TB 5-2520-551

TB 5-2520-551-24

TECHNICAL BULLETIN

INSTALLATION INSTRUCTIONS

FOR

TRUCK INSTALLATION KIT

T R Q - 3 2 ( V )

Approved for public release. Distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

12 JANUARY 1989

TECHNICAL BULLETIN

TB 5-2520-551-24

TB 5-2520-551-24

HEADQUARTERS

DEPARTMENT OF THE ARMY

WASHINGTON, D.C., 12 January 1989

INSTALLATION INSTRUCTIONS

FOR

TRUCK INSTALLATION KIT

TRQ-32(V)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual.

If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and

Blank Forms), or DA Form 2028-2 located in the back of this technical bulletin direct to: U.S. Army Troop Support Command, ATTN: AMSTR-

MCTS, 4300 Goodfellow Boulevard, St. Louis, MO 63120-1798. A reply will be furnished directly to you.

APPROVED FOR PUBLIC RELEASE. DISTRIBUTION IS UNLIMITED.

TABLE OF CONTENTS

Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Materials Supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION .........................................................

Preliminary .......................................................

PTO Unit ..................................................................

PTO Actuator Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometer ....................................................................

Tachometer Cable Assembly .....................................................

Tachometer Magnetic Pickup and RPM Sensor . . . . . . . . . . . . . . . . . . . . . .

Remote Radio Control Unit Mounting Bracket . . . . . . . . . . . . . . . . . . . . . .

Remote Radio Control . . . . . . . . . . .

W-33 Vehicle Cable Assembly ......

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat Sensor Switch ....................................................

W-65 Speed Control Cable Assembly ...................................

Speed Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Control Magnetic Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tandem Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Skid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

42

43

47

50

22

23

28

29

15

16

18

19

7

11

6

6

54

1

1

2

4

i

TB 5-2520-551-13

TABLE OF CONTENTS (Cont)

TEST AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Control RPM Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

56

56

WIRING DIAGRAMS

W-67 Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W-33 Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W-65 Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FP-1

FP-3

FP-5

INSTALLATION DRAWINGS

Truckbed Modification Drawing (2 sheets) . . . . . . . . . . . . . . . . .

Hydraulic Line Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FP-7

FP-11 ii

TB 5-2520-551-24

INSTALLATION INSTRUCTIONS

FOR

TRUCK INSTALLATION KIT

TRQ-32(V)

INTRODUCTION

The purpose of this Technical Bulletin is to provide procedures for modifying the

M1028A vehicle and installing a TRQ-32(V) Installation Kit. These instructions may also be used to retain the Installation Kit if a vehicle change-over is required.

When installed, the Installation Kit provides vehicle engine speed control, a hydraulic pump to drive the TRQ-32(V) system power generator and air conditioner, and a remote radio control unit.

PURPOSE

This document contains the information required to modify the M-1028A1 truck for use with the AN/TRQ-32(V) system.

PERSONNEL REQUIRED: 2

1

2

1

1

1

1

1

1

1

1

2

1

2

1

1

1

2

2

MATERIALS REQUIRED (Parts and Components required in addition to the Installation

Kit)

QTY

P/N

DESCRIPTION

1

AR

AR

1

AR

AR

AR

1

1

1

1

1

1

M-1028A1

C5118904-1

C5118905-1

C5122481-1

C5122498-1

C-2298/VRC

H250/U

M17111

825504-4

C5118949-1

2320-01-158-0820

5895-01-171-3476

5895-01-171-4049

5895-01-171-3475

5895-01-171-3477

5830-00-892-3338

5965-00-043-3463

9150-00-261-8317

9150-00-261-8317

8030-00-182-2508

8305-00-267-3015

TRUCK

SPEED CONTROL GROUP

POWER TAKE-OFF

RESERVOIR ASSEMBLY

PUMP ASSEMBLY

INTERCOM, REMOTE ELEMENT

HANDSET

FLUID, POWER TRANSMISSION

HYDRAULIC FLUID

PALLET, SHELTER ALIGNMENT

LOCKTIGHT

CLOTH

RTV MIL-A-46106

(TYPE 1)

C5122508-1

C5122509-1

C512251O-1

C5122511-1

C5122512-1

C5122512-2

C5131409-1

C5131409-2

C5131409-3

C5131409-4

C5131409-5

C5111OO8-1

C5111OO9-1

C511101O-1

C5111011-1

C5111012-1

C5111013-1

AN737TW46

HOSE ASSEMBLY

HOSE ASSEMBLY

HOSE ASSEMBLY

HOSE ASSEMBLY

HOSE ASSEMBLY

HOSE ASSEMBLY

QUICK DISCONNECT,

QUICK DISCONNECT,

QUICK DISCONNECT,

QUICK DISCONNECT,

QUICK DISCONNECT,

TUBE ASSEMBLY

TUBE ASSEMBLY

TUBE ASSEMBLY

TUBE ASSEMBLY

TUBE ASSEMBLY

TUBE ASSEMBLY

CLAMP, HOSE

HYDRAULIC

HYDRAULIC

HYDRAULIC

HYDRAULIC

HYDRAULIC

1

2

TB 5-2520-551-24

P/N

QTY

2

1

3

2

1

AN815-12D

AN815-4D

AN815-8D

M6000HO0304

M6000DO0307

33

34

35

36

37

38

39

40

24

25

26

27

28

29

20

21

22

23

30

31

32

13

14

15

16

8

9

10

11

12

17

18

19

1

2

3

4

5

6

7

1

1

8

16

9

2

10

1

1

1

1

1

1

1

1

3

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

NSN

C5110943-1

C5110944-1

C5118946-1

C5118947-1

C5118948-1

C5110651-1

C5110649-1

C5110649-2

C511065O-1

C511065O-2

C511065O-3

C511065O-4

C5122612-1

C5122613-1

C5131109-1

C5131109-2

C5131109-3

C5131109-4

C5131109-5

C5110654-1

C5110654-2

C5110654-3

C5110654-4

C5110529-1

C5110530-1

C5110559-1

C5110652-1

C5110698-1

C5110787-1

C5118950-1

C5118955-1

C5122557-1

C5122564-1

C512261O-1

C5122611-1

MS90725-6

MS90725-8

MS90725-62

MS90725-111

MS90726-13

DESCRIPTION

UNION

UNION

UNION

HOSE, RUBBER

HOSE, RUBBER

MATERIALS REQUIRED (cont.)

MATERIALS SUPPLIED (Parts and components included in the Installation Kit)

ITEM

NO.

