unit Cleaning Procedures ..........................................................................................................................4-17

4-16 Removal And Disassembly Of Components ..............................................................................................4-18

4-17 Painting .....................................................................................................................................................4-19

4-18 Lubrication.................................................................................................................................................4-19

4-19 Assembly...................................................................................................................................................4-19

4-20 Installation .................................................................................................................................................4-19

4-21 Adjustment ................................................................................................................................................4-19

4-22 Engine Oil And Filter Change ....................................................................................................................4-22

4-23 Engine Speed Adjustment .........................................................................................................................4-24

4-24 Engine Removal ........................................................................................................................................4-27

4-25 Motor Mounting Bracket Replacement .......................................................................................................4-29

4-26 Engine Shock And Mount Replacement.....................................................................................................4-30

4-27 Angle Bracket Replacement ......................................................................................................................4-31

4-28 Rocker Arm Cover Replacement ...............................................................................................................4-32

4-29 Oil Filter Housing Replacement .................................................................................................................4-33

4-30 Oil Pan Assembly Replacement.................................................................................................................4-34

4-31 Pressure Valve Replacement.....................................................................................................................4-36

4-32 Intake Manifold Replacement ....................................................................................................................4-37

4-33 Alternator Drive Pulley Replacement (Engine) ...........................................................................................4-39

4-34 Hydraulic Pump Drive Assembly Replacement ..........................................................................................4-40

4-35 Fuel Pump Replacement ...........................................................................................................................4-41

4-36 Fuel System Bleeding................................................................................................................................4-43

4-37 Air Cleaner Assembly Replacement...........................................................................................................4-45

4-38 Vapor Separator Replacement...................................................................................................................4-48

4-39 Fuel Strainer Replacement ........................................................................................................................4-50

4-40 Fuel Tank Replacement.............................................................................................................................4-52

4-41 Fuel Tank Shutoff Valve Replacement (Fuel Draining) ..............................................................................4-54

4-42 Fuel Line Replacement (Tank To Pump) ...................................................................................................4-56

4-43 Fuel Line Replacement (Pump To Filter) ...................................................................................................4-58

4-44 Fuel Line Replacement (Filter To Injector Line) .........................................................................................4-60

4-45 Fuel Line Replacement (Injector Pump To Nozzle) ....................................................................................4-62

4-46 Fuel Line Replacement (Bleed Lines) ........................................................................................................4-64

4-1

TM 5-3825-230-14&P

Page Para Contents

4-47 Throttle Control Cable And Engine Cut-Off Cable Replacement ................................................................4-66

4-48 Fuel Filter Replacement ............................................................................................................................4-68

4-49 Fuel Filter Housing Replacement...............................................................................................................4-70

4-50 Glow Plug Replacement ............................................................................................................................4-72

4-51 Muffler Replacement .................................................................................................................................4-74

4-52 Flywheel Guard Replacement....................................................................................................................4-76

4-53 Flywheel Housing Replacement.................................................................................................................4-77

4-54 Heat Deflector Replacement......................................................................................................................4-78

4-55 Noise Shrouds Replacement......................................................................................................................4-79

4-56 Alternator Belt Replacement ......................................................................................................................4-82

4-57 Alternator And Mounting Bracket Replacement/Repair ..............................................................................4-83

4-58 Starter Replacement..................................................................................................................................4-87

4-59 Gage Bulb Replacement............................................................................................................................4-89

4-60 Key Switch Replacement ...........................................................................................................................4-90

4-61 Push Button Replacement .........................................................................................................................4-91

4-62 Ammeter Scale Replacement ....................................................................................................................4-92

4-63 Fuel Gage Replacement............................................................................................................................4-94

4-64 Spray Pump Toggle Switch Replacement ..................................................................................................4-96

4-65 Fuse And Holder Replacement ..................................................................................................................4-97

4-66 Junction Box Replacement/Repair.............................................................................................................4-98

4-67 Circuit Breaker And Resistor Replacement (Junction Box).........................................................................4-101

4-68 Rear Light And Mount Replacement ..........................................................................................................4-102

4-69 Side Lamp Replacement ...........................................................................................................................4-104

4-70 Side Lamp Bracket Replacement (Front) ...................................................................................................4-105

4-71 Center Light And Mount Replacement ......................................................................................................4-107

4-72 Fuel Sending Unit Replacement ................................................................................................................4-108

4-73 Battery Cable Disconnect ..........................................................................................................................4-110

4-74 Battery Replacement .................................................................................................................................4-112

4-75 Battery Box Replacement ..........................................................................................................................4-113

4-76 Tow Vehicle To Junction Box Wire Harness (12V) Replacement/Repair ....................................................4-114

4-77 Tow Vehicle To Junction Box Wire Harness (24V) Replacement/Repair ....................................................4-117

4-78 Broom Hood Wiring Harness/Conduit Replacement/Repair .......................................................................4-120

4-79 Rear Light Wire Harness Replacement ......................................................................................................4-124

4-80 Control Panel Replacement .......................................................................................................................4-127

4-81 Engine And Battery Wire Harness Replacement ........................................................................................4-130

4-82 Fuel And Glow Plug Wire Harness Replacement .......................................................................................4-134

4-83 Terminal/Connector Replacement .............................................................................................................4-138

4-84 Hand Brake Lever Replacement ................................................................................................................4-139

4-85 Brake Assembly Adjustment ......................................................................................................................4-141

4-86 Brake Drum And Hub Replacement/Repair................................................................................................4-142

4-87 Brake Assembly/Modified Spindle Replacement/Repair.............................................................................4-147

4-88 Wheel Replacement ..................................................................................................................................4-152

4-89 Front Hub Assembly Replacement/Repair .................................................................................................4-154

4-90 Tire Replacement ......................................................................................................................................4-157

4-91 Tire Repair ................................................................................................................................................4-158

4-92 Decontamination Bracket Replacement .....................................................................................................4-159

4-93 Transport Chain Assembly Replacement ...................................................................................................4-160

4-94 Swing Frame Replacement........................................................................................................................4-161

4-95 Safety Chain Assembly Replacement ........................................................................................................4-163

4-96 Tow Pole Replacement..............................................................................................................................4-164

4-97 Steering Strut Replacement/Repair............................................................................................................4-165

4-98 Engine Enclosure Replacement .................................................................................................................4-169

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TM 5-3825-230-14&P

Page Para Contents

4-99 Data Plate Replacement............................................................................................................................4-177

4-100 Decal Replacement ...................................................................................................................................4-178

4-101 Hydraulic Pump Assembly Replacement ...................................................................................................4-179

4-102 Hydraulic Motor And Mount Replacement..................................................................................................4-180

4-103 Hydraulic Control Valve Replacement .......................................................................................................4-181

4-104 Breather Replacement...............................................................................................................................4-183

4-105 Hydraulic Hose Assembly Replacement/Repair .........................................................................................4-185

4-106 Hydraulic Oil Drain/Fill...............................................................................................................................4-193

4-107 Hydraulic Filter Replacement.....................................................................................................................4-195

4-108 Hydraulic Filter Housing Replacement .......................................................................................................4-196

4-109 Tachometer Gear Assembly Replacement.................................................................................................4-198

4-110 Tachometer And Tachometer Cable Replacement.....................................................................................4-199

4-111 Broom Pattern Adjustment.........................................................................................................................4-200

4-112 Front Dirt Deflector Assembly Replacement ..............................................................................................4-202

4-113 Side Dirt Deflector Replacement................................................................................................................4-203

4-114 Brush Frame Assembly Replacement ........................................................................................................4-204

4-115 Broom Hood Replacement.........................................................................................................................4-206

4-116 Motor Guard Replacement.........................................................................................................................4-208

4-117 Brush Replacement ...................................................................................................................................4-209

4-118 Hydraulic Core/Brush Set Replacement.....................................................................................................4-211

4-119 Hydraulic Cylinder Replacement................................................................................................................4-213

4-120 Spray Pump And Bracket Replacement .....................................................................................................4-215

4-121 Water Tank Assembly Replacement..........................................................................................................4-218

4-122 Saddle Replacement .................................................................................................................................4-221

4-123 Sprinkler Lines Replacement .....................................................................................................................4-222

4-124 Spray Bar Replacement/Repair .................................................................................................................4-225

4-125 General .....................................................................................................................................................4-228

4-126 Storage Instructions...................................................................................................................................4-228

4-127 Shipping Instructions .................................................................................................................................4-229

Section I. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC

EQUIPMENT, 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.

Refer to Section III of the Maintenance Allocation Chart (MAC) for a list of tool kits authorized for the sweeper.

4-3. REPAIR PARTS.

Repair parts are listed and illustrated in the Repair Parts and Special Tool List, Appendix F covering unit maintenance for

the sweeper.

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TM 5-3825-230-14&P

Section II. SERVICE UPON RECEIPT

4-4. SERVICE UPON RECEIPT.

The sweeper may be shipped or received with the motor guard and hydraulic motor temporarily attached to the main frame rather than the broom head. The hydraulic hoses are connected and bundled with the sprinkler hose. Perform the following to prepare the unit for use.

NOTE

Tie wraps are used only to secure lines and harness for shipping. Quantity of tie wraps used may vary.

(1) Remove tie wraps (1) securing broom motor hydraulic lines (2) to sprinkler line (3).

(2) Remove hydraulic motor and bracket assembly (4) from stowage position on frame (5) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket. Retain hardware for use during installation.

(3) Remove hydraulic motor guard (6) from stowage position on frame (5). Retain hardware for use during installation.

(4) Remove plastic tie wraps which secure wiring harnesses (7 and 8) together.

(5) Connect sprinkler line (3) to spray bar fitting (9) and tighten clamp (10) using a flat tip screwdriver.

(6)

Install hydraulic motor and mount (para 4-102).

(7)

Install hydraulic motor guard (para 4-116).

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TM 5-3825-230-14&P

4-5. SERVICE UPON RECEIPT FROM STORAGE.

If the unit has been received from long term storage, perform the steps in para 4-4 if applicable and change engine oil

and filter (para 4-22) and perform PMCS prior to operating engine.

Section III. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

4-6. INTRODUCTION.

a. PMCS Instructions. The PMCS table is used to prevent equipment failure as well as to detect defects. The following paragraphs explain the use of the PMCS table as well as instructions as to what to look for.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38 o

C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

b. Cleanliness. Dirt, grease, oil and debris only get in the way and may cover up a serious problem. Use dry

cleaning solvent P-D-680 (item 31, Appendix E) on all metal surfaces.

c. Bolts, Nuts and Screws. Check bolts, nuts and screws for obvious looseness, missing, bent, or broken condition.

Look for loose or chipped paint, bare metal, or rust around bolt heads. If any part seems loose, tighten it. If the part is missing, bent or broken, report it to the supervisor.

d. Welds. Look for loose or chipped paint, rust or gaps where parts are welded together. If a bad weld is found, report it.

e. Electrical Wires and Connectors. Look for cracked or broken insulation, bare wires and loose or broken connectors. Tighten loose connectors and make sure the wires are in good shape. If a bad wire or connector is found, report it.

f. Hydraulic Lines and Fittings. Look for wear, damage, leaks and make sure that clamps and fittings are tight.

Wet spots show leaks and a stain around a fitting or connector can mean a leak. If a leak comes from a loose fitting or connector, tighten it. If something is broken or worn out, report it.

g. Unusual Environment. When the sweeper is being used in an unusual environment, extreme heat, cold, wet and dry conditions, PMCS should be performed more often than indicated on the PMCS table.

h. First Use Inspections. When the sweeper is first being put into use or is being used for the first time after a long period of non-use, perform all the PMCS inspections.

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4-6. INTRODUCTION (CONT).

i. Fluid Leakage. It is necessary to know how fluid leakage affects the status of fuel, oil, coolant and the hydraulic systems. The following are definitions of the different types/classes of leakage that determine the status of the sweeper.

CAUTION

Equipment operation is allowable with minor leakage (hydraulic or water, class I or II).

Consideration must be given to the fluid capacity in the item/system being checked/inspected.

When in doubt, notify the supervisor. When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS. Class III leaks should be reported to your supervisor.

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

(2) Class II. Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected.

(3) Class III. Leakage of fluid great enough to form drops that fall from the item being checked/inspected.

4-7. PMCS TABLE.

a. Item Number Column. The checks and services are numbered in chronological order showing a logical sequence around the sweeper.

b. Interval Column. This column contains a dot (.) opposite the appropriate procedure. Thus if a given procedure is performed quarterly, a dot is opposite the procedure in the "Q" column; if the dot is in the "S" column, the procedure should be performed semiannually; and if the procedure is performed in two or more periods, a dot is placed in each applicable column.

c. Item to be Inspected Column. The items listed in this column are divided into groups indicating the portion of the equipment of which they are a part, i.e. fuel, brakes, engine. Under these groupings a few common words are to identify the specific item being checked.

d. Procedures Column. This column contains a brief description of the procedure by which the check is performed.

Refer to table 4-1 for the unit preventive maintenance checks and services for the sweeper.

4-6

10

11

12

3

4

5

6

7

8

9

Item

No.

1

2

TM 5-3825-230-14&P

Table 4-1. Unit Preventive Maintenance Checks and Services

Q - Quarter S - Semiannually A - Annually

Q

Interval

S A

Item to Be

Inspected

ENGINE

ENCLOSURE

Procedure

a. Check for dents, cracks and general damage.

b. Check for missing or loose nuts, screws and washers. Tighten as necessary.

ENGINE

Oil Filter Replace initially at 150 hours of operation and 300 hours of

operation thereafter (para 4-22).

FUEL SYSTEM

Fuel Tank Check for cracks, leaks, missing parts, and dents.

Fittings, Joints Check for cracks, leaks and dents.

and Valves

Fuel Filter Replace on a quarterly basis or after 300 hours of operation

(para 4-48).

HYDRAULIC

SYSTEM

Hydraulic Lines Check lines for leaks, kinks, cracks, dents, and for deteriorated rubber on flexible hoses.

Fittings Check for leaks, kinks, cracks, or dents.

Hydraulic Pump Check for leaks.

Reservoir a. Check reservoir for leaks.

b. Check filler cap for proper seal.

Breather

Controls

Cap should be present and not be cracked or dented. Check filter for

dirt or clogging. Clean per para 4-104.

Check for proper operation.

Hydraulic Filter Replace initially at 150 hours of operation and 300 hours of

operation thereafter (para 4-22).

4-7

14

15

16

17

Item

No.

13

18

19

TM 5-3825-230-14&P

Q

Q - Quarter

Interval

S A

Item to Be

Inspected

S - Semiannually

A - Annually

Procedure

WARNING

If NBC exposure is suspected, all air filter media should be handled by personnel wearing protective equipment.

Consult your unit NBC Officer or NBC NCO for appropriate handling or disposal procedures.

AIR CLEANER

Check for cracks and dents in housing, deteriorated gaskets and deterioration of the filter element. Replace filter quarterly or every

300 hours of operation (para 4-37).

BROOM

ASSEMBLY

Bearings

Broom

Dirt Guards

CONTROLS

AND GAGES

Check bearings for excessive endplay.

Check for missing pieces and excessive wear.

Check dirt guards for tears or missing nuts or screws.

Check gages for operation.

BRAKES

WARNING

Brake linings contain asbestos. Asbestos dust can cause cancer. Avoid breathing dust from brake linings or creating dust while servicing.

Check hand brakes and linkages for proper tension and missing or bent parts.

• MAINFRAME Check mainframe for broken welds, cracks or bent crossmembers.

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TM 5-3825-230-14&P

Section IV. TROUBLESHOOTING

4-8. TROUBLESHOOTING INTRODUCTION.

This section contains step by step procedures for identifying, locating and isolating equipment malfunctions at the unit maintenance level.

4-9. TROUBLESHOOTING INSTRUCTIONS.

Refer to table 4-2 for a list of common malfunctions. The troubleshooting procedures are in table 4-3 and contain tests,

inspections and corrective actions. Before troubleshooting, be sure all preventive maintenance checks and services

(PMCS) have been performed. Perform tests, inspections and corrective actions in the order listed. Try to return the sweeper or component to operation after each test, inspection and corrective action has been performed.

Table 4-2. System Symptom Index

Troubleshooting

Procedure Page

ENGINE

1.

2.

3.

4.

Engine fails to crank.........................................................................................................................

4-10

Engine fails to develop full power/does not run smoothly.................................................. ..........4-10

Engine overheats........................................................................................................................4-11

High oil consumption........................................................................................................................4-11

FUEL SYSTEM

1.

Engine will not start, or stalls.................................................. ....................................................4-12

2.

Fuel level gage does not register, or registers inaccurately............................. ............................4-12

ELECTRICAL SYSTEM

1.

2.

Battery weak or fails to maintain charge........................................ .............................................4-13

One or more lights not working.............................................. .....................................................4-13

SPRINKLER SYSTEM

1.

2.

3.

Failure of spray pump to prime............................................. ......................................................4-14

Spray pump motor fails to turn on....................................... ........................................................4-14

Low sprinkler flow and pressure............................................. .....................................................4-14

HYDRAULIC SYSTEM

1.

2.

Broom or lift does not operate......................................................................................................

Broom motor works but lift does not, or lift works but broom motor does not.............. .................4-15

4-15

4-9

TM 5-3825-230-14&P

Malfunction

Test or Inspection

Corrective Action

Table 4-3. Unit Troubleshooting

ENGINE

1. ENGINE FAILS TO CRANK.

Step 1. Check voltage at right battery for 24 volts.

If voltage is below 24 volts, service battery (para 3-11). Tighten loose battery

cable connections and clean corroded battery connections. Repair or replace any broken connections.

Step 2. Check engine key switch for loose or damaged connections.

Tighten or repair loose or damaged connections (para 4-60).

Step 3. Check starter solenoid wiring and connections for cracks, burns, or looseness.

Tighten loose connections or wiring. Replace damaged wiring and connections

(para 4-81).

Step 4. Check starter for looseness or damaged connections.

Tighten loose connections. Replace starter if damaged (para 4-58).

Step 5. If engine still fails to crank, notify the supervisor.

2. ENGINE FAILS TO DEVELOP FULL POWER/DOES NOT RUN SMOOTHLY.

Step 1. Check throttle position. Engine should run at 2100 RPM with throttle fully open.

Ensure throttle is in correct position.

WARNING

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

Step 2. Check air filter. Replace filter quarterly or every 300 hours of operation.

Change if needed (para 4-37).

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TM 5-3825-230-14&P

Malfunction

Test or Inspection

Corrective Action

ENGINE (CONT)

2. ENGINE FAILS TO DEVELOP FULL POWER/DOES NOT RUN SMOOTHLY

(CONT).

Step 3. Replace fuel filter quarterly or every 300 hours of operation (para 4-48).

Step 4. Inspect fuel lines and connections for leaks or damage.

Tighten or replace lines and connections as necessary (para 4-42 thru 4-46).

Step 5. If problem has not been solved, notify your supervisor.

3. ENGINE OVERHEATS.

Step 1. Inspect cylinder and cylinder head cooling fins for dirt or damage.

Notify direct support to clean cooling fins or repair damage as necessary.

Step 2. If still overheating, notify your supervisor.

4. HIGH OIL CONSUMPTION.

Step 1 Check oil filter, oil lines, engine cover, and oil pan for leaks.

Tighten leaking connections and covers. Tighten or replace oil filter (para 4-22).

Step 2. If high oil consumption continues, notify your supervisor.

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TM 5-3825-230-14&P

Malfunction

Test or Inspection

Corrective Action

1.

2.

FUEL SYSTEM

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 (15.24 m) of vehicle.

ENGINE WILL NOT START, OR STALLS.

Step 1. Check fuel level in tank and if fuel shutoff valve is open.

If tank is empty, check for damage.

If tank is damaged, replace (para 4-40).

If no damage, add fuel and bleed air from system (para 4-36).

Step 2. Check fuel lines for loose connections and fittings.

Tighten loose connections and fittings.

Step 3. Inspect for damaged fuel lines.

Replace damaged fuel lines (para 4-42 thru 4-46).

Step 4. Check fuel filter for damage. Replace quarterly or every 300 hours of operation.

Replace filter if damaged (para 4-48).

Step 5. If engine does not start, notify your supervisor.

FUEL LEVEL GAGE DOES NOT REGISTER, OR REGISTERS INACCURATELY.

Step 1. Check fuel level in tank.

Fill tank if necessary (para 3-8).

Step 2. Inspect fuel gage and sending unit.

Replace component that is malfunctioning (para 4-63 or 4-72).

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TM 5-3825-230-14&P

Table 4-3. Unit Troubleshooting - CONT.

Malfunction

Test or Inspection

Corrective Action

ELECTRICAL SYSTEM

NOTE

Refer to Appendix H for electrical schematics to aid in troubleshooting the electrical system.

1. BATTERY WEAK OR FAILS TO MAINTAIN CHARGE.

Step 1. Attach a multimeter between positive battery terminal of right battery and a good frame ground.

Check that battery produces 24 volts with engine switch on.

If not, service battery (para 3-11).

Step 2. Check for loose, corroded or damaged battery cables and posts.

Repair broken wires or connectors (para 4-83).

Step 3. Check battery cables and alternator wiring for continuity.

Replace or repair broken wires or connectors (para 4-81 or 4-83).

Step 4. Test alternator (para 4-57).

Replace alternator regulator as necessary (para 4-57).

2. ONE OR MORE LIGHTS NOT WORKING.

Step 1. Connect 12V wiring harness to tow vehicle. Make visual check for burned out light bulb.

Replace light bulb (para 4-68, 4-69, or 4-71).

Step 2. Check socket and/or contacts for corrosion.

Step 3. Check for proper ground.

Clean ground connection.

Step 4. Turn light switch on and check for voltage.

If there is voltage, replace defective lamp or bulb.

Step 5. Check wiring for loose connections or broken parts.

Repair or replace wiring or broken parts (para 4-79 or 4-83).

Step 6. If lights still do not work, notify supervisor.

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TM 5-3825-230-14&P

Table 4-3. Unit Troubleshooting - CONT.

Malfunction

Test or Inspection

Corrective Action

SPRINKLER SYSTEM

1. FAILURE OF SPRAY PUMP TO PRIME.

Step 1. Check for restricted intake or discharge lines. Open all lines and valves and check for jammed or clogged lines.

Clean or replace lines (para 4-123) or valves (para 4-124) as necessary.

Step 2. Check for air leak in intake line.

Replace line (para 4-123).

Step 3. Defective pump.

Replace pump or repair as needed; check for ruptured diaphragm, defective check valve,

crack in pump housing, debris in pump head (para 4-120).

2. SPRAY PUMP MOTOR FAILS TO TURN ON.

Step 1. Pump or equipment not plugged in electrically. Check for loose wiring connection.

Replace or repair as needed (para 4-120).

Step 2. Check switch.

Repair or replace as needed (para 4-64).

Step 3. Check motor.

Repair or replace as needed (para 4-120).

3. LOW SPRINKLER FLOW AND PRESSURE.

Step 1. Check for air leak at pump intake.

Tighten fittings or replace lines as needed (para 4-123).

Step 2. Check for dirt or debris inside pump or plumbing.

Clean pump and system (para 4-120 and 4-123).

Step 3. If excessively noisy, check for worn pump bearing.

Replace pump or bearing as necessary (para 4-120).

4-14

TM 5-3825-230-14&P

Table 4-3. Unit Troubleshooting - CONT.

Malfunction

Test or Inspection

Corrective Action

SPRINKLER SYSTEM (CONT)

3. LOW SPRINKLER FLOW AND PRESSURE (CONT).

Step 4. Check for punctured pump diaphragm.

Replace pump or repair diaphragm as necessary (para 4-120).

Step 5. Check for defective pump motor.

Replace as necessary (para 4-120).

Step 6. Check for insufficient voltage to pump.

Troubleshoot battery (see electrical system troubleshooting).

HYDRAULIC SYSTEM

NOTE

Refer to Appendix H for hydraulic schematic to aid in troubleshooting.

1. BROOM OR LIFT DOES NOT OPERATE.

Step 1. Check fluid level in hydraulic reservoir (para 3-13).

If fluid is low identify source of leak and repair.

If unit does not operate with full fluid level replace hydraulic pump (para 4-101).

2. BROOM MOTOR WORKS BUT LIFT DOES NOT, OR LIFT WORKS BUT BROOM MOTOR DOES NOT.

Step 1. Check fluid level in hydraulic reservoir (para 3-13).

If level is ok go to step 2.

If not, fill to operating level and test operation.

Step 2. Switch hydraulic lines at valve and check operation.

If component now operates, replace hydraulic control valve (para 4-103).

If component does not operate, replace component not operating.

4-15

TM 5-3825-230-14&P

Section V. UNIT MAINTENANCE PROCEDURES

4-10. UNIT MAINTENANCE INTRODUCTION.

Instructions in this section provide general procedures to be followed for inspection, removal, cleaning, repair, replacement, or installation of components and testing authorized at the unit level as specified by the Maintenance

Allocation Chart (MAC).

4-11. SERVICING EQUIPMENT.

a. Perform the PMCS contained in table 4-1.

b. Lubricate all points as shown in the lubrication table, Chapter 3, figure 3-1.

c. Schedule the next preventive maintenance checks and services on DD Form 314, Preventive Maintenance

Schedule and Record.

4-12. GROUND HANDLING.

a. Towing Forward. Sweeper must be properly attached to towing vehicle before use. Tow pole must be properly attached to towing pintle of towing vehicle. Safety chains must be properly attached to towing vehicle. The appropriate wiring hookup must be attached to the towing vehicle.

b. Towing Backward. Sweeper must not be towed backwards.

c. Jacking. Jacking of vehicle must be done with wheels blocked and hand brakes set. Select jack points only on the main frame. Jacks will not be used to support vehicle during maintenance procedures. Personnel must be careful to keep body parts out from under sweeper while it is in raised position. Jacks and jackstands must be capable of lifting and/or supporting 3000 lbs (1361 kg).

d. Parking. While parked, sweeper must have hand brakes set and wheels blocked.

e. Mooring. Sweeper can be moored by attaching tiedowns to lifting shackles.

f. Hoisting. Sweeper can be hoisted by attaching lifting devices to lifting shackles on sweeper. Water tank must he drained.

4-13. OPERATIONAL CHECKS.

All operational checks included in the maintenance procedures will include the techniques and methods required to assure the satisfactory performance of the sweeper. Reference the operator's instructions for starting, run-up and shutdown procedures.

4-14. INSPECTION OF COMPONENTS.

a. Examine bearings for rusted or pitted rollers, balls, i aces, or separator. Examine balls and races for abrasion and/or serious discoloration. The following are conditions for bearing rejection.

4-16

TM 5-3825-230-14&P

(1) Cuts or grooves parallel to ball or roller rotation.

NOTE

Nicks and gouges outside race load areas are not cause for rejection unless deep enough to cause bearing binding or misalignment.

(2) Fatigue pits (as opposed to minor machine marks or scratches).

(3) Clean all parts before inspection. Check for defects such as physical distortion, wear, cracks, and pitting.

b. Check all hose surfaces for broken or frayed fabric, breaks caused by sharp kinks, or chafing against other parts of the unit. Inspect metal tubing lines for kinks. Inspect fitting threads for damage. Replace any defective part.

Check for leaks after assembly and during initial operation period.

c. Visually inspect all castings and weldments for cracks.

d. Inspect all wiring for chafed or burned insulation. Inspect all terminal connectors for loose connections and broken parts.

e. Inspect gears and splines for cracks, pitting, and discoloration.

4-15. UNIT CLEANING PROCEDURES.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

a. When cleaning ball or roller bearings, place in a basket and suspend in a container of dry cleaning solvent, P-D-

680 (item 31, Appendix E). If necessary, use a brush (item 6, Appendix E) to remove caked grease or chips. Avoid

rotating bearings before solid particles are removed to prevent damaging races and balls.

b. Do not clean O-rings or other rubber parts in dry cleaning solvent. Wipe with a clean, dry, lint-free cloth.

c. For exterior cleaning of frame and structural components, use detergent (item 17, Appendix E) in a solution as

recommended on the container. Leave application on items surface for approximately 10 minutes before rinsing. Rinse with hot or cold water under pressure. If available, use hot water under 80 to 120 lb (36 to 54 kg) pressure. An ordinary garden hose may be used if no other equipment is available. If pressurized water supply is not available, wash painted

surfaces with a solution of 1/4 cup soap chips (item 7, Appendix E) to one gallon of water.

4-17

TM 5-3825-230-14&P

4-15. UNIT CLEANING PROCEDURES (CONT).

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

d. Electrical parts such as coils, connectors, switches, and insulated wiring, should not be soaked or sprayed with cleaning solutions. Clean these parts with a clean, dry cloth moistened with dry cleaning solvent P-D-680 (item 31,

Appendix E).

CAUTION

Do not use gasoline, diesel fuel, or other petroleum base products to clean or preserve hydraulic components. Use of petroleum based products can change the lubricating quality of hydraulic oil and cause failure or damage to equipment.

e. When cleaning hydraulic system components, use petroleum-free solvents. Clean and dry parts thoroughly to make sure no residue remains. If preservative is required before reassembly, apply a light film of hydraulic fluid (item

19, Appendix E).

4-16. REMOVAL AND DISASSEMBLY OF COMPONENTS.

a. Before removal of any electrical component, disconnect battery ground cables.

b. Ensure that adequate clearance is available for removal of the component. Disassemble the sweeper to the extent necessary to provide adequate working clearance.

WARNING

All personnel must stand clear during lifting operations. A swinging or shifting load may cause injury or death to personnel.

c. Use a chain hoist, jack or other aid when lifting heavier components. Lifting device should be positioned and attached to components to remove all strain from mounting hardware, before last hardware is removed.

d. Discard O-rings, gaskets, seals and similar material when removed. Be sure that all traces of oil, gaskets and sealants are removed. When possible, use wood or plastic probes and scrapers to prevent damage to machined surfaces.

e. Cotter pins, lockwashers, lockwire, self-locking nuts and similar devices should be discarded when removed.

Sell locking fasteners that loosen up must be replaced, not tightened.

4-18

TM 5-3825-230-14&P

f. To prevent moisture and foreign matter from entering open housings, lines, and other openings, use protective coverings as soon as possible after disassembly. Wrap all parts in clean paper or dip parts in preservative oil (item 27,

Appendix E) or equivalent.

g. Remove parts only if repair or replacement is required. Do not disassemble a component any further than necessary to accomplish needed repairs.

4-17. PAINTING.

Instructions for preparation of material to paint, how to paint and material to be used are in TM 43-0139. Instruction for

camouflage painting are contained in FM 5-20. Stenciling and marking military vehicles are listed in TB 43-0209. Data

plate location and description is listed in Chapter 2.

4-18. LUBRICATION.

Refer to Chapter 3 for lubrication procedures and requirements for the sweeper. The instructions include types and

grades of lubricant used, lube points, locations, and frequency of the required lubrication.

4-19. ASSEMBLY.

a. Remove protective grease coatings from new parts before installation.

b. To replace O-rings, first clean groove, then stretch ring into position. A light coating of fluid, which the ring will operate in, will make assembly easier.

c. Coat oil seals evenly with oil (item 25, Appendix E) or grease (item 22, Appendix E) before installing. Install oil

seals with seal lip facing in, applying an even force to the outer edge of seal. If oil seals are to be installed over keyed or splined shafts, use a guide to prevent sharp edges of the keyway or spline from cutting the seal. Guides can be very thin gauge sheet metal shaped to the required diameter. Make certain guide edges are not sharp and are bent slightly inward so they do not cut the seal.

d. Lubricate bearings before reassembly with the type of lubricant normally used in the related housing or container.

This will provide lubrication during the run-in until lubricant from the system can reach the bearings.

4-20. INSTALLATION.

Put hoses, tubes, lines and electrical wiring in place by matching identification tags, markings on equipment, and using

illustrations presented. Replace cable ties (item 36, Appendix E) as necessary. Use sealing compounds as required in

each maintenance task. When installing screws and nuts, be sure to tighten to torque values given. Refer to tables 4-4

and 4-5 for standard and metric torque values. All torques listed are dry torques.

4-21. ADJUSTMENT.

Make changes to equipment pressures, settings and positions only as required in each maintenance task. Adjustments will bring the equipment into proper operating conditions.

4-19

Thread Size

5/8-11

5/8-11

3/4-10

3/4-16

7/8-9

7/8-14

1-8

1-12

1-14

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

9/16-12

9/16-18

TM 5-3825-230-14&P

Table 4-4. U.S. Standard Torque Values.

Minimum Breakaway

Torque Valve

Grade 8.8

U.S.

Metric

100 lb-ft

110 lb-ft

170 Ib-ft

190 lb-ft

165 Ib-ft

180 Ib-ft

250 lb-ft

270 lb-ft

280 lb-ft

5 lb-ft

6 lb-ft

11 lb-ft

13 lb-ft

20 lb-ft

22 lb-ft

30 lb-ft

35 lb-ft

50 lb-ft

55 lb-ft

70 lb-ft

80 lb-ft

7 N•m

8 N•m

15 N•m

18 N•m

27 N•m

30 N•m

41 N•m

48 N•m

68 N•m

75 N•m

95 N•m

109 N•m

136 N•m

149 N•m

231 N•m

258 N•m

224 N•m

244 N•m

339 N•m

366 N•m

380 N•m

Minimum Breakaway

Torque Valve

U.S.

8 lb-ft

10 Ib-ft

17 lb-ft

19 lb-ft

30 lb-ft

35 lb-ft

50 lb-ft

55 lb-ft

75 Ib-ft

85 lb-ft

110 Ib-ft

120 lb-ft

150 lb-ft

170 Ib-ft

270 lb-ft

300 lb-ft

430 lb-ft

475 lb-ft

645 lb-ft

705 lb-ft

720 lb-ft

Grade R10

Metric

Minimum Breakaway

U.S.

11 N•m 12 lb-ft

14 N•m 14 lb-ft

23 N•m 24 lb-ft

26 N•m 27 lb-ft

41 N•m 45 lb-ft

48 N•m 50 lb-ft

68 N•m 70 Ib-ft

75 N•m 80 lb-ft

102 N•m 105 lb-ft

115 N•m 120 lb-ft

149 N•m 155 lb-ft

163 N•m 170 lb-ft

203 N•m 210 lb-ft

230 N•m 240 Ib-ft

366 N•m 375 lb-ft

407 N•m 420 lb-ft

583 N•m 610 lb-ft

642 N•m 670 lb-ft

875 N•m

956 N•m

1376 N•m

910

1000

1015

Torque Valve

Grade 12

Metric

285 N•m

325 N•m

508 N•m

569 N•m

827 N•m

908 N•m

1234 N•m

1356 N•m

1376 N•m

16 N•m

19 N•m

33 N•m

37 N•m

61 N•m

68 N•m

95 N•m

109 N•m

142 N•m

163 N•m

210 N•m

230 N•m

4-20

Thread Size

14 mm

16 mm

18 mm

20 mm

22 mm

24 mm

4 mm

5 mm

6 mm

7 mm

8 mm

9 mm

10 mm

12 mm

TM 5-3825-230-14&P

Minimum Breakaway

Torque Valve

Grade 8.8

U.S.

Metric

100 lb-ft

152 lb-ft

190 lb-ft

265 lb-ft

321 lb-ft

412 lb-ft

3 Ib-ft

5 lb-ft

9 lb-ft

15 lb-ft

22 lb-ft

28 Ib-ft

39 lb-ft

66 lb-ft

Table 4-5. Metric Torque Values

4 N•m

7 N•m

14 N•m

20 N•m

30 N•m

38 N•m

53 N•m

89 N•m

136 N•m

206 N•m

258 N•m

359 N•m

435 N•m

559 N•m

Minimum Breakaway

Torque Valve

U.S.

4 Ib-ft

7 Ib-ft

13 lb-ft

21 lb-ft

31 lb-ft

40 lb-ft

55 lb-ft

93 lb-ft

140 lb-ft

214 lb-ft

268 lb-ft

372 lb-ft

451 lb-ft

578 lb-ft

Grade R10

Metric

Minimum Breakaway

Torque Valve

Grade 12

U.S.

Metric

5 N•m 5 lb-ft

9 N•m 9 Ib-ft

18 N•m 15 lb-ft

28 N•m 25 lb-ft

42 N•m 37 lb-ft

54 N•m 47 lb-ft

75 N•m 66 lb-ft

126 N•m 111 lb-ft

190 N•m 169 lb-ft

290 N•m 256 lb-ft

363 N•m 321 lb-ft

504 N•m 447 lb-ft

611 N•m 542 lb-ft

784 N•m 695 lb-ft

7 N•m

14 N•m

20 N•m

34 N•m

50 N•m

64 N•m

89 N•m

150 N•m

229 N•m

347 N•m

435 N•m

606 N•m

735 N•m

942 N•m

4-21

TM 5-3825-230-14&P

4-22. ENGINE OIL AND FILTER CHANGE

This task covers: a. Drain b. Fill

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Oil filter

Oil, engine, item 25, Appendix E

a. Drain.

WARNING

Use caution when draining hot engine oil or severe injury to personnel may result.

NOTE

• Place a suitable container (2.9

qt, 2.75 1) under engine to catch oil as it drains.

• Drain engine oil while hot to ensure removing all contaminants.

(1) Remove drain plug (1) and washer (2) using a ratchet, extension and 3/4 in. socket.

(2) Allow oil to drain into suitable container. Dispose of oil in accordance with local policy.

(3) Remove oil filter (3) from housing (4) using a filter wrench. Discard filter in accordance with local policy.

(4) If necessary, remove any gasket material from housing (4).

4-22

Equipment Condition

TM or Para

Para 3-5

Para 4-98

Condition Description

Open left and right access covers.

Top access panel removed.

b. Fill.

(1) Install washer (2) and drain plug (1).

Tighten to 66 lb-ft (89 N•m) using a torque wrench, extension and 3/4 in. socket.

(2) Lubricate gasket on oil filter (3) using fresh engine oil.

(3) Install oil filter (3) on housing (4) hand tight, then tighten 1/3 turn using oil filter wrench.

(4) Remove filler cap (5).

(5)

Refer to lubrication chart (Chapter 3) and

fill engine with the proper amount and grade of oil.

(6) Replace filler cap (5).

(7)

Start engine to circulate oil (para 2-8).

Stop engine (para 2-8).

(8) Remove engine oil dipstick (6) and check engine oil level.

(9) Replace dipstick (6).

NOTE

Follow-on Maintenance:

Close left and right access

covers (para 3-5)

• Install top access panel (para 4-

98)

END OF TASK

4-23

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-23. ENGINE SPEED ADJUSTMENT

This task covers: a. Cable Initial Adjustment c. Throttle Adjustment b. Idle Speed Adjustment d. Injection Pump Delivery

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 3-5

Condition Description

Open right access cover.

Materials/Parts

Lockwire

a. Cable Initial Adjustment.

(1) Push throttle cable (1) and engine stop cable (2) in and adjust cable stops (3). Cables should be tight against stop lever (4) and throttle lever (5). All slack must be removed from cables.

WARNING

Hearing protection must be worn when performing adjustments in close proximity to the sweeper. Long term exposure may cause hearing damage.

CAUTION

If engine speed immediately exceeds 2850 RPM shut down engine. Damage to equipment may result.

(2)

Start engine (para 2-8) and let run for five minutes.

4-24

TM 5-3825-230-14&P b. Idle Speed Adjustment.

(1) With engine running, push both cables (1 and 2) all the way in.

(2) Remove lockwire (6) from idle speed adjustment screw (7) and nut (8). Loosen nut

(8) using 10 mm open end wrench.

(3) Turn adjusting screw (7) using 10 mm open end wrench clockwise to increase engine RPM and counterclockwise to decrease engine RPM.

Engine idle should be set to between 1100-1150

RPM.

(4) Shut off engine and tighten nut (8) and replace lockwire (6).

c. Throttle Adjustment.

WARNING

Hearing protection must be worn when performing adjustments in close proximity to the sweeper.

Long term exposure may cause hearing damage.

CAUTION

If engine speed immediately exceeds

2850 RPM shut down engine.

Damage to equipment may result.

(1) With engine running, slowly pull throttle cable

(1) all the way out. Engine speed should be

2850 RPM. If higher, shut down engine immediately. If engine does not reach 2850

RPM, note the reading and shutdown engine.

(2) Remove lockwire (6) and loosen nut (9) slightly.

NOTE

Engine must be shut off for this procedure.

(3) Turn screw (9), using 10 mm open end wrench, 1/4 to 1/2 turn clockwise to reduce RPM and counterclockwise to increase RPM.

(4) Start engine (para 2-8) and check RPM. If not correct, shut off engine; repeat step (3) until RPM of 2850 is

reached.

(5) Shut down engine (para 2-8). Tighten nut (10) using a 10 mm open end wrench and replace lockwire (6).

4-25

TM 5-3825-230-14&P

4-23. ENGINE SPEED ADJUSTMENT (CONT).

CAUTION

Injection pump delivery screw is preset at the factory and must never be adjusted.

d. Injection Pump Delivery. Injection pump delivery screw (11) must never be adjusted. It is set at the factory and is locked with a seal (12) that must not be removed.

NOTE

Follow-on Maintenance: Close right

access cover (para 3-5)

END OF TASK

4-26

TM 5-3825-230-14&P

4-24. ENGINE REMOVAL.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Lifting device and chains

Materials/Parts

Locknuts

a. Removal

(1) Remove four screws (1) and four locknuts

(2) from engine mounts (3) using a ratchet, 15/16 in. socket and 15/16 in.

open end wrench.

WARNING

Engine weighs 203 lbs (92 kg). All personnel must stand clear during lifting operations. A swinging or shifting load may cause serious injury or death to personnel.

(2) Attach a suitable lifting device to angle brackets

(4) and remove engine.

Equipment Condition

TM or Para

Para 4-22

Para 4-98

Para 4-101

Para 4-57

Para 4-47

Para 4-37

Para 4-42

Para 4-81

thru 4-82

Para 4-49

Condition Description

Engine oil drained.

Engine enclosure removed.

Hydraulic pump removed.

Alternator removed.

Throttle and engine cut-off cables disconnected.

Air cleaner removed.

Fuel line disconnected.

Engine wiring tagged and removed.

Fuel filter housing removed.

b. Installation.

(1) Attach a suitable lifting device to engine angle brackets (4) and lower engine into place

(2) Install four screws (1) and four locknuts (2) and tighten to 152 Ib-ft (206 N•m) using a torque wrench, 15/16 in.

socket and 15/16 in. open end wrench.

4-27

4-24. ENGINE REMOVAL (CONT).

NOTE

Follow-on Maintenance:

• Install fuel filter housing (para 4-49)

• Install engine wiring (para 4-81 thru 4-82)

• Connect fuel line (para 4-42)

• Install air cleaner (para 4-37)

• Connect throttle and engine cut-off cables (para 4-47)

• Install alternator (para 4-57)

• Install hydraulic pump (para 4-101)

• Install engine enclosure (para 4-98)

• Replace engine oil (para 4-22)

END OF TASK

4-28

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-25. MOTOR MOUNTING BRACKET REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Equipment Condition

TM or Para

Para 4-24

Condition Description

Engine removed.

NOTE

• Ground lead may be attached to mount. Tag and install lead when installing mount.

• This procedure is the same for all motor mount brackets.

a. Removal. Remove four screws (1), four lockwashers (2) and mounting bracket (3) from crankcase (4) using ratchet and 17 mm socket.

b. Installation. Install mounting bracket (3) on crankcase (4) using four screws (1) and four lockwashers (2).

Tighten using ratchet and 17 mm socket.

NOTE

Follow-on Maintenance: Install engine (para 4-24)

END OF TASK

4-29

TM 5-3825-230-14&P

4-26. ENGINE SHOCK AND MOUNT REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Locknuts

a. Removal.

(1) Remove four locknuts (1), four screws (2) and two engine mounts (3) using a 9/16 in. open end wrench, ratchet and 9/16 in. socket.

(2) Remove eight screws (4), eight nuts (5), eight lockwashers (6) and four shocks (7) from main frame (8) using a screwdriver and 3/8 in. open end wrench.

b. Installation.

(1) Install four shocks (7), using eight screws (4), eight lockwashers (6) and eight nuts (5).

Tighten using a screwdriver and 3/8 in. open end wrench.

Equipment Condition

TM or Para

Para 4-24

Condition Description

Engine removed.

(2) Install engine mounts (3) on mainframe (7) using four screws (2) and four locknuts (1). Tighten using a 9/16 in.

open end wrench, ratchet and 9/16 in. socket.

NOTE

Follow-on maintenance: Install engine (para 4-24)

END OF TASK

4-30

TM 5-3825-230-14&P

4-27. ANGLE BRACKET REPLACEMENT

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Equipment Condition

TM or Para

Para 4-98

Condition Description

Top access panel removed.

a. Removal Remove two screws (1) and two angle brackets (2) from rocker box caps (3) using a 6 mm hex head wrench.

b. Installation. Position two angle brackets (2) on rocker box caps (3) and install using two screws (1). Tighten to

108 lb-in (14 N•m) using a torque wrench and 6 mm hex head socket.

NOTE

Follow-on maintenance: Install top access panel (para 4-98)

END OF TASK

4-31

TM 5-3825-230-14&P

4-28. ROCKER ARM COVER REPLACEMENT.

This task covers: a. Removal

INITIAL SETUP

b. Installation

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Gaskets

Equipment Condition

TM or Para

Para 4-27

Condition Description

Angle brackets removed.

NOTE

• There is only one filler cap.

• This procedure is the same for both rocker arm covers.

a. Removal. Remove two screws (1), two rocker covers (2), two gaskets (3) and filler cap (4) using a 6 mm hex head wrench.

b. Installation. Install two gaskets (3), filler cap (4), two rocker covers (2) and two screws (1) and tighten to 108 lbin (14 N•m) using a torque wrench and 6 mm hex head socket.

NOTE

Follow-on maintenance: Install angle brackets (para 4-27)

END OF TASK

4-32

TM 5-3825-230-14&P

4-29. OIL FILTER HOUSING REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power Para 4-98

Materials/Parts

Gasket

Equipment Condition

TM or Para

Para 4-22

Para 4-75

Condition Description

Oil filter removed.

Left side battery box removed.

Engine enclosure removed.

a. Removal Remove four screws (1), housing (2), and gasket (3) from crankcase (4) using a 5 mm hex head wrench.

b. Installation. Install gasket (3) and housing (2) on crankcase (4) using four screws (1). Tighten to 60 lb-in (7

N•m) using a torque wrench and 5 mm hex head socket.

NOTE

Follow-on maintenance:

Install engine enclosure (para 4-98)

Install left side battery box (para 4-75)

Install oil filter (para 4-22)

END OF TASK

4-33

TM 5-3825-230-14&P

4-30. OIL PAN ASSEMBLY REPLACEMENT.

This task covers: a. Removal c. Installation

INITIAL SETUP

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Gasket

Copper Washers

a. Removal

Equipment Condition

TM or Para

Para 4-24

Condition Description

Engine removed and laying on right side.

(1) Remove 14 screws (1) and 14 washers (2) using a ratchet and 13 mm socket.

(2) Remove oil pan (3) and gasket (4).

(3) Remove two oil drain plugs (5) and two copper washers (6) using a ratchet and 19 mm socket.

(4) Remove setscrew (7) using a 5 mm hex head wrench.

4-34

(5) Remove screw (8), washer (9), and filter panel (10) using a 10 mm open end wrench.

b. Cleaning/Inspection. Clean out reservoir under filter panel (10), and filter panel with a clean cloth.

c. Installation.

(1) Install filter panel (10), washer (9), and screw (8) using a 10 mm open end wrench.

(2) Position gasket (4) on oil pan (3).

(3) Carefully position oil pan (3) on crankcase (11) using locking needle (12) as a guide.

(4) Install oil pan (3), 14 screws (1), and 14 washers

(2). Tighten to 22 lb-ft (30 N•m) using a torque wrench and 13 mm socket.

(5) Install setscrew (7) using a 5 mm hex head wrench.

(6) Install two oil drain plugs (5) and two copper washers (6). Tighten plugs to 22 lb-ft (30 N•m) using a torque wrench and 3/4 in. socket.

NOTE

Follow-on maintenance: Install engine

(para 4-24)

END OF TASK

4-35

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-31. PRESSURE VALVE REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power removed.

Materials/Parts

Copper gasket

Equipment Condition

TM or Para

Para 4-29

Condition Description

Oil filter housing

a. Removal. Remove cap (1), copper gasket (2), spring (3), and pressure valve (4) from oil filter housing (5) using a 14 mm open end wrench.

b. Installation. Install pressure valve (4), spring (3), copper gasket (2), and cap (1) in oil filter housing (5) using a

14 mm open end wrench.

NOTE

Follow-on maintenance: Install oil filter housing (para 4-29)

END OF TASK

4-36

TM 5-3825-230-14&P

4-32. INTAKE MANIFOLD REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Para 4-38

Materials/Parts

Gasket

Lockwashers

a. Removal

Equipment Condition

TM or Para

Para 4-50

Para 4-51

Condition Description

Glow plugs removed.

Muffler removed.

Vapor separator fitting removed

.

General Safety Instructions

Muffler and manifold cooled completely.

WARNING

Make sure that manifold has cooled before starting work or injury to personnel may result.

(1) Loosen clamp (1) using a flat tip screwdriver. Disconnect hose (2) from manifold (3).

(2) Remove four nuts (4), four lockwashers (5), manifold (3), and two gaskets (6) from studs (7) using a ratchet, extension and 13 mm socket.

(3) Loosen clamp (8) and remove rubber cap (9) using a flat tip screwdriver.

4-37

4-32. INTAKE MANIFOLD REPLACEMENT (CONT).

TM 5-3825-230-14&P b. Installation.

(1) Position gaskets (6) and manifold (3) on studs (7), and install four lockwashers (5) and four nuts (4). Tighten nuts to 22 Ib-ft (30 N•m) using a torque wrench, extension and 13 mm socket.

(2) Position clamp (1) loosely on hose (2) and install hose on manifold (3). Tighten clamp using a flat tip screwdriver.

(3) Position clamp (8) loosely on rubber cap (9) and install cap on manifold (3). Tighten clamp using a flat tip screwdriver.

NOTE

Follow-on maintenance:

Install glow plugs (para 4-50)

Install muffler (para 4-51)

Install vapor separator fitting (para 4-38)

END OF TASK

4-38

TM 5-3825-230-14&P

4-33. ALTERNATOR DRIVE PULLEY REPLACEMENT (ENGINE).

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Equipment Condition

TM or Para

Para 4-121

Para 4-98

Para 4-56

Condition Description

Water tank removed.

Rear panel removed.

Alternator belt removed.

NOTE

It may be necessary to hold flywheel screw with a ratchet and 24 mm socket to prevent it from turning.

a. Removal Remove six screws (1), six lockwashers (2), and alternator drive pulley (3) using a ratchet, extension and 13 mm socket.

b. Installation. Install alternator drive pulley (3), six screws (1), and six lockwashers (2). Tighten using a ratchet, extension and 13 mm socket.

NOTE

Follow-on maintenance:

Install alternator belt (para 4-56)

Install rear panel (para 4-98)

Install water tank (para 4-121)

END OF TASK

4-39

TM 5-3825-230-14&P

4-34. HYDRAULIC PUMP DRIVE ASSEMBLY REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Equipment Condition

TM or Para

Para 4-101

Condition Description

Hydraulic pump removed.

a. Removal

(1) Remove six nuts (1), six lockwashers (2), and hydraulic pump support (3) using a 13 mm open end wrench.

(2) Remove nine tooth coupling (4) and coupling (5).

(3) Remove four screws (6), four lockwashers (7), and half coupling (8) using a 6 mm hex head wrench.

b. Installation.

(1) Install half coupling (8), four lockwashers (7), and four screws (6) using a 6 mm hex head wrench.

(2) Install coupling (5) and nine tooth coupling (4).

(3) Install hydraulic pump support (3), six lockwashers (2), and six nuts (1) using a 13 mm open end wrench.

NOTE

Follow-on maintenance: Install hydraulic pump (para 4-101)

END OF TASK

4-40

TM 5-3825-230-14&P

4-35. FUEL PUMP REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Gasket

Lockwashers

Copper washers

Equipment Condition

TM or Para

Para 4-43

Condition Description

Disconnect fuel line

(pump to filter)

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 (15.24 m) of vehicle.

NOTE

Remove left nut first to aid in removal.

(1) Remove two nuts (1), two lockwashers (2), and fuel pump (3) using a ratchet, extension and 12 mm socket.

4-41

TM 5-3825-230-14&P

4-35. FUEL PUMP REPLACEMENT (CONT).

(2) Remove gasket (4) from fuel pump (3) and remove pin (5). Make sure all pieces of gasket are removed.

(3) Loosen clamp (6) and remove hose (7) from barbed fitting (8) using a flat tip screwdriver.

(4) Remove connecting bolt (9), copper washer (10), barbed fitting (8), and copper washer (11) from fuel pump (3) using a 19 mm open end wrench.

b. Installation.

NOTE

For ease of installation, install left nut first.

(1) Install pin (5), gasket (4), fuel pump (3), two lockwashers (2), and two nuts (1). Tighten nuts to 22 lb-ft (30 N•m) using a torque wrench, extension and 12 mm socket.

(2) Install copper washer (11), barbed fitting (8), copper washer (10), and connecting bolt (9) on fuel pump (3) using a 19 mm open end wrench.

(3) Position clamp (6) loosely on hose (7).

(4) Install hose (7) on barbed fitting (8). Tighten clamp (6) using a flat tip screwdriver.

NOTE

Follow-on maintenance: Connect fuel line (pump to filter) (para 4-43)

END OF TASK

4-42

TM 5-3825-230-14&P

4-36. FUEL SYSTEM BLEEDING.

This task covers:

System Bleeding

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 2-8

Para 3-5

Condition Description

Engine shut off.

Right side access cover opened.

Text begins on next page.

4-43

4-36. FUEL SYSTEM BLEEDING (CONT).

TM 5-3825-230-14&P

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 (15.24 m) of vehicle.

NOTE

After changing fuel filter or performing maintenance on fuel system, fuel system should be bled to remove air.

System Bleeding

(1) Loosen deaeration plug (1) using a flat tip screwdriver.

(2) Prime fuel system using lever (2) until fuel flows out of deaeration plug (1) hole.

(3) Tighten deaeration plug (1) using a flat tip screwdriver. Wipe off any spilled fuel.

NOTE

Follow-on maintenance: Close right side access cover (para 3-5) and check for any fuel leaks

END OF TASK

4-44

TM 5-3825-230-14&P

4-37. AIR CLEANER ASSEMBLY REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Gasket

Hose (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 3-5

Condition Description

Left and right side access covers opened.

WARNING

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

a. Removal.

(1) Remove wingstud (1) and air cleaner assembly (2).

4-45

TM 5-3825-230-14&P

4-37. AIR CLEANER ASSEMBLY REPLACEMENT (CONT).

(2) Remove cover (3).

(3) Remove air filter element (4) from air cleaner base (5).

(4) If damaged, loosen clamp (6) and remove flutter valve (7) using a flat tip screwdriver.

(5) Remove gasket (8) from bracket (9).

(6) Loosen two clamps (10) and remove hose

(11) using a flat tip screwdriver.

(7) Remove two locknuts (12), two screws

(13), two washers (14), and bracket (9) using a 9/16 in. open end wrench, ratchet and 9/16 in. socket.

b. Installation.

(1) Position bracket (9) and install two washers (14), two screws (13), and two locknuts (12). Tighten using a

9/16 in. open end wrench, ratchet and 9/16 in. socket.

(2) Install hose (11) and tighten clamps (10) using a flat tip screwdriver.

(3) Install gasket (8) on bracket (9).

(4) If removed, install flutter valve (7) and tighten clamp (6) using a flat tip screwdriver.

(5) Install air filter element (4) in air cleaner base (5).

(6) Install cover (3) on base (5).

4-46

(7) Install air cleaner assembly (2) using wingstud (1).

NOTE

Follow-on maintenance: Close left

and right side access covers (para 3-

5)

END OF TASK

4-47

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-38. VAPOR SEPARATOR REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Copper washer

Equipment Condition

TM or Para

Para 4-98

Para 3-5

Condition Description

Top access panel removed.

Right side access cover opened.

WARNING

Be sure engine is cool before starting this procedure. Injury to personnel may result.

a. Removal.

(1) Remove fitting (1) and copper washer (2) from intake manifold (3) using a 19 mm open end wrench.

4-48

TM 5-3825-230-14&P

(2) Remove hose (4) from vapor separator (5), and fitting (1).

(3) Remove vapor separator (5) and copper washer (6) from crankcase (7) using a 17 mm open end wrench.

b. Installation.

(1) Install copper washer (6) and vapor separator (5) in crankcase (7) using a 17 mm open end wrench.

(2) Install copper washer (2) and fitting (1) on intake manifold (3) using a 19 mm open end wrench.

(3) Install hose (4) on fitting (1) and vapor separator (5).

NOTE

Follow-on maintenance:

• Install top access panel (para 4-98)

• Close right side access cover (para 3-5)

END OF TASK

4-49

4-39. FUEL STRAINER REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Gasket

TM 5-3825-230-14&P

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 (15.24 m) of vehicle.

(1) Remove fuel cap (1).

(2) Remove six screws (2), bracket (3), gasket (4), strainer (5), and gasket (6) using a flat tip screwdriver.

4-50

TM 5-3825-230-14&P

b. Installation.

(1) Install gasket (6), strainer (5), gasket (4), bracket (3), and six screws (2) using a flat tip screwdriver.

(2) Install fuel cap (1).

END OF TASK

4-51

TM 5-3825-230-14&P

4-40. FUEL TANK REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Locknut

Compound, sealing, pipe thread, item 16

Appendix E

Equipment Condition

TM or Para

Para 4-41

Para 4-98

Para 4-72

Para 4-39

Condition Description

Fuel shutoff valve removed.

Engine enclosure removed.

Fuel sending unit removed.

Fuel strainer removed.

4-52

TM 5-3825-230-14&P

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 (15.24 m) of vehicle.

(1) Loosen clamp (1) using a flat tip screwdriver. Disconnect fuel hose (2) and remove elbow (3) and reducer fitting (4) using a 5/8 open end wrench.

(2) Remove four screws (5), four nuts (6), and four lockwashers (7) using a ratchet, 9/16 in. socket and 9/16 in. open end wrench.

(3) Remove screw (8), two washers (9), and locknut (10) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(4) Remove fuel tank (11).

b. Installation.

(1) Position fuel tank (11). and install four screws (5), four nuts (6), and four lockwashers (7). Tighten using a ratchet, 9/16 in. socket and 9/16 in. open end wrench.

(2) Install two washers (9), screw (8), and locknut (10) using a 7/16 open end wrench, ratchet and 7/16 in.

socket.

(3) Install reducer fitting (4) and elbow (3) using a 5/8 in. open end wrench.

(4) Position clamp (1) on fuel hose (2) and install hose on fitting (3) using a flat tip screwdriver.

NOTE

Follow-on maintenance:

• Install fuel strainer (para 4-39)

• Install fuel sending unit (para 4-72)

• Install fuel shutoff valve (para 4-41)

• Install engine enclosure (para 4-98)

• Bleed fuel system (para 4-36)

END OF TASK

4-53

TM 5-3825-230-14&P

4-41. FUEL TANK SHUTOFF VALVE REPLACEMENT (FUEL DRAINING).

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Compound, locking, thread item 14 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 (15.24 m) of vehicle.

(1) Place a suitable container (8 gal, 301) under valve (1).

(2) Shut off fuel valve (1) by turning clockwise.

(3) Loosen clamp (2) and remove hose (3) using a flat tip screwdriver. Allow fuel to drain from hose.

(4) Open fuel valve (1) and allow fuel to drain from tank (4).

(5) Remove valve (1) from tank (4) using a 11 mm open end wrench.

4-54

TM 5-3825-230-14&P

b. Installation.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Apply thread locking compound to threads of valve (1).

(2) Install valve (1) in tank (4) using a 11 mm open end wrench.

(3) Position clamp (2) on hose (3).

(4) Install hose (3) on valve (1) and tighten clamp (2) using a flat tip screwdriver.

(5)

Fill fuel tank (para 3-8).

(6) Check for leaks.

END OF TASK

4-55

TM 5-3825-230-14&P

4-42. FUEL LINE REPLACEMENT (TANK TO PUMP).

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Fuel hose (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 3-15

Para 3-5

Condition Description

Fuel valve shut off.

Right side access cover opened.

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 (15.24 m) of vehicle.

(1) Loosen clamp (1) and disconnect fuel line (2) from fuel shutoff valve (3) using a flat tip screwdriver.

(2) Loosen clamp (4) and remove fuel line (2) from barbed fitting (5).

4-56

TM 5-3825-230-14&P

b. Installation.

(1) Position clamp (4) on fuel line (2).

(2) Install fuel line (2) on barbed fitting (5). Tighten clamp (4) using a flat tip screwdriver.

(3) Position clamp (1) on fuel line (2).

(4) Install fuel line (2) on fuel shutoff valve (3). Tighten clamp (1) using a flat tip screwdriver.

NOTE

Follow-on maintenance:

• Open fuel shutoff valve (para 3-15)

• Bleed fuel system (para 4-36)

END OF TASK

4-57

TM 5-3825-230-14&P

4-43. FUEL LINE REPLACEMENT (PUMP TO FILTER).

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Copper washers

Equipment Condition

TM or Para

Para 3-15

Para 3-5

Condition Description

Fuel valve shut off.

Right side access cover opened.

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 (15.24.m) of vehicle.

1) Remove connecting bolt (1), copper washer (2), barbed fitting (3), copper washer (4), and fuel line (5) from fuel pump (6) using a 14 mm open end wrench.

4-58

TM 5-3825-230-14&P

(2) Remove connecting bolt (7), copper washer (8), barbed fitting (9), copper washer (10), and fuel line (5) from fuel filter housing (11) using a 19 mm open end wrench.

b. Installation.

(1) Install copper washer (2), barbed fitting (3), fuel line (5), copper washer (4), and connecting bolt (1) to fuel pump (6). Tighten using a 14 mm open end wrench.

(2) Install copper washer (8), barbed fitting (9), fuel line (5), copper washer (10), and connecting bolt (7) to fuel filter housing (11). Tighten using a 19 mm open end wrench.

NOTE

Follow-on maintenance:

• fuel valve (para 3-15)

• fuel system (para 4-36)

END OF TASK

4-59

TM 5-3825-230-14&P

4-44. FUEL REPLACEMENT (FILTER TO INJECTOR LINE).

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Copper washers

Plastic washer

Equipment Condition

TM or Para

Para 3-15

Para 3-5

Condition Description

Fuel valve shut off.

Right side access cover opened.

4-60

TM 5-3825-230-14&P

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 (15.24 m) of vehicle.

(1) Remove connecting bolt (1), copper washer (2), barbed fitting (3), copper washer (4), and fuel line (5) from fuel filter housing (6) using a 19 mm open end wrench.

(2) Remove connecting bolt (7), copper washer (8), deaeration plug (9), plastic washer (10), barbed fitting

(11), copper washer (12), and fuel line (5) from injector pump (13) using a 17 mm open end wrench and flat tip screwdriver.

(3) Remove clamp (14) and hose (15) using pliers.

b. Installation.

(1) Install copper washer (4), barbed fitting (3), fuel line (5), copper washer (2), and connecting bolt (1) to fuel filter housing (6). Tighten using a 19 mm open end wrench.

(2) Install copper washer (12), barbed fitting (11), fuel line (5), plastic washer (10), deaeration plug (9), copper washer (8), and connecting bolt (7) to injector pump (13). Tighten using a 17 mm open end wrench and flat tip screwdriver.

(3) Install clamp (14) and hose (15) using a crimper.

NOTE

Follow-on maintenance:

• Fuel valve opened (para 3-15)

• Bleed fuel system (para 4-36)

END OF TASK

4-61

TM 5-3825-230-14&P

4-45. FUEL LINE REPLACEMENT (INJECTOR PUMP TO NOZZLE).

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Tags, identification, item 35 Appendix E

Equipment Condition

TM or Para

Para 4-98

Para 4-46

Condition Description

Top access panel removed.

Fuel lines (bleed lines) removed.

NOTE

Both lines are removed and installed the same way.

4-62

TM 5-3825-230-14&P

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 (15.24 m) of vehicle.

NOTE

Tag fuel lines before removal to aid in installation.

a. Removal

(1) Tag and remove two fuel lines (1) from injector pump (2) using a 17 mm and 19 mm open end wrenches.

(2) Remove two fuel lines (1) from injectors (3) using a 17 mm and 19 mm open end wrenches.

(3) Remove two screws (4) and clamps (5) using a ratchet and 8 mm socket and remove two fuel lines (1) from sweeper.

b. Installation.

(1) Install two fuel lines (1) on injector pump (2) using a 17 mm and 19 mm open end wrenches.

(2) Install two fuel lines (1) on injectors (3) using a 17 mm and 19 mm open end wrenches.

(3) Install two screws (4) and clamps (5) using a ratchet and 8 mm socket.

NOTE

Follow-on maintenance:

• Install bleed lines (para 4-46)

• Bleed fuel system (para 4-36)

• Install top access panel (para 4-98)

END OF TASK

4-63

TM 5-3825-230-14&P

4-46. FUEL LINE REPLACEMENT (BLEED LINES).

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Copper washers

Washer Para 4-98

Loop clamp

Fuel hose (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 3-15

Para 3-5

Condition Description

Fuel valve shut off.

Left and right side access covers opened.

Top access panel removed.

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 (15.24 m) of vehicle.

(1) Remove connecting bolt (1), copper washer (2), deaeration valve (3), washer (4), copper washer (5), barbed fitting (6), bleed line (7), and clamp (8) using a 17 mm open end wrench and flat tip screwdriver.

4-64

(2) Remove two connecting bolts (9), four copper washers (10), two barbed fittings

(11), and bleed line (12) from injector assemblies (13) using a 12 mm open end wrench.

(3) Remove screw (14) and wire clamp (15) using a cross tip screwdriver.

b. Installation.

(1) Install copper washer (5), barbed fitting

(6), washer (4), deaeration plug (3), copper washer (2), and connecting bolt

(1). Tighten with 17 mm open end wrench and flat tip screwdriver.

(2) Install clamp (8) on bleed line (7).

(3) Install bleed line (7) on barbed fitting (6), and crimp clamp (8) using crimpers.

(4) Install two copper washers (10), two barbed fittings (11), two copper washers

(10), bleed line (12), and two connecting bolts (9) on injector assemblies (13).

Tighten using a 12 mm open end wrench.

(5) Install screw (14) and wire clamp (15) using a cross tip screwdriver.

NOTE

Follow-on maintenance:

• Fuel valve opened (para 3-15)

• Bleed fuel system (para 4-36)

• Top access panel installed (para 4-98)

• Left and right side access covers

closed (para 3-5)

END OF TASK

4-65

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-47. THROTTLE CONTROL CABLE AND ENGINE CUT-OFF CABLE REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 3-5

Materials/Parts

Tags, identification, item 35 Appendix E

Para 4-98

Condition Description

Left and right access covers removed.

Top access panel removed.

NOTE

Tag cables prior to removal to aid in installation.

a. Removal

(1) Tag throttle cable (1).

(2) Loosen screw (2) using a flat tip screwdriver and remove cable lock (3).

4-66

TM 5-3825-230-14&P

(3) Remove nut (4), screw (5), and throttle cable (1) from throttle assembly (6) using a 12 mm and 13 mm open end wrenches.

(4) Remove screw (7), handle (8), two nuts (9), and washer (10) using a cross tip screwdriver and 7/8 in. open end wrench.

(5) Pull throttle cable (1) out of engine cowling (11) (to inside).

(6) Tag engine cut-off cable (12).

(7) Remove handle (13) and nut (14) using a 3/8 in. open end wrench.

(8) Remove two nuts (15) using a 1/2 in. open end wrench.

(9) Loosen screw (16) using a flat tip screwdriver and remove cable lock (17).

(10) Remove nut (18), screw (19), and engine cut-off cable (12) from throttle assembly (6) using a 12 mm and

13 mm open end wrenches.

(11) Pull engine cut-off cable (12) out of engine cowling (11).

b. Installation.

(1) Install engine cut-off cable (12), screw (19), and nut (18) on throttle assembly (6) using a 12 mm and 13 mm open end wrenches.

(2) Install cable lock (17) on engine cut-off cable (12) and tighten screw (16) using a flat tip screwdriver.

(3) Install engine cut-off cable (12) and two nuts (15) in engine cowling (11). Tighten nuts using a 1/2 in. open end wrench.

(4) Install handle (13) and nut (14). Tighten nut using a 3/8 in. open end wrench.

(5) Install throttle cable (1), screw (5), and nut (4) on throttle assembly (6) using a 12 mm and 13 mm open end wrenches.

(6) Install cable lock (3) on throttle cable (1) and tighten screw (2) using a flat tip screwdriver.

(7) Install throttle cable (1), washer (10), two nuts (9), handle (8), and screw (7). Tighten using a 7/8 in. open end wrench.

NOTE

Follow-on maintenance:

• Adjust engine speed (para 4-23)

• Install top access panel (para 4-98)

• Install left and right access covers (para 3-5)

END OF TASK

4-67

TM 5-3825-230-14&P

4-48. FUEL FILTER REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive

TM or Para

Para 3-15

Shop Equipment, Automotive Maintenance and

Para 3-5

Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Fuel filter Gasket

Condition Description

Fuel valve shut off.

Open right side access Repair; cover.

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 (15.24 m) of vehicle.

a. Removal. Remove filter (1) and gasket (2) from housing (3) using a filter wrench.

4-68

TM 5-3825-230-14&P

CAUTION

Do not over-tighten fuel filter. Damage to equipment may result.

b. Installation. Coat gasket (2) and filter (1) with diesel fuel and install gasket and filter on housing (3). Tighten until gasket seats and then an additional 1/4 turn.

NOTE

Follow-on maintenance:

• · Fuel valve opened (para 3-15)

• · Bleed fuel system (para 4-36)

END OF TASK

4-69

TM 5-3825-230-14&P

4-49. FUEL FILTER HOUSING REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Copper washers

Lockwashers

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common Equipment Condition

No. 1, Less Power TM or Para Condition

Para 4-48

Description

Fuel filter removed.

4-70

TM 5-3825-230-14&P

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 (15.24 m) of vehicle.

(1) Remove connecting bolt (1), copper washer (2), fuel filter-to-injector pump line (3), and copper washer (4) from housing (5) using a 19 mm open end wrench.

(2) Remove connecting bolt (6), copper washer (7), pump-to-filter line (8), and copper washer (9) from housing

(5) using a 19 mm open end wrench.

(3) Remove two screws (10), two nuts (11), and two lockwashers (12) using two 17 mm open end wrenches.

(4) Remove housing (5) from mounting bracket (13).

(5) Remove two screws (14), two lockwashers (15), and mounting bracket (13) using a 17 mm open end wrench.

(6)

Do not remove bleed screw (16). Bleeding the fuel system is accomplished in para 4-36.

b. Installation.

(1) Install bracket (13), two lockwashers (15), and two screws (14). Tighten screws 39 lb-ft (53 N•m) using a torque wrench, extension and 17 mm socket.

(2) Install housing (5), two screws (10), two lockwashers (12), and two nuts (11). Tighten screws 39 lb-ft (53

N•m) using a torque wrench, 17 mm socket and 17 mm open end wrench.

(3) Install copper washer (9), pump-to-filter line (8), copper washer (7), and connecting bolt (6) on housing (5) using a 19 mm open end wrench.

(4) Install copper washer (4), filter-to-injector pump line (3), copper washer (2), and connecting bolt (1) on housing (5) using a 19 mm open end wrench.

NOTE

Follow-on maintenance: Fuel filter installed (para 4-48)

END OF TASK

4-71

TM 5-3825-230-14&P

4-50. GLOW PLUG REPLACEMENT.

This task covers: a. Removal b. Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Compound, locking, thread item 14 Appendix E

Tags, identification, item 35 Appendix E

Equipment Condition

TM or Para

Para 4-98

Para 4-73

Condition Description

Top access panel removed.

Battery cables disconnected.

4-72

TM 5-3825-230-14&P

WARNING

Be sure engine is cool before starting this procedure or injury to personnel may result.

a.

Removal.

NOTE

Tag all wires before removal to aid installation.

(1) Remove nut (1), lockwasher (2), and tag and remove wire (3) from glow plug (4) using a 5/16 in. open end wrench.

(2) Remove nut (5), lockwasher (6), wire (3) and tag and remove wire (7) from glow plug (8) using a 5/16 in. open end wrench.

(3) Remove glow plugs (4 and 8) from intake manifold (9) using a 1 in. box end wrench.

(4) Remove washers (10) from glow plugs (4 and 8).

b.

Installation.

(1) Install washers (10) on glow plugs (4 and 8).

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(2) Apply thin coat of thread locking compound to glow plugs (4 and 8) threads.

(3) Install glow plugs (4 and 8) in intake manifold (9) using a 1 in. box end wrench.

(4) Refer to tags and install wires (3 and 7), lockwasher (6), and nut (5) on glow plug (8) using a 5/16 in. Open end wrench.

(5) Refer to tags and install wire (3), lockwasher (2), and nut (1) on glow plug (4) using a 5/16 in. open end wrench.

NOTE

Follow-on Maintenance:

Install top access panel (para 4-98)

Connect battery cables (para 4-73)

END OF TASK

4-73

TM 5-3825-230-14&P

4-51.

MUFFLER REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No.1, Less Power

Materials/Parts

Gasket

Equipment Condition

TM or Para

Para 4-98

Para 3-5

Condition Description

Top access panel removed.

Right side access cover opened.

a.

Removal.

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.

(1) Loosen clamp (1) using a 1/2 in. open end wrench. Remove pipe (2) from muffler (3).

(2) Remove four nuts (4) and muffler (3) from engine (5) using a 12 mm open end wrench.

NOTE

Make sure all old gasket material is removed from engine.

(3) Remove two gaskets (6) from engine (5), muffler (3), and studs (7).

4-74

TM 5-3825-230-14&P

(4) If damaged, remove four studs (7) using pliers.

(5) Remove rain cap (8) from pipe (2) by loosening nut (9) using a 7/16 in. open end wrench.

b.

Installation.

(1) If removed, install four studs (7) using pliers.

(2) Position gasket (6) on studs (7) and install muffler (3) and four nuts (4). Tighten nuts to 22 Ib-ft (30 N•m) using a torque wrench and 12 mm socket.

(3) Position clamp (1) on pipe (2).

(4) Install pipe (2) on muffler (3). Tighten clamp (1) using a 1/2 in. open end wrench.

(5) Install rain cap (8) on pipe (2) and tighten nut (9) using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance:

Install top access panel (para 4-98)

Close right side access cover (para 3-5)

END OF TASK

4-75

TM 5-3825-230-14&P

4-52.

FLYWHEEL GUARD REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive

Para 4-33

a.

b.

Removal. Remove four screws (1) and flywheel guard (2) using a cross tip screwdriver.

Installation. Install flywheel guard (2) and four screws (1) using a cross tip screwdriver.

NOTE

Follow-on maintenance: Install

alternator drive pulley (para 4-33)

END OF TASK

TM or Para

Alternator drive pulley removed.

Condition Description

4-76

TM 5-3825-230-14&P

4-53.

FLYWHEEL HOUSING REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive

Para 4-52

a.

Removal Remove seven screws (1) and flywheel housing (2) using a cross tip screwdriver.

b.

Installation. Install flywheel housing (2) and seven screws (1) using a cross tip screwdriver.

NOTE

Follow-on maintenance: Install

flywheel guard (para 4-52)

END OF TASK

TM or Para

Flywheel guard removed.

Condition Description

4-77

TM 5-3825-230-14&P

4-54.

HEAT DEFLECTOR REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 4-98

Para 4-32

Para 4-45

Condition Description

Right side door panel removed.

Intake manifold removed.

Injector pump fuel lines removed.

a.

b.

Removal Remove screw (1) and heat deflector (2) using a 6 mm hex head wrench.

Installation. Install heat deflector (2) and screw (1) using a 6 mm hex head wrench.

NOTE

Follow-on maintenance:

Install injector fuel lines (para 4-45)

Install intake manifold (para 4-32)

END OF TASK

Install right side door panel (para 4-98)

4-78

TM 5-3825-230-14&P

4-55.

NOISE SHROUDS REPLACEMENT.

This task covers: a.

Front Shroud b.

Fan Shroud c.

d.

Left Shroud

Rear Shroud

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No.1, Less Power

Materials/Parts

Lockwashers

Equipment Condition

TM or Para

Para 4-98

Para 3-5

Condition Description

Rear and top panels removed.

Left and right access covers removed.

a.

Front Shroud.

(1) Remove front shroud (1) as follows:

(a) Remove two screws (2) using a cross tip off-set screwdriver.