QTY P/N NSN DESCRIPTION

BRACKET, MOUNTING

BRACKET, MOUNTING

SKID PLATE

BRACKET, SKID PLATE

BRACKET, SKID PLATE

BRACKET, CHANNEL

BRACKET, CHANNEL

BRACKET, CHANNEL

BRACKET, CLAMP

BRACKET, CLAMP

BRACKET, CLAMP

BRACKET, CLAMP

PLATE, CLEARANCE, HOLE

PLATE, RETAINER HOSE

CLAMP

CLAMP

CLAMP

CLAMP

CLAMP

PLATE, COVER

PLATE, COVER

PLATE, COVER

PLATE, COVER

BRACKET, MOUNTING

BRACKET, MOUNTING

BRACKET, SPEED CONTROL

BRACKET, MOUNTING

GAUGE PANEL

CABLE ASSEMBLY (W33)

TRANSFER CASE LOCKOUT ASSEMBLY


RPM REGULATOR ASSEMBLY


BRACKET, HEAT SENSOR

COVER, HEAT SENSOR

5305-00-068-0502 SCREW, CAP, HEXAGON





ITEM

NO.

69

70

71

72

73

74

75

59

60

61

62

63

64

65

66

67

68

48

49

50

51

52

53

54

55

56

57

58

41

42

43

44

45

46

47

80

81

82

83

84

76

77

78

79

85

86

87

88

89

90

91

QTY

2

2

1

AR

45

1

1

2

2

4

4

2

2

4

4

1

1

AR

AR

2

8

AR

45

2

2

4

9

28

11

2

9

6

2

2

24

8

1

1

AR

1

AR

2

6

2

2

1

1

4

1

1

1

P/N

MS90726-14

MS90726-17

MS51971-1

MS51971-3

AN960C416

AN960C616

NAS1640-416

NAS1640-616

MS35338-143

MS51959-70B

C5131383-1

C5131353-1

C5131037-1

C5131118-1

C5131118-2

C5131118-3

MS3367-3-O

AN737TW22

AN737TW30

AN737TW58

C51107O8-1

MS35307-333

NAS1640-516

MS51971-2

MS51957-29

MS24693C3

NAS1640-4

NAS671C4

C5131106-1

MS35498-4

MS25036-148

M16878/4BGB9

MS3367-2-O

MS35307-312

MS35307-309

MS51958-62

NAS164O-10

MS24693C272

MS51958-64

NAS671C1O

C5110621-1

MS20913-1S

MS35489-18

C5131401-1

MS35309-31O

C5131400-1

AN960C6

M7928/5-3

M7928/5-4

M7928/5-5

MS35333-11O

TB 5-2520-551-24

MATERIALS SUPPLIED (cont.)

NSN DESCRIPTION

5305-00-071-2237

5305-00-071-2234

5310-00-903-5966

5310-00-913-8881

5310-00-531-9515

5310-00-167-0804

5310-00-933-8121

5310-00-984-6042

5310-00-933-8778

5305-00-733-3041

5975-00-074-2072

4730-00-278-9200

4730-00-720-0167

4730-00-278-0424

5306-00-817-4989

5310-00-767-0445

5305-00-054-6653

5305-00-957-2383

5310-00-208-3786

5325-00-174-5317

5940-00-813-0698

6145-01-203-4055

5975-00-899-4606

5305-00-207-2297

5305-00-579-5283

5305-00-059-3658

5310-00-442-6911

5305-00-957-7811

5305-00-059-3660

5310-00-812-4292

4730-00-221-2136

5325-00-276-6090

5305-00-550-3935

5310-00-531-9514

5940-01-079-1647

5940-01-079-1375

5940-01-079-1936

5310-00-022-8847

SCREW, CAP, HEXAGON

SCREW, CAP, HEXAGON

NUT, PLAIN

NUT, PLAIN

WASHER, FLAT

WASHER, FLAT

WASHER, LOCK

WASHER, LOCK

WASHER, LOCK

SCREW, MACHINE

NUT, U

NUT, CLIP

FILTER ASSY

SLEEVE, PROTECTIVE

SLEEVE, PROTECTIVE

SLEEVE, PROTECTIVE

STRAP, TIEDOWN

CLAMP, HOSE

CLAMP, HOSE

CLAMP, HOSE

TACHOMETER

SCREW, CAP

WASHER, LOCK

NUT, PLAIN

SCREW, MACHINE

SCREW, MACHINE

WASHER, LOCK

NUT, PLAIN HEXAGON

NUT, LOCK

GROMMET, RUBBER

TERMINAL, LUG

WIRE, ELECTRICAL

STRAP, TIEDOWN

SCREW, CAP

SCREW, CAP

SCREW, MACHINE

WASHER, LOCK

SCREW, MACHINE

SCREW, MACHINE

NUT, PLAIN HEXAGON

COVER, FLYWHEEL

PLUG, PIPE

GROMMET, RUBBER

THREAD LUBRICANT

SCREW, CAP

THERMAL JOINT COMPOUND

WASHER, FLAT

TERMINAL, LUG & SPLICES



WASHER, LOCK

3

TB 5-2520-551-24

MATERIALS SUPPLIED (cont.)

ITEM

NO.

92

93

94

QTY P/N

AR

1

12

M23053/5-108-O

C5132683-1

MS27130S31

NSN DESCRIPTION

INSULATION SLEEVING, ELECTRICAL

SPACER, SKID PLATE

5310-01-015-1021 NUT, PLAIN

1

1

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

TOOLS REQUIRED (All necessary tools required to install the kit)

QTY NSN DESCRIPTION

2

1

SIZE/TYPE

12"

15"

5120-00-264-3796

5120-00-423-6728

ADJUSTABLE WRENCH

ADJUSTABLE WRENCH

1 5120-00-293-3509 CENTER PUNCH

3/16"

1/4"

5/16"

3/8"

7/16"

1/2"

9/16"

11/16"

3/4"

7/8"

1"

1-1/4"

10 mm

15 mm

5120-00-132-0496

5120-00-288-9997

5120-00-228-9503

5120-00-228-9504

5120-00-228-9505

5120-00-228-9506

5120-00-228-9507

5120-00-228-9509

5120-00-228-9510

5120-00-228-9512

5120-00-228-9514

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

COMBINATION WRENCH

1 5120-00-132-6913 CRIMPING TOOL

4"