(b) Remove screw (3) and washer (4) using a 10 mm open end wrench.

(c) Remove rubber seal (5) and front shroud (1).

(c) Remove rubber seal (5) and front shroud (1).

4-79

4-55. NOISE SHROUDS REPLACEMENT (CONT).

TM 5-3825-230-14&P

(2) Install front shroud (1) as follows:

(a) Install rubber seal (5) on front shroud (1).

(b) Position front shroud (1) and install screw (3), and washer (4) using a 10 mm open end wrench.

(c) Install two screws (2) using a cross tip off-set screwdriver.

b.

Fan Shroud.

(1) Remove fan shroud (6) as follows:

(a) Remove two screws (7), four washers (8), and two lockwashers (9) using a 17 mm open end wrench.

(b) Remove screw (10) and lockwasher (11) using a 13 mm open end wrench.

(c) Remove fan shroud (6).

(2) Install fan shroud (6) as follows:

(a) Position fan shroud (6) and install lockwasher (11), and screw (10) using a 13 mm open end wrench.

(b) Install two lockwashers (9), two screws (7), and four washers (8) using a 17 mm open end wrench.

4-80

TM 5-3825-230-14&P c.

Left Shroud.

(1) Remove left shroud (12) as follows:.

(a) Remove three screws (13) using a cross tip screwdriver.

(b) Remove screw (14) and washer (15) using a ratchet, extension and 13 mm socket.

(c) Remove left shroud (12).

(d) Remove spacer (16) from left shroud (12).

(2) Install left shroud (12) as follows:.

(a) Install spacer (16) in left shroud (12).

(b) Position left shroud (12) and install screw (14) and washer (15) using a ratchet, extension and 13 mm socket.

d.

(c) Install three screws (13) using a cross tip screwdriver.

Rear Shroud.

(1) Remove rear shroud (17) as follows:

(a)

Remove vapor separator (para 4-38).

(b) Remove two screws (18) using a cross tip screwdriver.

(c) Remove screw (19) and lockwasher (20) using a ratchet and 10 mm socket.

(d) Remove rear shroud (17).

(2) Install rear shroud (17) as follows:

(a) Position rear shroud (17) and install screw (19) and lockwasher (20) using a ratchet and 10 mm socket.

(b) Install two screws (18) using a cross tip screwdriver.

(c)

Install vapor separator (para 4-38).

NOTE

Follow-on maintenance:

Install rear and top panels (para 4-98)

Install left and right access covers (para 3-5)

END OF TASK

4-81

TM 5-3825-230-14&P

4-56.

ALTERNATOR BELT REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Alternator belt

a.

Removal

(1) Loosen screw (1) on mounting ear (2) using a

1/2 in. open end wrench.

(2) Loosen nut (3) using a ratchet and 3/4 in.

socket.

(3) Pivot alternator (4) and remove belt (5).

b.

Installation.

(1) Install belt (5) on alternator (4), and pivot alternator away from engine until thumb pressure at center of belt causes approximately

1/2 in. (13 mm) deflection.

(2) Tighten screw (1) to 24 Ib-ft (33 N•m) using a torque wrench and 1/2 in. socket.

(3) Tighten nut (3) using a ratchet and 3/4 in.

socket.

END OF TASK

Equipment Condition

TM or Para

Para 3-5

Condition Description

Right side access cover opened.

NOTE

Follow-on maintenance: Close right access cover (para 3-5)

4-82

TM 5-3825-230-14&P

4-57.

ALTERNATOR AND MOUNTING BRACKET REPLACEMENT/REPAIR.

This task covers: a.

Removal b.

Disassembly

INITIAL SETUP

c.

d.

Assembly

Installation e.

Testing

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No.2, Less Power

Materials/Parts

Locknuts

Lockwashers

Tags, identification, item 35 Appendix E

Equipment Condition

TM or Para

Para 4-73

Para 4-56

NOTE

Tag all wires before removal to aid in installation.

Condition Description

Battery cables disconnected.

Alternator belt removed.

a.

Removal.

(1) Remove nut (1), washer (2), and tag and remove ground wire (3) from alternator (4) using a 7/16 in. Open end wrench.

(2) Remove nut (5), washer (6), and tag and remove main harness wire (7) from alternator (4) using a 7/16 in. open end wrench.

4-83

4-57

ALTERNATOR AND MOUNTING BRACKET REPLACEMENT/REPAIR (CONT).

(3) Remove screw (8), lockwasher (9), and washer

(10) using a 1/2 in. open end wrench.

(4) Remove locknut (11) using a 3/4 in. Open end wrench.

(5) Remove alternator (4) from mounting bracket

(12).

(6) Remove two screws (13) and two lockwashers

(14) using a ratchet and 1/2 in. socket.

b.

(7) Remove mounting bracket (12) from engine

(15). Remove spacer (16).

Disassembly.

(1) Place alternator (1) in a vise and remove nut (2) and washer (3) using a ratchet and 3/4 in.

socket.

(2) Using a puller, remove pulley (4).

(3) Remove woodruff key (5).

(4) Remove wire (6) from regulator (7).

(5) Remove two screws (8), two washers (9), and regulator (7) from alternator (1) using a flat tip screwdriver.

TM 5-3825-230-14&P c.

Assembly.

(1) Install regulator (7), two washers (9), and two screws (8) on alternator (1) using a flat tip screwdriver.

(2) Connect wire (6) on regulator (7).

(3) Install woodruff key (5).

(4) Install pulley (4).

(5) Place alternator (1) in a vise and install washer (3) and nut (2). Tighten to 50 lb-ft (68 N•m) using a torque wrench and 3/4 in. socket.

4-84

TM 5-3825-230-14&P d.

Installation.

(1) Install spacer (16) on mounting bracket (12).

(2) Install mounting bracket (12) on engine (15) using two lockwashers (14) and screws (13).

Tighten using a ratchet and 1/2 in. socket.

(3) Align alternator (4) on mounting bracket (12) and install locknut (11) finger tight.

(4) Install washer (10), lockwasher (9), and screw

(8) finger tight.

NOTE

Ground wire to engine is connected to terminal marked BAT- on alternator. Main harness wire is connected to terminal marked BAT+ on alternator.

(5) Install main harness wire (7), washer (6), and nut (5) on alternator (4) using a 7/16 in. open end wrench.

(6) Install ground wire (3), washer (2), and nut (1) on alternator (4) using a 7/16 in. open end wrench.

4-85

TM 5-3825-230-14&P

4-57.

ALTERNATOR AND MOUNTING BRACKET REPLACEMENT/REPAIR (CONT).

e.

Testing.

NOTE

If testing is to be accomplished, alternator follow-on tasks must be performed first.

(1) Turn all lights and accessories on, then pull shutoff handle while cranking engine 10-15

seconds (para 2-8). This discharges the battery.

(2) Release fuel shutoff handle and turn off lights and accessories.

(3) Open right side access cover and attach voltmeter and ammeter as shown.

CAUTION

If voltmeter reading exceeds 30.3

volts, shut engine down immediately or damage to equipment may result.

Refer to table 4-6.

(4) Start engine (para 2-8), and accelerate to 1500-

2000 RPM. Normal voltage is 24 V, and normal amperage is 28.2 to 28.8 amps. Take readings

and refer to table 4-6.

(5) Remove voltmeter and ammeter and close right side engine access cover.

NOTE

Follow-on maintenance:

Connect battery cables (para 4-73)

Install alternator belt (para 4-56)

END OF TASK

Amps

High

High

High

Low

Low

Low

Table 4-6. Alternator Testing.

Volts

Low

Diagnosis

Charging system OK. Battery not yet fully charged. Wait for charging system to bring battery to full charge: amps should fall and volts should stabilize within Normal

Range.

Normal Watch until amps fall or volts exceed Normal Range. If amps fall and volts remain normal, charging system OK If volts exceed normal, regulator should be replaced.

High

Low

Regulator should be replaced.

Make sure voltmeter leads are attached to alternator, not battery. If no affect observed, replace alternator.

Normal Charging system OK

High If battery checks OK, regulator should be replaced.

4-86

TM 5-3825-230-14&P

4-58.

STARTER REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Installation

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Starwasher

Tags, identification, item 35 Appendix E

a.

Removal

Equipment Condition

TM or Para

Para 4-73

Condition Description

Battery cables disconnected.

Left shroud removed.

Para 4-55

General Safety Instructions

Engine completely cooled.

WARNING

Make sure engine has completely cooled before starting this procedure. Injury to personnel may result.

NOTE

Tag all wires before removal to aid in installation.

(1) Remove nut (1), lockwasher (2), and tag and remove three wires (3) using a 13 mm open end wrench.

(2) Remove screw (4), starwasher (5), and tag and remove wire (6) using a flat tip screwdriver.

(3) Remove two screws (7), lockwashers (8), and starter (9) using a 8 mm hex head wrench.

4-87

4-58.

STARTER REPLACEMENT (CONT).

b.

Installation.

TM 5-3825-230-14&P

(1) Position starter (9) and install two lockwashers (8) and two screws (7) using a 8 mm hex head wrench.

(2) Install three wires (3), lockwasher (2), and nut (1) using a 13 mm open end wrench.

(3) Install wire (6), starwasher (5), and screw (4) using a flat tip screwdriver.

NOTE

Follow-on maintenance:

Connect battery cables (para 4-73)

Install left noise shroud (para 4-55)

END OF TASK

4-88

TM 5-3825-230-14&P

4-59.

GAGE BULB REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

a.

Removal

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

(2) Pull socket (5) from rear of gage (6).

(3) Remove bulb (7) from socket (5).

b.

Installation.

(1) Install bulb (7) in socket (5).

(2) Install socket (5) in rear of gage (6).

Materials/Parts

Lockwasher

Bulb

(3) Raise panel (4) and install washer (3), lockwasher (2), and screw (1) using a 7/16 in. open end wrench.

END OF TASK

4-89

TM 5-3825-230-14&P

4-60.

KEY SWITCH REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Tags, identification, item 35 Appendix E

a.

Removal

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

NOTE

Tag all wires before removal to aid in installation.

(2) Tag and disconnect four wires (5).

(3) Remove nut (6) using pliers.

(4) Remove cover (7).

b.

(5) Remove switch (8) from rear of panel (4).

Installation.

(1) Install switch (8) in rear of panel (4).

(2) Install cover (7).

Equipment Condition

TM or Para

Para 4-73

Condition Description

Battery cables disconnected.

(3) Install nut (6) using pliers.

(4) Install four wires (5).

(5) Raise panel (4) install washer (3), lockwasher

(2), and screw (1) using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-90

TM 5-3825-230-14&P

4-61.

PUSH BUTTON REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Tags, identification, item 35 Appendix E

a.

Removal.

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

NOTE

Tag all wires before removal to aid in installation.

Equipment Condition

TM or Para

Para 4-73

Condition Description

Battery cables disconnected.

(2) Tag and disconnect two wires (5) using a flat tip screwdriver.

(3) Raise panel (4) and remove push-button housing (6).

b.

(4) Lower panel (4) and remove push-button (7).

Installation.

(1) Lower panel (4) and install push-button (7).

(2) Raise panel (4) and install push-button housing

(6).

(3) Lower panel (4) and install two wires (5) using a flat tip screwdriver.

(4) Raise panel (4) and install washer (3), lockwasher (2), and screw (1) using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-91

TM 5-3825-230-14&P

4-62.

AMMETER SCALE REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Installation

a.

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive

Para 4-73

Materials/Parts

Lockwashers

Star washers

Tags, identification, item 35 Appendix E

Removal

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

NOTE

Tag all wires before removal to aid in installation.

(2) Remove three nuts (7), star washers (8), and tag and disconnect three wires (5) using a ratchet and 11/32 in. socket.

(3) Remove bulb (6) from socket attached to lead behind gage (9).

CAUTION

Hold gage from front or damage to gage may occur.

(4) Remove two nuts (7), two star washers (8), and bracket (10) using a 11/32 in. open end wrench.

(5) Remove gage (9) from front of panel (4).

4-92

TM or Para

Battery cables disconnected.

Condition Description

TM 5-3825-230-14&P b.

Installation.

(1) Install gage (9) in front of panel (4).

(2) Install bracket (10), two star washers (8), and two nuts (7) on panel (4) using a 11/32 in. open end wrench.

(3) Install bulb (6) in socket and secure on back of gage (9).

(4) Install three wires (5), three star washers (8), and three nuts (7) using a ratchet and 11/32 in. socket.

(5) Raise panel (4) and install lockwasher (2), washer (3), and screw (1), using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-93

TM 5-3825-230-14&P

4-63.

FUEL GAGE REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Star washers

Tags, identification, item 35 Appendix E

a.

Removal.

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

NOTE

Tag all wires before removal to aid in installation.

(2) Remove three nuts (7), three star washers (8), and tag and disconnect five wires (5) using a

11/32 in. open end wrench.

(3) Remove bulb (6) from socket.

CAUTION

Hold gage from front or damage to gage may result.

(4) Remove two nuts (7), two star washers (8), and bracket (9) using a 11/32 in. open end wrench.

(5) Remove gage (10) from front of panel (4).

4-94

Equipment Condition

TM or Para

Para 4-73

Condition Description

Battery cables disconnected.

TM 5-3825-230-14&P b.

Installation.

(1) Install gage (10) in front of panel (4).

(2) Install bracket (9), two star washers (8), and two nuts (7) on panel (4) using a 11/32 in. open end wrench.

(3) Install bulb (6).

(4) Install five wires (5), three nuts (7), and three star washers (8) using a 11/32 in. open end wrench.

(5) Raise panel (4) and install washer (3), lockwasher (2), and screw (1) using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-95

TM 5-3825-230-14&P

4-64.

SPRAY PUMP TOGGLE SWITCH REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwasher

Tags, identification, item 35 Appendix E

a.

Removal.

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

NOTE

Tag all wires before removal to aid in installation.

(2) Tag and disconnect two wires (5) using a flat tip screwdriver.

NOTE

Nut and plastic cover are one piece that can be pulled off the switch.

(3) Remove nut (6) using a 5/8 in. open end wrench.

Equipment Condition

TM or Para

Para 4-73

Condition Description

Battery cables disconnected.

b.

(4) Remove switch (7) from rear of panel (4).

Installation.

(1) Install switch (7).

(2) Install nut (6) using a 5/8 in. open end wrench.

(3) Install two wires (5) using a flat tip screwdriver.

(4) Raise panel (4) and install washer (3), lockwasher (z), and screw (1) using a 7l/b in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-96

TM 5-3825-230-14&P

4-65. FUSE AND HOLDER REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwasher

Fuse

Fuse holder

Tags, identification, item 35 Appendix E

b.

Installation

Equipment Condition

TM or Para

Para 4-73

Condition Description

Battery cables disconnected.

a. Removal.

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

NOTE

Tag all wires before removal to aid in installation.

(2) Tag wire (5) and unplug connector (6) from back of ignition switch (7).

(3) Tag wire (8) and remove screw (9) from back of spray pump toggle switch (10) using a flat tip screwdriver. Remove wires (5 and 8).

(4) Remove fuse holder (11), and fuse (12).

b. Installation.

(1) Install fuse (12) in holder (11).

(2) Install wire (8) and screw (9) on back of spray pump toggle switch (10) using a flat tip screwdriver.

(3) Connect wire (5) on back of ignition switch (7).

(4) Raise panel (4) and install washer (3), lockwasher (2), and screw (1) using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-97

TM 5-3825-230-14&P

4-66. JUNCTION BOX REPLACEMENT/REPAIR.

This task covers: a.

b.

Removal

Disassembly

INITIAL SETUP

c.

Assembly d.

Installation

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Lockwashers

Tags, identification, item 35 Appendix E

NOTE

• Ensure harness (12V or 24V) to tow vehicle is disconnected.

• Refer to Appendix H for electrical

schematic.

a. Removal

(1) Remove four screws (1) and cover (2) using flat tip screwdriver.

NOTE

Tag and mark all wires before removal.

(2) Tag and remove wires (3) and three resistors (4) using 3/8 in. socket and drive.

(3) Remove four locking rings (5) using pliers.

(4) Loosen four knurled knobs (6) and remove four wiring cables (7) from junction box (8) using pliers.

(5) Remove four screws (9), four locknuts (10), eight washers (11) and junction box (8) using

7/16 in. open end wrench, ratchet and 7/16 in.

socket.

4-98

TM 5-3825-230-14&P

b. Disassembly.

(1) Remove screw (1), lockwasher (2), washer (3) and terminal block (4) from junction box (5) using flat tip screwdriver.

(2) Remove two screws (6), two lockwashers (7), two washers (8) and circuit breaker base (9) using flat tip screwdriver.

(3) Remove four screws (10), four lockwashers (11) and plate (12) using flat tip screwdriver.

c. Assembly.

(1) Install plate (12), four lockwashers (11) and four screws (10) in junction box (5) using flat tip screwdriver.

(2) Install circuit breaker base (9), two washers (8), two lockwashers (7) and two screws (6) using flat tip screwdriver.

(3) Install terminal block (4), washer (3), lockwasher (2) and screw (1) in junction box (5) using flat tip screwdriver.

4-99

4-66. JUNCTION BOX REPLACEMENT/REPAIR (CONT).

d. Installation.

(1) Install junction box (8), four screws (9), eight washers (11) and four nuts (10) using 7/16 in.

open end wrench, ratchet and 7/16 in. socket.

(2) Install four cables (7), four locking rings (5) and tighten four knurled knobs (6) using pliers.

(3) Install wires (3) and three resistors (4) using 3/8 in. socket and drive.

(4) Install cover (2) and four screws (1) using flat tip screwdriver.

END OF TASK

4-100

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-67. CIRCUIT BREAKER AND RESISTOR REPLACEMENT (JUNCTION BOX).

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive b.

Installation

Materials/Parts

Star washers

Tags, identification, item 35 Appendix E

NOTE

• wire harness (12V or 24V) to tow vehicle is disconnected.

• fuses and resistors are removed and replaced in the same manner.

• all wires before removal to aid in installation.

• to Appendix H for electrical schematics.

a. Removal

(1) Remove four screws (1) and junction box cover (2) using a flat tip screwdriver.

(2) Remove two nuts (3), star washer (4), and resistor (5) using a 3/8 in. socket and drive.

(3) Remove two nuts (6), tag and remove wires (7), and circuit breaker (8) using a 3/8 in. socket and drive.

b. Installation.

(1) Install circuit breaker (8), wires (7), and two nuts (6) using a 3/8 in. socket and drive.

(2) Install resistor (5), star washer (4), and two nuts (3) using a 3/8 in. socket and drive.

(3) Install junction box cover (2) and four screws (1) using a flat tip screwdriver.

END OF TASK

4-101

TM 5-3825-230-14&P

4-68. FUSE AND HOLDER REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive TM or Para Condition Description

Para 4-69 Side lamp removed.

Materials/Parts

Locknut

a. Removal.

NOTE

Ensure the wiring harness (12V or 24V) to tow vehicle is disconnected.

(1) Unplug wire (1) from light (2).

(2) Remove nut (3) and two wires (4) from fender (5) using a 7/16 in. open end wrench.

(3) Remove screw (6), two washers (7), and locknut (8) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

(4) Remove screw (9), two washers (10), locknut (11), and fender (5) using a 3/4 in. open end wrench, ratchet and

3/4 in. socket.

(5) Remove light (2) and diaphragm (12) from back of fender (5).

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TM 5-3825-230-14&P

b. Installation.

(1) Install light (2) into diaphragm (12).

(2) Install diaphragm (12) into back of fender (5).

(3) Position fender (5) and install screw (9), washers (10), and locknut (11) using a 3/4 in. open end wrench and 3/4 in. socket.

(4) Install screw (6), two washers (7), and locknut (8) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

(5) Install wires (4) and nut (3) on fender (5) using a 7/16 in. open end wrench.

(6) Plug wire (1) on light (2).

NOTE

Follow-on maintenance: Install side lamp (para 4-69)

END OF TASK

4-103

4-69. SIDE LAMP REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive b.

Installation

Materials/Parts

Lamp

NOTE

• All side lamps are removed the same.

• Ensure the wiring harness (12V or 24V) to tow vehicle is disconnected.

a. Removal.

(1) Remove wire (1).

(3) Remove light (2) and diaphragm (3).

b. Installation.

(1) Install diaphragm (3) and light (2).

(2) Install wire (1).

END OF TASK

TM 5-3825-230-14&P

4-104

TM 5-3825-230-14&P

4-70. SIDE LAMP BRACKET REPLACEMENT (FRONT).

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 4-69

Materials/Parts

Lockwashers

Locknuts

a. Removal

NOTE

Both side lamp brackets are replaced the same way.

Condition Description

Side lamp removed.

(1) Remove two nuts (1), two lockwashers (2), two screws (3), and bracket (4) using a 9/16 in. open end wrench, ratchet and 9/16 in. socket.

(2) Remove two locknuts (5), two washers (6), two screws (7), and bracket assembly (8) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

4-105

4-70. SIDE LAMP BRACKET REPLACEMENT (CONT).

b. Installation.

TM 5-3825-230-14&P

(1) Position bracket assembly (8) and install two screws (7), two washers (6), and two locknuts (5) using a 3/4 in.

open end wrench, ratchet and 3/4 socket.

(2) Position bracket (4) and install two screws (3), two lockwashers (2), and two locknuts (1) using a 9/16 in. open end wrench, ratchet and 9/16 in. socket.

NOTE

Follow-on maintenance: Install side lamp (para 4-69)

END OF TASK

4-106

4-71. CENTER LIGHT AND MOUNT REPLACEMENT.

This task covers : a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive b.

Installation

Materials/Parts

Lockwashers

TM 5-3825-230-14&P

NOTE

Ensure wire harness (12V or 24V) to tow vehicle is disconnected.

a. Removal

(1) Unplug wire (1) from connector (2).

(2) Remove four screws (3), four lockwashers (4), ground wire (5), and bracket (6) from frame (7) using a flat tip screwdriver.

(3) Remove three lamps (8) from bracket (6).

b. Installation.

(1) Install three lamps (8) in bracket (6).

(2) Position bracket (6) and install ground wire (5), four lockwashers (4), and screws (3) using a flat tip screwdriver.

(3) Connect wire (1) to connector (2).

END OF TASK

4-107

TM 5-3825-230-14&P

4-72. FUSE AND HOLDER REPLACEMENT.

This task covers: a.

Removal b.

Cleaning/Inspection c. Installation

INITIAL SETUP

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive TM or Para Condition Description

Para 4-73 Battery cables

Materials/Parts disconnected.

Lockwasher

Gasket

Compound, sealing, item 15 Appendix E

Solvent, dry cleaning, item 31 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 (15.24 m) of vehicle.

(1) Remove nut (1) and lockwasher (2) using a 3/8 in. open end wrench.

(2) Disconnect wire (3).

(3) Remove five screws (4) using a flat tip screwdriver.

(4) Lift sending unit (5) out of fuel tank (6).

(5) Remove gasket (7) from tank (6) using a putty knife. Discard gasket.

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TM 5-3825-230-14&P

b. Cleaning/Inspection.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38 o

C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(1) Remove any remaining gasket material from fuel tank using dry cleaning solvent P-D-680.

(2) Visually inspect inside of fuel tank for any debris that may have fallen in during removal of the sending unit.

c. Installation.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Coat gasket (7) with sealing compound and slide gasket over float (8) and install on sending unit (5).

(2) Install sending unit (5) in fuel tank (6). Align holes in fuel tank and sending unit.

(3) Install five screws (4) in sending unit (5) using a flat tip screwdriver.

(4) Install wire (3), lockwasher (2), and nut (1) using a 3/8 in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

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TM 5-3825-230-14&P

4-73. BATTERY CABLE DISCONNECT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive b.

Installation

Materials/Parts

Tags, identification, item 35, Appendix E

NOTE

• Refer to Appendix H for electrical

schematic.

• Tag all clamps prior to removal to aid in installation.

a. Removal

(1) Remove strap (1) and battery box cover (2).

WARNING

• Do not wear watches, rings, or other jewelry which could short out battery terminals while servicing batteries. Do not smoke or use open flame around batteries. Batteries may explode from a spark. Battery acid is harmful to skin and eyes.

• Always remove negative (ground) cable on right (muffler) side first, or injury to personnel may occur.

(2) Loosen nut (3) on negative clamp (4) using a

1/2 in. open end wrench.

(3) Tag and remove negative clamp (4) from negative post (5) using battery clamp puller.

(4) Loosen nut (6) on positive battery clamp (7) using a 1/2 in. open end wrench.

(5) Tag and remove clamp (7) from positive post (8) using a battery clamp puller.

(6) Repeat steps (1) through (5) for left side battery.

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TM 5-3825-230-14&P

b. Installation.

WARNING

Always install left side battery clamps first or injury to personnel may occur.

(1) Install positive battery clamp (7) on positive post (8) and tighten nut (6) using a 1/2 in. open end wrench.

(2) Install negative battery clamp (4) on negative post (5) and tighten nut (3) using a 1/2 in. open end wrench.

(3) Install battery box cover (2) and strap (1).

(4) Repeat steps (1) through (3) for right side battery.

END OF TASK

4-111

TM 5-3825-230-14&P

4-74. FUSE AND HOLDER REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive TM or Para Condition Description

Para 4-73 Battery cables

Materials/Parts disconnected.

Locknuts

a. Removal.

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.

NOTE

Right and left side batteries are positioned differently but removed the same way.

(1) Remove two locknuts (1), two washers (2), and bracket (3) using a 7/16 in. open end wrench.

(2) Note placement of terminals and lift out battery

(4).

b. Installation.

(1) Position battery (4) in battery box (5) with terminals in proper position.

(2) Secure battery using bracket (3), two locknuts

(1), and two washers (2). Tighten locknuts using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-112

TM 5-3825-230-14&P

4-75. BATTERY BOX REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive b.

Installation

Equipment Condition

TM or Para

Para 4-74

a.

Removal. Unhook two J-bolts (1) from sweeper frame (2) and remove battery box (3), strap (4), and

J-bolts.

b. Installation. Position strap (4) and battery box (3) on frame (2) and hook two J-bolts (1) on sweeper frame.

NOTE

Follow-on maintenance: Install battery

(para 4-74)

END OF TASK

Condition Description

Battery removed.

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TM 5-3825-230-14&P

4-76. TOW VEHICLE TO JUNCTION BOX WIRE HARNESS (12V) REPLACEMENT/REPAIR.

This task covers: a.

Removal b.

Repair c.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Star washers

Tags, identification, item 35 Appendix E

Equipment Condition

TM or Para

Para 4-66

Condition Description

Junction box cover removed.

NOTE

• Ensure the wiring harness (12V or 24V) to tow vehicle is disconnected.

• Refer to Appendix H for electrical

schematic.

a. Removal

(1) If stowed, unwrap 12V wiring harness from harness stowage pegs.

(2) Remove three nuts (1), three lockwashers (2), three washers (3), and three clamps (4) from front boom (5) using a ratchet and 7/16 in.

socket.

(3) Remove screw (6), washer (7), nut (8), lockwasher (9), clamp (4), and red wiring harness (10) from front boom (5) using a ratchet, 7/16 in. socket and 7/16 in. open end wrench.

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TM 5-3825-230-14&P

NOTE

Tag and mark all wires prior to removal to aid in installation.

(4) Remove seven nuts (11), seven star washers (12), and tag and remove seven wires (13) from terminal block (14) in junction box (15) using a 3/8 in. socket and drive.

(5) Remove knurled nut (16) and harness (10) from junction box (15).

b. Repair. Repair of the 12V wire harness consists of replacing damaged terminals (para 4-83). Refer to the electrical

schematic, Appendix H, for cable lead diagram.

c. Installation.

(1) Install harness (10) in junction box (15) using knurled nut (16). Tighten using split jaw pliers.

(2) Install seven wires (13), seven nuts (11), and seven star washers (12) using a 3/8 in. socket and drive.

4-115

TM 5-3825-230-14&P

4-76. TOW VEHICLE TO JUNCTION BOX WIRE HARNESS (12V) REPLACEMENT/REPAIR (CONT).

(3) Install harness (10), three clamps (4), three nuts

(1), three lockwashers (2), and three washers (3) on front boom (6) using a ratchet and 7/16 in.

socket.

(4) Install clamp (4), screw (6), washer (7), lockwasher (9), and nut (8) using a ratchet, 7/16 in. socket and 7/16 in. open end wrench.

(5) Wrap unused 12V wiring harness around harness stowage pegs.

NOTE

Follow-on maintenance: Install

junction box cover (para 4-66)

END OF TASK

4-116

TM 5-3825-230-14&P

4-77. TOW VEHICLE TO JUNCTION BOX WIRE HARNESS (24V) REPLACEMENT/REPAIR.

This task covers: a.

Removal b.

Repair c.

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Star washer

Tags, identification, item 35 Appendix E

Equipment Condition

TM or Para

Para 4-66

Condition Description

Junction box cover removed.

NOTE

• Ensure the wiring harness (12V or 24V) to tow vehicle is disconnected.

• Refer to Appendix H for electrical

schematic.

a. Removal

(1) If stowed, unwrap 24V wiring harness from harness stowage pegs.

(2) Remove three nuts (1), three lockwashers (2), three washers (3), and clamps (4) from front boom (5) using a ratchet and 7/16 in. socket.

(3) Remove screw (6), washer (7), nut (8), lockwasher (9), clamp (4), and black 24V harness (10) from front boom (5) using a ratchet, 7/16 in. socket and 7/16 in. open end wrench.

4-117

TM 5-3825-230-14&P

4-77. TOW VEHICLE TO JUNCTION BOX WIRE HARNESS (24V) REPLACEMENT/REPAIR (CONT).

NOTE

Tag and mark all wires prior to removal to aid in installation.

(4) Remove four nuts (11), four star washers (12), and tag and remove five wires (13) from terminal block (14) in junction box (15) using a 3/8 in. socket and drive.

(5) Remove knurled nut (16) using pliers and remove harness (10).

b. Repair. Repair of the 24V wire harness consists of replacing damaged terminals (para 4-83). Refer to the electrical

schematic, Appendix H, for cable lead diagram.

c.

Installation.

(1) Install harness (10) and knurled nut (16) on junction box (15).

(2) Install five wires (13), four star washers (12), and four nuts (11) on terminal block (14) using a 3/8 in. socket and drive.

4-118

(3) Install harness (10), clamp (4), three nuts (1), three lockwashers (2), and three washer (3) on front boom (5) using a ratchet and 7/16 in.

socket.

(4) Install clamp (4), screw (6), washer (7), lockwasher (9), and nut (8) using a ratchet, 7/16 in. socket and 7/16 in. open end wrench

(5) Wrap unused 24V wiring harness around harness stowage pegs.

NOTE

Follow-on maintenance: Install

junction box cover (para 4-66)

END OF TASK

4-119

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-78. BROOM HOOD WIRING HARNESS/CONDUIT REPLACEMENT/REPAIR.

This task covers: a.

Removal b.

Repair

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Star washers

Adhesive, PVC, item 1, appendix E

Primer, PVC, item 28, appendix E

Tags, identification, item 35 appendix E

Conduit (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 4-66

NOTE

• Ensure the wiring harness (12V or 24V) to tow vehicle is disconnected.

• Refer to Appendix H for electrical

schematic.

a. Removal.

(1) Remove 10 screws (1), 10 lockwashers (2), 10 washers (3), and 10 conduit clamps (4) from hood (5) using a flat tip screwdriver.

(2) Disconnect two connectors (6) from front lights

(7).

(3) Disconnect pigtail connector (8) and remove hood wiring conduit assembly (9) from front hood (5).

c.

Installation

Condition Description

Junction box cover removed.

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TM 5-3825-230-14&P

NOTE

Tag and mark all wires prior to removal to aid in installation.

(4) Remove two nuts (10), two star washers (11), and tag and remove three wires (12) from terminal block (13) in junction box (14) using a 3/8 in. socket and drive.

(5) Remove knurled nut (15) and harness (16) from junction box (14).

4-121

4-78. BROOM HOOD WIRING HARNESS/CONDUIT REPLACEMENT/REPAIR (CONT).

b. Repair.

TM 5-3825-230-14&P

NOTE

Repair is accomplished with front hood wiring harness and conduit removed from vehicle.

(1) Carefully open holes in end of conduit and pull wires through.

(2) Cut out or remove damaged conduit.

(3) Cut replacement conduit (refer to Appendix G).

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(4) Clean outside diameter of conduit, inside diameter of couplings, tees, elbows and end caps using PVC primer.

(5) Pull wires through elbows, couplings, replacement conduit, tee, existing conduit and end caps.

(6) Apply PVC adhesive to inside diameter of couplings, tees, elbows and end cap and assemble items.

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TM 5-3825-230-14&P

c. Installation.

(1) Install harness (16) and knurled nut (15) on junction box (14) using pliers.

(2) Install three wires (12), two nuts (10), and two star washers (11) on terminal block (13) in junction box (14) using a 3/8 in. socket and drive.

(3) Install conduit assembly (9) on front hood (5) and connect pigtail (8) and two connectors (6) to front lights (7).

(4) Install 10 conduit clamps (4), 10 washers (3), 10 lockwashers (2), and 10 screws (1) on front hood (5) using a flat tip screwdriver.

NOTE

Follow-on maintenance: Install

junction box cover (para 4-66)

END OF TASK

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TM 5-3825-230-14&P

4-79. REAR LIGHT WIRE HARNESS REPLACEMENT

This task cover: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's Automotive

Materials/Parts

Star washers

Tags, identification, Item 35 Appendix E

Equipment Condition

TM or Para

Para 4-66

a. Removal.

Condition Description

Junction box Cover removed

NOTE

• Tag all wires and connectors prior to removal to aid in installation.

• Ensure wiring harness (12V or 24V) to tow vehicle is disconnected.

• Refer to Appendix H for electrical schematic.

(1) Remove three nuts (1), three star washers (2), and tag and remove three wires (3) from terminal block (4) in junction box (5) using a 3/8 in. socket and drive.

(2) Loosen knurled nut (6) and remove harness (7) from junction box (5) using a pliers.

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TM 5-3825-230-14&P

(3) Remove 14 screws (8), 14 washers (9), and 14 conduit grommets (10) from harness (7) using a ratchet and 7/16 in. socket.

(4) Tag and remove 10 connectors (12) from rear lights (11).

(5) Tag and remove wire (14) from center light mount (13).

b. Installation .

(1) Install wire (14) on center light mount (13).

(2) Install 10 connectors (12) to rear lights (11).

(3) Install 14 conduit grommets (10), 14 washers (9), and 14 screws (8) on harness (7) using a ratchet and 7/16 in.

socket.

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4-79. REAR LIGHT WIRE HARNESS REPLACEMENT (CONT).

TM 5-3825-230-14&P

(4) Install harness (7) in junction box (4) and tighten knurled nut (6) using pliers.

(5) Install three wires (3), three star washers (2), and three nuts (1) on terminal block (4) using a 3/8 in. Socket and drive.

NOTE

Follow-on maintenance: Install junction box cover (para 4-66)

END OF TASK

4-126

TM 5-3825-230-14&P

4-80. REAR LIGHT WIRE HARNESS REPLACEMENT

This task cover: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's Automotive

Materials/ Parts

Lockwashers

Star washers

Tags, identification, Item 35 Appendix E

Equipment Condition

TM or Para

Para 4-73

Condition Description

Battery Cables

Disconnected

NOTE

Tag all wires prior to removal to aid installation.

a. Removal

(1) Remove screw (1), lockwasher (2), and washer (3) using a ratchet and 7/16 in. socket. Lower panel (4).

(2) Tag and remove bulb wire (5) from tachometer gage (6).

(3) Remove tachometer cable (7) from tachometer gage (6).

4-127

TM 5-3825-230-14&P

4-80. CONTROL PANEL REPLACEMENT (CONT).

(4) Tag and remove four wires (8) from key switch

(9).

(5) Loosen two screws (10) using a flat tip screwdriver and tag and remove two wires (11) from push-button (12).

(6) Remove three nuts (13) and three star washers

(14) using a 11/32 in. open end wrench.

(7) Tag and remove five wires (15) from fuel gage

(16).

(8) Remove three nuts (17) and three star washers

(18) using a 11/32 in. open end wrench.

(9) Tag and remove three wires (19) from ammeter scale (20).

(10) Remove two screws (21) using a flat tip screwdriver and tag and remove two wires (22) from spray pump switch (23).

(11) Remove two nuts (24), four lockwashers (25), two washers (26), and two screws (27) using a

7/16 in. open end wrench, ratchet, and 7/16 in.

socket. Remove panel (4) from vehicle.

(12) Tag and remove panel ground wire (28).

(13) Tag and remove panel light sockets (29) from ammeter scale (20) and fuel gage (16).

b. Installation.

(1) Install panel ground wire (28), two screws (27), two washers (26), four lockwashers (25), and two nuts (24) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(2) Install two wires (22) and two screws (21) on spray pump switch (23) using a flat tip screwdriver.

(3) Install three wires (19), three star washers (18), and three nuts (17) on ammeter gage (20) using a 11/32 in. open end wrench.

(4) Install five wires (15), three star washers (14), and three nuts (13) on fuel gage (16) using a 11/32 in. open end wrench.

(6) Install three wires (8) on key switch (9).

4-128

(7) Install tachometer cable (7) on tachometer gage (6).

(8) Install bulb wire (5) on tachometer gage (6).

(9) Install light socket (29) on fuel gage (16), and ammeter scale (20).

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

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TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-81. ENGINE AND BATTERY WIRE HARNESS REPLACEMENT

This task cover: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's Automotive

Materials/ Parts

Star washers lockwashers

Tags, identification, Item 35 Appendix E

Equipment Condition

TM or Para

Para 4-73

Para 3-5

Condition Description

Batteries cables disconnected

Left and right access covers opened.

NOTE

Tag all wires before removal to aid in installation.

a. Removal.

(1) Remove nut (1), washer (2), and tag and remove ground wire (3) from alternator (4) using a 7/16 in. open end wrench.

(2) Remove nut (5), washer (6), and tag and remove main harness wire (7) from alternator (4) using a 7/16 in. open end wrench.

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TM 5-3825-230-14&P

(3) Tag and disconnect spray pump wire (8) from connector (9).

(4) Remove nut (10), lockwasher (11), and tag and remove three wires (12) from solenoid (13) using a 13 mm open end wrench.

(5) Remove screw (14), star washer (15), and tag and remove wire (16) from solenoid (13) using a flat tip screwdriver.

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4-81. ENGINE AND BATTERY WIRE HARNESS REPLACEMENT (CONT).

TM 5-3825-230-14&P

(6) Remove nut (17), washer (18), star washer (19), screw (20), and tag and remove ground wire (21) from frame

(22) using a 9/16 in. open end wrench.

(7) Remove screw (23), lockwasher (24), tag and remove ground wire (25), and wire (21) from motor mount (26) using a 17 mm open end wrench.

(8) Remove key switch wires (para 4-60).

(9) Remove ammeter wires (para 4-62).

b. Installation.

(1) Install ammeter wires (para 4-62).

(2) Install key switch wires (para 4-60).

(3) Install ground wires (21 and 25), lockwasher (24), and screw (23) on motor mount (26) using a 17 mm open end wrench.

(4) Install ground wire (21), star washer (19), screw (20), washer (18), and nut (17) on frame (22) using a 9/16 in.

open end wrench.

4-132

(5) Install wire (16), star washer (15), and screw

(14) on solenoid (13) using a flat tip screwdriver.

(6) Install three wires (12), lockwasher (11), and nut

(10) on solenoid (13).

(7) Connect spray pump wire (8) on connector (9).

NOTE

Ground wire to engine is connected to terminal marked BAT- on alternator. Main harness wire is connected to terminal marked BAT+ on alternator.

(8) Install main harness wire (7), washer (6), and nut (5) on alternator (4) using a 7/16 in. open end wrench.

(9) Install ground wire (3), washer (2), and nut (1) on alternator (4) using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance:

Connect battery cables (para 4-73)

Close access covers (para 3-5)

END OF TASK

4-133

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-82. FUEL AND GLOW PLUG WIRE HARNESS REPLACEMENT

This task cover: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's Automotive

Materials/ Parts

Star washers

Lockwashers

Tags, identification, Item 35 Appendix E

Equipment Condition

TM or Para

Para 4-73

Para 4-98

a. Removal

Condition Description

Junction box Cover removed

Top Access and right door panels removed

NOTE

• Crossover wire between glow plugs is not removed.

• Tag wires before removal to aid in installation.

(1) Remove nut (1), lockwasher (2), and tag and remove wire (3) from glow plug (4) using a 5/16 in. open end wrench.

4-134

(2) Remove nut (5), and lockwasher (6), and tag and remove wire (7) from fuel sending unit (8) using a 3/8 in. open end wrench.

TM 5-3825-230-14&P

(3) Remove screw (9), lockwasher (10), and washer (11) using a 7/16 in. open end wrench.

(4) Remove tachometer cable (12) from tachometer gage (13).

(5) Remove screw (14), and tag and remove wire (15) using a flat tip screwdriver.

(6) Remove nut (16), star washer (17), and tag and remove wire (18) using a 11/32 in. open end wrench.

4-135

4-82. FUEL AND GLOW PLUG WIRE HARNESS REPLACEMENT (CONT).

TM 5-3825-230-14&P b. Installation.

(1) Install wire (18), star washer (17), and nut (16) using a 11/32 in. open end wrench.

(2) Install wire (15), and screw (14) using a flat tip screwdriver.

(3) Install tachometer cable (12) on tachometer gage (13).

(4) Install washer (11), lockwasher (10), and screw (9) using a 7/16 in. open end wrench.

(5) Install wire (7), lockwasher (6), and nut (5) on fuel sending unit (8) using a 3/8 in. Open end wrench.

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TM 5-3825-230-14&P

(6) Install wire (3), lockwasher (2), and nut (1) on glow plug (4) using a 5/16 in. open end wrench.

NOTE

Follow-on maintenance:

• Connect battery cables (para 4-73)

• Install top access and right door panels (para 4-98)

END OF TASK

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TM 5-3825-230-14&P

4-83. TERMINAL/CONNECTOR REPLACEMENT

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 4-73

NOTE

Ensure the wiring harness (12V or 24V) to tow vehicle is disconnected.

a. Removal

(1) Remove components as necessary to gain access to damaged terminal.

NOTE

• Record wire to terminal relationship for ease of assembly.

• Refer to Appendix H for electrical schematic.

(2) Cut off damaged terminal or connector.

b.

(3) Strip wire as appropriate for replacement terminal or connector.

Installation.

(1) Connect wire(s) to terminal or connector and crimp or tighten as necessary.

(2) Reconnect terminal or connector to unit.

(3) Install any components removed.

NOTE

Follow-on maintenance: Connect battery cables (para 4-73)

END OF TASK

4-138

Condition Description

Battery cables disconnected.

TM 5-3825-230-14&P

4-84. HAND BRAKE LEVER REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Installation

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Lockwashers

Cotter pin

General Safety Instructions

Sweeper on level ground and wheels blocked.

a. Removal

NOTE

This procedure is the same for both hand brake levers.

(1) Remove four screws (1), nuts (2), and lockwashers (3) using a 7/16 in. open end wrench, ratchet and 7/16 in.

socket.

(2) Remove bracket (4), and bushing (5).

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TM 5-3825-230-14&P

4-84. HAND BRAKE LEVER REPLACEMENT (CONT).

(3) Remove four screws (6), four lockwashers (7), and four nuts (8) using a.1/2 in. open end wrench, ratchet and 1/2 in. socket.

(4) Remove screw (9), locknut (10), and socket shaft linkage (11) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(5) Remove hand brake assembly (12).

(6) Remove cotter pin (13), washer (14), two bars

(16), and pin (15) using needle nose pliers.

b. Installation.

(1) Install washer (14), two bars (16), pin (15), and cotter pin (13) using needle nose pliers.

(2) Install hand brake assembly (12), four screws

(6), washers (7), and locknuts (8) using a 1/2 in.

open end wrench, ratchet and 1/2 in. socket.

(3) Install screw (9), locknut (10), and socket shaft linkage (11) on hand brake assembly (12) using a 7/16 in. open end wrench, ratchet and 7/16 in.

socket.

(4) With end of shaft linkage in bushing, install bushing (5) on bracket (4) using four screws (1), four lockwashers (3), and four nuts (1). Tighten using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

NOTE

Follow-on maintenance: Adjust hand brake (para 3-12)

END OF TASK

4-140

TM 5-3825-230-14&P

4-85. BRAKE ASSEMBLY ADJUSTMENT.

This task covers:

Adjustment

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

General Safety Instructions

Sweeper supported on jackstand under affected side of axle and hand brake released.

NOTE

• This task will normally be done when brake shoes are replaced. It is the same for both sides.

• Be careful not to loose dust covers.

Adjustment.

(1) Block wheels and set hand brake on unaffected side of vehicle.

(2) Jack up axle and support it with jackstand.

(3) Remove dust caps (1) from backing plate (2).

(4) Turn adjusting wheels (3) equally but in opposite directions with flat tip screwdriver until unable to rotate wheel.

(5) Back off adjustment until wheel turns.

(6) Replace dust caps (1).

(7) Raise sweeper, remove jackstand and lower sweeper.

NOTE

Follow-on maintenance: Test operation of hand brakes (para 3-12)

END OF TASK

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TM 5-3825-230-14&P

4-86. BRAKE DRUM AND HUB REPLACEMENT/REPAIR.

This task covers: a.

b.

Removal

Disassembly

INITIAL SETUP

c.

Cleaning/Inspection d.

Assembly

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance Common

No. 1, Less Power

Materials/Parts

Seal

Cotter pin

Grease, item 22 Appendix E

Solvent, dry cleaning, item 31 Appendix E

e.

Installation

Equipment Condition

TM or Para

Para 4-88

Condition Description

Wheel removed.

General Safety Instructions

Sweeper on level ground and unaffected wheel blocked.

a. Removal.

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TM 5-3825-230-14&P

WARNING

Brake linings contain asbestos. Asbestos dust can cause cancer. Avoid breathing dust from brake linings or creating dust while servicing.

NOTE

This procedure is the same for the left or right side.

(1) Remove dust cap (1) using a hammer and chisel, and cotter pin (2) using pliers.

(2) Remove nut (3), washer (4), and outer bearing (5) using a ratchet and 1-1/8 in. socket.

(3) Remove hub (6) using a slide hammer.

b. Disassembly.

(1) Remove inner seal (7), inner bearing (8), and inner bearing race (9) using a brass drift and hammer.

(2) If damaged, drive out outer bearing race (10) using a brass drift and hammer.

4-143

TM 5-3825-230-14&P

4-86. BRAKE DRUM AND HUB REPLACEMENT/REPAIR (CONT).

c. Cleaning/Inspection.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flash point for type I dry cleaning solvent is 100°F (38 o

C), and for type II is 140°F (60 o

C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

DO NOT use a dry brush or compressed air to clean brake shoes. There may be asbestos dust on brake shoes which can be dangerous to your health if you breath it. (Brake shoes must be wet and a soft bristle brush must be used.)

CAUTION

Do not "spin dry" bearings with compressed air, the bearing may fly apart.

(1) Clean all metal parts with dry cleaning solvent P-D-680 and dry.

(2) Check bearings for pitting, rusting or wear.

(3) Check races for grooves.

NOTE

Brake shoes, drums and brake adjustment mechanisms must be cleaned of dirt, mud and debris before inspection.

(4) Measure edge thickness of brake lining. If brake lining is less than 1/8 in. (3.18 mm) at thinnest point, replace brake shoes.

(5) Inspect brake linings and drums for obvious grooves and uneven wear.

(a) If brake linings are worn unevenly and less than 1/8 in. (3.18 mm), replace brake shoes.

(b) If drum has deep grooves, replace drum.

4-144

d. Assembly.

(1) Pack bearing (8) with grease.

(2) Install inner bearing race (9), inner bearing (8), and inner seal (7) using a block of wood and ball peen hammer.

(3) If removed, install outer bearing race (10) using a block of wood and ball peen hammer.

e. Installation.

TM 5-3825-230-14&P

(1) Install hub (6).

(2) Pack outer bearing (5) with grease and install bearing in hub (6).

(3) Install washer (4), and nut (3).

(4) Using a torque wrench and 1-1/8 in. socket, tighten nut (3) to 40 lb.-ft (54 N.m) while rotating hub right and left.

Wheel should turn freely. Backoff nut 1/4 to 1/3 turn.

(5) Install cotter pin (2) using pliers and dust cap (1) using a hammer.

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4-86. BRAKE DRUM AND HUB REPLACEMENT/REPAIR (CONT).

NOTE

Follow-on maintenance:

Install wheel (para 4-88)

Adjust brake assembly (para 4-85)

END OF TASK

4-146

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-87. BRAKE ASSEMBLY/MODIFIED SPINDLE REPLACEMENT/REPAIR

This task covers: a.

Disassembly b.

Assembly

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Locknuts

Equipment Condition

TM or Para

Para 4-86

Para 4-84

Text begins on next page.

4-147

Condition Description

Brake drum/hub removed.

Hand brake linkage disconnected.

4-87.

BRAKE ASSEMBLY/MODIFIED SPINDLE REPLACEMENT/REPAIR (CONT) a. Disassembly.

TM 5-3825-230-14&P

WARNING

Brake linings contain asbestos. Asbestos dust can cause cancer. Avoid breathing dust from brake linings or creating dust while servicing.

NOTE

Procedure is the same for both right and left sides.

(1) Remove springs (1) using brake spring pliers and remove brake shoes (2).

(2) Remove two adjusting screw assemblies (3).

(3) Remove two snap rings (4) using snap ring pliers and remove two anchor pins (5).

(4) Remove brake shoes (2) from two shoe levers (6).

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TM 5-3825-230-14&P

(5) Remove two locknuts (7), and two screws (8) using a 15/16 in. open end wrench, ratchet and 15/16 in. socket.

(6) Remove spindle (9) from frame (10).

(7) Remove four locknuts (11), four screws (12), and backing plate (13) using a ratchet and 5/8 in. socket.

(8) Remove actuating camshaft (14), spacer (15), and manual control lever (16) from backing plate (13).

b. Assembly .

(1) Install control lever (16), spacer (15), and actuating camshaft (14) on backing plate (13).

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4-87.

BRAKE ASSEMBLY/MODIFIED SPINDLE REPLACEMENT/REPAIR (CONT)

TM 5-3825-230-14&P

(2) Install backing plate (13), four screws (12), and four locknuts using a ratchet and 5/8 in. socket.

(3) Install spindle (9) in frame (10).

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TM 5-3825-230-14&P

(5) Install two shoe levers (6), two anchor pins (5), and two snap rings (4) using snap ring pliers on brake shoes

(2).

(6) Install two adjusting screw assemblies (3).

(7) Position top brake shoe assembly (2), and hook springs (1).

(8) Position bottom brake shoe assembly (2), and install spring (1) using brake spring pliers.

NOTE

Follow-on maintenance:

Install brake drum/hub (para 4-86)

Hand brake linkage connected (para 4-84)

END OF TASK

4-151

TM 5-3825-230-14&P

4-88. WHEEL REPLACEMENT.

This task covers: a.

Front Wheel

INITIAL SETUP

b.

Rear Wheel

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Lifting device with chains

Jack stands

General Safety Instructions

Sweeper on level ground, wheels blocked, hand brake set.

a.

Front Wheel

WARNING

If wheel must be changed during travel, set out markers to avoid an accident.

(1) Removal.

(a) Loosen five lug nuts (1) slightly using a breaker bar, extension and 13/16 in.

socket.

NOTE

Do not raise sweeper any higher than needed to remove wheel off hub.

(b) Raise front of sweeper using a suitable lifting device with chains attached to front lifting eye/tie down point.

(c) Remove five lug nuts (1), and wheel

(2) from hub (3).

(2) Installation.

(a) Position wheel (2) on hub (3), and install five lug nuts (1) using a breaker bar, extension and 13/16 in.

socket.

(b) Slowly lower and remove lifting device and chains.

(c) Tighten lug nuts to 80 lb-ft (108 N.m) using a torque wrench and 13/16 in. socket in pattern shown.

(d) If used, stow markers.

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TM 5-3825-230-14&P

b.

Rear Wheel.

WARNING

If wheel must be changed during travel, set out markers to avoid an accident.

NOTE

This procedure is the same for both left and right rear tires.

(1) Removal.

(a) Loosen five lug nuts (1) slightly using a breaker bar, extension and 13/16 in.

socket.

WARNING

Do not work on any item supported only by lift jacks or hoist. Always use blocks or proper stands to support the item prior to any work.

Equipment may fall and cause injury or death to personnel.

NOTE

Do not raise sweeper any higher than needed to remove wheel off hub.

(b) Raise side of sweeper with bad wheel using a jack positioned under rear lifting eye. Install jack stands.

(c) Remove five lug nuts (1), and wheel (2) from hub (3).

(2) Installation.

(a) Position wheel (2) on hub (3), and install five lug nuts (1) using a breaker bar, extension and 13/16 in.

socket.

(b) Remove jackstands and slowly lower and remove jack.

(c) Tighten lug nuts to 80 lb-ft (108 N.m) using a torque wrench and 13/16 in. socket in pattern shown.

(d) If used, stow markers.

END OF TASK

4-153

TM 5-3825-230-14&P

4-89. FRONT HUB ASSEMBLY REPLACEMENT/REPAIR.

This task covers: a.

b.

Removal

Disassembly

INITIAL SETUP

c.

Cleaning/Inspection d.

Assembly

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Cotter pins

Seal

Grease, item 22 Appendix E

Solvent, dry cleaning, item 31 Appendix E

Equipment Condition

TM or Para

Para 4-88

e.

Installation

Condition Description

Front wheel and tire removed.

a.

Removal.

(1) Remove dust cap (1) using a hammer and chisel.

4-154

b.

TM 5-3825-230-14&P

NOTE

Washer and outer bearing may fall out during this step.

(2) Remove cotter pin (2) using pliers and remove nut (3) using a ratchet and 15/16 in. socket.

(3) Remove washer (4) and outer bearing (5) from hub (6).

(4) Remove hub (6) from spindle (7).

Disassembly.

(1) Remove seal (1) using pliers, chisel and ball peen hammer.

(2) Remove inner bearing (2) and race (3) using a drift and ball peen hammer.

(3) Remove outer race (4) using a drift and ball peen hammer.

c.

Cleaning/Inspection.

(1) Clean grease out of hub.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (380C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

CAUTION

Do not "spin dry" bearings with compressed air, the bearing may fly apart.

(2) Clean all metal parts with dry cleaning solvent P-D-680 and dry.

(3) Check bearings for pitting, rusting and wear.

(4) Check races for grooves.

4-155

4-89. FRONT HUB ASSEMBLY REPLACEMENT/REPAIR (CONT).

d.

Assembly.

NOTE

Bearings must be packed with fresh grease before assembly.

• For ease of installation use a block of wood and ball peen hammer to start the race in the hub, then use a drift and ball peen hammer to seat the race fully.

e.

(1) Pack inner bearing (2) with grease and install inner bearing, race (3), and seal (1) using a block of wood and ball peen hammer.

(2) Install outer race (4) in hub (5) using a block of wood and ball peen hammer.

Installation.

(1) Coat spindle (7), and hub races (6) with grease.

(2) Position hub (6) on spindle (7).

(3) Pack outer bearing (5) with grease and install bearing, washer (4), and nut (3).

(4) Using a torque wrench and 15/16 in.

socket, tighten nut (3) to approximately 40 lb-ft (54 N.m) while rotating hub right and left. The hub should turn freely. Back off nut ¼ to 1/3 turn.

(5) Install cotter pin (2) using pliers and dust cap (1) using a hammer.

NOTE

Follow-on maintenance: Install front

wheel and tire (para 4-88)

END OF TASK

4-156

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-90. TIRE REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Cleaning/Inspection

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Lubricant, tire bead, item 23 Appendix E

Equipment Condition

TM or Para

Para 4-88

c.

Installation

Condition Description

Wheel removed.

General Safety Instructions

Always inflate tire in a safety cage.

a.

b.

Removal.

(1) Slowly remove valve core (1), and allow all air to escape.

(2) Place rim (2), and tire assembly (3) on wooden blocks.

(3) Attach pneumatic tire bead breaker to sides of tire (3), and break tire bead away from rim (2).

(4) Insert curved end of two tire irons between rim and tire bead about 5 in. (12 cm) apart.

(5) Force both tools down and out to lift bead over wheel rim.

(6) Leave one tool in place and put second 5 in. (12 cm) away from first position. Repeat steps (5) and (6) until side of tire is removed from rim.

(7) Turn tire over and repeat steps (3) thru (6) driving other edge of tire over same side of rim as the first.

(8) Remove valve stem (4) from rim (2).

Cleaning/lnspection.

(1) Use wire brush to remove all dirt and corrosion from rim.

(2) Inspect rim (2) for cracks, deep pitting or dents.

(3) Replace rim (2) if any significant damage is found (e.g. cracked weld, bent rim.)

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TM 5-3825-230-14&P

4-90. TIRE REPLACEMENT (CONT).

c.

Installation.

(1) Install valve stem (4) in rim (2), and remove valve cap (5).

(2) Place rim (2) on wooden blocks.

(3) Lubricate bead and rim (2) with tire bead lubricant.

(4) Place tire (3) on top of rim (2). Move tire

(3) until part of lower bead is resting between rims of wheel.

(5) Insert tire iron between wheel rim (2), and lower tire bead. Lever bead over rim.

(6) Force part of top tire bead over edge of rim

(2). Insert tire iron between wheel rim and top tire bead. Lever the bead over rim.

WARNING

To avoid personal injury, never stand close to tire while inflating; inflate in safety cage.

(7) Place tire in safety cage and inflate tire to 40 psi (276 kPa) until tire bead moves over center of rim

(8) Inflate tire to a maximum pressure of 65 psi (448 kPa), and ensure tire bead is seated on rim.

(9) Adjust to operating pressure of 65 psi (448 kPa), and fit valve cap (5).

(10) Remove tire from safety cage.

NOTE

Follow-on maintenance: Install wheel and tire (para 4-88)

END OF TASK

4-91. TIRE REPAIR.

Refer to TM 9-2610-200-14, Operator/Unit/Direct Support/General Support Maintenance Manual for care, maintenance, repair and inspection of pneumatic tires and inner tubes.

4-158

4-92. DECONTAMINATION BRACKET REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

a.

Removal

(1) Remove strap (1) from bracket (2).

(2) Remove four locknuts (3), four screws (4), and bracket (2) from frame (5) using a 9/16 in. open end wrench, ratchet, extension and 9/16 in. socket.

Installation.

b.

(1) Install bracket (2) on frame (5) using four screws (4), and four locknuts (3). Tighten using a 9/16 in. open end wrench, ratchet, extension and 9/16 in. socket.

(2) Install strap (1) on bracket (2).

END OF TASK

4-159

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-93. TRANSPORT CHAIN ASSEMBLY REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Chain (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 2-8

Condition Description

Broom head raised.

NOTE

Procedure is the same for both ends of chain on both sides of vehicle.

a.

b.

Removal. Remove screw (1), and U-bolt (2) from each end of chain (3) using pliers.

Installation. Position chain (3), and install using U-bolt (2), and screw (1) using pliers.

END OF TASK

4-160

TM 5-3825-230-14&P

4-94. SWING FRAME REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Lifting device and chains

Materials/Parts

Lockwashers

Locknut

Chain (See Appendix G for fabrication)

b.

Installation

Equipment Condition

TM or Para

Para 4-78

Para 4-105

Para 4-123

Condition Description

Broom hood wiring harness disconnected.

Hydraulic hoses disconnected.

Sprinkler lines disconnected.

General Safety Instructions

Be sure to attach a suitable lifting device to frame before starting this procedure.

a.

Removal

(1) Attach lifting device and chains to transport brackets (1).

(2) Remove screw (2), lockwasher (3), and pivot pin (4) using a ratchet and 1/2 in. socket.

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4-94. SWING FRAME REPLACEMENT (CONT).

TM 5-3825-230-14&P

b.

(3) Remove two locknuts (5), two washers (6), and swing frame (7), two screws (8), and spacers (9) from brush frame (10) using a ratchet and 1-1/16 in. socket.

(4) If damaged, remove securing pin (11), chain (12), and cotter pin (13).

Installation.

(1) If removed, install securing pin (11), chain (12), and cotter pin (13).

(2) Install two spacers (9) and screws (8) and align swing frame (7) over brush frame (10) and install two washers (6) and two locknuts (5) using a ratchet and 1-1/16 in. socket.

(3) Install pivot pin (4), screw (2) and lockwasher (3) using a ratchet and 1/2 in. socket.

(4) Remove lifting device and chains from transport brackets (1).

NOTE

Follow-on maintenance:

Connect broom hood wiring harness (para 4-78)

Connect hydraulic hoses (para 4-105)

Connect sprinkler lines (para 4-123)

END OF TASK

4-162

4-95. SAFETY CHAIN ASSEMBLY REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

a.

b.

Removal.

(1) Remove four nuts (1), four lockwashers (2), and two U-bolts (3) using a ratchet, extension and 9/16 in. socket.

(2) Pull chains (4) through guides (5) in tow pole (6).

Installation.

(1) Install chains (4) through guides (5) in tow pole (6).

(2) Install two U-bolts (3), and chains (4).

(3) Install four lockwashers (2), and four nuts

(1) using a ratchet, extension and 9/16 in.

socket.

END OF TASK

4-163

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-96. TOW POLE REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Cotter pins b.

Installation

Equipment Condition

TM or Para

Para 3-12

Para 4-95

a.

b.

Removal.

(1) Using pliers, remove two cotter pins (1), and drive out pivot pin (2) using a brass drift and ball peen hammer to release tow pole (3) from strut (4).

(2) Remove tow pole (3).

(3) Remove grease fitting (5) using a 5/16 in.

open end wrench.

Installation.

(1) Align hole in tow pole (3) with hole in steering strut (4), and install pivot pin (2).

(2) Using pliers install two cotter pins (1) in pivot pin (2).

(3) Install grease fitting (5) using a 5116 in.

Open end wrench.

NOTE

Follow-on maintenance: Install safety

chains (para 4-95)

END OF TASK

4-164

Condition Description

Hand brake set.

Safety chains removed.

TM 5-3825-230-14&P

4-97. STEERING STRUT REPLACEMENT/REPAIR.

This task covers: a.

b.

Removal

Disassembly

INITIAL SETUP

c.

Cleaning/Inspection d.

Assembly

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power e.

Installation

Personnel Required

MOS 62B Construction Equipment Repairer (2)

Equipment Condition

TM or Para

Para 3-12

Para 4-96

Para 4-89

Condition Description

Hand brake set.

Tow pole removed.

Front hub removed.

Materials/Parts

Locknuts

Seal

Cotter pins

Grease, item 22 Appendix E

Solvent, dry cleaning, item 31, Appendix E

4-165

4-97. STEERING STRUT REPLACEMENT/REPAIR (CONT).

a.

Removal

WARNING

• Frame weighs 1500 lbs (680 kg).

Attach suitable lifting device prior to removal to prevent possible injury to personnel.

• Steering strut weighs 100 lbs

(45.4 kg). Two mechanics are required for removal to prevent possible injury to personnel.

b.

(1) Attach a suitable lifting device to frame (1) behind strut (2).

(2) Remove five locknuts (3) from hub (4) using a ratchet, extension and 3/4 in.

socket.

(3) Lower strut (2), and move it away from mainframe (1).

(4) Remove dust cap (5) using a chisel and hammer.

(5) Remove cotter pin (6) using pliers.

(6) Remove nut (7), and hub (4) using a ratchet and 15/16 in. socket.

Disassembly.

(1) Remove washer (1), and outer bearing (2) from hub (3).

(2) Remove seal (4), inner bearing (5), and inner bearing race (6) using a drift and ball peen hammer.

(3) Remove outer bearing race (7) using a drift and ball peen hammer.

4-166

TM 5-3825-230-14&P

c.

d.

TM 5-3825-230-14&P

Cleaning/Inspection.

(1) Clean grease out of hub.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

CAUTION

Do not "spin dry" bearings with compressed air. The bearings may fly apart.

(2) Clean all metal parts with dry cleaning solvent P-D-680 and dry.

(3) Check bearings for pitting, rusting and wear.

(4) Check races for grooves.

Assembly.

NOTE

• Bearings must be packed with fresh grease before assembly.

• When installing bearing races, use a block of wood, drift, and a hammer to seat races in hub.

(1) Pack inner bearing (5) with grease and install inner bearing race (6), bearing and seal (4) using a block of wood and a ball peen hammer.

(2) Install outer bearing race (7) using a block of wood and a ball peen hammer.

(3) Pack outer bearing (2) with grease and install bearing in hub (3).

(4) Install washer (1).

4-167

4-97. STEERING STRUT REPLACEMENT/REPAIR (CONT).

e.

Installation.

(1) Coat spindle (8), and inner hub (4) with grease.

(2) Position hub (4) on spindle (8).

(3) Install nut (7) finger tight.

(4) Using a torque wrench and 15/16 in.

socket, tighten nut (7) to 40 Ib-ft (54 N.m) while rotating hub left and right. Hub should move freely.

(5) Back off nut (7) 1/4 to 1/3 turn.

(6) Install cotter pin (6) using pliers and dust cap (5) using a hammer.

(7) Lift strut (2), and position it under mainframe (1).

(8) Install five locknuts (3) on hub (4) using a ratchet, extension and 3/4 in. socket.

(9) Remove lifting device from frame.

NOTE

Follow-on maintenance:

Install front hub (para 4-89)

Install tow pole (para 4-96)

END OF TASK

4-168

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-98. ENGINE ENCLOSURE REPLACEMENT.

This task covers: a.

Door Panels b.

Front Panels c.

Instrument Panel d.

Rear Panel e.

Top Access Panel

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Lockwashers

Rivets

Equipment Condition

TM or Para

Instrument Panel:

Para 4-80

Para 4-47

Rear Panel:

Para 4-37

Para 4-51

Main Engine Enclosure:

Para 4-80

Para 4-47

Para 4-37

Para 4-51

f.

Main Engine Enclosure g.

Hasp and Latch

Condition Description

Control panel wires removed.

Throttle control cable and engine cut off cable removed.

Air cleaner removed.

Exhaust pipe removed.

Control panel wires removed.

Throttle control cable and engine cut off cable removed.

Air cleaner removed.

Exhaust pipe removed.

NOTE

Each panel may be removed separately or the entire engine enclosure may be removed as one piece with panels attached.

Text begins on next page.

4-169

4-98. ENGINE ENCLOSURE REPLACEMENT (CONT).

a.

Door Panels.

TM 5-3825-230-14&P

(1) Removal.

(a) Slide door panel (1) (instrument side) off main engine enclosure (2).

(b) Slide door panel (3) (muffler side) off main engine enclosure (2).

(2) Installation.

(a) Slide door panel (3) (muffler side ) on main engine enclosure (2).

(b) Slide door panel (1) (instrument side) on main engine enclosure (2).

4-170

TM 5-3825-230-14&P

b.

Front Panels.

(1) Removal.

(a) Remove two screws (1), two lockwashers (2), and two washers (3) from fuel tank (4) using a ratchet and 7/16 in. socket.

(b) Remove screw (5), lockwasher (6), washer (7), nut (8), and panel (9) (instrument side) from main engine enclosure (10) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(c) Remove screw (11), lockwasher (12), washer (13), nut (14), and panel (15) (muffler side) from main engine enclosure (10) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(2) Installation .

(a) Install washer (13), lockwasher (12), screw (11), panel (15) (muffler side), and nut (14) on main engine enclosure (10) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(b) Install washer (7), lockwasher (6), screw (5), panel (9) (instrument side) and nut (8) on main engine enclosure (10) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(c) Install two washers (3), two lockwashers (2), and two screws (1) on fuel tank (4) using a ratchet and

7/16 in. socket.

4-171

4-98. ENGINE ENCLOSURE REPLACEMENT (CONT).

c.

Instrument Panel.

TM 5-3825-230-14&P

(1) Removal. Remove two screws (1), two washers (2), two lockwashers (3), two nuts (4), and panel (5) from main engine enclosure (6) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(2) Installation. Install two washers (2), two screws (1), panel (5), two lockwashers (3), and two nuts (4) on main engine enclosure (6) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

4-172

TM 5-3825-230-14&P

d.

Rear Panels.

(1) Removal. Remove seven screws (1), seven lockwashers (2), seven washers (3), and rear panel (4) from main engine enclosure (5) using a 7/16 in. open end wrench.

(2) Installation. Install rear panel (4), seven washers (3), seven lockwashers (2), and seven screws (1) on main engine enclosure (5) using a 7/16 in. open end wrench.

4-173

4-98. ENGINE ENCLOSURE REPLACEMENT (CONT).

e.

Top Access Panel

TM 5-3825-230-14&P

(1) Removal. Remove four screws (1), four lockwashers (2), four washers (3), and panel (4) from main engine enclosure (5) using a ratchet, and 7/16 in. socket.

(2) Installation. Install panel (4), four washers (3), four lockwashers (2), and four screws (1) on main engine enclosure (5), using a ratchet and 7/16 in. socket.

4-174

f.

Main Engine Enclosure.

TM 5-3825-230-14&P

(1) Removal. Remove six screws (1), six lockwashers (2), six washers (3), and main engine enclosure (4) using a 7/16 in. open end wrench.

(2) Installation. Position main engine enclosure (4), and install six washers (3), six lockwashers (2), and six screws (1) using a 7/16 in. open end wrench.

4-175

4-98. ENGINE ENCLOSURE REPLACEMENT (CONT).

g.

Hasp and Latch.

TM 5-3825-230-14&P

(1) Removal. Drill out four rivets (1) using an electric drill and 1/8 in. drill bit and remove hasps (2), and latches

(3) from door panels (4), and main engine enclosure (5).

(2) Installation. Install latch (3) on main engine enclosure (5), and hasps (2) on door panels (4). Secure latches and hasps with rivets (1) using a rivet gun.

NOTE

Follow-on maintenance:

Instrument Panel:

.

Install Control panel wires (para 4-80)

.

Install throttle control cable and engine cut off cable (Para 4-47)

Rear Panel:

.

Install air cleaner (para 4-37)

.

Exhaust pipe removed (para 4-51)

Main Engine Enclosure:

.

Install control panel wires (pa ra 4-80)

.

Install throttle control cable and engine cut off cable (para 4-47)

.

Install air cleaner (para 4-37)

.

Install exhaust pipe (para 4-51)

END OF TASK

4-176

4-99. DATA PLATE REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive b.

Installation

Materials/Parts

Lockwashers

a.

Removal. Remove four screws (1), lockwashers

(2), and plate (3).

NOTE

Make sure surface is clean and dry before installing data plate.

b.

Installation. Install plate (3), lockwashers (2), and screws (1).

END OF TASK

4-177

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-100. DECAL REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive b.

Cleaning/Inspection

Materials/Parts

Decal c.

Installation

Solvent, dry cleaning, item 31, Appendix E

a.

Removal Peal damaged decal from vehicle using a putty knife.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor.

Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is

140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

b.

Cleaning/Inspection. Using dry cleaning solvent P-D-680, thoroughly clean area where decal will be installed.

NOTE

Surface should be clean and dry before applying new decal.

Installation. Remove paper backing and install new decal.

c.

END OF TASK

4-178

TM 5-3825-230-14&P

4-101. HYDRAULIC PUMP ASSEMBLY REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

Equipment Condition

TM or Para

Para 4-105

Condition Description

Hydraulic hoses disconnected from pump.

a.

b.

NOTE

Place suitable container beneath hydraulic pump prior to removal.

Removal. Remove two mounting screws (1), two lockwashers (2), two washers (3), and hydraulic pump (4) using a 17 mm open end wrench.

Installation. Install hydraulic pump (4), two washers (3), two lockwashers (2), and two mounting screws (1) using a 17 mm open end wrench.

NOTE

Follow-on maintenance: Connect hydraulic hoses (para 4-105)

END OF TASK

4-179

TM 5-3825-230-14&P

4-102. HYDRAULIC MOTOR AND MOUNT REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Locknuts

Equipment Condition

TM or Para

Para 4-116

Para 4-105

Condition Description

Motor guard removed

Hydraulic motor inlet and outlet hoses removed.

a.

b.

Removal.

(1) Remove two locknuts (1), two screws (2), two washers (3), and mount (4) using a 3/4 in. open end wrench, ratchet and 3/4 in.

socket.

(2) Remove two locknuts (5) using a 3/4 in.

open end wrench.

(3) Remove motor (6) by pulling out and away from mount (4)

Installation.

NOTE

Make sure hose connections are pointing to rear of sweeper.

(1) Position motor (6) on mount (4), and install two locknuts (5) using a 3/4 in. open end wrench.

(2) Install motor (6) shaft into core shaft (7).

(3) Install screws (2), washers (3), and locknuts (1) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

NOTE

Follow-on maintenance:

Install motor inlet and outlet hoses (para 4-105)

Install motor guard (para 4-116)

END OF TASK

4-180

TM 5-3825-230-14&P

4-103. HYDRAULIC CONTROL VALVE REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Locknuts

O-ring

Tape, Teflon, item 34 Appendix E

Equipment Condition

TM or Para

Para 4-108

Para 4-105

Condition Description

Hydraulic filter housing removed.

Hydraulic hoses disconnected from valve.

a. Removal

(1) Remove tee pipe (1), adapter (2), and O-ring (3) from valve (4) using a 1-1/4 in. open end wrench.

(2) Remove three screws (5), three locknuts (6), and remove valve (4) using two 9/16 in. open end wrenches.

4-181

4-103. HYDRAULIC CONTROL VALVE REPLACEMENT (CONT).

TM 5-3825-230-14&P

b. Installation.

(1) Install valve (4), three screws (5), and three locknuts (6) using two 9/16 in. open end wrenches.

NOTE

Teflon tape is applied to threads of adapter opposite O-ring side.

(2) Wrap Teflon tape on threads of adapter (2) .

(3) Install O-ring (3), adapter (2), and tee pipe (1) using a 1-1/4 in. open end wrench.

NOTE

Follow-on maintenance:

•. Install hydraulic filter housing (para 4-108)

•. Connect hydraulic hoses to control valve (para 4-105)

END OF TASK

4-182

TM 5-3825-230-14&P

4-104. BREATHER REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Appendix E

Solvent, dry cleaning, item 31, Appendix E

b.

Installation

Materials/Parts

Compound, sealing, pipe thread item 16

a. Removal

(1) Remove screw (1), breather (2), and filter (3) using a cross tip screwdriver.

(2) Remove reducer (4) using a 7/8 in. open end wrench.

(3) Remove reducer fitting (5), connector (6), and breather pipe (7) from hydraulic reservoir (8) using pliers and 5/8 in. Open end wrench.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38

°C) and for type II is 140°F (60

°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

b. Cleaning/ Inspection. Clean filter (3) in P-D-680 and allow to dry.

4-183

4-104. BREATHER REPLACEMENT (CONT) c. Installation.

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 a well ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Apply pipe thread sealing compound to all threads.

(2) Assemble connector (6), and breather pipe (7) using pliers.

(3) Install breather pipe (7) in hydraulic reservoir

(8), and tighten using pliers.

(4) Install reducer fitting (5), and reducer (4) using a

7/8 in. and 5/8 in. open end wrenches.

(5) Install filter (3), breather (2), and screw (1) using cross tip screwdriver.

END OF TASK

4-184

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-105. HYDRAULIC HOSE ASSEMBLY REPLACEMENT/REPAIR.

This task covers: a.

Return Tube Replacement b.

Motor Inlet Hose Replacement c Motor Outlet Hose Replacement d.

Cylinder Hose Replacement f.

Pump Inlet Hose Replacement e.

Pump Outlet Hose Replacement g.

Hose Repair

INITIAL SETUP:

Tools

Tool Kit General Mechanic: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Locknuts

O-rings

Compound, sealing, pipe thread, item 16

Appendix E

Fluid, hydraulic, item 19 Appendix E

Ties, plastic, item 36 Appendix E

Hydraulic hose (See Appendix G for fabrication )

Hose Guard (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 4-98

Para 4-106

Condition Description

Front panel (instrument side) removed.

Hydraulic system drained.

General Safety Instructions

Hydraulic system is under extreme pressure, do not remove hydraulic lines while engine is running.

CAUTION

Plug all hydraulic lines, ports and fittings to prevent contamination when removed.

4-185

4-105. HYDRAULIC HOSE ASSEMBLY REPLACEMENT/REPAIR (CONT) .

a. Return Tube Replacement .

TM 5-3825-230-14&P

(1) Removal.

(a) Remove clamps (1), and hose (2) using a flat tip screwdriver.

(b) Remove insert bead (3), and elbow (4) using a 1-1/8 in. open end wrench and pipe wrench.

(c) Remove two locknuts (5) using a ratchet and 7/16 in. socket. Remove clamps (6) using a flat tip screwdriver.