5110-00-239-8253 DIAGONAL CUTTING PLIERS

1

.201

.332

.375

.406

.500

5120-00-240-5396

DRILL BIT

DRILL BIT

DRILL BIT

DRILL BIT

DRILL BIT

DRIVE RATCHET HANDLE

1

3/8"

3/8" 5120-00-240-5364 DRIVE SWIVEL

1

2

1

3"

6"

16 OZ.

5120-00-061-8543

EXTENSION

EXTENSION

HAMMER

1

1

1/8"

5/32"

5120-00-240-5292

5120-00-198-5392

HEX KEY WRENCH

HEX KEY WRENCH

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

QTY

1

SIZE/TYPE

1-1/2"

9/32"

3/8"

1/2"

NO.1

NO.2

1/4"

1/8"

3/16"

1/4"

NO.1

NO.2

3/16"

7/16"

1/2"

9/16"

5/8"

10 mm

15 mm

17 mm

ROLL

60 WATT

.250-20UNC-2B

20-30 AWG

TB 5-2520-551-24

NSN

5120-00-294-8913

TOOLS REQUIRED (cont.)

DESCRIPTION

HOLE SAW

NUT DRIVER

PORTABLE ELECTRIC DRILL

PORTABLE ELECTRIC DRILL

PUTTY KNIFE

RIVET NUT INSTALLATION TOOL

ROUND FILE 5110-00-234-6551

SABER SAW

5120-00-240-8716

5120-00-240-8713

5120-00-596-8502

SCREW DRIVER CROSS TIP

SCREW DRIVER CROSS TIP

SCREW DRIVER FLAT TIP (1-1/2" SHAFT)

5120-00-236-2140

5120-00-278-1270

5120-00-222-8852

SCREW DRIVER FLAT TIP





SCREW DRIVE OFFSET FLAT TIP

5120-00-223-7397 SLIP JOINT PLIERS

5120-00-227-6703

5120-00-237-0977

5120-00-227-6704

5120-00-237-4973

3493-00-185-4708

SOCKET

SOCKET

SOCKET

SOCKET

SOCKET

SOCKET

SOCKET

SOLDER

3493-00-134-9202 SOLDERING IRON

TAP

5120-01-020-7755 TIEDOWN TOOL

5110-00-364-2854 WIRE STRIPPER

5

TB 5-2520-551-24

INSTALLING THE KIT

WARNING

Disconnect batteries before performing following steps.

PRELIMINARY

6

1.

2.

3.

CAUTION

Prevent damage to engine electronic components.

Disconnect batteries in following order: First, disconnect negative (-) terminal from rear battery.

Second, disconnect negative (-) terminal from front battery.

Remove tailgate from truck, if necessary.

Lift protective cover on negative (-) terminal of rear battery. Using

9/16" combination wrench, loosen nut and disconnect cable from battery terminal.

Lift protective cover on negative (-) terminal of front battery. Using

9/16" combination wrench, loosen nut and disconnect cable from battery terminal.

4.

5.

6.

7.

TB 5-2520-551-24

PTO UNIT

Using a 9/16" combination wrench, remove and discard PTO cover plate and mounting hardware from transfer case.

Remove and discard old cover plate gasket from the transfer case and clean surface.

Install two 9/16" nuts onto PTO mounting stud to

9/16" combination wrenches, tighten nuts against mounting stud into transfer case.

Using a 9/16" tighten stud.

be installed. Using each other.

Install combination wrench, two

PTO

Using a 9/16" combination wrench, remove two nuts from PTO mounting stud.

Using the same procedure, install the remaining five PTO mounting studs.

8.

9.

Apply RTV (MIL-A-46106, type 1) to both sides of new PTO gasket. Place gasket on transfer case.

Install PTO actuator cable bracket on PTO unit and tighten using 1/2" combination wrench.

10.

Using 1/2" combination wrench, remove and retain bolt holding actuator arm.

Move actuator arm from shipping position to normal operating position and reinstall bolt.

11.

Using 5/16" combination wrench, install pipe plug (item 82, MS20913-1S) in

PTO flange adapter.

12.

13.

Install PTO unit on transfer case.

Tighten six nuts and washers securing

PTO unit, using 9/16" combination wrench.

Using 3/4" combination wrench, remove and retain mounting nut from PTO actuator cable.

7

TB 5-2520-551-24 PTO UNIT (cont.)

14.

Below steering column, remove four screws securing plastic collar to instrument panel cover using NO.2 cross tip screwdriver. Remove and retain collar and hardware.

15.

Using NO.2 cross tip screwdriver, remove eight screws securing instrument panel cover.

Remove and retain hardware.

16.

Pull top of instrument panel cover out about two inches and remove two warning lights by rotating 1/4 turn clockwise.

8

TB 5-2520-551-24

PTO UNIT (cont.)

17.

Measure 1.25" down and 1.5" left of lower right mounting screw on the instrument panel. Mark location with center punch. This is the center point of the hole to be drilled in the next step.

18.

Using electric drill with 1/8" drill bit, drill pilot hole in dashboard.

19.

Using electric drill with .500 drill bit, drill hole in dashboard. Clean burrs from hole using file.

9

TB 5-2520-551-24


10

20.

On firewall, locate insulation knockout 6" above upper mounting screws of accelerator pedal and 4" right of steering column support bolts.

Remove and discard insulation knockout.

Mark center of hole using center punch.

21.

Using electric drill with 1/8" drill bit, drill pilot hole in firewall.

22.

Using electric drill with .375" drill bit, drill hole in firewall.

23.

On rear of instrument panel cover, using 7mm wrench, remove and discard bolt and bracket securing radio block-off cover.

TB 5-2520-551-24

PTO ACTUATOR CABLE

24.

In truck cab, insert PTO actuator cable through hole in firewall and install through hole previously drilled in dashboard.

25.

Place PTO actuator cable between engine and firewall towards PTO unit.

11

TB 5-2520-551-24


26.

On PTO unit, place cable housing in mounting bracket on PTO assembly.

Cable should have enough slack with no kinks to keep it from rubbing against engine or firewall.

27.

28.

Under dashboard, reinstall nut holding PTO actuator cable to dashboard.

Using 3/4" combination wrench, hold cable housing. Using 3/4" combination wrench, tighten nut.

Install nut and knob on end of PTO cable using 9/16" combination wrench.

29.

Pull PTO actuator cable out of housing about half way in truck cab.

30.

On PTO unit, remove cable housing from bracket. Mark point to cut on cable housing.

Using diagonal cutting pliers, cut cable housing. Cable housing end should not be crimped closed after cutting.

31.

Place cable housing in bracket on PTO unit. Using a 1/2" combination wrench, hold bolt.

Using a 7/16" combination wrench, tighten nut onto bolt.

12

TB 5-2520-551-24

PTO ACTUATOR CABLE (cont.)

32.

Rotate PTO actuator arm fully toward rear of truck.

33.

In truck cab, push PTO control knob forward leaving about 1/4" between control knob and dashboard.

13

TB 5-2520-551-24

PTO ACTUATOR CABLE (cont.)

34.

35.

36.

37.

On PTO unit, place cable through hole in bolt at end of actuator arm.

Using a 1/2" combination wrench, hold actuator arm bolt. Using a 1/4” combination wrench, tighten nut securing cable to bolt in actuator arm.

Cut off excess cable cutting pliers. Bend slip joint pliers.

about one inch past actuator arm, using diagonal end of cable at a right angle to actuator arm using

In truck cab, engage and disengage PTO control knob to insure cable travel.

Inside engine compartment, apply RTV (MIL-A-46106, type 1) to hole where

PTO actuator cable passes through firewall.

14

38.

39.

TB 5-2520-551-24

TACHOMETER

Using electric drill and 1/8" bit, drill out two rivets securing gauge panel to instrument panel.

Behind instrument panel cover, using 11/32" wrench, remove and retain two nuts securing wires to voltmeter terminals.

Tag and remove wires. Remove voltmeter lamp and housing from voltmeter.

40.

Using 3/8” combination wrench, remove and retain two nuts securing voltmeter bracket to mounting studs.

Remove and retain voltmeter bracket.

41.

Install voltmeter into right side of new gauge panel (item 28, C5110698-1).

Secure voltmeter bracket onto mounting studs with two nuts. Using a 3/8" combination wrench, tighten nuts.

42.

Install tachometer (item 61, C51107O8-1) into left side new gauge panel

(item 28, C5110698-1).

Secure tachometer bracket to panel with two nuts.

Using a 3/8" combination wrench, tighten nuts.

43.

Splice W-67 cable to tachometer wires with splices (item 88, M7928/5-3 and item 89, M7928/5-4).

Using crimping pliers, crimp splices. Reference figure 1 at back of this bulletin.

44.

Reconnect wires to voltmeter terminals.

Secure wires with two nuts.

Using

11/32" combination wrench, tighten nuts. Reinstall lamp into voltmeter.

45.

Install and tighten two screws (item 65, MS51957-29) and washers (item 87,

AN960C6) securing gauge panel (item 28, C5110698-1) to instrument panel using NO.1 cross tip screwdriver.

15

TACHOMETER CABLE ASSY.

TB 5-2520-551-24

46.

Route W67E1 and W67E2 through radio hole in dashboard. Connect W67E1 to

TB2-3 and W67E2 to TB2-5 on rear of RPM regulator assembly (item 32,

C5122577-1) using 3/16" flat tip screwdriver. Ensure W-67 cable (item 33,

C5122564-1) is clear of heater controls in dashboard.

47.

Install W-67 cable (item 33, C5122564-1) through hole in firewall and into engine compartment.

16

TB 5-2520-551-24

TACHOMETER CABLE ASSEMBLY (cont.)

48.

In engine compartment, route W-67 cable (item 33, C5122564-1) to sensor pickup at harmonic balancer.

17

TB 5-2520-551-24

TACH MAGNETIC PICKUP & RPM SENSOR

49.

Apply thread lock (MIL-S-22743, grade JV) on the threads of the magnetic pickups.

50.

On harmonic balancer, install magnetic pickups at opposite holes using

3/16” flat tip offset screwdriver.

51.

Strip insulation from ends of W67 MAG PICKUP and RPM sensor wires.

52.

Connect each end of RPM sensor wire to each W67 MAG PICKUP wire with splice

(item 88, M7928/5-3). Using crimping tool, crimp wire splices.

53.

On oil pan, remove and retain bolt closest to harmonic balancer using 3/8" drive ratchet handle, 6" extension, and 10 MM socket.

54.

Install RPM sensor holding bracket (item 34, C512261O-1) and secure with bolt using 3/8" drive ratchet handle, 6" extension, and 10 MM socket.

55.

Insure magnetic pickups on harmonic balancer pass in front of RPM sensor.

18

TB 5-2520-551-24

REMOTE RADIO CONTROL MOUNTING BRACKET

56.

In truck cab, remove and retain four bolts and one screw securing dashboard cover using 9/32" nut driver and NO.2 cross tip screwdriver.

Remove dashboard cover.

Refer to TM 9-2320-289-34.

57.

Using 3/8" combination wrench, remove and retain nut securing instrument panel molding to dashboard cover.

58.

Measure 6-5/8" left of center post on molding. Cut molding using saber saw.

59.

Measure 2" right from right side edge of left hole and mark a vertical line.

Measure 1-1/2" right from the vertical line, and mark another vertical line.

Measure 2-3/4" down from upper edge where molding is attached to dashboard cover and mark a horizontal line.

Cut a new opening where marked using saber saw.

60.

Reinstall instrument panel molding onto dashboard cover. Secure molding with a nut.

Using a 3/8" combination wrench, tighten nut.

19

TB 5-2520-551-24

REMOTE RADIO CONTROL MOUNTING BRACKET (cont.)

61.

62.

63.

Install four clip nuts (item 52, C5131353-1) in holes on dashboard understructure.

Clip nuts must be accessible through new opening and existing opening on left side of dashboard cover.

Reinstall four bolts and one screw holding dashboard cover using 9/32" nut driver and NO.2 cross tip screwdriver.

Install mounting bracket for remote radio control (C-2298/VRC) with four bolts and secure using 3/8" drive ratchet handle, 6" extension, and 7/16" socket.

20

TB 5-2520-551-24

REMOTE RADIO CONTROL MOUNTING BRACKET (cont.)

64.

Move instrument panel cover into place and reinstall two warning lights.

Turn light housings 1/4 turn counterclockwise to lock into panel.

65.

Reinstall eight screws securing instrument panel cover and four screws securing collar under steering column and tighten using NO.2 cross tip screwdriver.

21

TB 5-2520-551-24 REMOTE RADIO CONTROL C2298/VRC

66.

Install remote radio control (C2298/VRC) on mounting bracket and secure with bolts using a 3/8" drive ratchet handle, 3" extension, 1/2" socket, and 1/2" combination wrench.

67.

Install handset (H250/U) on remote radio control (C2298/VRC).