(d) Remove two clamps (7), and tube (8) using a flat tip screwdriver.

(2) Installation.

(a) Install hose (2), and clamps (1) using a flat tip screwdriver.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(b) Apply pipe thread sealing compound on elbow (4) threads.

(c) Install insert bead (3), and elbow (4) using a 1-1/8 in. open end wrench and a pipe wrench.

(d) Install two clamps (6), and two locknuts (5) using a ratchet and 7/16 in. socket.

(e) Install hose (8) using two clamps (7). Tighten using a flat tip screwdriver.

4-186

b. Motor Inlet Hose Replacement.

(1) Removal.

(a) Loosen couplings (1) using a 1-1/4 in.

open end wrench and remove hose (2) from fittings (3 and 4).

(b) Remove fittings (3 and 4) using a 1-1/4 in.

and 1-1/8 in. open end wrenches.

(c) Remove nut (5), and clamp assembly (6) using a ratchet and 7/16 in. socket.

Remove plastic ties (7).

(d) Remove O-rings (8 and 9) from fittings (3 and 4).

(2) Installation.

(a) Install 0-rings (8 and 9) on fittings (3 and

4).

(b) Install fittings (3 and 4) using a 1-1/4 in.

and 1-1/8 in. open end wrench.

(c) Secure hose (2) to fittings (3 and 4) using couplings (1). Tighten using a 1-1/4 in.

open end wrench.

(d) Install clamp (6), and locknut (5) on hose

(2) using a ratchet and 7/16 in. socket.

Install plastic ties (7), as needed.

4-187

TM 5-3825-230-14&P

4-105. HYDRAULIC HOSE ASSEMBLY

REPLACEMENT/REPAIR (CONT).

c. Motor Outlet Hose Replacement.

(1) Removal.

(a) Remove two clamps (1), and plastic ties

(2), and pull hose (3) off insert beads (4 and 5).

(b) Remove nut (6), clamp assembly (7), and hose (3) using a ratchet and 7/16 in.

socket.

(c) Remove insert bead (4) using a 1-1/8 in.

open end wrench.

(d) Remove insert bead (5) using a 1 in. open end wrench.

(e) Remove O-ring (8) from insert bead (5).

(2) Installation.

(a) Install O-ring (8) on insert bead (5).

(b) Install insert bead (5) using a 1 in. Open end wrench.

(b) Install insert bead (4) using a 1-1/8 in.

open end wrench.

(c) Install hose (3) using clamp assembly (7), nut (6), and clamps (1). Tighten using a ratchet and 7/16 in. socket.

(d) Install plastic ties (2), as needed.

4-188

TM 5-3825-230-14&P

d. Cylinder Hose Replacement.

(1) Removal.

(a) Remove coupling (1) using a 9/16 in.

open end wrench and remove cylinder hose (2).

(b) Remove fitting (3) using a 1/2 in. open end wrench.

(c) Remove hose coupling (4) using a 9/16 open end wrench.

(d) Remove restrictor (5), straight adapter (6), and pipe nipple (7) using a 11/16 in. open end wrench and pliers.

(2) Installation.

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 a well ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(a) Apply pipe thread sealing compound to threads of pipe nipple (7).

(b) Install pipe nipple (7), adapter (6), and restrictor fitting (5) using a 11/16 open end wrench and pliers.

(c) Install hose (2), and coupling (4). Tighten using a 9/16 in. open end wrench.

(d) Install fitting (3) using a 1/2 in. open end wrench.

(e) Install hose (2), and coupling (1). Tighten using a 9/16 in. open end wrench.

4-189

TM 5-3825-230-14&P

4-105. HYDRAULIC HOSE ASSEMBLY REPLACEMENT/REPAIR (CONT).

e. Pump Outlet Hose Replacement.

(1) Removal.

(a) Loosen two couplings (1) using a 1-1/4 in.

open end wrench and remove hose (2).

(b) Remove fitting (3) using a 1-1/4 in. open end wrench.

(c) Remove fitting (4) using a 1-1/4 in. open end wrench.

(d) Remove O-ring (5) from fitting (3).

(e) Remove O-ring (6) from fitting (4).

(2) Installation.

(a) Install O-ring (6) on fitting (4).

(b) Install fitting (4) using a 1-1/4 in. Open end wrench.

(c) Install O-ring (5) on fitting (3).

(d) Install fitting (3) using a 1-1/4 in. Open end wrench.

(e) Install hose (2) and couplings (1) on fittings (3 and 4) using a 1-1/4 in. Open end wrench.

TM 5-3825-230-14&P

4-190

TM 5-3825-230-14&P

f. Pump Inlet Hose Replacement.

(1) Removal.

(a) Remove clamp (1) and hose (2) using a flat tip screwdriver.

(b) Remove O-ring (3) from fitting (4).

(c) Remove fitting (4) using a 1-5/8 in. open end wrench.

(d) Remove clamp (5) from hose (2).

(e) Remove bead insert (6) using a 1-3/8 in. open end wrench.

(f) Remove reducer bushing (7) using a 1-13/16 in. open end wrench and elbow

(2) Installation .

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(a) Apply thread sealing compound to threads of elbow (8).

(b) Install reducer bushing (7), using a 1-13/16 in. open end wrench and elbow (8) using a pipe wrench.

(c) Install bead insert (6) using a 1-3/8 in. open end wrench.

(d) Install hose (2) on bead insert (6) using clamp (5). Tighten using a flat tip screwdriver.

(e) Install fitting (4) using a 1-5/8 in. open end wrench.

(f) Install O-ring (3) on fitting (4).

(g) Install hose (2) on fitting (4) using clamp (1). Tighten using a flat tip screwdriver.

4-191

g. Hose Repair. Refer to Appendix G for hydraulic hose repair.

NOTE

Follow-on maintenance:

• Front panel (instrument side) installed (para 4-98)

• Fill hydraulic system as needed (para 4-106)

• Start vehicle and check hydraulic system for leaks

END OF TASK

4-192

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-106. HYDRAULIC OIL DRAIN/FILL.

This task covers: a.

Drain b.

Fill

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Fluid, hydraulic, item 19, Appendix E

Equipment Condition

TM or Para

Para 3-13

Condition Description

Bleed hydraulic system.

a. Drain.

NOTE

Hydraulic system capacity is 7.5 gal. (28.38 1).

(1) Place a suitable container under sweeper.

(2) Loosen clamp (1) using a flat tip screwdriver and remove hose (2). Allow oil to drain.

(3) Dispose of hydraulic oil in accordance with local policy.

b. Fill.

(1) Install hose (2), and tighten clamp (1) using a flat tip screwdriver.

4-193

4-106. HYDRAULIC OIL DRAIN/FILL (CONT).

(2) Remove dipstick (3) and fill hydraulic reservoir

(4) in accordance with lubrication instructions

(Chapter 3, Section I).

(3) Install dipstick (3).

NOTE

Follow-on maintenance: Start vehicle and check hydraulic system for leaks.

END OF TASK

4-194

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-107. HYDRAULIC FILTER REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Filter

Equipment Condition

TM or Para

Para 4-106

Condition Description

Hydraulic system drained.

NOTE

Place a suitable container beneath hydraulic filter prior to removal.

a.

Removal. Remove filter (1) from housing (2) using a filter wrench. Dispose of filter in accordance with location policy.

b.

Installation. Lubricate gasket on filter (1) with fresh hydraulic oil and install filter on housing (2). Tighten using a filter wrench.

NOTE

Follow-on maintenance: Fill hydraulic system (para 4-106)

END OF TASK

4-195

TM 5-3825-230-14&P

4-108. HYDRAULIC FILTER HOUSING REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Compound, sealing, pipe thread item 16

Appendix E

Fluid, hydraulic, item 19 Appendix E

Equipment Condition

TM or Para

Para 4-105

Para 4-107

Condition Description

Hydraulic hoses disconnected from filter housing.

Hydraulic filter removed.

a. Removal.

(1) Remove straight adapter (1), and filter housing (2) as an assembly using a 1-3/8 in. open end wrench.

(2) Remove straight adapter (1) from filter housing (2) using a 1-3/8 in. open end wrench.

(3) Remove bead insert (3) from reducer bushing (4) using a 1-1/8 and 1-3/8 in. open end wrenches.

(4) Remove reducer bushing (4) from filter housing (2) using a 1-3/8 in. open end wrench.

4-196

TM 5-3825-230-14&P

b. Installation.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Apply pipe thread sealing compound to threads of adapter (1), reducer bushing (4), and bead insert (3).

(2) Install reducer bushing (4) into filter housing (2) using a 1-3/8 in. open end wrench.

(3) Install bead insert (3) into reducer bushing (4) using a 1-1/8 in. open end wrench.

(4) Install straight adapter (1) into filter housing (2) using a 1-3/8 in. open end wrench.

(5) Install straight adapter (1), and filter housing (2) as an assembly using a 1-3/8 in. open end wrench.

NOTE

Follow-on maintenance:

Install hydraulic filter (para 4-107)

Connect hydraulic hoses to filter housing (para 4-105)

END OF TASK

4-197

TM 5-3825-230-14&P

4-109. TACHOMETER GEAR ASSEMBLY REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 3-5

Condition Description

Open right access cover.

a.

b.

Removal

(1) Remove tachometer cable end (1) from tachometer gear assembly (2) using a 14 mm wrench.

(2) Remove two screws (3) and tachometer gear assembly (2) using a 4 mm hex head wrench.

Installation.

(1) Install tachometer gear assembly (2) using two screws (3). Tighten using a 4 mm hex head wrench.

(2) Install tachometer cable end (1) on tachometer gear assembly (2) using a 14 mm wrench.

NOTE

Follow-on maintenance: Close right access cover (para 3-5)

END OF TASK

4-198

TM 5-3825-230-14&P

4-110. TACHOMETER AND TACHOMETER CABLE REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 4-73

Para 4-109

Materials/Parts

Star washers

Lockwashers tachometer gear.

a. Removal

(1) Remove screw (1), lockwasher (2), and washer

(3) using a 7/16 in. open end wrench. Lower panel (4).

(2) Remove wire and bulb (5).

(3) Remove tachometer cable (6).

CAUTION

Hold gage from front or damage to gage may result.

(4) Remove two nuts (7), two star washers (8), and two brackets (9) using a 5/16 in. Open end wrench.

(5) Remove gage (10) from front of panel (4).

Condition Description

Battery cable disconnected.

Tachometer cable disconnected from

b. Installation.

(1) Install gage (10) in front of panel (4).

(2) Lower panel (4), and install two brackets (9), two star washers (8), and two nuts (7) using a 5/16 in. Open end wrench.

(3) Install tachometer cable (6) using pliers.

(4) Install wire and bulb (5).

(5) Raise panel (4), and install washer (3), lockwasher (2), and screw (1) using a 7/16 in. open end wrench.

NOTE

Follow-on maintenance:

Connect battery cables (para 4-73)

Connect tachometer cable to tachometer gear (para 4-109)

END OF TASK

4-199

TM 5-3825-230-14&P

4-111. BROOM PATTERN ADJUSTMENT.

This task covers:

Adjustment

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Hearing protection must be worn when performing adjustments in close proximity to the sweeper. Long term exposure may cause hearing damage.

NOTE

This adjustment must be made frequently to compensate for brush wear.

(1) Start engine (para 2-8a), and raise brush (1) two inches (10 cm) above a smooth surface.

4-200

TM 5-3825-230-14&P

(2) Shutdown engine (para 2-8b), and loosen locknut (2), and adjust spring adjustment nuts (3) on spring assemblies

(4) on each side of cylinder attachment until there is no space between nuts (3), spring spacer (5), and spring (4) using a 1-1/8 in. open end wrench.

(3) Start engine (para 2-8a) and lower brush by moving valve lever (6) until it catches in full lowered position.

(4) Raise brush (1), and measure width of area contacted by brush (para 2-8h).

NOTE

Ideal width of brush contact (brush pattern) should be 2-4 in. (5 to 10 cm).

(5) If brush pattern (7) is wider than 4 in. (10 cm), increase spring tension by turning adjusting nuts away from brush.

If pattern is less than 2 in. (5 cm) decrease spring tension by turning adjusting nuts toward brush.

(6) Repeat steps (3) through (5) until correct pattern is attained. Tighten locknuts (2) against adjusting nuts (3) to

secure spring tension. Shut down engine (para 2-8b).

END OF TASK

4-201

4-112. FRONT DIRT DEFLECTOR ASSEMBLY REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Lockwashers

TM 5-3825-230-14&P

a. Removal Remove seven screws (1), seven washers (2), retainer bar (3), dirt deflector (4), seven lockwashers

(5), and seven nuts (6) from hood (7) using a 1/2 in. open end wrench, ratchet and 1/2 in. socket.

b. Installation. Install dirt deflector (4) on hood (7) using retaining bar (3), screws (1), washers (2), lockwashers (5), and nuts (6). Tighten using a 1/2 in. open end wrench, ratchet and 1/2 in. socket.

END OF TASK

4-202

4-113. SIDE DIRT 'DEFLECTOR REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

NOTE

Procedure is the same for both right and left sides.

a. Removal Remove two locknuts (1), two screws

(2), two washers (3), and deflector (4) using a

7/16 in. open end wrench, ratchet, extension and 7/16 in. socket.

b. Installation. Install deflector (4) using two screws (2), two washers (3), and two locknuts

(1). Tighten using a 7/16 in. open end wrench, ratchet, extension and 7/16 in. socket.

END OF TASK

4-203

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-114. BRUSH FRAME ASSEMBLY REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Lockwashers

Personnel Required

MOS 62B Construction Equipment Repairer (2)

Equipment Condition

TM or Para

Para 4-102

Para 4-78

Para 4-105

Para 4-117

NOTE

This task requires a mechanic and an assistant.

a. Removal.

Condition Description

Hydraulic motor removed.

Broom hood wiring harness disconnected.

Hydraulic hoses disconnected.

Brush removed.

(1) Remove two locknuts (1), and two washers (2) using a ratchet and 1-1/16 in. socket. Remove brush frame assembly.

4-204

TM 5-3825-230-14&P

(2) Remove two nuts (3), two lockwashers (4), two washers (5), two screws (6), and snubber bracket (7) using a 9/16 in. open end wrench, ratchet and 9/16 in. socket.

(3) Remove two screws (8) and two carriage washers (9) from brush frame (10) using a ratchet and 1-1/16 in.

socket.

b. Installation.

(1) Install snubber bracket (7) using two screws (6), two washers (5), two lockwashers (4), and two locknuts (3).

Tighten using a 9/16 in. open end wrench, ratchet and 9/16 in. socket

(2) Install two screws (8) and two carriage washers (9) on brush frame (10) using a ratchet and 1-1/6 in. socket.

(3) Install brush frame assembly on swing frame (11) using two washers (2) and two locknuts (1).

END OF TASK

NOTE

Follow-on maintenance:

• Install brush (para 4-117)

• Install hydraulic motor (para 4-102)

• Connect hydraulic hoses (para 4-105)

• Connect broom hood wiring harness (para 4-78)

4-205

TM 5-3825-230-14&P

4-115. BROOM HOOD REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts Para 4-113

Personnel Required

MOS 62B Construction Equipment Repairer (2)

Equipment Condition

TM or Para

Para 4-112

Para 4-124

Para 4-78

NOTE

• This task requires a mechanic and an assistant.

• Brush shown removed for clarity.

4-206

Condition Description

Front dirt deflector removed.

Side dirt deflectors removed.

Spray bar removed.

Broom hood wiring harness removed.

TM 5-3825-230-14&P

a.

Removal. Remove six locknuts (1), six screws (2), and 12 washers (3) using a 7/16 in. open end wrench, ratchet, extension and 7/16 in. socket. Remove broom hood (4) from brush frame (5).

b. Installation. Install broom hood (4) on brush frame (5), and secure with 12 washers (3), six screws (2), and six locknuts (1) using a 7/16 in. open end wrench, ratchet, extension and 7/16 in. socket.

NOTE

Follow-on Maintenance:

Install broom hood wiring harness (para 4-78)

Install spray bar (para 4-124)

Install side dirt deflectors (para 4-113)

Install front dirt deflector (para 4-112)

END OF TASK

4-207

TM 5-3825-230-14&P

4-116. MOTOR GUARD REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Installation

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Equipment Condition

TM or Para

Para 4-70

a.

Removal. Remove two screws (1), two washers (2), two locknuts (3), and guard (4) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

b. Installation. Install guard (4) using two locknuts (3), two washers (2), and two screws (1). Tighten using a 3/4 in. open end wrench, ratchet and 3/4 in.

socket.

NOTE

Follow-on maintenance: Install right

side lamp bracket assembly (para 4-

70).

END OF TASK

Condition Description

Right side lamp bracket assembly removed.

4-208

TM 5-3825-230-14&P

4-117. BRUSH REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Installation

Equipment Condition

TM or Para

Para 4-115

Para 4-102

Condition Description

Broom hood removed.

Hydraulic motor removed.

NOTE

This task may also be used to reverse the entire brush assembly as one piece to increase the lift of the brush.

a.

Removal

CAUTION

Release spring tension on hydraulic cylinder to allow brush to drop.

Damage to equipment may occur.

(1)

Refer to para 4-119 to back off nut and

release tension on hydraulic cylinder.

NOTE

Bracket is located on right side only.

(2) Remove two locknuts (1), two washers (2), two screws (3), and bracket (4) using a ratchet and 3/4 in. socket.

(3) Repeat step (2) for opposite side.

(4) Remove brush assembly (5) from brush frame (6).

(5) Loosen setscrew (7) using a 15/16 in. Hex head wrench.

4-209

TM 5-3825-230-14&P

4-117.

BRUSH REPLACEMENT (CONT).

NOTE

Collar contains an unthreaded hole to insert drift pin.

(6) Using a drift and hammer, tap locking collar (8) counterclockwise to loosen and remove collar from bearing (9).

(7) Remove bearing (9) from end of brush assembly (5).

(8) Repeat steps (5), (6), and (7) on opposite side.

b. Installation.

(1) Install locking collar (8), and bearings (9) on end of brush assembly (5).

NOTE

Bearing and locking collar are slightly oval shaped.

(2) Rotate collar (8) clockwise until it matches with bearing (9), and bearing slides into lock against the rotation of broom. Tap in collar until it locks using a drift and hammer.

(3) Tighten setscrew (7) in locking collar (8) using a 15/16 in. hex head wrench.

(4) Repeat steps (1), (2), and (3) on opposite side.

(5) Position brush assembly (5) within brush frame (6).

(6) Install bracket (4) on right side of frame (6).

(5) Secure bearing (9) to brush frame (6) using two screws (3), two washers (2), and two locknuts (1). Tighten using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

(6) Repeat steps (5) and (6) on opposite side.

NOTE

Follow-on maintenance:

Install broom hood (para 4-115)

Install hydraulic motor (para 4-102)

Adjust broom pattern (para 4-111)

END OF TASK

4-210

TM 5-3825-230-14&P

4-118. HYDRAULIC CORE/BRUSH SET REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic: Automotive

Materials/Parts

Lockwashers

Personnel Required

MOS 62B Construction Equipment Repairer (2)

Equipment Condition

TM or Para

Para 4-117

Condition Description

Brush assembly removed.

a.

Removal .

(1) Remove eight screws (1), eight lockwashers (2), and two discs (3) using a ratchet and 1/2 in. socket.

(2) Slide plastic bristle wafers (4), and spacers (5) off core (6).

4-211

TM 5-3825-230-14&P

4-118.

HYDRAULIC CORE/BRUSH SET REPLACEMENT (CONT)

b. Installation.

(1) Install disk (3), four lockwashers (2), and four screws (1) using a ratchet and 1/2 in.

socket.

CAUTION

Use a pallet or suitable cribbing to support core upright during assembly to prevent damage to brush.

(2) Stand core (6) upright, on disc (3).

NOTE

• A ladder is required to install wafers and spacers on core.

• Plastic bristle wafers are located at both ends.

(3) Alternately install plastic bristle wafers (4) and spacers (5) over full length of core (6).

(4) Install remaining disc (3), four lockwashers

(2), and four screws (1) on upper end of core (6) using a ratchet and 1/2 in. socket.

WARNING

Stand clear of brush assembly during lowering procedure. Personal injury may result from falling brush.

(5) Lower brush assembly to horizontal position.

NOTE

Follow-on maintenance: Install brush assembly (para 4-117)

END OF TASK

4-212

TM 5-3825-230-14&P

4-119. HYDRAULIC CYLINDER REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Cotter pins

Personnel Required

MOS 62B Construction Equipment Repairer (2)

Equipment Condition

TM or Para

Para 4-114

Condition Description

Brush frame assembly removed.

a.

Removal .

(1) Turn nuts (1), and release tension on springs (2) using a 1-1/8 in. open end wrench.

(2) Remove cotter pins (3) using pliers and drive out pin (4) using a drift and ball peen hammer.

(3) Remove balance rod assemblies (5).

(4) Remove cotter pins (6) using pliers and drive out pins (7) using a drift and ball peen hammer.

4-213

4-119.

HYDRAULIC CYLINDER REPLACEMENT (CONT).

TM 5-3825-230-14&P

(5) Remove cotter pins (8) using pliers and drive out pin (9) using a drift and ball peen hammer.

(6) Remove hydraulic cylinder (10).

(7) Remove two springs (2), and four washers (11).

b. Installation.

(1) Install hydraulic cylinder (10).

(2) Install pin (9), and cotter pin (8) using pliers and ball peen hammer.

(3) Install pin (7), and install cotter pins (6) using pliers and ball peen hammer.

(4) Install two springs (2), and four washers (11) on balance rod assemblies (5).

(5) Install balance rod assemblies (5) with washers (11), and springs (2).

(6) Install pin (4), and cotter pins (3) using pliers.

(7) Tighten nuts (1) using a 1-1/8 in. open end wrench.

NOTE

Follow-on maintenance:

Install brush frame (para 4-114)

Adjust broom pattern (para 4-111)

END OF TASK

4-214

TM 5-3825-230-14&P

4-120. SPRAY PUMP AND BRACKET REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Rubber Grommets

Compound, pipe sealing, item 16 Appendix E

Equipment Condition

TM or Para

Para 4-73

Para 2-8

Condition Description

Battery cables disconnected.

Water tank shutoff valve closed.

a.

Removal.

(1) Remove nut (1), lockwasher (2), and ground wire (3) from frame (4) using a ratchet and 7/16 in. socket.

4-215

4-120.

SPRAY PUMP AND BRACKET REPLACEMENT (CONT).

TM 5-3825-230-14&P

(2) Remove wire (5) from connector (6).

(3) Loosen clamps (7 and 8) using a screwdriver and remove hoses (9 and 10).

(4) Remove two locknuts (11), brackets (12 and 13), and screws (14) from frame (4) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

(5) Remove four screws (15), four washers (16), four grommets (17), and four locknuts (18) using a 7/16 in.

open end wrench, ratchet and 7/16 in. socket. Remove bracket (12) from pump (19).

(6) Remove beaded adapters (20 and 21) from pump (19) using a 11/16 in. open end wrench.

4-216

TM 5-3825-230-14&P

b. Installation.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Lightly apply pipe thread sealing compound to threads of beaded adapters (20 and 21).

(2) Install beaded adapters (20 and 21) in pump (19) using a 11/16 in. open end wrench.

(3) Position bracket (12) on pump (19) and install four screws (15), four washers (16), four grommets (17), and four locknuts (18) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

NOTE

Position rear of pump facing tire.

(4) Install brackets (13 and 12), screws (14), and locknuts (11) on frame (4) using a 3/4 in. open end wrench, ratchet and 3/4 in. socket.

(5) Install hoses (9 and 10) on beaded inserts (20 and 21), and tighten clamps (7 and 8) using a screwdriver.

(6) Connect wire (5) to connector (6).

(7) Position ground wire (3) on frame (4) and install lockwasher (2) and nut (1) using a ratchet and 7/16 in.

socket.

NOTE

Follow-on maintenance:

Connect battery cables (para 4-73)

8)

Open water tank shut off valve (para 2-

• Check spray system for leaks

END OF TASK

4-217

TM 5-3825-230-14&P

4-121. WATER TANK ASSEMBLY REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Locknuts

Gaskets

Personnel Required

MOS 62B Construction Equipment Repairer (2)

Equipment Condition

TM or Para

Para 4-123

Condition Description

Sprinkler lines disconnected from water tank.

a.

Removal.

(1) Remove drain plug (1) using a 13/16 in.

Open end wrench. Allow tank (2) to drain.

(2) Install drain plug (1).

(3) Remove cap (3) from tank (2).

(4) If necessary, remove rope (4) from tank

(2), and cap (3).

(5) Slowly loosen two locknuts (5) to take pressure off straps (6) using a 3/4 in. Open end wrench.

(6) Remove two locknuts (5), and washers (7).

(7) Remove two J-bolts (8) from saddle (9).

Remove two clips (10) from J-bolts.

(8) Remove two straps (6) from tank (2).

(7) Carefully lift tank (2), and remove from saddle (9).

4-218

TM 5-3825-230-14&P

NOTE

Water tank fittings are all left hand

threads.

(8) While assistant holds pipe plug (1) using a

13/16 in. open end wrench, remove nut

(12) using a pipe wrench.

(9) Remove plastic seal (13), and rubber seal

(14).

(10) Remove fitting (11), reducer (15), and drain plug (1) as an assembly through tank.

(11) Remove drain plug (1) from reducer (15) using a 13/16 in. open end wrench.

(12) Remove reducer (15) from fitting (11) using a pipe wrench.

(13) Remove rubber seal (16) from fitting (11).

(14) While assistant reaches through tank (2), and holds fitting (17) with channel locks, remove nut (18) using a pipe wrench.

(15) Remove plastic seal (19), rubber seals (20 and 21), and fitting (17).

b. Installation.

NOTE

Water tank fittings are all left hand threads.

(1) Install rubber seal (21) on fitting (17).

(2) While assistant reaches through tank (2), and holds fitting (17) with channel locks, install rubber seal (20), plastic seal (19), and nut (18) using a pipe wrench.

(3) Install rubber seal (16) on fitting (11).

(4) While assistant reaches through tank (2), and holds fitting (11) with channel locks, install rubber seal (14), plastic seal (13), and nut (12) using a pipe wrench.

(5) Install reducer (15) in fitting (11) using a pipe wrench.

(6) Install drain plug (1) using a 13/16 in. open end wrench.

4-219

4-121.

WATER TANK ASSEMBLY REPLACEMENT (CONT).

(7) Position tank (2) on saddle (9).

(8) Adjust two straps (6) over tank (2).

(9) Install two clips (10) on straps (6).

(10) Install clips (10) on two J-bolts (8).

(11) Install two J-bolts (8) on saddle (9).

(12) Install two washers (7) and locknuts (5) on

J-bolts (8) using a 3/4 in. open end wrench.

(13) If removed, install rope (4) on tank (2) and cap (3).

(14) Install cap (3) on tank (2).

NOTE

Follow-on maintenance: Connect

sprinkler lines (para 4-123)

END OF TASK

4-220

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-122. SADDLE REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Installation

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Locknuts

Foam pad and edge trim (See Appendix G for

fabrication)

Equipment Condition

TM or Para

Para 4-121

Para 4-68

Condition Description

Water tank removed.

Rear light mount removed.

a.

Removal. Remove four locknuts (1), eight washers (2), four screws (3), and saddle (4) from support (5) using a

3/4 in. open end wrench, ratchet and 3/4 in. socket.

b. Installation. Position saddle (4) on support (5), and secure with screws (3), washers (2), and locknuts (1) using a

3/4 in. open end wrench, ratchet and 3/4 in. socket.

NOTE

Follow-on maintenance:

Install rear light mount kit (para 4-68)

Install water tank (para 4-121)

END OF TASK

4-221

TM 5-3825-230-14&P

4-123. SPRINKLER LINES REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Compound, pipe sealing, item 15 Appendix E

Ties, cable, item 36 Appendix E

Water lines (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 3-14

Para 4-124

Condition Description

Spray system drained.

Spray bar removed.

a.

Removal.

(1) Remove cable ties as necessary.

(2) Loosen clamps (1) using a flat tip screwdriver and remove hose (2) from beaded adapter (3).

4-222

TM 5-3825-230-14&P

(3) Loosen clamp (4) using a flat tip screwdriver and remove hose (5) from beaded adapter (6).

(4) Loosen clamp (7) using a flat tip screwdriver and remove hose (5) from beaded adapter (6).

(5)

Remove beaded adapter (8) from coupling (9) using a 7/8 in. open end wrench and adjustable wrench.

(6) Remove coupling (9), and reducer bushing (10) from line strainer (11) using a 7/8 in. open end wrench and adjustable wrench.

(7) Remove line strainer (11) from elbow (12).

(8) Remove elbow (12) with nipple (13) from tank (14) using a pipe wrench.

(9) Remove nipple (13) from elbow (12) using a pipe wrench.

b. Installation.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Lightly apply pipe sealing compound to elbow (12), and nipple (13).

(2) Install nipple (13) in elbow (12) using a pipe wrench.

(3) Install nipple (13), and elbow (12) in tank (14).

(4) Install line strainer (11) on elbow (12).

(5) Lightly apply pipe sealing compound to coupling (9), and install coupling and reducer bushing (10) using a

7/8 in. open end wrench and adjustable wrench.

4-223

TM 5-3825-230-14&P

4-123.

SPRINKLER LINES REPLACEMENT (CONT).

(6) Install beaded adapter (8) on coupling (9) using a 7/8 in. open end wrench and adjustable wrench.

(7) Loosely position clamp (7) on hose (5) and install hose on beaded adapter (8) using clamp (7). Tighten using a flat tip screwdriver.

(8) Loosely position clamp (4) on hose (5) and install hose on beaded adapter (6) using clamp (4). Tighten using a flat tip screwdriver.

(9) Loosely position clamps (1) on hose (2) and install hose on beaded adapter (3) using clamp (1). Tighten using a flat tip screwdriver.

(10) Install cable ties as necessary.

NOTE

Follow-on maintenance:

Fill water tank (para 2-8)

Install spray bar (para 4-124)

• Check system for leaks

END OF TASK

4-224

TM 5-3825-230-14&P

4-124. SPRAY BAR REPLACEMENT/REPAIR.

This task covers: a.

b.

Removal

Disassembly

INITIAL SETUP

c.

Assembly d.

Installation

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No.2, Less Power

Materials/Parts

Lockwashers

Compound, sealing, pipe thread, item 16,

Appendix E

Equipment Condition

TM or Para

Para 2-8

Para 4-112

Condition Description

Water shut off.

Front dirt deflector removed.

a.

Removal

(1) Loosen hose clamp (1) using a flat tip screwdriver and disconnect hose (2) from adapter (3).

(2) Remove six nuts (4), three U-bolts (5), and six lockwashers (6) using a ratchet and 7/16 in. socket.

(3) Remove spray bar (11).

(4) If damaged, remove three screws (7), brackets (8), lockwashers (9), and nuts (10) using a 1/2 in. open end wrench, ratchet and 1/2 in. socket.

4-225

TM 5-3825-230-14&P

4-124.

SPRAY BAR REPLACEMENT/REPAIR (CONT).

b. Disassembly.

NOTE

• To ensure proper spray pattern when reassembled, note orientation of spray bar nozzles.

Groove in nozzles should be parallel with spray bar.

• Before removing elbow, note its direction to ensure proper orientatio n upon installation.

(1) Clamp spray bar in a vise and remove end cap (1) from spray bar (2) using a pipe wrench.

(2) Remove beaded insert (3) using a 1-1/8 in. open end wrench.

(3) Remove elbow (4) using a pipe wrench.

(4) Remove eight nozzles (5) using a 9/16 in. open end wrench.

c.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Apply pipe thread sealing compound to threads of nozzles (5).

(2) Install nozzles (5) on spray bar (2) using a 9/16 in. open end wrench.

(3) Apply pipe thread sealing compound to threads of elbow (4).

(4) Install elbow (4) using a pipe wrench.

(5) Install beaded insert (3) using a 1-1/8 in. open end wrench.

(6) Install end cap (1) using a pipe wrench.

4-226

TM 5-3825-230-14&P

d. Installation.

(1) If removed, install three brackets (8), three screws (7), three lockwashers (9), and three nuts (10) using a 12 in. open end wrench, ratchet and 1/2 in. socket.

(2) Install spray bar (11), three U-bolts (5), six lockwashers (6), and six nuts (4) using a 7/16 in. open end wrench, ratchet and 7/16 in. socket.

(3) Position hose clamp (1) and connect hose (2) to adapter (3). Tighten hose clamp with flat

NOTE

Follow-on maintenance:

Install front dirt deflector (para 4-112)

Open water tank shut off valve (para 2-

8)

• Check system for leaks

END OF TASK

4-227

TM 5-3825-230-14&P

Section VI. PREPARATION FOR STORAGE OR SHIPMENT

4-125. GENERAL.

Commanders are responsible for insuring that all material issued or assigned to their command is maintained in a serviceable condition, properly cared for, and that personnel under their command comply with technical instructions.

Lack of time, lack of trained personnel or lack of proper tools may result in a unit being incapable of performing maintenance for which it is responsible. In such cases, unit commanders, with approval of major commanders, may place material that is beyond the maintenance capability of the unit in administrative storage or return it to supply agencies. When preparing the sweeper for administrative storage, the unit commander will be responsible for processing the material, including all tools and equipment, in such a manner as to protect it against corrosion, deterioration and physical damage during shipment or periods of administrative storage.

4-126. STORAGE INSTRUCTIONS.

a.

Short Term Storage. No special provisions are required for short term storage of the sweeper. The unit should be started and operated at intervals no greater than 90 days.

b. Long Term Storage. To prepare the unit for long term storage:

(1)

Lubricate all fittings and oil can points in accordance with Chapter 3, Section I.

(2)

Fill fuel tank to capacity (para 3-8).

(3)

Drain oil and replace oil filter (para 4-22).

(4)

Fill crankcase to operating level with Type II Grade 30, MIL-L-21260 preservation oil (item 27, Appendix E).

(5)

Remove air cleaner (para 4-37).

(6) With fuel shut-off valve pulled out to prevent engine from starting, crank engine while spraying preservative

oil (item 27, Appendix E) into intake manifold to coat valves and combustion chamber.

(7)

Install air cleaner (para 4-37).

(8)

Disconnect battery cables (para 4-73).

(9)

Wipe a thin coat of grease (item 22, Appendix E) on exposed portion of hydraulic lift cylinder.

(10) Tag unit using identification tag (item 35, Appendix E) indicating crankcase is filled with preservative oil and

batteries are disconnected.

(11) Drain water tank and lines completely (para 2-9).

4-228

TM 5-3825-230-14&P

4-127. SHIPPING INSTRUCTIONS.

a.

Preparation for Shipment. Preservation and other protective measures taken in the preparation of material and accompanying tools and equipment for shipment must be sufficient to protect the sweeper against deterioration and physical damage during shipment.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (380C) and for type II is 140°F (600C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(1)

Cleaning. Use P-D-680 dry cleaning solvent (item 31, Appendix E) to clean or wash grease or oil from all

metal parts. All exposed machined surfaces must be cleaned to insure removal of corrosion, soil, grease, or other acid alkali residues.

(2) Drying. After cleaning, use cold water to rinse all parts. Use a clean cloth to dry all parts thoroughly.

(3)

Lubrication. Lubricate items as specified in Chapter 3, Section I.

(4) Preservation.

(a) All critical unpainted metal surfaces must be protected during shipment. Coat frame, unpainted

exterior hardware and chassis with corrosion preventive compound (item 11, Appendix E).

(b)

Spray data plates with a thin coating of ignition insulation compound (item 13, Appendix E). Control

overspray to avoid coating adjacent surfaces.

(c)

Cover all exterior reflectors and lights with masking tape (item 33, Appendix E).

(d)

Drain water tank (para 2-9).

4-229

4-127. SHIPPING INSTRUCTIONS (CONT).

TM 5-3825-230-14&P

(5) To reduce the width of the unit for shipping the hydraulic motor and mount and motor guard can be removed from the broom head for shipment. They are then stowed on the main frame as follows:

(a)

Remove hydraulic motor guard (1) (para 4-116).

(b)

Remove hydraulic motor and mount (2) (para 4-102).

(c) Disconnect sprinkler hose (3) at spray bar (4).

(d) Connect hydraulic motor and mount (2) to mainframe (5) using hardware removed.

(e) Connect hydraulic motor guard (1) to opposite side of main frame (5) using hardware removed.

(f) Secure sprinkler line (6) to hydraulic lines with cable ties (7) as required.

(g) Wind vehicle connection harnesses (8 and 9) around posts (10) on main frame (11). Secure with cable ties

(7) as required.

(6) Marking. Refer to AR 746 -80 for Marking of Supplies for Shipment.

b. Army Shipping Documents. Prepare all Army shipping documents accompanying freight in accordance with

AR 725-5.

4-230

Para

5-20

5-21

5-22

5-23

5-24

5-25

5-26

5-27

5-13

5-14

5-15

5-16

5-17

5-18

5-19

5-1

5-2

5-3

5-4

5-5

5-6

5-7

5-8

5-9

5-10

5-11

5-12

5-35

5-36

5-37

5-38

5-39

5-40

5-41

5-42

5-43

5-28

5-29

5-30

5-31

5-32

5-33

5-34

TM 5-3825-230-14&P

CHAPTER 5

DIRECT SUPPORT/GENERAL SUPPORT MAINTENANCE INSTRUCTIONS

Contents Page

Common Tools and Equipment ................................ ................................ ...............................

5-2

Special Tools, TMDE and Support Equipment ................................ ................................ .........

5-2

Repair Parts ................................ ................................ ................................ ............................

5-2

Troubleshooting Introduction ................................ ................................ ................................ ...

5-2

Troubleshooting Instructions ................................ ................................ ................................ ....

5-2

Maintenance Introduction ................................ ................................ ................................ ........

5-4

Engine Timing ................................ ................................ ................................ .........................

5-11

Engine Bumping Clearance ................................ ................................ ................................ .....

5-13

Engine Cylinder Replacement ................................ ................................ ................................ .

5-14

Crankcase Assembly Replacement ................................ ................................ .........................

5-18

Tachometer Gear Wheel and Housing Replacement ................................ ...............................

5-20

Rear Engine Housing Replacement ................................ ................................ .........................

5-21

Cylinder Head Assembly Replacement/Repair ................................ ................................ ........

5-23

Crankshaft Replacement ................................ ................................ ................................ .........

5-26

Front Support Replacement ................................ ................................ ................................ ..... 5-31

Rear Support Replacement ................................ ................................ ................................ .....

5-33

Flywheel With Crown Gear Replacement ................................ ................................ ................

5-35

Crown Gear Replacement ................................ ................................ ................................ .......

5-38

Piston Assembly Replacement................................ ................................ ................................ .

5-39

Piston Repair/Ring Set Replacement ................................ ................................ .......................

5-41

Connecting Rod Assembly Replacement/Repair................................ ................................ ......

5-43

Rocker Arm Cover Assembly Repair ................................ ................................ .......................

5-46

Rocker Arm Assembly Replacement ................................ ................................ .......................

5-48

Intake And Exhaust Valve Replacement ................................ ................................ ..................

5-51

Valve Adjustment ................................ ................................ ................................ ....................

5-56

Camshaft Replacement ................................ ................................ ................................ ...........

5-57

Oil Pump Replacement ................................ ................................ ................................ ............

5-60

Throttle Control Assembly Replacement/Repair................................ ................................ .......

5-62

Governor Control Lever Assembly Replacement/Repair................................ ...........................

5-64

Fuel Injector Assembly Replacement ................................ ................................ .......................

5-67

Fuel Injector Nozzle Assembly Service ................................ ................................ ....................

5-69

Injection Pump Timing ................................ ................................ ................................ .............

5-71

Injection Pump Replacement ................................ ................................ ................................ ...

5-74

Speed Governor And Support Yoke Replacement/Repair................................ .........................

5-78

Starter Repair ................................ ................................ ................................ ..........................

5-83

Battery Repair ................................ ................................ ................................ .........................

5-91

Main Frame Repair ................................ ................................ ................................ ..................

5-92

Hydraulic Hose Fabrication And Testing ................................ ................................ ..................

5-93

Hydraulic Pump Assembly Repair ................................ ................................ ...........................

5-94

Hydraulic Motor Repair................................ ................................ ................................ .............

5-99

Hydraulic Control Valve Repair ................................ ................................ ............................... 5-102

Hydraulic Cylinder Repair ................................ ................................ ................................ ........ 5-111

Spray Pump Repair ................................ ................................ ................................ ................. 5-113

5-1

TM 5-3825-230-14&P

Section I. REPAIR PARTS, SPECIAL TOOLS, TEST, MEASUREMENT AND DIAGNOSTIC EQUIPMENT AND

SUPPORT EQUIPMENT

5-1.

COMMON TOOLS AND EQUIPMENT.

For authorized common tools and equipment refer to Modified Table of Organization and Equipment (MTOE) applicable to your unit.

5-2.

SPECIAL TOOLS, TMDE AND SUPPORT EQUIPMENT.

Refer to Section III of the Maintenance Allocation Chart (MAC) for a list of tool kits authorized for the sweeper. Refer to

the Repair Parts and Special Tools List (RPSTL), Appendix F for a list of special tools.

5-3.

REPAIR PARTS.

Repair parts are listed and illustrated in the RPSTL, Appendix F, covering direct support/general support maintenance for

the sweeper.

Section II. TROUBLESHOOTING

5-4.

TROUBLESHOOTING INTRODUCTION.

This section contains step by step procedures for identifying, locating and isolating equipment malfunctions.

5-5.

TROUBLESHOOTING INSTRUCTIONS.

Refer to table 5-1 for a list of common malfunctions. The troubleshooting procedures are in table 5-2 and contain tests,

inspections and corrective actions. Before troubleshooting, be sure all preventive maintenance checks and services

(PMCS) have been performed. Perform tests, inspections and corrective actions in the order listed. Try to return the sweeper or component to operation after each test, inspection and corrective action has been performed.

Table 5-1. DS/GS System Symptom Index

Troubleshooting

Procedure Page

ENGINE

1.

Engine does not develop full power ................................ ................................ ................................ .......

5-3

2.

Engine overheats................................ ................................ ................................ ................................ ....

5-3

3.

Low oil pressure ................................ ................................ ................................ ................................ .....

5-3

4.

High oil consumption ................................ ................................ ................................ ..............................

5-4

5.

Excessive black or gray smoke................................ ................................ ................................ ...............

5-4

6.

Blue exhaust smoke ................................ ................................ ................................ ...............................

5-4

5-2

TM 5-3825-230-14&P

Malfunction

Test or Inspection

Corrective Action

Table 5-2. DS/GS Troubleshooting

ENGINE

1. ENGINE DOES NOT DEVELOP FULL POWER.

Step 1. Check manifold and gasket for leaks or damage.

If no leaks or damage are present go to step 2.

Repair or replace gaskets or manifold as needed (para 4-32).

Step 2. Check engine timing.

If timing is correct go to step 3.

If timing is off, reset (para 5-7).

Step 3. Check for misfiring cylinder.

Remove and check each fuel injector and inspect for clogged parts. If clogged, clean or replace

as necessary (para 5-30 or 5-31).

Step 4. Check engine compression.

2. ENGINE OVERHEATS.

Check cooling fins for dirt or debris.

Clean fins.

3. LOW OIL PRESSURE.

Step 1. Check for clogging of oil filter.

Remove oil filter. Replace as required (para 4-22).

Step 2. Inspect oil pressure valve for clogging or damage.

Remove and clean oil pressure valve. Inspect valve, valve seat, and valve spring for damage.

Replace damaged parts (para 4-31).

Step 3. Inspect oil pump for damaged parts.

Remove and clean oil pump. Inspect oil pump for worn, scored, or damaged parts. Replace

worn or damaged parts (para 5-27).

5-3

TM 5-3825-230-14&P

Table 5-2. DS/GS Troubleshooting - CONT.

Malfunction

Test or Inspection

Corrective Action

ENGINE (CONT)

4. HIGH OIL CONSUMPTION.

Step 1. Check for head gasket leaks.

Replace leaking gasket (para 5-13).

Step 2. Check for damaged or broken piston rings, pistons, or cylinders.

Replace damaged or broken piston rings, pistons, or cylinders (para 5-19).

Step 3. Check exhaust pipe for wetness or oil discharge.

If wetness or oil discharge is present, replace valve guides.

5. EXCESSIVE BLACK OR GRAY SMOKE.

Step 1. Check throttle control screws for proper adjustment.

Reset adjustments if not properly set (para 4-23).

If settings are OK go to step 2.

Step 2. Check for worn or clogged fuel injectors.

Replace injectors as required (para 5-30).

6. BLUE EXHAUST SMOKE.

Indicates oil being burned in cylinder. Refer to "High Oil Consumption" troubleshooting procedure.

Section lIl. MAINTENANCE PROCEDURES

MAINTENANCE INTRODUCTION.

5-6.

Instructions in this section provide general procedures to be followed for inspection, removal, cleaning, repair, replacement, or installation of components, and testing authorized at the direct support/general support maintenance level as specified by the Maintenance Allocation Chart (MAC).

a.

Servicing. All services are performed at the unit support level of maintenance according to the MAC. If the

sweeper needs further service, refer to Chapter 4, paragraph 4-11.

5-4

TM 5-3825-230-14&P

b. Ground Handling. For ground handling instructions refer to Chapter 4, paragraph 4-12.

c.

Operational Checks. All operational checks included in the maintenance procedures will include the techniques and methods required to assure the satisfactory performance of the sweeper. Reference the operator's instructions,

Chapter 2, for starting, sweeping, and shutdown procedures.

d. Inspection of Components.

(1) Inspect all surfaces in contact with gaskets, packings, or seals for nicks and burrs which might damage the new seal upon assembly. If any defect is found, remove it before assembly.

NOTE

Defects which may cause bearing binding or misalignment are cause for rejection. Nicks or gouges outside race load areas are not cause for rejection.

(2) Inspect bearings for rusted or pitted balls, races, or separators. Inspect balls and races for abrasion and serious discoloration.

(3) Cuts or grooves parallel to ball or roller rotation and fatigue pits (not minor machine marks or scratches and cracks found during magnetic particle inspection) are causes for bearing rejection.

(4) Remove drain plugs from engine system components and inspect the sediment sticking to the plug. Grit or fine metal particles may indicate actual or potential component failure. A few fine particles are normal. This inspection will help to show defective parts before internal inspection of the component.

(5) Guidelines for rejection of gears by visual inspection are not listed because of varying conditions for gear application. The following descriptions of wear conditions may help to determine when parts are defective.

(a) Initial pitting may occur when gears are first started in service. When pitting reduces local high spots to allow enough contact area to carry load without further impairment, initial pitting is not serious.

(b) Destructive pitting continues to progress after initial pitting. If there is not enough contact area remaining to carry the load, rapid destruction may occur from continued use.

(c) Abrasive wear is surface damage caused by fine particles carried in lubricant or particles imbedded in tooth surfaces. Particles may be metal, sand, scale, or other impurities in oil or surrounding atmosphere.

(6) Inspect all hose surfaces for broken or frayed fabric. Check for breaks caused by shar with other parts of the sweeper. Inspect the fitting threads for damage. Replace any defective part. After assembly and during initial sweeper operation, check for leaks.

(7) Inspect all wiring for chafed or burned insulation. Inspect all terminal connectors for loose connections and broken parts.

(8) Visually inspect all castings and weldments for cracks.

(9) Clean all parts before inspection. Check for defects such as physical distortion, wear, cracks and pitting.

5-5

TM 5-3825-230-14&P

5-6.

MAINTENANCE INTRODUCTION (CONT).

e.

Cleaning Procedures.

WARNING

• Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60

°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

• Compressed air used for cleaning and drying purposes will be reduced to 30 psi. (207 kPa.) and used only with adequate chip guarding and personal protection equipment.

(1) Do not use wire brushes, abrasive wheels, or compounds to clean parts, unless specifically approved in the detailed instructions. Dimensional characteristics of machined surfaces can be altered and may weaken a highly stressed part.

(2)

Soak parts in dry cleaning solvent P-D-680 (item 31, Appendix E) and wash away deposits by sloshing or

spraying. When necessary, brush with a soft bristle brush (not wire) moistened in dry cleaning solvent. Use a jet of dry compressed air to dry parts, except bearings, after cleaning. Bearings must drip and air dry.

(3) Do not clean rubber parts in dry cleaning solvent. Wipe clean with a dry, clean, lint-free cloth.

WARNING

Trichloroethylene is toxic to skin, eyes and breathing passages. Avoid all exposure. Skin and eye protection and exhaust hood are required. Contact safety officer for local procedure regulations concerning the use of trichloroethylene before using.

(4) A degreasing tub may be used to remove heavy grease and oil from metal parts. Trichloroethylene is used as a degreasing agent.

CAUTION

To prevent corrosion, part should be dipped in rust preventive within two hours of degreasing.

(5) Remove parts from degreasing machine and check all oil passages and cavities for cleanliness and freedom from obstruction before coating with rust preventive. Run a thin, flexible wire through oil passages to make sure they are not clogged. Use a pressure spray gun and dry cleaning solvent to clean dirty passages.

(6) Parts soaked in carbon removal solution should be rinsed with dry cleaning solvent. Rinse in a solvent spray booth equipped with a filter and hand spray gun, then use a soft bristle brush to remove carbon deposits. A cloth buffing wheel may also be used.

5-6

TM 5-3825-230-14&P

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(7) Electrical parts, such as coils, connectors, junction blocks, insulated wiring and switches, should not be soaked or sprayed with cleaning solutions. Clean these parts with a clean lint-free cloth moistened with dry cleaning

solvent P-D-680 (item 31, Appendix E).

(8) When cleaning ball or roller bearings, place in a basket and suspend in a container of dry cleaning solvent,

P-D-680 (item 31, Appendix E). If necessary, use brush to remove caked grease or chips. Avoid rotating bearings

before solid particles are removed to prevent damage to races and balls. When bearings have been cleaned, spin

immediately in light lubricating oil (item 27, Appendix E) to remove solvent.

free cloth.

(9) Do not clean preformed packings or other rubber parts in dry cleaning solvent. Wipe with clean, dry lint-

(10) For exterior cleaning of frame and structural components, use detergent (item 17, Appendix E), in a

solution as recommended on the container. Leave application on items surface for approximately 10 minutes before rinsing. Rinse with hot or cold water under pressure. If available, use hot water under 80 to 120 lb (36 to 54 kg) pressure. An ordinary garden hose may be used if no other equipment is available. If pressurized water supply is not

available, wash painted surfaces with a solution of 1/4 cup of soap chips (item 7, Appendix E), to one gallon of water.

(11) Before disassembly of sweeper, clean exterior parts of sweeper thoroughly with dry cleaning solvent P-

D680 (item 31, Appendix E) to remove accumulated mud, tar and grease.

CAUTION

Do not use gasoline, diesel fuel, or other petroleum base products to clean or preserve hydraulic system components. Use of petroleum base products can change the lubricating quality of hydraulic oil and cause failure or damage to equipment.

(12) When cleaning hydraulic system components, use petroleum-free solvents. Clean and dry parts thoroughly to make sure no residue remains. If preservative coating is required before reassembly, apply a light film of

preservative oil, (item 27, Appendix E). If petroleum-free solvents are not available for cleaning, use hydraulic fluid

compatible with that used in the sweeper system.

f. Removal and Disassembly of Components.

(1) When unpacking items, remove all packing material, barrier paper, tape, plastic bags, protective caps, and protective grease coatings.

5-7

TM 5-3825-230-14&P

5-6.

MAINTENANCE INTRODUCTION (CONT).

(2) Use protective covers on open housings, lines, engine inlets, exhaust ducts, and other openings as soon as possible after disassembly to prevent moisture and foreign matter from entering engine. Wrap all parts in clean paper or

dip parts in preservative oil, (item 27, Appendix E) or equivalent.

removed.

(3) Cap or tape over all open tubes, hoses, fittings and engine component openings as soon as parts are

CAUTION

Do not use tape to close off fuel or oil openings. Sticky surface of tape can mix with fuel and oil and cause engine malfunctions.

(4) Use suitable containers to catch fuel or oil when removing hoses and fittings. Dispose of fuel and oil in accordance with local policy.

(5) Remove and handle components carefully.

(6) Inspect parts as removed for breaks, dents, cracks, surface defects or other obvious damage.

(7) Remove burrs from gear teeth with a fine-cut file.

(8)

Remove residue from bearing races with crocus cloth (item 8, Appendix E).

(9) Welding and brazing processes may be used to repair cracks in external parts, such as brackets, panels, and framework. Because of time required and the chance of subsequent failure, such repairs should be attempted only when replacement parts are not available. Welding and brazing of castings and running parts or parts under great stress will only be done in emergencies.

(10) When installing studs in engine block use a proper driver. A worn stud driver may damage the end thread.

Then a chasing die must be used before a nut can be screwed on. This procedure will remove plating and allow corrosion. Before installing a stud, inspect hole for chips. Blow out foreign matter and start stud by hand. Before final insertion, coat thread with a film of anti-seize compound. Install stud to proper "setting height," which is the total projecting length.

(11) Replace all broken, worn, or burned electrical wiring. Wires with broken strands must be replaced.

(12) Replace all broken, frayed, crimped, or soft flexible hoses. Replace stripped or damaged fittings. Replace entire flexible hose if fittings are damaged. Hose clamp should not crimp hoses.

(13) Replace any screw, nut, or fitting with damaged threads. Inspect tapped holes for thread damage. If cross threading is evident, retap the hole for the next oversize screw or stud. If retapping will weaken the part, or if the cost of the part makes retapping impractical, replace the part. Chasing the threads with proper size tap or die may be adequate.

(14) Reshape elongated mounting holes to round and drill to receive bushing with required inner diameter.

Stake bushing in place with center punch.

(15) Remove protective grease coatings from new parts before installation.

5-8

TM 5-3825-230-14&P

(16) To replace a preformed packing, first clean groove, then stretch packing and place into position. Place component on flat surface and uniformly press packing into position.

piping.

(17) Use a nonhardening pipe-joint compound (item 16, Appendix E) or Teflon tape (item 34 Appendix E) to join

(18)

Coat both sides of gasket with sealant (item 15, Appendix E). Remove all traces of previous gasket and

sealant before installing new gasket.

(19) Coat oil seals evenly with oil or grease before installing. Install oil seals with seal lip facing in, applying an even force to outer edge of seal. If oil seals are to be installed over keyed or splined shafts, use a guide to prevent sharp edge of the keyway or splines from cutting the seal. Construct guides of very thin gauge sheet metal and shape to the required diameter. Make certain guide edges are not sharp and are bent slightly inward so they do not cut the seal.

(20) When mounting bearings on shafts, always apply force to the inner races. When mounting bearings into housing, always apply the force to the outer races. Lubricate bearings before assembly with lubricant used in the related housing or container to provide the first run-in until lubricant from the system can reach the bearings.

(21) To ease assembly and installation, tag and mark shims, connectors, wires, and mating ends of lines before disconnecting them. Identify similar parts to ensure correct assembly.

(22) Before removal of any electrical component, disconnect battery cables (para 4-73) and ensure 12V or 24V

wire harness to tow vehicle is disconnected.

(23) Ensure that adequate clearance is available for removal of component. Disassemble sweeper to the extent necessary to provide adequate working clearance.

(24) Use chain hoist, jack, or other aid when lifting heavy components. Lifting device should be positioned and attached to components to remove all strain from mounting hardware before last hardware is removed.

(25) Discard preformed packings, gaskets, seals, and similar material when removed. Be sure that all traces of oil, gaskets, and sealants are removed. When possible, use wood or plastic probes and scrapers to prevent damage to machines surfaces.

(26) Cotter pins, lockwashers, star washers, lockwire, self-locking nuts, and any similar locking devices must be discarded when removed. Self-locking fasteners that loosen up must be replaced, not tightened.

(27) Remove parts only if repair or replacement is required. Do not disassemble a component any further than necessary to accomplish needed repairs.

g. Painting. Instructions for preparation of material for paint, how to paint, and materials to be used are in TM 43-

0139. Instructions for camouflage painting are contained in FM 5-20. Stenciling and marking military vehicles are called

out in TB 43-0209. Data plates location and description are referenced in Chapter 2.

h. Lubrication. Refer to Chapter 3, Section I for lubrication procedures and requirements for the sweeper. The

instructions include types and grades of lubrications used, lube points, locations and frequency of required lubrication.

i. Assembly.

(1) Remove protective grease coatings from new parts before installation.

(2) To replace preformed packings, first clean groove, then stretch packing into position. Rotate component on flat surface applying downward pressure to uniformly press packing into position. A light coating of fluid which the packing will operate in, will make assembly easier.

5-9

TM 5-3825-230-14&P

5-6.

MAINTENANCE INTRODUCTION (CONT).

(3) Coat oil seals evenly with oil or grease before installing. Install oil seals with seal lip facing in, applying an even force to the outer edge of seal. If oil seals are to be installed over keyed or splined shafts, use a guide to prevent sharp edges of the keyway or splines from cutting the seal. Guides can be very thin gauge sheet metal shaped to the required diameter. Make certain guide edges are not sharp and are bent slightly inward so they do not cut the seal.

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

j. Installation. Put hoses, tubes, lines and, electrical wiring in place by matching identification tags, markings on

equipment, and using illustrations presented. Replace cable ties (item 36, Appendix E) as necessary. Use sealing

compounds as required in each maintenance task. When installing screws and nuts, be sure to tighten to torque values given. For torque values, refer to tables 4-4 and 4-5.

k. Welding Procedures. Welding may be used to repair cracks in steel parts. These repairs should be made only when replacement parts are not available. Do not weld running parts. Visually inspect all welds for cracks. Parts that carry a great load should receive magnetic particle inspection. Critical nonferrous parts may be inspected with fluorescent penetrant.

l. Sheet Metal Repair. Straighten minor body dents by bumping with a soft-faced hammer while using a wooden block backing. Repair minor skin cracks by installing patches.

5-10

TM 5-3825-230-14&P

5-7.

ENGINE TIMING.

This task covers: a.

Gear Timing

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power b.

Flywheel Timing

Equipment Condition

TM or Para

Para 5-12

Para 5-13

a. Gear Timing.

NOTE

This task is required after engine crankshaft or camshaft have been removed from crankcase.

(1) Turn crankshaft (1) so that No. 1 piston

(on drive end of engine) is at Top Dead

Center (TDC). Piston bumping clearance must be 0.00275 to 0.0295 in. (0.70 to

0.75 mm) (para 5-8).

(2) Timing mark (2) on crankshaft gear (3) should be at 3 o'clock position.

(3) Position gear (4) to align timing marks (2 and 5). Timing mark (5) should be in 9 o'clock position.

Condition Description

Rear engine housing removed.

No. 1 cylinder head removed.

5-11

TM 5-3825-230-14&P

5-7.

ENGINE TIMING (CONT).

b. Flywheel Timing.

(1)

Refer to para 5-12 and install rear engine housing.

(2)

Refer to para 5-17 and install flywheel.

NOTE

This step is normally done as part of troubleshooting or valve adjustment (para 5-25).

(3) Piston (1) in No. 1 cylinder (2) should be at TDC. No. 1 cylinder is cylinder on drive side of engine. Top of piston must be between 0. to 0.0295 in. (0.70 to 0.75 mm) from top of head gasket. This clearance is called bumping clearance.

(4) Align flywheel timing mark (3) with timing mark (4) on rear engine housing.

NOTE

Follow-on maintenance:

Install No. 1 cylinder head (para 5-13)

Install rear engine housing (para 5-12)

Check injection pump timing (para 5-32)

5-12

TM 5-3825-230-14&P

5-8.

ENGINE BUMPING CLEARANCE.

This task covers:

Adjustment

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials/Parts

Head gaskets

Adjustment.

NOTE

Procedure is the same for both cylinders.

(1) Move piston (1) to TDC (para 5-7).

(2) Measure depth of piston (1) in cylinder (2) with piston at highest point using a depth gage. Clearance should be 0.0275 to

0.0295 in. (0.70 to 0.75 mm) from top of piston to top of head gaskets (3).

CAUTION

Make sure cylinder does not "ride up" during this procedure or damage to cylinder may result.

NOTE

Gaskets are available in different thicknesses and must be measured before installing.

(3) Adjust clearance by adding or removing gaskets (3) to obtain proper clearance.

NOTE

Follow-on maintenance: Install

cylinder heads (para 5-13)

END OF TASK

Equipment Condition

TM or Para

Para 5-13

5-13

Condition Description

Cylinder heads removed.

TM 5-3825-230-14&P

5-9.

ENGINE CYLINDER REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Cleaning/Inspection

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials/Parts

Copper washers

Compound, thread locking, item 14 Appendix E

Oil, engine, item 26 Appendix E

Solvent, dry cleaning, item 31 Appendix E

Equipment Condition

TM or Para

Para 4-30

Para 5-13

a. Removal.

NOTE

Matchmark cylinders to crankcase before removal.

(1) Remove cylinder (1) from studs (2), crankcase (3), and piston (4).

NOTE

It may be necessary to tap out rod bearings.

(2) Remove two rod cap screws (5) connecting rod cap (6), and bearings (7) at crankshaft (8), using a ratchet, extension and a 10 mm socket.

NOTE

Matchmark pistons to cylinder before removal. Note orientation of notch in piston to ensure correct assembly.

(3) Remove piston (4) and connecting rod assembly (9) as an assembly.

(4)

Remove piston rings (para 5-20).

c.

Installation

Condition Description

Oil pan removed.

Cylinder head removed.

5-14

TM 5-3825-230-14&P

b. Cleaning/lnspection.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(1) Clean all parts with dry cleaning solvent

P-D-680.

(2) Inspect cylinder bore for wear, pits or scratches.

(3) Inspect pistons for scratches, cracks and scoring.

(4) Measure and record cylinder bore using a micrometer. Acceptable tolerance is

3.3858 to 3.3866 in. (86 to 86.02 mm). If out of tolerance, replace cylinder.

3.3858 TO 3.3866 in. (86 to 86.02 mm)

5-15

TM 5-3825-230-14&P

5-9.

ENGINE CYLINDER REPLACEMENT (CONT).

c. Installation.

(1)

Install piston rings (para 5-20).

(2) Coat inside of cylinder (1) with fresh engine oil.

NOTE

Compress piston rings by hand or use a piston ring compressor.

Compress rings enough to insert in cylinder.

(3) Using matchmarks made during removal align piston (4) to cylinder (1), compress piston rings with fingers and install piston with connecting rod (9) in cylinder.

CAUTION

Do not allow connecting rod to scratch crankshaft or damage to equipment may result.

(4) Lubricate with engine oil and install rod bearing half (7) in connecting rod (9).

(5) While moving crankshaft (8) to align with connecting rod assembly (9), place cylinder (1) on studs (2) and crankcase

(3).

WARNING

Adhesives, solvents, and sealing compounds can burn easily, give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(6) Install rod bearing half (7) and connecting rod cap (6) with two screws (5) using a ratchet, extension and 10 mm socket. Apply thread locking compound to screws.

(7) Tighten screws (5) to 29 Ib-ft (39 N•m) using a torque wrench and 10 mm socket.

5-16

END OF TASK

NOTE

Follow-on maintenance:

Check engine bumping clearance (para 5-8)

Install cylinder heads (para 5-13)

Install engine oil pan (para 4-30)

5-17

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-10.

CRANKCASE ASSEMBLY REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials/Parts

Copper washer

Compound, sealing, pipe thread, item 16,

Appendix E

Equipment Condition

TM or Para

Para 5-14

a. Removal

NOTE

Remove expansion cap only if necessary.

(1) Remove expansion cap (1) using a 17 mm hex head wrench.

(2) Remove nut (2) and lever stop (3) using a

13 mm open end wrench.

(3) Remove all studs (4) using a stud remover/installer.

(4) Remove plug (5) and copper washer (6) using a 13 mm open end wrench.

(5) Remove taper pins (7) using pliers.

(6) Remove pin (8) and sending unit (9) using a 10 mm and 24 mm open end wrenches.

(7) Remove setscrew (10) using a 4 mm hex head wrench.

5-18

Condition Description

Crankshaft removed.

TM 5-3825-230-14&P

b. Installation.

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 a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(1) Apply pipe thread sealing compound to threads of setscrew (10) and plug (5).

(2) Install setscrew (10) using a 4 mm hex head wrench.

(3) Install sending unit (9) and pin (8) using a 10 mm and 24 mm open end wrenches.

(4) Install taper pins (7) using a hammer and drift.

(5) Install plug (5). and copper washer (6) using a 13 mm open end wrench.

(6) Install studs (4) using a stud remover/installer.

(7) Install lever stop (3) and nut (2) using a 13 mm open end wrench.

(8) Install expansion cap (1) using a 17 mm hex head wrench.

NOTE

Follow-on maintenance: Install crankshaft (para 5-14)

END OF TASK

5-19

TM 5-3825-230-14&P

5-11.

TACHOMETER GEAR WHEEL AND HOUSING REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Gasket

Equipment Condition

TM or Para

Para 5-12

Condition Description

Rear engine housing removed.

a. Removal.

(1) Remove three screws (1) and housing (2) using a 6 mm hex head wrench.

(2) Remove gearwheel (3), retaining ring (4) using retaining ring pliers, washer (5), and housing (6).

(3) Remove gasket (7) and bushing (8) from housing (2).

b. Installation.

(1) Install gear wheel (3) in housing (6) with washer (5), and retaining ring (4).

(2) Install parts assembled in step (1) in housing (9).

(3) Install gasket (7) on housing (2).

(4) Install bushing (8) and housing (2) with three screws (1). Tighten screws to 108 lb-in. (14 N•m) using a torque wrench and 6 mm hex head socket.

NOTE

Follow-on maintenance: Install rear engine housing (para 5-12).

END OF TASK

5-20

TM 5-3825-230-14&P

5-12.

REAR ENGINE HOUSING REPLACEMENT.

This task covers: b.

Installation a.

Removal

INITIAL SETUP

Equipment Condition

TM or Para

Para 5-17

Tools

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Seal

Gaskets

Adhesive, sealant, item 3 Appendix E

a. Removal

(1) Remove 13 screws (1) and rear engine housing (2) using a 6 mm hex head wrench.

(2) Remove oil seal (3).

(3) Remove two screws (4), cover (5), and Oring (6) using a 6 mm hex head wrench.

(4) Remove two screws (7) and panel (8) using a 10 mm open end wrench.

(5) Remove gaskets (9 and 10).

Condition Description

Flywheel removed.

5-21

5-12.

REAR ENGINE HOUSING REPLACEMENT (CO NT).

b. Installation.

(1) Install panel (8) and two screws (7) using a 10 mm open end wrench.

(2) Install O-ring (6), cover (5), two screws

(4), and oil seal (3) using a 6 mm hex head wrench.

WARNING

Adhesives, solvents, and sealing compounds can burn easily, give off harmful vapors, and are harmful to skin and clothing. To avoid injury or death, keep away from open fire and use in a well-ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(3) Coat gasket (10) with sealing compound.

(4) Install gasket (10), rear engine housing

(2), and 13 screws (1). Tighten screws to

22 lb-ft (30 N•m) using a torque wrench and 6 mm hex head socket.

(5) Install gasket (9).

NOTE

Follow-on maintenance: Install fly-

wheel (para 5-17).

END OF TASK

5-22

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-7.

CYLINDER HEAD ASSEMBLY REPLACEMENT/REPAIR.

This task covers: a.

b.

Removal

Disassembly

INITIAL SETUP

b.

Cleaning/Inspection d.

Assembly

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Spring Compressor (7535.1460.009)

Materials/Parts

Gasket

Head gasket

Equipment Condition

TM or Para

Para 4-24

Para 4-32

Para 4-55

Para 4-42 thru 4-44

Para 5-30

Para 5-23

c.

Installation

Condition Description

Engine removed.

Intake manifold removed.

Noise shrouds removed.

Fuel lines removed.

Fuel injectors removed.

Rocker arms removed.

Text begins on next page.

5-23

5-13.

CYLINDER HEAD ASSEMBLY REPLACEMENT/REPAIR (CONT).

CAUTION

Do not remove cylinder head while it is hot. Damage to cylinder head may occur.

NOTE

Procedure is the same for both cylinder heads.

a. Removal

(1) Remove four pushrods (1) from crankcase

(2).

(2) Remove four nuts (3), washers (4), and cylinder head (5) using a ratchet and 17 mm socket.

WARNING

Spring is under extreme pressure when compressed. Wear eye protection to avoid injury.

(3) Remove oil tube (6), gasket (7), spacer

(8), spring (9), pushrod tube (10), and gasket (11) from crankcase (2).

NOTE

Measure and record thickness of head gasket after removal.

(4) Remove head gasket (12).

b. Disassembly.

NOTE

Matchmark position of long nut on each cylinder head.

(1) Remove studs (13, 14 and 15), if required.

(2)

Refer to para 5-24 and remove valves if

required.

5-24

TM 5-3825-230-14&P

TM 5-3825-230-14&P

c. Cleaning/Inspection. Inspect cylinder head for cracks or warping. Warpage that causes leaks is not acceptable.

d. Assembly.

(1)

Refer to para 5-24 and install valves, if

removed.

(2) If removed, install studs (13, 14, and 15).

NOTE

When installing cylinder head, it will be necessary to compress spring that is around pushrod tube. If spring is not compressed, gasket on top of pushrod tube will not seat properly.

(3) Install gasket (11), pushrod tube (10), spring (9) spacer (8), gasket (7), oil tube (6), and pushrods (1) in crankcase (2).

(4)

Install head gasket (12) and check engine bumping clearance (para 5-8).

e. Installation. Install cylinder head (5), four washers (4), and four nuts (3). Follow torque sequence shown and tighten nuts to 36 lb-ft (48 N•m) using a torque wrench and 17 mm socket. Remove spring compressor.

NOTE

Follow-on maintenance:

Install rocker arms (para 5-23)

Install fuel injectors (para 5-30)

Install fuel lines (para 4-42 thru 4-44)

Install noise shrouds (para 4-55)

Install intake manifold (para 4-32)

Install engine (para 4-24)

END OF TASK

5-25

TM 5-3825-230-14&P

5-14.

CRANKSHAFT REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials/Parts

Safety plate

Gage: Plastic adjustment, item 20 Appendix E

Oil, engine, item 26 Appendix E

Cleaning/Inspection

Equipment Condition

TM or Para

Para 5-9

Para 5-28

Para 5-34

Para 5-11

Para 5-27

Para 5-15

Para 5-16

a. Removal

(1) Flatten tabs on safety plate (1) and remove screw (2), and safety plate using a ratchet and 17 mm socket.

(2) Tap crankshaft (3) towards drive side of engine using a ball peen hammer and drift. Center support (4) will slide out of its position in crankcase (5).

(3) Once center support (4) has cleared its support in crankcase (5), remove two screws (6) using a 6 mm hex head wrench and separate halves of center support (4).

(4) Remove center support halves (4) and center support bearing halves (7).

(5) Continue sliding crankshaft (3) toward drive end of crankcase (5) and remove crankshaft.

c.

Installation

Condition Description

Cylinders removed.

Throttle control assembly removed.

Speed governor support yoke assembly removed.

Tachometer gear wheel and housing removed.

Oil pump removed.

Front support removed.

Rear support removed.

5-26

TM 5-3825-230-14&P

b. Cleaning/Inspection.

NOTE

Oversize bearings are available at 0.010 and 0.020 in. (0.25 and 0.50 mm).

(1) Inspect crankshaft for scratches and grooves.

(2) Measure five crankshaft journals using calipers:

(a) Shaft end (flywheel side) 2.8338 to 2.8346 in. (71.98 to 72.00 mm).

(b) Two connecting rod journals 1.5748 to 1.5755 in. (40.00 to 40.02 mm).

(c) Center support journal 2.1787 to 2.1791 in. (55.34 to 55.35 mm).

(d) Shaft end (drive side) 2.1625 to 2.1633 in. (54.93 to 54.95 mm).

(3) Replace crankshaft if journal dimension is out of tolerance.

(4) Check crankshaft clearance bores in crankcase using calipers:

(a) Clearance (flywheel side) 0.0027 to 0.0043 in. (0.0685 to 0.1092 mm).

(b) Clearance (drive side) 0.0019 to 0.0031 in. (0.0482 to 0.0787 mm).

(5) If clearance is not within tolerances, check respective crankshaft journal. If journal diameter is acceptable replace respective bearing and recheck tolerances. If crankshaft journal diameter is not acceptable, replace crankshaft .

(6) Inspect crankshaft for straightness using a dial indicator at center support bearing journal. Runout should not exceed 0.0019 to 0.0031 in. (0.0482 to 0.0787 mm).

5-27

5-14.

CRANKSHAFT REPLACEMENT (CONT).

(7) Center support bearing to crankshaft clearance inspection:

(a) Insert plastic gage in center journal.

(b) Install center support (1) and bearings (2) on crankshaft (3) with two screws (4). Tighten to 22 lb-ft

(30 N•m) using a torque wrench and

6 mm hex head socket.

(c) Remove two screws (4), bearings

(2), and center support (1).

(d) Measure plastic gage. Clearance should be 0.0019 to 0.0035 in. (0.05

to 0.09 mm) on wrapper scale.

(e) Clean plastic gage off bearings.

(8) If clearance is not within tolerance check center support journal. If journal diameter is acceptable replace center support bearing and recheck tolerance.

5-28

TM 5-3825-230-14&P

c. Installation.

(1) Coat all parts with clean engine oil.

NOTE

• Be sure when bearings are installed, they are not covering lubrication passages.

• Center supports are beveled. Be sure to install supports so they match bevels on crankcase.

• Ensure that bearings do not bind on shaft.

(2) Install center support bearings (7), center supports (4), and two screws (6), on shaft

(3). Tighten to 22 lb-ft (30 N•m) using a torque wrench and 6 mm hex head socket.

(3) Install crankshaft (3) in crankcase (5).

(4) Install screw (1) and safety plate (2) using a ratchet and 17 mm socket.

(5)

Install rear support (para 5-16).

(6)

Install front support (para 5-15).

(7) Check crankcase end play by:

(a) Mount dial indicator as shown on crankcase with needle against crankshaft counter weight.

(b) Move crankshaft fully towards flywheel, then fully towards drive end. Crankshaft endplay (movement) should be between 0.0078

and 0.0118 in. (0.200 to 0.0300

mm).

5-29

TM 5-3825-230-14&P

5-14.

CRANKSHAFT REPLACEMENT (CONT).

NOTE

Follow-on maintenance:

Install oil pump (para 5-27)

Install tachometer gear wheel and housing (para 5-11)

Install speed governor support yoke assembly (para 5-34)

Install throttle control assembly (para 5-28)

Install pistons (para 5-19)

Install cylinders (para 5-9)

Check bumping clearance (para 5-8)

Reset engine timing (para 5-7)

Reset valve clearance (para 5-25)

Reset engine speed adjustment (para 4-23)

END OF TASK

5-30

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-15.

FRONT SUPPORT REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials/Parts

Lockwashers b.

Cleaning/Inspection

Equipment Condition

TM or Para

Para 5-27

Para 5-34

Para 5-11

c.

Installation

Condition Description

Oil pump gear wheel removed.

Speed governor removed.

Tachometer gear wheel and housing removed.

a. Removal

WARNING

Unsafe torching practices can cause serious injury from fire, explosions, or harmful gasses.

Allow only authorized personnel to heat metals. Protective clothing and goggles must be worn.

Adequate protective equipment must be used. A suitable fire extinguisher must be kept near by, and requirements of TM 9237 strictly followed.

NOTE

Gear will normally have to be heated to allow it to slip off and on. Be careful not to heat gear too much, since this may remove temper from the metal.

(1) Using a torch, heat gear (1).

(2) Using a gear puller remove gear (1) from crankshaft (2).

(3) Remove two screws (3), lockwashers (4), washers (5), and front support (6) using a ratchet and 13 mm socket.

(4) If required, remove bearing (7) from support (6) using a press.

5-31

TM 5-3825-230-14&P

5-15.

FRONT SUPPORT REPLACEMENT (CONT).

b. Cleaning/Inspection. Measure clearance between crankshaft and bearing using a micrometer by subtracting

OD of crankshaft from ID of bearing. Clearance must be 0.0019 to 0.0031 in. (0.05 to 0.08 mm). If out of

tolerance refer to para 5-14, Cleaning/Inspection step (4).

c. Installation.

(1) If removed, install bearing (7) in front support (6).

(2) Install front support (6), two lockwashers

(4), and screws (3) using a ratchet and 13 mm socket.

CAUTION

Do not overheat gear. Damage may result.

NOTE

If heated properly, gear will drop onto shaft easily.

(3) Heat gear (1) and install on crankshaft (2) using pliers and/or mallet.