22

TB 5-2520-551-24

W-33 VEHICLE CABLE ASSEMBLY

68.

Place W-33 vehicle cable (item 29, C5110787-1) through existing hole in the right front corner of the floor of the truck bed. Make sure existing grommet is in good condition. Route W-33 vehicle cable (item 29,

C5110787-1) under vehicle along upper vehicle frame, and up through engine compartment to firewall.

23

TB 5-2520-551-24

W-33 VEHICLE CABLE ASSEMBLY (cont.)

69.

Remove covers from TB1 (+28 VDC BUSS) and TB2 (-28 VDC BUSS) on engine compartment firewall.

70.

Locate portion of the W-33 vehicle cable that is labeled 28V VEHICLE PWR.

Connect the WHITE wire to TB1 and the BLACK wire to TB2 on the firewall using 3/8" drive ratchet handle, 6" extension, and 1/2" socket.

71.

Route W-33P2 (A20A1J801) and field current relay wire (item 29, C5110787-1) through hole in firewall to remote radio control (C2298/VRC).

24

TB 5-2520-551-24


72.

73.

74.

N O T E

Most wires are shielded.

Ensure that the shielding is stripped and only the center conductor is connected to the solder cups and/or crimp terminal.

In truck cab, install five wires of W-33 cable to pin terminals of W33P2 according to bandmarkers.

Solder five wires to proper pin terminals using

45 watt soldering iron.

Connect W33P2 to J801 of remote radio control (C2298/VRC).

Remove and retain two bolts securing relay mounting bracket and diagnostic equipment connector under dashboard using 7/16" combination wrench.

75.

76.

77,

78.

Cut brown and white striped wire connected to relay on right using diagonal cutting pliers.

Strip insulation from both ends of the brown and white stripped wire.

Splice both ends of the brown and white stripped wire to W33 FIELD CUR

RELAY wire with splices (item 89, M7928/5-4). Using crimping tool, crimp wire splices.

Reinstall relay mounting bracket and diagnostic equipment connector under dashboard with two bolts using 7/16" combination wrench.

25

TB 5-2520-551-24


79.

83.

84.

N O T E

For truck wiring diagrams, refer to truck technical manuals, TM 9-2320-289-20 or TM 9-2320-289-34.

In engine compartment, cut oil pressure sensor wire on top rear of engine using diagonal cutting pliers.

Strip insulation from both ends of oil pressure sensor wires.

80.

81.

82.

Connect both ends of the oil pressure sensor wires to W33 OIL PRESS wire with splice (item 89, M7928/5-4) using crimping tool.

Cut fuel level sensor wire located at rear of engine using diagonal cutting pliers.

Strip insulation from both ends of the fuel level sensor wires.

Connect both ends of the fuel level sensor wires to W33 FUEL SENSOR wire with splice (item 89, M7928/5-4) using crimping tool.

26

TB 5-2520-551-24


85.

Cut engine temperature sensor wire located below roadside alternator using diagonal cutting pliers.

86.

Strip insulation from both ends of the engine temperature sensor wires.

87.

Connect both ends of the engine temperature sensor wires to W33 ENG TEMP wire with splice (item 89, M7928/5-4) using crimping tool.

88.

Cut -12V alternator wire located behind roadside alternator using diagonal cutting pliers.

89.

Strip insulation from ends of -12V alternator wire.

90.

Connect ends of -12V alternator wire to W33 12V ALTNTR (NEG) wire with splice fastener (item 89, M7928/5-4) using crimping tool.

91.

Using 10 mm wrench, connect W33E2 to ground terminal post on roadside alternator.

Tighten nut on ground terminal post.

92.

Using cable ties, secure W-33 vehicle cable (item 29, C5110787-1) away from exhaust manifold along with existing routed wires and fasteners.

27

TB 5-2520-551-24 HEAT SENSOR SWITCH

93.

94.

Solder terminal lug (item 71, MS25036-148) on ground wire (item 72,

M16878/4BCB9) to heat sensor switch terminal using 45 watt soldering iron.

Solder W-33 DRIVE TRAIN shielded wire to heat sensor switch terminal using

45 watt soldering iron.

95.

96.

97.

98,

99.

Insert grommet (item 70, MS35489-4) in heat sensor cover.

Place heat sensor cover (item 35, C5122611-1) on mounting bracket. Place ground wire terminal lug (item 71, MS25036-14B) on one screw. Tighten screws (item 66, MS24693C3), nuts (item 68, NAS671C4), and washers (item

67, NAS1640-4) using NO.1 cross tip screwdriver and 3/16" combination wrench.

Under truck bed, route W-33 cable (item 29, C5110787-1) over curbside frame of vehicle.

Remove and retain bolt located on the right rear of the transfer case using

3/8" drive ratchet handle, 6" extension, and 9/16" socket. Install the mounting bracket on the transfer case and secure with bolt.

Check fluid level of transfer case and fill (refer to TM 9-2320-289-20) if necessary.

28

TB 5-2520-551-24

W-65 SPEED CONTROL CABLE ASSEMBLY

100. In engine compartment, route W-65 cable (item 31, C5118955-1)(TB1 and TB2 terminal connectors and W65 S1 and S2 wires) through hole in firewall.

101. Pull W-65 cable (item 31, C5118955-1) (TB1 and TB2 terminal connectors and

W65 S1 and S2 wires) through firewall into truck cab. Route W-65 cable (S1 and S2 wires) behind dashboard and under floor mat to transfer case shift lever assembly.

29

TB 5-2520-551-24

W-65 SPEED CONTROL CABLE ASSEMBLY (cont.)

102. Remove and retain retaining nut from toggle switch barrel using 9/16" combination wrench.

Remove switch from mounting hole in lockout assembly housing.

103. Connect W65S1 and W65S2 to transfer case lockout switch (terminals 1 and 2) using 3/16" flat tip screwdriver.

Secure W-65 cable (item 31, C5118955-1) with tiedowns (item 73, MS3367-2-0) using tiedown tool.

N O T E

The spring-loaded toggle switch is a normally-open switch.

Ensure switch toggle lever is in an upward position when door is open.

For proper operation, listen for an audible click when closing door.

104. Place switch through mounting hole in housing. Reinstall retaining nut and tighten using 9/16" combination wrench.

30

TB 5-2520-551-24


105. Using a no.2 cross-tip screwdriver, remove and retain four escutcheon screws from transfer case shift lever assembly.

plate

N O T E

To install left front screw in following step, insert screw through hole at corner of lockout assembly.