NOTE

Follow-on maintenance:

• Install tachometer gear wheel and

housing (para 5-11)

Install speed governor (para 5-34)

Install oil pump gear wheel (para 5 -27)

Check engine timing (para 5-7)

END OF TASK

5-32

TM 5-3825-230-14&P

5-16.

REAR SUPPORT REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials/Parts

Gasket

Seal b.

Cleaning/Inspection

Equipment Condition

TM or Para

Para 4-34

Para 4-24

c.

Installation

Condition Description

Hydraulic pump drive removed.

Engine removed.

a. Removal. Remove six nuts (1), rear support (2), gasket (3), seal (4), and rear support bearing (5) from engine block (6) using a ratchet and 13 mm socket.

b. Cleaning/inspection. Measure clearance, using a micrometer, between crankshaft and rear support bearing (5) by subtracting OD of crankshaft from ID of rear support bearing (5) Clearance must be 0.0019 to 0.0031 in. (0.05

to 0.08 mm). If clearance is out of tolerance refer to para 5-14, Cleaning/Inspection step (4).

5-33

5-16.

REAR SUPPORT REPLACEMENT (CONT).

TM 5-3825-230-14&P

c.

Installation. If removed install rear support bearing (5) and seal (4), in rear support (2). Install gasket (3), rear support (2), and six nuts (1). Tighten nuts to 30 to 35 Ib-ft (41 to 48 N•m) using a torque wrench and

13 mm socket.

NOTE

• Follow-on maintenance:

Install hydraulic pump drive assembly (para 4-34)

Install engine (para 4-24)

END OF TASK

5-34

TM 5-3825-230-14&P

5-17. FLYWHEEL WITH CROWN GEAR REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's; Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Equipment Condition

TM or Para

Para 4-53

Para 4-58

a. Removal

Condition Description

Flywheel housing removed.

Starter removed.

NOTE

Flywheel bolt is removed in a clockwise direction.

(1) Remove flywheel bolt (1) and washer (2) from flywheel (3) using a ratchet and 24 mm socket.

5-35

5-17. FLYWHEEL WITH CROWN GEAR REPLACEMENT (CONT)

TM 5-3825-230-14&P

(2) Remove flywheel (3) and key (4) using flywheel puller.

b. Installation.

(1) Install key (4) and flywheel (3) on shaft.

5-36

TM 5-3825-230-14&P

(2) Install flywheel washer (2) and bolt (1). Tighten to 130 lb-ft (176 N•m) using a torque wrench and 24 mm socket.

NOTE

Follow-on maintenance:

Install flywheel housing (para 4-53)

Install starter (para 4-58)

END OF TASK

5-37

TM 5-3825-230-14&P

5-18. CROWN GEAR REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection c. Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's; Automotive,

Equipment Condition

TM or Para

Para 5-17

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Condition Description

Flywheel removed.

WARNING

Unsafe torching practices can cause serious injury from fire, explosions, or harmful gasses.

Allow only authorized personnel to heat metals. Protective clothing, gloves and goggles must be worn. Adequate protective equipment must be used. A suitable fire extinguisher must be kept near by, and requirements of TM 9-237 strictly followed.

a. Removal

CAUTION

When heating crown gear, be careful not to heat flywheel or damage to equipment may result.

(1) Heat crown gear (1) evenly on all sides using a torch.

(2) Remove crown gear (1) by tapping using a hammer and drift.

b. Cleaning/inspection. Check crown gear for chipped or missing teeth and cracks. Replace if necessary.

c. Installation.

(1) Heat crown gear (1) evenly on all sides using a torch.

(2) Install crown gear (1) using a hammer and drift.

NOTE

Follow-on maintenance: Install

flywheel (para 5-17)

END OF TASK

5-38

TM 5-3825-230-14&P

5-19. PISTON ASSEMBLY REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection

INITIAL SETUP

Tools

Tool Kit, Master Mechanic's

Shop Equipment, Machine Shop, Field

Maintenance, Basic, Less Power

Materials/Parts

Oil, engine, item 26 Appendix E

Equipment Condition

a.Removal

(1) Remove and discard piston rings (1, 2, and 3).

(2) Remove two retaining rings (4) using retaining ring pliers and remove wrist pin (5) using a press.

(3) Remove piston (6) from connecting rod (7).

b.Cleaning/inspection.

(1) Inspect pistons for scratches, cracks and scoring.

Replace if visually damaged.

(2) Measure pistons for wear using calipers.

Replace piston if diameter is not within 3.

to 3.3866 in. (86.00 to 86.02 mm).

TM or Para

Para 5-9

c. Installation

Condition Description

Engine cylinder removed.

5-39

5-19. PISTON ASSEMBLY REPLACEMENT (CONT).

c. Installation.

(1) Coat wrist pin bore in piston (6) with clean engine oil.

(2) Install piston (6) on connecting rod (7).

(3) Use press to install wrist pin (5) into piston (6), and connecting rod (7).

(4) Install two retaining rings (4) into wrist pin bore of piston (6) using snap ring pliers.

(5) Refer to ring set replacement (para 5-20), and

install piston rings (1, 2, and 3) on piston (6).

NOTE

Follow-on maintenance: Install

engine cylinder (para 5-9)

END OF TASK

5-40

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-20. PISTON REPAIR/RING SET REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection

INITIAL SETUP

Tools

Shop Equipment, Machine Shop, Field

Maintenance, Basic, Less Power removed.

Materials/Parts

Ring set, piston

Equipment Condition

TM or Para

Para 5-9

c. Installation

Condition Description

Engine cylinder

a.Removal. Remove compression rings (1 and 2), and oil ring (3) using a piston ring expander.

b.Cleaning/lnspection.

(1) Measure new ring end gap (3 rings) by placing ring to be checked in cylinder and pushing down with top of piston approximately one inch.

(2) Remove piston and measure gap between ring ends using calipers. Gaps should be as follows:

(a) Two compression rings 0.011 to

0.019 in. (0.3 to 0.5 mm).

(b) Oil control ring 0.009 to 0.019 in.

(0.25 to 0.5 mm).

(3) If gap is too small, file ring ends to achieve desired gap.

5-41

5-20. PISTON REPAIR/RING SET REPLACEMENT (CONT).

TM 5-3825-230-14&P c. Installation.

(1) Install compression rings (1 and 2) using a piston ring expander, mount with ring end gaps staggered 180° starting just to either side of wrist pin.

Mount chromium-edged ring at top.

(2) Install oil ring (3) 180° staggered from bottom compression ring (2).

(3) Coat rings and piston with lubricating oil.

(4) Measure ring to ring groove clearance using calipers. If excessive, replace piston.

(a) Top compression ring clearance 0.0098 in. (0.25 mm).

(b) Second compression ring clearance 0.0059 in. (0.15 mm).

(c) Lower ring (oil control) clearance 0.0059 in. (0.15 mm).

NOTE

Follow-on maintenance: Install engine cylinder (para 5-9)

END OF TASK

5-42

TM 5-3825-230-14&P

5-21. CONNECTING ROD ASSEMBLY REPLACEMENT/REPAIR

This task covers:

a. Removal b. Cleaning/Inspection

INITIAL SETUP

Tools

Tool Kit, Master Mechanic's

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials Parts

Bushings

Gage: Plastic adjustment, item 20 Appendix E

Oil, engine, item 26 Appendix E

Equipment Condition

TM or Para

Para 5-9

a.Disassembly.

(1) Remove two retaining rings (1) from piston (2) using snap ring pliers.

(2) Remove wrist pin (3) from piston (2) using a press.

(3) Remove piston (2) from connecting rod

(4).

(4) Drive out upper bushing (5) from connecting rod (4) using a press.

(5) Remove bearing (6) from connecting rod

(4).

(6) Remove lower bearing (7) from rod cap

(8) using a drift and ball peen hammer.

c. Installation

Condition Description

Engine cylinder removed.

5-43

TM 5-3825-230-14&P

5-21. CONNECTING ROD ASSEMBLY REPLACEMENT/REPAIR (CONT).

b.

Cleaning/lnspection.

(1) Inspect rod for cracks or warping.

(2) Inspect rod bearings and crankshaft for excessive wear.

(3) Measure crankshaft rod journal using a micrometer (1.5748 to 1.5755 in. [40.0 to

40.01 mm]).

(4) Measure connecting rod bearings (6 and

7) to crankshaft clearance:

(a) Install bearings (6) in connecting rod

(4).

(b) Install bearing (7) in rod cap (8).

(c) Place plastic gage strip on bearing

(7).

(d) Install two screws (9) into rod cap (8) and install on connecting rod (4). Tighten to 29 lb-ft (39 N•m).

(e) Remove two screws (9) and rod cap (8).

(f) Width on plastic gage should be 0.0013 to 0.0029 in. (0.033 to 0.073 mm) on wrapper scale.

(g) Clean plastic gage off bearing (7).

(5) If connecting rod bearing to crankshaft clearance is not within tolerance, refer to step (3).

(6) If crankshaft rod journal diameter measurement is within tolerance, replace connecting rod bearings and recheck.

(7) Measure inside diameter of upper connecting rod bushing and the outside diameter of wrist pin using calipers. The difference between the two must be between 0.0005 to 0.0011 in. (0.015 to

0.030 mm).

5-44

(8) Attach dial indicator to connecting rod as shown and inspect connecting pin for side play. Value should not exceed 0.0019 in.

(0.05 mm).

c. Assembly.

(1) Coat upper bushing (5) with engine oil and install into connecting rod (4) using a press.

(2) Install piston (2) on connecting rod (4).

(3) Coat wrist pin bore in piston (2) with clean engine oil.

(4) Coat wrist pin (3) with clean engine oil and install in piston (2) and connecting rod (4).

(5) Install two retaining rings (1) into wrist pin bore in piston (2) using snap ring pliers.

(6) Coat lower bearing half (7) with engine oil and install on lower part of connecting rod

(8).

NOTE

Follow-on maintenance: Install

engine cylinder (para 5-9)

END OF TASK

5-45

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-22. ROCKER ARM COVER ASSEMBLY REPAIR

This task covers: a. Disassembly

INITIAL SETUP

Tools

Tool Kit, Master Mechanic's

Materials/Parts

Seal

O-ring b. Cleaning/Inspection

Equipment Condition

TM or Para

Para 4-28

c. Assembly

Condition Description

Rocker arm cover removed.

a. Disassembly.

NOTE

This task shows repair of the right rocker arm cover.

(1) Remove screw (1), pin (2), seal (3), ball (4), and spring (5) using a 4 mm hex head wrench.

(2) Remove screw (6) and washer (7) using a 17 mm open end wrench.

(3) Remove pin (8) and lever (9) from pin (2).

(4) If necessary, remove O-ring (10) and cap (11) from cover (12).

5-46

TM 5-3825-230-14&P

b. Cleaning/lnspection . Inspect cover for cracks and warping sufficient to cause leaks. Replace if damaged.

c. Assembly.

(1) Install pin (8) and lever (9) on pin (2).

(2) Install spring (5), ball (4), seal (3), pin (2), and screw (1) on cover (12) using a 4 mm hex head wrench.

(3) Install washer (7) and screw (6) using a 17 mm open end wrench.

(4) If removed, install O-ring (10) and cap (11).

NOTE

Follow-on Maintenance: Install rocker arm cover (para 4-28)

END OF TASK

5-47

TM 5-3825-230-14&P

5-23. ROCKER ARM ASSEMBLY REPLACEMENT.

This task covers:

a. Removal b. Installation

INITIAL SETUP

Tools

Tool Kit, Master Mechanic's

Materials/Parts

Tags, identification, item 35 Appendix E

removed.

Equipment Condition

TM or Para

Para 4-28

removed.

Para 4-45

Condition Description

Rocker arm covers

Fuel injector lines

a. Removal.

NOTE

There are two rocker arm assemblies. Left and right rocker arm assemblies are not the same. Be sure to tag both arms in each assembly before removal.

(1) Remove two screws (1) and two washers (2) from lubrication pin (3) using a 6 mm hex head wrench.

(2) Lift rocker assembly (4) from cylinder head (5).

5-48

NOTE

Shims are on left rocker arm only.

Rocker arms on flywheel side of pins will not have plate.

(3) Remove two nuts (6), plate (7), two shims

(8), and two screws (9) from rocker arm

(10) using a 11 mm open end wrench.

(4) Remove rocker arm (10) from lubrication pin (3).

(5) Remove lubrication tube (11) from lubrication pin (3).

(6) Measure the OD of lubrication pin (3), and

ID of rocker arm (10). If difference exceeds 0.03937 (1 mm) replace parts.

5-49

TM 5-3825-230-14&P

5-23. ROCKER ARM ASSEMBLY REPLACEMENT (CONT).

b. Installation.

NOTE

Right rocker arm does not have a shim.

(1) Install two shims (8), plate (7), two nuts

(6), and two screws (9) on rocker arm (10) using a 11 mm open end wrench.

(2) Install lubrication tube (11). and align it in lubrication pin (3).

(3) Install rocker arms (4) on lubrication pin

(3).

(4) Ensure that rocker arm assembly (4) aligns with push rods and install two screws (1) and two washers (2) in lubrication pin (3) using a 6 mm hex head wrench.

(5) Install rocker assembly (4) onto head (5).

Tighten two screws (1) 66 to 72 lb-in (7.4 to 8.1 N•m) using a torque wrench and 6 mm hex head socket.

NOTE

Follow-on maintenance:

Reset valve clearance (para 5-25)

Install fuel injector lines (para 4-45)

Install rocker arm covers (para 4-28)

END OF TASK

5-50

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-24. INTAKE AND EXHAUST VALVE REPLACEMENT.

This task covers:

a. Removal b. Cleaning/Inspection

INITIAL SETUP

Tools

Tool Kit, General Mechanic's; Automotive

Equipment Condition

TM or Para

Para 5-13

Shop Equipment, Automotive Maintenance and

Para 5-23

Repair; Organizational Maintenance, Common

No. 1, Less Power

I

Materials/Parts

Seal

Cloth, abrasive, item 8, Appendix E

Compound, grinding, item 12 Appendix E

Oil, lubricating engine, item 25 Appendix E

Solvent, dry cleaning, item 31 Appendix E

c. Installation

Condition Description

Cylinder head removed.

Rocker arm assembly removed.

Text begins on next page.

5-51

5-24. INTAKE AND EXHAUST VALVE REPLACEMENT (CONT).

a. Removal

NOTE

Intake and exhaust valves are removed and installed the same way.

(1) If same valves are to be installed, matchmark each valve head, so they can be installed in same positions.

CAUTION

Make sure valve spring is compressed parallel to valve stem or valve stem can be damaged.

(2) Using valve spring compressor, compress valve spring (1) and remove circlips (2).

(3) Release valve stem compressor.

Remove retainer (3), valve spring (1), seal (4), washer (5), and valve (6).

NOTE

Refer to b. Cleaning/inspection, to determine damage to valve seats and guides.

(4) If damaged, remove valve seats (7).

(5) If damaged, remove valve guides (8) from head (9).

5-52

TM 5-3825-230-14&P

b. Cleaning/Inspection.

TM 5-3825-230-14&P

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60

°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(1) Clean all parts with dry cleaning solvent P-D-680.

(2) Inspect valves for pits, evidence of burrs, or cracks.

(3) Measure valve stem and valve guides for wear using calipers.

(a) If valve stem OD (0.311 to 0.312 in. [7.90 to 7.92 mm]) is not within tolerance, replace valve.

(b) If valve guide ID (0.313 to 0.314 in. [7.95 to 7.98 mm]) is not within tolerance, replace guide.

5-53

5-24. INTAKE AND EXHAUST VALVE REPLACEMENT (CONT).

(4) Measure valve springs using calipers.

Length should be 2.12 in. (53.85 mm).

Replace springs if length is shorter than specified.

TM 5-3825-230-14&P c. Installation.

WARNING

Unsafe torching practices can cause serious injury from fire, explosions, or harmful gasses. Allow only authorized personnel to heat metals.

Protective clothing and goggles must be worn. Adequate protective equipment must be used. A suitable fire extinguisher must be kept near by, and requirements of TM 9-237 strictly followed.

(1) Heat head (9) uniformly to 328° to 356°F

(164

°

to 180

°

C) using a torch.

(2) If removed, press valve guides (8) into head (9), while hot, until seated firmly.

(3) Heat head (9) uniformly to 320

°

to 360°F

(160° to 182°C) using a torch.

(4) If removed, press valve seats (7) into head (9), while hot, until seated firmly.

5-54

(5) Install valve (6) in cylinder head (9).

(6) Seat valve using a valve seating tool and small amount of grinding compound.

(7) Remove valve (6). Clean grinding compound from valve (6), and cylinder head (9) using a clean cloth. Inspect valve and valve seat for continuous ring indicating proper contact.

(8) Lubricate valve stems with engine oil.

(9) Install valve (6), washer (5), seal (4), spring (1), and retainer (3).

(10) Using a valve spring compressor, compress spring (1) and install circlips (2).

(11) Valve heads should seat 0.0295 to 0.0492 (0.75

to 1.25 mm) deep in cylinder head.

(a) If valve head is too shallow in cylinder head, check proper valve seat installation.

(b) If valve head is too deep in cylinder, check valve seat and valve face for excessive wear. Replace as necessary.

NOTE

Follow-on maintenance:

Install cylinder head (para 5-13)

Install rocker arm assemblies (para 5-23)

Reset engine timing (para 5-7)

Bleed fuel system (para 4-36)

END OF TASK

5-55

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-25.

VALVE ADJUSTMENT.

This task covers:

Adjustment

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 4-28

Para 4-98

Condition Description

Rocker arm covers removed.

Rear panel removed.

General Safety Instructions

Be sure engine is cool before starting this procedure or injury to personnel may result.

Adjustment.

(1) Turn flywheel until piston is in TDC (top dead center) position and piston is in compression stroke (para 5-7).

(2) Loosen nut (1) slightly with a 11 mm box end wrench. Insert a feeler gage between rocker arm (2), and top of valve (3).

(3) Adjust valve clearance by turning adjusting screw (4) while holding nut (1) with a 11 mm box end wrench. Adjust channel to between 0.005 to 0.007 in. (0.15 to 0.20 mm). Repeat step for other valve.

(4) Repeat steps (1) thru (3) for other cylinder.

NOTE

Follow-on maintenance:

Install rear panel (para 4-98)

Install rocker arm covers (para 4-28)

END OF TASK

5-56

TM 5-3825-230-14&P

5-26.

CAMSHAFT REPLACEMENT.

This task covers: a.

Removal b.

Cleaning/Inspection

INITIAL SETUP

Tools

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Materials/Parts

Gasket

Oil, lubricating, item 25 Appendix E

a.

Equipment Condition

TM or Para

Para 4-24

Para 5-13

Para 4-58

Removal

Condition Description

Engine removed.

Cylinder head removed.

Starter removed.

c. Installation

Equipment Condition

TM or Para

Para 4-29

Para 4-49

Para 5-33

Para 5-34

Para 4-30

Para 4-35

Condition Description

Oil filter housing removed.

Fuel filter housing removed.

Injection pump removed.

Speed governor and support yoke removed.

Oil pan removed.

Fuel pump removed.

CAUTION

• To prevent damage to the camshaft and lobes during camshaft removal, turn engine on its side or upside down. This will prevent tappets from falling down between camshaft lobes during removal.

• When removing or installing camshaft, rotate camshaft continuously to avoid damage.

(1) Remove camshaft (1) from crankcase (2).

(2) Remove four valve tappets (3).

5-57

5-26.

CAMSHAFT REPLACEMENT (CONT).

b.

Cleaning/inspection.

(1) Inspect camshaft lobes for cracks, scratches, grooves, or pitting.

(2) Check camshaft for wear using a micrometer.

(3) If camshaft does not measure within indicated tolerances, replace camshaft.

c.

Installation.

(1) Coat all parts with clean engine oil.

(2) Install four valve tappets (3).

(3) Install camshaft (1) in crankcase (2).

5-58

TM 5-3825-230-14&P

END OF TASK

TM 5-3825-230-14&P

Follow-on maintenance:

NOTE

Install oil pan (para 4-30)

Install speed governor and support yoke assembly (para 5-34)

Install injection pump (para 5-33)

Install fuel filter housing (para 4-49)

Install fuel pump (para 4-35)

Install oil filter housing (para 4-29)

Install starter (para 4-58)

Install cylinder head (para 5-13)

Check valve clearance (para 5-25)

Install engine (para 4-24)

Reset engine timing (para 5-7)

5-59

TM 5-3825-230-14&P

5-27.

OIL PUMP REPLACEMENT.

This task covers: a.

Removal b.

Installation

INITIAL SETUP

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Oil, engine, item 25 Appendix E

TM or Para

Para 5-12

Condition Description

Rear engine housing removed.

a.

Removal

(1) Remove nut (1), washer (2), and gear wheel (3) using a ratchet and 17 mm socket.

5-60

TM 5-3825-230-14&P

CAUTION

Be sure to matchmark oil pump housing in relation to crankcase before removal to ensure correct installation. Holes in oil pump must align with oil flow holes in crankcase.

(2) Remove two screws (4), two washers (5), and oil pump assembly (6) from crankcase (7) using a ratchet and 13 mm socket.

b.

Installation.

(1) Coat pump housing with fresh engine oil and install pump assembly (6) in crankcase (7).

(2) Install two washers (5) and two screws (4). Tighten to 66 lb-in (7.4 N•m) using a ratchet and 13 mm socket.

(3) Install gear wheel (3), washer (2), and nut (1). Tighten to 92 lb-in (10.4 N•m) using a ratchet and 17 mm socket.

NOTE

Follow-on maintenance: Install rear engine housing (para 5-12)

END OF TASK

5-61

TM 5-3825-230-14&P

5-28.

THROTTLE CONTROL ASSEMBLY REPLACEMENT/REPAIR.

This task covers: a.

Removal b.

Disassembly c.

d.

Assembly

Installation

INITIAL SETUP

Tools

Tool Kit, General Mechanic's; Automotive

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Materials/Parts

Gasket

Seals

Locknuts

Tag, identification, item 35 Appendix E

Lockwire (See Appendix G for fabrication)

Equipment Condition

TM or Para

Para 4-47

Condition Description

Throttle control cable and engine cut-off cable disconnected.

5-62

TM 5-3825-230-14&P a.

Removal.

(1) Remove six screws (1) using a 5 mm hex head wrench.

NOTE

Tag spring and note its mounting position.

(2) Remove cover (2) and disconnect spring (3) from lever (4).

(3) Remove gasket (5) from cover (2).

b.

Disassembly.

(1) Remove nut (6) and lever (7) using a 13 mm open end wrench.

(2) Remove nut (8) and lever (9) using a 13 mm open end wrench.

(3) Remove lever (4), spring (10), and seal (11) using pliers.

(4) Remove lever (12), spring (13), and seal (14) using pliers .

(5) Cut lockwire (15).

NOTE

Matchmark positions of screws and nuts to assure correct depth at assembly. (6) Remove two screws (16) and two locknuts (17) with 10 mm open end wrench.

CAUTION

Tampering with preset screw will cause damage to equipment.

(7) Do not remove lockwire (18) and screw (19). The screw is preset by the manufacturer.

c.

Assembly.

(1) Refer to matchmarks and install two locknuts (17), two adjusting screws (16), and lockwire (15) using a 10 mm open end wrench.

(2) Install seal (14), spring (13), and lever (12) using pliers.

(3) Install seal (11), spring (10), and lever (4) using pliers.

(4) Install lever (9) and nut (8) using a 13 mm open end wrench.

(5) Install lever (7) and nut (6) using a 13 mm open end wrench.

d.

Installation.

(1) Install gasket (5) on cover (2) and install spring (3) on lever (4).

(2) Install cover (2) and six screws (1). Tighten screws to 60 lb-in (7 N•m) using a torque wrench and 5 mm hex head socket.

NOTE

Follow-on maintenance: Connect throttle control cable and engine cut-off cable (para 4-47)

END OF TASK

5-63

TM 5-3825-230-14&P

5-29.

GOVERNOR CONTROL LEVER ASSEMBLY REPLACEMENT/REPAIR.

This task covers: a.

Removal b.

Disassembly c.

d.

Cleaning/Inspection

Assembly e. Installation f. Adjustment

INITIAL SETUP

Tools Materials/Parts

Tool Kit, General Mechanic's; Automotive Lockwashers

Solvent, dry cleaning, item 31 Appendix E

Shop Equipment, Automotive Maintenance and

Repair; Organizational Maintenance, Common

No. 1, Less Power

Equipment Condition

TM or Para

Para 5-28

Condition Description

Throttle control assembly removed.

a.

Removal

(1) Remove two screws (1), two lockwashers (2), support (3), and governor control assembly (4) using a 6 mm hex head wrench.

(2) Disconnect spring (5) from pin (6).

5-64

TM 5-3825-230-14&P b.

Disassembly.

(1) Remove retaining ring (1) and washer (2) using snap ring pliers.

c.

(2) Separate levers (3 and 4) from control lever (5).

(3) Remove screw (6), lockwasher (7), and brass lever (8) using a 6 mm hex head wrench.

(4) Remove retaining ring (9) using snap ring pliers, from brass lever (8) and drive out two bearings

(10) using a hammer and drift.

(5) Remove nut (11), washer (12), and pin (13) from control lever (5) using a 10 mm open end wrench.

(6) Remove retaining ring (14) and drive out bearing (15) from lever (4) using snap ring pliers, hammer and drift.

Cleaning/Inspection.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(1) Clean all parts with dry cleaning solvent P-D-680.

(2) Inspect bearings for pits, cracks, and signs of wear.

d.

Assembly.

(1) Install bearing (15) in lever (4) using a hammer and drift and install retaining ring (14).

(2) Install pin (13) on control lever (5) with washer (11) and nut (12) using a 10 mm open end wrench.

(3) Install two bearings (10) using a hammer and drift and retaining ring (9), in brass lever (8).

(4) Install brass lever (8) on control lever (5), screw (6), and washer (7). Tighten using a 6 mm hex head wrench.

(5) Install control lever (5) on lever (4), and install on lever (3).

(6) Install washer (2) and retaining ring (1).

5-65

5-29.

GOVERNOR CONTROL LEVER ASSEMBLY REPLACEMENT/REPAIR (CONT).

e.

Installation.

NOTE

Make sure that fork fits on slide knob of injector pump.

(1) Install governor control assembly (4), support

(3), two lockwashers (2), and two screws (1) using a 6 mm hex head wrench.

(2) Connect spring (5) to pin (6

TM 5-3825-230-14&P f.

Adjustment.

(1) Push governor control lever (1) all the way right.

(2) Pin (2), located on lower governor control lever

(1), must just make contact with pin

(3) that connects governor control lever with lower speed governor lever (4).

(3) Adjust by turning screw (5) using a 6 mm hex head wrench.

END OF TASK

NOTE

Follow-on maintenance: Install throttle control assembly (para 5-28)

5-66

TM 5-3825-230-14&P

5-30.

FUEL INJECTOR ASSEMBLY REPLACEMENT.

This task covers: a.

Removal b.

Cleaning/Inspection

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Copper washers c. Installation

Equipment Condition

TM or Para

Para 4-45 and 4-46

Condition Description

Fuel lines removed.

a.

Removal.

WARNING b.

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 (15.24 m) of vehicle.

(1) Remove two nuts (1) and flange (2) using a 10 mm open end wrench.

(2) Remove injector assembly (3) and copper washer (4).

Cleaning/lnspection. Measure opening in injector nozzle using calipers. Opening should be 0.0110 (0.28 mm) in diameter.

5-67

5-30.

FUEL INJECTOR ASSEMBLY REPLACEMENT (CONT).

TM 5-3825-230-14&P c.

Installation.

(1) Install copper washer (4) and injector assembly (3).

NOTE

Be sure to line up locating pin on flange with locating hole on top of injector assembly.

(2) Install flange (2) and two nuts (1). Tighten to 66 lb-in (7.4 N•m) using a torque wrench and 10 mm open end wrench.

NOTE

Follow-on maintenance: Install fuel lines (para 4-45 and 4-46)

END OF TASK

5-68

TM 5-3825-230-14&P

5-31.

FUEL INJECTOR NOZZLE ASSEMBLY SERVICE.

This task covers: a.

Disassembly b.

Cleaning/Inspection

INITIAL SETUP

Tools

Tool Kit, Master Mechanic's

a.

Materials/Parts

Copper washer

Solvent, dry cleaning, item 31 Appendix E

Disassembly.

NOTE

• Fuel injector is replaced as an assembly.

Take care not to lose any parts of the fuel injector assembly.

b.

c. Assembly

Equipment Condition

TM or Para

Para 5-30

removed.

Condition Description

Fuel injector assembly

Cleaning/Inspection.

• Both injectors are serviced the same way.

(1) Remove tube fitting (1) and copper washer (2) from injector body (3) using a 14 mm open end wrench.

(2) Remove nozzle holder (4) using a 19 mm open end wrench and remove nozzle (5), pin (6), cap

(7), spacer (8), spring (9), and washer (10).

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(1) Clean using dry cleaning solvent P-D-680.

(2) Inspect parts for cracks, pits, and signs of burned ports.

5-69

5-31.

FUEL INJECTOR NOZZLE ASSEMBLY SERVICE (CONT).

(3) Measure opening of injector nozzle using calipers, it should be 0.0110 in. (0.28 mm).

(4) If any parts are damaged or lost, replace fuel injector assembly.

c.

Assembly.

(1) Install washer (10), spring (9), spacer (8), cap

(7), pin (6), and nozzle (5) on injector (3).

(2) Install nozzle holder (4) onto injector body (3), tighten using a 19 mm open end wrench.

(3) Install copper washer (2) and tube fitting (1) on injector body (3) using a 14 mm open end wrench.

NOTE

Follow-on maintenance: Install fuel

injector assembly (para 5-30)

END OF TASK

5-70

TM 5-3825-230-14&P

TM 5-3825-230-14&P

5-32.

INJECTION PUMP TIMING.

This task covers:

Adjustment

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Equipment Condition

TM or Para

Para 4-121

Para 4-98

Para 4-53

Para 4-73

Condition Description

Water tank removed.

Rear panel removed.

Flywheel housing removed.

Battery cables disconnected.

NOTE

If engine is installed, completely bleed fuel lines (para 4-36) before starting this procedure.

If engine is removed, attach fuel intake and return lines to fuel source and bleed system (para 4-36)

before starting this procedure.

Adjustment.

(1) Mark out a distance of 2.40 to 2.59 in. (61 to 66 mm) along the circumference of the flywheel (1) beginning at the No. 1 cylinder timing mark (2) and moving clockwise.

5-71

5-32.

INJECTION PUMP TIMING (CONT).

TM 5-3825-230-14&P

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 (15.24 m) of vehicle.

• Wear safety goggles while performing this procedure.

• Flywheel must be slowly rotated by hand during this procedure to prevent the engine from starting. Be careful not to let your hands or fingers become caught between the flywheel and engine.

(2) Using a 17 mm open end wrench remove fuel pipe (3) to No. 1 cylinder (No. 1 cylinder is nearest the hydraulic pump side of the engine), and tube fitting (4).

5-72

TM 5-3825-230-14&P

(3) Rotate flywheel clockwise 2.40 to 2.59 in. (61 to

66 mm), fuel should squirt out of tube fitting (4) when measured distance is passing timing mark

(5) on engine.

NOTE

If fuel does not appear, refer to para

4-36 and bleed the fuel system again.

(4) If timing is not correct refer to para 5-33 and

add or remove injector pump shims.

(a) If fuel squirts before timing marks meet, add one injector pump shim and recheck.

Repeat step if fuel still appears before timing marks meet.

(b) If fuel squirts after timing marks meet, remove one injector pump shim and recheck. Repeat step if fuel still appears after timing marks meet.

(5) Refer to para 5-33 to install pump.

(6) Repeat previous procedures until timing is correct.

(7) Install tube fitting (4) and pipe (3) using a 17 mm open end wrench.

NOTE

Follow-on maintenance:

Connect battery cables (para 4-73)

Install flywheel housing (para 4-53)

Install rear panel (para 4-98)

Install water tank (para 4-121)

END OF TASK

5-73

TM 5-3825-230-14&P

5-33.

INJECTION PUMP REPLACEMENT.

This task covers: a.

Removal

INITIAL SETUP

b.

Cleaning/Inspection

Tools

Tool Kit, General Mechanic's: Automotive

Spring compressor 7535.1460.009

a.

Materials/Parts

Copper washers

Solvent, dry cleaning, item 31 Appendix E

Removal

c. Installation

Equipment Condition

TM or Para

Para 4-24

Para 4-32

Condition Description

Engine removed.

Intake manifold removed.

Para 5-29

Governor control lever assembly removed.

Para 4-44 and 4-45 Injector fuel lines

removed.

5-74

TM 5-3825-230-14&P

NOTE

Injection pump is replaced as an assembly. Take care not to lose any parts of the injection pump.

(1) Remove tube fitting (1) and oil seal (2) from fuel injector pump (3) using a 19 mm open end wrench.

(2) Remove spring (4), shim (5), and filler (6) from tube fitting (1).

NOTE

The spring, shim and filler, may drop out of tube fitting when you remove it and remain on delivery valve. Both fittings are same.

(3) Remove copper gasket (7) and delivery valve (8) from injector pump (3).

(4) Repeat steps (1) through (3) to remove other injector side.

(5) Compress springs (9) on push rod tube (10).

(6) Remove three screws (11) and three washers (12) using a 6 mm hex head wrench.

(7) Remove nut (13) and washer (14) using a 13 mm open end wrench.

NOTE

Be sure to keep metal shims in proper order. These shims are available in three thicknesses and

are used to adjust injector timing (para 5-32).

b.

(8) Remove injector pump (3) and metal shims (15).

Cleaning/lnspection.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38

°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

c.

(1) Clean all parts with dry cleaning solvent P-D-680.

(2) Inspect parts for pits and corrosion.

Installation.

(1) Install delivery valves (8) and copper gaskets (7) in injector pump (3).

(2) Install oil seals (2) on tube fittings (1).

(3) Install fillers (6), shims (5), and springs (4) in tube fittings (1).

(4) Install tube fittings (1) on injector pump (3) using a 19 mm open end wrench.

5-75

TM 5-3825-230-14&P

5-33. INJECTION PUMP REPLACEMENT (CONT).

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 (15.24 m) of vehicle.

• Compressed air must be used only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

(5) Check pump for internal leakage.

(a) Connect air gage and air line to pump inlet.

(b) Submerge pump in diesel fuel.

(c) Apply 70 to 75 psi (482 to 516 kPa) air pressure, using compressed air and air gage, for 20 seconds.

(d) If bubbles are present, internal leakage is indicated, replace pump.

5-76

TM 5-3825-230-14&P

(6) Remove two tube fittings (1) using a 19 mm open end wrench.

(7) Compress springs (9) on push rod tubes (10).

(8) Install metal shims (15) and injector pump (3).

(9) Install washer (14) and nut (13). Tighten to 66 lb-in (7.4 N•m) using a torque wrench and 13 mm open end wrench.

(10) Install three washers (12) and screws (11). Tighten to 66 lb-in (7.4 N•m) using a torque wrench and 6 mm hex head wrench.

(11) Install tube fittings (1) using a 19 mm open in wrench.

NOTE

Follow-on maintenance:

Install injector pump fuel lines (para

4-44 and 4-45)

• Install governor control lever assembly

(para 5-29)

END OF TASK

Install intake manifold (para 4-32)

Check injector timing (para 5-32)

Install engine (para 4-24)

5-77

TM 5-3825-230-14&P

5-34.

SPEED GOVERNOR AND SUPPORT YOKE REPLACEMENT/REPAIR.

This task covers: a.

b.

Removal

Disassembly

INITIAL SETUP

c.

Cleaning/Inspection d.

Assembly e. Installation

a.

Tools Equipment Condition

Tool Kit, General Mechanic's: Automotive

Materials/Parts

Solvent, dry cleaning item 31 Appendix E

Removal.

TM or Para

Para 5-12

Condition Description

Rear engine housing removed.

(1) Remove screw (1) and washer (2) using a ratchet and 17 mm socket.

(2) Remove speed governor (3) and key (4).

(3) Remove two screws (5), two washers (6), and governor support yoke assembly (7) using a ratchet and 13 mm socket.

(4) Remove pin (8).

5-78

b. Disassembly.

(1) Remove retaining ring (1), thrust bearing (2), and governor bell (3), from speed governor (4).

(2) Remove retaining ring (5) using snap ring pliers, washer (6), and upper part of governor lever (7) from governor support yoke (8).

5-79

TM 5-3825-230-14&P

5-34. SPEED GOVERNOR AND SUPPORT YOKE REPLACEMENT/REPAIR (CONT).

(3) Remove retaining ring (9) using snap ring pliers, washer (10), lower part of governor lever (11), and washer (12) from governor support yoke (8).

(4) Drive out two bearings (13) using a hammer and drift from governor support yoke (8).

(5) Matchmark lower part of governor lever (11) and lever (14).

(6) Remove screw (15) and lever (14) using a 5 mm hex head wrench.

c. Cleaning/inspection.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area.

Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(1) Clean all parts with dry cleaning solvent P-D-680.

(2) Inspect parts for burrs, cracks or obvious signs of wear.

(3) Replace any defective parts.

d. Assembly.

(1) Install screw (15) and lever (14) on lever (11) using a 5 mm hex head wrench.

(2) Install two bearings (13) in governor support yoke (8) using a press.

(3) Install washer (12) and lower part of governor lever (11) on governor support yoke (8).

(4) Install washer (10) and retaining ring (9) on shaft of lower part of governor lever (11).

5-80

TM 5-3825-230-14&P

(5) Install upper part of governor (7), washer (6), and retaining ring (5) on governor support yoke

(8).

(6) Install governor bell (3), thrust bearing (2), and retaining ring (1) on speed governor (4).

5-81

TM 5-3825-230-14&P

5-34. SPEED GOVERNOR AND SUPPORT YOKE REPLACEMENT/REPAIR (CONT).

e. Installation.

TM 5-3825-230-14&P

(1) Install pin (8) in crankcase.

(3) Install governor support yoke assembly (7) using two washers (6) and two screws (5). Tighten using a ratchet and 13 mm socket.

NOTE

Insure that key is aligned with slots in speed governor and shaft.

(4) Install speed governor assembly (3) using key (4), washer (2), and screw (1). Tighten using a ratchet and 17 mm socket.

NOTE

Follow-on maintenance:

• Set engine timing (para 5-7).

• rear engine housing (para 5-12).

• engine speed adjustments (para 4-23).

END OF TASK

5-82

TM 5-3825-230-14&P

4-76. TOW VEHICLE TO JUNCTION BOX WIRE HARNESS (12V) REPLACEMENT/REPAIR.

This task covers: a.

Disassembly b.

Cleaning/Inspection c. Assembly

INITIAL SETUP

Tools Equipment Condition

Shop Equipment, Automotive Maintenance and

Repair; Field Maintenance, Basic No. 1, Less

Power

Materials/Parts

Lockwashers

Compound, locking, thread item 14 Appendix E

Solder, item 30 Appendix E

Solvent, dry cleaning, item 31 Appendix E

Cloth, abrasive, item 8 Appendix E

TM or Para

Para 4-58

Condition Description

Starter removed.

a. Disassembly.

(1) Matchmark starter assembly and solenoid.

(2) Remove nut (1), connector (2), and copper washer (3) from solenoid (4) using a 13 mm open end wrench.

5-83

5-35. STARTER REPAIR (CONT).

(3) Remove three screws (5) and solenoid (4) using a cross tip screwdriver.

(4) Remove spring (6) and actuator (7) by pushing down and out.

(5) Remove two screws (8) and two washers (9) from starter (10) using a 9 mm open end wrench.

(6) Matchmark drive housing (11) and starter (10) and separate.

(7) Remove planetary gear cover (12), weather seal

(13), and planetary assembly (14) from drive housing (11).

5-84

TM 5-3825-230-14&P

(8) Remove gear ring (15).

(9) Push in on bushing (16) to expose stop ring

(17). Remove stop ring using needle nose pliers.

(10) Remove drive gear (18) from planetary (14).

(11) Remove snap ring (19) using snap ring pliers and remove drive fork (20).

(12) Remove fork pivot (21) from drive fork (20).

(13) Remove snap ring (22) using snap ring pliers, fiber washer (23), planetary housing (24), and fiber washer (25) from planetary (14).

5-85

TM 5-3825-230-14&P

5-35. STARTER REPAIR (CONT).

TM 5-3825-230-14&P

(14) Remove two screws (26), capsule (27), washer (28), clip (29), O-ring (30), and armature (31) using a cross tip screwdriver.

(15) Matchmark commutator end shield (32) and starter (10).

(16) Separate commutator end shield (32) from starter (10).

(17) If damaged, press out bushing (33) from commutator end shield (32) using a press.

5-86

TM 5-3825-230-14&P

(18) Remove four clips (34), four springs (35), and four brushes (36) from brush plate (37).

b. Cleaning/Inspection.

WARNING

• cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 1000F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

• Compressed air used for cleaning purposes will not exceed 30 psi (206 kPa). Use only with effective chip guarding and personal protective equipment (goggles/shield, gloves, etc).

(1) Clean all non-electrical parts with dry cleaning solvent P-D-680.

(2) Clean electrical components with compressed air.

(3) Inspect all wiring for damage. Replace any component with damaged wiring.

(4) Inspect brushes for excessive wear. Brushes must be long enough to contact commutator segments on armature.

(5) Inspect brush springs for wear, distortion, or discoloration. Replace if damaged.

(6) Inspect frame for deformities which would affect fit of windings. Replace if damaged.

(7) Inspect armature for signs of wear or missing segments.

(8) Perform continuity check of solenoid to check for an open or shorted coil. Replace defective solenoid.

(9) Perform continuity check between contacts of solenoid by applying 24 VDC to coil. When coil is energized contacts should be closed.

(10) Apply voltage to solenoid coil. Armature of solenoid should retract.

5-87

TM 5-3825-230-14&P

5-35. STARTER REPAIR (CONT).

(11) Perform continuity check of windings for shorted or open condition. Replace if shorted or open.

(12) Visually inspect windings for evidence of extreme heat or chafing against armature. Replace winding if damaged.

(13) Check for binding of clutch on shaft. If shaft is damaged, dress with crocus cloth. If bore of clutch is damaged, replace clutch or bushing.

(14) Inspect bushings for cracks or chipping.

c. Assembly.

NOTE

• If brushes were removed from brush plate, it may be necessary to solder wires leading from the brush plate.

• Brushes must be in contact around end of armature as they are installed.

(1) Install four brushes (36), four springs (35), and four clips (34) on brush plate (37).

(2) If removed install bushing (33) in commutator end shield (32) using a press.

5-88

TM 5-3825-230-14&P

(3) Refer to matchmarks and install commutator end shield (32) on starter (10).

(4) Install armature (31), washer (28), clip (29), O-ring (30), capsule (27), and two screws (26) using a cross tip screwdriver.

(5) Install fiber washer (25), planetary housing (24), fiber washer (23), and snap ring (22) on planetary (14).

5-89

5-35. STARTER REPAIR (CONT).

(6) Install fork pivot (21) on drive fork (20).

(7) Install drive fork (20) and snap ring (19) on drive gear (18).

(8) Install drive gear (18) on planetary (14).

(9) Install stop ring (17) and bushing (16).

(10) Install gear ring (15).

(11) Install planetary assembly (14), weather seal

(13), and planetary gear cover (12) in drive housing (11).

(12) Refer to matchmarks and install drive housing

(11) on starter (10).

5-90

TM 5-3825-230-14&P

TM 5-3825-230-14&P

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 a well ventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

(13) Coat threads of two screws (8) and three screws

(5) using thread locking compound.

(14) Install two washers (9) and two screws (8) in starter (10) using a 9 mm open end wrench.

(15) Install actuator (7) and spring (6).

(16) Refer to matchmarks and install solenoid (4) and three screws (5) using a cross tip screwdriver.

(17) Install copper washer (3), connector (2), and nut

(1) on solenoid (4) using a 13 mm open end wrench.

NOTE

Follow-on maintenance: Install

starter (para 4-58)

END OF TASK

5-36. BATTERY REPAIR.

Refer to TM 9-6140-200-14, Operator/Unit/Direct Support/General Support Maintenance Manual for care, maintenance, repair, and inspection of lead-acid storage batteries.

5-91

TM 5-3825-230-14&P

5-37. MAIN FRAME REPAIR.

This task covers: a. Repair b. Cleaning/Inspection

INITIAL SETUP

Tools

Tool Kit, Master Mechanic's

Shop Equipment, Machine Shop; Field

Maintenance, Basic, Less Power

Equipment Condition

TM or Para

Para 4-24

Para 4-94

Para 4-123

Para 4-105

Para 4-76

Condition Description

Engine removed.

Swing frame removed.

Sprinkler lines removed.

Hydraulic hoses removed.

12V wire harness removed.

a. Repair.

(1) Welding and brazing may be used to repair cracks in external steel parts, such as brackets, panels, and light framework. Do not weld or braze parts under great stress.

(2) Bent or dented frame parts may be repaired by straightening.

(3) Painting. Instructions for preparation of material for painting, how to paint, and material to be used are in TM 43-0139. Stenciling and working markings for military vehicles are called out in

TB 43-0209. Data plates location and

description are referenced in Chapter 2.

Equipment Condition

TM or Para

Para 4-77

Para 4-78

Para 4-75

Para 4-122

Para 4-87

Para 4-40

Para 4-106

Condition Description

24V wire harness removed.

Broom hood wire harness removed.

Battery box removed.

Saddle removed.

Modified spindle removed.

Fuel tank removed.

Hydraulic reservoir drained.

b. Cleaning/inspection. Inspect mainframe for cracks, dents, corrosion and warpage.

5-92

NOTE

Follow-on maintenance:

• Install fuel tank (para 4-40)

• Install modified spindle (para 4-87)

• Install saddle (para 4-122)

• Install battery box (para 4-75)

• Install broom hood wire harness (para

4-78).

• 24V wire harness (para 4-77)

• Install 12V wire harness (para 4-76)

• Install hydraulic hoses (para 4-105)

• Install sprinkler lines (para 4-123)

• Install swing frame (para 4-94)

• Install engine (para 4-24)

• Fill hydraulic reservoir (para 4-106)

END OF TASK

5-38. HYDRAULIC HOSE FABRICATION AND TESTING.

Refer to Appendix G for fabrication and testing of hydraulic hoses.

5-93

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-76. TOW VEHICLE TO JUNCTION BOX WIRE HARNESS (12V) REPLACEMENT/REPAIR.

This task covers: a.

Disassembly b.

Cleaning/Inspection c. Assembly

INITIAL SETUP

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop, Field

Maintenance, Basic Less Power

Materials/Parts

Seals

Thrust plates

Compound, thread locking, item 14 Appendix E

Solvent, dry cleaning, item 31 Appendix E

Equipment Condition

TM or Para

Para 4-101

Condition Description

Hydraulic pump removed.

a. Disassembly.

(1) Remove four screws (1) and separate rear cover (2) from pump body (3) using a 5/16 in.

hex head wrench.

(2) Remove static seal (4) and loading seal (5) from rear cover (2).

5-94

(3) Remove thrust plate (6).

(4) Pull driven gear (7) from body (3).

(5) Push drive gear (8) out to rear of body (3).

(6) Remove remaining thrust plate (9).

TM 5-3825-230-14&P

(7) Separate front cover (10) from body (3).

(8) Remove loading seal (11) and static seal (12) from front cover (10).

5-95

TM 5-3825-230-14&P

5-39. HYDRAULIC PUMP ASSEMBLY REPAIR (CONT).

(9) Remove snap ring (13) and seal (14) from front cover (10) using snap ring pliers.

b. Cleaning/inspection.

(1) Inspect pump parts for wear, warped, parts or corrosion.

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(2) Clean all metal parts with dry cleaning solvent P-D-680.

(3) Replace any damaged or worn parts.

c. Assembly.

(1) Install seal (14) and snap ring (13) in front cover (10) using snap ring pliers.

5-96

NOTE

Smooth side of loading seal faces up.

(2) Install static seal (12) and loading seal

(11) on front cover (10).

NOTE

Smooth side of thrust plates should be against seals.

(3) Align pins (15), assemble body (3), and front cover (10).

(4) Install thrust plate (9), driven gear (7), drive gear (8), and thrust plate (6) on pump body (3).

TM 5-3825-230-14&P

5-97

TM 5-3825-230-14&P

5-39. HYDRAULIC PUMP ASSEMBLY REPAIR (CONT).

NOTE

Smooth side of loading seal faces up.

(5) Install static seal (4) and loading seal (5) c rear cover (2).

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.

(6) Apply thread locking compound to threads of four screws (1).

(7) Install rear cover (2) and four screws (1) on body (3). Tighten screws to 35 to 40 lb-ft (47 to 54 N•m) using a torque wrench and 5/16 in. hex head socket.

NOTE

Follow-on maintenance: Install hydraulic pump (para 4-101)

END OF TASK

5-98

TM 5-3825-230-14&P

5-40. HYDRAULIC MOTOR REPAIR.

This task covers: a. Disassembly b. Cleaning/Inspection c. Assembly

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic Less Power

Materials/Parts

Seal kit (PE4440002)

Seal kit (PE444003)

Compound, thread locking, item 14 Appendix E

Equipment Condition

TM or Para

Para 4-102

Condition Description

Hydraulic motor removed.

a. Disassembly.

(1) Matchmark motor assembly.

(2) Remove seven bolts (1), end cover (2), and seal (3) using a ratchet and 9/16 in. socket.

5-99

5-40. HYDRAULIC MOTOR REPAIR (CONT).

TM 5-3825-230-14&P

(3) Remove balance plate (4) and four steel balls (5) from balance plate (4).

(4) Matchmark exposed side of rotor assembly (6) and remove from motor assembly.

(5) Remove two seals (7) from rotor assembly (6).

(6) Matchmark exposed side of manifold boot (8) and manifold plate (9).

(7) Remove manifold boot (8) and manifold plate (9).

(8) Remove thrust bearing (10) and drive link (11).

(9) Push shaft (12) out to rear of housing (26) and remove seal (13) from housing (26).

(10) Remove seal (15).

(11) Press seal carrier (17) in and remove snap wire (16) using needle nose pliers.

(12) Remove seal carrier (17), (includes: backup shim (18), backup seal (19), and shaft seal (20)), backup shim

(21), square cut seal (22), thrust washer (23), and thrust bearing (24).

(13) Drive out front roller bearing (25) and rear roller bearing (14) from housing (26) using a drift and ball peen hammer.

5-100

TM 5-3825-230-14&P

b. Cleaning/Inspection.

(1) Inspect motor parts for signs of wear, warping, or corrosion.

(2) Replace any damage or worn parts.

c. Assembly.

(1) Install rear roller bearing (14) and front roller bearing (25) in housing (26) using a press.

(2) Install thrust bearing (24), thrust washer (23), square cut seal (22), backup shim (21), shaft seal (20), backup seal (19), backup shim (18), seal carrier (17), snap wire (16), and seal (15).

(3) Install shaft (12) into rear of housing (26) and install seal (13).

NOTE

Flat end of drive link goes in first.

(4) Install thrust bearing (10) and drive link (11) in housing (26).

(5) Refer to matchmarks and install manifold plate (9) and manifold boot (8) over drive link (11) .

(6) Install two seals (7) on rotor assembly (6).

(7) Refer to matchmarks and install rotor assembly (6) on end of drive link (11).

(8) Install four steel balls (5) in holes in balance plate (4) and place flat side of balance plate (4) against rotor assembly (6).

(9) Install seal (3) on cover (2).

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.

(10) Apply thread locking compound to threads of seven screws (1) and install cover (2). Tighten screws to 45 to 55 lb-ft (61 to 74 N•m) using a torque wrench and 9/16 in. socket.

NOTE

Follow-on maintenance: Install hydraulic motor (para 4-102)

END OF TASK

5-101

TM 5-3825-230-14&P

5-41. HYDRAULIC CONTROL VALVE REPAIR.

This task covers: a. Disassembly b. Cleaning/Inspection c. Assembly

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop; Field

Maintenance, Basic Less Power

Materials/Parts

Cotter pins

O-rings

Lockwasher

Compound, thread sealing, item 14 Appendix E

Solvent, dry cleaning, item 31 Appendix E

Tags, identification, item 35 Appendix E

Equipment Condition

TM or Para

Para 4-103

Condition Description

Hydraulic control valve removed.

a. Disassembly.

NOTE

Both control handles are removed the same way.

(1) Remove three cotter pins (1), bracket (2), three pins (3), bracket (4), and control handle (5) using pliers.

(2) Remove two screws (6) and handle bracket (7) using a 3/16 in. hex head wrench.

5-102

(3) Remove two port plugs (8) and two Orings (9) using a 1-1/4 in. open end wrench.

(4) Remove plug (10) and O-ring (11) using a

1-1/4 in. open end wrench.

TM 5-3825-230-14&P

(5) Remove four screws (12) and end cap

(13) using a 3/16 in. hex head wrench.

(6) Remove four screws (14) and end cap

(15) using a 3/16 in. hex head wrench.

5-103

5-41. HYDRAULIC CONTROL VALVE REPAIR (CONT).

TM 5-3825-230-14&P

(7) Disassemble control valve as follows:

(a) Remove three flat washers (16).

(b) Remove control valve spool (17).

(c) Remove detent retainer (18), lockwasher (19), and detent sleeve (20) as one piece using a flat tip screwdriver.

WARNING

Steel balls and springs in detent retainer are under extreme pressure and may come out with velocity. Wear eye protection during this procedure.

(d) Remove detent retainer (18) from detent sleeve (20).

(e) Remove four steel balls (21) and two springs (22).

(f) Remove retainer (23).

(g) Tag valve spool (17) and remove two O-rings (24).

5-104

TM 5-3825-230-14&P

WARNING

Spring is under extreme pressure and may come out with velocity. Use extreme caution and wear eye protection.

(h) Remove screw (25), washer (26), stop collar (27), spring (28), lockwasher (29), and detent sleeve housing (30) using a 3/16 in. hex head wrench.

(i) Remove detent plug (31), spring (32), steel ball (33), and detent sleeve (34) using a 5/8 in. open end wrench.

(j) Tag and remove valve spool (35) and two O-rings (36).

5-105

TM 5-3825-230-14&P

5-41. HYDRAULIC CONTROL VALVE REPAIR (CONT).

(k) Remove cartridge (37) and O-ring

(38) from valve body (39) using a 1 in. open end wrench.

b. Cleaning/Inspection.

(1) Inspect valve spools for cracks, wear, and signs of corrosion

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medical aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

(2) Clean valves and pump body with dry cleaning solvent P-D-680.

(3) Replace any worn or damaged parts.

c. Assembly.

(1) Assemble valve as follows:

(a) Install relief cartridge (37) and O-ring (38) in valve body (39) using a 1 in. open end wrench.

5-106

TM 5-3825-230-14&P

(b) Install two O-rings (36) on valve spool (35), and install spool.

(c) Install detent sleeve (34) in detent sleeve housing (30) aligning groove in detent sleeve with hole in top of detent sleeve housing.

(d) Install steel ball (33) and spring (32) in hole and install detent plug (31) using a 5/8 in. open end wrench.

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 a wellventilated area. If adhesive, solvent, or sealing compound gets on skin or clothing, wash immediately with soap and water.

• Spring is under extreme pressure and may come out with velocity. Use extreme caution and wear eye protection.

(e) Apply thread sealing compound to lockwasher (29) and install lockwasher, spring (28), stop collar

(27), washer (26), and screw (25) on valve spool (35).

5-107

5-41. HYDRAULIC CONTROL VALVE REPAIR (CONT).

TM 5-3825-230-14&P

(f) Install two O-rings (24), valve spool (17), and retainer (23).

WARNING

Steel balls and springs in detent retainer are under extreme pressure and may come out with velocity. Wear eye protection during this procedure.

(g) Install two springs (22) and four steel balls (21) in detent retainer (18).

(h) Install detent retainer (18) in detent sleeve (20) making sure threaded part of retainer protrudes on other side of sleeve. Install lockwasher (19) on retainer.

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.

NOTE

The narrow end of detent sleeve should be towards valve body.

(i) Apply thread locking compound to threads of detent retainer (18) and assemble detent retainer, lockwasher (19), and detent retainer sleeve (20) on valve spool (17) as one piece.

(j) Install three washers (16).

5-108

TM 5-3825-230-14&P

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.

NOTE

Thread locking compound must be applied to all screws during installation procedures.

(2) Apply thread locking compound to threads of screws (14, 12, and 6).

(3) Install four screws (14) and endcap (15) using a 3/16 in. hex head wrench.

(4) Install four screws (12) and endcap (13) using a 3/16 in. hex head wrench.

(5) Install O-ring (11) and plug (12) in valve body using a 1-1/4 in. open end wrench.

(6) Install two O-rings (9) and two port plugs

(8) using a 1-1/4 in. open end wrench.

5-109

5-41. HYDRAULIC CONTROL VALVE REPAIR (CONT).

NOTE

Both control handles are installed same way.

(7) Install handle bracket (7) and two screws

(6) using a 3/16 in hex head wrench.

(8) Install control handle (5), bracket (4), three pins (3), bracket (2), and three cotter pins (1) using a pliers.

NOTE

Follow-on maintenance: Install

hydraulic control valve (para 4-103)

END OF TASK

5-110

TM 5-3825-230-14&P

TM 5-3825-230-14&P

4-38. VAPOR SEPARATOR REPLACEMENT.

This task covers: a. Disassembly b. Cleaning/Inspection c. Assembly

INITIAL SETUP:

Tools Equipment Condition

Shop Equipment, Automotive Maintenance and TM or Para

Repair; Organizational Maintenance, Common

Para 4-119

No. 1, Less Power

Materials/Parts

O-rings

Seals

Condition Description

Hydraulic cylinder removed.

a. Disassembly.

(1) Remove head gland (1) and cylinder rod (2) as one piece from cylinder barrel (3) using a crescent wrench.

(2) Remove retaining ring (4) from end of cylinder rod (2).

(3) Slide head gland (1) off of cylinder rod (2).

(4) Remove O-ring (5) from head gland (1).

(5) Remove seals (6 and 7) from head gland (1).

5-111

5-42. HYDRAULIC CYLINDER REPAIR (CONT).

TM 5-3825-230-14&P

b. Cleaning/Inspection.

(1) Inspect cylinder barrel (3), cylinder rod (2), and head gland (1) for cracks, dents, warpage or corrosion.

(2) Replace any damaged or worn parts.

c. Assembly.

(1) Install seals (7 and 6) in head gland (1).

(2) Install O-ring (5) on head gland (1).

(3) Slide head gland (1) onto cylinder rod (2).

(4) Install retaining ring (4) on end of cylinder rod (2).

(5) Install head gland (1) and cylinder rod (2) as one piece in cylinder barrel (3) using a crescent wrench.

NOTE

Follow-on maintenance: Install hydraulic cylinder (para 4-119)

END OF TASK

5-112

TM 5-3825-230-14&P

5-43. SPRAY PUMP REPAIR.

This task covers: a Disassembly b. Assembly

INITIAL SETUP:

Tools

Tool Kit, General Mechanic's: Automotive

Shop Equipment, Machine Shop, Field

Maintenance, Basic Less Power

Materials/Parts

Pump diaphragms

Equipment Condition

TM or Para

Para 4-120

Condition Description

Spray pump removed.

a. Disassembly.

(1) Remove screw (1), and cover (2) using a cross tip screwdriver.

5-113

5-43. SPRAY PUMP REPAIR (CONT).

TM 5-3825-230-14&P

(2) Remove two screws (3), two wires (4), and pressure switch assembly (5) using a cross tip screwdriver.

(3) Remove spring (6), spring holder (7), base plate (8), and two seals (9 and 10).

(4) Remove four screws (11) using a cross tip screwdriver and remove pump housing (12).

(5) Remove check valve assembly (13) from pump housing (12).

(6) Remove seal (14) from check valve assembly (13).

(7) Remove two screws (15) using a cross tip screwdriver.

NOTE

Bearing cover may have to be rotated several times in order to locate setscrew.

(8) Twist bearing cover (16) to expose two rectangular holes and insert 1/8 in. hex head wrench through hole in bearing cover and loosen setscrew (17)on cam bearing (18).

(9) Remove bearing cover (16) by sliding it off motor (19).

5-114

(10) Remove two screws (20) using a cross tip screwdriver and remove cam bearing (18).

TM 5-3825-230-14&P

(11) Remove two screws (21), inner piston (22), outer pistons (23), and diaphragm (24) using a cross tip screwdriver.

(12) Remove two screws (25) and plate (26) using a ratchet and 5/16 in. socket.

b. Assembly.

(1) Install plate (26) and two screws (25) using a ratchet and 5/16 in. socket.

(2) Install diaphragm (24), outer pistons (23), inner piston (22), and two screws (21) on bearing cover (16) using a cross tip screwdriver.

(3) Install cam bearing (18) and two screws (20) using a cross tip screwdriver.

(4) Slide bearing cover (16) on motor (19).

(5) Tighten setscrew (17) using a 1/8 in. hex head wrench.

(6) Install two screws (15) using a cross tip screwdriver.

(7) Install seal (14) on check valve assembly (13).

(8) Install check valve assembly (13), pump housing (12), and four screws (11) using a cross tip screwdriver.

(9) Install two seals (10 and 9), base plate (8), spring holder (7), and spring (6).

(10) Install pressure switch assembly (5) and two screws (3) using a cross tip screwdriver. I (11) Connect two wires (4).

(12) Install cover (2) and screw (1) using a cross tip screwdriver .

NOTE

Follow-on maintenance: Install spray pump (para 4-120)

END OF TASK

5-115/(5-116 blank)

TM 5-3825-230-14&P

APPENDIX A

REFERENCES

A-1. SCOPE

This appendix lists forms, field manuals, technical manuals, and other publications either referenced in this manual or which apply to the operation and maintenance of the Sweeper.

A-2. DEPARTMENT OF THE ARMY PAMPHLETS

Consolidated Index of Army Publications and Blank Forms................................ ................................ ........ DA Pam 25-30

Using Unit Supply System (Manual Procedures)................................ ................................ ..................... DA Pam 710-2-1

The Army Maintenance Management System (TAMMS) ................................ ................................ ........ DA Pam 738-750

A-3. FORMS

Recommended Changes to Publications and Blank Forms................................ ................................ ......... DA Form 2028

Recommended Changes to Equipment Technical Publications................................ ............................... DA Form 2028-2

Organizational Control Record for Equipment................................ ................................ ............................ DA Form 2401

Equipment Inspection and Maintenance Worksheet................................ ................................ ................... DA Form 2404

Maintenance Request................................ ................................ ................................ ................................ . DA Form 2407

Preventive Maintenance Schedule and Record................................ ................................ ............................ DD Form 314

Product Quality Deficiency Report (NSN 7540-00-105-0078)................................ ................................ ................. SF 368

A-4. FIELD MANUALS

NBC Contamination Avoidance................................ ................................ ................................ .............................. FM 3-3

NBC Protection ................................ ................................ ................................ ................................ ......................FM 3-4

NBC Decontamination................................ ................................ ................................ ................................ ............FM 3-5

NBC Handbook................................ ................................ ................................ ................................ ......................FM 3-7

Camouflage ................................ ................................ ................................ ................................ ......................... FM 5-20

Operation and Maintenance of Ordnance Materiel in Extreme Cold

Weather (0 Deg. to Minus 65 Deg. F)................................ ................................ ................................ ......... FM 9-207

Vehicle Recovery Operations................................ ................................ ................................ ............................. FM 20-22

First Aid for Soldiers................................ ................................ ................................ ................................ ........... FM 21-11

Basic Cold Weather Manual................................ ................................ ................................ ............................... FM 31-70

Northern Operations................................ ................................ ................................ ................................ ........... FM 31-71

Army Motor Transport Units and Operators................................ ................................ ................................ ........ FM 55-30

Desert Operations (How to Fight)................................ ................................ ................................ ......................... FM 90-3

Operational Symbols................................ ................................ ................................ ................................ .......FM 101-5-1

A-5. SUPPLY BULLETIN

Storage Serviceability Standard - Tracked Vehicles,

Wheeled Vehicles, and Component Parts................................ ................................ ................................ ..... SB 740-98-1

A-1

TM 5-3825-230-14&P

A-6. TECHNICAL BULLETINS

Equipment Improvement Report and Maintenance Digest

(US Army Tank-Automotive Command) Tank-Automotive Equipment................................ .............. TB 43-0001-39-

Series

Color, Marking, and Camouflage Painting of Military Vehicles,

Construction Equipment, and Materiels Handling Equipment................................ ................................ ...TB 43-0209

Maintenance in the Desert................................ ................................ ................................ ............................... TB 43-0239

Description, Use, Bonding Techniques, and Properties of Adhesives................................ .......................... TB ORD 1032

A-7. TECHNICAL MANUALS

Inspection, Care, and Maintenance of Antifriction Bearings................................ ................................ ................ TM 9-214

Operator's Manual for Welding Theory and Application................................ ................................ ...................... TM 9-237

Deepwater Fording of Ordnance Materiel................................ ................................ ................................ ........... TM 9-238

Materials Used for Cleaning, Preserving, Abrading, and Cementing

Ordnance Materiel and Related Items Including Chemicals................................ ................................ ........ TM 9-247

Organizational, Direct Support, and General Support Care, Maintenance, and Repair of Pneumatic Tires and Inner Tubes................................ ................................ ........... TM 9-2610-200-24

Tool Outfit Hydraulic System Test and Repair Unit (HYSTRU)................................ ............................. TM 9-4940-468-14

Painting Instructions for Field Use................................ ................................ ................................ .................. TM 43-0139

Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use ................................ ................................ ................................ ........................ TM 750-244-6

A-8. OTHER PUBLICATIONS

Army Logistics Readiness and Sustainability................................ ................................ ................................ .. AR 700-138

Packaging of Army Material for Storage and Shipment................................ ................................ ...................... AR 746-1

Expendable/Durable Items (Except Medical, Class V,

Repair Parts, and Heraldic Items)................................ ................................ ................................ ........... CTA 50-970

Abbreviations for Use on Drawings Specifications, Standards, and

Technical Documents................................ ................................ ................................ .............................. MILSTD-12

A-2

TM 5-3825-230-14&P

APPENDIX B

MAINTENANCE ALLOCATION CHART (MAC)

Section I. INTRODUCTION

B-1. GENERAL.

a. This section provides a general explanation of all maintenance and repair functions authorized at various maintenance levels.

b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility for the

performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component will be consistent with the capacities and capabilities of the designated maintenance levels.

II.

c. Section III lists the tools and test equipment required for each maintenance function as referenced from section

B-2. MAINTENANCE FUNCTIONS.

Maintenance functions will be limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination (e.g., by sight, sound, or feel).

b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards .

c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.

d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or by setting the operating characteristics to specified parameters.

e. Aline. To adjust specified variable elements of an item to bring about optimum or desired performance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test, measuring, and diagnostic equipments used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.

g. Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system.

h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace" is authorized by the MAC and is shown as the 3rd position code of the SMR code.

B-1

TM 5-3825-230-14&P

i. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, and disassembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system.

B-3. EXPLANATION OF COLUMNS IN SECTION II.

a. Column 1, Group Number. Column 1 lists functional group code numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the next higher assembly. End item group number shall be "OO."

b. Column 2, Component/Assembly. Column 2 contains the names of components, assemblies, subassemblies, and modules for which maintenance is authorized.

c. Column 3, Maintenance Function. Column 3 lists the functions to be performed on the item listed in column 2.

d. Column 4, Maintenance Level Column 4 specifies, by the listing of a work time figure in the appropriate subcolumn(s), the level of maintenance authorized to perform the function listed in Column 3. This figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function vary at different maintenance levels, appropriate work time figures will be shown for each level. The work time figure represents the average time required to restore an item

(assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance/quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. The symbol designations for the various maintenance levels are as follows:

C Operator or Crew

O Organizational Maintenance

H General Support Maintenance

D Depot Maintenance

F Direct Support

e. Column 5, Tools and Equipment. Column 5 specifies, by code, those common tool sets (not individual tools) and special tools, TMDE, and support equipment required to perform the designated function.

f. Column 6, Remarks. This column shall, when applicable, contain a letter code in alphabetic order, which shall

be keyed to the remarks contained in Section IV.

B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENT, SECTION III.

a. Column 1, Reference Code. The tool and test equipment reference code correlates with a code used in the

MAC, Section II, Column 5.

b. Column 2, Maintenance Level The lowest level of maintenance authorized to use the tool or test equipment.

c. Column 3, Nomenclature. Name or identification of the tool or test equipment.

d. Column 4, Tool Kit. The national stock number of the tool or test equipment.

B-2

(1)

GROUP

NUMBER

01

0100

0101

0102

0103

0104

0105

0106

0108

0109

03

0301

0302

TM 5-3825-230-14&P

(2)

Section II. MAINTENANCE ALLOCATION CHART

(3)

MAINTENANCE

FUNCTION

(4) (5) (6)

MAINTENANCE LEVEL

UNIT INTMED

C O F H D

TOOLS &

EQUIPMENT

REMARKS COMPONENT ASSEMBLY

ENGINE

Engine Assembly 0.2

Inspect

Service

Adjust

Replace

Repair

1.0

0.3

1.8

8.6

Crankcase, Block, and

Cylinder Head

Crankshaft

Flywheel Assembly

Pistons and Connecting

Rods

Valves, Camshafts, and

Timing System

Engine Lubrication System

Manifolds

Accessory Driving

Mechanisms

FUEL SYSTEM

Fuel Injector

Replace

Repair

Replace

Replace

Repair

Replace

Repair

Adjust

Replace

Repair

Inspect

Replace

Replace

Replace

0.1

2.4 1.1

0.5

1.0

8.6

0.4

8.3

1.1

1.2

5.2

0.7

0.4

5.5

0.7

6

9

4, 6, 9

1, 4, 6, 7, 9,

11

1, 7, 9, 11

1, 4, 6, 8, 9,

11

1, 4, 6, 8, 9,

11

1, 4, 8, 9

8, 9

1, 4, 8, 9, 11

1, 8

4, 9

1, 4, 6, 8, 9,

11

1, 4, 6, 8, 9

4, 9

4, 9

4, 9

A

Fuel Pumps

Service

Replace

Adjust

Replace

1.2

1.0

0.9

0.4 3.2

1

9

4, 9

4, 9, 11

B

* MAINTENANCE LEVELS:

C - OPERATOR/CREW = UNIT

O - ORGANIZATIONAL = UNIT

D - DEPOT F - DIRECT SUPPORT

H - GENERAL SUPPORT

B-3

(1)

GROUP

TM 5-3825-230-14&P

(2)

Section II. MAINTENANCE ALLOCATION CHART

COMPONENT ASSEMBLY

(3)

MAINTENANCE

FUNCTION

(4) (5) (6)

MAINTENANCE LEVEL

UNIT INTMED

C O F H D

TOOLS &

EQUIPMENT

REMARKS NUMBER

0304 Air Cleaner

0306

0308

0309

0311

04

0401

05

0502

06

0601

0603

0607

0608

Vapor Separator

Tanks, Lines, Fittings, and Headers

Engine Speed Governor and Controls

Fuel Filters

Glow Plugs

EXHAUST SYSTEM

Muffler and Pipes

COOLING SYSTEM

Cowling, Deflectors, Air

Ducts, Shrouds

ELECTRICAL SYSTEM

Generator, Alternator

Starting Motor

Instruments or Engine

Control Panel

Miscellaneous Items

Inspect

Replace

Replace

Service

Replace

Adjust

Replace

Repair

Replace

Replace

Replace

Replace

Replace

Repair

Replace

Replace

Repair

0.1

0.2

0.1

0.2

1.1

0.3

2.0

1.1

0.4

0.3

0.3

2.8

1.0

0.4

1.0

0.7

1.9

0.4

9

9

9

9

6, 9

4, 9

8

9

4, 9

9

1, 4, 8, 9

4, 9

4, 9

9

4

4, 9

* MAINTENANCE LEVELS:

C - OPERATOR/CREW = UNIT

O - ORGANIZATIONAL = UNIT

D - DEPOT F - DIRECT SUPPORT

H - GENERAL SUPPORT

B-4

(1)

GROUP

TM 5-3825-230-14&P

(2)

Section II. MAINTENANCE ALLOCATION CHART

COMPONENT ASSEMBLY

(3)

MAINTENANCE

FUNCTION

(4) (5) (6)

MAINTENANCE LEVEL

UNIT INTMED

C O F H D

TOOLS &

EQUIPMENT

REMARKS NUMBER

0609 Light Mount

Lights

0610

0612

0613

12

1201

Fuel Sending Unit

Battery, Storage

(Wet or Dry)

Hull or Chassis Wiring

Harness

BRAKES

Hand Brakes

Replace

Inspect

Replace

Replace

Inspect

Service

Replace

Repair

Replace

Repair

Inspect

Service

Adjust

Replace

Repair

1.0

0.1

0.3

0.2

0.2

0.2

0.4

0.5

1.9

0.4

0.1

0.2

0.1

1.2

0.7

1.1

9

9

9

9

9

9

9

9

4, 9

C

13

1311

WHEELS

Wheels and Axles

1313 Tires

Inspect

Replace

Repair

Inspect

Service

Replace

Repair

0.1

0.7

0.6

0.1

0.1

1.1

0.2 0.8

4, 9

4, 9

4, 9

D

* MAINTENANCE LEVELS:

C - OPERATOR/CREW = UNIT

O - ORGANIZATIONAL = UNIT

F - DIRECT SUPPORT

H - GENERAL SUPPORT

B-5

D - DEPOT

(1)

GROUP

1503

TM 5-3825-230-14&P

(2)

Section II. MAINTENANCE ALLOCATION CHART

COMPONENT ASSEMBLY

(3)

MAINTENANCE

FUNCTION

(4) (5) (6)

MAINTENANC E LEVEL

UNIT INTMED

C O F H D

TOOLS &

EQUIPMENT

REMARKS NUMBER

15

1501

FRAME, TOWING

ATTACHMENTS, AND

DRAWBAR

Main Frame Assembly

Modified Spindle

Pintle and Towing

Attachments

Tow Pole and Strut

Inspect

Service

Repair

Replace

0.2

0.2

1.7

10.1

1, 4, 6, 8, 9

4, 9

Service

Replace

Repair

0.2

0.5

0.2

4, 9

4, 9

18

22

2210

24

2401

BODY, CAB, HOOD

AND HULL

Body, Cab, Hood and

Hull Assemblies

BODY CHASSIS

OR HULL AND

ACCESSORY ITEMS

Data Plates and Instrument

Holders

HYDRAULIC LIFT

COMPONENTS

Hydraulic Pump

Replace

Replace

1.6

0.8

4, 9

9

2402

Hydraulic Motor

Hydraulic Control Valve

Replace

Repair

Replace

Repair

Replace

Repair

0.5

0.5

0.8

1.0

1.0

1.2

4, 9

4, 8, 9

4, 9

4, 8, 9

4, 9

4, 8, 9

* MAINTENANCE LEVELS:

C - OPERATOR/CREW = UNIT

O - ORGANIZATIONAL = UNIT

D - DEPOT F - DIRECT SUPPORT

H - GENERAL SUPPORT

B-6

(1)

GROUP

TM 5-3825-230-14&P

(2)

Section II. MAINTENANCE ALLOCATION CHART

COMPONENT ASSEMBLY

(3)

MAINTENANCE

FUNCTION

(4) (5) (6)

MAINTENANCE LEVEL

UNIT INTMED

C O F H D

TOOLS &

EQUIPMENT

REMARKS NUMBER

2406 Hydraulic Lines and

Fittings

Inspect

Service

Replace

Repair

0.1

0.5

1.0

0.5

4, 9

4, 9, 10

47

4701

71

7111

NON-ELECTRICAL

GAUGES

Tachometer

SWEEPING

EQUIPMENT

COMPONENTS

Sweeper Head

Replace 0.5 9

7113

7114

Hydraulic Cylinder

Spray System

Inspect

Service

Adjust

Replace

Inspect

Replace

Repair

Inspect

Service

Replace

Repair

0.1

0.3

0.4

3.4

0.1

2.3

0.5

0.1

0.2

1.4

0.2 0.4

9

6, 9

6, 9

4

6, 9

6, 8, 9 E

* MAINTENANCE LEVELS:

C - OPERATOR/CREW = UNIT

O - ORGANIZATIONAL = UNIT

F - DIRECT SUPPORT

H - GENERAL SUPPORT

B-7

D - DEPOT

TM 5-3825-230-14&P

TOOL OR TEST

EQUIPMENT

REF CODE

MAINTENANCE

LEVEL

1

2

3

F, H

O

O, F, H

4 O

5

6

7

8

9

10

11

F, H

0

F

F

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

Table B-1. Tool and Test Equipment Requirements

O

O

F, H

NOMENCLATURE

Tool Kit, Master Mechanic's

Tool Kit, Body & Fender Repair

Tool Kit, Automotive and

Electrical System Repair

Shop Equipment, Automotive

Maintenance and Repair;

Organizational Maintenance,

Common No. 1, Less Power

Shop Equipment, Automotive

Maintenance and Repair;

Organizational Maintenance,

Supplemental Set No. 1,

Less Power

Shop Equipment, Automotive

Maintenance and Repair

Organizational Maintenance

Common No. 2, Less Power

Shop Equipment, Fuel and Electrical

System Engine, Field Maintenance,

Basic, Less Power

Shop Equipment, Machine Shop

Field Maintenance; Basic, Less Power

Tool Kit, General Mechanic's: Automotive

Tool Outfit, Hydraulic Systems Test and Repair (HYSTRU)

Special Tool: Spring Compressor

TOOL KIT

STOCK NUMBER

5180-00-699-5273

5180-00-754-0643

5180-00-754-0655

4910-00-754-0654

4910-00-754-0653

4910-00-754-0650

4910-00-754-0714

3470-00-754-0708

5180-00-177-7033

4740-01-036-5784

CAGE: 2X179

PN 7535.1460.009

B-8

REFERENCE CODE

A

(O),

B

C

D

E

TM 5-3825-230-14&P

Section IV. REMARKS

REMARKS

The oil pan and oil filter housing are replaced at the Organizational Level

paragraph 4-29 and paragraph 4-30. The oil pump is replaced at the Direct

Support Level (F), paragraph 5-27.

The fuel pump is replaced at the Organizational Level (O) using tool kits 4

and 9, paragraph 4-35. The injector pump is replaced at the Direct Support

Level (F) using tool kits 4, 9, and 11, paragraph 5-33.

The Crew (C) adjustment is addressed in paragraph 3-12. The Organiza-

tional Level (O) adjustment is addressed in paragraph 4-85.

Repair of tires at Organizational Level (O) is limited to plugging the tire.

The spray bar repair is performed at the Organizational Level (O) using tool

kits 6 and 9, paragraph 4-124. The spray pump repair is performed at the

Direct Support Level (F) using tool kits 6, 8, and 9, paragraph 5-43.

B-9/(B-10 blank)

TM 5-3825-230-14&P

APPENDIX C

COMPONENTS OF END ITEM AND BASIC ISSUE ITEMS LIST

The Rotary Towed Sweeper does not have any Components of End Item or Basic Issue Items.

APPENDIX D

ADDITIONAL AUTHORIZATION LIST

The Rotary Towed Sweeper does not have any Additional Authorized items for its support.

C-1/D-1(D-2 blank)

TM 5-3825-230-14&P

APPENDIX E

EXPENDABLE SUPPLIES AND MATERIALS LIST

Section I. INTRODUCTION

E-1. SCOPE.

This appendix lists expendable supplies and materials you will need to operate and maintain the Rotary Towed Sweeper.

These items are authorized to you by CTA 50-970, Expendable Items (Except Medical, Class V, Repair Parts and

Heraldic Items) or CTA 8-100, Army Medical Department Expendable/Durable Items.

E-2. EXPLANATION OF COLUMNS. I

a. Column (1) - Item Number . This number is assigned to the entry in the listing and is referenced in the narrative

task box to identify the material (e.g., "Compound, cleaning, item 5, appendix E).

b. Column (2) - Level This column identifies the lowest level of maintenance that requires the listed items.

C - Operator/Crew

O - Organizational Maintenance

F - Direct Support Maintenance

H - General Support Maintenance

c. Column (3) - National Stock Number . This is the National Stock Number assigned to the item; use it to request or requisition the item.

d. Column (4) - Description . Indicates the Federal item name and, if required, a description to identify the item.

The last line for each item indicates the Commercial And Government Entity (CAGE) code in parentheses followed by the part number.

e. Column (5) - Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance function. This measure is expressed by a two-character alphabetical abbreviation (e.g., ea., in pr). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements. I

E-1

9

10

11

12

13

14

15

16

17

18

19

(1) (2)

ITEM

NUMBER LEVEL

4

5

6

7

8

1

2

3

O

O

O

C

O

O

O

O

O

O

O

H

O

O

O

O

C

O

O

TM 5-3825-230-14&P

Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST

(3)

NATIONAL

STOCK

NUMBER

(4)

DESCRIPTION

8040-00-573-1502

8040-01-152-8104

8040-00-995-0590

8020-00-207-6658

8020-00-559-0389

7920-00-291-5815

7930-00-634-3935

5350-00-221-0872

5350-00-161-9066

6850-01-146-8003

8030-00-027-4929

5350-00-927-3867

5970-00-166-5697

8030-00-833-9116

8040-00-843-0802

8030-01-054-0740

7930-00-282-9699

8010-00-297-2124

9150-00-082-7524

(5)

UM/UI

Adhesive, PVC

Adhesive No. PL200

Adhesive, Sealant: Silicone RTV, general purpose

(MIL-A-46106A) 108 (CAGE 01139)

Brush, Paint: Oval, 1-1/8 in. wide

Brush, Paint: 2 in. wide

Brush, S-Wire: Curved handle, wire lg. outside block:

1-1/8 to 1-1/4 in. 4 rows wide, 18 rows long, 14 in. long

Chips, Soap, P-S-579

Cloth, Abrasive: Crocus, ferric oxide and quartz. Jeancloth backing. Exposed coat, 9x11 sh, 50-sh sheave

(81348) P-C-458, 42-C-20420-50.

Cloth, Abrasive: Al-oxide, jean-cloth backing, closed coat

9x11 sh, 50-sh sheave, P-C-451A, type 1, class 1.

Compound, Cleaning

Compound, Corrosion Preventive

Compound, Grinding (8 oz jar)

Compound, Ignition Insulation

Compound, Locking, Thread: Grade AV red

MIL-S-22473, 6 oz tube.

Compound, Sealing, Permatex #14

Compound, Sealing, Pipe Thread

Detergent: Non sudsing, general purpose, liquid (80244)

MIL-D-16791 type 1, 1 gal container

Enamel: Green color no. 2430 (81340) Fed Std No. 595 brush and spray application (81348) TT-E-485, type II, 1 gal can.

Fluid, Hydraulic, Petroleum Base: Aircraft, missile, and ordinance (MIL-H-5606).

ea ea ea ea ea ea lb sh gl ea ea ea oz oz cc kt cc gl gl

E-2

23

24

25

26

27

28

29

30

31

32

(1) (2)

ITEM

NUMBER LEVEL

20

21

22

O

O

C

F

C

C

O

C

O

C

F

O

O

(3)

NATIONAL

STOCK

NUMBER

5210-01-222-8068

5210-00-640-6177

9150-00-065-0029

9150-00-935-1017

9150-00-190-0904

9150-00-190-0905

9150-00-190-0907

2640-00-256-5526

9140-00-286-5294

9140-00-286-5294

9140-00-286-5296

9140-00-286-5297

9159-00-186-6681

9150-00-189-6727

9150-00-186-6668

9150-00-191-2772

9150-01-152-4117

9150-01-152-4118

9150-01-152-4119

9150-01-293-2772

8040-01-004-2705

7920-00-148-9666

3439-01-088-3256

6850-00-664-5685

6850-00-274-5421

5970-00-644-3167

TM 5-3825-230-14&P

(4)

DESCRIPTION

(5)

Gage: Plastic adjustment

Gaging Plastic: Green

Grease, Automotive and Artillery (MIL-6-10924)

2-1/4 oz tube

14-oz cartridge

1-lb can

5-lb can

35-lb can

Lubricant, Tire Bead (1 qt can)

Oil, Fuel, Diesel DF-Z regular (VV-F-800)

Bulk

5-gal drum

55-gal drum, 16 gauge

55-gal drum, 18 gauge

Oil, Lubricating Engine: MIL-L-2104, OE/HDO 10

(81349)

1 qt can

5-gal can

55-gal drum

Oil, Lubricating Engine: Internal Combustion Engine,

OE/HDO 15 W/40 (81349) MIL-L-2104

1-qt can

5-gal drum

55-gal drum

Oil, Lubricating: General purpose, preservative,

MIL-L-21260

Primer, PVC

Rag, Wiping: Cotton and cotton-synthetic (58356)

A-A-531

Solder

Solvent, Dry Cleaning, SD Type II (P-D-680) (81348)

1-qt can

5-gal can

Tape, Insulation Electrical (MIL-T-50886) 3/4", 82.5 ft roll

UM/UI

ea ea oz oz lb lb lb ea gl gl gl gl qt gl gl gl qt gl gl pt lb lb qt gl ft

E-3

(1) (2)

ITEM

NUMBER LEVEL

33

34

35

36

O

O

O

O

(3)

NATIONAL

STOCK

NUMBER

7510-00-266-6711

9320-01-053-8266

8135-00-178-9200

5975-00-984-6582

(4)

DESCRIPTION

Tape, Masking, A-A-883

Tape, Teflon

Tags, Identification (MIL-T-12755) 1, 000/pk

Ties, Cable: Plastic MIL-S-29190

TM 5-3825-230-14&P

(5)

U/M

yd rl pk hd

E-4

TM 5-3825-230-14&P

APPENDIX F

UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE

REPAIR PARTS AND SPECIAL TOOLS LIST

Section I. INTRODUCTION

F-1. SCOPE.

This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, and diagnostic equipment (TMDE); and other special support equipment required for performance of unit, direct support, and general support maintenance of the rotary towed sweeper. It authorizes the requisitioning, issue, and disposition of spares, repair parts and special tools as indicated by the source, maintenance, and recoverability (SMR) codes.

F-2. GENERAL.

In addition to Section I, Introduction, this Repair Parts and Special Tools List is divided into the following sections:

a. Section II. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the

performance of maintenance. The list also includes parts which must be removed for replacement of the authorized parts. Parts Lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and item number sequence. Bulk materials are listed by item name in FIG BULK at the end of

the section. Repair parts kits or sets are listed separately in their own functional group within Section II. Repair parts for

repairable special tools are also listed in the section.

b. Section IlI. Special Tools List . A list of special tools, special TMDE, and other special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE

(UOC) column) for the performance of maintenance.

c. Section IV. Cross-Reference Indexes. A list, in National item identification number (NIIN) sequence, of all

National stock numbered items appearing in the listings, followed by a list in alphanumeric sequence of all part numbers appearing in the listings. National stock numbers and part numbers are cross-referenced to each illustration figure and item number appearance. The figure and item number index lists figure and item numbers in alphanumeric sequence and cross-references NSN, CAGEC, and part numbers.

F-3. EXPLANATION OF COLUMNS (SECTIONS II AND III).

a. ITEM NO. (Column (1)). Indicates the number used to identify items called out in the illustration.

b. SMR CODE (Column (2)). The Source, Maintenance, and Recoverability (SMR) code is a 5-position code containing supply/requisitioning information, maintenance category authorization criteria, and disposition instruction, as shown in the following breakout:

F-1

TM 5-3825-230-14&P

* Complete Repair: Maintenance capacity, capability, and authority to perform all corrective maintenance tasks for the

"Repair" function in a use/user environment in order to restore serviceability to a failed item.

(1) Source Code. The source code tells you how to get an item needed for maintenance, repair, or overhaul of an end item/equipment. Explanations of source codes follows:

Explanation

Stocked items; use the applicable NSN to request/requisition items with these source codes. They are authorized to the category indicated by the code entered in the 3rd position of the SMR code.

**NOTE: Items coded PC are subject to deterioration.

Items with these codes are not to be requested/requisitioned individually. They are part of a kit which is authorized to the maintenance category indicated in the 3 rd

position of the SMR code. The complete kit must be requisitioned and applied.

F-2

Items with these codes are not to be requested/requisitioned individually. They must be made from bulk material which is identified by the part number in the DESCRIPTION AND USABLE ON CODE

(UOC) column and listed in the Bulk Material group of the repair parts list in this RPSTL. If the item is authorized to you by the 3rd position code of the SMR code, but the source code indicates it is made at a higher level, order the item from the higher level of maintenance.

TM 5-3825-230-14&P

Explanation

Items with these codes are not to be requested/requisitioned individually. The parts that make up the assembled item must be requisitioned or fabricated and assembled at the level of maintenance indicated by the source code. If the 3 rd

position code of the SMR code authorizes you to replace the item, but the source code indicated the item is assembled at a higher level, order the item from the higher level of maintenance.

Code

C

O

F

H

L

D

XA- Do not requisition an "XA"-coded item. Order its next higher assembly. (Also, refer to the NOTE below.)

XBIf an "XB" item is not available from salvage, order it using the CAGEC and part number given.

XC Installation drawing, diagram, instruction sheet, field service drawing, that is identified by manufacturer's part number.

XD- Item is not stocked. Order an "XD"-coded item through normal supply channels using the CAGEC and part number given, if no NSN is available.

NOTE

Cannibalization or controlled exchange, when authorized, may be used as a source of supply for items with the above source codes, except for those source coded "XA".

(2) Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to USE and REPAIR support items. The maintenance codes are entered in the third and fourth positions of the SMR Code as follows:

(a) The maintenance code entered in the third position tells you the lowest maintenance level authorized to remove, replace, and use an item. The maintenance code entered in the third position will indicate authorization to one of the following levels of maintenance.

Application/Explanation

- Crew or operator maintenance done within organizational maintenance.

- Organizational can remove, replace, and use the item .

- Direct support level can remove, replace, and use the item.

- General support level can remove, replace, and use the item.

- Specialized repair activity can remove, replace, and use the item.

- Depot level can remove, replace, and use the item.

F-3

TM 5-3825-230-14&P

Z

B

L

D

O

F

H

(b) The maintenance code entered in the fourth position indicates whether the item is to be repaired and identifies the lowest maintenance level with the capability to perform complete repair (i.e., all authorized maintenance functions). (NOTE: Some limited repair may be done on the item at a lower level of maintenance, if authorized by the Maintenance Allocation Chart (MAC) and SMR codes.) This position will contain one of the following maintenance codes:

Code Application/Explanation

- Organizational is the lowest level that can do complete repair of the item.

- Direct support is the lowest level that can do complete repair of the item.

- General support is the lowest level that can do complete repair of the item.

- Specialized repair activity is the lowest level that can do complete repair of the item.

- Depot is the lowest level that can do complete repair of the item.

- Nonreparable. No repair is authorized.

- No repair is authorized. (No parts or special tools are authorized for the maintenance of a "B"-coded item.)

However, the item may be reconditioned by adjusting, lubrication, etc., at the user level.

(3) Recoverability Code. Recoverability codes are assigned to items to indicate the disposition action on unserviceable items. The recoverability code is entered in the fifth position of the SMR Code as follows:

Code

Z

Application/Explanation

- Nonreparable item. When unserviceable, condemn and dispose of the item at the level of maintenance shown in the 3rd position of SMR Code.

0

F

- Reparable item. When uneconomically reparable, condemn and dispose of the item at organizational level.

- Reparable item. When uneconomically reparable, condemn and dispose of the item at the direct support level.

L

A

H - Reparable item. When uneconomically reparable, condemn and dispose of the item at the general support level.

D - Reparable item. When beyond lower level repair capability, return to depot. Condemnation and disposal of item not authorized below depot level.

- Reparable item. Condemnation and disposal not authorized below specialized repair activity (SRA).

- Item requires special handling or condemnation procedures because of specific reasons (e.g., precious metal content, high dollar value, critical material or hazardous material). Refer to appropriate manuals/directives for specific instructions.

F-4

TM 5-3825-230-14&P

c. CAGEC (Column (3)). The Commercial and Government Entity Code (CAGEC) is a 5-digit numeric code which is used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item.

d. PART NUMBER (Column (4 )). Indicates the primary number used by the manufacturer (individual, company, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications standards, and inspection requirements to identify an item or range of items.

NOTE

When you use a NSN to requisition an item, the item you receive may have a different part number from the part ordered.

e. DESCRIPTION AND USABLE ON CODE (UOC) (Column (5)). This column includes the following information:

(1) The Federal item name and, when required, a minimum description to identify the item.

(2) Part numbers for bulk materials are referenced in this column in the line item entry for the item to be manufactured/fabricated.

(3) In the Special Tools List section, the basis of issue (BOI) appears as the last line(s) in the entry for each special tool, special TMDE, and other special support equipment. When density of equipments supported exceeds density spread indicated in the BOI, the total authorization is increased proportionately.

(4) The statement "END OF FIGURE" appears just below the last item description in Column 5 for a given

figure in both Section II and Section III.

f. QTY (Column (6)). The QTY (quantity per figure column) indicates the quantity of the item used in the breakout shown on the illustration figure, which is prepared for a functional group, subfunctional group, or an assembly. A "V" appearing in this column in lieu of a quantity indicates that the quantity is variable and the quantity may vary from application to application.

F-4. EXPLANATION OF COLUMNS (SECTION IV).

a. NATIONAL STOCK NUMBER (NSN) INDEX

(1) STOCK NUMBER column. This column lists the NSN by National Item Identification Number

(NIIN) sequence. The NIIN consists of the last nine digits of the NSN i.e.

NSN

NSN i.e. (5305-01-574-1467).

NIIN

When using this column to locate an item, ignore the first 4 digits of the NSN. However, the complete NSN should be used when ordering items by stock number.

(2) FIG. column. This column lists the number of the figure where the item is identified/located. The figures

are in numerical order in Section II and Section III.

(3) ITEM column. The item number identifies the item associated with the figure listed in the adjacent FIG.

column. This item is also identified by the NSN listed on the same line.

F-5

TM 5-3825-230-14&P

b. PART NUMBER INDEX. Part numbers in this index are listed by part number in ascending alphanumeric sequence (i.e., vertical arrangement of letter and number combination which places the first letter or digit of each group in order A through Z, followed by the numbers 0 through 9 and each following letter or digit in like order).

(1) CAGEC column. The Commercial and Government Entity Code (CAGEC) is a 5-digit numeric code used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item.

(2) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications, and inspection requirements to identify an item or range of items.

(3) STOCK NUMBER column. This column lists the NSN for the associated part number and manufacturer identified in the PART NUMBER and CAGEC columns to the left.

II and III.

(4)

FIG. column. This column lists the number of the figure where the item is identified/located in Sections

(5) ITEM column. This item number is that number assigned to the item as it appears in the figure referenced in adjacent figure number column.

c. FIGURE AND ITEM NUMBER INDEX

(1) FIG. column. This column lists the number of the figure where the item is identified/located in Section II and III.

(2) ITEM column. This item number is that number assigned to the item as it appears in the figure referenced in the adjacent figure number column.

(3) STOCK NUMBER column. This column lists the NSN for the item.

(4) CAGEC column. The Commercial and Government Entity Code (CAGEC) is a 5-digit numeric code used to identify the manufacturer, distributor, or Government agency, etc., that supplies the item.

(5) PART NUMBER column. Indicates the primary number used by the manufacturer (individual, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications standards, and inspection requirements to identify an item or range of items.

F-5. SPECIAL INFORMATION.

a. USABLE ON CODE. The usable on code appears in the lower left corner of the Description column heading.

Usable on codes are shown as "UOC. in the Description Column (justified left) on the last line applicable item description/nomenclature. Uncoded items are applicable to all models. Identification of the usable code used in this publication is:

Code

874

Used On

Model 53MH

F-6

TM 5-3825-230-14&P

F-6. HOW TO LOCATE REPAIR PARTS.

a. When National Stock Number or Part Number is NOT Known.

(1) First. Using the table of contents, determine the assembly group or subassembly group to which the item belongs. This is necessary since figures are prepared for assembly groups and subassembly groups, and listings are divided into the same groups.

(2) Second. Find the figure covering the assembly group or subassembly group to which the item belongs.

(3) Third. Identify the item on the figure and note the item number.

(4) Fourth. Refer to the Repair Parts List for the figure to find the part number for the item number noted on the figure.

(5) Fifth. Refer to the Figure and Item Number Index to find the NSN, if assigned.

b. When National Stock Number or Part Number is Known.

(1) First. Using the Index of National Stock Numbers and Part Numbers, find the pertinent National Stock Number

or Part Number. The NSN index is in National Item Identification Number (NIIN) sequence (see paragraph F-4a.(1)).

The part numbers in the Part Number index are listed in ascending alphanumeric sequence (see paragraph F-4b.). Both

indexes cross-reference you to the illustration figure and item number of the item you are looking for.

(2) Second. After finding the figure and item number, verify that the item is the one you are looking for, then locate the item number in the repair parts list for the figure.

F-7. ABBREVIATIONS.

Abbreviations used in this manual are listed in MIL-STD-12.

F-7

SECTION II TM 5-3825-230-14&P

Figure 1. Engine Assembly

F-8

*

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

1

2

3

4

5

6

15

16

PAOFF 66234

PFOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

PFOZZ 80204

7 PFOZZ 66234

8 PFOZZ 96906

9 PFOZZ 96906

10 PFOZZ 76005

11 PFOZZ 96906

12 PFOZZ 96906

13 PFOZZ 96906

14 PFOZZ 96906

PFOZZ 96906

PFOZZ 66234

TM5-3825-230-14&PCO2

(4)

PART

NUMBER

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 01 ENGINE

GROUP 0100 ENGINE ASSEMBLY

FIG. 1 ENGINE ASSEMBLY

500-92018

904.8506.003

560.6429.033

9.7565.011

ENGINE, DIESEL................................ ......................

.BRACKET, ANGLE ................................ ..................

.MOUNT, RESILIENT ................................ ................

.WASHER, LOCK M10................................ .............

9.1780.007

.SCREW, CAP, HEXAGON H M10X1, 50X35.9.........

81821BH063C350N SCREW, CAP, HEXAGON H 5/8-11UNCX3.5...........

GR8 ................................ ................................ ..........

410-92704

MS51922-49

MS35206-267

200XPD-60

MS35338-43

MS35649-202

MS27183-13

MS90725-68

MS51922-17

401-94420

BRACKET, VEHICULAR ................................ ...........

NUT, SELF-LOCKING, HE 5/8-11UNC.....................

SCREW, MACHINE 10-24UNCX3/4.........................

MOUNT, RESILIENT ................................ .................

WASHER, LOCK NO.10................................ ...........

NUT, PLAIN, HEXAGON 10-24UNC.........................

WASHER, FLAT 3/3................................ .................

SCREW, CAP, HEXAGON H 3/8-16UNCX2.5..........

GR5 ................................ ................................ ..........

NUT, SELF-LOCKING, HE 3/8-16UNC.....................

TUBE, METALLIC ................................ .....................

END OF FIGURE

(6)

QTY

8

8

4

8

4

1

4

8

8

1

4

16

1

2

16

4

1-1

SECTION II TM 5-3825-230-14&P

Figure 2. Cylinder and Crankcase Assembly

1 PFFZZ 2X179

2 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

3 KFFZZ 2X179

4 PAFZZ 2X179

5 KFFZZ 2X179

6 PFFZZ 2X179

7 PAFZZ 2X179

8 PAFZZ 2X179

9 PFFZZ 2X179

10 PAFFF 2X179

11 PAFZZ 2X179

12 PAFZZ 2X179

13 PAFZZ 2X179

14 PAFZZ 2X179

15 PAFZZ 2X179

16 PAFZZ 2X179

17 PAFZZ 2X179

18 PAFZZ 2X179

19 PAFZZ 2X179

20 PFFZZ 2X179

21 PAFZZ 2X179

22 PAFZZ 2X179

23 PFFZZ 2X179

24 PAFZZ 2X179

25 PFFZZ 2X179

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

276.8460.055

360.4701.041

395.4730.185

395.4730.186

395.4730.089

395.4730.187

395.4730.090

395.4730.188

395.4730091

395.4730.189

395.4730.092

395.4730.190

435.2380.214

625.4740.029

625.7625.108

625.5801.153

435.9520.055

625.4740.029

435.1510.222

9.8400.048

9.8965.003

276.4670.014

9.9765.111

9.6780.005

360.9000.072

9.6780.008

9.9080.083

435.6850.124

99730.032

8903.050

1213.173

560.4776.087

1240.016

1300.101

(4)

PART

NUMBER

(5)

TM5-3825-230-14&P

(6)

QTY DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0101 CRANKCASE, BLOCK, CYLINDER

HEAD

FIG. 2 CYLINDER AND CRANKCASE

ASSEMBLY

PIN, TAPERED, PLAIN ................................ .............

GASKET, CRANKCASE PART OF KIT P/N ..............

395.8180.062................................ ............................

GASKET, HEAD(0, 50) PART OF KIT P/N ................

395.8180.062................................ ............................

GASKET, HEAD(0, 55) PART OF KIT P/N ................

395.8180.062................................ ............................

GASKET, HEAD(0, 60) PART OF KIT P/N ................

395.8180.062................................ ............................

GASKET, HEAD(0, 65) PART OF KIT P/N ................

395.8180.062................................ ............................

GASKET, HEAD(0, 70) PART OF KIT P/N ................

395.8180.062. ................................ ..........................

GASKET, HEAD(0, 75) PART OF KIT P/N 2

395.8180.062................................ ............................

GASKET, HEAD(0, 80) PART OF KIT P/N ................

395.8180.062................................ ............................

GASKET, HEAD(0, 85) PART OF KIT P/N ................

395.8180.062................................ ............................

GASKET, HEAD(0, 90) PART OF KIT P/N ................

395.8180.062................................ ............................

GASKET, HEAD(0, 95) PART OF KIT P/N ................

395.8180.3062................................ ...........................

CYLINDER HEAD, DIESE................................ .........

GASKET, GUARD TUBE PART OF KIT P/N .............

435.8150.017................................ ............................

WASHER, FLAT................................ ........................

SPRING, HELICAL, COMP ................................ ......

TUBE, METALLIC ................................ .....................

GASKET PART OF KIT P/N 435.8150.017................

ENGINE BLOCK, DIESEL................................ .........

.PIN, TAPERED, PLAIN ................................ ............

.PLUG, MACHINE THREAD................................ ......

.WASHER, FLAT................................ .......................

.SCREW, MACHINE ................................ .................

.STUD, PLAIN ................................ ...........................

.PLUG, EXPANSION................................ .................

.STUD, PLAIN ................................ ...........................

.CAP, FILLER OPENING ................................ ..........

.ROD, THREADED END ................................ ...........

SCREW, CAP, HEXAGON H ................................ ....

RACKET, MOUNTING ................................ .............

SEAL, PLAIN................................ .............................

GASKET PART OF KIT P/N 395.8180.062................

RING, RETAINING ................................ ....................

BEARING, WASHER, THRU................................ .....

2-1

2

2

2

2

2

1

2

C

2

2

2

2

1

6

1

1

1

1

1

2

2

2

2

1

1

1

1

8

3

2

1

1

2

2

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

26 PAFZZ 2X179

27 PAFZZ 2X179

28 PFOZZ 2X179

(4)

PART

NUMBER

8780.015

4936.077

9.8430.065

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

COVER, ACCESS................................ .....................

GEAR, HELICAL ................................ .......................

LOCKING PLATE, NUT A ................................ .........

END OF FIGURE

TM5-3825-230-14&P

(6)

QTY

1

1

1

2-2

SECTION II TM 5-3825-230-14&P

Figure 3. Cylinder Head Assembly

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

1

2

3

4

5

6

7

8

9

PFFZZ 2X179

PFFZZ 2X179

PFFZZ 2X179

PAFFF 2X179

PFFZZ 2X179

PFFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

PFFZZ 2X179

(4)

PART

NUMBER

9.3240.032

9.7625.067

560.3300.100

435.9200.243

9.6780030

9.6780.084

560.8000.066

560.8000.065

9.6760.045

(5)

TM5-3825-230-14&P

(6)

QTY DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0101 CRANKCASE, BLOCK, CYLINDER

HEAD

FIG. 3 CYLINDER HEAD ASSEMBLY

NUT, PLAIN, HEXAGON................................ ...........

WASHER, FLAT. ................................ ......................

NUT, PLAIN, HEXAGON................................ ...........

CYLINDER HEAD, DIESE................................ .........

.STUD, PLAIN ................................ ...........................

.STUD, PLAIN ................................ ...........................

.SEAT, VALVE ................................ ..........................

.SEAT, VALVE ................................ ..........................

.STUD, PLAIN ................................ ...........................

END OF FIGURE

1

1

1

1

2

2

2

6

8

3-1

SECTION II TM 5-3825-230-14&P

Figure 4. End Plate Assembly

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

1 PFFZZ 2X179

2 PFFZZ 2X179

3 PFFZZ 2X179

4 PFFZZ 2X179

5 PFFZZ 2X179

6 PFFZZ 2X179

7

8

9

10

11

PFFZZ 2X179

PFFZZ 2X179

PFFZZ 2X179

PAFZZ 2X179

PFFZZ 2X179

360.4776089

360.5055.026

9.1760.001

9.9732.063

9.9732.074

9.9730.034

99730.035

435.2615.075

9.1200.174

9.1212.006

435.8900.291

(4)

PART

NUMBER

(5)

TM5-3825-230-14&P

(6)

QTY DESCRIPTION AN D USABLE ON CODES (UOC)

GROUP 0101 CRANKCASE, BLOCK, CYLINDER

HEAD

FIG. 4 END PLATE ASSEMBLY

GASKET ................................ ................................ ...

BRACKET, ANGLE ................................ ...................

BOLT, MACHINE M6X1, 00X10 ...............................

SCREW, CAP, SOCKET HE ................................ .....

SCREW, CAP, SOCKET HE . ................................ .

SCREW, CAP, SOCKET HE ................................ .....

SCREW, CAP, SOCKET HE ................................ .....

COVER, ACCESS................................ .....................

SEAL, PLAIN PART OF KIT P/N ...............................

435, 8 150.017 ................................ ......................... ,

SEAL, PLAIN................................ .............................

HOUSING, MECHANICAL ................................ ........

END OF FIGURE

2

10

1

1

3

1

3

1

1

1

1

4-1

SECTION II TM 5-3825-230-14&P

Figure 5. Crankshaft Assembly

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

1 PAFZZ 2X179

1 PAFZZ 2X179

1 PAFZZ 2X179

2 PAFZZ 2X179

3 PFFZZ 2X179

4 PAFZZ 2X179

4 PAFZZ 2X179

4 PAFZZ 2X179

5 PFFZZ 2X179

5 KFFZZ 2X179

6 PAFZZ 2X179

7 PAFZZ 2X179

8 PFFZZ 2X179

9 PFFZZ 2X179

10 PFFZZ 2X179

11 PFFZZ 2X179

11 PFFZZ 2X179

11 PFFZZ 2X179

12 PAFZZ 2X179

13 PFFZZ 2X179

14 PFFZZ 2X179

15 PFFZZ 2X179

16 PAFZZ 2X179

17 PAFZZ 2X179

904.1610.082

904.1610.098

904.1610.099

360.8676.055

9.9732.075

560.1611.055

560.1611.054

560.1611.053

360.4701.058

360.4701.059

395.8676.090

9.1210.079

9.3203.047

560.5111.069

560.1862.057

560.8676.061

560.8676.070

560.8676.071

360.4936.035

9.7625.010

9.7565.007

9.1770.005

435.1050.284

9.2280.056

(4)

PART

NUMBER

(5)

TM5-3825-230-14&P

(6)

QTY DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0102 CRANKSHAFT

FIG 5. CRANKSHAFT ASSEMBLY

HOUSING, BEARING UNI STANDARD ....................

HOUSING, BEARING UNI -0, 25...............................

HOUSING, BEARING UNI -0, 50...............................

CLAMP, HUB ................................ ...........................

.SCREW, CAP, SOCKET HE M8X1, 25X50.............

BEARING, SLEEVE STANDARD .............................

HOUSING, BEARING UNI -0125...............................

HOUSING, BEARING UNI -0, 50...............................

GASKET 0, 20 PART OF KIT P/N ............................

395.8180.062 ................................ ...........................

GASKET, CSHAFT SPRT 0, 40 PART OF KIT.........

P/N 395.8180.062................................ ......................

HOUSING, BEARING UNI................................ .........

SEAL RING, METAL ................................ .................

NUT, PLAIN, HEXAGON................................ ...........

RETAINER, NUT AND BO ................................ ........

SCREW, CAP, HEXAGON H ................................ ....

HOUSING, MECHANICAL STANDARD ....................

HOUSING, MECHANICAL.-0, 50...............................

HOUSING, FLYWHEEL -025 ................................ ...

GEAR, HELICAL ................................ .......................

WASHER, FLAT M8................................ ..................

WASHER, FLAT M8................................ ..................

SCREW, CAP, HEXAGON H M8X1, 25X22.............

CRANKSHAFT, ENGINE, ................................ .........

KEY, WOODRUFF ................................ ...................

END OF FIGURE

2

1

1

1

1

1

1

1

1

1

2

2

1

1

2

1

1

2

1

1

6

1

1

1

5-1

SECTION II TM 5-3825-230-14&P

Figure 6. Flywheel Assembly

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

1

2

3

4

PFFZZ 2X179

PFFZZ 2X179

PAFFF 2X179

XDFZZ 2X179

(4)

PART

NUMBER

360.7626.033

9.1805.025

435.9880.639

435.2816.052

(5)

TM5-3825-230-14&PCO2

(6)

QTY DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0103 FLYWHEEL ASSEMBLY

FIG. 6 FLYWHEEL ASSEMBLY

WASHER, FLAT................................ ........................

SCREW CAP, HEXAGON H ................................ .....

FLYWHEEL, ENGINE ................................ ...............

.GEAR, SPUR ................................ ...........................

END OF FIGURE

1

1

1

1

6-1

SECTION II TM 5-3825-230-14&P

Figure 7. Piston and Connecting Rod Assembly

*

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

1

1

1

2

2

2

3

3

3

XDFFF 2X179

PAFFF 2X179

PAFFF 2X179

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

4 PAFZZ 2X179

4 PAFZZ 2X179

4 PAFZZ 2X179

5 PAFZZ 2X179

5 PAFZZ 2X179

5 PAFZZ 2X179

6 PAFFF 2X179

7 PFFZZ 2X179

8 PAFZZ 2X179

435.6500.315

435.6500.316

435.6500.317

435.8480.050

43598480.050

435.8480.050

9.1240.017

9.1240.017

9.1240.017

395.8211.071

435.8211.089

395.8211.073

435.1640.082

435.1640.083

435.1640.084

435.1526.098

9.1770.101

435.1630.018

(4)

PART

NUMBER

TM5-3825-230-14&PCO2

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

GROUP 0104 PISTONS, CONNECTING RODS

FIG. 7 PISTON AND CONNECTING ROD

ASSEMBLY

PISTON, INTERNAL COM STANDARD ....................

PISTON, INTERNAL COM +0, 50 .............................

PISTON, INTERNAL COM +1, 00 .............................

.PIN, PISTON INCLUDED WITH STANDARD..........

PISTON ................................ ................................ ....

.PIN, PISTON INCLUDED WITH +0, 50 ...................

PISTON................................ ................................ .....

.PIN, PISTON INCLUDED WITH +1, 00 ...................

PISTON................................ ................................ .....

.RING, RETAINING INCLUDED WITH .....................

STANDARD PISTON ................................ ................

.RING, RETAINING INCLUDED WITH +0, ..............

50 PISTON................................ ................................

.RING, RETAINING INCLUDED WITH +11 ..............

00 PISTON................................ ................................

.RING SET, PISTON STANDARD .............................

.RING SET, PISTON +0, 50 ................................ ......

.RING SET, PISTON ................................ .................

BUSHING, SLEEVE , STANDARD............................

BUSHING, SLEEVE.-0, 25 ................................ ........

BEARING, SLEEVE -0, 50, ................................ ......

CONNECTING ROD, PIST................................ ........

.SCREW, CAP, HEXAGON H ................................ ...

.BUSHING, SLEEVE ................................ .................

END OF FIGURE

7-1

2

2

2

2

2

1

2

2

1

1

2

1

1

1

1

2

1

2

2

SECTION II TM 5-3825-230-14&P

Figure 8. Rocker Cover Assembly

(1)

SECTION II

(2)

ITEM SMR

(3)

NO CODE CAGEC

1 PFOZZ 2X179

2 PFOFF 2X179

3 PFOZZ 2X179

4 PFFZZ 2X179

5 PFFZZ 2X179

6 PFFZZ 2X179

7

14

25

26

PFFZZ 2X179

8 PFFZZ 20072

9 PFFZZ 2X179

10 XAFZZ 2X179

11 PFFZZ 2X179

12 PFFZZ 2X179

13 PFFZZ 2X179

PAOZZ 2X179

15 PFOFF 2X179

16 PFOZZ 2X179

17 PFFZZ 2X179

18 PFFZZ 2X179

19 PFFZZ 2X179

20 PFFZZ 2X179

21 PFFZZ 2X179

22 PFFZZ 2X179

23 XAFZZ 2X179

24 PFFZZ 2X179

PFFZZ 2X179

PFFZZ 2X179

(4)

PART

NUMBER

9.9732.075

560.2125.100

560.2125.093

276.4670.014

9.9000.064

9040.5780.011

9.8245.005

9.1200.034

560.6095.010

LEVER

9.8430.005

9.8430.004

560.9820.085

560.4400.022

560.2125.101

560.2125.094

276.4670.014

9.9000.064

9040.5780.011

9.8245.005

9.1200.034

560.6095.010

LEVER

9.8430.005

9.8430.004

560.9820.085

(5)

TM5-3825-230-14&P

(6)

QTY DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0105 VALVES, CAMSHAFTS, AND

TIMING SYSTEM

FIG. 8 ROCKER COVER ASSEMBLY

SCREW, CAP, SOCKET HE ................ M8X1, 25X50

COVER, ENGINE POPPET................................ .......

.COVER, ACCESS................................ ....................

.WASHER, FLAT................................ .......................

.PLUG, EXPANSION................................ .................

.SPRING, HELICAL, COMP. ................................ ....

.BALL, BEARING ................................ ......................

.SEAL................................ ................................ ........

.PIN, STRAIGHT, HEADLE ................................ .......

.LEVER, COVER, VALVE................................ ..........

.PIN, SPRING ................................ ...........................

.PIN, SPRING ................................ ...........................

.SCREW, CAP, SOCKET HE ................................ ....

GASKET PART OF KIT P/N 395.8180.062................

COVER, ENGINE POPPET................................ .......

.COVER, ACCESS................................ ....................

.WASHER, FLAT................................ .......................

.PLUG, EXPANSION................................ .................

.SPRING, HELICAL, COMP ................................ ......

.BALL, BEARING ................................ ......................

.SEAL, PLAIN................................ ............................

.PIN, STRAIGHT, HEADLE ................................ .......

.LEVER, COVER, VALVE................................ ..........

.PIN, SPRING ................................ ...........................

.PIN, SPRING ................................ ...........................

.SCREW, CAP, SOCKET HE ................................ ....

END OF FIGURE

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

4

1

8-1

SECTION II TM 5-3825-230-14&P

Figure 9. Rocker Arm Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PAFFF 2X179

2 PFFZZ 2X179

3 PFFZZ 2X179

4 PFFZZ 2X179

5 PFFZZ 2X179

6 PFFZZ 2X179

7 PFFZZ 2X179

8 PFFZZ 2X179

9 PFFZZ 2X179

10 PFFZZ 2X179

11 PFFZZ 2X179

12 PAFZZ 2X179

12 PAFZZ 2X179

13 PAFZZ 2X179

14 PAFZZ 2X179

15 PAFZZ 2X179

16 PAFZZ 2X179

16 PAFZZ 2X179

17 PAFZZ 2X179

18 PAFZZ 2X179

560.4330.037

9.3240.010

9.9730.100

276.8335.084

9.7565.007

560.6372.098

560.6045.040

270.9850.002

560.9455.053

560.1350.011

500.2135.072

629.4845.184

629.4845.185

435.9685.067

435.9652.061

710.3430.067

560.4845.182

4845-181

395.5755.065

260.6410.018

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0105 VALVES, CAMSHAFTS, AND

TIMING SYSTEM

QTY

FIG. 9. ROCKER ARM ASSEMBLY

ROCKER ARM, ENGINE P ................................ ................... 2

.NUT, PLAIN, HEXAGON................................ ...................... 2

.SCREW, CAP, SOCKET HE M8X1125X25........................ 2

.SHIM ................................ ................................ .................... 1

.WASHER, FLAT M8................................ ............................ 2

.SPACER, PLATE, ................................ ............................... 1

.PIN, STRAIGHT, HEADLE ................................ ................... 1

.SCREW, ADJUSTING, VAL ................................ ................. 2

.TUBE, BENT, METALLIC ................................ ..................... 1

.RING, WIPER ................................ ................................ ...... 1

CAP, PROTECTIVE, DUST PART OF KIT P/N ..................... 2

435.8150.017................................ ................................ ..........

GUIDE, VALVE STEM STANDARD ................................ ..... 2

GUIDE, VALVE STEM +0, 50................................ ................ 2

VALVE, POPPET, ENGINE................................ ................. 2

VALVE, POPPET, ENGINE................................ .................. 2

LOCK, VALVE SPRING R................................ ..................... 4

GUIDE, VALVE STEM STANDARD ................................ ...... 2

GUIDE, VALVE STEM +0, 50................................ ................ 2

SPRING, HELICAL, COMP ................................ .................. 4

LOCK, VALVE SPRING R................................ ..................... 4

END OF FIGURE

9-1

SECTION II TM 5-3825-230-14&P

Figure 10. Camshaft Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

4

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

(4)

PART

NUMBER

9.2280.047

904.7215.043

435.1410.088

435.1011.110

TM 5-3825-230-14&P

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

GROUP 0105 VALVES, CAMSHAFTS, AND

TIMING SYSTEM

FIG.10. CAMSHAFT ASSEMBLY

KEY, WOODRUFF ................................ ............................... 1

TAPPET, ENGINE POPPE ................................ .................. 4

PUSH ROD, ENGINE POP ................................ .................. 4

CAMSHAFT, ENGINE ................................ .......................... 1

END OF FIGURE

10-1

SECTION II TM 5-3825-230-14&P

Figure 11. Oil Cap Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

PAOZZ 2X179

PAOZZ 2X179

(4)

PART

NUMBER

276.9032.019

9.1200.015

TM 5-3825-230-14&P

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

GROUP 0106 ENGINE LUBRICATION

SYSTEM

FIG. 11. OIL CAP ASSEMBLY

CAP, FILLER OPENING ................................ ....................... 1

SEAL, PLAIN................................ ................................ ......... 1

END OF FIGURE

11-1

SECTION II TM 5-3825-230-14&P

Figure 12. Oil Filter Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

5

10

PAOZZ 2X179

PAOZZ 2X179

3 PAOZZ 2X179

4 PAOZZ 2X179

PFOZZ 2X179

6 PAOZZ 2X179

7 PAOZZ 2X179

8 PAOZZ 2C072

9 PAOZZ 2X179

PAOZZ 2X179

(4)

PART

NUMBER

TM 5-3825-230-14&P

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

904.2175.040

9.1770.042

9.4670.058

560.4501.022

5600.3902.052

560.9680.013

500.5755.049

9.4670.021

500.9070.012

9.9730.012

GROUP 0106 ENGINE LUBRICATION

SYSTEM

FIG.12. OIL FILTER ASSEMBLY

FILTER ELEMENT,FLUI ................................ ...................... 1

SCREW, CAP, HEXAGON H ................................ ............... 2

WASHER, FLAT ................................ ................................ ... 2

GASKET PART OF KIT P/N 395.8180.062 ........................... 1

ELBOW, FLANGE TO PIP ................................ ................... 1

VALVE, REGULATING, FL ................................ .................. 1

SPRING, HELICAL, COMP ................................ ................. 1

SEAL, PLUG ................................ ................................ ....... 1

CAP, ENGINE POPPET V ................................ ................... 1

SCREW, CAP, SOCKET HE ................................ ............... 4

END OF FIGURE

12-1

SECTION II TM 5-3825-230-14&P

Figure 13. Oil Pump Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PAFZZ 2X179

2 PAOZZ 2X179

3

6

7

8

9

PFFZZ 2X179

4 PFFZZ 2X179

5 PFFZZ 2X179

PFFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

(4)

PART

NUMBER

435.9455.074

1400-077

9.7565.007

9.1770.009

9.3240.036

9.7565.011

560.4936.009

9.2200.001

560.6605.037

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0106 ENGINE LUBRICATION

SYSTEM

FIG. 13 OIL PUMP ASSEMBLY

QTY

TUBE, METALLIC ................................ ................................ 2

GAGE ROD, LIQUID LEV ................................ .................... 1

WASHER, FLAT M8 ................................ ............................ 2

SCREW, CAP, HEXAGON H M8X1,25X35 ......................... 2

NUT, PLAIN, HEXAGON ................................ ...................... 1

WASHER, LOCK ................................ ................................ .. 1

GEAR, SPUR ................................ ................................ ....... 1

KEY, MACHINE ................................ ................................ .... 1

OIL PUMP ASSEMBLY, E ................................ .................... 1

END OF FIGURE

13-1

SECTION II TM 5-3825-230-14&P

Figure 14. Oil Pan Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

7

8

9

10

PAOZZ 2X179

PAOOO 2X179

PAOZZ 2X179

4 PAOZZ 2X179

5 PAOZZ 2X179

6 PAOZZ 2X179

PAOZZ 2X179

PAOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

(4)

PART

NUMBER

360.4601.042

3600.6645.113

9.1760.001

9.7565.004

560.5090.010

4670.016

9.8965.005

9.9765.108

9.1770.039

9.7625.010

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0106 ENGINE LUBRICATION

SYSTEM

FIG. 14 OIL PAN ASSEMBLY

QTY

GASKET PART OF KIT P/N 395.8180.062............................ 1

OIL PAN................................ ................................ ................ 1

.BOLT, MACHINE, ................................ ............................... 1

.WASHER, LOCK................................ ................................ .. 1

.FILTER ELEMENT, FLUI ................................ ..................... 1

.WASHER, FLAT................................ ................................ ... 2

.PLUG, MACHINE THREAD................................ .................. 2

.SCREWICAP1SOCKET HE ................................ ................. 2

SCREW, CAP, HEXAGON H ................................ ...............14

WASHER, FLAT................................ ................................ ...14

END OF FIGURE

14-1

SECTION II TM 5-3825-230-14&P

Figure 15. Intake Manifold Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

4

5

6

PAOZZ 2X179

PAOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

(4)

PART

NUMBER

5600.2486.068

560.4420.020

560.2145.013

9.3630.023

9.7565.007

9.3240.018

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0108 MANIFOLDS

QTY

FIG.15. INTAKE MANIFOLD ASSEMBLY

MANIFOLD, INTAKE ................................ ............................. 1

GASKET PART OF KIT P/N 395.8180.062............................ 2

CAP, AIR CLEANER INT................................ ....................... 1

CLAMP, LOOP................................ ................................ ...... 1

WASHER, FLAT M8................................ ............................. 4

NUT, PLAIN, HEXAGON M8X1,25................................ ....... 4

END OF FIGURE

15-1

SECTION II TM 5-3825-230-14&P

Figure 16. Hydraulic Pump Drive Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PAOZZ 2X179

2 PFOZZ 2X179

3 PFOZZ 2X179

4 PAOZZ 2X179

5 PAOZZ 2X179

6 PAOZZ 2X179

7 PFOZZ 2X179

(4)

PART

NUMBER

3600.8061.096

9.7565.007

9.9730.100

2760.4240.028

2830.8061.372

3600.8836.084

3240.018

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0109 ACCESSORY DRIVING

MECHANISMS

FIG 16. HYDRAULIC PUMP DRIVE

ASSEMBLY

QTY

COUPLING, HALF, SHAFT PART OF KIT P/N .................... 1

3600.8888.529................................ ................................ .........

WASHER, LOCK MB ................................ ..........................10

SCREW, CAP, SOCKET HE M8X1, 25X25........................ 4

INSERT, FLEXIBLE COU PART OF KIT P/N ........................ 1

3600.8888.529................................ ................................ .........

COUPLING, SHAFT, FLEX PART OF KIT P/N..................... 1

3600.8888.529................................ ................................ .........

HOUSING, MECHANICAL PART OF KIT P/N ....................... 1

3600, 8888.529................................ ................................ ........

NUT, PLAIN, HEXAGON MBX125................................ ........ 6

END OF FIGURE

16-1

SECTION II TM 5-3825-230-14&P

Figure 17. Alternator Drive Pulley

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

PAOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

(4)

PART

NUMBER

7051-060

9.7565.007

9.1770.009

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0109 ACCESSORY DRIVING

MECHANISMS

FIG.17. ALTERNATOR DRIVE PULLEY

QTY

PULLEY, GROOVE................................ ............................... 1

WASHER, FLAT M8................................ ............................. 6

SCREW, CAP, HEXAGON H M8X1,25X35.......................... 6

END OF FIGURE

17-1

SECTION II TM 5-3825-230-14&P

Figure 18. Injector Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

7

7

PFFZZ 2X179

PAFZZ 2X179

PFFZZ 2X179

4 PFFZZ 2X179

* 5 XBFZZ 2X179

6 PAFZZ 2X179

PFFZZ 2X179

PFFZZ 2X179

(4)

PART

NUMBER

9.3240.008

500.3790.042

260.4650.037

500.7301.006

395.6615.045

395.6531.104

9.4670.064

9.4670.065

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 03 FUEL SYSTEM

GROUP 0301 CARBURETOR, FUEL INJECTOR

FIG.18. INJECTOR ASSEMBLY

QTY

NUT, PLAIN, HEXAGON ................................ ...................... 4

COVERT ACCESS................................ ................................ 2

GASKET ................................ ................................ ............... 2

REDUCER, TUBE ................................ ................................ . 2

NOZZLE, FUEL INJECTI................................ ....................... 2

.NOZZLE, INJECTION ................................ .......................... 1

GASKET 1,00................................ ................................ ........ 2

GASKET 1,50................................ ................................ ........ 2

END OF FIGURE

18-1

SECTION II TM 5-3825-230-14&P

Figure 19. Injector Pump Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PAOZZ 2X179

2 PAOZZ 2X179

* 3 PFFZZ 2X179

4 PFFZZ ZX179

5 PAFZZ 2X179

6 PFFZZ 2X179

7

7

7

PAFZZ 2X179

PAFZZ 2X179

PAFZZ 2X179

8 PAFZZ 2X179

9 PFFZZ 2X179

10 PFFZZ 2X179

11 PAOZZ 2X179

12 PFOZZ 2X179

13 PFOZZ 56161

435.9375.280

435.9375.279

3240.018

9.6780.089

560.5168.041

560.3240.131

276.4580.002

276.4580.009

672.4580.068

435.6590.076

9.7625.010

9.9730.100

276.5400.046

276.3616.018

10503657

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0302 FUEL PUMPS

QTY

FIG.19. INJECTOR PUMP ASSEMBLY

SPRAY TIP, NOZZLE, FU ................................ ..................... 1

ADAPTER, STRAIGHT, PI ................................ .................... 1

NUT, PLAIN,HEXAGONN ................................ ..................... 1

STUD PLAIN ................................ ................................ ......... 1

STOP, ELECTRICAL SWI................................ ..................... 1

NUT, PLAIN, HEXAGON................................ ....................... 1

GASKET 0110 PART OF KIT P/N ................................ ........ 1

395.8180.062................................ ................................ ..........

GASKET 0, 50 PART OF KIT P/N ................................ ........ 1

395 8180.062................................ ................................ ..........

GASKET 0105 PART OF KIT P/N ................................ ........ 1

395.8180.062 ................................ ................................ .........

PUMP, FUEL, METERING ................................ .................... 1

WASHER, FLAT................................ ................................ .... 4

SCREW, CAP, SOCKET HE ................................ ................. 3

GASKET ................................ ................................ .............. 2

CLAMP, LOOP................................ ................................ ...... 2

SCREW, CAP, HEXAGON H M5X0, 8X12........................... 2

END OF FIGURE

19-1

SECTION II TM 5-3825-230-14&P

Figure 20. Fuel Pump Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

4

5

PAOZZ 2X179

PFOZZ 2X179

PAOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

(4)

PART

NUMBER

560.4580.047

560.7200.78

6585.030

9.7565.007

9.3203.047

TM 5-3825-230-14&P

(5)

DESCRIPTION AND USABLE O N CODES (UOC)

(6)

QTY

GROUP 0302 FUEL PUMPS

FIG.20. FUEL PUMP ASSEMBLY

GASKET PART OF KIT P/N 395.8180.062............................ 1

PIN,STRAIGHT, THREAD................................ ..................... 1

PUMP, RECIPROCATING ................................ .................. 1

WASHER, FLAT M8................................ ............................. 2

NUT, PLAIN, HEXAGON M8X1, 25................................ ...... 2

END OF FIGURE

20-1

SECTION II TM 5-3825-230-14&P

Figure 21. Air Cleaner and Vapor Separator Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PFOZZ 78940

2 PFOZZ 78940

3

6

7

PFOZZ 78940

4 PFOZZ 78940

* 5 PFOZZ 80204

PFOZZ 96906

MOOZZ 66234

8 PFOZZ 96906

9 PFOZZ 66295

10 PAOZZ 2X179

11 PFOZZ 2X179

12 PFOZZ 2X179

13 PFOZZ 2X179

14 PAOZZ 2X179

15 PFOZZ 78940

16 PAOZZ 78940

17 PFOZZ 78940

18 PFOZZ 78940

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0304 AIR CLEANER

FIG.21. AIR CLEANER AND VAPOR

SEPARATOR ASSEMBLY

QTY

F221B6K01B

0629A84

OA7419

F2218B4 .BRACKET, FILTER MOUT ................................ ................... 1

B1821BH038C100N SCREW, CAP, HEXAGON H 3/8-16UNCX1......................... 2

MS27183-13 WASHER, FLAT 3/8................................ ............................. 2

204-92008

BRACKET, MOUNTING ................................ ........................ 1

.STUD, TAPPING, THREAD ................................ ................. 1

.GASKET, ................................ ................................ ........... .1

MS51922-17

28KS3

HOSE MAKE FROM HOSE P/N CWC2INDIA ...................... 1

(81518), 12INCHES................................ ................................ .

NUT, SELF-LOCKING, HE 3/8-16UNC................................ . 2

CLAMP, LOOP. ................................ ................................ .... 2

360.1901.039

560.9400.054

9.4670.060

276.4670.014

560.9050.041

E105BIK18B

250816A

OA11861

0638A1

BOLT, MACHINE ................................ ................................ .. 1

TUBE, BENT METALLIC ................................ ....................... 1

WASHER, FLAT . ................................ ................................ . 1

WASHER, FLAT ................................ ................................ ... 1

FILTER,FLUID ................................ ................................ ...... 1

AIR CLEANER, INTAKE................................ ........................ 1

.FILTER ELEMENT, INTA ................................ ..................... 1

.CLAMP, SPECIAL................................ ................................ 1

.BOWL, SEDIMENT, ................................ ............................ 1

END OF FIGURE

21-1

SECTION II TM 5-3825-230-14&P

Figure 22. Fuel Lines and Fittings

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

4

5

PFOZZ 2X179

PFOZZ 2X179

PFOZZ 2X179

PAOZZ 70842

MOOZZ 79470

6 PAOZZ 22031

7 PFOZZ 72423

8 PFOZZ 2X179

9 PFOZZ 2X179

10 PFOZZ 2X179

11 PFOZZ 2X179

12 PAOZZ 2X179

13 MOOZZ 79470

14 PFOZZ 2X179

15 PFOZZ 2X179

16 PAOZZ 2X179

17 PAOZZ 2X179

18 PAOZZ 2X179

19 PAOZZ 2X179

20 PFOZZ 2X179

560.9571.077

9.4670.058

91901.029

705-1171

H05704

4501-4

2071-059

9.4670.060

9.1901.031

9.4775.196

9.9080.037

560.9375.351

H05704

9.1901.030

9.4670.059

9375.022

7270.104

1901.032

4670.016

9.3630.050

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0306 TANKS, LINES, FITTINGS,

HEADERS

FIG. 22 FUEL LINES AND FITTINGS

QTY

TUBE, BENT, METALLIC ................................ ...................... 1

WASHER, FLAT................................ ................................ .... 4

BOLT, MACHINE ................................ ................................ .. 2

CLAMP, HOSE................................ ................................ ..... 4

HOSE, NONMETALLIC MAKE FROM HOSE ....................... 1

P/N H05704 (79470), 16 INCHES................................ ...........

ELBOW, PIPE TO HOSE 1/4 HOSE X 1/4 PIPE.................. 1

BUSHING, PIPE 3/8X1/4................................ ...................... 1

WASHER, FLAT................................ ................................ .... 2

BOLT, MACHINE ................................ ................................ . 1

WASHER, FLAT................................ ................................ .... 1

PLUG, MACHINE THREAD................................ ................... 1

TUBE ASSEMBLY, METAL................................ ................... 1

HOSE, NONMETALLIC MAKE FROM HOSE ....................... 1

P/N H05704(79470),10 INCHES................................ ..............

BOLT, MACHINE ................................ ................................ . 1

WASHER, FLAT................................ ................................ .... 4

TUBE ASSEMBLY, METAL................................ ................... 1

COUPLING, HOSE ................................ ............................... 1

BOLT, MACHINE, ................................ ................................ 2

WASHER, FLAT................................ ................................ .... 4

CLAMP, LOOP ................................ ................................ ...... 1

END OF FIGURE

22-1

SECTION II TM 5-3825-230-14&P

Figure 23. Fuel Tank Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PAOZZ 66234

2 PBOZZ 57648

* 3 PFOZZ 80204

4 PFOZZ 96906

5 PFOZZ 96906

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0306 TANKS, LINES, FITTINGS, HEADERS

FIG.23 FUEL TANK ASSEMBLY

QTY

410-92713

100-43

TANK, FUEL, ENGINE ................................ .......................... 1

VALVE, REGULATING, FL................................ .................... 1

B1821BH038C125N SCREW, CAP, HEXAGON H 3/8-16UNCX1.25 GR8............ 4

MS35338-46 WASHER, LOCK 3/8................................ ............................ 4

MS51967-8 NUT, PLAIN HEXAGON, 3/8 - 16 UNC................................ .. 4

END OF FIGURE

23-1

SECTION II TM 5-3825-230-14&P

Figure 24. Governor and Governor Lever Assemblies

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PFFZZ 15526

2 PFFZZ 2X179

3 PAFFF 2X179

4 PAFZZ 2X179

5 PAFZZ 2X179

6 PAFZZ 2X179

7 PAFZZ 2X179

8 PAFZZ 2X179

9 PAFFF 2X179

10 PFFZZ 2X179

11 PFFZZ 2X179

12 PFFZZ 2X179

13 PFFZZ 2X179

14 PFFZZ 2X179

15 PAFZZ 2X179

16 PFFZZ 2X179

17 PFFZZ 56161

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0308 ENGINE SPEED GOVERNOR

AND CONTROLS

QTY

FIG. 24. GOVERNOR AND GOVERNOR LEVER

ASSEMBLIES

DIN933-M10X35-8 .SCREW, CAP, HEXAGON H M10X1, 5X35........................ 1

8-A4C

9.7626.038

435.7362.186

2086.034

WASHER, FLAT M10................................ ........................... 1

GOVERNOR, DIESEL ENG., ................................ ................ 1

.END BELL, ELECTRICAL ................................ .................... 1

560.1160.022

9.3110.058

560.8785.069

9.1585.025

5200-300

9.1240.005

9.7626.040

.RING, RETAINING ................................ ............................... 1

BEARING, ROLLER, THRU ................................ .................. 1

BRACKET, MOUNTING ................................ ........................ 1

.BUSHING, SLEEVE ................................ ............................. 2

LEVER ASSEMBLY, GOVE ................................ .................. 1

.RING, RETAINING ................................ ............................... 1

.WASHER, FLAT................................ ................................ ... 2

9.7625.007

9.1240.077

9.9730.107

560.6080.022

9.7565.007

10501759

.WASHER, FLAT................................ ................................ ... 1

.RING, RETAINING ................................ ............................... 1

.SCREW, CAP, SOCKET HE M6X1X14............................... 1

PIN, STRAIGHT, HEADLE ................................ .................... 1

WASHER, FLAT M8................................ ............................. 2

SCREW, CAP, HEXAGON H M8X1, 25X25......................... 2

END OF FIGURE

24-1

SECTION II TM 5-3825-230-14&P

Figure 25. Throttle Control Lever Assembly

1 PAOZZ 66234

2 PFOZZ 96906

3 PAOZZ 66234

4 PFFFF 2X179

5 PFFZZ 2X179

6 PFFZZ 2X179

6 PFFZZ 2X179

7 PFFZZ 2X179

8 PAFZZ 2X179

9 PFFZZ 2X179

* 10 PFFZZ 2X179

11 PFFZZ 2X179

12 PFFZZ 2X179

13 PAFZZ 2X179

* 14 XDFZZ 2C072

15 PFFZZ 2X179

16 PFFZZ 2X179

17 PFFZZ 2X179

18 PAFZZ 2X179

19 PFFZZ 2X179

20 MFOZZ 96906

21 PFOZZ 2X179

22 PFOZZ 2X179

23 PAFFF 2X179

24 XAFZZ 2X179

25 XAFZZ 2X179

26 XAFZZ 2X179

27 XAFZZ 2X179

28 XAFZZ 2X179

29 XAFZZ 2X179

30 XAFZZ 2X179

31 XAFZZ 2X179

32 XAFZZ 2X179

33 PFOZZ 2X179

34 PFOZZ 2X179

35 PFFZZ 2X179

36 PFFZZ 2X179

37 PAOZZ 2X179

38 PAFZZ 2X179

39 PFFZZ 2X179

40 PAFZZ 2X179

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

(4)

PART

NUMBER

401-94733

MS35207-263

401-94732

560.5200.265

9.1240.001

9.7625.103

9.7625.104

395.5200.250

9.3000.004

9.3240.008

7555.004

560.5200.200

560.6140.100

9.1241.009

9.7625.012

395.5200.271

9.9732.092

395.8785.070

560.3521.038

9.9732.063

MS20995C20

2760.9180.042

9.3240.019

560.2516.061

560.5200.194

9.1200.034

560.5680.077

560.5200.154

9.1760.041

9.3240.008

560.2690,121

560.5200.108

9.3203.047

9.9790.023

9.6000.021

9.9732.078

276.8460.055

560.4776.083

560.5655.076

560.5801.088

560.6040.015

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0308 ENGINE SPEED GOVERNOR

AND CONTROLS

QTY

FIG. 25. THROTTLE CONTROL LEVER

ASSEMBLY

CONTROL ASSEMBLY, PU................................ .................. 1

.SCREW, MACHINE 10-32UNFX1/2 ................................ .... 1

CONTROL ASSEMBLY, PU................................ .................. 1

LEVER, REMOTE CONTRO ................................ ................. 1

.RING, RETAINING ................................ ............................... 1

.WASHER, FLAT 0, 50................................ .......................... 1

.WASHER, FLAT 1, 00................................ .......................... 1

.LEVER, REMOTE CONTRO ................................ ................ 1

.BEARING, BALL, ANNULA ................................ .................. 3

.NUT, PLAIN, HEXAGON................................ ...................... 1

.WASHER ................................ ................................ ............. 1

.LEVER, REMOTE CONTRO ................................ ............... 1

.PIN, STRAIGHT, HEADED................................ ................... 1

.RING, RETAINING ................................ ............................... 2

.WASHER M8 ................................ ................................ ...... 1

.LEVER, REMOTE CONTRO ................................ ................ 1

.SCREW, CAP, SOCKET HE M8X1, 25X18......................... 1

.BRACKET, MOUNTING ................................ ....................... 1

SPACER, SLEEVE................................ ................................ 1

SCREW, CAP, SOCKET HE M8X1, 25X35........................... 2

WIRE, NONELECTRICAL MAKE FROM WIRE

P/N MS20995C20(96906), 12 INCHES................................ ....

1

BOLT, FLUID PASSAGE................................ ....................... 2

NUT, PLAIN, HEXAGON................................ ....................... 2

CONTROL ASSEMBLY, RE................................ .................. 1

.LEVER ................................ ................................ ................. 1

.SEAL, PLAIN................................ ................................ ........ 2

.SPRING. ................................ ................................ .............. 2

.LEVER ................................ ................................ ................. 1

.SCREW, CAP, HEX HD M6X1X40................................ ....... 2

.NUT, PLAIN, HEXAGON M6X1................................ ............ 2

.COVER, REMOTE CONT ................................ .................... 1

.LEVER ................................ ................................ ................. 2

.NUT, PLAIN, HEXAGON................................ ...................... 2

SCREW, CAP, SOCKET HE M5X0, 8X7.............................. 2

NUT, PLAIN, HEXAGON................................ ....................... 2

SCREW, CAP, SOCKET HE. ................................ ............... 5

PIN, TAPERED, PLAIN ................................ ......................... 2

GASKET PART OF KIT P/N 395.8180.062............................ 1

SPRING, HELICAL, EXTE................................ ..................... 1

SPRING, HELICAL, EXTE................................ ..................... 1

PIN, SPRING ................................ ................................ ........ 1

END OF FIGURE

25-1

SECTION II TM 5-3825-230-14&P

Figure 26. Fuel Filter Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

4

5

6

7

13

PAOZZ 55524

PFOZZ 39428

PFOZZ 55524

PFOZZ 96906

PFOZZ 55524

PFOZZ 55524

PFOZZ 55524

8 PAOZZ 2X179

9 PAOZZ 2X179

10 PAOZZ 2C072

11 PFOZZ 2X179

12 PAOZZ 2X179

PFOZZ 5X475

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0309 FUEL FILTERS

QTY

FIG. 26. FUEL FILTER ASSEMBLY

AB-1000-3

3603T17

AB-CAP

MS35207-263

FILLER BREATHER FIL................................ ........................ 1

.CHAIN, WELDLESS................................ ............................. 1

.CAP, FILLER OPENING ................................ ...................... 1

.SCREW, MACHINE 10-32UNFX1/2 ................................ .... 1

AB-NECK

AB-GASKET

.FILLER NECK ................................ ................................ ...... 1

.GASKET ................................ ................................ .............. 2

AB-3INCHBASKET .STRAINER ELEMENT, SE................................ ................... 1

2830.3730.036

2830.2175.045

9.3240.066

9.7565.011

0000-J1G

9.1780.007

FILTER, FLUID ................................ ................................ ..... 1

.FILTER ELEMENT, FLUI ................................ ..................... 1

NUT, PLAIN, HEXAGON M10X1, 5................................ ...... 2

WASHER, LOCK M10. ................................ ........................ 2

BRACKET, MOUNTING ................................ ........................ 1

SCREW, CAP, HEXAGON H ................................ ................ 2

END OF FIGURE

26-1

SECTION II TM 5-3825-230-14&P

Figure 27. Glow Plug Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

4

PFOZZ 2X179

PAOZZ 2X179

PFOZZ 96906

PFOZZ 24617

(4)

PART

NUMBER

9.4670.026

9040.2100.026

MS35338-44

11505913

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0311 ENGINE STARTING AIDS

QTY

FIG. 27. GLOW PLUG ASSEMBLY

WASHER, FLAT................................ ................................ .... 2

GLOW PLUG ................................ ................................ ........ 2

WASHER, LOCK 1/4................................ ............................ 2

NUT, PLAIN, HEXAGON M5X0, 8................................ ........ 2

END OF FIGURE

27-1

SECTION II TM 5-3825-230-14&P

Figure 28. Muffler and Pipe Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

6

7

PFOZZ 70842

PAOZZ 66234

3 PAOZZ 70842

4 PFOZZ 2X179

5 PFOZZ 2X179

PAOZZ 2X179

PAOZZ 2X179

(4)

PART

NUMBER

703-1500

209-92052

732-1026

9.3240.019

6780.085

560.4420.019

5460.256

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 04 EXHAUST SYSTEM

GROUP 0401 MUFFLER AND PIPES

QTY

FIG. 28. MUFFLER AND PIPE ASSEMBLY

CAP ASSEMBLY, PROTEC ................................ .................. 1

PIPE, EXHAUST ................................ ................................ .. 1

CLAMP, LOOP................................ ................................ ...... 1

NUT, PLAIN, HEXAGON................................ ....................... 4

STUD, PLAIN ................................ ................................ ........ 4

GASKET PART OF KIT P/N 395.8180.062............................ 2

MUFFLER, EXHAUST................................ ........................... 1

END OF FIGURE

28-1

SECTION II TM 5-3825-230-14&P

Figure 29. Shrouds and Guards

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

20

PFOZZ 2X179

2 PFOZZ 2X179

3 PFOZZ 2X179

4 PFOZZ 2X179

5 PFOZZ 2X179

6 PFOZZ 2X179

7 PFOZZ 2X179

8 PFOZZ 2X179

9 PAOZZ 2X179

10 PFOZZ 2X179

* 11 PAOZZ 2X179

12 PFOZZ 2X179

13 PFOZZ 2X179

14 PAOZZ 66234

15 PFOZZ 24617

16 PFOZZ 96906

17 PFOZZ 24617

18 PFOZZ 96906

19 PFOZZ 96906

PFOZZ 2X179

435.2920.104

9.1770.002

9.7565.007

360.4776.090

9.9790.039

435.5066.070

9.9731.092

435.3350.094

435.5066.074

9.1760.003

7555.004

435.2569.203

360.6927.056

401-94506

11500713

MS35338-45

11500723

MS35338-47

MS27183-15

904.3527.018

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODE S (UOC)

GROUP 05 COOLING SYSTEM

GROUP 0502 COWLING, DEFLECTORS,

AIR DUCTS, SHROUDS, ETC.

QTY

FIG. 29. SHROUDS AND GUARDS

COVER, ACCESS ................................ ................................ 1

SCREW, CAP, HEXAGON H M8X1, 25X16......................... 1

WASHER, FLAT M8................................ ............................. 1

GASKET ................................ ................................ ............... 1

SCREW, CAP, SOCKET HE M6X1X12............................... 18

PANEL, BODY, VEHICULA................................ ................... 1

SCREW, CAP, SOCKET HE MBX1, 25X14.......................... 1

DEFLECTOR, DIRT AND ................................ ...................... 1

SHROUD, FAN, RADIATOR ................................ ................. 1

SCREW, CAP, HEXAGON H M6X1X12............................... 2

WASHER M6 ................................ ................................ ....... 2

HOUSING, FLYWHEEL ................................ ........................ 1

GUARD, ENGINE................................ ................................ .. 1

SHROUD, FAN, RADIATOR ................................ ................ 1

BOLT, MACHINE M8X1, 25X20 ................................ ............ 1

WASHER, LOCK 5/16................................ ........................... 1

SCREW, CAP, HEXAGON H M10X1, 50X20........................ 2

WASHER, LOCK 7/16................................ ........................... 2

WASHER, FLAT 7/16................................ ............................ 4

SPACER, SLEEVE................................ ................................ 1

END OF FIGURE

29-1

SECTION II TM 5-3825-230-14&P

Figure 30. Alternator Installation

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

13

14

15

16

PFOZZ 66234

PFOZZ 96906

3 PFOZZ 24617

4 PAOZZ 76761

5 PFOZZ 96906

6 PFOZZ 96906

7 PAOZZ 76761

8 PFOZZ 76761

9 PFOZZ 76761

10 PFOZZ 96906

11 PAOZZ 76761

12 PFOZZ 96906

PFOZZ 96906

PFOZZ 96906

PAOZZ 66234

PAOZZ 20796

410-92705

MS35338-45

11500713

A2-101

MS35207-264

MS27183-7

A1-103

A9-506

A4-510

MS21044-N8

A3-300

MS51922-33

MS90725-34

MS27183-12

401-94419

15350LA

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 06 ELECTRICAL SYSTEM

GROUP 0601 GENERATOR, ALTERNATOR

QTY

FIG. 30. ALTERNATOR INSTALLATION

BRACKET, MOUNTING ................................ ........................ 1

WASHER, LOCK 5/16................................ ........................... 3

BOLT, MACHINE M8X1, 25X20 ................................ ............ 2

REGULATOR, VOLTAGE ................................ ..................... 1

SCREW, MACHINE 10-32UNFX5/8 ................................ ..... 2

WASHER, FLAT NO.10 ................................ ....................... 2

GENERATOR, ALTERNATI ................................ .................. 1

.KEY FAE NO. 6................................ ................................ ... 1

.WASHER, FLAT 1/2................................ ............................ 1

.NUT, SELF-LOCKING, HE 1/2-20UNF................................ 1

PULLEY, GROOVE................................ ............................... 1

NUT, SELF-LOCKING, HE 1/2-13UNC................................ . 1

BOLT, MACHINE 5/16-18UNCX1 GR5................................ .. 1

WASHER, FLAT 5/16................................ ............................ 1

SPACER, RING................................ ................................ ..... 1

BELT, V................................ ................................ ................. 1

END OF FIGURE

30-1

SECTION II TM 5-3825-230-14&P

Figure 31. Starter Motor Assembly

1 PFOZZ 2X179

2 PFOZZ 2X179

3 PAOFF 53867

4 PFFZZ 53867

5 PAFFF 55683

6 XAFZZ 66234

7 XAFZZ 66234

8 PFFZZ 96906

9 PFFZZ 24617

10 PFFZZ 53867

11 PFFZZ 53867

12 KFFZZ 66234

13 PAFFF 53867

14 XAFZZ 66234

15 XAFZZ 66234

16 XAFZZ 66234

17 XAFZZ 66234

18 XAFZZ 66234

19 PAFZZ 53867

20 XAFZZ 66234

21 PAFZZ S3465

* 22 PAFFF 53867

* 23 PAFZZ 53867

24 KFFZZ 66234

25 KFFZZ 66234

26 KFFZZ 66234

27 PFFZZ 53867

28 PAFZZ 53867

29 PFFZZ 53867

30 PFFZZ 96906

* 31 PAFFF 53867

32 PAFZZ 53867

33 PAFZZ 53867

34 PAFZZ 53867

35 PFFZZ 53867

36 XAFZZ 66234

* 37 PAFFF 66234

38 PAFZZ 53867

39 KFFZZ 66234

40 KFFZZ 66234

41 PAFZZ S3465

42 KFFZZ 66234

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

9.7565.011

9.9730.045

0 001 219 010

9 001 333 409

0 331 303 096

700-92010

700-92011

MS35335-31

11502892

2 916 069 084

2 913 051 107

700-92019

9 001 337 056

700-92050

700-92049

700-92048

700-92023

700-92024

9 002 338 850

700-92029

4537769-643

9001 140 349

100322005

700-92034

700-92035

700-92036

9 001 333 411

1 000 505 010

9 001 333 417

MS27183-5

9 003 334 157

9 001 140 383

1 004 615 001

9 003 337 001

9 001 140 371

700-92047

700-92051

1 000 301 031

700-92053

700-92054

4537769-635

700-92020

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0603 STARTING MOTOR

QTY

FIG. 31. STARTER MOTOR ASSEMBLY

WASHER, LOCK M10................................ .......................... 2

SCREW, CAP, SOCKET HE M10X1, 50X30........................ 2

STARTER, MOTOR ................................ .............................. 1

.SCREW, MACHINE ................................ ............................. 3

.SOLENOID, ELECTRICAL ................................ ................... 1

..ACTUATOR, ELECTRIC-M ................................ ................. 1

..SPRING, HELICAL, COMP ................................ ................. 1

..WASHER, LOCK NO.8 ................................ ...................... 1

..SCREW, MACHINE M4X0, 7X6 ................................ ......... 1

.WASHER, FLAT................................ ................................ ... 2

.NUT, PLAIN, HEXAGON................................ ...................... 2

.SEAL, PLAIN PART OF KIT P/N 1 007 ................................ 1

010 040

.PARTS KIT, MOTOR, DIR ................................ ................... 1

..RING, RETAINING ................................ .............................. 1

..WASHER, FLAT................................ ................................ .. 1

..END BELL, ELECTRICAL ................................ ................... 1

..WASHER, FLAT................................ ................................ .. 1

..GEARSHAFT, MULTIPULE................................ ................. 1

..WHEEL, GEARED, INTRNL................................ ................ 1

..COVER, ACCESS................................ ............................... 1

.ARMATURE, MOTOR ................................ .......................... 1

.PROTECTOR, THERMAL-0 ................................ ................. 1

..BEARING, SLEEVE ................................ ............................ 1

.WASHER, FLAT PART OF KIT P/N 1 007 ........................... 1

010 040

.CLIP, RETAINING PART OF KIT P/N 1 ............................... 1

007 010 040

.PACKING, PREFORMED PART OF KIT P/N 1 .................... 1

007 010 040

.SCREW, MACHINE ................................ ............................. 2

.CAP, ELECTRICAL................................ .............................. 1

.BOLT, MACHINE ................................ ................................ . 2

.WASHER, FLAT NO.6 ................................ ........................ 2

.WINDING, STARTER-GEN ................................ .................. 1

..CLIP, ELECTRICAL ................................ ............................ 4

..SPRING, HELICAL, COMP ................................ ................. 4

.BRUSH SET, ELECTRICA ................................ ................... 1

.SCREW, MACHINE ................................ ............................. 4

.HOUSING, ELECTRICAL................................ ..................... 1

.GEARSHAFT, SPUR................................ ............................ 1

..BEARING, SLEEVE ................................ ............................ 1

.BUSHING, SLEEVE PART OF KIT P/N 1............................. 1

007 010 040................................ ................................ ............