106. Install lockout assembly on truck floor and secure with four screws using

NO.2 cross tip screwdriver.

107. Pull W-65 wire terminals through instrument panel opening.

31

TB 5-2520-551-24 W-65 SPEED CONTROL CABLE ASSEMBLY (cont.)

N O T E

There are two wires on terminals A3TB2-3 and A3TB2-5.

108. Using 3/16" flat tip screwdriver, connect six wires from W-65 cable (item

31, C5118955-1) (TB1-1 through TB1-6) to terminal block TB1 of RPM regulator (item 32, C5122557-1).

Observe wire band markers for proper installation.

109. Using 3/16" flat tip screwdriver, connect six wires from W-65 cable (item

31, C5118955-1) (TB2-1 through TB2-6) to terminal block TB2 of RPM regulator (item 32, C5122557-1).

Observe wire band markers for proper installation.

110.

On dashboard, install two U-nuts (item 51, C5131383-1) to RPM regulator mounting holes.

111.

Install RPM regulator assembly (item 32, C5122557-1) and secure with two screws (item 50, MS51959-70B) using NO.2 cross tip screwdriver.

32

TB 5-2520-551-24

W-65 SPEED CONTROL CABLE ASSY (cont.)

112. Cut fuel shutoff valve wire located at front of engine using diagonal cutting pliers.

113. Strip insulation from ends of fuel shutoff valve wire.

N O T E

Most wires are shielded.

Ensure that the shielding is stripped and only the center conductor is connected to the solder cups and/or crimp terminal.

114. Connect ends of fuel shutoff valve wires to W65 FUEL SHUTOFF non-shielded wire with splice (item 90, M7928/5-5) using crimping tool.

33

TB 5-2520-551-24

W-65 SPEED CONTROL CABLE ASSY (cont.)

115. Connect W65E1 to TB1 (+28 VDC BUSS) and W65E2 to TB2 (-28 VDC BUSS) on the firewall using 3/8" drive ratchet handle, 6" extension, and 1/2" socket.

116. Reinstall covers on TB1 and TB2 on engine compartment firewall.

34

TB 5-2520-551-24


117. On PTO unit, connect W65E3 to PTO sensor switch using 1/4" flat tip screwdriver with 1 1/2" shaft.

Secure W-65 cable (item 31, C5118955-1) with tiedowns (item 73, MS3367-2-0) using tiedown tool.

118. Apply RTV (MIL-A-46106, type 1) around cable hole in firewall.

35

TB 5-2520-551-24

SPEED CONTROL GROUP

36

119. Remove air cleaner assembly from engine. Using cloth, cover intake manifold opening.

120. Apply thread lock (MIL-S-22473, grade C) to four screws from speed control actuator and controller units.

Install four screws and washers and tighten using 1/4" flat tip screwdriver.

TB 5-2520-551-24

SPEED CONTROL GROUP (cont.)

121. Using 5/16" combination wrench and NO.2 cross tip screwdriver, remove fast idle control unit from throttle cable bracket.

Attach bracket (item 25,

C511053O-1) to throttle cable bracket.

122. Secure fast idle control unit to new bracket with screws (item 68,

MS51958-62; item 78, MS24693C272; item 79, MS51958-64) and nut (item 80,

NAS671C1O).

37

TB 5-2520-551-24


38

123. Using two l/2" combination wrenches, loosely connect bracket (item 27,

C5110652-1) to bracket next to roadside alternator with two bolts (item 62,

MS35307-333), nuts (item 64, MS51971-2), lock washers (item 63,

NAS1640-516).

124. Using 15mm socket, remove forward nut on second intake port bolt. Position bracket (item 26, C5110559-1) over bolt and thread on lock nut (item 69,

C5131106-1) from installation kit. Using 17mm socket, tighten nut. Other end of bracket should be aligned with top holes in bracket (item 27,

C5110652-1).

TB 5-2520-551-24


125. Using two 1/2" open end wrenches, remove and retain nut from oil filler pipe clamp.

Attach bracket (item 24, C5110529-1) to oil filler pipe clamp and tighten nut using 1/2" combination wrench.

126. Using two 1/2" combination wrenches, loosely connect bracket (item 24,

C5110529-1) to bracket (item 27, C5110652-1) with two bolts (item 75,

MS35307-309), nuts (item 43, MS51971-1), flat washers (item 45, AN960C416), and lock washers (item 47, NAS1640-416). Tighten all hardware loosely installed in previous steps.

127, Using 1/8" and 5/32" hex key wrenches, attach actuator linkage to vehicle throttle lever.

128. Install bolt (item 104, MS35309) on actuator lever (item 91, C5131375-1) and tighten using 3/8" drive ratchet handle, 7/16" socket, and 7/16" combination wrench.

129. Connect actuator linkage and throttle lever together. Tighten lock nut on actuator linkage using 3/8" combination wrench. Tighten lock nut on throttle lever using 7/16" combination wrench.

130. Using 5/32" hex key wrench, attach modified actuator lever to speed control actuator arm shaft.

39

TB 5-2520-551-24


131. Position speed control actuator and controller assembly on (item 27,

C5110652-1) mounting bracket. Mate actuator linkage to linkage on throttle.

Install four nuts (item 36, MS51971-1), bolts (item 74, MS35307-312) flat washers (item 45, AN960C416) and lock washers (item 47, NAS1640-416) securing controller assembly to (item 27, C5110652-1) mounting bracket.

Using 3/8" drive ratchet handle, 7/16" socket, and 7/16" combination wrench, tighten nuts (item 36, MS51971-1).

132. Attach linkage to actuator lever with bolt (item 85, MS35309) lock washer,

(item 47, NAS1640-416) and nut (item 43, MS51971-1). Loosen locking nut, and thread the large portion of the linkage in or out until the accelerator is in the fully forward position.

Idle is not affected, but the accelerator moves with the actuator arm. Tighten locking nut.

40

TB 5-2520-551-24


133. Install speed control filter assembly (item 53, C5131037-1) on speed control controller.

134. Connect W65P1 to front of filter assembly (item 53, C5131037-1). Using tiedown tool, secure W-65 cable (item 31, C5118955-1) with tiedowns (item

73, MS3367-2-0) leaving some slack for servicing.

135. On engine, remove cloth from intake manifold and replace air cleaner assembly.

41

TB 5-2520-551-24

SPEED COOL MAGNETIC SENSOR

136.

Remove clamp securing transmission coolant lines to flywheel cover using

3/8" drive ratchet handle, 6" extension, and 5/8" socket.