.SPACER, RING PART OF KIT P/N 1 007 ............................ 1

010 040

.SHIFTER FORK ................................ ................................ ... 1

.PIVOT, FORK PART OF KIT P/N 1 007 ............................... 1

31-1

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

* 43

* 44

PAFFF 66234

PAFZZ 53867

(4)

PART

NUMBER

700-92009

1000301031

TM 5-3825-230-14&PCO2

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

010 040

.HOUSING, ELECTRICAL,................................ .................... 1

..BEARING, SLEEVE ................................ ............................ 1

END OF FIGURE

31-2

SECTION II TM 5-3825-230-14&P

Figure 32. Instrument Panel Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

* 1

27

MOOZZ 58961

2 PFOZZ 06383

3 PFOZZ 2X179

4 PAOZZ 66234

5 PFOZZ 96906

6 PFOZZ 96906

7 PFOZZ 96906

8 PFOZZ 2X179

9 PFOZZ 2X179

10 PAOZZ 2X179

11 PFOZZ 81640

* 12 PAOZZ 13445

13 PFOZZ 33955

14 PFOZZ 33955

15 PFOZZ 33955

16 PAOZZ 66234

17 PFOZZ 96906

18 PFOZZ 96906

19 PFOZZ 96906

20 PFOZZ 96906

* 21 MOOZZ 58961

22 PFOZZ 06383

23 PFOZZ 75915

24 PFOZZ 71400

25 PFOZZ 96906

* 26 MOOZZ 58961

PAOZZ 06383

(4)

PART

NUMBER

WG-16-0-6IN

DV14-250-C

5175-119

410-92916

MS27183-10

MS35338-44

MS90725-6

9040.7195.056

2760.2750.111

5041-020

7500K14

81264

1838575

6219371

9154571

402-92008

MS51967-2

MS25036-108

MS35335-87

MS35649-286

WG-16-0-8IN

BSV10X-L

155100

ACG-10

MS35206-226

WG-16-0-12IN

D-250A-C

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0607 INSTRUMENT OR ENGINE

CONTROL PANEL

FIG. 32. INSTRUMENT PANEL ASSEMBLY

QTY

WIRE, 16GA MAKE FROM WIRE P/N 950B

(16764), 6 INCHES................................ ................................ ..

2

TERMINAL, LUG 205X.032X16-14GA................................ .. 3

LAMP, INCANDESCANT. ................................ ..................... 1

PLATE, MOUNTING, FLAT ................................ ................... 1

WASHER, FLAT 1/4................................ .............................. 3

WASHER, LOCK 1/4................................ ............................. 5

SCREW, CAP, HEXAGON H 1/4-2 OUNCX3/4.................... 3

SWITCH, PUSH ................................ ................................ .... 1

GUARD, SWITCH ................................ ................................ . 1

KEY, SWITCH................................ ................................ ....... 1

SWITCH, TOGGLE ................................ ............................... 1

BOOT, DUST AND MOIST................................ .................... 1

LAMP, INCANDESCANT ................................ ...................... 2

RESISTOR, FIXED, WIRE ................................ .................... 1

AMMETER ................................ ................................ ............ 1

SPACER, PLATE ................................ ................................ .. 1

NUT, PLAIN, HEXAGON 1/4-20UNC................................ .... 2

TERMINAL, LUG 3/16X16-14GA................................ ........... 5

WASHER, LOCK NO. 8 ................................ .......................10

NUT, PLAIN, HEXAGON 8-32UNC ................................ .....10

WIRE, 16GA MAKE FROM WIRE P/N 950B

(16764), 8 INCHES................................ ................................ ..

1

SPLICE, CONDUCTOR 12-10GA................................ ......... 1

FUSEHOLDER, EXTRACTO................................ ................. 1

FUSE, CARTRIDGE................................ .............................. 1

SCREW, MACHINE 6-32UNCX1/4................................ ....... 2

WIRE, 6GA MAKE FROM WIRE P/N 950B 1

(16764), 12 INCHES................................ ................................

ADAPTER, CONNECTOR................................ ..................... 1

END OF FIGURE

32-1

SECTION II TM 5-3825-230-14&P

Figure 33. Wire Harness Mounting Parts

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

4

5

6

PFOZZ 96906

PFOZZ 96906

PFOZZ 96906

PFOZZ 96906

AOOOO 19207

MOOZZ 66234

7 PFOZZ 14889

8 MOOZZ 66234

9 PFOZZ 14007

10 MOOZZ 66234

11 PFOZZ 14889

12 PFOZZ 93908

13 PFOZZ 96906

14 PFOZZ 96906

15 PFOZZ 96906

16 PFOZZ 96906

* 17 PFOZZ 80204

18 PFOZZ 96906

19 PFOZZ 96906

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0608 MISCELLANEOUS ITEMS

QTY

FIG. 33. WIRE HARNESS MOUNTING PARTS

MS21333-105

MS35338-44

MS51967-2

MS3367-1-0

406-005E

402-92110

CLAMP, LOOP 3/4 ................................ ................................ 8

WASHER, LOCK 1/4................................ ............................20

NUT, PLAIN, HEXAGON 1/4-20UNCO................................ . 7

STRAP, TIEDOWN, ELECT ................................ .................. 6

CONDUIT ASSY CONDUIT 1/2 ................................ ................................ ........ 1

402-92109 .PIPE, ELECTRICAL, PVC MAKE FROM 1

PIPE P/N A52AE12 (23823), 12 INCHES................................

401-005

402-92111

.TEE, PIPE 1/2 PVC................................ ............................. 1

.PIPE, ELECTRICAL, PVC MAKE FROM 2

PIPE P/N A52AE12 (23823), 48.5 INCHES.............................

.ELBOW, PIPE 1/2 PVC................................ ....................... 2

447-005

.PIPE, ELECTRICAL, PVC MAKE FROM

PIPE P/N A52AE12 (23823), 16 INCHES ................................

2

.CAP, PIPE 1/2 PVC ................................ ............................ 3

E940D

MS21333-73

MS27183-8

MS35206-263

COUPLING, ELECTRICAL 1/2 PVC................................ ..... 1

CLAMP, LOOP 5/8 ................................ ............................... 10

WASHER, FLAT NO.10 ................................ .......................10

SCREW, MACHINE 10-24UNCX1/2................................ ....10

MS27183-10 WASHER, FLAT 1/4................................ ............................. 8

B1821BH025C100N SCREW, CAP, HEXAGON H 1/4-20UNCX1 GR8................. 4

MS21333-98

MS90725-3

CLAMP, LOOP 1/4 ................................ ..............................14

SCREW, CAP, HEXAGON H 1/4-20UNCX1/2 GR5.............14

END OF FIGURE

33-1

SECTION II TM 5-3825-230-14&P

Figure 34. Junction Box and Jumper Wire Assemblies

1 AOOOO 66234

2 PFOZZ 96906

* 3 MOOZZ 66234

4 AOOOO 66234

5 PFOZZ 96906

* 6 MOOZZ 66234

* 7 PFOZZ 80204

8 PFOZZ 96906

9 PFOZZ 96906

10 PFOZZ 96906

11 PFOZZ 96906

12 PAOZZ 66234

* 13 PAOZZ 12697

14 PFOZZ 96906

15 PFOZZ 13445

16 PFOZZ 96906

17 PAOZZ 13445

18 PFOZZ 96906

19 PFOZZ 96906

20 PFOZZ 96906

21 PFOZZ 96906

22 PFOZZ 81992

* 23 PFOZZ 03743

24 PFOZZ 74545

25 PFOZZ 96906

26 PFOZZ 96906

27 PFOZZ 96906

28 PFOZZ 81992

29 PFOZZ 81992

30 PFOZZ 49367

31 PFOZZ 66234

32 PFOZZ 13548

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0608 MISCELLANEOUS ITEMS

QTY

FIG. 34. JUNCTION BOX AND JUMPER WIRE

ASSEMBLIES

703-92133

MS25036-157

703-92132

703-92097

MS25036-125

WIRE ASSY, GP JUMPER................................ .................... 1

.TERMINAL, LUG 1/4X12-O1GA................................ .......... 2

.WIRE, 10GA MAKE FROM WIRE P/N 1

572DO (79550), 9 INCHES................................ ......................

WIRE ASSY, GND JMPR................................ ...................... 1

.TERMINAL, LUG 3/8X4GA................................ .................. 2

703-92096 .WIRE, 4GA MAKE FROM WIRE P/N 1

736102 (16428), 10 INCHES................................ ................. 1

B1821BH038C100N SCREW, CAP, HEXAGON H 3/8-16UNCX1 GR5................. 1

MS35335-35 WASHER, LOCK 3/8................................ ............................. 1

MS27183-13

MS51922-17

MS35207-265

401-94431

VK100NA-5

MS25036-108

30090-3

WASHER, FLAT 3/8................................ .............................. 1

NUT, SELF-LOCKING, HE 3/8-16UNC................................ . 1

SCREW, MACHINE 10-32UNCX3/4................................ ..... 4

JUNCTION BOX................................. ................................ ... 1

RESISTOR, ADJUSTABLE 6.8 OHM ................................ ... 3

TERMINAL, LUG 3/16X16-14GA................................ .......... 6

BASE, CIRCUIT BREAKE ................................ ..................... 1

MS35650-302

30055-20

MS35206-280

MS35338-44

MS51957-65

MS35338-43

003-22-003

BL50

SHC-1025

MS51922-9

MS27183-12

MS90725-34

SHC-1037

003-22-002

08-1478

401-94499

50820

NUT, PLAIN, HEXAGON 10-32UNF................................ ....14

CIRCUIT BREAKER 20 AMP ................................ ............... 3

SCREW, MACHINE 1/4-20UNCX5/8................................ .... 2

WASHER, LOCK 1/4................................ ............................ 2

SCREW, MACHINE 10-24UNCX3/4................................ ..... 5

WASHER, LOCK NO. 1 ................................ ......................19

LOCKNUT. ................................ ................................ ............ 1

LOCKNUT, ELECTRICAL ................................ ..................... 2

BOX CONNECTOR, ELECT,................................ ................. 2

NUT, SELF-LOCKING, HE 5/16-18UNC............................... 4

WASHER, FLAT 5/16................................ ............................ 8

BOLT, MACHINE 5/16-18UNCX1 GR5................................ .. 4

BOX CONNECTOR, ELECT................................ .................. 1

NUT ................................ ................................ ...................... 1

BOX CONNECTOR, ELECT................................ .................. 1

PLATE, MOUNTING, FLAT ................................ ................... 1

TERMINAL BOARD................................ ............................... 1

END OF FIGURE

34-1

SECTION II TM 5-3825-230-14&P

Figure 35. Lights and Light Mounts

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

*

1

2

3

4

5

6

7

8

9

10

PFOZZ 66234

PAOZZ 70184

PAOZZ 70184

PFOZZ 96906

PFOZZ 96906

PFOZZ 96906

PFOZZ 06383

PFOZZ 06383

MOOZZ 58961

PAOZZ 13548

11 PAOZZ 13548

12 PFOZZ 13548

13 PAOZZ 13548

14 PAOZZ 13548

15 PFOZZ 96906

16 PFOZZ 96906

17 PAOZZ 13548

* 18 PFOZZ 80204

19 PFOZZ 66234

20 PFOZZ 96906

21 PFOZZ 96906

22 PFOZZ 66234

22 PFOZZ 66234

* 23 PFOZZ 80204

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0609 LIGHTS

QTY

FIG. 35. LIGHTS AND LIGHT MOUNTS

701-68471

6-40301

88-40700

MS27183-18

10403

LAMP UNIT, VEHICULAR ................................ ..................... 4

.LAMP UNIT, VEHICULAR ................................ .................... 1

.GROMMET, NOMETALLIC ................................ .................. 1

WASHER, FLAT 1/2................................ ............................. 4

MS51922-33

MS25036-108

NUT, SELF-LOCKING, HE 1/2-13UNC................................ . 2

TERMINAL, LUG 3/16X16-14GA................................ .......... 5

DNF18-250F1B-C TERMINAL .250X.032X22-18GA................................ ........... 1

BSV10X-L

WG-16-0-6IN

SPLICE, CONDUCTOR 12-10GA................................ ......... 2

WIRE, 16GA MAKE FROM WIRE P/N 9505 2

(16764), 6 INCHES ................................ ................................ .

GROMMET, NONMETALLIC ................................ ................ 2

10205R

10744R

93906

10205R

MS35206-245

MS35338-42

10401

LAMP UNIT, VEHICULAR ................................ ..................... 4

LAMP UNIT, VEHICULAR. ................................ ................... 1

.LEAD ASSEMBLY, ELECT ................................ .................. 1

.LAMP UNIT, VEHICULAR ................................ .................... 3

SCREW, MACHINE 8-32UNCX1/2................................ ....... 4

WASHER, LOCK NO.8 ................................ ........................ 4

GROMMET, NONMETALLIC ................................ ................ 2

B18218H038C125N SCREW, CAP, HEXAGON H 3/8-16UNCX1.25 GR8............ 4

401-94117 BRACKET, MOUNTING ................................ ........................ 2

MS35338-46

MS51967-8

WASHER, LOCK 3/8................................ ............................ 4

NUT, PLAIN, HEXAGON 3/8-16UNC................................ ..... 4

401-94438

401-94439

BRACKET, MOUNTING RIGHT HAND ................................ . 1

BRACKET, LIGHT LEFT HAND ................................ ........... 1

B1821BH050C150N SCREW, CAP, HEXAGON H 1/2-13UNCX1.5 GR8.............. 2

END OF FIGURE

35-1

SECTION II TM 5-3825-230-14&P

Figure 36. Sending Units and Warning Switches

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

*

1

2

6

7

PFOZZ 96906

PFOZZ 96906

3 PFOZZ 96906

4 PFOZZ 33955

5 PFOZZ 33955

PAOZZ 2X179

XBOZZ 2X179

(4)

PART

NUMBER

MS35206-263

MS35650-302

MS35338-43

1501775

9610070

276.4670.014

9040.6745.031

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0610 SENDING UNITS AND

WARNING SWITCHES

QTY

FIG. 36. SENDING UNITS AND WARNING

SWITCHES

SCREW, MACHINE 10-24UNCX1/2................................ ..... 5

NUT, PLAIN, HEXAGON 10-32UNF................................ ..... 1

WASHER, LOCK NO. 10................................ ...................... 1

INDICATOR, LIQUID ................................ ............................. 1

GASKET ................................ ................................ ............... 1

WASHER, FLAT................................ ................................ .... 1

SWITCH, PRESSURE ................................ .......................... 1

END OF FIGURE

36-1

SECTION II TM 5-3825-230-14&P

Figure 37. Battery Installation

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

7

8

PFOZZ 66234

PFOZZ 96906

PFOZZ 96906

4 PAOZZ 66234

5 PFOZZ 66234

6 PAOFA 96906

PFOZZ 39428

PAOZZ 70842

(4)

PART

NUMBER

401-94303

MS51922-1

MS27183-10

401-94773

401-94756

MS52149-1

3705T101

728197

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0612 BATTERIES, STORAGE

(WET OR DRY)

FIG. 37. BATTERY INSTALLATION

QTY

BATTERY BOX., ................................ ................................ ... 2

NUT, SELF-LOCKING, HE 1/4-20UNC................................ . 4

WASHER, FLAT 1/4................................ ............................. 4

COVER, BATTERY RETAI................................ .................... 2

ROD END, THREADED ................................ ........................ 4

BATTERY, STORAGE ................................ .......................... 2

STRAP, RETAINING ................................ ............................. 2

CAP, PROTECTIVE, DUST................................ ................... 2

END OF FIGURE

37-1

SECTION II TM 5-3825-230-14&P

Figure 38. 12V, 24V, Rear Tail Light, and Broom Head Wire Harnesses

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 XBOOO 66234

2 PFOZZ 96906

3 PAOOO 66234

4 PFOZZ 06383

5 PFOZZ 96906

6 PAOZZ 66234

7 PFOZZ 06383

8 PFOZZ 96906

*9 XBOOO 66234

10 PFOZZ 96906

11 PAFZZ 81349

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0613 HULL OR CHASSIS WIRING HARNESS

FIG. 38. 12V, 24V, REAR TAIL LIGHT,

AND BROOM HEAD WIRE HARNESSES

QTY

703-92065 WIRE HARNESS, 24V ................................ .......................... 1

MS25036-156

703-92127

.TERMINAL, LUG 3/16 X 12-10GA................................ ....... 5

CABLE ASSEMBLY, SPEC................................ ................... 1

DNF18-250FIM-C .TERMINAL, QUICK DISC 250 X . 032X22-18GA...............11

MS25036-108 .TERMINAL, LUG 3/16 X 16-14 GA................................ ...... 3

703-92128

BSV14X-C

MS25036-108

703-92152

MS25036-108

JAN1N3611

WIRING HARNESS, BRAN ................................ ................... 1

.SPLICE, CONDUCTOR 16-14GA................................ ........ 4

.TERMINAL PLUG 3/16 X 16-14GA................................ ...... 3

WIRE HARNESS, 12V ................................ .......................... 1

.TERMINAL, LUG 3/16X16-14GA................................ ......... 1

SEMICONDUCTOR DEVIC ................................ ................... 2

END OF FIGURE

38-1

SECTION II TM 5-3825-230-14&P

Figure 39. Starter Relay, Engine, and Fuel and Glow Plug Wire Harnesses

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1

16

17

PAOZZ 66234

2 PFOZZ 96906

3 PFOZZ 96906

4 PFOZZ 96906

5 PFOZZ 06383

6 PAOZZ 66234

7 PFOZZ 96906

8 PAOZZ 79550

9 PFOZZ 96906

10 PFOZZ 06383

11 PFOZZ 96906

12 PFOZZ 96906

13 PFOZZ 96906

* 14 PFOZZ 00779

15 PFOZZ 96906

PAOZZ 66234

PFOZZ 96906

(4)

PART

NUMBER

703-92130

MS25036-115

MS25036-153

MS25036-112

DV14-250-C

703-92131

MS25036-125

61

MS25036-116

DNF18-250M-C

MS25036-154

MS25036-115

MS25036-108

61198-1

MS25036-112

703-92129

MS25036-108

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 0613 HULL OR CHASSIS WIRING HARNESS

FIG. 39. STARTER RELAY, ENGINE AND FUEL AND

GLOW PLUG WIRE HARNESSES

QTY

LEAD ASSEMBLY, ELECT ................................ ................... 1

.TERMINAL, LUG 3/8X8GA................................ .................. 2

.TERMINAL, LUG 11/64X16-14GA................................ ....... 1

.TERMINAL, LUG 3/16X10GA................................ .............. 1

.TERMINAL, LUG . 205X .032X16-14GA............................. 1

WIRING HARNESS, BRAN ................................ ................... 1

.TERMINAL, LUG 3/8X4GA................................ .................. 2

.TERMINAL, LUG................................ ................................ .. 4

.TERMINAL, LUG 1/4X8GA................................ .................. 1

.TERMINAL, LUG................................ ................................ .. 1

.TERMINAL, LUG 1/4X16-14GA................................ ........... 1

.TERMINAL, LUG 3/16X8GA................................ ................ 1

.TERMINAL, LUG 3/16X16-14GA................................ ......... 1

.TERMINAL, QUICK DISC .250X .032X12-10GA.................. 1

.TERMINAL, LUG 3/16X12-10GA................................ ......... 1

CABLE ASSEMBLY, SPEC................................ ................... 1

.TERMINAL, LUG 3/16X16-14GA................................ ......... 3

END OF FIGURE

39-1

SECTION II TM 5-3825-230-14&P

Figure 40. Hand Brake Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 PAOOO 94189

2 PAOZZ 94189

3 PAOZZ 94189

4 PFOZZ 94189

5 PFOZZ 96906

6 PAOZZ 94189

7 PFOZZ 94189

8 PAOZZ 94189

9 PAOZZ 94189

10 PAOZZ 94189

11 PAOZZ 96906

12 PAOZZ 94189

(4)

PART

NUMBER

17122

16691

16690

7029

MS51967-41

0101668800

8798

12560

23319

8780

MS16624-1050

8785

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 12 BRAKES

GROUP 1201 HAND BRAKES

FIG. 40. HAND BRAKE ASSEMBLY

QTY

BRAKE, SHOE TYPE................................ ............................ 2

.BRAKE, SHOE TYPE................................ ........................... 1

.CAMSHAFT, ACTUATING ................................ ................... 1

.SPACER, SLEEVE ................................ .............................. 1

.NUT, PLAIN, HEXAGON 7/16-14UNC................................ . 4

.HOUSING, BEARING UNI................................ .................... 1

.BOLT, RIBBED SHOULDE................................ ................... 4

.PIN, ANCHOR, MUNITION ................................ .................. 2

.ADJUSTING SCREW ASS................................ ................... 2

.BRAKE SHOE................................ ................................ ...... 2

.RING, RETAINING ................................ ............................... 2

.SPRING, HELICAL, EXTE................................ .................... 2

END OF FIGURE

40-1

SECTION II TM 5-3825-230-14&P

Figure 41. Hand Brake Lever Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1

2

PFOZZ 96906

PFOZZ 96906

3 PFOZZ 96906

4 PAOZZ 66234

5 PAOZZ 4Y310

6 PAOZZ 66234

6 PAOZZ 66234

7 PFOZZ 96906

8 PAOZZ 66234

9 PAOZZ 92867

10 PFOZZ 96906

11 PFOZZ 96906

(4)

PART

NUMBER

MS90725-34

MS35338-45

MS51967-5

401-94816

BCSM6700

410-92827

410-92834

MS51922-9

401-94504

01215601

MS27183-12

MS24665-283

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 1201 HAND BRAKES

FIG. 41. HAND BRAKE LEVER ASSEMBLY

QTY

BOLT, MACHINE 5/16-18UNCX1 GR5,............................... 18

WASHER, LOCK 5/16................................ .........................16

NUT, PLAIN, HEXAGON 5/16-18UNC................................ .16

PLATE, MOUNTING, FLAT ................................ ................... 2

BEARING, SLEEVE ................................ .............................. 2

LEVER, MANUAL CONTRO RIGHT HAND.......................... 1

LEVER, MANUAL CONTRO LEFT HAND ............................ 1

NUT, SELF-LOCKING, HE 5/16-18UNC............................... 2

LEVER, MANUAL CONTRO................................ .................. 4

LEVER, MANUAL CONTRO................................ .................. 2

.WASHER, FLAT 5/16................................ .......................... 1

.PIN, COTTER 3/32X3/4................................ ....................... 1

END OF FIGURE

41-1

SECTION II TM 5-3825-230-14&P

Figure 42. Wheel and Hub Assembly.

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 PAOOO 8H836

2 PAOZZ 8H836

3 PAOZZ 60038

4 PAOZZ 60038

5 PAOZZ 8H836

6 PAOZZ 8H836

7 PAOZZ 60038

8 PAOZZ 60038

9 PAOZZ 8H836

10 PAOZZ 8H836

11 PFOZZ 27783

12 PFOZZ 8H836

13 PFOZZ 96906

14 PFOZZ 96906

15 PFOZZ 96906

700-1

806-1

LM67048

LM67010

263-2

009-1

LM11910

LM11949

114-1

262-2

TR415

902-1

MS9358-17

MS24665-495

MS27183-23

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 13 WHEELS AND TRACKS

GROUP 1311 WHEEL ASSEMBLY

FIG. 42. WHEEL AND HUB ASSEMBLY

QTY

SPRING, HELICAL, EXTE................................ ..................... 1

.SEAL, PLAIN ENCASED ................................ ..................... 1

.CONE AND ROLLERS, TA ................................ .................. 1

.CUP, TAPERED ROLLER ................................ ................... 1

.STUD, SELF-LOCKING ................................ ....................... 5

.HUB, BODY ................................ ................................ ........ 1

.CUP, TAPERED ROLLER ................................ ................... 1

.CONE AND ROLLERS, TA ................................ .................. 1

.CAP, PROTECTIVE, DUST................................ .................. 1

.NUT, PLAIN, CONE SEAT ................................ ................... 5

VALVE, PNEUMATIC TIR ................................ ..................... 2

WHEEL, PNEUMATIC TIR ................................ .................... 2

NUT, PLAIN, CASTELLAT 3/4-16UNF ................................ . 1

PIN, COTTER 3/16X1. 5................................ ...................... 1

WASHER, FLAT 3/4................................ ............................. 1

END OF FIGURE

42-1

SECTION II TM 5-3825-230-14&P

Figure 43. Wheel, Hub, and Drum Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 PAOZZ 94189

2 PAOZZ 94189

3 PAOZZ 60038

4 PAOZZ 60038

5 PFOZZ 94189

6 PAOZZ 94189

7 PAOZZ 60038

8 PAOZZ 94189

9 PFOZZ 94189

10 PFOZZ 94189

11 PAOZZ 17875

12 PAOZZ 8H836

13 PFOZZ 96906

14 PFOZZ 96906

15 PFOZZ 96906

16622

15529

L68149

L68111

5081

16626

L44649

8019

14286

5082

T-15R-50

902-1

MS24665-495

MS9358-17

MS27183-23

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 1311 WHEEL ASSEMBLY

FIG. 43. WHEEL, HUB AND DRUM ASSEMBLY

QTY

HUB, WHEEL, VEHICULAR................................ .................. 2

.SEAL, PLAIN ENCASED................................ ...................... 1

.CONE AND ROLLERS, TA ................................ .................. 1

.CUP, TAPERED ROLLER,................................ ................... 1

.BOLT, RIBBED SHOULDE................................ ................... 5

.BRAKE DRUM ................................ ................................ .... 1

.CONE AND ROLLERS, TA ................................ .................. 1

.CONE AND ROLLERS, TA ................................ .................. 1

.CAP, DUST ................................ ................................ .......... 1

.NUT, PLAIN, CONE SEAT ................................ ................... 5

VALVE, PNEUMATIC TIR ................................ ..................... 2

WHEEL, PNEUMATIC TIR ................................ .................... 2

PIN, COTTER 3/16X1. 5................................ ...................... 2

NUT, PLAIN, CASTELLAT 3/4-16UNF ................................ . 2

WASHER, FLAT 3/4................................ ............................. 2

END OF FIGURE

43-1

SECTION II TM 5-3825-230-14&P

Figure 44. Tires

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 PAOFH 73842

(4)

PART

NUMBER

ST225/75R15

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 1313 TIRES, TUBES, TIRE CHAINS

FIG. 44. TIRES

QTY

TIRE, PNEUMATIC ................................ ............................... 3

END OF FIGURE

44-1

SECTION II TM 5-3825-230-14&P

Figure 45. Main Frame Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1

12

PBOFH 66234

2 PAOZZ 19207

3 PFOZZ 96906

4 PAOZZ 07860

5 MOOZZ 66234

6

7

8 PFOZZ 96906

9 PAOZZ 66234

10 PFOZZ 96906

11 PAOZZ 66234

13

14

15

16

17

* 18

19

20

PFOZZ 12128

PFOZZ 96906

PFOZZ 96906

MFOZZ 66234

PFOZZ 96652

PAOZZ 66234

PAOZZ 66234

PFOZZ 96906

PFOZZ 80204

PFOZZ 55017

PFOZZ 55017

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC) QTY

GROUP 15 FRAME, TOWING ATTACHMENTS AND DRAWBARS

GROUP 1501 FRAME ASSEMBLY

FIG. 45. MAIN FRAME ASSEMBLY

410-92613

8690528

MS90725-68

C21452

509-90329

FRAME SECTION, STRUC ................................ ................... 1

STRAP, WEBBING ................................ ............................... 1

SCREW, CAP, HEXAGON H 3/8-16UNCX2.5 GR5.............. 4

BRACKET ASSEMBLY, LI ................................ .................... 1

CHAIN MAKE FROM CHAIN P/N 2

M647

MS51922-17

MS90725-168

410-92672

MS51922-49

400-65650

MS24665-495

509-92004

671442 (12128), 32 LINKS................................ .....................

SWIVEL, EYE AND JAW ................................ ...................... 4

NUT, SELF-LOCKING, HE 3/8-16UNC................................ . 4

SCREW, CAP, HEXAGON H 3/8-16UNCX3 GR5................ 4

SHAFT, SHOULDERED................................ ........................ 2

NUT, SELF-LOCKING, HE 5/8-11UNC................................ 4

PIN, STRAIGHT, HEADED................................ .................... 1

29-10

410-92669

410-92668

MS35338-45

PIN, COTTER 3/16X1. 5................................ ...................... 1

CHAIN, STUD LINK MAKE FROM P/N 1

3607T21 (39428) 21 LINKS................................ .....................

RING, RETAINING ................................ ................................ 1

FRAME SECTION, STRUC ................................ ................... 1

PIN, STRAIGHT, HEADED................................ .................... 1

WASHER, LOCK 5/16................................ .......................... 1

B1821BH031C075N BOLT, MACHINE 5/16-18UNCX3/4................................ ...... 1

100100 BRACKET, PIPE 1. 00 ................................ ........................ 1

100112 CLAMP, PIPE, ANCHORA 1. 05 ................................ ......... 1

END OF FIGURE

45-1

SECTION II TM 5-3825-230-14&P

Figure 46. Tow Pole and Strut Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1

2

9

16

21

22

23

AOOOO 66234

PFOZZ 10001

3 PAOZZ 80205

4 PFOZZ 82918

5 PFOZZ 66234

6 PFOZZ 96906

7 PFOZZ 66234

8 PAOZZ 96906

PFOZZ 66234

10 PFOZZ 66234

11 PFOZZ 96906

12 PFOZZ 96906

13 PFOZZ 96906

14 PAOZZ 96906

15 PAOOO 8H836

PAOZZ 8H836

17 PAOZZ 60038

18 PAOZZ 60038

19 PAOZZ 8H836

20 PAOZZ 8H836

PAOZZ 60038

PAOZZ 60038

PAOZZ 8H836

509-92013

1784995

NAS1042-18

F310190-437

387-91668

MS35338-46

410-92667

MS24665-495

383-72815

410-92666

MS24665-495

MS9358-17

MS27183-23

MS21044-N8

700-1

806-1

LM67048

LM67010

263-2

009-1

LM11910

LM11949

114-1

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 1503 PINTLES AND TOWING ATTACHMENTS

QTY

FIG. 46. TOW POLE AND STRUT ASSEMBLY

CHAIN ASSEMBLY ................................ ............................... 2

.HOOK, HOIST................................ ................................ ...... 1

.SHACKLE ................................ ................................ ............ 1

.LINK, CHAIN, COLD SHU ................................ .................... 1

CLAMP, LOOP................................ ................................ ...... 2

WASHER, LOCK 3/8................................ ............................ 4

HOUSING, STEERING CO ................................ ................... 1

PIN, COTTER 3/16X15................................ ......................... 2

PIN, STRAIGHT, HEADLE ................................ .................... 1

TOW, BAR ................................ ................................ ............ 1

PIN, COTTER 3/16X15................................ ......................... 1

NUT, PLAIN, CASTELLAT 3/4-16UNF ................................ . 1

WASHER, FLAT 3/4................................ ............................. 1

NUT, SELF-LOCKING, HE 1/2-20UNF................................ . 5

SPRING, HELICAL, EXTE................................ ..................... 1

.SEAL, PLAIN ENCASED................................ ...................... 1

.CONE AND ROLLERS, TA ................................ .................. 1

.CUP, TAPERED ROLLER................................ .................... 1

.STUD, SELF-LOCKING ................................ ....................... 1

.HUB, B0DY ................................ ................................ .......... 1

.CUP, TAPERED ROLLER ................................ ................... 1

.CONE AND ROLLERS, TA ................................ .................. 1

.CAP, PROTECTIVE, DUST................................ .................. 1

END OF FIGURE

46-1

SECTION II TM 5-3825-230-14&P

Figure 47. Engine Enclosure

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 PAOZZ 66234

2 PFOZZ 96906

3 PFOZZ 96906

4 PFOZZ 96906

5 PFOZZ 96906

6 PFOZZ 66234

7 PAOZZ 66234

8 PAOZZ 66234

9 PFOZZ 66234

10 PAOZZ 66234

11 PFOZZ 96906

12 PAOZZ 66234

(4)

PART

NUMBER

387-92022

MS20604B5W8

MS90725-6

MS35338-44

MS27183-10

402-92006

410-93039

410-92727

410-92718

410-93040

MS51922-1

402-92326

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 18 BODY,CAB,HOOD AND HULL

QTY

GROUP 1801 BODY, CAB, HOOD AND HULL ASSEMBLIES

FIG. 47. ENGINE ENCLOSURE

LEVER, LOCK-RELEASE ................................ ..................... 2

RIVET, BLIND ................................ ................................ ....... 8

SCREW, CAP, HEXAGON H 1/4-20UNCX3/4 GR5.............25

WASHER, LOCK 1/4................................ ...........................23

WASHER, FLAT 1/4................................ ............................17

COVER, ACCESS................................ ................................ . 1

COVER, ACCESS................................ ................................ . 1

PANEL, BODY, VEHICULA................................ ................... 1

COVER, ACCESS................................ ................................ . 1

COVER, ACCESS................................ ................................ . 1

NUT, SELF-LOCKING, HE 1/4-20UNC................................ . 2

GUARD, ENGINE................................ ................................ .. 2

END OF FIGURE

47-1

SECTION II TM 5-3825-230-14&P

Figure 48. Decals

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 PFOZZ 66234

2 PFOZZ 66234

3 PFOZZ 66234

4 PFOZZ 66234

5 PFOZZ 66234

6 PFOZZ 66234

7 PFOZZ 96906

8 PFOZZ 96906

9 PFOZZ 66234

10 PFOZZ 66234

11 PFOZZ 66234

* 12 PAOZZ 66234

13 PFOZZ 66234

14 PFOZZ 66234

390-92042

390-65617

390-92026

390-92043

390-76001

390-92044

MS35206-245

MS35333-38

390-72016

390-65608

390-65607

390-92041

390-92045

390-65643

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC) QTY

GROUP 22 BODY, CHASSIS,OR HULL AND ACCESSORY ITEMS

GROUP 2210 DATA PLATES AND INSTRUCTION HOLDERS

FIG. 48. DECALS

PLATE, INSTRUCTION................................ ......................... 1

MARKER, IDENTIFICATI ................................ ...................... 1

MARKER, IDENTIFICATI ................................ ...................... 2

PLATE, INSTRUCTION................................ ......................... 1

PLATE, INSTRUCTION ................................ ........................ 1

PLATE, IDENTIFICATIO ................................ ....................... 1

SCREW, MACHINE 8-32UNCX3/8................................ ......12

WASHER, LOCK NO. 8 ................................ .....................12

MARKER, IDENTIFICATI ................................ ..................... 2

MARKER, IDENTIFICATI ................................ ..................... 1

MARKER, IDENTIFICATI ................................ ...................... 1

PLATE, INSTRUCTION................................ ......................... 1

PLATE, INSTRUCTION................................ ......................... 1

MARKER, IDENTIFICATI ................................ ...................... 1

END OF FIGURE

48-1

SECTION II TM 5-3825-230-14&P

Figure 49. Hydraulic Pump Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1

16

17

PAOFF 11341

2 PAFZZ 11341

3 PAFZZ 11341

4 KFFZZ 11341

5 KFFZZ 11341

6 PAFZZ 11341

7 PAFZZ 11341

8 PAFZZ 88044

9 PAFZZ 11341

10 PAFZZ 11341

11 PAFZZ 11341

12 PAFZZ 11341

13 PAFZZ 11341

14 KFFZZ 11341

15 PFOZZ 96906

PFOZZ 96906

PFOZZ 96906

40007RAASA

4P0004-002

4P0013-001

5A0078

5A0048

2A0310-604

4P0007-007

AN933-3

4P0012-008

4P0011-008

4P0003-002

2A0079-634

2A0466-150

5A0050

MS27183-18

MS35338-48

MS90725-109

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USA BLE ON CODES (UOC)

GROUP 24 HYDRAULIC LIFT COMPONENTS

GROUP 2401 HYDRAULIC PUMP

FIG. 49. HYDRAULIC PUMP ASSEMBLY

QTY

PUMP UNIT, ROTARY ................................ .......................... 1

.HOUSING, LIQUID PUMP................................ .................... 1

.PLATE, THRUST, ROTARY................................ ................. 2

.SEAL, LOADING PART OF KIT P/N 4P0017--001 ............... 2

.SEAL, STATIC PART OF KIT P/N 4P0017--001................... 2

.PIN, STRAIGHT, HEADLE ................................ ................... 4

.HOUSING, OIL PUMP................................ .......................... 1

..PLUG, PIPE 3/8 ................................ ................................ . 1

.GEARSHAFT, SPUR................................ ............................ 1

.GEARSHAFT, SPUR................................ ............................ 1

.COVER, HYDRAULIC, PUM ................................ ............... 1

.SCREW, CAP, SOCKET HE ................................ ................ 4

.RING, RETAINING ................................ ............................... 1

.SEAL, SHAFT PART OF KIT P/N 4P0017--001.................... 1

WASHER, FLAT 1/2................................ ............................. 2

WASHER, LOCK 1/2................................ ............................ 2

SCREW, CAP, HEXAGON H 1/2-13UNCX1 GR5................ 2

END OF FIGURE

49-1

SECTION II TM 5-3825-230-14&P

Figure 50. Hydraulic Motor Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1 PAOZZ 66234

2 PFOZZ 96906

3 PAOFF 63050

4 PFFFF 63050

5 PAFZZ 63050

6 PAFZZ 63050

7 KFFZZ 63050

8 PAFZZ 63050

9 PAFZZ 63050

10 PAFZZ 63050

11 PAFZZ 63050

12 PAFZZ 63050

13 PAFZZ 63050

14 PAFZZ 63050

15 KFFZZ 63050

16 KFFZZ 63050

17 KFFZZ 63050

18 PAFZZ 63050

19 KFFZZ 63050

20 KFFZZ 63050

21 KFFZZ 63050

22 KFFZZ 63050

23 KFFZZ 63050

24 KFFZZ 63050

25 KFFZZ 63050

26 KFFZZ 63050

27 KFFZZ 63050

* 28 PFOZZ 80204

29 PFOZZ 96906

(4)

PART

NUMBER

TM 5-3825-230-14&PC02

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

GROUP 2401 HYDRAULIC PUMP

FIG. 50. HYDRAULIC MOTOR ASSEMBLY

410-92658

MS51922-33

RE-1808020

PE130823

PE018003

PE018002

RE018030

PE011600

PE018059

PE014007

PE015006

PE018041

BRACKET, MOUNTING ................................ ........................ 1

NUT, SELF-LOCKING, HE 1/2-13UNC................................ . 4

MOTOR, HYDRAULIC ................................ .......................... 1

.HOUSING, BEARING UNI................................ .................... 1

..BEARING, ROLLER, CYLI ................................ .................. 1

..BEARING, ROLLER CYLI ................................ ................... 1

.SEAL PART OF KIT P/N PE444002................................ ... 3

.SHAFT, SHOULDERED................................ ....................... 1

.BEARING, WASHER, THRU................................ ................ 2

.CONNECTING LINK, RIG ................................ .................... 1

.PLATE, MOUNTING FLAT ................................ ................... 1

.B00T, DUST AND MOIST ................................ .................... 1

PE013019

PE016001

RS018013

RE018048

RE012001

PE247005

RE018170

RE018001

RE018163

RE018977

RE018006

RE018005

RE018138

RE018153

.SCREW, CAP, HEXAGON H ................................ ............... 7

.COVER, ACCESS................................ ................................ 1

.SEAL, SQUARE CUT PART OF KIT P/N PE444002............ 1

.BALL, 3/16 DIAMETER PART OF KIT P/N PE012001......... 4

.PLATE, PRESSURE PART OF KIT P/N PE012001.............. 1

.ROTOR ASSEMBLY ................................ ............................ 1

.WASHER, THRUST PART OF KIT P/N PE444003 .............. 1

.SPACER PART OF KIT P/N PE444002.............................. 1

.RING, BACKUP, TEFLON PART OF KIT P/N PE444002..... 1

.CARRIER, SEAL PART OF KIT P/N PE444003 ................... 1

.SEAL, DUST PART OF KIT P/N PE444002 ....................... 1

.RING, RETAINING PART OF KIT P/N PE444002 ................ 1

.RING, BACKUP PART OF KIT P/N PE444002..................... 1

.SEAL, SHAFT PART OF KIT P/N PE444002 ..................... 1

RE018187 .SEAL, SQUARE CUT PART OF KIT P/N PE444002............ 1

B1821BH050C150N SCREW, CAP, HEXAGON H 1/2-13UNCX1.5 GR8.............. 2

MS27183-18 WASHER, FLAT 1/2................................ ............................. 2

END OF FIGURE

50-1

SECTION II TM 5-3825-230-14&P

Figure 51. Hydraulic Control Valve Assembly

1 PFOZZ 96906

2 PAOFF 11341

3 PAFZZ 11341

4 PFFZZ 24617

5 PAFZZ 11341

6 PAFZZ 80205

7 PAFZZ 11341

8 PAFZZ 11341

9 PAFZZ 11341

10 PAFZZ 11341

11 PAFZZ 11341

12 PAFZZ 11341

13 PAFZZ 11341

14 PAFZZ 11341

15 PAFZZ 11341

16 PAFZZ 11341

17 PAFZZ 11341

18 PAFZZ 11341

19 PAFZZ 11341

20 PAFZZ 11341

21 PAFZZ 11341

22 PAFZZ 11341

23 PFFZZ 96906

24 PAFZZ 11341

25 PAFZZ 96906

26 PAFZZ 11341

27 PAFZZ 11341

28 PAFZZ 11341

29 PAFZZ 11341

30 PAFZZ 11341

31 PFOZZ 96906

32 PFOZZ 96906

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

(4)

PART

NUMBER

TM 5-3825-230-14&P

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

GROUP 2402 HYDRAULIC CONTROL VALVE

FIG. 51. HYDRAULIC CONTROL VALVE ASSEMBLY

MS51922-17

CA237NBEEO

V1702

103374

1V1703

NUT, SELF-LOCKING, HE 3/8-16UNC................................ . 3

VALVE, LINEAR, DIRECT................................ ..................... 1

.SET, STRAIGHT, HEADED................................ .................. 2

.PIN, COTTER 3/32X1 ................................ ......................... 1

.LEVER, MANUAL CONTRO. ................................ .............. 2

NAS1352-4LE8P .SCREW, SELF-LOCKING 1/4-20UNCX1/2......................... 8

4Z4306 .BRACKET, EYE, ROTATIN................................ .................. 2

1V0006 .VALVE, LINEAR, DIRECT. ................................ ................ 1

2A0283-7214

1R0037

1V1426

2A0354-112

.SEAL................................ ................................ .................... 4

.PLUG, RELIEF, PRESSUR ................................ .................. 1

.BODY, VALVE ................................ ................................ ..... 1

.PLUG, MACHINE THREAD................................ .................. 2

2A0017-8

1A0610

1V0217

1V0070

1A0291

1A0332

1A0292

1A0290

2A0079-414

1A0294

MS16998-42

1V0269

MS27183-17

1A0739

1V0272

2A0736-104P

1A0710

1V0046

MS-90728-66

MS27183-13

.BALL, BEARING ................................ ................................ .. 5

.SPRING, HELICAL, COMP ................................ .................. 1

.PLUG, MACHINE THREAD. ................................ .............. 1

.RETAINER, HELICAL CO ................................ .................... 1

.WASHER, FLAT................................ ................................ ... 2

.SPRING, HELICAL, COMP ................................ .................. 1

.RETAINER, HELICAL CO ................................ .................... 1

.WASHER, FLAT................................ ................................ ... 1

.SCREW, CAP, SOCKET HE ................................ ................ 5

.PLATE, RETAINING, BEA ................................ .................. 2

SCREW, CAP, SOCKET HE 1/4-28UNCX5/8....................... 4

.BEARING, SLEEVE ................................ ............................ 1

.WASHER, FLAT 1/2................................ ............................ 3

.SPRING, HELICAL, COMP ................................ ................. 2

.RETAINER SLEEVE, SEA ................................ ................... 1

.WASHER, LOCK................................ ................................ .. 1

.RETAINER, DISC, VALVE ................................ ................... 1

.VALVE, LINEAR, DIRECT................................ .................... 1

SCREW, CAP, HEXAGON H 3/8-16UNCX2 GR8................ 3

WASHER, FLAT 3/8................................ ............................. 3

END OF FIGURE

51-1

SECTION II TM 5-3825-230-14&P

Figure 52. Hydraulic Pressure Lines and Fittings

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGE C

1

6

7

18

PFOZZ 96906

2 PFOZZ 66234

3 PFOZZ 22031

4 AFOFF 66234

5 PAFZZ 30327

MFFZZ 66234

PFOZZ 96906

8 PFOZZ 96906

9 PFOZZ 01276

10 PAOZZ 66234

11 AFOFF 66234

12 PAFZZ 30327

13 MFFZZ 66234

14 PAFZZ 30327

15 AFOFF 66234

16 PAFZZ 61424

17 MFFZZ 66234

PFOZZ 96906

(4)

PART

NUMBER

MS51527A12

400-72806

2501-4

213-91779

HL12-12NJ

204-85451

MS51527A12

MS51953-365

2046-4-4S

206-34005

213-91901

HA04-04MB

204-85041

HG04-04NJ

213-91767

10655-12-12

204-85493

MS39324-12-10

TM 5-3825-230-14&P

(5)

DESCRIPTION AND USABLE ON CODES (UOC)

(6)

QTY

GROUP 2406 HYDRAULIC LINES AND FITTINGS

FIG. 52. HYDRAULIC PRESSURE LINES AND FITTINGS

ELBOW, TUBE TO BOSS................................ ..................... 2

PLUG, MACHINE THREAD................................ ................... 1

ELBOW, PIPE TO TUBE................................ ....................... 1

HOSE ASSEMBLY................................ ................................ 1

.ADAPTER, STRAIGHT, TU................................ .................. 2

.HOSE MAKE FROM HOSE P/N J412 ................................ . 1

(30327) 51 INCHES................................ ................................

ELBOW, TUBE TO BOSS................................ ..................... 1

NIPPLE, PIPE 1/4X4 ................................ ............................ 1

COUPLING, PIPE ................................ ................................ 1

ADAPTER, STRAIGHT, TU................................ ................... 1

HOSE ASSEMBLY,................................ ............................... 1

.ADAPTER, STRAIGHT, PI ................................ ................... 1

.HOSE MAKE FROM HOSE P/N SAE100R1........................ 1

TYAT SZ4(81343), 41 INCHES ................................ ..............

.ADAPTER, STRAIGHT, TU,................................ ................. 1

HOSE ASSEMBLY................................ ................................ 1

.ADAPTER, STRAIGHT, TU................................ .................. 2

.HOSE MAKE FROM HOSE P/N 1

J412(09505), 93 INCHES................................ .......................

ADAPTER, STRAIGHT, TU................................ ................... 1

END OF FIGURE

52-1

SECTION II TM 5-3825-230-14&P

Figure 53. Hydraulic Return Lines and Fittings

1 PFOZZ 98441

2 PFOZZ 96906

3 MOOZZ 66234

4 PFOZZ 55017

5 PAOZZ 66234

6 PFOZZ 76280

7 PFOZZ 90005

8 PFOZZ 72423

9 PFOZZ 88044

10 PFOZZ 96906

11 PFOZZ 72423

12 PFOZZ 22031

13 PFOZZ 66295

14 PFOZZ 72423

* 15 XBOZZ 22031

16 MOOZZ 66234

17 MOOZZ 66234

18 PFOZZ 99103

19 PFOZZ 96906

20 MOOZZ 66234

21 PFOZZ 22031

22 PFOZZ 72423

23 PFOZZ 22031

24 PAOZZ 60827

25 PAOZZ 60827

26 PFOZZ 72423

27 PFOZZ 72423

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

(4)

PART

NUMBER

0188-12-12

MS35842-11

204-85611

100075

205-74425

208-72630

569020-02

2071-039

AN910-2

MS51953-36

1003-250

4601-16-NWO

20H

2071-249

4404-16

204-85730

212-91159

OM-1012

MS35842-11

204-85690

6401-12-0

1021-150

5404-16-12

AF-10-25-0

AE-10

2071-199

1001-199

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 2406 HYDRAULIC LINES AND

FITTINGS

QTY

FIG. 53. HYDRAULIC RETURN LINES AND

FITTINGS

ADAPTER, STRAIGHT, PI ................................ .................... 3

CLAMP, HOSE,................................ ................................ ..... 4

HOSE MAKE FROM HOSE P/N 2556-12

(01276), 11 INCHES................................ ................................

2

CLAMP ASSEMBLY 0.75................................ ...................... 2

TUBE, METALLIC ................................ ................................ . 1

GAGE ROD, LIQUID, LEV ................................ .................... 1

BREATHER,................................ ................................ .......... 1

BUSHING, PIPE 1/4X1/8................................ ....................... 1

COUPLING, PIPE 1/4................................ ............................ 1

NIPPLE, PIPE 1/4X4 ................................ ............................. 1

ELBOW, PIPE 1.25................................ ............................... 1

ELBOW, HOSE TO BOSS ................................ ................... 1

CLAMP, HOSE................................ ................................ ...... 2

BUSHING, PIPE 1.25X1.00................................ ................... 1

ADAPTER, STRAIGHT, PI ................................ .................... 1

HOSE, NONMATALLIC MAKE FROM HOSE

P/N U216-6 (30327),30 INCHES................................ ..............

1

GUARD, HOSE MAKE FROM PLASTIC COIL

P/N 1722-95 (09505),12 INCHES................................ ............

1

ADAPTER, STRAIGHT, TU................................ ................... 1

CLAMP, HOSE .,................................ ................................ ... 2

HOSE MAKE FROM HOSE P/N 2556-12 1

(01276) 990 INCHES................................ ...............................

ADAPTER, STRAIGHT, PI ................................ .................... 1

TEE, PIPE 3/4 ................................ ................................ ....... 1

REDUCER, PIPE 1X3/4 ................................ ........................ 1

FILTER ELEMENT, FLUI ................................ ...................... 1

FILTER ELEMENT, FLUI,, ................................ .................... 1

BUSHING, PIPE 1X3/4................................ .......................... 1

ELBOW, PIPE 1X3/4................................ ............................. 1

END OF FIGURE

53-1

SECTION II TM 5-3825-230-14&P

Figure 54. Tachometer and Tachometer Drive

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PAOZZ 2X179

2 PFOZZ 96906

3 PFOZZ 24617

4 PAOZZ 2X179

5 PAOZZ 2X179

6 PFOZZ 96906

7 PFOZZ 2X179

(4)

PART

NUMBER

2529.007

MS35335-33

11505913

9282.003

7475018

MS15003-1

9730.004

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 47 GAGES (NON-ELECTRICAL)

WEIGHING AND MEASURING

DEVICES

QTY

GROUP 4701 INSTRUMENTS (SPEED AND

DISTANCE)

FIG. 54. TACHOMETER AND TACHOMETER

DRIVE

TACHOMETER, MECHANIC................................ ................. 1

WASHER, LOCK 1/4................................ ............................ 2

NUT, PLAIN, HEXAGON M5X0,8................................ ......... 2

CONTROL ASSEMBLY, PU................................ .................. 1

.GEAR ASSEMBLY, SPEED ................................ ................. 1

.FITTING, LUBRICATION ................................ ..................... 1

SCREW, CAP, SOCKET HE ................................ ................. 1

END OF FIGURE

54-1

SECTION II TM 5-3825-230-14&P

Figure 55. Dirt Deflector Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

PFOZZ 96906

PFOZZ 96906

PFOZZ 96906

4 PFOZZ 96906

5 PFOZZ 66234

6 PAOZZ 66234

7 PAOZZ 66234

(4)

PART

NUMBER

MS90725-34

MS27183-11

MS51967-5

MS35338-45

401-94242

401-94292

101-75791

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 71 SWEEPING EQUIPMENT

COMPONENTS

GROUP 7111 CUTTER AND/OR BOOM

ASSEMBLY

FIG. 55. DIRT DEFLECTOR ASSEMBLY

QTY

BOLT, MACHINE 5/16-18UNCX1 GR5................................ .10

WASHER, FLAT 5/16................................ ...........................10

NUT, PLAIN, HEXAGON 5/16-18UNC................................ .10

WASHER, LOCK 5/16................................ .........................10

BRACKET, MOUNTING ................................ ........................ 3

STRAP, RETAINING ................................ ............................. 1

GUARD, SPLASH, VEHICU ................................ .................. 1

END OF FIGURE

55-1

SECTION II TM 5-3825-230-14&P

Figure 56. Brush Frame Assembly

1 PFOZZ 96906

* 2 PFOZZ 80204

3 PFOZZ 96906

4 PAOZZ 66234

5 PFOZZ 96906

6 PFOZZ 96906

7 PFOZZ 96906

8 PFOZZ 66236

9 PFOZZ 66234

* 10 PFOZZ 80204

11 PFOZZ 96906

12 PFOZZ 66234

13 PFOZZ 96906

14 PFOZZ 96906

15 PFOZZ 96906

16 PFOZZ 96906

17 PFOZZ 96906

18 PAOZZ 66234

19 PFOZZ 96906

20 PFOZZ 66234

21 PFOZZ 56988

22 PFOZZ 66234

23 PFOZZ 66234

24 PFOZZ 96906

25 PAOZZ 66234

26 PFOZZ 96906

27 PFOZZ 96906

28 PFOZZ 96906

29 PFOZZ 66234

30 PFOZZ 66234

30 PFOZZ 66234

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 7111 CUTTER AND/OR BOOM

ASSEMBLY

FIG. 56. BRUSH FRAME ASSEMBLY

QTY

MS27183-9 WASHER, FLAT 1/4................................ ................................ 16

B1821BH025C125N SCREW, CAP, HEXAGON H 1/4-20UNCX3/4 GR8................... 4

MS90725-6 SCREW, CAP, HEXAGON H 1/4-20UNCX1 GR5...................... 6

410-92663

MS51922-33

MS27183-18

COVER, ACCESS................................ ................................ ...... 1

NUT, SELF-LOCKING, HE 1/2-13UNC................................ ...... 8

WASHER, FLAT 1/2................................ ................................ .. 8

MS35751-130

401-94280

BOLT, SQUARE NECK 1/2-13UNCX2.75 GR5.......................... 4

BRACKET, ANGLE ................................ ................................ .... 1

401-94240 GUARD, MECHANICAL ................................ ............................. 1

B1821BH050C150N SCREW, CAP, HEXAGON H 1/2-13UNCX1.5 GR8................. 12

MS35751-183

401-94233

MS51922-57

BOLT, SQUARE NECK 3/4-10UNCX2.5 GR5........................... 2

WASHER, FLAT................................ ................................ ......... 2

NUT, SELF-LOCKING, HE 3/4-O1UNC................................ ..... 2

MS27183-23

MS51922-17

MS27183-13

MS90725-64

410-92657

MS15002-1

372-92034

D97

410-92655

383-92046

MS24665-357

410-92664

MS51922-1

MS35338-48

MS51967-14

401-94118

401-94230

401-94231

WASHER,FLAT 3/4................................ ................................ ... 2

NUT, SELF-LOCKING, HE 3/8-16UNC................................ ...... 2

WASHER, FLAT 3/8................................ ................................ .. 4

SCREW, CAP, HEXAGON H 3/8-16UNCX1.5 GR5................... 2

BRACKET, ANGLE ................................ ................................ .... 1

FITTING, LUBRICATION . ................................ ........................ 5

WASHER, CONVEX ................................ ................................ .. 2

SPRING, HELICOPTER ................................ ............................. 2

ROD END, THREADED ................................ ............................. 2

PIN, STRAIGHT, HEADLE ................................ ......................... 1

PIN, COTTER 1/8X15 ................................ ............................... 2

FRAME SECTION, STRUC ................................ ........................ 1

NUT, SELF-LOCKING, HE 1/4-20UNC................................ .... 10

WASHER, LOCK 1/2................................ ................................ . 2

NUT, PLAIN, HEXAGON 1/2-13UNC................................ ......... 2

PLATE, MOUNTING ................................ ................................ .. 2

DEFLECTOR, DIRT AND LEFT HAND................................ ....... 1

DEFLECTOR, DIRT AND RIGHT HAND ................................ .... 1

END OF FIGURE

56-1

SECTION II TM 5-3825-230-14&P

Figure 57. Hydraulic Core and Brush Kit Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

* 1

2

6

7

PFOZZ 80204

PFOZZ 96906

3 PAOZZ 66234

4 PAOOO 66234

5 PFOZZ 66234

PFOZZ 21335

PFOZZ 96906

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 7111 CUTTER AND/OR BOOM

ASSEMBLY

QTY

FIG. 57. HYDRAULIC CORE AND BRUSH KIT

ASSEMBLY

B18218H031C075N BOLT, MACHINE 5/16-18UNCX3/4 GR8............................... 8

MS35338-45 WASHER, LOCK 5/16................................ ........................... 8

907-46665

410-92662

401-94232

VAS 1 7/16

MS15003-1

BRUSH, FIBER, ROTARY................................ ..................... 1

CORE, HYDRAULIC, SWEE ................................ ................. 1

SHIM ................................ ................................ ..................... 2

BEARING UNIT, BALL ................................ .......................... 2

.FITTING, LUBRICATION ................................ ..................... 1

END OF FIGURE

57-1

SECTION II TM 5-3825-230-14&P

Figure 58. Hydraulic Cylinder Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3

12

PFOZZ 66234

PFOZZ 93334

PAOFF 67029

4 PAFZZ 67029

5 KFFZZ 67089

6 KFFZZ 67029

7 KFFZZ 67029

* 8 PAFZZ 67089

9 KFFZZ 67029

10 PAFZZ 67029

11 PFOZZ 66234

PFOZZ 96906

(4)

PART

NUMBER

383-92045

444654

72276

DHA1-216

RST-150

2-221

DH5-116

DH3-145

DH14-65

DH2-218

383-92044

MS24665-360

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 7113 LIFTING AND TILTING

DEVICES

FIG. 58. HYDRAULIC CYLINDER ASSEMBLY

QTY

PIN, STRAIGHT, HEADLE ................................ .................... 1

PLUG, PIPE ................................ ................................ .......... 1

CYLINDER ASSEMBLY, A................................ .................... 1

.CYLINDER, ACTUATING ................................ ..................... 1

.RING, RETAINING PART OF KIT P/N DH24-82 .................. 1

.PACKING, PREFORMED PART OF KIT P/N DH24-82 ........ 1

.SEAL, PISTON ROD PART OF KIT P/N DH24-82 ............... 1

.PACKING, PREFORMED................................ ..................... 1

.SEAL, DIRT PART OF KIT P/N DH24-82 ............................. 1

.PISTON, LINEAR ACTUA ................................ .................... 1

PIN, STRAIGHT, HEADLE ................................ .................... 1

PINT, COTTER 1/8X2 ................................ .......................... 4

END OF FIGURE

58-1

SECTION II TM 5-3825-230-14&P

Figure 59. Spray Pump Assembly

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

* 1 PAOZZ 80204

* 2 PAOZZ 80204

3 PFOZZ 66234

4 PAOZZ 66234

5 PAOFF 0FDH7

6 PFFZZ 0FDH7

7 PFFZZ 0FDH7

8 PAFZZ 0FDH7

9 PFFZZ 0FDH7

10 PAFFF 0FDH7

11 PFFZZ 0FDH7

12 PFFZZ 0FDH7

13 PFFZZ 0FDH7

14 PFFZZ 0FDH7

15 PFFZZ 0FDH7

16 PFFZZ 0FDH7

17 PFFZZ 0FDH7

18 PFFZZ 0FDH7

19 PAFZZ 0FDH7

20 PFFZZ 0FDH7

21 PFOZZ 96906

22 PFOZZ 96906

23 PFOZZ 96906

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 7114 SPRAY SYSTEM

FIG. 59. SPRAY PUMP ASSEMBLY

QTY

B18218H025C100N SCREW, CAP, HEXAGON H 1/4-20UNCX1 GR8.................. 4

B1821BH050C150N SCREW, CAP, HEXAGON H 1/2-13UNCX15 GR8................ 2

402-92239

401-94254

SPACER, PLATE ................................ ................................ .. 1

BRACKET, MOUNTING ................................ ........................ 1

2100-332

20131-002

20132-000

PUMP, RECIPROCATING ................................ .................... 1

.SCREW, CAP, HEXAGON. ................................ ................. 2

.GROMMET, NONMETALLIC ................................ ............... 4

20050-132

21131-000

21195-003

21041-001

20028-008

02095-100

20131-001

.HOUSING, LIQUID PUMP................................ .................... 1

..SCREW, CAP, HEXAGON................................ .................. 4

..PARTS KIT, RECIPROCA................................ ................... 1

...PARTS KIT, RECIPROCA................................ .................. 2

..VALVE, CHECK ................................ ................................ .. 1

..SWITCH, PRESSURE ................................ ........................ 1

..SCREW, CAP, SOCKET HE ................................ ............... 1

20500-507

20428-000

21033-002

91008-000

02019-001

11028-101

MS51922-1

MS51922-33

MS27183-10

..HOUSING, LIQUID PUMP................................ ................... 1

..CONNECTOR, FLUID, PUM ................................ ............... 1

..CAM, CONTROL ................................ ................................ . 1

..SET SCREW................................ ................................ ....... 1

.MOTOR, DIRECT CURREN ................................ ................. 1

.BASE, MOTOR ................................ ................................ .... 1

NUT, SELF-LOCKING, HE 1/4-20UNC................................ .. 4

NUT, SELF-LOCKING, HE 1/2-13UNC................................ .. 2

WASHER,FLAT 1/4................................ ............................... 4

END OF FIGURE

59-1

SECTION II TM 5-3825-230-14&P

Figure 60. Spray System Installation

1 PFOZZ 72423

2 PAOZZ 66234

3 PAOZZ 96906

4 PAOZZ 96906

5 PFOZZ 72423

6 PFOZZ 61424

7 PAOZZ 96906

8 MOOZZ 66234

9 PFOZZ 66234

10 PAOZZ 73124

11 PFOZZ 73124

* 12 XBOZZ 7R531

13 PFOZZ 72423

14 PAOZZ 96906

15 PFOZZ 96906

16 PFOZZ 66234

17 PFOZZ 66234

18 PAOZZ 05779

19 MOOZZ 66234

20 PFOZZ 96906

21 PFOZZ 72423

22 PAOZZ 39428

23 PFOZZ 72423

24 PFOZZ 8K002

25 PFOZZ 72423

26 PAOZZ 96906

27 PFOZZ 72423

* 28 PAOZZ 80204

29 MOOZZ 66234

30 PAOZZ 66234

31 MOOZZ 66234

32 PFOZZ 73124

* 33 XBOZZ 7R531

34 PFOZZ 73124

35 PAOZZ 66234

* 36 MOOZZ 66234

37 PAOZZ 66234

* 38 PAOZZ 7J925

39 PAOZZ 82247

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PCO2

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 7114 SPRAY SYSTEM

FIG. 60. SPRAY SYSTEM INSTALLATION

QTY

1145-150

401-94241

MS51967-2

MS35338-44

1101-150

P8MCB-12

MS35842-11

204-85299

401-94253

BF10125SXT

BF0150PP

RT56125

2171-249

CAP, PIPE 3/4................................ ................................ ...... 1

PIPE, METALLIC 3/4................................ ............................ 1

NUT, PLAIN, HEXAGON 1/4-20UNC................................ .... 6

WASHER, LOCK 1/4................................ ............................. 6

ELBOW, PIPE 3/4................................ ................................ . 1

ADAPTER, STRAIGHT, PI 1/2HOSE X 3/4 PIPE ................. 1

CLAMP, HOSE................................ ................................ ...... 4

HOSE MAKE FROM HOSE P/N 3708

(82271),99INCHES................................ ................................ ..

1

STRAP, WEBBING,.,,,, ................................ ......................... 2

ADAPTER BUSHING 1 1/4 ................................ .................. 1

GASKET 1-1/4 ................................ ................................ ..... 1

SPACER, RING 1 1/4................................ ............................ 1

BUSHING, PIPE 1-1/4X1................................ ....................... 1

MS51922-33

MS27183-18

401-94252

401-94251

P8MCB-6

204-85227

NUT, SELF-LOCKING, HE 1/2-13UNC................................ . 8

WASHER,FLAT 1/2................................ .............................12

BRACKET, MOUNTING ................................ ....................... 4

BOLT, HOOK ................................ ................................ ........ 4

ADAPTER, STRAIGHT, PI 1/2HOSE X 3/8 PIPE ................. 2

HOSE MAKE FROM HOSE P/N 1

B708(82271), 27 INCHES................................ ........................

NIPPLE, PIPE ¼ CLOSE ................................ ...................... 1 MS51953-29

2071-098

4887K33

2071-099

2P130

1101-148

MS51953-97

2173-200

BUSHING, PIPE 1/2X1/4................................ ....................... 1

VALVE, BALL 1/2................................ ................................ . 1

BUSHING, PIPE 1/2X3/8................................ ...................... 1

STRAINER, SEDIMENT ................................ ........................ 1

ELBOWIPIPE3/4X3/8 90 DEG ................................ .............. 1

NIPPLE,PIPE3/4 CLOSE................................ ....................... 1

PLUG, PIPE 1.00 ................................ ................................ . 1

B1821BH050C450N SCREW, CAP, HEXAGON H1/2-13UNCX4.5 GR8................ 4

488-49720 TRIM, EDGE, BLACK MAKE FROM MOLDING 1

P/N 75000317(82654),76 INCHES................................ ...........

410-92661

488-72394

BF10075SXT

BRACKET, MOUNTING ................................ ........................ 1

TAPE, FOAM MAKE FROM TAPE P/N N-200 1

(57364),94 INCHES,................................ ...............................

BUSHING, SLEEVE 3/4 ................................ ........................ 1

RT5675

BF0075PP

221-92018

221-92023

221-92022

370-74138-05

H1/4VVL-8002

RING, RETAINING 3/4 ................................ .......................... 1

GASKET 3/4................................ ................................ ......... 1

TANK, LIQUID STORAGE,, ................................ .................. 1

STRING MAKE FROM ROPE P/N 3-16WHITE

(84093), 18 INCHES................................ ...............................

1

CAP, FILLER OPENING ................................ ....................... 1

BOLT, U ................................ ................................ ................ 3

NOZZLE, SPRAY, FLUID 1/4 ................................ ................ 8

END OF FIGURE

60-1

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1 PEFZZ 2X179

(4)

PART

NUMBER

7535.1460.009

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 26 TOOLS AND TEST EQUIPMENT

GROUP 2604 SPECIAL TOOLS

QTY

FIG. 61. ENGINE SPECIAL TOOLS

SPRING COMPRESSOR ................................ ........................

BOI:1 PER BN HQ WHEN BN HAS SVC CO

END OF FIGURE

61-1

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

PAFZZ 67089

PAOZZ 63050

PAFZZ 63050

PAFZZ 63050

PAOZZ 2X179

PAFZZ 2X179

(4)

PART

NUMBER

DH24-82

PE012001

PE444002

PE444003

3600.8888.529

395.8180.062

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 94 REPAIR KITS

QTY

GROUP 9401 REPAIR KITS

PARTS KIT, LINEAR AC ................................ ....................... 1

PACKING PREFORMED ( 1) 58-6

RING, RETAINING

SEAL, DIRT

( 1)

( 1)

58-5

58-9

SEAL, PISTON ROD ( 1) 58-7

SPACER, PLATE ................................ ................................ .. 1

BALL 3/16 DIAMETER ( 4) 50-16

PLATE, PRESSURE ( 1) 50-17

SEAL ASSEMBLY, SHAFT ................................ ................... 1

RING, BACKUP ( 1)

RING, BACKUP, TEFLON ( 1)

50-25

50-21

RING, RETAINING

SEAL

SEAL, DUST

( 1)

( 3)

( 1)

50-24

50-7

50-23

SEAL, SHAFT

SEAL, SQUARE CUT

SEAL, SQUARE CUT

SPACER

( 1)

( 1)

( 1)

( 1)

50-26

50-27

50-15

50-20

PARTS KIT, SEAL REPL ................................ ...................... 1

CARRIER, SEAL ( 1) 50-22

WASHER, THRUST ( 1) 50-19

CONNECTOR, FLUID, PUM ................................ ................. 1

COUPLING, SHAFT, FLEX ( 1)

COUPLING, HALF, SHAFT ( 1)

HOUSING, MECHANICAL ( 1)

16-5

16-1

16-6

INSERT, FLEXIBLE COU ( 1) 16-4

GASKET SET................................ ................................ ........ 1

GASKET

GASKET

( 2)

( 1)

8-14

5-5

GASKET

GASKET

GASKET

GASKET

GASKET

GASKET

GASKET

GASKET

GASKET

GASKET

( 1)

( 2)

( 2)

GASKET, CSHAFT SPRT ( 1)

GASKET, CRANKCASE ( 1)

GASKET, HEAD(0,50)

GASKET, HEAD(0,55)

( 2)

( 2)

( 1)

( 1)

( 1)

( 1)

( 1)

( 1)

( 1)

GASKET, HEAD(0,60)

GASKET, HEAD(0,65)

GASKET, HEAD(0,70)

GASKET, HEAD(0,75)

GASKET, HEAD(0,80)

( 2)

( 2)

( 2)

( 2)

( 2)

12-4

19-7

19-7

19-7

2-23

14-1

20-1

25-37

28-6

15-2

5-5

2-2

2-3

2-3

2-3

2-3

2-3

2-3

2-3

KITS-1

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

PAFZZ 11341

PAFZZ 2X179

PAFZZ 53867

(4)

PART

NUMBER

4P0017-001

435.8150.017

1 007 010 040

(5)

TM 5-3825-230-14&P

(6)

DESCRIPTION AND USABLE ON CODES (UOC) QTY

GASKET HEAD (0,85) ( 2) 2-3

GASKET, HEAD (0,90)

GASKET, HEAD (0,95)

( 2)

( 2)

2-3

2-3

PARTS KIT, SEAL REPL ................................ ...................... 1

SEAL, LOADING

SEAL, SHAFT

( 2)

( 1)

49-4

49-14

SEAL, STATIC ( 2) 49-5

PARTS KIT, LINEAR AC ................................ ....................... 1

CAP, PROTECTIVE, DUST ( 2)

GASKET ( 2)

GASKET, GUARD TUBE ( 2)

9-11

2-9

2-5

SEAL, PLAIN ( 1) 4-9

SHIM SET ................................ ................................ ............. 1

BUSHING, SLEEVE

CLIP, RETAINING

( 1)

( 1)

31-39

31-25

PACKING, PREFORMED ( 1)

PIVOT, FORK ( 1)

SEAL, PLAIN ( 1)

SPACER, RING

WASHER, FLAT

( 1)

( 1)

31-26

31-42

31-12

B1-40

31-24

END OF FIGURE

KITS-2

SECTION II

(1) (2) (3)

ITEM SMR

NO CODE CAGEC

1

2

3 PAOZZ 81519

4 PAOZZ 30327

5

6

7

V

PAOZZ 12128

PAOZZ 23823

PAOZZ 01276

PAOZZ 30327

PAOZZ 81343

8 PAOZZ 82271

9 PAOZZ 79470

10

* 13

18

PAOZZ 82654

* 11 XBOZZ 84093

12 PAOZZ 39428

XDOZZ 57364

14 PAOZZ 09505

* 15 PAOZZ 16764

* 16 PAOZZ 16428

* 17 PAOZZ 79550

PAFZZ 96906

(4)

PART

NUMBER

(5)

TM 5-3825-230-14&PC02

(6)

DESCRIPTION AND USABLE ON CODES (UOC)

GROUP 95 GENERAL USE STANDARDIZED

PARTS

QTY

GROUP 9501 HARDWARE SUPPLIES AND

BULK MATERIAL, COMMON

671442

A52AE12

CWC2INDIA

J412

2556-12

CHAIN, WELDLESS................................ .............................. V

CONDUIT, NONMETALLIC ................................ ................... V

HOSE, AIR DUCT ................................ ................................ . V

HOSE, NONMETALLIC ................................ ......................... V

HOSE-NONMETALLIC................................ .......................... V

U216-6 HOSE, NONMETALLIC ................................ ......................... V

SAE100R1 TYAT SZ................................ ............................ HOSE, NONMETALLIC

4

B708

H05704

75000317

HOSE, NONMETALLIC ................................ ......................... V

HOSE, NONMETALLIC., ................................ ....................... V

MOLDING, QUICKEDGE ................................ ...................... V

3-16WHITE

3559T47

ROPE, FIBROUS ................................ ................................ .. V

SHACKLE ................................ ................................ ............. V

N-200AWHITE188X TAPE, PRESSURE SENSI.,................................ .................. V

4X400

1722-95

950B

736102

572D0

MS20995C20

TUBING, PLASTIC, SPIR................................ ...................... V

WIRE, ELECTRICAL................................ ............................. V

WIRE, ELECTRICAL................................ ............................. V

WIRE ELECTRICAL,, ,................................ .......................... V

WIRE, NONELECTRICAL, ................................ .................... V

END OF FIGURE

BULK-1

SECTION II

Figure 61. Engine Special Tools

TM 5-3825-230-14&P

SECTION IV

STOCK NUMBER

5305-00-044-4153

5310-00-045-3296

5310-00-045-3299

4730-00-050-4208

5305-00-050-9231

4720-00-054-6358

5340-00-057-2906

4730-00-058-3353

5310-00-067-6356

5305-00-068-0500

5305-00-068-0502

5305-00-068-0509

5305-00-068-0510

5305-00-068-0511

5305-00-071-2069

5305-00-071-2081

5310-00-081-4219

5310-00-087-4652

5310-00-087-7493

5310-00-088-1251

5310-00-088-6897

5940-00-114-1305

5310-00-119-2090

5305-00-121-2420

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

37

47

56

59

42

43

46

39

43

51

51

56

1

21

34

51

56

30

34

41

1

21

34

45

50

56

59

60

34

23

35

35

56

33

32

47

56

56

21

35

54

57

34

BULK

33

52

49

1

34

36

2

11

26

21

13

14

12

9

10

6

1

15

13

32

16

6

9

14

26

10

15

8

10

7

28

10

2

28

18

23

7

3

13

19

7

3

3

2

5

16

6

7

20

4

13

14

17

11

21

3

5940-00-143-4774

5940-00-143-4775

5940-00-143-4777

5940-00-143-4780

5940-00-143-4794

5940-00-143-5284

5975-00-152-1075

4730-00-172-0010

5340-00-186-5085

4730-00-196-1468

4730-00-196-1502

4730-00-196-1539

5310-00-209-0786

5310-00-209-0965

9505-00-221-2650

4730-00-223-9255

5305-00-225-3843

5310-00-225-6993

5306-00-225-84699

5306-00-226-4825

5940-00-230-0515

5315-00-234-1664

4730-00-239-2803

4030-00-243-4439

5340-00-253-1910

5305-00-269-3218

I-1

TM 5 3825-230-14&PC02

ITEM

14

13

12

8

11

23

5

9

14

3

13

27

1

1

18

1

11

1

12

5

22

14

2

5

18

18

9

17

26

20

10

2

4

15

2

12

23

19

2

14

6

5

8

10

13

17

3

2

2

18

FIG.

42

43

45

46

46

53

46

43

1

45

30

34

41

55

45

57

39

59

30

35

50

56

59

60

29

BULK

53

33

60

60

53

54

39

39

39

39

34

56

45

34

35

38

38

38

39

39

39

38

34

32

SECTION IV

STOCK NUMBER

5310-00-269-4040

4730-00-277-9997

4730-00-278-2523

4030-00-282-4885

5975-00-295-9696

5315-00-298-1481

5315-00-298-1499

5930-00-359-5500

5310-00-407-9566

4730-00-414-5962

5940-00-432-2660

5940-00-434-6062

4720-00-460-3915

6145-00-468-1261

6145-00-471-0428

2590-00-473-6331

4730-00-476-5865

4730-00-476-7135

4010-00-494-2326

4720-00-541-8859

4030-00-542-3184

5315-00-550-7397

5360-00-553-2039

2640-00-555-2841

5940-00-557-4338

5310-00-559-0070

3040-00-570-6161

5310-00-582-5965

5310-00-584-5272

5310-00-596-7693

3110-00-606-1839

3110-00-606-1840

3110-00-606-1841

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

60

49

56

31

42

46

42

46

42

46

48

58

27

32

33

34

47

46

40

40

42

43

34

39

BULK

BULK

BULK

45

33

33

46

BULK

41

45

55

57

58

39

39

45

34

56

58

32

29

30

1

45

52

53

4

16

27

22

4

8

8

18

3

17

19

4

6

2

8

3

3

3

8

12

11

11

5

7

4

5

7

9

7

17

15

4

2

17

4

2

2

14

8

6

30

24

12

11

16

2

8

10

8

13

3110-00-606-1842

5310-00-627-6128

5310-00-637-9541

4030-00-684-6346

5306-00-702-4483

4730-00-702-5694

5305-00-724-5914

5305-00-724-7247

4720-00-730-0116

5310-00-732-0558

2940-00-755-6584

5310-00-761-6882

5310-00-762-6223

3110-00-763-0259

5310-00-768-0318

3110-00-769-1426

5305-00-782-9489

5365-00-803-7301

5340-00-809-1490

5340-00-809-1494

5310-00-809-3078

5310-00-809-4058

5310-00-809-4061

5310-00-809-5997

5310-00-809-5993

5310-00-809-8533

5310-00-809-8544

5310-00-809-8546

5315-00-816-1794

5310-00-823-8804

5315-00-842-3044

4730-00-871-6729

5310-00-877-5795

I-2

TM 5 3825-230-14&PC02

ITEM

15

13

14

6

14

4

1

11

4

10

25

4

15

29

6

15

15

2

5

16

23

19

3

5

31

11

18

1

28

4

5

3

21

25

3

5

17

3

3

20

6

2

7

8

8

6

7

21

8

4

FIG.