137.

Under truck, remove six bolts securing flywheel cover (GM PN 14036187) using 3/8" drive ratchet handle, 6" extension, and 15 MM socket.

138.

Install new flywheel cover (item 81 C5110621-1) and secure with six bolts using 3/8" drive ratchet handle, 6" extension, and 15 MM socket.

139.

Replace clamp securing transmission coolant lines to flywheel cover using

3/8" drive ratchet handle, 6" extension, and 5/8" socket.

140.

On magnetic sensor, position lock nut one inch from outer end of threads.

141.

Insert magnetic sensor in mounting hole of flywheel. Rotate magnetic sensor to right until it contacts flywheel. Back out magnetic sensor one full turn.

142.

While holding magnetic sensor, tighten lock-nut using 3/4" combination wrench.

143.

Connect W65P2 to magnetic sensor connector.

144.

Using tiedown (item 73, MS3367-2-0) secure W-65 cable.

42

TB 5-2520-551-24

TANDEM HYDRAULIC PUMP

145.

On tandem pump assembly, remove and retain two existing bolts where bracket

(item 2, C5110944-1) will attach to tandem pump assembly (C5122498-1).

146.

Place C5110944-1 mounting bracket on tandem pump assembly (C5122498-1) and secure with two existing bolts and lock washers (item 48, NAS1640-616).

Using 3/8" drive ratchet handle, 6" extension, and 9/16" socket, tighten bolts.

147.

On transfer case, where bracket (item 1, C5110943-1) will be attached, using a ratchet handle, two 6" extensions, 3/8" drive swivel, and 9/16"

148.

Install mounting bracket (item 1, C5110943-1) on transfer case for mounting tandem pump bracket (item 2, C5110944-1).

Using 3/8" drive ratchet handle, two 6" extensions, 3/8" drive swivel, and 9/16" socket, reinstall three bolts (item 38, MS90725-62), flat washers (item 46, AN960C616), and lock washers (item 48, NAS1640-616) enough to hold bracket in place.

149.

Coat tandem pump splines with thread lubricant (item 84, C5131401-1), and install tandem pump (C5122498-1) on power take-off. Carefully push tandem pump forward to engage splines.

150.

Secure tandem pump assembly (C5122498-1) to PTO with two bolts (item 39,

MS90725-111) and lock washers (item 49, MS35338-143). Using a 3/4" combination wrench, tighten bolts.

43

TB 5-2520-551-24

TANDEM HYDRAULIC PUMP (cont.)

151.

Using 3/8" drive ratchet handle, 6" extension, and 9/16" socket, tighten three bolts (item 38, MS90725-62) securing mounting bracket (item 1,

C5110943-1) to transfer case.

152.

Secure tandem pump mounting bracket (item 2, C5110944-1) to mounting bracket (item 1, C5110943-1) on transfer case with two bolts (item 38,

MS90725-62), flat washers (item 46, AN960C616), lock washers (item 48,

NAS1640-616), and two nuts (item 44, MS51971-3). Using a ratchet handle,

9/16" socket, and 9/16" combination wrench tighten bolts.

44

TB 5-2520-551-24


153. Connect W33P3 to tandem pump linear actuator connector.

154. Connect ground lug terminal W33E1 to frame of vehicle.

N O T E

Refer to figure 5 for installation of hydraulic lines.

Observe line tags for proper installation to connect hydraulic hoses in following steps.

155. Secure generator pump low pressure return flex hose (item 100, C5122512-2) to elbow on tandem pump (C5122498-1) using 1 1/4" combination wrench. Hold elbow on pump using 12" adjustable wrench.

156. Secure tandem pump case drain flex hose (item 98, C5122511-1) to elbow on tandem pump (C5122498-1) using 7/8" combination wrench. Hold elbow on pump using 12” adjustable wrench.

157. Secure A/C sense flex hose (item 95, C5122508-1) to elbow on tandem pump

(C5122498-1) using 9/16" combination wrench. Hold elbow on pump using 12" adjustable wrench.

45

TB 5-2520-551-24


158. Secure A/C pump high pressure flex hose (item 96, C5122509-1) to union on tandem pump (C5122498-1) using 1" combination wrench. Hold union on pump using 12" adjustable wrench.

159. Secure generator pump high pressure flex hose (item 99, C5122512-1) to tandem pump (C5122498-1) using 1-1/4" combination wrench. Hold elbow on

pump using 12" adjustable wrench.

46

TB 5-2520-551-24

HYDRAULIC RESERVOIR ASSEMBLY

N O T E

Before drilling holes in truck bed, cover ends of flex hoses attached to tandem pump assembly with a cloth.

Remove cloth when all holes have been drilled in truck bed.

160.

In truck bed, mark location of four holes in accordance with Figure 4 using

center punch.

Using electric drill with 1/8" drill bit, drill four pilot holes in truck bed.

Enlarge pilot holes with .332" drill bit.

161.

Using riv-nut installation tool, install four riv-nuts (MS27130S31) in front wall of truck bed.

162.

Mark location of four holes to cut in truck bed floor in accordance with

Figure 4.

Using electric drill with 1/8" drill bit, drill pilot holes.

Enlarge holes with 1-1/2" hole saw.

163.

Using saber saw, cut between 1-1/2" holes from curbside to roadside.

Clean burrs in hole using file.

164.

Drill six pilot holes in truck bed using 1/8" drill bit in accordance with

Figure 4.

Enlarge pilot holes with .332" drill bit. Install six riv-nuts in holes using riv-nut installation tool.

165.

Drill four pilot holes in forward tiedown crossmember using 1/8" drill bit.

Enlarge pilot holes with .201" drill bit. Tap holes with .250-20UNC-2B thread.

166.

Install two channel brackets (item 7, C5110649-1 and item 8, C5110649-2) on forward tiedown crossmember using four 7/16" bolts (item 36, MS90725-6), and lock washers (item 47, NAS1640-416). Tighten bolts with 7/16" combination wrench.

167.

Slide clamps (item 9, C511065O-1, item 11, C511065O-3, item 12, C511065O-4) on channel bracket (item 8, C5110649-2).

Position clamps equally along bracket (item 8, C5110649-2).

168.

Slide clamp (item 10, C511065O-2) on channel bracket (item 7, C5110649-1).

169.

Under truck bed, drill two pilot holes in front crossmember using 1/8" drill bit in accordance with Figure 4.

Enlarge pilot holes with .332 drill bit.

170.