43

46

56

30

33

51

56

41

22

30

51

35

49

50

56

60

42

55

32

33

37

47

59

29

BULK

23

35

53

32

33

60

51

40

33

33

40

43

56

43

35

46

46

56

49

45

1

42

46

34

23

SECTION IV

STOCK NUMBER

5310-00-877-5795

5310-00-880-7744

5310-00-905-5159

4730-00-908-3194

3110-00-926-1379

5310-00-934-9751

5310-00-934-9758

5310-00-934-9762

4730-00-938-7849

5306-00-952-0964

5320-00-957-2493

5961-00-957-6865

4730-00-965-6538

5305-00-983-6659

5310-00-983-8483

5310-00-984-3806

5305-00-984-4983

5305-00-984-6193

5305-00-984-6210

5305-00-984-6214

5975-00-984-6582

5305-00-988-1724

5305-00-989-7434

5305-00-989-7435

5305-00-993-1848

4730-01-007-7158

4730-01-011-7736

3020-01-045-2627

4730-01-049-3251

5330-01-055-3870

5306-01-055-6876

2530-01-061-1351

2530-01-069-4213

5340-01-069-5306

2530-01-069-9174

5365-01-070-2350

3130-01-070-5629

5306-01-071-1309

4730-01-075-1920

4130-01-075-5547

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

43

32

40

53

40

40

40

40

52

26

34

52

52

52

30

52

43

36

1

33

34

25

26

30

32

35

48

33

51

31

34

41

1

32

33

56

47

38

53

53

53

60

43

43

34

36

46

41

55

32

5

12

10

4

6

4

3

7

16

1

11

9

1

7

11

12

2

18

2

4

5

1

9

4

25

15

7

15

23

30

25

7

12

20

11

11

2

11

1

2

19

7

7

8

16

2

14

3

3

19

5905-01-082-0849

4310-01-094-0791

5995-01-096-0733

4730-01-096-9138

4730-01-099-7329

4730-01-102-6544

5310-01-113-5659

5975-01-123-8811

4720-01-125-4474

5940-01-134-1722

6110-01-134-9981

5340-01-135-1030

5940-01-135-2403

5315-01-136-8328

5310-01-141-8704

5975-01-145-7210

4030-01-146-6160

5340-01-153-9240

5310-01-154-0712

5310-01-154-0713

5365-01-154-8557

4820-01-155-0302

5920-01-156-6878

5305-01-158-0826

5305-01-159-0065

3110-01-160-2471

3040-01-170-9751

2510-01-176-1177

4730-01-178-9654

6220-01-183-4557

1450-01-204-7742

5975-01-207-0229

6140-01-210-1964

3040-01-211-2255

5330-01-217-8918

5340-01-220-6352

5925-01-222-0059

5925-01-222-3650

6145-01-229-3621

5330-01-236-0495

5330-01-247-2403

5330-01-247-2409

5310-01-247-2425

5310-01-247-2452

2530-01-250-1624

5975-01-256-0876

3120-01-265-2462

I-3

TM 5 3825-230-14&PC02

ITEM

16

1

8

8

10

11

10

9

24

9

28

6

5

9

19

15

17

22

7

10

12

11

14

7

10

23

13

17

19

17

20

14

22

12

12

7

8

4

9

29

2

6

6

9

22

8

13

7

13

18

FIG.

BULK

20

8

12

25

29

26

40

34

50

51

51

BULK

53

35

35

35

34

37

51

51

45

34

34

30

21

38

30

34

33

BULK

51

32

19

24

51

51

51

45

60

22

34

BULK

BULK

32

35

34

53

35

52

SECTION IV

STOCK NUMBER

5360-01-268-2610

4720-01-272-4672

5305-01-274-1264

4720-01-288-3893

5306-01-289-9197

5330-01-290-2621

5905-01-291-4426

4730-01-292-4698

6625-01-297-2005

6220-01-301-5411

2920-01-302-6304

3010-01-302-6310

5310-01-303-2728

5365-01-303-2965

5945-01-303-3353

6680-01-309-6450

4320-01-317-8940

2530-01-322-0673

5330-01-323-1574

5330-01-323-2757

5330-01-323-2758

3120-01-323-2785

5330-01-323-2834

3130-01-323-2885

3130-01-323-2886

3130-01-323-2887

3130-01-323-2888

2805-01-323-4357

4730-01-323-5042

4810-01-323-5044

4730-01-323-5079

4730-01-323-5080

4730-01-323-5107

4320-01-323-5114

4320-01-323-5123

4320-01-323-5149

4320-01-323-5157

5330-01-323-5455

5305-01-323-5473

5305-01-323-5474

5305-01-323-5477

3120-01-323-5480

3120-01-323-5481

3130-01-323-5516

3130-01-323-5517

5306-01-323-5539

3040-01-323-5936

2520-01-323-5940

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

59

59

59

5

5

7

5

60

5

56

60

60

59

49

49

49

11

13

25

3

60

5

5

5

20

40

KITS

29

5

5

4

7

35

31

31

31

KITS

31

53

42

46

BULK

24

BULK

29

30

36

32

52

32

6

9

18

1

1

5

4

25

1

11

11

2

3

2

17

2

30

9

21

8

5

6

4

4

4

7

1

1

5

3

2

5

6

6

15

3

5

14

3

15

12

21

41

10

1

15

8

1

2520-01-323-5941

2815-01-323-5942

3040-01-323-5943

2930-01-323-5959

2510-01-323-5966

2815-01-323-5968

2815-01-323-5992

2815-01-323-5993

3040-01-323-5994

2815-01-323-5995

3020-01-323-5998

3020-01-323-6006

4320-01-323-6028

2990-01-323-6030

2815-01-323-6038

2815-01-323-6039

2815-01-323-6043

2815-01-323-6044

2540-01-323-6045

2530-01-323-6048

2540-01-323-6051

2910-01-323-7057

4730-01-323-7313

2510-01-323-7322

4320-01-323-7364

4320-01-323-7481

2815-01-323-7633

4710-01-323-8541

4710-01-323-8545

4710-01-323-8546

4730-01-323-8614

2510-01-323-8677

5306-01-323-8814

5315-31-323-8823

5315-31-323-8821

5315-01-323-8822

5315-01-323-8824

5360-01-323-8830

5360-01-323-8831

5360-01-323-8844

5305-01-323-8924

5305-01-323-8925

5305-01-323-8926

5305-01-323-8927

I-4

TM 5 3825-230-14&PC02

ITEM

30

8

24

12

25

7

6

19

17

3

17

11

2

7

1

9

38

12

3

1

13

26

7

1

39

1

7

16

1

2

12

3

8

10

12

12

7

11

1

9

7

1

7

3

9

6

13

16

4

FIG.

25

49

5

8

8

8

9

8

8

29

22

5

8

8

9

8

8

59

1

60

22

9

19

1

19

60

29

49

46

42

43

55

13

50

28

7

9

10

9

56

29

KITS

29

29

29

5

3

4

9

56

SECTION IV

2805-01-324-1211

2510-01-324-1216

2510-01-324-1217

2510-01-324-1218

3040-01-324-1228

3040-01-324-1275

3040-01-324-1276

2910-01-324-1304

2815-01-324-1332

5315-01-324-1748

5315-01-324-1750

2815-01-324-2149

5365-01-324-2562

3825-01-324-2743

5365-01-324-3425

5315-01-324-3993

5340-01-324-4260

5340-01-324-4262

5340-01-324-4496

5365-01-324-4872

5365-01-324-4919

5306-01-324-4962

4820-01-324-5045

4730-01-324-5074

STOCK NUMBER

5305-01-323-8928

5305-01-323-8929

5305-01-323-8930

5305-01-323-8931

5305-01-323-8932

2990-01-323-9508

5315-01-324-0422

5315-01-324-0423

2815-01-324-0765

5340-01-324-0904

5307-01-324-0945

5305-01-324-0949

5305-01-324-0950

5305-01-324-0951

5340-01-324-0961

5340-01-324-0962

5340-01-324-0963

2815-01-324-1147

2815-01-324-1151

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

19

13

56

60

50

25

9

60

59

53

45

58

KITS

7

57

7

7

45

56

59

49

49

23

7

29

45

7

7

8

18

7

7

8

28

5

29

13

17

8

25

25

49

8

8

9

8

29

31

12

25

12

1

2

2

4

2

3

2

18

5

15

2

4

3

16

15

25

17

9

10

1

1

16

1

33

23

6

9

22

15

5

5

2

10

35

16

1

18

6

38

12

18

11

8

18

3

4

3

3

2815-01-324-5084

4320-01-324-5113

2815-01-324-5147

2815-01-324-5148

2815-01-324-5149

2940-01-324-5153

2530-01-324-5178

2315-01-324-5192

4730-01-324-6492

4710-01-324-6528

4710-01-324-6529

4710-01-324-6530

4730-01-324-6572

4730-01-324-6595

5340-01-324-6754

5315-01-324-6779

5340-01-324-6783

5340-01-324-6784

5340-01-324-6794

5340-01-324-6798

5340-01-324-6799

2910-01-324-6897

2910-01-324-6898

2910-01-324-6899

2815-01-324-6906

5975-01-324-7837

4320-01-324-7898

5310-01-324-8237

5310-01-324-6238

5310-01-324-8239

5310-01-324-8240

5310-01-324-8242

5310-01-324-8243

5310-01-324-8245

5310-01-324-8246

5360-01-324-8264

5330-01-324-8286

3120-01-324-8319

3120-01-324-8320

5310-01-324-8325

5310-01-324-8326

I-5

TM 5 3825-230-14&PC02

ITEM

8

13

4

17

7

3

8

13

6

2

22

4

34

7

3

3

6

15

2

1

5

5

9

8

2

12

8

9

9

29

4

14

11

18

24

8

11

30

22

27

16

1

1

6

3

1

4

1

4

4

FIG.

2

18

7

24

2

8

8

21

36

3

25

28

25

3

15

16

19

59

9

18

25

5

20

13

26

26

10

34

60

56

59

21

21

60

60

56

45

60

56

6

12

40

7

60

1

13

7

49

10

2

SECTION IV

STOCK NUMBER

5310-01-324-8327

5310-01-324-8331

5310-01-324-8332

5310-01-324-8333

5310-01-324-8334

5310-01-324-8335

5310-01-324-8336

5310-01-324-8343

5305-01-324-8352

5305-01-324-8354

5305-01-324-8355

5305-01-324-8356

5305-01-324-8388

5305-01-324-8389

5340-01-324-8392

5330-01-324-8399

5307-01-324-8407

5340-01-324-8414

5340-01-324-8427

5360-01-324-8510

2920-01-324-8512

3040-01-324-8554

2815-01-324-8556

3130-01-324-8895

5930-01-324-8927

5930-01-324-8933

5930-01-324-8942

4710-01-325-0258

4730-01-325-0445

2990-01-325-0716

5305-01-325-2646

5340-01-325-2827

3020-01-325-3038

5330-01-325-5151

5315-01-325-5456

3110-01-325-5757

5315-01-325-5779

5315-01-325-5782

5315-01-325-5786

5365-01-325-5876

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

42

46

56

10

24

8

8

2

25

29

32

2

18

24

24

35

17

27

42

46

9

57

59

32

14

1

KITS

42

46

47

30

56

26

31

4

4

4

59

2

5

14

19

27

2

1

13

14

24

24

24

2

16

23

7

20

1

15

9

14

22

1

9

8

4

1

36

20

2

6

20

18

6

13

8

5

19

9

1

21

13

10

9

1

6

4

6

4

2

11

12

11

1

7

6

5

14

20

9

10

5340-01-325-5892

5340-01-325-5916

5305-01-325-5918

5340-01-325-5943

5340-01-325-5955

6680-01-325-6281

5310-01-325-7141

5365-01-325-7217

5365-01-325-7219

5365-01-325-7220

5305-01-325-8387

5340-01-326-0035

5315-01-326-0083

5310-01-326-1053

5365-01-326-1152

5340-01-326-1256

5340-01-326-2078

7690-01-326-5393

7690-01-326-5394

3110-01-326-5461

5306-01-326-5519

5340-01-326-5620

5305-01-326-5632

5365-01-326-5660

2815-01-326-5977

3020-01-326-6014

5340-01-326-8059

4730-01-326-8076

4810-01-326-9021

2815-01-326-9076

4710-01-326-9210

3120-01-326-9402

2815-01-327-0117

3040-01-327-0187

3040-01-327-0188

3020-01-327-0209

3825-01-327-0530

5330-01-327-2630

5330-01-327-2631

5310-01-327-3340

5365-01-327-3353

5365-01-327-3393

5310-01-327-3418

5310-01-327-3419

5307-01-327-3437

5307-01-327-3438

5307-01-327-3439

5340-01-327-3444

I-6

TM 5 3825-230-14&PC02

ITEM

10

11

5

10

12

8

9

5

6

12

13

11

11

12

3

7

7

3

22

5

7

14

12

5

9

10

15

11

11

10

6

9

17

19

9

12

5

20

1

28

8

4

1

13

10

13

9

23

20

7

FIG.

42

22

24

22

21

22

3

3

3

19

5

57

18

18

9

5

5

24

35

12

22

7

3

9

30

5

5

5

48

48

24

22

56

35

46

56

57

45

11

36

3

2

4

49

24

24

42

46

22

7

SECTION IV

STOCK NUMBER

5305-01-327-3448

5340-01-327-3492

5340-01-327-3590

5340-01-327-5561

5310-01-327-8913

6150-01-327-9402

5340-01-328-2257

7690-01-331-8267

7690-01-331-9013

7690-01-332-1839

5310-01-332-8236

7690-01-332-8948

5306-01-333-2649

2815-01-333-2944

2940-01-333-2952

5365-01-333-3765

5365-01-333-3823

5340-01-333-3856

5306-01-333-5094

5315-01-333-5119

5340-01-333-5127

5365-01-333-5128

5365-01-333-5129

5360-01-333-5157

5305-01-333-5260

5365-01-333-5286

5305-01-333-5380

5305-01-333-5381

5340-01-333-5385

5315-01-333-5735

4320-01-333-5914

2990-01-333-6069

2815-01-333-8251

2910-01-333-8271

5310-01-334-0415

5310-01-334-0416

6220-01-334-0613

3040-01-334-2288

3040-01-334-2289

3040-01-334-2290

5306-01-334-2758

5307-01-334-2759

5305-01-334-2761

5305-01-334-2762

5330-01-334-2770

5310-01-334-3502

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

25

25

25

14

25

2

2

9

14

22

59

25

2

19

25

25

35

2

25

29

1

26

1

58

2

14

2

25

9

25

22

2

22

48

4

14

14

14

25

6

24

55

48

48

48

12

6

59

56

4

7

15

11

19

15

8

16

10

6

19

10

4

10

6

1

8

6

14

5

10

5

13

3

11

16

7

12

39

4

17

14

11

2

5

13

3

3

2

3

2

14

3

5

9

1

4

2

20

4

2

5340-01-335-9944

5940-01-336-5780

6680-01-336-7050

2610-01-336-8828

5330-01-339-0180

3130-01-339-0849

5340-01-339-0873

6105-01-339-1220

3040-01-339-1580

5340-01-339-2129

2940-01-339-3846

4730-01-339-4496

4730-01-339-4524

2520-01-339-6520

4730-01-339-6733

5305-01-339-6960

9330-01-339-8081

4710-01-339-8103

4730-01-339-8108

2815-01-339-8323

4820-01-339-8402

2815-01-339-8409

2510-01-339-8413

4710-01-339-8435

4730-01-339-8515

4730-01-339-8517

2530-01-339-8589

3040-01-339-8603

2940-01-339-8611

5430-01-339-8677

3110-01-339-8793

3110-01-339-8794

5315-01-339-8804

5360-01-339-8825

5360-01-339-8826

5360-01-339-8827

5360-01-339-8828

3120-01-339-8891

5340-01-339-8910

5330-01-339-8916

5305-01-339-8924

5340-01-339-8929

5340-01-339-8940

5340-01-339-8956

5340-01-339-8960

5340-01-339-8961

5325-01-339-8989

5340-01-339-9000

5340-01-339-9006

5340-01-339-9007

I-7

TM 5 3825-230-14&PC02

ITEM

11

6

16

35

6

13

3

27

5

7

5

21

9

6

1

10

14

12

22

13

14

16

4

11

18

8

14

24

21

4

7

16

7

10

7

14

18

26

8

27

7

5

12

31

4

18

32

2

1

FIG.

51

15

37

51

47

47

59

26

34

32

51

51

51

12

41

37

51

51

41

21

60

50

51

51

52

53

50

53

50

BULK

22

46

53

53

52

60

12

12

15

KITS

50

50

50

50

50

53

2

34

13

44

SECTION IV

STOCK NUMBER

5340-01-339-9010

5340-01-339-9011

5340-01-339-9012

3030-01-340-0183

2805-01-340-0201

4820-01-340-0285

4730-01-340-0303

5340-01-340-0329

3040-01-340-0358

4810-01-340-0375

2940-01-340-0444

5340-01-340-0481

4820-01-340-1074

2930-01-340-1450

2815-01-340-1458

2940-01-340-1582

2590-01-340-1606

2590-01-340-1607

2805-01-340-1629

4730-01-340-1680

5306-01-340-2012

5306-01-340-2013

5315-01-340-2021

5365-01-340-2025

5365-01-340-2026

3120-01-340-2063

5307-01-340-2073

5305-01-340-2076

5365-01-340-2091

5365-01-340-2092

5340-01-340-2093

5340-01-340-2094

2920-01-340-2367

4010-01-340-4736

5330-01-340-4776

3020-01-340-4809

4730-01-340-5597

3110-01-340-8032

5310-01-340-8085

5365-01-340-8121

5330-01-340-8158

5365-01-340-8313

3120-01-340-8324

5310-01-340-8352

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

12

15

25

4

23

10

18

40

8

14

12

15

4

1

16

7

3

16

26

21

28

1

22

11

3

10

29

3

4

1

16

12

8

6

54

59

32

31

BULK

2

2

KITS

2

22

50

19

52

4

2

51

5

9

13

15

16

17

20

51

51

2

19

60

21

22

25

51

29

47

21

54

25

9

60

53

28

50

51

15

41

41

41

47

30

9

27

17

5

6

2

10

24

24

14

5

3

5

2

2

4

5310-01-340-8352

5310-01-340-8371

4730-01-340-8701

6680-01-340-8840

4730-01-340-8883

4730-01-340-8885

3010-01-341-2459

5305-01-341-2906

5307-01-341-2950

5315-01-341-2956

5305-01-341-2968

5325-01-341-3023

5325-01-341-3024

5340-01-341-3049

5305-01-341-3087

5940-01-341-4709

4320-01-341-5051

2990-01-341-5119

5940-01-341-5267

4010-01-341-5442

2910-01-341-6173

5365-01-341-8842

5340-01-341-8869

5306-01-341-8905

5305-01-341-8919

5340-01-342-0233

2990-01-342-0645

5940-01-342-1641

5940-01-342-1642

3110-01-342-3049

4820-01-342-3185

5310-01-342-4964

9905-01-342-5306

9905-01-342-5307

9905-01-342-8191

3040-01-342-8732

9905-01-343-1207

6160-01-343-1320

4730-01-343-8719

3040-01-346-6383

6150-01-346-8206

6150-01-347-2512

4330-01-347-2849

4730-01-347-2853

4730-01-347-4139

I-8

TM 5 3825-230-14&PC02

16

4

4

3

7

17

13

10

1

4

6

4

8

10

4

5

1

8

2

20

3

3

10

1

5

5

3

2

2

6

ITEM

26

7

5

4

19

17

2

16

3

28

21

.1

2

17

10

9

17

27

FIG.

25

51

56

48

48

48

58

9

16

19

19

28

39

38

48

37

53

58

38

39

21

26

21

18

KITS

21

37

28

32

39

25

12

35

35

41

29

32

KITS

53

22

54

4

25

2

20

24

29

51

53

54

SECTION IV

STOCK NUMBER

2920-01-347-6069

2520-01-347-6388

2590-01-347-7451

4320-01-347-8626

5307-01-348-3416

5340-01-348-6116

5340-01-348-6222

5330-01-348-6928

5330-01-348-6929

5340-01-348-7050

5325-01-348-7059

7690-01-349-3926

6150-01-349-5316

6240-01-349-5507

6240-01-349-8489

2815-01-350-1664

2815-01-350-1665

3040-01-350-6348

6220-01-350-7889

5310-01-350-8553

3010-01-350-9152

3010-01-350-9155

5330-01-351-7597

5330-01-351-7675

5330-01-351-7676

5310-01-351-7802

2510-01-352-2334

2530-01-352-9090

5340-01-353-2677

6150-01-354-4400

6150-01-354-4401

4820-01-354-5223

5340-01-355-0276

5315-01-355-3636

5330-01-355-5154

5340-01-355-5188

5330-01-355-6725

5330-01-355-6732

5330-01-356-7144

5330-01-356-7145

4730-01-356-8760

4730-01-356-8761

3040-01-356-9853

3040-01-357-3557

5330-01-357-3791

5310-01-357-4595

5340-01-357-6222

5330-01-357-6929

3120-01-357-8019

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER

60

60

60

16

31

2

31

60

19

31

55

25

25

2

60

9

4

22

47

43

1

38

39

23

16

8

28

15

35

27

54

16

48

39

32

32

8

8

16

21

60

47

26

21

26

35

30

21

26

59

34

10

13

1

37

22

11

32

7

38

6

2

37

11

9

9

11

15

8

1

6

2

2

6

5

21

6

2

3

4

2

4

3

13

5

1

2

15

6

2

37

6

6

3

3

3

7

18

5

8

3120-01-357-8019

3120-01-357-8020

5330-01-358-1288

6110-01-358-3505

5330-01-358-3541

5330-01-358-3542

5330-01-358-3543

5330-01-358-3544

5330-01-358-3545

5330-01-358-3546

2530-01-358-7719

2815-01-358-8549

4320-01-358-8565

3040-01-358-8598

5310-01-359-1523

5305-01-360-1959

6105-01-360-5571

6160-01-360-6492

6150-01-361-4810

5305-01-361-7506

5120-01-361-9773

2920-01-362-1812

5999-01-362-3373

6105-01-362-4207

5305-01-363-8836

5305-01-363-9102

5340-01-364-1516

4820-01-364-3406

2815-01-364-3417

5305-01-364-4775

5930-01-364-5374

5920-01-364-9164

6110-01-365-8948

9905-01-366-4743

5977-01-367-1508

5330-01-367-6594

I-9

TM 5 3825-230-14&PC02

ITEM

32

13

27

4

43

9

1

31

35

19

1

9

9

4

5

14

5

4

7

23

1

6

44

23

7

22

7

30

16

29

10

24

3

12

34

8

FIG.

31

31

31

31

31

31

61

31

7

59

45

30

31

59

37

12

19

8

5

2

14

43

31

31

19

31

24

51

9

31

32

32

31

48

31

58

80204

80204

82271

11341

19207

81518

07860

06383

49367

67029

67029

67029

67089

SECTION IV

CROSS- REFERENCE-INDEXES

FIG.

NATIONAL STOCK NUMBER INDEX

ITEM STOCK NUMBER STOCK NUMBER

76761

76761

76761

23823

76761

4Y310

73124

73124

73124

73124

03743

06383

55524

55524

55524

55524

55524

71400

60827

60827

88044

88044

76761

06383

80204

80204

80204

80204

80204

80204

AB-CAP

AB-GASKET

AB-NECK

AB-1000-3

AB-3INCHBASKET

ACG-10

AE-10

AF-10-25-0

AN910-2

AN933-3

A1-103

A2-101

A3-300

A4-510

A52AE12

A9-506

BCSM6700

BF0075PP

3F0150PP

BF10075SXT

BF10125SXT

BL50

BSV10X-L

BSV14X-C

B1821BH025C100N

B1821BH025C125N

B1821BH031C075N

B18213H038C100NN

B1821BH038C125N

B1821BH050C150N

5340-01-348-7050

5330-01-348-6928

2590-01-347-7451

4130-01-075-5547

4730-01-347-2853

5920-01-364-9164

2940-00-755-6584

2940-01-339-3846

4730-00-223-9255

4730-00-702-5694

2920-01-347-6069

6110-01-134-9981

3020-01-045-2627

5310-01-359-1523

5975-01-123-8811

5315-01-136-8328

3120-01-339-8891

5330-01-356-7145

5330-01-356-7144

5340-01-357-6222

4730-01-356-8760

5975-00-152-1075

5940-01-134-1722

5940-01-135-2403

5305-00-225-3843

5305-00-068-0509

5306-00-226-4825

5305-00-068-0513

5305-00-068-0511

5305-00-071-2069

TM 5 3825-230-14&PC02

B1821BH050C450N

B1821BH063C350N

B703

CA237NBEE0

CONDUIT ASSY

CWC2INDIA

C21452

D-250A-C

DB-1478

DHA1-216

DH14-65

DH2-218

DH24-82

ITEM

27

30

3

4

3

2

5

4

9

10

18

23

28

10

2

23

6

1

2

18

7

3

1

5

22

8

7

17

11

32

10

23

4

11

9

2

8

5

34

7

24

25

24

9

8

7

3

6

5

1

FIG.

BULK

51

33

BULK

45

32

34

58

53

58

KITS

35

35

50

56

59

60

1

59

56

45

57

21

34

23

30

30

30

BULK

30

41

60

32

35

38

33

60

60

60

34

26

32

53

53

53

49

30

26

26

26

26

I-10

5305-00-071-2081

5305-00-724-7247

4720-01-272-4672

4820-01-342-3185

4720-00-730-0116

2590-00-473-6331

5940-01-341-4709

5975-00-295-9696

3040-01-346-6383

3040-01-342-8732

3040-01-323-5943

SECTION IV

82247

81349

30327

2X179

60038

60038

60038

60038

60038

60038

60038

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

CAGEC

67089

67029

15526

06383

06383

06383

06383

56988

78940

93908

78940

78940

82918

30327

30327

30327

79470

H1/4VVL-8002

JAN1N3611

J412

LEVER

LM11910

LM11949

LM67010

LM67048

L44649

L68111

L68149

MS-90728-66

MS15002-1

MS15003-1

MS16624-1050

MS16998-42

MS20604B5W8

MS20995C20

MS21044-N8

MS21333-105

MS21333-73

MS21333-98

PART NUMBER

DH3-145

DH5-116

DIN933-M10X35-8.

8-A4C

DNF18-250F1M-C

DNF18-250F1B-C

DNF18-250M-C

DV14-250-C

097

E105B1K01B

E9400D

F22134

F22186K01B

F310190-437

HA04-04MB

HG04-04NJ

HL12-12NJ

H05704

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5330-01-367-6594

5305-01-274-1264

5940-01-342-1642

1450-01-204-7742

5940-01-342-1641

5940-01-341-5267

5360-01-324-8510

2940-01-340-1582

5975-01-145-7210

4330-01-347-2849

5340-01-341-8869

4010-00-494-2326

4730-01-049-3251

4730-00-058-3353

4730-01-339-8517

4720-01-125-4474

4730-01-323-7313

5961-00-957-6865

4720-00-054-6358

3110-00-606-1842

3110-00-606-1839

3110-00-606-1840

3110-00-636-1841

3110-00-926-1379

3110-00-769-1426

3110-00-763-0259

5305-00-782-9489

4730-00-172-0010

4730-00-050-4208

5365-00-833-7301

5305-00-983-6659

5320-00-957-2493

9505-00-221-2650

5310-00-877-5795

5340-00-809-1494

5340-00-057-2906

5340-00-809-1490

I-11

TM5-3825-230-14&PC02

FIG.

58

58

24

22

22

BULK

60

38

BULK

8

8

42

46

42

46

42

46

42

33

21

21

46

52

52

52

38

35

39

32

39

56

21

57

40

51

47

25

BULK

30

46

33

33

33

46

43

43

43

51

56

54

ITEM

8

7

1

7

21

8

22

4

18

3

11

4

10

23

5

13

9

39

12

4

1

4

12

14

5

10

2

4

7

5

21

15

7

11

23

2

20

18

10

14

1

13

18

17

7

4

3

31

19

6

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

SECTION IV

CAGEC

96906

96906

96906

96906

PART NUMBER

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

MS24665-283

MS24665-357

MS24665-360

MS24665-495

5315-00-842-3044

5315-00-298-1481

5315-00-298-1499

5315-00-234-1664

96906 MS25036-108 5940-00-143-4780

MS25036-112

MS25036-115

MS25036-116

MS25036-125

MS25036-153

MS25036-154

MS25036-156

MS25036-157

MS27133-10

MS27183-11

MS27183-12

MS27183-13

MS27183-15

MS27183-17

MS27183-18

MS27133-23

5940-00-143-4794

5940-00-143-5284

5940-00-114-1305

5940-00-557-4333

5940-00-143-4774

5940-00-230-0515

5940-00-143-4775

5940-00-143-4777

5310-00-809-4058

5310-00-809-3078

5310-00-081-4219

5310-00-087-749

5310-00-809-4061

5310-00-809-5997

5310-00-809-5998

5310-00-809-8533

I-12

TM5-3825-230-14&PC02

FIG.

41

1

21

34

51

56

29

33

37

47

59

55

30

34

56

60

42

43

51

35

49

50

46

34

39

39

39

38

34

32

39

39

39

39

39

39

39

46

32

34

35

38

38

38

41

56

58

42

43

45

46

ITEM

10

13

6

9

32

16

19

16

3

5

23

2

14

26

6

15

15

15

25

4

15

29

13

3

11

5

7

2

2

5

13

17

4

15

2

12

9

11

18

14

8

10

6

5

11

24

12

14

13

12

8

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

SECTION IV

CAGEC

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

PART NUMBER

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

MS27133-23

MS27183-5

MS27183-7

MS27183-8

MS27183-9

MS3367-1-0

MS35206-226

MS35206-245

MS35206-263

MS35206-267

MS35206-280

MS35207-263

MS35207-264

MS35207-265

MS35333-38

MS35335-31

MS35335-33

MS35335-35

MS35335-87

MS35338-42

MS35338-43

MS35338-44

5310-00-809-8533

5310-00-983-8483

5310-00-809-8544

5310-00-809-8546

5310-00-823-8804

5975-00-984-6582

5305-00-984-4983

5305-00-984-6193

5305-00-984-6210

5305-00-984-6214

5305-00-988-1724

5305-00-989-7434

5305-00-989-7435

5305-00-993-1848

5310-00-559-0070

5310-00-596-7693

5310-30-209-0786

5310-30-627-6128

5310-00-905-5159

5310-00-045-3299

5310-00-045-3296

5310-00-582-5965

MS35338-45

MS35338-46

MS35338-47

MS35338-48

MS35649-202

MS35649-286

MS35650-302

MS35751-130

MS35751-183

MS35842-11

5310-00-407-9566

5310-00-637-9541

5310-00-209-0965

5310-00-584-5272

5310-00-934-9758

5310-00-934-9762

5310-00-934-9751

5306-00-702-4483

5306-00-952-0964

4730-00-908-3194

I-13

TM5-3825-230-14&PC02

FIG.

45

55

57

23

35

46

29

33

34

47

60

29

30

41

34

36

56

56

49

56

1

32

53

32

35

1

34

36

27

32

26

30

34

48

31

54

34

35

48

33

36

1

34

25

56

31

30

33

56

33

32

ITEM

17

4

2

4

20

6

18

2

19

4

4

16

2

2

16

2

7

11

16

27

12

20

2

19

16

11

21

3

3

6

4

5

11

2

8

8

8

15

7

15

18

2

1

9

14

30

6

14

1

4

25

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

96906

SECTION IV

CAGEC

96906

96906

96906

96906

96906

PART NUMBER

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

MS35842-11

MS39324-12-10

MS51527A12

MS51922-1

4730-00-908-3194

4730-01-096-9138

4730-01-011-7736

5310-00-088-1251

MS51922-17 5310-00-087-4652

MS51922-33

MS51922-49

MS519Z2-57

MS51922-9

MS51953-29

MS51953-36

MS51953-36B

MS51953-97

MS51957-65

MS51967-14

MS51967-2

MS51967-41

MS51967-5

MS51967-8

MS52149-1

MS90725-109

MS90725-168

MS90725-3

MS90725-34

MS90725-6

5310-00-225-6993

5310-00-269-4040

5310-00-067-6356

5310-00-984-3806

4730-00-196-1502

4730-00-196-1539

4730-00-2'77-9997

4730-00-196-1463

5305-00-050-9231

5310-00-768-0318

5310-00-761-6882

5310-00-762-6223

5310-00-880-7744

5310-00-732-0558

6140-01-210-1964

5305-00-044-4153

5305-00-724-5914

5305-00-068-0500

5306-00-225-8499

5305-00-068-0502

I-14

TM5-3825-230-14&PC02

FIG.

40

41

55

23

35

37

49

52

60

34

56

32

33

60

41

55

32

47

45

33

30

34

56

1

45

56

34

41

60

53

56

30

35

50

56

59

60

56

59

1

21

34

45

51

53

60

52

52

52

37

47

ITEM

21

6

17

3

5

5

3

8

26

20

28

17

3

3

7

3

1

1

8

19

13

27

3

8

10

13

25

7

20

10

15

12

5

22

14

2

5

26

21

15

8

10

7

1

19

7

18

2

11

1

7

SECTION IV

CAGEC

96906

96906

96906

12128

57364

63050

63050

63050

63050

61424

05779

63050

63050

63050

63050

63050

63050

63050

63050

80205

80205

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

67089

63050

7R531

7R531

81343

74545

81992

73842

17875

27783

PART NUMBER

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

MS90725-64

MS90725-68

MS9358-17

M647

N-200AWHITE.188X

4X400

NAS1042-18

NAS1352-4LEBP

PE011600

PE012001

PE014007

PE015006

PE016001

PE018002

PE018003

PE018019

PE018041

PE018059

PE130823

PE247005

PE444002

PE444003

P8MCB-12

P8MCB-6

RE-1808020

RE012001

RE018001

RE018005

RE018006

RE018030

RE018048

RE018138

RE018153

RE018163

RE018170

RE018187

RE018977

RST-150

RS018013

RT56125

RT5675

SAE100R1 TYAT SZ

4

SHC-1025

SHC-1037

ST225/75R15

T-15R-50

TR415

5305-01-325-8387

5305-00-269-3218

5310-00-088-6897

4030-00-282-4885

4030-00-542-3184

5305-00-121-2420

3040-01-339-1580

5365-01-341-8842

3040-01-340-0353

5340-01-339-0873

5340-01-339-2129

3110-01-339-8793

3110-01-340-8032

5305-01-339-6960

2520-01-339-6520

3120-01-265-2462

3130-01-339-0849

6105-01-339-1220

5330-01-339-0180

5330-01-340-4776

4730-01-099-7329

4730-01-324-6572

4320-01-323-6028

4720-00-460-3915

5975-01-256-0376

5975-01-207-0229

2610-01-336-8828

2640-00-555-2841

2640-00-555-2841

I-15

TM5-3825-230-14&PC02

FIG.

50

50

50

50

50

50

50

50

50

KITS

KITS

60

60

50

46

51

50

KITS

50

50

50

50

50

50

50

50

50

50

50

50

50

58

50

60

60

BULK

56

1

45

42

43

46

45

BULK

34

34

44

43

42

ITEM

17

14

3

13

14

12

6

13

3

6

8

5

13

12

9

4

18

10

11

14

6

7

16

25

26

21

19

27

6

18

3

17

20

24

23

22

5

15

12

33

7

24

28

1

11

11

SECTION IV

CAGEC

30327

21335

12697

58961

58961

58961

53867

55683

78940

78940

99103

2X179

81992

81992

8H836

11341

11341

11341

11341

11341

11341

11341

11341

11341

11341

11341

11341

11341

11341

94189

92867

98441

0FDH7

0FDH7

78940

78940

53867

53867

53867

53867

11341

11341

11341

11341

57648

53867

55017

72423

55017

PART NUMBER

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

U216-6

VAS 1 7/16

VK100NA-5

WG-16-0-12IN

WG-16-0-6IN

WG-16-0-81N

0 001 219 010

0 331 303 096

0A11861

0A7419

0M-1012

0000-J1G

003-22-002

003-22-003

009-1

1A0332

1A0610

1A0710

1A0739

1R0037

1V0006

1V0046

1V0070

1V0217

1V0269

1V0272

1V1426

1V1702

1V1703

0101668800

01215601

0188-12-12

02019-001

02095-100

0629A84

0638A1

1 000 301 031

1 000 505 010

1 004 615 001

1 007 010 040

1A0290

1A0291

1A0292

1A0294

100-43

1000301031

100075

1001-199

100100

4720-01-288-3893

3130-01-324-8895

5905-01-082-0849

6110-01-365-8948

5945-01-303-3353

4730-01-347-4139

5330-01-348-6929

4730-01-324-5074

5340-01-339-9000

5310-01-113-5659

5310-01-141-8704

3040-01-324-8554

3130-01-070-5629

5340-01-341-3049

4730-00-965-6538

6105-01-360-5571

5930-01-324-8927

5307-01-348-3416

2520-01-347-6388

3120-01-357-8019

2920-01-340-2367

5365-01-303-2965

5310-01-154-0713

5310-01-154-0712

5340-01-153-9240

3110-01-160-2471

5360-01-339-8826

5360-01-339-8825

4810-01-340-0375

5360-01-339-8827

4820-01-155-0302

4820-01-340-1074

4820-01-364-3406

5340-01-339-8956

5365-01-340-2026

3120-01-340-8324

5330-01-339-8916

2530-01-339-8589

5315-01-339-8804

3040-01-211-2255

4820-01-354-5223

3120-01-357-8019

5340-01-069-5306

4730-01-339-8515

5340-01-220-6352

I-16

TM5-3825-230-14&PC02

FIG.

51

51

51

51

51

51

51

51

51

51

51

51

51

51

23

31

53

53

51

51

51

51

45

59

21

21

31

31

31

KITS

34

42

46

40

41

53

59

BULK

57

34

32

32

35

32

31

31

21

21

53

26

34

ITEM

26

10

8

30

16

15

24

20

17

19

22

18

14

29

2

44

4

27

27

11

3

5

19

13

2

18

38

28

33

22

6

20

1

19

6

9

3

5

17

3

18

12

29

6

6

13

26

1

9

21

SECTION IV

72423

24617

24617

24617

24617

94189

09505

10001

33955

2X179

53867

53867

67029

11341

11341

11341

2X179

2X179

94189

2X179

2X179

94189

33955

20796

75915

94189

94189

94189

94189

94189

CAGEC

55017

72423

53867

66234

13548

72423

24617

13548

13548

56161

56161

61424

13548

72423

72423

0FDH7

8H836

1145-150

11500713

11500723

11502892

11505913

1213.173

1240.016

12560

1300.101

1400-077

14286

1501775

15350LA

155100

15529

16622

16626

16690

16691

17122

1722-95

1784995

1838575

1901.032

2 913 051 107

2 916 069 084

2-221

2A0017-8

2A0379-414

2A0079-634

PART NUMBER

100112

1003-250

100322005

101-75791

10205R

1021-150

103374

10401

10403

10501759

10503657

10655-12-12

10744R

1101-148

1101-150

11028-101

114-1

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5340-01-326-1256

4730-01-340-0303

3120-01-357-8020

2540-01-323-6051

6220-01-183-4557

4730-01-339-6733

5315-00-816-1794

5325-01-341-3023

5325-01-341-3024

5305-01-159-0065

5305-01-158-0826

4730-01-075-1920

6220-01-301-5411

4730-01-323-5080

4730-01-323-5079

5340-01-327-3492

5340-01-325-5892

4730-01-323-5107

5306-01-289-9197

5305-01-341-3087

5305-01-361-7506

5310-01-350-8553

5330-01-357-3791

5365-01-340-8313

5315-00-550-7397

3120-01-340-2063

6680-01-336-7050

5340-00-253-1910

6680-01-325-6281

3030-01-340-0183

5920-01-156-6878

5330-01-055-3870

2530-01-352-9090

2530-01-358-7719

2530-01-069-9174

2530-01-322-0673

2530-01-324-5178

9330-01-339-8081

4030-00-684-6346

6240-01-349-8489

5306-01-340-2013

5310-01-357-4595

5310-01-303-2723

3110-01-339-8794

5305-01-339-8924

5305-01-323-8924

I-17

TM5-3825-230-14&PC02

FIG.

40

BULK

46

32

22

31

31

58

51

51

49

30

32

43

43

43

40

40

2

2

40

2

13

43

36

29

31

27

54

46

60

29

30

19

52

35

60

60

59

42

35

35

53

51

35

35

24

45

53

31

55

ITEM

1

14

2

13

18

11

10

6

13

21

12

16

23

2

3

2

1

6

22

24

8

25

2

9

4

17

9

4

3

23

1

15

3

13

16

12

25

5

20

9

11

14

22

4

17

10

17

20

11

23

7

SECTION IV

CAGEC

0FDH7

66234

66234

66234

66234

72423

72423

66234

66234

66234

94189

66234

72423

72423

72423

72423

72423

72423

76280

2X179

66234

0FDH7

0FDH7

0FDH7

0FDH7

0FDH7

0FDH7

66234

66234

66234

66234

66234

66234

66234

66234

66234

0FDH7

01276

66234

0FDH7

11341

11341

11341

11341

11341

8K002

66295

76005

0FDH7

0FDH7

0FDH7

PART NUMBER

206-34005

2371-039

2071-059

2071-098

2071-099

2071-199

2071-249

208-72630

2086.084

209-92052

2100-332

21033-002

21041-001

21131-000

21195-003

212-91159

213-91767

213-91779

213-91901

2171-249

2173-200

221-92018

221-92022

221-92023

23319

2A0283-7214

2A0310-604

2A0354-112

2A0466-150

2A0736-104P

2P130

20H

200XPD-60

20028-008

20050-132

20131-001

20131-002

20132-000

204-85041

204-85227

204-85299

204-85451

204-85493

204-85611

204-85690

204-85730

204-92008

20428-000

2046-4-4S

205-74425

20500-507

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5330-01-217-8918

5315-01-324-0422

5365-01-340-2025

5365-01-325-7217

5310-01-340-8371

4730-01-324-6595

4730-00-278-2523

5340-01-324-8392

4820-01-324-5045

4320-01-347-8626

5305-01-324-8356

5305-01-323-5473

5325-01-339-8989

4320-01-323-7481

4730-01-007-7158

4710-01-339-8435

4320-01-324-7898

4730-01-339-4496

4730-01-343-8719

4730-01-340-8885

4730-01-339-8108

4730-01-340-1680

4730-01-340-8883

4730-01-339-4524

6680-01-309-6450

6150-01-327-9402

2990-01-341-5119

4320-01-358-8565

3040-01-324-1228

4320-01-323-5114

5305-01-323-5474

4320-01-333-5914

4730-01-356-8761

4730-01-324-6492

5430-01-339-8677

5340-01-348-6116

2530-01-250-1624

I-18

TM5-3825-230-14&PC02

FIG.

59

53

52

52

52

60

60

60

60

60

40

53

24

28

59

59

59

59

52

53

22

60

60

53

53

59

52

53

59

53

53

53

21

59

59

52

60

60

52

52

51

60

53

1

59

59

59

51

49

51

49

ITEM

10

17

15

4

11

13

27

35

37

36

9

5

17

11

9

6

4

2

10

8

7

21

23

26

14

16

9

5

15

3

20

16

7

13

19

6

7

8

6

17

28

24

13

10

12

8

14

9

6

12

13

2X179

2X179

2X179

2X179

2X179

2X179

2X179

66295

2X179

2X179

2X179

96652

84093

13445

13445

2X179

39428

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

SECTION IV

CAGEC

78940

22031

2X179

01276

2X179

2X179

8H836

8H836

2X179

2X179

2X179

2X179

2X179

PART NUMBER

250B16A

2501-4

2529.007

2556-12

260.4650.037

260.6410.018

262-2

263-2

270.9850.002

276.3616.018

276.4580.002

276.4580.009

276.4670.014

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

2940-01-339-8611

4730-01-292-4698

6680-01-340-8840

4720-00-541-8859

5330-01-324-8286

2815-01-324-8556

5310-01-327-3340

5307-01-324-8407

2815-01-323-6044

5340-01-327-3444

5330-01-358-1288

5330-01-358-3544

5310-01-324-8325

276.5400.046

276.8335.084

276.8460.055

276.9032.019

2760.2750.111

2760.4240.028

2760.9180.042

28KS3

2830.2175.045

2830.3730.036

2830.8061.372

29-10

3-16WHITE

30055-20

30090-3

3240.018

3559T47

360.1901.039

360.4601.042

360.4701.041

360.4701.058

360.4701.059

360.4776.089

360.4776.090

360.4936.035

360.5055.026

360.6927.056

360.7626.033

360.8676.055

360.9000.072

5365-01-324-3425

5365-01-333-3323

5315-01-325-5786

5340-01-326-2078

5930-01-324-8942

3010-01-350-9152

4730-01-323-5042

5340-01-135-1030

2910-01-324-6899

2910-01-324-6898

3010-01-350-9155

5365-01-154-8557

5925-01-222-3650

5925-01-222-0059

5310-01-324-8246

4030-01-146-6160

5306-01-340-2012

5330-01-358-3546

5330-01-358-3542

5330-01-323-2758

5330-01-323-2757

3020-01-327-0209

5340-01-327-5561

2815-01-323-5968

5310-01-327-3913

3040-01-323-5936

5340-01-333-5127

I-19

TM5-3825-230-14&PC02

FIG.

4

29

5

4

2

5

5

29

6

5

2

21

26

26

16

45

BULK

34

34

15

16

19

BULK

21

14

11

32

16

25

19

9

2

25

19

19

2

8

8

21

36

21

52

54

BULK

18

9

42

42

46

9

19

ITEM

12

2

1

4

2

5

5

13

1

2

16

15

6

7

3

12

10

1

5

14

11

17

9

9

8

4

21

1

9

11

4

1

36

13

4

7

7

17

13

6

3

18

10

5

19

8

12

16

3

1

5

SECTION IV

CAGEC

2X179

2X179

2X179

2X179

2X179

2X179

11341

11341

11341

11341

11341

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2Xi79

2X179

ZX179

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

2X179

2X179

2X179

2X179

39428

7J925

39428

66234

66234

66234

66234

PART NUMBER

395.4730.089

395.4730.090

395.4730.091

395.4730.092

395.4730.185

395.4730.186

395.4730.187

395.4730.188

395.4730.189

395.4730.190

395.5200.250

395.5200o271

395.5755.065

395.6531.104

395.6615.045

395.8180.062

395.8211.071

395.8211.073

395.8676.090

395.8785.070

4P0003-002

4P0004-002

4P0007-007

4P0011-008

4P0012-008

3600.6645.113

3600.3061.096

3600.8836.084

3600.8888.529

3603T17

370-74138-05

3705T101

372-92034

383-72815

383-92044

393-92045

383-92046

337-91668

387-92022

390-65607

390-65608

390-65617

390-65643

390-72016

390-76001

390-92026

390-92041

390-92042

390-92043

390-92044

390-92045

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

2815-01-333-2944

3040-01-356-9853

3040-01-350-6348

4320-01-341-5051

5306-01-324-4962

5340-01-339-8940

5310-01-342-4964

5315-01-326-0083

5315-01-333-5735

5315-01-324-1750

5315-01-325-5456

4030-00-243-4439

5340-01-339-9012

7690-01-326-5393

7690-01-326-5394

7690-01-331-9013

7690-01-332-1839

7690-01-331-8267

7690-01-349-3926

7690-01-332-8948

9905-01-366-4743

9905-01-342-5306

9905-01-342-5307

9905-01-343-1207

9905-01-342-8191

3040-01-334-2288

3040-01-334-2289

5360-01-323-8831

2910-01-341-6173

5330-01-324-8399

2915-01-324-1147

2815-01-324-5084

3130-01-323-2886

5340-01-333-3856

4320-01-323-5157

4320-01-323-5149

4320-01-323-7364

3040-01-324-1276

3040-01-324-1275

I-20

TM5-3825-230-14&PC02

FIG.

13

KITS

7

25

49

7

5

49

49

49

49

25

25

9

18

2

2

2

2

2

2

2

2

2

2

48

48

48

48

48

48

48

48

56

46

47

43

48

48

48

14

16

16

KITS

26

60

37

56

46

58

58

ITEM

2

1

6

3

3

3

3

3

3

3

6

13

1

4

3

12

9

5

7

15

17

6

3

3

3

5

23

5

1

11

10

2

14

2

38

7

20

9

11

1

4

17

11

4

6

10

9

2

7

SECTION IV

CAGEC

66234

66234

66234

14007

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

11341

11341

11341

11341

66234

66234

14889

66234

66234

66234

66234

PART NUMBER

401-94438

401-94439

401-94499

401-94504

401-94506

401-94732

401-94733

401-94756

401-94773

401-94816

402-92006

402-92008

402-92109

402-92110

402-92111

402-92239

402-92326

406-005E

410-92613

410-92655

410-92657

410-92658

410-92661

410-92662

410-92663

4P0013-001

4P0017-001

4Z4306

40P007RAASA

400-65650

400-72806

401-005

401-94117

401-94118

401-94230

401-94231

401-94232

401-94233

401-94240

401-94241

401-94242

401-94251

401-94252

401-94253

401-94254

401-94280

401-94292

401-94303

401-94419

401-94420

401-94431

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

4320-01-323-5128

5330-01-323-1574

3040-01-170-9751

4320-01-324-5113

5315-01-324-6779

5365-01-340-8121

4730-00-476-5865

5340-01-326-0035

5340-01-324-6798

2520-01-323-5940

2520-01-323-5941

5365-01-326-1152

5310-01-326-1053

3020-01-323-5998

4710-01-323-8541

5340-01-328-2257

5306-01-323-5539

5340-01-324-4262

5340-01-324-6794

5340-01-324-6799

5340-01-324-6754

5340-01-355-0276

6160-01-360-6492

5365-01-326-5660

4710-01-324-6528

5975-01-324-7837

5340-01-326-8059

5340-01-325-2827

5340-01-339-9006

5340-01-339-9010

2930-01-340-1450

4010-01-341-5442

2590-01-340-1607

5306-01-341-8905

6160-01-343-1320

5340-01-340-0481

5340-01-348-6222

5365-01-340-2092

5365-01-340-2091

2815-01-340-1458

4730-00-476-7135

2510-01-324-1216

5340-01-324-6784

5340-01-324-4260

5340-01-324-4496

5340-01-324-6783

3825-01-324-2743

5340-01-327-3590

I-21

TM5-3825-230-14&PC02

FIG.

33

59

47

33

45

56

56

50

60

57

56

37

37

41

47

32

33

33

35

35

34

41

29

25

25

37

30

1

34

60

59

56

55

57

56

56

60

55

60

60

49

KITS

51

49

45

52

33

35

56

56

56

ITEM

3

6

16

6

10

8

3

12

8

14

3

1

5

4

4

1

30

4

4

22

18

9

1

1

15

16

12

22

22

31

5

17

16

8

6

9

4

29

30

30

5

12

9

2

11

2

7

19

7

1

SECTION IV

CAGEC

66234

66234

66234

66234

66234

2X179

2X179

2X179

2X179

2X179

2Xl79

2X179

2X179

2X179

2X179

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

PART NUMBER

410-92664

410-92666

410-92667

410-92668

410-92669

410-92672

410-92704

410-92705

410-92713

410-92718

410-92727

410-92827

410-92834

410-92916

410-93039

410-93040

435.1011.110

435.1050.284

435.1410.088

435.1510.222

435.1526.098

435.1630.018

435.1640.082

435.1640.083

435.1640.084

435.2330.214

435.2569.203

435.2615.075

435.2816.052

435.2920.104

435.3350.094

435.5066.070

435.5066.074

435.6500.315

435.6500.316

435.6500.317

435.6590.076

435.6850.124

435.7362.186

435.8150.017

435.8211.089

435.8480.050

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

2510-01-324-1218

2540-01-323-6045

2510-01-339-8413

5315-01-324-1748

2510-01-324-1217

3040-01-358-8598

2510-01-323-8677

5340-01-324-8427

2910-01-324-1304

5340-01-324-8414

2510-01-352-2334

3040-01-339-8603

5340-01-339-9011

5340-01-339-9007

5340-01-339-8960

5340-01-339-8961

2815-01-324-5147

2815-01-323-5992

2815-01-323-6043

2815-01-333-8251

2815-01-324-5192

3120-01-324-8319

3120-01-326-9402

3120-01-323-2785

3120-01-323-5480

2815-01-324-5148

2805-01-324-1211

5340-01-325-5955

2510-01-323-7322

2815-01-323-5942

2510-01-323-5966

2930-01-323-5959

2815-01-323-6038

2815-01-324-1332

2910-01-333-8271

5306-01-334-2758

3020-01-326-6014

2815-01-324-2149

2815-31-358-8549

2815-01-324-1151

435.8900.291

435.9200.243

435.9375.279

435.9375.280

435.9455.074

435.9520.055

435.9652.061

3040-01-323-5994

2815-01-323-5993

4730-01-323-8614

2910-01-323-7057

4710-01-324-6529

4710-01-325-0258

2815-01-326-9076

I-22

TM5-3825-230-14&PC02

FIG.

3

19

7

4

7

7

7

19

13

2

9

19

2

24

KITS

7

7

7

29

4

6

29

29

29

29

7

2

7

7

10

2

7

7

41

41

32

47

47

10

5

45

45

1

30

23

47

47

56

46

46

45

ITEM

5

4

5

5

3

10

6

8

10

4

16

4

7

6

6

15

9

7

1

1

9

8

25

10

7

16

8

19

3

1

1

1

12

8

4

6

9

1

8

2

11

4

2

4

2

2

8

14

1

1

SECTION IV

CAGEC

2X179

2X179

22031

93334

14889

22031

S3465

S3465

22031

2X179

94189

94189

13548

66234

66234

66234

2X179

2X179

22031

2X179

2X179

2X179

2X179

2X179

2X179

66234

66234

39428

2X179

11341

11341

11341

2X179

2X179

2X179

2X179

2X179

66234

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

PART NUMBER

435.9685.067

435.9880.639

4404-16

444654

447-005

4501-4

4537769-635

4537769-643

4601-16-NWO

4670.016

4845-181

488-49720

488-72394

4887K33

4936.077

5A0048

5A0050

5A0078

500.2135.072

500.3790.042

500.5755.049

500.7301.006

500.9070.012

500-92018

5041-020

5081

5082

50820

509-90329

509-92004

509-92013

5175-119

5200-300

5404-16-12

5460.256

560.1160.022

560.1350.011

560.1611.053

560.1611.054

560.1611.055

560.1862.057

560.2125.093

560.2125.094

560.2125.100

560.2125.101

560.2145.013

560.2516.061

560.2690.121

560.3240.131

560.3300.100

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

2815-01-327-0117

2815-01-324-5149

4730-00-414-5962

4730-00-938-7849

4730-01-102-6544

3010-01-302-6310

2920-01-302-6304

4730-01-178-9654

5310-01-334-3502

2805-01-340-1629

4820-01-340-0285

3020-01-340-4809

5340-01-355-5188

5340-01-324-0963

5360-01-339-8828

4730-01-325-0445

2815-01-339-8323

2815-01-323-7633

5930-01-364-5374

5306-01-055-6876

5310-00-119-2090

5940-01-336-5780

6240-01-349-5507

2990-01-325-0716

4730-00-239-2803

2990-01-323-6030

5365-01-327-3393

5330-01-334-2770

3130-01-323-2888

3130-01-323-2887

3120-01-323-5481

5305-01-326-5632

5340-01-324-0962

5340-01-324-0961

2815-01-350-1664

2815-01-350-1665

2940-01-340-0444

2990-01-323-9508

5310-01-340-8085

5310-01-324-8245

I-23

TM5-3825-230-14&PC02

FIG.

8

15

8

8

5

5

8

25

25

19

3

24

53

28

24

9

5

5

43

43

34

45

45

46

32

18

12

1

32

49

9

18

12

9

60

60

60

2

49

49

33

22

31

31

53

14

22

9

6

53

58

ITEM

4

10

3

16

2

15

3

23

30

6

3

9

23

7

5

10

4

4

5

10

32

5

13

1

3

1

10

4

9

4

11

2

7

16

29

31

22

27

5

14

11

6

41

21

12

6

19

13

3

15

2

SECTION IV

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

90005

79550

70184

CAGEC

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

560.6140.100

560.6372.098

560.6429.033

560.6605.037

560.7200.078

560.8000.065

560.8000.066

560.8676.061

560.8676.070

560.8676.071

560.8785.069

560.9050.041

560.9375.351

560.9400.054

560.9455.053

560.9571.077

560.9680.013

560.9320.085

5600.2486.068

5600.3902.052

569020-02

57200

6-40301

PART NUMBER

560.3521.038

560.4330.037

560.4400.022

560.4420.019

560.4420.020

560.4501.022

560.4580.047

560.4776.083

560.4776.087

560.4845.182

560.4936.009

560.5090.010

560.5111.069

560.5168.041

560.5200.108

560.5200.154

560.5200.194

560.5200.200

560.5200.265

560.5655.076

560.5680.077

560.5801.088

560.6040.015

560.6045.040

560.6080.022

560.6095.010

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5365-01-324-4872

2815-01-323-5995

5330-01-358-3541

5330-01-351-7675

5330-01-351-7676

5330-01-358-3543

5330-01-236-0495

5330-01-355-5154

5330-01-358-3545

2815-01-364-3417

3020-01-323-6006

2940-01-333-2952

5340-01-326-5620

5340-01-342-0233

3040-01-334-2290

2990-01-333-6069

5360-01-323-8844

5360-01-333-5157

5315-01-340-2021

5315-01-323-8824

5315-01-325-5782

5315-01-324-0423

5315-01-355-3636

5365-01-324-4919

5340-01-333-5385

2805-31-323-4357

5315-01-341-2956

4810-01-323-5044

4810-01-326-9021

3040-01-327-0187

3040-01-327-0188

2815-01-326-5977

5340-01-364-1516

2910-01-324-6897

4710-01-326-9210

4710-01-324-6530

4710-01-323-8546

4710-01-323-8545

4820-01-339-8402

5305-01-323-8926

2815-01-339-8409

4730-01-326-8076

4310-01-094-0791

6145-00-468-1261

6220-01-350-7889

I-24

TM5-3825-230-14&PC02

FIG.

12

53

BULK

35

21

9

22

12

8

8

15

5

24

21

22

3

5

5

8

25

9

1

13

20

3

25

9

24

8

25

25

25

25

14

5

19

25

25

25

25

15

12

20

25

2

9

13

25

9

8

28

ITEM

11

9

1

6

13

26

1

17

2

5

7

7

11

11

11

7

14

12

22

12

6

2

8

3

9

40

7

15

9

4

38

26

39

5

31

5

9

27

24

11

1

37

2

4

23

16

7

18

1

14

6

SECTION IV

CAGEC

79550

00779

33955

2X179

66234

66234

66234

66234

66234

66234

94189

70842

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

66234

70842

2X179

2X179

2X179

2X179

2X179

2X179

22031

2X179

12128

2X179

2X179

8H836

PART NUMBER

61

61198-1

6219371

625.4740.029

625.5801.153

625.7625.108

62914845.184

629.4845.185

6401-12-0

6585.030

671442

672.4580.068

6780.085

700-1

700-92009

700-92010

700-92011

700-92019

700-92020

700-92023

700-92024

700-92029

700-92034

700-92035

700-92036

700-92047

700-92048

700-92049

700-92050

700-92051

700-92053

700-92054

701-68471

7029

703-1500

703-92065

703-92096

703-92097

703-92127

703-92128

703-92129

703-92130

703-92131

703-92132

703-92133

703-92152

705-1171

7051-060

710.3430.067

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5940-00-434-6062

5940-00-432-2660

5905-01-291-4426

5330-01-355-6732

5360-01-324-8264

5310-01-324-8336

2815-01-323-6039

2805-01-340-0201

4730-01-340-8701

4320-01-317-8940

4010-01-340-4736

5330-01-357-6929

5307-01-324-0945

5360-01-268-2610

6150-01-361-4810

3040-01-357-3557

6220-01-334-0613

5365-01-070-2350

2990-01-342-0645

6150-01-346-8206

6150-01-354-4400

6150-01-347-2512

6150-01-349-5316

6150-01-354-4401

4730-00-871-6729

3020-01-325-3038

2815-01-324-0765

I-25

TM5-3825-230-14&PC02

FIG.

38

38

39

39

39

34

34

38

22

17

9

31

35

40

28

38

34

34

31

31

31

31

31

31

31

BULK

19

28

42

46

31

31

31

31

31

31

31

31

31

31

9

53

20

2

9

2

2

39

39

32

2

ITEM

3

6

16

3

1

1

6

1

15

9

4

40

1

4

6

4

1

1

26

36

16

15

14

37

39

18

20

24

25

7

12

42

17

15

43

6

5

1

1

7

6

12

9

7

12

21

3

8

14

14

5

SECTION IV

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

94189

8H836

13445

19207

94189

2X179

94189

94189

70184

2X179

53867

53867

53867

53867

53867

53867

53867

53867

53867

2X179

20072

CAGEC

67029

2X179

70842

70842

16428

2X179

81640

82654

2X179

2X179

PART NUMBER

72276

7270.104

728197

732-1026

736102

7475018

7500K14

75000317

7535.1460.009

7555.004

7565.004

8019

806-1

81264

8690528

8780

8780.015

8785

8798

88-40700

8903.050

9 001 140 371

9 001 140 383

9 001 333 409

9 001 333 411

9 001 333 417

9 001 337 056

9 002 338 850

9 003 334 157

9 003 337 001

9.1200.015

9.1200.034

9.1200.174

9.1210.079

9.1212.006

9.1240.001

9.1240.005

9.1240.017

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

3040-00-570-6161

4730-01-340-5597

5340-01-339-8910

5340-01-340-0329

6145-01-229-3621

3010-01-341-2459

5930-00-359-5500

2510-01-176-1177

5120-01-361-9773

5310-01-247-2425

5310-01-324-8327

3110-00-926-1379

5330-01-325-5151

2530-01-061-1351

5340-00-186-5085

2530-01-069-4213

5340-01-340-2093

5360-00-553-2039

5306-01-071-1309

5325-01-348-7059

5340-01-340-2094

5305-01-360-1959

5999-01-362-3373

5305-01-363-9102

5305-01-363-8836

5305-01-364-4775

6105-01-362-4207

2920-01-362-1812

5977-01-367-1508

5330-01-323-5455

5330-01-247-2403

5330-01-351-7597

5330-01-355-6725

5330-01-323-2834

5330-01-340-8158

5365-01-333-5286

5365-01-325-7219

5365-01-324-2562

9.1240.077

9.1241.009

9.1585.025

9.1760.001

9.1760.003

9.1760.041

5365-01-325-7220

5365-01-333-3765

3120-01-324-8320

5306-01-333-2649

5305-01-333-5380

I-26

TM5-3825-230-14&PC02

FIG.

24

7

7

7

24

25

24

4

14

29

25

8

8

25

4

25

4

5

31

31

31

31

31

31

11

2

31

31

31

2

40

40

35

14

43

42

46

32

45

40

BULK

54

32

BULK

61

25

29

58

22

37

28

ITEM

10

3

3

3

13

13

8

10

28

3

3

8

21

25

10

5

9

7

27

29

13

19

31

34

2

21

35

32

4

26

12

7

3

2

16

4

8

12

2

10

16

5

11

10

1

10

11

3

17

8

3

SECTION IV

CAGEC

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2C072

2X179

2X179

2C072

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

9.3240.010

9.3240.019

9.3240.032

9.3240.036

9.3240.066

9.3630.023

9.3630.050

9.4670.021

9.4670.026

9.4670.058

9.4670.059

9.4670.060

9.4670.064

9.4670.065

9.4775.196

9.6000.021

9.6760.045

9.6780.005

9.6780.008

9.6780.030

9.6780.084

9.6780.089

9.7565.007

PART NUMBER

9.1770.002

9.1770.005

9.1770.009

9.1770.039

9.1770.042

9.1770.101

9.1780.007

9.1305.025

9.1901.029

9.1901.030

9.1901.031

9.2200.001

9.2280.047

9.2280.056

9.3000.004

9.3110.058

9.3203.047

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5305-01-324-0950

5305-01-324-0949

5305-01-324-0951

5305-01-324-8389

5305-01-341-2968

5305-01-325-5918

5305-01-333-5381

5305-01-327-3448

5306-01-323-8814

5306-01-333-5094

5306-01-326-5519

5315-01-324-3993

5315-01-325-5779

5315-01-323-8820

3110-01-342-3049

3110-01-326-5461

5310-01-324-8239

9.3240.008

5310-01-324-8238

5310-01-324-8237

5310-01-324-8242

5310-01-325-7141

5310-01-324-8240

5310-01-247-2452

5340-01-339-8929

5340-01-325-5916

5330-01-247-2409

5310-01-324-8335

5310-01-332-8236

5310-01-351-7802

5310-01-327-3419

5330-01-327-2630

5330-01-327-2631

5310-01-327-3418

5310-01-324-8243

5307-01-327-3437

5307-01-334-2759

5307-01-341-2950

5307-01-327-3438

5307-01-327-3439

5307-01-340-2073

5310-01-340-8352

I-27

TM5-3825-230-14&PC02

FIG.

18

22

25

2

3

3

2

3

19

5

9

27

12

22

22

21

22

18

28

3

13

26

15

22

12

25

25

9

25

5

20

25

18

22

22

13

10

5

25

24

14

12

7

1

26

6

22

29

5

13

17

ITEM

7

10

34

9

15

17

5

14

5

6

4

15

12

8

7

1

3

2

10

4

20

8

4

1

5

9

29

2

22

32

1

8

5

14

9

8

1

17

8

6

13

2

3

7

5

9

2

2

15

4

3

9.7565.011

9.7625.007

9.7625.010

9.7625.012

9.7625.067

9.7625.103

9.7625.104

9.7626.038

9.7626.040

9.8245.005

9.8400.048

9.8430.004

9.8430.005

9.8430.065

9.8965.003

9.8965.005

9.9000.064

9.9080.037

9.9080.083

9.9730.012

9.9730.032

9.9730.034

9.9730.035

9.9730.045

9.9730.100

9.9730.107

9.9731.092

9.9732.063

9.9732.074

9.9732.075

9.9732.078

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2C072

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

SECTION IV

CAGEC

2X179

PART NUMBER

9.7565.007

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5310-01-340-8352

5310-01-324-834

5310-01-324-8333

5310-01-324-8334

5310-01-324-8326

5310-01-334-0415

5310-01-334-0416

5310-01-324-8331

5310-01-324-8332

3110-01-325-5757

5315-01-333-5119

5315-01-323-8822

5315-01-323-8821

5340-01-325-5943

5365-01-333-5129

5365-01-333-5128

5340-01-324-0904

5365-01-327-3353

5340-01-335-9944

5305-01-323-8930

5305-01-324-8388

5305-01-324-8354

5305-01-324-8352

5305-01-323-8929

5305-01-341-8919

5305-01-325-2646

5305-01-323-8927

5305-01-341-2906

5305-01-324-8355

5305-01-323-8925

5305-01-323-8931

I-28

TM5-3825-230-14&PC02

FIG.

9

16

19

24

29

4

25

8

25

4

5

22

2

12

4

31

2

4

2

14

8

8

8

8

2

8

8

8

2

25

24

24

8

24

5

14

19

25

3

25

20

24

29

31

13

26

31

13

15

16

17

ITEM

3

3

10

14

7

4

19

1

35

5

3

11

18

10

20

6

7

2

11

24

28

12

7

5

18

20

11

12

25

11

7

6

2

12

13

10

9

14

2

6

4

16

3

4

6

11

1

3

5

2

2

SECTION IV

CAGEC

2X179

2X179

2X179

2X179

2X179

53867

8H836

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

66234

0FDH7

33955

2X179

2X179

13548

16764

33955

2X179

PART NUMBER

9.9732.092

9.9765.108

9.9765.111

9.9790.023

9.9790.039

9001 140 349

902-1

904.1610.082

904.1610.098

904.1610.099

904.2175.040

904.3527.018

904.7215.043

904.8506.003

9040.2100.026

9040.5780.011

9040.6745.031

9040.7195.056

907-46665

91008-000

9154571

9282.003

9375.022

93906

9508

9610070

9730.004

CROSS-REFERENCE INDEXES

PART NUMBER INDEX

STOCK NUMBER

5305-01-334-2762

5305-01-334-2761

5305-01-333-5260

5305-01-323-8932

5305-01-323-8928

6110-01-358-3505

2530-01-323-6048

3130-01-323-2885

3130-01-323-5516

3130-01-323-5517

2940-01-324-5153

5365-01-325-5876

2815-01-324-6906

5340-01-353-2677

2920-01-324-8512

5360-01-323-8830

5930-01-324-8933

3825-01-327-0530

5305-01-323-5477

6625-01-297-2005

2590-01-340-1606

4710-01-339-8103

5995-01-096-0733

6145-00-471-0428

5330-01-290-2621

5305-01-340-2076

I-29

TM5-3825-230-14&PC02

FIG.

32

54

22

35

36

32

57

59

12

29

10

1

27

8

8

BULK

36

54

29

31

42

43

5

5

5

25

14

2

25

ITEM

15

4

16

13

3

18

7

8

1

20

2

2

2

6

19

15

5

7

5

22

12

12

1

1

1

16

8

14

33

SECTION IV

BULK

BULK

BULK

BULK

BULK

BULK

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

1

1

KITS

KITS

KITS

KITS

KITS

KITS

KITS

BULK

BULK

BULK

BULK

BULK

KITS

KITS

FIG.

BULK

BULK

BULK

BULK

BULK

BULK

BULK

14

15

16

17

18

8

9

10

11

12

13

ITEM

1

2

3

4

5

6

7

10

11

8

9

12

13

14

5

6

7

3

4

1

2

3

3

3

3

15

16

1

2

9330-01-339-8081

6145-00-471-0428

6145-01-229-3621

6145-00-468-1261

9505-00-221-2650

2815-01-324-2149

3040-01-323-5943

4320-01-341-5051

5330-01-323-1574

5330-01-324-8399

5330-01-339-0180

5330-01-340-4776

5365-01-303-2965

5365-01-341-8842

2815-01-323-7633

5340-01-353-2677

5340-01-333-5385

5310-01-324-8343

5305-01-333-5381

5305-00-724-7247

2510-01-323-8677

5310-00-269-4040

5305-00-984-6214

5340-01-324-8392

5310-00-045-3296

5310-00-934-9758

5310-00-087-7493

5305-00-269-3218

5310-00-087-4652

4710-01-324-6523

5315-01-325-5786

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

4010-01-340-4736

5975-01-123-8811

4720-00-730-0116

4720-00-054-6358

4720-00-541-8859

4720-01-288-3893

4720-00-460-3915

4720-01-272-4672

4720-01-125-4474

2510-01-176-1177

4030-01-146-6160

82271

79470

82654

84093

39428

57364

66234

2X179

2X179

2X179

2X179

80204

66234

96906

96906

76005

96906

96906

96906

96906

09505

16764

16428

79550

96906

2X179

67089

2X179

11341

2X179

63050

63050

53867

63050

96906

66234

2X179

2X179

2X179

2X179

2X179

2X179

CAGEC

12128

23823

81518

30327

01276

30327

81343

I-30

TM5-3825-230-14&PC02

PART NUMBER

671442

A52AE12

CWC2INDIA

J412

2556-12

U216-6

SAE100R1 TYAT SZ

4

8708

H05704

75000317

3-16WHITE

3559T47

N-200AWHITE.188X

4X400

1722-95

9508

736132

57200

MS20995C20

435.8150.017

DH24-82

3600.8888.529

4P0017-001

395.8180.062

PE444002

PE444003

1 007 010 040

PE012001

500-92018

904.8506.003

560.6429.033

9.7565.011

9.1780.007

818218H063C350N

410-92704

MS51922-49

MS35206-267

Z00XP0-60

MS35338-43

MS35649-202

MS27183-13

MS90725-68

MS51922-17

401-94420

276.8460.055

36304701.041

395.4730.089

395.4730.090

395.4730.091

395.4730.092

SECTION IV

FIG.

4

4

4

4

4

4

4

4

4

4

4

3

3

3

3

3

3

3

3

3

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

ITEM

6

7

4

5

1

2

3

10

11

8

9

8

9

6

7

3

4

5

24

25

26

27

28

1

2

20

21

22

23

16

17

18

19

9

10

11

12

13

14

15

6

7

8

4

5

3

3

3

3

3

3

2815-01-324-5143

5310-01-324-8336

5360-01-324-8264

4710-01-325-0258

5330-01-355-6732

2815-01-333-8251

5315-01-333-5119

5365-01-333-5129

5310-01-324-8325

5305-01-333-5260

5307-01-334-2759

5340-01-333-5127

5307-01-341-2950

5340-01-335-9944

5306-01-334-2758

5305-01-324-8388

5340-01-340-2094

5330-01-357-3791

5330-01-358-3545

5365-01-340-8313

3120-01-340-2063

5340-01-340-2093

3020-01-340-4809

5340-01-325-5943

5310-01-325-7141

5310-01-324-8326

5310-01-324-8245

2815-01-323-5993

5307-01-327-3438

5307-01-327-3439

4810-01-326-9021

4810-01-323-5044

5307-01-327-3437

5330-01-323-2758

5340-01-327-5561

5306-01-333-2649

5305-01-341-2906

5305-01-324-8355

5305-01-324-8354

5305-01-324-8352

5340-01-325-5955

5330-01-355-6725

5330-01-340-8158

3040-01-323-5994

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER CAGEC

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

I-31

TM5-3825-230-14&PC02

PART NUMBER

1240.016

1300.101

8780.015

4936.077

9.8430.065

9.3240.032

9.7625.067

560.3300.100

435.9200.243

9.6780.030

9.6780.084

560.8000.066

560.8000.065

9.6760.045

360.4776.089

360.5055.026

9.1760.001

9.9732.063

9.9732.074

9.9730.034

9.9730.035

435.2615.075

9.1200.174

9.1212.006

435.8900.291

395.4730.185

395.4730.186

395.4730.187

395.4730.188

395.4730.189

395.4730.190

435.2380.214

625.4740.029

625.7625.108

625.5801.153

435.9520.055

625.4740.029

435.1510.222

9.8400.048

9.8965.003

276.4670.014

9.9765.111

9.6780.005

360.9000.072

9.6780.008

9.9080o083

435.6850.124

9.9730.032

8903.050

1213.173

560.4776.087

SECTION IV

FIG.

8

8

8

8

8

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

7

6

6

7

6

6

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

5

ITEM

1

2

3

4

5

7

8

5

6

4

5

5

4

4

3

3

2

2

3

1

1

2

3

4

1

16

17

1

2

12

13

14

15

9

10

7

8

11

11

11

5

5

6

4

4

3

4

1

1

1

2

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

3130-01-323-2885

3130-01-323-5516

3130-01-323-5517

3040-01-323-5936

5305-01-323-8925

3120-01-323-5481

3130-01-323-2887

3130-01-323-2883

5330-01-358-3542

3130-01-323-2886

5330-01-323-2834

5310-01-324-8239

5340-01-326-5620

5305-01-326-5632

2815-01-326-5977

3040-01-327-0187

3040-01-327-0188

3020-01-327-0209

5310-01-324-8334

5310-01-340-8352

5305-01-324-0949

2815-01-323-5992

5315-01-323-8320

5310-01-327-8913

5305-01-327-3448

2815-01-324-5149

2815-01-323-6038

2815-01-324-1332

2815-01-324-1151

2815-01-324-1151

2815-01-324-1151

5365-01-324-2562

5365-01-324-2562

5365-01-324-2562

2815-01-324-1147

2815-01-324-5084

2815-01-358-8549

3120-01-323-2785

3120-01-323-5480

3120-01-326-9402

2815-01-324-5192

5305-01-325-5918

3120-01-324-8319

5305-01-323-8925

2815-01-350-1664

5340-01-324-0962

5310-01-324-8325

5340-01-324-0904

CAGEC

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

I-32

TM5-3825-230-14&PC02

PART NUMBER

435.9880.639

435.2816.052

435.6500.315

435.6500.316

435.6500.317

435.8480.050

435.8480.050

435.8480.050

9.1240.017

9.1240.017

9.1240.017

395.8211.071

395.8211.073

435.8211.089

435.1640.083

435.1640.084

435.1640.082

435.1526.098

9.1770.101

435.1630.018

9.9732.075

560.2125.100

560.2125.093

276.4670.014

9.9000.064

904.1610.082

904.1610.098

904.1610.099

360.8676.055

9.9732.075

560.1611.055

560.1611.054

560.16l1.053

360.4701.059

360.4701.058

395.8676.090

9.1210.079

9.3203.047

560.5111.069

560.1862.057

560.8676.071

560.8676.061

560.8676.070

360.4936.035

9.7625.010

9.7565.007

9.1770.005

435.1050.284

9.2280.056

360.7626.033

9.1805.025

SECTION IV

FIG.

9

10

10

13

10

11

11

12

12

12

12

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

8

9

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

8

B

ITEM

18

1

2

1

2

3

4

3

4

1

2

12

13

14

15

16

16

17

9

10

11

12

6

7

8

4

5

2

3

24

25

26

1

17

18

19

20

21

22

23

10

11

12

13

14

15

16

6

7

8

9

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5360-01-323-8830

3110-01-325-5757

5330-01-247-2403

5315-01-324-0423

5315-01-323-8821

5315-01-323-8822

5305-01-323-8926

5330-01-358-3541

2815-01-350-1665

5340-01-324-0961

5310-01-324-8325

5340-01-324-0904

5360-01-323-8830

3110-01-325-5757

5330-01-351-7597

5315-01-324-0423

5315-01-323-8821

5315-01-323-8822

5305-01-323-8926

2815-01-323-5995

5310-01-324-8237

5305-01-341-8919

5365-01-333-3823

5310-01-340-8352

5365-01-324-4919

5315-01-323-8824

2815-01-323-6044

4710-01-323-8546

5330-01-334-2770

5340-01-355-5188

2805-01-340-0201

2815-01-323-6039

2815-01-327-0117

2815-01-326-9076

2815-01-324-0765

2805-01-340-1629

2815-01-364-3417

5360-01-323-8831

2315-01-324-8556

5315-01-325-5779

2815-01-324-6906

2815-01-323-6043

2815-01-324-5147

5340-01-326-2078

5330-01-323-5455

2940-01-324-5153

5305-01-341-2968

5310-01-332-8236

5330-31-358-3543

I-33

CAGEC

2X179

2X179

2X179

2Xl79

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2C072

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

TM5-3825-230-14&PC02

PART NUMBER

560.6372.098

560.6045.040

270.9850.002

560.9455.053

560.1350.011

500.2135.072

629.4845.185

629.4845.184

435.9685.067

435.9652.061

710.3430.067

4845-181

560.4845.182

395.5755.065

260.6410.018

9.2280.047

904T7215.043

435.1410.088

435.1011.110

276.9032.019

9.1200.015

904.2175.040

9.1770.042

9.4570.058

560.4501.022

9040.5780011

9.8245.005

9.1200.034

560.6095.010

LEVER

9.8430.005

9.8430.004

560.9820.085

560.4400.022

560.2125.101

560.2125.094

276.4670.014

9.9000.064

9040.5780.011

9.8245.005

9.1200.034

560.6095.010

LEVER

9.8430.005

9.8430.004

560.9820.085

560.4330.037

9.3240.010

9.9730.100

276.8335.084

9.7565.007

SECTION IV

FIG.

17

18

18

18

18

18

18

18

18

19

19

16

16

16

16

16

17

17

15

15

15

15

15

16

16

14

14

14

15

14

14

14

14

13

13

13

13

14

14

14

12

12

13

13

13

13

13

12

12

12

12

ITEM

5

6

3

4

3

1

2

1

2

7

7

1

2

6

7

3

4

5

1

2

5

6

2

3

4

10

1

8

9

6

7

4

5

1

2

3

8

9

6

7

9

10

1

2

3

4

5

5

6

7

8

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

4730-01-326-8076

4820-01-339-8402

5360-01-339-8828

5330-01-247-2409

2815-01-339-8323

5305-01-323-8930

4710-01-324-6529

6680-01-336-7050

5310-01-340-8352

5305-01-324-0951

5310-01-324-8240

5310-01-324-8343

3020-01-323-6006

5315-01-324-3993

2805-01-323-4357

5330-01-358-3546

2815-01-333-2944

5306-01-333-2649

5310-01-324-8327

2940-01-333-2952

5310-01-334-3502

5365-01-333-5128

5305-01-334-2761

5305-01-324-8389

5310-01-324-8334

2815-01-339-8409

5330-01-351-7676

2940-01-340-0444

5340-01-339-8929

5310-01-340-8352

5310-01-324-8246

3040-01-356-9353

5310-01-340-8352

5305-01-341-8919

3010-01-350-9152

3010-01-350-9155

3040-01-350-6348

5310-01-324-8246

3020-01-325-3038

5310-01-340-8352

5305-01-324-0951

5310-01-324-8238

5340-01-324-0963

5330-01-324-8286

4730-01-325-0445

2910-01-341-6173

5330-01-327-2630

5330-01-327-2631

2910-01-323-7057

4730-01-323-8614

I-34

CAGEC

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2XI79

2X179

2X179

2X179

2X179

2C072

2X179

2X179

2X179

2X179

2X179

2X179

2X179

TM5-3825-230-14&PC02

PART NUMBER

560.4420.020

560.2145.013

9.3630.023

9.7565.007

3240.018

3600.8061.096

9.7565.007

9.9730.100

2760.4240.028

2830.8061.372

3600.8836.084

3240.018

7051-060

9.7565.007

9.1770.009

9.3240.008

500.3790.042

260.4650.037

500.7301.006

395.6615.045

395.6531.104

9.4670.064

9.4670.065

435.9375.280

435.9375.279

5600.3902.052

560.9680.013

500.5755.049

9.4670.021

500.9070.012

9.9730.012

435.9455.074

1400-077

9.7565.007

9.1770.009

9.3240.036

9.7565.011

560.4936.009

9.2200.001

560.6605.037

360.4601.042

3603.6645.113

9.1760.001

7565.004

560.5090.010

4670.016

9.8965.005

9.9765.108

9.1770.039

9.7625.010

5600.2486.068

SECTION IV

FIG.

22

22

22

22

22

22

22

22

22

22

22

21

21

21

22

22

22

22

21

21

21

21

21

21

21

21

21

21

21

21

21

21

21

19

19

20

20

20

20

20

19

19

19

19

19

19

19

19

19

19

19

ITEM

10

11

8

9

5

6

7

12

13

14

15

16

17

18

3

4

1

2

9

10

11

12

13

14

15

7

8

5

6

3

4

1

2

12

13

1

2

3

4

5

9

10

11

7

8

7

7

3

4

5

6

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5310-01-324-8246

5307-01-340-2073

5340-01-342-0233

5310-01-340-8085

5330-01-357-6929

5330-01-358-1288

5330-01-358-3544

2910-01-333-8271

5310-01-324-8334

5305-01-341-8919

5365-01-324-3425

5340-01-327-3444

5305-01-158-0826

5330-01-236-0495

5315-01-341-2956

4320-01-317-8940

5310-01-340-8352

5310-01-324-8239

5340-01-341-8869

5307-01-348-3416

5330-01-348-6929

4330-01-347-2849

5305-00-068-0510

5310-00-087-7493

5310-00-087-4652

5340-01-135-1030

5306-01-340-2012

4710-01-324-6530

5310-01-327-3419

5310-01-324-8325

2910-01-324-6897

2940-01-340-1582

2940-01-339-8611

4730-01-347-4139

2520-01-347-6388

4710-01-323-8545

5310-01-332-8236

5306-01-323-8814

4730-00-871-6729

4730-01-102-6544

4730-01-340-8885

5310-01-327-3419

5306-01-326-5519

5310-01-327-3418

5365-01-327-3353

4710-01-326-9210

5306-01-333-5094

5310-01-351-7802

I-35

CAGEC

79470

22031

72423

2X179

2X179

2X179

2X179

2X179

79470

2X179

2X179

66295

2X179

2X179

2X179

2X179

2X179

78940

78940

78940

78940

2X179

2X179

2X179

70842

2X179

56161

2X179

2X179

2X179

2X179

2X179

78940

78940

78940

78940

80204

96906

66234

96906

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

TM5-3825-230-14&PC02

PART NUMBER

28KS3

360.901.039

560.9400.054

9.4670.060

276.4670.014

560.9050.041

E105BIK018

250816A

0A11861

0638A1

560.9571.077

9.4670.058

9.1901.029

705-1171

H05704

4501-4

2071-059

9.4670.060

9.1901.031

9.4775.196

9.9080.037

560.9375.351

H05704

9.1901.030

9.4670.059

3240.018

9.6780.089

560.5168.041

560.3240.131

672.4580.068

276.4580.002

276.4580.009

435.6590.076

9.7625.010

9.9730.100

276.5400.046

276.3616.018

10503657

560.4580.047

560.7200.078

6585.030

9.7565.007

9.3203.047

F22136K01B

0629A84

0A7419

F221B4

B1821BH038C100N

MS27183-13

204-92008

MS51922-17

SECTION IV

FIG.

22

23

23

23

23

23

24

22

22

22

22

25

25

25

25

25

25

25

24

24

25

25

25

25

25

24

24

24

24

24

24

24

24

24

24

24

24

24

24

25

25

25

25

25

25

25

25

25

25

25

ITEM

20

1

2

3

4

5

1

16

17

18

19

10

11

8

9

6

6

7

16

17

1

4

5

2

3

12

13

14

15

10

11

8

9

5

6

7

2

3

4

12

13

14

15

16

17

18

19

20

21

22

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

4710-01-339-8103

4730-01-340-5597

5306-01-340-2013

5310-01-334-3502

5340-01-325-5916

2910-01-324-1304

4820-01-354-5223

5305-00-068-0511

5310-00-637-9541

5310-00-732-0558

5305-01-274-1264

5310-01-324-8331

3020-01-326-6014

6150-01-327-9402

5365-01-327-3393

3110-01-326-5461

5340-01-364-1516

3120-01-324-8320

2990-01-325-0716

5365-01-325-7219

5310-01-324-8332

5310-01-324-8333

5365-01-325-7220

5305-01-325-2646

5315-01-325-5782

5310-01-340-8352

5305-01-159-0065

2590-01-340-1607

5305-00-989-7434

4010-01-341-5442

2990-01-333-6069

5365-01-333-5286

5310-01-334-0415

5310-01-334-0416

3040-01-334-2288

3110-01-342-3049

5310-01-324-8238

5310-01-247-2425

3040-01-334-2290

5315-01-355-3636

5365-01-333-3765

3040-01-334-2289

5305-01-334-2762

5340-01-333-3856

5365-01-324-4872

5305-01-341-2906

4730-01-323-5042

5310-01-324-8242

I-36

CAGEC

2X179

2X179

2X179

2X179

2X179

66234

57648

80204

96906

96906

15526

2X179

56161

66234

96906

66234

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2C072

2X179

2X179

2X179

2X179

2X179

96906

2X179

2X179

TM5-3825-230-14&PC02

PART NUMBER

9.7565.007

10501759

401-94733

MS35207-263

401-94732

560.5200.265

9.1240.001

9.7625.103

9.7625.104

395.5200.250

9.3000.004

9.3240.008

7555.004

560.5200.200

560.6140.100

9.1241.009

9.7625.012

395.5200.271

9.9732.092

395.8785.070

560.3521.038

9.9732.063

MS20995C20

2760.9180.042

9.3240.019

9375.022

7270.104

1901.032

4670016-

9.3630.050

410-92713

100-43

B1821BH038C125N

MS35338-46

MS51967-8

DIN933-M10X35-8.

8-A4C

9.7626.038

435.7362.186

2086.084

560.1160.022

9.3110.058

560.8785.069

9.1585.025

5200-300

9.1240.005

9.7626.040

9.7625.007

9.1240.077

9.9730.107

560.6080.022

SECTION IV

FIG.

28

28

29

29

29

29

29

29

29

29

29

27

27

28

28

28

28

28

26

26

26

26

26

27

27

26

26

26

26

26

26

26

26

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

ITEM

4

5

2

3

6

7

1

8

9

6

7

4

5

2

3

3

4

1

9

10

11

12

13

1

2

7

8

5

6

3

4

1

2

34

35

36

37

38

39

40

27

28

29

30

31

32

33

23

24

25

26

5305-01-323-8932

5310-01-324-8243

5305-01-323-8931

5315-01-325-5786

5330-01-355-5154

5360-01-323-8844

5360-01-333-5157

5315-01-340-2021

4130-01-075-5547

5340-01-348-7050

5305-00-989-7434

2590-01-347-7451

5330-01-348-6928

4730-01-347-2853

2910-01-324-6898

2910-01-324-6899

5310-01-247-2452

5310-01-324-8343

5340-01-339-9000

5305-01-333-5381

5310-01-324-8335

2920-01-324-8512

5310-00-582-5965

5310-01-350-8553

2990-01-342-0645

2990-01-341-5119

5340-01-340-0329

5310-01-324-8242

5307-01-324-0945

5330-01-351-7675

2990-01-323-6030

2510-01-323-7322

5305-01-324-0950

5310-01-340-8352

5330-01-323-2757

5305-01-323-8928

2510-01-323-5966

5305-01-323-8927

2815-01-323-5942

2930-01-323-5959

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

2990-01-323-9508

CAGEC

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2C072

2X179

2X179

5X475

2X179

2X179

96906

24617

70842

66234

70842

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

55524

39428

55524

96906

55524

55524

55524

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

2X179

I-37

TM5-3825-230-14&PC02

PART NUMBER

2830.2175.045

9.3240.066

9.7565.011

0000-J1G

9.1780.007

9.4670.026

9040.2100.026

MS35338-44

11505913

703-1500

209-92052

732-1026

9.3240.019

6780.085

560.4420.019

5460.256

435.2920.104

9.1770.002

9.7565.007

360.4776.090

9.9790.039

435.5066.070

9.9731.092

435.3350.094

435.5066.074

560.2516.061

560.5200.194

9.1200.034

560.5680.077

560.5200.154

9.1760.041

9.3240.008

560.2690.121

560.5200.108

9.3203.047

9.9790.023

9.6000.021

9.9732.078

276.8460.055

560.4776.083

560.5655.076

560.5801.088

560.6040.015

AB-1000-3

3603T17

AB-CAP

MS35207-263

AB-NECK

AB-GASKET

AB-3INCHBASKET

2830.3730.036

SECTION IV

FIG.

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

30

31

31

31

31

31

31

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

29

29

29

29

29

29

29

29

29

29

29

ITEM

14

15

16

17

18

19

20

21

22

23

24

10

11

12

13

7

3

9

16

1

2

5

6

3

4

12

13

14

15

10

11

8

9

5

6

7

3

4

1

2

14

15

16

17

18

19

20

10

11

12

13

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5305-01-333-5380

5310-01-247-2425

2805-01-324-1211

2815-01-323-5968

2930-01-340-1450

5306-01-289-9197

5310-00-407-9566

5305-01-341-3087

5310-00-209-0965

5310-00-809-4061

5365-01-325-5876

5340-01-324-8427

5310-00-407-9566

5306-01-289-9197

6110-01-134-9981

5305-00-989-7435

5310-00-809-8544

2920-01-347-6069

5315-01-136-8328

5310-01-359-1523

5310-00-877-5795

3020-01-045-2627

5310-00-225-6993

5306-00-225-8499

5310-00-081-4219

5365-01-326-5660

3030-01-340-0183

5310-01-324-8343

5305-01-323-8929

6113-01-365-8948

5305-01-363-9102

5945-01-303-3353

5310-00-596-7693

5305-01-361-7506

5310-01-303-2728

5310-01-357-4595

6105-01-362-4207

2920-01-302-6304

6110-01-358-3505

3120-01-357-8020

CAGEC

66234

66234

66234

66234

66234

53867

66234

S3465

53867

53857

66234

20796

2X179

2X179

53867

53867

55653

66234

66234

96906

24617

53867

53867

66234

53867

66234

96906

24617

76761

96906

96906

76761

76761

76761

96906

76761

96906

96906

96906

66234

2X179

2X179

2X179

2X179

66234

24617

96906

24617

96906

96906

2X179

I-38

TM5-3825-230-14&PC02

PART NUMBER

15350LA

9.7565.011

9.9730.045

0 001 219 010

9 001 333 409

0 331 303 096

700-92010

700-92011

MS35335-31

11502892

2 916 069 084

2 913 051 107

700-92019

9 001 337 056

700-92050

700-92049

700-92048

700-92323

700-92024

9 002 338 850

700-92029

4537769-643

9001 140 349

100322005

700-92034

9.1760.003

7555.004

435.2569.203

360.6927.056

401-94506

11500713

MS35338-45

11500723

MS35338-47

MS27183-15

904.3527.018

410-92705

MS35338-45

11500713

A2-101

MS35207-264

MS27183-7

A1-103

A9-506

A4-510

MS21044-N8

A3-300

MS51922-33

MS90725-34

MS27183-12

401-94419

SECTION IV

FIG.

32

32

32

32

32

32

32

33

33

33

33

32

32

32

32

32

32

32

32

32

32

32

32

32

32

32

32

32

32

31

31

32

32

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

31

ITEM

21

22

23

24

25

26

27

3

4

1

2

14

15

16

17

18

19

20

10

11

12

13

7

8

9

5

6

3

4

43

44

1

2

36

37

38

39

40

41

42

29

30

31

32

33

34

35

25

26

27

28

5305-01-363-8836

2920-01-340-2367

5305-01-364-4775

5310-00-983-8483

2920-01-362-1812

5999-01-362-3373

5977-01-367-1508

5305-01-360-1959

3040-01-357-3557

3120-01-357-8019

3010-01-302-6310

6150-01-361-4810

3120-01-357-8019

5940-01-341-5267

6240-01-349-5507

5340-01-339-9007

5310-00-809-4058

5310-00-582-5965

5305-00-068-0502

5933-01-324-8933

5930-01-324-8942

5930-01-364-5374

5930-00-359-5500

2530-01-061-1351

6240-01-349-8489

5905-01-291-4426

6625-01-297-2005

5365-01-340-2092

5310-00-761-6882

5940-00-143-4780

5310-00-905-5159

5310-00-934-9762

5940-01-134-1722

5920-01-156-6878

5920-01-364-9164

5305-00-984-4983

5940-01-341-4709

5340-00-809-1494

5310-00-582-5965

5310-00-761-6882

5975-00-984-6582

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER CAGEC

58961

06383

75915

71400

96906

58961

06383

96906

96906

96906

96906

96906

2X179

2X179

2X179

81640

13445

33955

33955

33955

66234

96906

96906

96906

96906

66234

66234

53867

66234

66234

S3465

66234

66234

53867

58961

06383

2X179

66234

96906

96906

66234

66234

53867

53867

53867

96906

53867

53867

53837

53867

53867

I-39

TM5-3825-230-14&PC02

PART NUMBER

MS90725-6

9040.7195.056

2760.2750.111

5041-020

7500K14

81264

1838575

6219371

9154571

402-92008

MS51967-2

MS25036-108

MS35335-87

MS35649-286

WG-16-0-8IN

BSV10X-L

155100

ACG-10

MS35206-226

WG-16-0-121N

D-250A-C

MS21333-105

MS35338-44

MS51967-2

MS3367-1-0

700-92035

700-92036

9 001 333 411

1 000 505 010

9 001 333 417

MS27183-5

9 003 334 157

9 001 140 383

1 004 615 001

9 003 337 001

9 001 140 371

700-92047

700-92051

1 000 301 031

700-92053

700-92054

4537769-635

700-92020

700-92009

1000301031

WG-16-0-6IN

DV14-250-C

5175-119

410-92916

MS27183-10

MS35338-44

SECTION IV

FIG.

34

34

34

34

34

34

34

35

35

35

35

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

34

33

33

33

33

34

34

34

33

33

33

33

33

33

33

33

33

33

33

ITEM

26

27

28

29

33

31

32

3

4

1

2

19

20

21

22

23

24

25

12

13

14

15

16

17

18

10

11

8

9

6

7

4

5

16

17

18

19

1

2

3

9

10

11

12

13

14

15

5

6

7

8

4730-00-476-5865

4730-00-476-7135

4730-00-938-7849

5975-01-145-7210

5340-00-057-2906

5310-00-809-8546

5305-00-984-6210

5310-00-809-4058

5305-00-225-3843

5340-00-809-1490

5305-00-068-0500

5940-00-143-4777

5940-00-557-4338

5305-00-068-0510

5310-00-627-6128

5310-00-087-7493

5310-00-087-4652

5305-00-993-1848

5975-01-324-7837

5905-01-082-0849

5940-00-143-4780

5925-01-222-0059

5310-00-934-9751

5925-01-222-3650

5305-00-988-1724

5310-00-582-5965

5305-00-050-9231

5310-00-045-3296

5310-01-141-8704

5975-00-152-1075

5975-01-256-0876

5310-00-984-3806

5310-30-081-4219

5306-00-225-8499

5975-01-207-0229

5310-01-113-5659

5975-00-295-9696

5340-01-339-9006

5940-01-336-5783

6220-01-334-0613

6220-01-350-7889

5325-31-348-7059

5310-00-809-5998

I-40

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER CAGEC

96906

96906

81992

81992

49367

66234

13546

66234

70184

70184

96906

66234

12697

95906

13445

96906

13445

96906

96906

96906

96906

81992

03743

74545

96906

96906

80204

95936

96906

66234

96906

66234

66234

96906

66234

80204

96906

96906

96906

96906

19207

62234

14889

66234

14007

66234

14889

93908

96906

96906

96906

TM5-3825-230-14&PC02

PART NUMBER

401-94431

VK100NA-5

MS25036-108

30090-3

MS35650-302

30055-20

MS35206-280

MS35338-44

MS51957-65

MS35338-43

003-22-003

BL50

SHC-1025

MS51922-9

MS27183-12

MS90725-34

SHC-1037

003-22-002

DB-1478

401-94499

50820

701-68471

6-40301

38-40700

MS27183-18

CONDUIT ASSY

402-92109

401-005

402-92111

406-005E

402-92110

447-005

E940D

MS21333-73

MS27183-8

MS35206-263

MS27183-10

B1821BH025C100N

MS21333-98

MS90725-3

703-92133

MS25035-157

703-92132

703-92097

MS25036-125

703-92096

B1821BH038C100N

MS35335-35

MS27183-13

MS51922-17

MS35207-265

SECTION IV

FIG.

38

38

38

38

38

38

39

39

39

39

39

37

37

38

38

38

38

38

36

37

37

37

37

37

37

36

36

36

36

35

35

36

36

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

35

ITEM

9

10

11

1

6

7

8

4

5

2

3

4

5

2

3

7

8

1

5

6

3

4

7

1

2

5

6

3

4

22

23

1

2

16

17

18

19

20

21

22

9

10

11

12

13

14

15

5

6

7

8

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5310-00-225-6993

5940-00-143-4780

1450-01-204-7742

5940-01-134-1722

5325-01-341-3024

6220-01-183-4557

6220-01-301-5411

5995-01-096-0733

6220-01-183-4557

5305-00-984-6193

5310-00-045-3299

5325-01-341-3023

5305-00-068-0511

5340-01-326-0035

5310-00-637-9541

5310-00-732-0558

5340-01-325-2827

5340-01-326-8059

5305-00-071-2069

5305-00-984-6210

5310-00-934-9751

5310-00-045-3296

6680-01-325-6281

5330-01-290-2621

5310-01-324-8325

6160-01-360-6492

5310-00-088-1251

5310-00-809-4058

6160-01-343-1320

5306-01-341-8905

6140-01-210-1964

5340-01-339-8940

5340-01-339-8910

5940-00-143-4775

6150-01-346-8206

5940-01-342-1642

5940-00-143-4780

6150-01-354-4400

5943-01-135-2403

5940-00-143-4780

5940-00-143-4780

5961-00-957-6865

6150-01-349-5316

5940-00-143-5284

5940-00-143-4774

5940-00-143-4794

5940-01-341-5267

1-41

CAGEC

66234

05383

96906

66234

96906

81349

66234

96906

96906

96906

06383

2X179

66234

96906

96936

66234

66234

96906

39428

70842

66234

96906

66234

06383

96936

96906

13548

80204

66234

96906

96906

66234

66234

80204

96906

96906

96906

33955

33955

2X179

96906

96906

06383

06383

58961

13548

13548

13548

13548

13548

96906

TM5-3825-230-14&PC02

PART NUMBER

9040. 6745.031

401-94303

MS51922-1

MS27183-10

401-94773

401-94756

MS52149-1

3705T101

728197

703-92065

MS25036-156

703-92127

DNF18-250F1M-C

MS25036-108

703-92128

BSV14X-C

MS25036-108

703-92152

MS25036-108

JAN1N3611

703-92130

MS25036-115

MS25036-153

MS25036-112

DV14-250-C

MS51922-33

MS25036-108

DNF18-250F1B-C

BSV10X-L

WG-16-0-6IN

10403

10205R

10744R

93906

10205R

MS35205-245

MS35338-42

10401

B1821BH03BC125N

401-94117

MS35333-46

MS51967-8

401-94439

401-94438

B1821BH050C150N

MS35206-263

MS35650-302

MS35338-43

1501775

9610070

276.4670, 014

SECTION IV

FIG.

42

42

42

42

42

42

42

42

42

42

42

41

41

41

42

42

42

42

41

41

41

41

41

41

41

40

40

41

41

40

40

40

40

39

40

40

40

40

40

40

39

39

39

39

39

39

39

39

39

39

39

ITEM

10

11

8

9

5

6

7

12

13

14

15

9

10

11

3

4

1

2

7

8

6

6

3

4

5

11

12

1

2

9

10

7

8

17

1

2

3

4

5

6

10

11

12

13

14

15

16

6

7

8

9

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5310-00-880-7744

5340-01-340-0481

3120-01-339-8891

3040-01-339-8603

5340-01-339-9011

5310-00-984-3806

5340-01-339-9010

5340-01-341-3049

5310-00-081-4219

5315-00-842-3044

5360-01-268-2610

5330-01-325-5151

3110-00-606-1841

3110-00-606-1840

5307-01-324-8407

3040-01-324-8554

3110-00-606-1842

3110-00-606-1839

5340-01-325-5892

5310-01-327-3340

2640-00-555-2841

2530-01-323-6048

5310-00-088-6897

5315-00-234-1664

5310-00-809-8533

6150-01-354-4401

5940-00-557-4338

5940-00-434-6062

5940-00-114-1305

5940-01-342-1641

5940-00-230-0515

5940-00-143-5284

5940-00-143-4780

5940-00-432-2660

5940-00-143-4794

6150-01-347-2512

5940-00-143-4780

2530-01-324-5178

2530-01-322-0673

2530-01-069-9174

5365-01-070-2350

5310-00-762-6223

3130-01-070-5629

5306-01-071-1309

5315-00-550-7397

2530-01-250-1624

2530-01-069-4213

5365-00-803-7301

5360-00-553-2039

5306-00-225-8499

5310-00-407-9566

1-42

CAGEC

8H836

8H836

60038

60038

8H836

8H836

27783

8H836

96906

96906

96936

96906

66234

4Y310

66234

66234

96906

66234

92867

96906

96906

8H836

8H836

60038

60038

96906

94189

94189

94189

94189

96906

94189

94189

94189

94189

94189

96906

94189

96906

96906

66234

96906

79550

96906

06383

96906

96906

96906

00779

96906

66234

TM5-3825-230-14&PC02

PART NUMBER

MS51967-5

401-94816

BCSM6700

410-92827

410-92834

MS51922-9

401-94504

01215601

MS27183-12

MS24665-283

700-1

806-1

LM67048

LM67010

263-2

0C9-1

LM11910

LM11949

114-1

262-2

TR415

902-1

MS9358-17

MS24665-495

MS27163-23

703-92131

MS25036-125

61

MS25036-116

DNF18-250M-C

MS25036-154

MS25036-115

MS25036-108

61198-1

MS25036-112

703-92129

MS25036-108

17122

16691

16690

7029

MS51967-41

0101663800

8798

12560

23319

8780

MS16624-1050

8785

MS90725-34

MS35333-45

SECTION IV

FIG.

46

46

46

46

46

46

46

46

46

46

46

45

45

45

46

46

46

46

45

45

45

45

45

45

45

45

45

45

45

45

45

45

45

43

43

43

43

44

45

45

43

43

43

43

43

43

43

43

43

43

43

ITEM

10

11

8

9

5

6

7

12

13

14

15

18

19

20

3

4

1

2

11

12

13

14

15

16

17

9

10

7

8

5

6

3

4

12

13

14

15

1

1

2

9

10

11

7

8

5

6

1

2

3

4

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

2530-01-352-9090

5330-01-055-3870

3110-00-763-0259

3110-00-769-1426

5306-01-055-6876

2530-01-358-7719

3110-00-926-1379

3110-00-926-1379

5340-00-253-1910

5310-00-119-2090

2640-00-555-2841

2530-01-323-6048

5315-00-234-1664

5310-00-088-6897

5310-00-809-8533

2610-01-336-8828

2510-01-324-1216

5340-00-186-5085

5305-00-269-3218

2590-00-473-6331

4030-00-282-4885

5310-00-087-4652

5305-00-724-5914

3040-01-358-8598

5310-00-269-4340

5315-01-324-6779

5315-00-234-1664

5365-01-154-8557

2510-01-324-1217

5315-01-324-1748

5310-00-407-9566

5306-00-226-4825

5340-01-220-6352

5340-01-326-1256

4030-00-684-6346

4033-00-542-3184

4010-00-494-2326

4030-00-243-4439

5310-00-637-9541

2510-01-339-8413

5315-00-234-1664

5315-01-326-0083

2540-01-323-6045

5315-00-234-1664

5310-00-088-6897

5310-00-809-8533

5310-00-877-5795

5360-01-268-2610

1-43

CAGEC

66234

96906

66234

96906

66234

66234

96906

96906

96906

96906

8H836

66234

96936

66234

96652

66234

66234

96906

80204

55017

55017

66234

10001

80205

82918

8H836

96906

96906

96906

73842

66234

19207

96906

07860

66234

12128

96906

96906

66234

96906

94189

94189

60038

60038

94189

94189

60038

94189

94189

94189

17875

TM5-3825-230-14&PC02

PART NUMBER

16622

15529

L68149

L68111

5081

16626

L44649

8019

14286

5082

T-15R-50

902-1

MS24665-495

MS9358-17

MS27183-23

ST225/75R15

410-92613

8690523

MS90725-68

C21452

509-90329

M647

MS51922-17

MS90725-168

410-92672

MS51922-49

400-65650

MS24665-495

509-92004

29-10

410-92669

410-92668

MS35338-45

B18213H031C075N

100100

100112

509-92013

1784995

NAS1042-18

F310190-437

387-91668

MS35333-46

410-92667

MS24665-495

383-72815

410-92666

MS24665-495

MS9358-17

MS27183-23

MS21044-N8

700-1

SECTION IV

FIG.

49

49

49

49

49

49

49

49

49

49

49

48

49

49

49

49

49

49

48

48

48

48

48

48

48

48

48

48

48

47

47

48

48

47

47

47

47

47

47

47

46

46

46

46

47

47

47

46

46

46

46

ITEM

10

11

12

13

7

8

9

14

15

16

17

14

1

2

5

6

3

4

10

11

12

13

7

8

9

5

6

3

4

11

12

1

2

8

9

10

6

7

4

5

20

21

22

23

1

2

3

16

17

18

19

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5330-01-325-5151

3110-00-606-1841

3110-00-606-1840

5307-01-324-8407

3040-01-324-8554

3110-00-606-1842

3110-00-606-1839

5340-01-325-5892

5340-01-339-9012

5320-00-957-2493

5305-00-068-0502

5310-00-582-5965

5310-00-809-4058

5340-01-348-6222

5340-01-339-8960

2510-01-352-2334

5340-01-324-8414

5340-01-339-8961

5310-00-088-1251

2815-01-340-1453

9905-01-342-5306

7690-01-331-9013

7690-01-332-8948

9905-01-342-5307

7690-01-349-3926

9905-01-343-1207

5305-00-984-6193

5310-00-559-0070

7690-01-331-8267

7690-01-326-5394

7690-01-326-5393

9905-01-366-4743

9905-01-342-8191

7690-01-332-1839

4320-01-324-5113

4320-01-323-5149

4320-01-323-5128

5315-01-324-0422

4320-01-323-7364

4730-00-702-5694

3040-01-324-1275

3040-01-324-1276

4320-01-323-5157

5305-01-323-8924

5365-01-325-7217

5310-00-809-5998

5310-00-584-5272

5305-00-044-4153

CAGEC

11341

88044

11341

11341

11341

11341

11341

11341

96906

96906

96906

96906

96906

66234

66234

66234

66234

66234

66234

11341

11341

11341

11341

11341

11341

96906

96906

66234

66234

66234

66234

66234

96906

66234

66234

66234

66234

66234

66234

66234

8H836

60038

60038

8H836

8H836

60038

60038

8H836

66234

96906

96906

I-44

TM5-3825-230-14&PC02

PART NUMBER

MS35206-245

MS35333-38

390-72016

390-65608

390-65607

390-92041

390-92045

390-65643

40P007RAASA

4P0004-002

4P0013-001

5A0078

5A0048

2A0310-604

4P0007-007

AN933-3

4P0012-008

4P0011-008

4P0003-002

2A0079-634

2A0466-150

5A0050

MS27183-18

MS35338-48

MS90725-109

806-1

LM67048

LM67010

263-2

009-1

LM11910

LM11949

114-1

387-92022

MS20604B5W8

MS90725-6

MS35338-44

MS27183-10

402-92006

410-93039

410-92727

410-92718

410-93040

MS51922-1

402-92326

390-92042

390-65617

390-92026

390-92043

390-76001

390-92044

SECTION IV

FIG.

51

51

51

51

51

51

51

51

51

51

51

51

51

51

51

51

51

51

50

50

50

51

51

51

51

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

ITEM

12

13

14

15

16

17

18

19

20

21

22

10

11

8

9

5

6

7

27

28

29

3

4

1

2

23

24

25

26

19

20

21

22

12

13

14

15

16

17

18

9

13

11

7

8

5

6

1

2

3

4

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5340-01-324-4496

5310-00-225-6993

4320-01-323-6028

3130-01-339-0849

3110-01-340-8032

3110-01-339-8793

3040-01-339-1580

3120-01-265-2462

3040-01-340-0353

5340-01-339-0873

2520-01-339-6520

5305-01-339-6960

5340-01-339-2129

6105-01-339-1220

5305-00-071-2069

5310-00-809-5998

5310-00-087-4652

4820-01-342-3185

5315-01-339-8804

5315-00-816-1794

3040-01-211-2255

5305-00-121-2420

3040-01-170-9751

4820-01-340-1074

5330-01-217-8918

4820-01-155-0302

2530-01-339-8589

5365-01-340-2025

3110-01-339-8794

5360-01-339-8825

5365-01-340-2026

5340-01-339-8956

5310-01-154-0712

5360-01-339-8826

5340-01-153-9240

5310-01-154-0713

5305-01-339-8924

3110-01-160-2471

CAGEC

11341

11341

11341

11341

11341

11341

11341

11341

11341

11341

11341

63050

80204

96906

96906

11341

11341

24617

11341

80205

11341

11341

11341

11341

11341

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

63050

66234

96906

63050

63050

63050

63050

63050

63050

63050

63050

63050

I-45

TM5-3825-230-14&PC02

PART NUMBER

410-92658

MS51922-33

RE-1808020

PE130823

PE018003

PE018002

RE018030

PE011600

PE018059

PE014007

PE015006

PE018041

PE018019

PE016001

RS018013

RE018048

RE012001

PE247005

RE018170

RE018001

RE018163

RE018977

RE018006

REO18005

RE018138

RE018153

RE018187

B18213H050C150N

MS27183-18

MS51922-17

CA237NBEEO

1V1702

103374

1V1703

NAS1352-4LE8P

4Z4306

1V0006

2A0283-7214

1R0037

1V1426

2A0354-112

2A0017-8

1A0610

1V0217

1V0370

1A0291

1A0332

1A0292

1A0290

2A0079-414

1A0294

SECTION IV

FIG.

53

53

53

53

53

53

53

53

53

53

53

53

53

53

53

53

53

53

52

52

53

53

53

53

53

52

52

52

52

52

52

52

52

52

52

52

52

52

52

52

51

51

51

51

51

51

52

51

51

51

51

ITEM

13

14

15

16

17

18

19

20

21

22

23

9

10

11

12

6

7

8

17

18

1

4

5

2

3

13

14

15

16

9

10

11

12

6

7

8

4

5

2

3

27

28

29

30

31

32

1

23

24

25

26

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

5305-00-983-6659

3120-01-340-8324

5310-00-809-5997

5360-01-339-3827

5330-01-339-8916

5310-01-340-8371

4810-01-340-0375

4820-01-364-3406

5305-00-782-9489

5310-00-087-7493

4730-01-011-7736

5365-01-340-3121

4730-01-292-4698

4730-01-339-8517

4730-01-011-7736

4730-00-277-9997

4730-01-007-7158

4730-01-339-4496

4730-01-049-3251

4730-00-058-3353

4730-01-075-1920

4730-01-096-9138

4730-00-965-6538

4730-00-908-3194

5340-01-069-5306

4710-01-339-8435

6680-01-309-6450

4310-01-094-0791

4730-01-343-8719

4730-00-223-9255

4730-00-196-1539

4730-01-340-0303

4730-01-178-9654

4730-00-278-2523

4730-01-339-4524

4730-01-324-5074

4730-00-908-3194

4730-01-340-8701

4730-01-339-6733

4730-00-239-2803

CAGEC

66295

72423

22031

66234

66234

99103

96906

66234

22031

72423

22031

66234

96906

98441

96906

66234

55017

66234

76280

90005

72423

88044

96906

72423

22031

66234

22031

66234

30327

66234

96906

96936

01276

66234

66234

30327

66234

31327

65234

61424

96906

11341

96906

11341

11341

11341

11341

11341

96906

96906

96906

I-46

TM5-3825-230-14&PC02

PART NUMBER

204-35493

MS39324-12-10

0188-12-12

MS35842-11

204-85611

100075

205-74425

208-72630

569020-02

2071-039

AN910-2

MS51953-36

1003-253

4601-16-NWO

20H

2071-249

4404-16

204-85730

212-91159

0M-1012

MS35842-11

204-85693

6401-12-0

1021-150

5404-16-12

MS16998-42

1V0269

MS27183-17

1A0739

1V0272

2A0736-104P

1A0710

1V0046

MS-90728-66

MS27183-13

MS51527A12

400-72806

2501-4

213-91779

HL12-12NJ

204-85451

MS51527A12

MS51953-36B

2046-4-4S

206-34005

213-91901

HA04-04MB

204-85041

HG04-04NJ

213-91767

10655-12-12

SECTION IV

FIG.

56

56

56

56

56

56

56

56

56

57

57

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

56

55

55

55

55

55

55

55

54

54

54

54

54

54

54

53

53

53

53

ITEM

23

24

25

26

27

28

29

30

30

1

2

16

17

18

19

20

21

22

9

10

11

12

13

14

15

7

8

5

6

3

4

1

2

5

6

7

3

4

1

2

5

6

7

3

4

1

2

24

25

26

27

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

3020-01-323-5998

5305-00-071-2069

5306-00-952-0964

5310-01-326-1053

5310-00-067-6356

5310-00-809-8533

5310-00-087-4652

5310-00-087-7493

5305-01-325-8387

5340-01-324-4260

4730-00-172-0010

5310-01-342-4964

5360-01-324-8510

5340-01-324-6784

5315-01-325-5456

5315-00-298-1481

2510-01-324-1218

5310-30-088-1251

5310-00-584-5272

5310-00-768-0318

5340-01-324-6798

2520-01-323-5940

2520-01-323-5941

5306-00-226-4825

5310-00-407-9566

2940-01-339-3846

2940-00-755-6584

4730-01-340-8883

4730-01-339-8515

6680-01-340-8840

5310-00-209-0786

5310-01-350-8553

2590-01-340-1606

3010-01-341-2459

4730-00-050-4208

5305-01-340-2076

5306-00-225-8499

5310-00-809-3078

5310-00-880-7744

5310-00-407-9566

5340-01-328-2257

5340-01-355-0276

2540-01-323-6051

5310-00-823-8804

5305-00-068-0509

5305-00-068-0502

5340-01-327-3590

5310-00-225-6993

5310-00-809-5993

5306-00-702-4483

5340-01-324-6754

I-47

CAGEC

66234

96906

66234

96906

96906

96906

66234

66234

66234

80204

96906

66234

80204

96906

66234

96906

96906

96906

96996

96906

66234

96906

66234

56988

66234

96906

96906

96906

96906

66234

66234

66234

96906

83204

96906

66234

96906

96906

96906

66234

60827

60827

72423

72423

2X179

96906

24617

2X179

2X179

96906

2X179

TM5-3825-230-14&PC02

PART NUMBER

AF-10-25-0

AE-10

2071-199

1001-199

2529.007

MS35335-33

11505913

9282.003

7475018

MS15003-1

9730.004

MS90725-34

MS27183-11

MS51967-5

MS35338-45

401-94242

401-94292

101-75791

MS27183-9

B1821BH025C125N

MS90725-6

410-92663

MS51922-33

MS27183-18

MS35751-130

401-94280

401-94240

B1821BH050C150N

MS35751-183

401-94233

MS51922-57

MS27183-23

MS51922-17

MS27183-13

MS90725-64

410-92657

MS15002-1

372-92034

D97

410-92655

383-92046

MS24665-357

410-92664

MS51922-1

MS35338-48

MS51967-14

401-94118

401-94230

401-94231

B1821BH031C075N

MS35338-45

SECTION IV

FIG.

60

60

60

60

60

60

60

60

60

60

60

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

59

58

58

58

58

58

58

59

57

58

58

58

58

58

58

57

57

57

57

ITEM

6

7

4

5

1

2

3

10

11

8

9

17

18

19

20

21

22

23

10

11

12

13

14

15

16

8

9

6

7

4

5

2

3

9

10

7

8

11

12

1

4

5

6

2

3

7

1

3

4

5

6

5330-01-367-6594

3040-01-342-8732

5315-01-333-5735

5315-00-298-1499

5305-00-225-3843

5305-00-071-2069

5365-01-340-2091

5340-01-324-6799

4320-01-358-8565

5305-01-323-5473

5325-01-339-8969

4320-01-347-8626

5305-01-323-5474

4320-01-333-5914

4320-01-323-5114

4820-01-324-5045

5930-01-324-8927

5305-01-324-8356

4320-01-324-7898

4320-01-323-7481

3040-01-324-1223

5305-01-323-5477

6105-01-360-5571

5340-01-327-3492

5310-00-088-1251

5310-00-225-6993

5310-00-809-4058

4730-01-323-5107

4710-01-323-8541

5310-00-761-6882

5310-00-582-5965

4730-01-323-5079

4730-31-099-7329

4730-00-908-3194

5340-01-324-6794

4730-01-356-8760

5330-01-356-7144

CROSS REFERENCE INDEXES

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

3825-01-327-0530

3825-01-324-2743

5365-01-326-1152

3130-01-324-8895

4730-00-050-4208

5315-01-324-1750

4730-00-414-5962

3040-00-570-6161

3040-01-346-6383

CAGEC

72423

66234

96906

96906

72423

61424

96906

66234

66234

73124

73124

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

96906

96906

96906

67029

67089

67029

67029

66234

96906

80204

80204

66234

66234

OFDH7

OFDH7

OFDH7

OFDH7

OFDH7

66234

66234

66234

21335

96906

66234

93334

67029

67029

67089

67029

1-48

TM5-3825-230-14&PC02

PART NUMBER

21195-003

21041-001

20028-008

02095-100

20131-001

20500-507

20428-000

21033-002

91003-000

02019-001

11028-101

MS51922-1

MS51922-33

MS27183-10

1145-150

401-94241

MS51967-2

MS35333-44

1101-150

P8MCB-12

MS35842-11

204-85299

401-94253

BF10125SXT

BF0150PP

907-46665

410-92662

401-94232

VAS 1 7/16

MS15003-1

383-92045

444654

72276

DHA1-216

RST-150

2-221

DH5-116

DH3-145

DH14-65

DH2-218

383-92044

MS24665-360

B1821BH025C100N

B1821BH050C150N

402-92239

401-94254

2100-332

20131-002

20132-00

20050-132

21131-000

SECTION IV

CROSS REFERENCE INDEXES

FIG.

ITEM

FIGURE AND ITEM NUMBER INDEX

STOCK NUMBER

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

60

61

60

60

60

60

60

60

60

60

60

60

60

16

17

18

19

20

21

22

12

13

14

15

34

35

36

37

30

31

32

33

23

24

25

26

27

28

29

33

39

1

4730-01-356-8761

5310-00-225-6993

5310-00-809-5998

5340-01-324-4262

5306-01-323-5539

4730-01-324-6572

4730-00-196-1502

4730-01-339-8103

4820-01-340-0285

4730-01-340-1680

4730-01-324-6595

4730-01-323-5080

4730-00-196-1468

4730-01-324-6492

5305-00-071-2081

5340-01-324-6783

5340-01-357-6222

5330-01-356-7145

5430-01-339-8677

5343-01-348-6116

5306-01-324-4962

4730-01-323-7313

5120-01-361-9773

¶U.S GOVERNMENT PRINTING OFFICE 1993 -746 -017/80275

I-49

CAGEC

72423

8K002

72423

96906

72423

50204

66234

66234

66234

73124

7R531

73124

65234

66234

66234

7J925

82247

2X179

7R531

72423

96906

96906

66234

66234

05779

66234

96906

72423

39428

TM5-3825-230-14&PC02

PART NUMBER

RT56125

2171-249

MS51922-33

MS27183-18

401-94252

401-94251

P8MCB-6

204-85227

MS51953-29

2071-098

4887K33

2071-099

2P130

1101-148

MS51953-97

2173-200

B1821BH050C450N

483-49720

410-92661

488-72394

BF10075SXT

RT5675

BF0075PP

221-92018

221-92023

221-92322

370-74138-05

H1/4VVL-8002

7535.14603.009

TM 5-3825-230-14&P

APPENDIX G

ILLUSTRATED LIST OF MANUFACTURED ITEMS

G-1.

INTRODUCTION.

This appendix includes complete instructions for manufacturing or fabricating authorized items locally. All bulk materials needed to manufacture an item are listed by part number or specification number in a tabular list with an illustration, as needed.

Section I. UNIT MAINTENANCE MANUFACTURED ITEMS

G-2.

AIR DUCT HOSE FABRICATION .

The air duct hose for the air cleaning assembly is fabricated from bulk hose stock, P/N CWC2INDIA It is fabricated by

cutting a 12 in. (305 mm) length of bulk hose with a fine-toothed hacksaw or suitable cutting device. Refer to paragraph

4-37 for installation instructions.

G-3.

FUEL HOSE FABRICATION.

There are two fabricated fuel hoses in the fuel system, one is a supply line and one is a return line. Locations and

installation instructions are found in paragraph 4-42 and paragraph 4-46. Table G-1 lists the two hoses.

Table G-1. Fuel System Hoses

Item

Supply

Return

Hose Assy

Part Number

204-92148

204-92149

Bulk Hose Cutoff Length

Part Number Inches (mm)

H05704

H05704

10 (254)

16 (406)

Fitting

A

100-43

4501-4-4

Fitting

B

7270.104

560.9571.077

G-1

TM 5-3825-230-14&P

G-4.

ELECTRICAL GROUND AND JUMPER WIRES FABRICATION.

There are six ground and jumper wires in the electrical system. Locations are shown in the RPSTL, figures 32, 34, and

35. Refer to paragraph 4-83 for terminal or connector installation.

Table G-2. Ground and Jumper Wires

Wire Part Number

WG-16-0-6IN

WG-16-0-8IN

WG-16-0-12IN

703-92132

703-92096

WG-16-0-6IN

Bulk Wire Part Number

WG-16-0-1000

WG-16-0-1000

WG-16-0-1000

WG-10-0-1000

WB-4-0-500

WG-16-0-1000

Cutoff Length

Inches (mm)

6 (152)

8 (203)

12 (305)

9 (228)

10 (254)

6 (152)

Wire Gauge

16 ga

16 ga

16 ga

10 ga

4 ga

16 ga

G-5.

CONDUIT FABRICATION.

Conduit for the broom hood wiring harness is fabricated from bulk PVC pipe stock, P/N A52AE12. Cut conduit using a fine-toothed hacksaw or suitable cutting device. Drill endcaps with a drill and 1/2" drill bit. Coupling, P/N E940D can be

used for repair of damaged conduit. Refer to paragraph 4-78 for installation instructions.

Table G-3. Conduit Fabrication

PVC

Part Number

402-92109

402-92111

402-92110

Bulk PVC

Part Number

A52AE12

A52AE12

A52AE12

Cutoff Length

Inches (mm)

2 (51)

48.5 (1221)

16 (406)

G-2

Quantity

1

2

2

Fitting A

401-005

401-005

406-005E

Fitting B

N/A

406-005E

447-005

G-6.

TRANSPORT CHAIN FABRICATION.

The transport chain is used in two places. The length is the same for each application.

TM 5-3825-230-14&P

NOTES:

1.

Obtain enough bulk chain, P/N 671442, to fabricate transport chain to desired length.

2.

Use a fine-toothed hacksaw or suitable cutting device and cut chain.

3.

Install two eye and jaw swivels, P/N M647, on chain.

Figure G-1. Transport Chain

G-3

TM 5-3825-230-14&P

G-7.

STUD LINK CHAIN FABRICATION.

One stud link chain is located on the main frame assembly.

NOTES:

1.

Obtain enough bulk ch ain, P/N 3607T21, to fabricate stud link chain to desired length.

2.

Use a fine-toothed hacksaw or suitable cutting device and cut chain.

3.

Install retaining ring, P/N 29-10, and cotter pin, P/N MS24665-495, on chain.

Figure G-2. Stud Link Chain

G-8.

HYDRAULIC HOSE FABRICATION.

The following hydraulic hoses are cut from bulk hose using a fine-toothed hacksaw or suitable cutting device, and are

clamped on to the hydraulic fittings. Refer to paragraph 4-105 for installation instructions.

Table G-4. Hydraulic Hoses

Hose Assembly

Part Number

204-85611

204-85730

204-85690

Bulk Hose

Part Number

2556-12

U216-6

2556-12

G-4

Cutoff Length

Inches (mm)

11(279)

30 (762)

90 (2286)

TM 5-3825-230-14&P

G-9.

HOSE GUARD FABRICATION.

Plastic hose guard for the hydraulic motor hoses is fabricated from bulk hose guard stock, P/N 1722-95. It is fabricated by cutting 12 in. (305 mm) length of the bulk hose guard using tin snips. Wrap hose guard around hydraulic hoses.

Figure G-3. Hose Guard

G-10.

WATER LINES FABRICATION.

The two water lines are fabricated from bulk hose stock, P/N B708. Locations and installation instructions are found in

paragraph 4-123. Cut bulk hose to desired length using a fine-toothed hacksaw or suitable cutting device. Table G-5

lists the hoses.

Table G-5. Water Hoses

Hose Assembly

Part Number

204-85299

204-85227

Bulk Hose

Part Number

B708

B708

Cutoff Length

Inches (mm)

99 (2515)

27 (686)

G-5

TM 5-3825-230-14&P

G-11.

WATER TANK LID STRING FABRICATION.

The water tank lid string is fabrication from bulk string stock, P/N 3852T36. It is fabricated by cutting an 18 in. (457 mm)

length of bulk string using scissors or a suitable cutting device. Refer to paragraph 4-121 for installation instructions.

G-12.

WATER TANK SADDLE TRIM AND PAD FABRICATION.

Edge trim for the water tank saddle is fabricated from bulk trim stock, P/N 75000317. Foam pad is fabricated from bulk

pad stock, P/N N-200. Table G-6 lists bulk items and lengths; all widths are 4 inches.

Table G-6. Saddle Trim and Pads

Item

Item Assembly

Part Number

Bulk Part

Number

Cutoff Length

Inches (mm)

Trim

Pad A

Pad B

488-49720

488-72394

488-72394

75000317

N-200

N-200

76 (1930)

41(1041)

16 (406)

G-6

TM 5-3825-230-14&P

WARNING

Dry cleaning solvent P-D-680 is toxic and flammable. Wear protective goggles, face mask, and gloves and use only in a well ventilated area. Avoid contact with skin, eyes, and clothes and don't breathe vapor. Do not use near open flame or excessive heat. The flashpoint for type I dry cleaning solvent is 100°F (38°C) and for type II is 140°F (60

°C). If you become dizzy while using cleaning solvent, get fresh air immediately and get medial aid. If contact with eyes is made, flush eyes with water and get medical aid immediately.

NOTES:

1.

Scrape old foam pads from saddle with scraper and clean affected areas with dry cleaning solvent P-D-

680.

2.

Remove edge trim from the saddle and clean affected area with dry cleaning solvent P-D-680.

3.

Cut foam pads A and B and/or edge trim to lengths specified In table G-6.

4.

Install foam pads A and B and/or edge trim to saddle with self-adhesive side facing down.

Figure G-4. Saddle Trim and Pads

G-7

TM 5-3825-230-14&P

Section II. DIRECT SUPPORT MAINTENANCE MANUFACTURED ITEMS

G-13.

THROTTLE CONTROL LOCKWIRE FABRICATION.

Lockwire for the throttle control lever assembly is fabricated from bulk wire stock, P/N MS20995C20. It is fabricated by

cutting a 12 in. (305 mm) length of the bulk wire with wire cutters. Refer to paragraph 5-28 for installation instructions.

G-14.

HYDRAULIC HOSE FABRICATION.

The following hydraulic hoses are cut from bulk stock. Refer to paragraph 4-105 for installation instructions. Table G-7

lists the hoses and adapters.

Table G-7. Hydraulic Hose Assembly Components

Hose Assembly

Part Number

204-85451

204-85041

204-85493

Bulk Hose

Part Number

J412

SAE100R1TY-ATSZ4

J412

Cutoff Length

Inches (mm)

51(1295)

41(1041)

93(2362)

Adapter A

HL12-12NJ

HA04-04MB

10655-12-12

Adapter B

HL12-12NJ

HG04-04NJ

10655-12-12

NOTES:

1.

Obtain all components required to fabricate desired hose assembly (table G-7).

2.

Use a fine-toothed hacksaw or suitable cutting device and cut hose to desired length.

3.

Slide adapter A on hose and crimp as necessary.

4.

Slide adapter B on hose and crimp as necessary.

5.

Prior to installation, test hose and adapter assembly to 2, 000 psi (13, 800 kPa) using methods found in

TM 9-4940-468-14, Tool Outfit Hydraulic System Test and Repair.

Figure G-5. Hydraulic Hose Assembly Components

G-8

APPENDIX H

SCHEMATICS

ELECTRICAL LIGHTING DIAGRAM

TM 5-3825-230-14&P

12V AND 24V WIRING HARNESSES

LEGEND

7

8

5

6

9

2

3

No.

1

4

Qty

4

4

2

3

1

3

1

1

1

H-1

Description

LAMP, TURN SIGNAL

LAMP, RED SIDE LAMP

DIODE

RESISTOR

TERMINAL BLOCK

CIRCUIT BREAKER

WIRE HARNESS

WIRE HARNESS

I.D. LIGHT BAR

ENGINE AND BATTERY WIRING HARNESS

TM 5-3825-230-14&P

12

13

14

15

7

8

9

10

11

5

6

3

4

No.

1

2

1

1

1

1

1

1

1

1

1

2

1

1

1

Qty

1

1

LEGEND

Description

SWITCH, TOGGLE

FUSE

PUMP

ALTERNATOR

BATTERY

AMMETER

FUEL GAGE

FUEL SENDING UNIT

SWITCH, IGNITION

SWITCH, PUSH BUTTON

GLOW PLUG

STARTER RELAY

FUSE HOLDER

ENGINE

WIRE ASSY, GROUND

H-2

H-3/(H-4 blank)

TM 5-3825-230-14&P

Subject, Para

A

Access Covers, Left and Right, 3-5

Abbreviations, 1-6

Adjustments

Broom Pattern, 4-111

Engine Speed, 4-23

Administrative Storage Instructions, 4-126

Air Cleaner Assembly Replacement, 4-37

Air Filter Inspection, 3-7

Alternator

Belt Check, 3-9

Belt Replacement, 4-56

Mounting Bracket Replacement, 4-57

Drive Pulley Replacement (Engine), 4-33

Replacement, 4-57

Ammeter Scale Replacement, 4-62

Angle Bracket Replacement, 4-27

B

Bar, Spray Repair, 4-124

Battery

Box Replacement, 4-75

Cable Disconnect, 4-73

Replacement, 4-74

Repair, 5-36

Service, 3-11

Belt, Alternator Replacement, 4-56

Bleeding, Fuel System, 4-36

Box, Battery Replacement, 4-75

Bracket

Alternator Mounting Bracket Replacement, 4-57

Angle Bracket Replacement, 4-27

Decontamination Bracket Replacement, 4-92

Motor Mounting Bracket Replacement, 4-25

Side Lamp Bracket Replacement, 4-70

Spray Pump Bracket Replacement, 4-120

Brake

Assembly Adjustment, 4-85

Assembly Repair, 4-87

Drum and Hub Repair/Replacement, 4-86

Hand Brake Adjustment, 3-12

Hand Brake Lever Replacement, 4-84

Breather Replacement, 4-104

Broom Pattern Adjustment, 4-111

Broom Hood Replacement, 4-115

Broom Hood Wiring Harness Replacement, 4-78

TM 5-3825-230-14&P

INDEX

Subject, Para

B (CONT)

Brush

Frame Assembly Replacement, 4-114

Replacement, 4-117

Bulb, Gage Replacement, 4-59

Button, Push Replacement, 4-61

C

Cable

Battery Disconnect, 4-73

Engine Cut-off Cable Replacement, 4-47

Throttle Control Cable Replacement, 4-47

Camshaft Replacement, 5-26

Center Light Mount Replacement, 4-71

Chain

Safety Chain Assembly Replacement, 4-95

Transport Chain Assembly Replacement, 4-93

Checks,

Hydraulic Fluid, 3-13

Engine Oil, 3-6

Circuit Breaker Replacement (Junction Box), 4-67

Cleaner, Air Assembly Replacement, 4-37

Cleaning Procedures, Unit 4-15

Clearance, Engine Bumping, 5-8

Common Tools and Equipment, 4-1

Components

Inspection of Components, 4-14

Removal and Disassembly of Components, 4-16

Connecting Rod Assembly Repair, 5-21

Control Panel Replacement, 4-80

Control Valve, Hydraulic Replacement, 4-103

Controls and Indicators, Location and Use of, 2-2

Core, Hydraulic, Replacement, 4-118

Cover Assembly, Rocker Arm Repair, 5-22

Cover, Rocker Arm, Replacement, 4-28

Covers, Left and Right Access, 3-5

Crankcase Assembly Replacement, 5-10

Crankshaft Replacement, 5-14

Crown Gear Replacement, 5-18

Cylinder

Head Assembly, Repair/Replacement, 5-13

Engine Cylinder, Replacement, 5-9

Hydraulic Cylinder, Repair, 5-42

Hydraulic Cylinder, Replacement, 4-119

Index 1

TM 5-3825-230-14&P

Subject, Para

E

Enclosure, Engine Replacement, 4-98

Engine

Alternator Drive Pulley Replacement, 4-33

Battery and Engine Wire Harness

Replacement, 4-81

Bumping Clearance, 5-8

Enclosure Replacement, 4-98

Engine and Battery Wire Harness

Replacement, 4-81

Flywheel Housing, 4-53

Cut-off Cable Replacement, 4-47

Cylinder Replacement, 5-9

Housing, Rear Engine Replacement, 5-12

Oil Check, 3-6

Removal, 4-24

Shock and Mount Replacement, 4-26

Speed Adjustment, 4-23

Timing, 5-7

Equipment

Characteristics, Capabilities, and Features, 1-10

Data, 1-12

Servicing Unit, 4-11

Exhaust Valve Replacement, 5-24

INDEX (CONT)

Subject, Para

D

Data Plate Replacement, 4-99

Data, Equipment, 1-12

Decal Replacement, 4-100

Decontamination Bracket Replacement, 4-92

Deflector Assembly, Dirt, Front Replacement, 4-112

Deflector, Heat Replacement, 4-54

Destruction of Army Materiel to Prevent Enemy Use, 1-3

Direct Support Troubleshooting Instructions, 5-5

Dirt Deflector

Front Dirt Deflector Assembly Replacement, 4-113

Side Dirt Deflector Replacement, 4-114

Draining

Fuel Tank, 4-41

Hydraulic, 4-106

Filter

F

Air Filter Inspection, 3-7

Fuel Filter Replacement, 4-49

Fuel Filter Housing Replacement, 4-49

Hydraulic Filter Replacement, 4-107

Hydraulic Filter Housing Replacement, 4-108

Oil Filter Replacement, 4-22

Oil Filter Housing Replacement, 4-29

Flywheel

Guard Replacement, 4-52

Housing Replacement, 4-53

Replacement with Crown Gear, 5-17

Forms, Maintenance Records, and Reports, 1-2

Frame

Brush Frame Assembly Replacement, 4-114

Swing Frame Replacement, 4-94

Front

Hub Assembly Repair/Replacement, 4-89

Support Replacement, 5-15

Tire Change, 4-88

Fuel

Filter Housing Replacement, 4-49

Filter Replacement, 4-48

Gage Replacement, 4-63

Injector Nozzle Assembly Repair, 5-31

Injector Assembly Replacement, 5-30

Line Replacement (Bleed Lines), 4-49

Line Replacement (Filter to Injector Line), 4-46

Line Replacement (Injector Pump to Nozzle), 4-45

Line Replacement (Pump to Filter), 4-43

Line Replacement (Tank to Pump), 4-42

Pump Replacement, 4-35

Sending Unit Replacement, 4-72

Strainer Replacement, 4-39

System Bleeding, 4-36

Tank Filling, 3-8

Tank Replacement, 4-40

Tank Screen Service, 3-8

Tank Valve Replacement (Fuel Draining), 4-41

Wire Harness Replacement, 4-82

Fuse and Holder Replacement, 4-65

INDEX 2

TM 5-3825-230-14&P

Subject, Para

G

Gage

Ammeter Scale Replacement, 4-62

Bulb Replacement, 4-59

Fuel Replacement, 4-63

Gear Assembly, Tachometer, Replacement, 4-109

General Lubrication Instructions, 3-1

General Support Troubleshooting Instructions, 5-5

Glow Plug

Replacement, 4-50

Wire Harness Replacement, 4-82

Governor Control Lever Assembly Repair, 5-29

Ground Handling, 4-12

Guard

Flywheel Guard Replacement, 4-52

Hydraulic Motor Guard Replacement, 4-116

H

Hand Brakes

Adjustment, 3-12

Inspection, 3-12

Replacement, 4-84

Heat Deflector Replacement, 4-54

Holder, Fuse Replacement, 4-65

Hose Assembly, Hydraulic Replacement, 4-105

Housing, Filter, Hydraulic Replacement, 4-108

Hub Assembly, Front Repair/Replacement, 4-89

Hydraulic

Control Valve Repair, 5-41

Control Valve Replacement, 4-103

Core/Brush Set Replacement, 4-118

Cylinder Repair, 5-42

Cylinder Replacement, 4-119

Fabrication and Testing, 5-38

Filter Housing Replacement, 4-108

Filter Replacement, 4-107

Fluid Check, 3-13

Hose Assembly Replacement, 4-105

Motor Repair, 5-40

Motor Replacement, 4-102

Mount Replacement, 4-102

Oil Draining, 4-106

Pump Assembly Repair, 5-39

Pump Assembly Replacement, 4-101

Pump Drive Assembly Replacement, 4-34

INDEX (CONT)

Subject, Para

Injection Pump

Replacement, 5-33

Timing, 5-32

Inspection of Components, 4-14

Air Filter, 3-7

Hand Brakes, 3-12

Intake Manifold Replacement, 4-32

Intake Valve Replacement, 5-24

Junction Box

Repair/Replacement, 4-66

Resistor Replacement, 4-67

I

J

Circuit Breaker Replacement, 4-67

Wire Harness (12V) to Tow Vehicle, Replacement, 4-76

Wire Harness (24V) to Tow Vehicle Replacement, 4-77

Key Switch Replacement, 4-60

L

Lamp

Bracket Replacement, Side, 4-70

Replacement, Side, 4-69

Light Mount Kit Replacement, 4-68

Light Mount, Center Replacement, 4-71

Lights, Inspection 3-10

Lines, Sprinkler Replacement, 4-123

Location and Description of Major Components, 1-11

Lubrication Instructions, General, 3-1

Mainframe Repair, 5-37

K

M

Maintenance Forms, Records, and Reports, 1-2

Major Components, Location and Description of, 1-11

Manifold, Intake Replacement, 4-32

Modified Spindle Replacement, 4-87

Index 3

TM 5-3825-230-14&P

Subject, Para

M (CONT)

Motor

Guard Replacement, 4-116

Mounting Bracket Replacement, 4-25

Hydraulic Motor Repair, 5-40

Hydraulic Motor Replacement, 4-102

Mount, Hydraulic Motor, Replacement, 4-102

Mounting Bracket

Alternator Mounting Bracket Replacement, 4-57

Motor Mounting Bracket Replacement, 4-25

Muffler Replacement, 4-51

N

INDEX (CONT)

Subject, Para

Noise Shroud Replacement, 4-55

Oil

O

Check, Engine, 3-6

Filter Housing Replacement, 4-29

Filter Replacement, 4-22

Pan Assembly Replacement, 4-30

Pump Replacement, 5-27

Hydraulic Oil Draining, 4-106

Operating

Instructions on Decals and Instruction

Plates, 2-10

Operating Procedures, 2-8

Operation

Under Unusual Conditions, 2-11

Assembly and Preparation For Use, 2-7

Emergency Procedures, 2-13

Fording, 2-12

Technical Principles

Electrical System, 1-14

Fuel System, 1-16

Hydraulic System, 1-15

Mechanical System, 1-13

Sprinkler System, 1-17

Operational Checks, Unit, 4-13

Operator's PMCS Table, 2-6

Operator's Troubleshooting Symptoms, 3-3

P

Painting, 4-17

Pan, Oil Replacement, 4-30

Parts, Repair, 4-3

Pattern, Broom, Adjustment, 4-111

Piston Assembly Replacement, 5-19

Plate, Data Replacement, 4-99

Plug, Glow Replacement, 4-50

PMCS Table

Operator's, 2-6

Unit, 4-7

Pole, Tow Replacement, 4-96

Preparation For Storage Or Shipment, 1-7

Pressure Valve Replacement, 4-31

Pulley, Alternator Drive, Replacement, 4-33

Pump

Fuel Pump Replacement, 4-35

Hydraulic Pump Drive Assembly Replacement, 4-34

Injection Pump Timing, 5-32

Injection Pump Replacement, 5-33

Oil Pump Replacement, 5-27

Spray Pump Bracket Replacement, 4-120

Spray Pump Repair, 5-43

Spray Pump Replacement, 4-120

Pump Assembly, Hydraulic

Repair, 5-39

Replacement, 4-101

Push Button Replacement, 4-61

Quality Assurance/Quality Control (QA/QC), 1-8

R

Rear Light and Mount Replacement, 4-68

Rear Light Wire Harness Replacement, 4-79

Rear Support Replacement, 5-16

Rear Tire Change, 4-88

Records and Reports, Maintenance Forms, 1-

Removal and Disassembly of Components, 4-16

Removal, Engine, 4-24

Q

INDEX 4

TM 5-3825-230-14&P

Subject, Para

R (CONT)

Repair Parts, 4-3

Reporting Equipment Improvement Recommendations

(EIR), 1-4

Reports and Records, Maintenance Forms, 1-2

Resistor Replacement (Junction Box), 4-67

Ring Set Replacement, 5-20

Rocker Arm

Assembly Replacement, 5-23

Cover Assembly Repair, 5-22

Cover Replacement, 4-28

Rod Assembly, Connecting, Repair, 5-21

S

Saddle Replacement, 4-122

Safety Chain Assembly Replacement, 4-95

Safety, Care, and Handling, 1-9

Scale, Ammeter Replacement, 4-62

Screen, Fuel Tank Service, 3-8

Sending Unit, Fuel Replacement, 4-72

Separator, Vapor Replacement, 4-38

Service

Fuel Tank Screen, 3-8

Battery, 3-11

Sprayer System Strainer, 3-14

Equipment, 4-11

Shipment or Storage, Preparation of, 1-7

Shipping Instructions, 4-127

Shock and Mount, Engine, Replacement, 4-26

Shroud, Noise Replacement, 4-57

Side Dirt Deflector Replacement, 4-113

Side Lamp Bracket Replacement (Front), 4-70

Side Lamp Replacement, 4-69

Special Tools, TMDE and Support Equipment, 4-2

Speed Governor Repair, 5-34

Spindle, Modified Replacement, 4-87

Spray

Bar Repair, 4-124

Pump Bracket Replacement, 4-120

Pump Repair, 5-43

Pump Replacement, 4-120

Sprayer System Strainer Service, 3-14

Sprinkler Lines Replacement, 4-123

INDEX (CONT)

Subject, Para

S (CONT)

Starter

Repair, 5-35

Replacement, 4-58

Steering Strut Repair/Replacement, 4-97

Storage Instructions, Administrative 4-126

Storage or Shipment, Preparation of, 1-7

Strainer

Fuel Replacement, 4-41

Sprayer System Service, 3-14

Strut, Steering Repair/Replacement, 4-97

Support Yoke Repair, 5-34

Support

Front Support Replacement, 5-15

Rear Support Replacement, 5-16

Swing -Frame Replacement, 4-94

Switch

Key Switch Replacement, 4-60

Spray Pump Toggle Switch Replacement, 4-64

T

Tachometer

Gear Assembly Replacement, 4-109

Gearwheel Housing Replacement, 5-11

Gearwheel Replacement, 5-11

Tachometer and Tachometer Cable Replacement,

4-110

Tank Assembly, Water Replacement, 4-121

Tank, Fuel Replacement, 4-40

Technical Principles of Operation

Electrical System, 1-14

Fuel System, 1-16

Hydraulic System, 1-15

Mechanical System, 1-13

Sprinkler System, 1-17

Throttle Control Assembly Repair, 5-28

Throttle Control Cable Replacement, 4-47

Timing

Engine, 5-7

Injection Pump, 5-32

Tire Change

Front, 4-88

Tire

Rear, 4-88

Repair, 4-91

Replacement, 4-90

Toggle Switch, Spray Pump, Replacement, 4-64

Index 5

Subject, Para

T (CONT)

Tools

Common, 4-1

Special, TMDE and Support Equipment, 4-2

Torque Charts, U.S. Standard and Metric, 4-20

Tow Pole Replacement, 4-96

Tow Vehicle to Junction Box Wire Harness (12V)

Replacement, 4-76

Tow Vehicle to Junction Box Wire Harness (24V)

Replacement, 4-77

Transport Chain Assembly Replacement, 4-93

Troubleshooting

Instructions, DS/GS, 5-5

Symptoms, Operators, 3-3

Troubleshooting, Unit 4-8

U

Unit

Cleaning Procedures, 4-15

Maintenance Introduction, 4-10

PMCS Table, 4-7

Troubleshooting, 4-8

TM 5-3825-230-14&P

INDEX (CONT)

INDEX 6

Subject, Para

V

Valve

Control Valve, Hydraulic Replacement, 4-103

Fuel Tank Replacement, 4-40

Hydraulic Control Valve Repair, 5-41

Pressure Valve Replacement, 4-31

Vapor Separator Replacement, 4-38

W

Warranty Information, 1-5

Water Tank Assembly Replacement, 4-121

Wheel Replacement, 4-88

Wire Harness

12V Tow Vehicle to Junction Box Wire Harness

Replacement, 4-76

24V Tow Vehicle to Junction Box Wire Harness

Replacement, 4-77

Broom Hood Wire Harness Replacement, 4-78

Engine and Battery Wire Harness Replacement, 4-

81

Fuel Plug Wire Harness Replacement, 4-82

Glow Plug Wire Harness Replacement, 4-82

Rear Light Wire Harness Replacement, 4-79

THE METRIC SYSTEM AND EQUIVALENTS

SQUARE MEASURE LINEAR MEASURE

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches

1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches

1 kilometer = 1000 Meters = 0.621 Miles

WEIGHTS

1 Sq. Centimeter = 100 Sq. Millimeters = 0.155 Sq. Inches

1 Sq. Meter = 10,000 Sq. Centimeters = 10.76 Sq. Feet

1 Sq. Kilometer = 1,000,000 Sq. Meters = 0.386 Sq. Miles

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces

1 Kilogram = 1000 Grams = 2.2 Lb.

1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

CUBIC MEASURE

1 Cu. Centimeter = 1000 Cu. Millimeters = 0.06 Cu. Inches

1 Cu. Meter = 1,000,000 Cu. Centimeters = 35.31 Cu. Feet

TEMPERATURE

LIQUID MEASURE

1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces

1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

5/9 (°F - 32) = °C

212° Fahrenheit is equivalent to 100° Celsius

90° Fahrenheit is equivalent to 32.2° Celsius

32° Fahrenheit is equivalent to 0° Celsius

9/5 (°C + 32) = F°

APPROXIMATE CONVERSION FACTORS

TO CHANGE TO MULTIPLY BY

Inches....................................................................

Feet.......................................................................

Yards.....................................................................

Miles......................................................................

Square Inches.......................................................

Square Feet...........................................................

Square Yards........................................................

Square Miles.........................................................

Acres.....................................................................

Cubic Feet.............................................................

Cubic Yards...........................................................

Fluid Ounces.........................................................

Pints ......................................................................

Quarts ...................................................................

Gallons..................................................................

Ounces..................................................................

Pounds..................................................................

Short Tons.............................................................

Pound-Feet............................................................

Pounds per Square Inch........................................

Miles per Gallon.....................................................

Miles per Hour.......................................................

Centimeters...........................................................

Meters...................................................................

Meters...................................................................

Kilometers.............................................................

Square Centimeters..............................................

Square Meters.......................................................

Square Meters.......................................................

Square Kilometers.................................................

Square Hectometers.............................................

Cubic Meters.........................................................

Cubic Meters.........................................................

Milliliters ................................................................

Liters.....................................................................

Liters.....................................................................

Liters.....................................................................

Grams...................................................................

Kilograms..............................................................

Metric Tons...........................................................

Newton-Meters......................................................

Kilopascals............................................................

Kilometers per Liter...............................................

Kilometers per Hour..............................................

2.540

0.305

0.914

1.609

6.451

0.093

0.836

2.590

0.405

0.028

0.765

29.573

0.473

0.946

3.785

28.349

0.454

0.907

1.356

6.895

0.425

1.609

TO CHANGE TO MULTIPLY BY

Centimeters...........................................................

Meters ...................................................................

Meters ...................................................................

Kilometers.............................................................

Square Centimeters...............................................

Square Meters.......................................................

Square Meters.......................................................

Square Kilometers.................................................

Square Hectometers..............................................

Cubic Meters.........................................................

Cubic Meters.........................................................

Milliliters.................................................................

Liters .....................................................................

Liters .....................................................................

Liters .....................................................................

Grams ...................................................................

Kilograms..............................................................

Metric Tons ...........................................................

Newton-Meters......................................................

Kilopascals............................................................

Kilometers per Liter...............................................

Kilometers per Hour...............................................

Inches ...................................................................

Feet.......................................................................

Yards.....................................................................

Miles......................................................................

Square Inches.......................................................

Square Feet..........................................................

Square Yards........................................................

Square Miles.........................................................

Acres.....................................................................

Cubic Feet.............................................................

Cubic Yards..........................................................

Fluid Ounces.........................................................

Pints......................................................................

Quarts...................................................................

Gallons..................................................................

Ounces .................................................................

Pounds..................................................................

Short Tons............................................................

Pound-Feet...........................................................

Pounds per Square Inch.......................................

Miles per Gallon....................................................

Miles per Hour.......................................................

0.394

3.280

1.094

0.621

0.155

10.764

1.196

0.386

2.471

35.315

1.308

0.034

2.113

1.057

0.264

0.035

2.205

1.102

0.738

0.145

2.354

0.621

PIN: 069815-002

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