Install riv-nuts (item 94, MS27130S31) in front crossmember using riv-nut installation tool.

171.

Secure channel bracket (item 6, C5110651-1) on crossmember with two bolts.

(item 37, MS90725-8) flat washers, (item 45, AN960C416) and lock washers

(item 47, NAS1640-416).

Tighten bolts using 7/16" combination wrench.

172. Using putty knife, apply thermal joint compound (item 86, C5131401-1) to wall side of hydraulic reservoir (C5122481-1).

47

TB 5-2520-551-24

HYDRAULIC RESERVOIR ASSEMBLY (cont.)

173. Install hydraulic reservoir and secure with four bolts (item 37,

MS90725-8), lock washers (item 47, NAS1640-416), and flat washers (item 45,

AN960C416) using 3/8" drive ratchet handle, 6“ extension, and 7/16" socket.

174. Install clearance plate ( item 13, C5122612-1) over the 1-1/2" slots cut into bed.

The lines will be routed through this plate. It is not necessary to secure the pl ate at this time.

175. Install generator pump suction hose to union on reservoir (C5122481-1) and feed through the clearance plate in bed of truck. Using 1/4" flat tip screwdriver, tighten clamp (item 59, AN737TW30) on generator pump suction hose (M6000DO0307).

176. Connect A/C pump suction hose (M6000HO0304) to union on reservoir

(C5122481-1), and feed through the clearance plate in bed of truck. Using

1/4" flat tip screwdriver, tighten clamp (item 112, AN737TW46) on A/C pump suction hose (M6000HO0304).

48

TB 5-2520-551-24

HYDRAULIC RESERVOIR ASSEMBLY (cont.)

177. Feed tandem pump case drain tube through clearance plate in bed of truck and connect to union on reservoir (C5122481-1). Using 7/8" combination wrench, tighten tandem pump case drain tube (item 106, C5111OO8-1) while using 12" adjustable wrench to hold union on reservoir (C5122481-1).

178. Feed generator pump low pressure return line through clearance plate in bed of truck, and connect to reservoir (C5122481-1). Using 1 1/4" combination wrench, tighten generator pump low pressure line (item 107, C5111OO9-1) while using 12" adjustable wrench to hold union on reservoir (C5122481-1).

179. Connect HG/AC case drain

(C5122481-1). Using 7/8" line (item 111, C5111013-1) to reservoir combination wrench, tighten HG/AC case drain line

(item 111, C5111013-1) whi le using 12" adjustable wrench to hold elbow on reservoir (C5122481-1).

180. Connect HG/AC return line (item 97, C512251O-1) to reservoir (C5122481-1).

Using 1 1/2" combination wrench, tighten HG/AC return line (item 97,

C512251O-1) while using 15" adjustable wrench to hold elbow on reservoir

(C5122481-1).

181. Position a 24" piece of insulation sleeving (item 92, M23053/5-108-0) over

W-33 cable where wire connections are to be made to reservoir. Connect three wires of W-33 cable (item 29, C5110787-1) to hydraulic reservoir

(C5122481-1).

Observe tags for proper installation (blue to white, red to red, and yellow to green).

Crimp splice fasteners (item 89, M7928/5-4) using crimping pliers.

49

TB 5-2520-551-24

HYDRAULIC LINES

N O T E

Refer to figure 5 for hydraulic line installation. Observe line tags for proper installation while connecting hydraulic lines.

182. In truck bed, place sense, A/C high pressure, and generator high pressure hydraulic lines through holes in truck bed floor. Secure hydraulic lines in clamps on forward tiedown crossmember in accordance with figure 4.

183. Install second plate (item 14, C5122613-1) in truck bed and secure with six bolts (item 37, MS90725-8), flat (item 45, AN960C416) and lock washers

(item 47, NAS1640-416).

Using 7/16" combination wrench, tighten bolts.

184. Under truck bed, secure hydraulic lines in clamps on forward crossmember in accordance with figure 4.

50

185. Position protective sleeve (item 56, C5131118-3) over generator pump low pressure return line (item 107, C5111OO9-1). Slide sleeve up hose, until top of sleeve is positioned just below channel bracket (item 6,

C5110651-1).

Trim sleeve as necessary.

Using 1/4" flat tip screwdriver, tighten hose clamp (item 60, AN737TW58) securing protective sleeve (item

56, C5131118-3).

TB 5-2520-551-24

HYDRAULIC LINES (cont.)

186. Tighten union (item 113, AN815-12D) on generator pump low pressure return flex hose (item 100, C5122512-2) using 12" adjustable wrench and 1-1/4" combination wrench.

187. Connect generator pump low pressure return line (item 107, C5111OO9-1) on union (item 113, AN815-12D) and tighten using 1-1/4" combination wrench.

Hold union (item 113, AN815-12D) connected to generator pump low pressure return hose (item 100, C5122512-2) using 12" adjustable wrench.

188. Position protective sleeve (item 55, C5131118-2) over tandem pump case drain line (item 106, C5111OO8-1).

Slide sleeve up hose until top of sleeve is positioned just below channel bracket (item 6, C5110651-1). Trim sleeve as necessary.

Using 1/4" flat tip screwdriver, tighten hose clamp

(item 59, AN737TW30) securing protective sleeve (item 55, C5131118-2).

189. Connect union (item 115, AN815-8D) to tandem pump case drain flex hose

(item 98, C5122511-1) and tighten using 12" adjustable wrench while holding flex hose (item 98, C5122511-1) using 7/8" combination wrench.

190. Connect tandem pump case drain line (item 106, C5111OO8-1) onto union (item

115, AN815-8D) and tighten using 7/8" combination wrench. Hold union (item

115, AN815-8D) connected to tandem pump case drain flex hose (item 98,

C5122511-1) using 12" adjustable wrench.

191. Position protective sleeve (item 54, C5131118-1) over A/C pump sense line

(item 11O, C5111012-1).


Using 1/4" flat tip screwdriver, tighten hose clamp (item 58,

AN737TW22) securing protective sleeve (item 54, C5131118-1).

192. Connect union (item 114, AN815-4D) to A/C pump sense flex hose (item 95,

C5122508-1) and tighten using 12" adjustable wrench while holding flex hose

(item 95, C5122508-1) using 9/16" combination wrench.

193. Connect A/C pump sense line (item 110, C5111012-1) onto union (item 114,

AN815-4D) and tighten using 9/16" combination wrench. Hold union (item

114, AN815-4D) connected to A/C pump sense flex hose (item 95, C5122508-1) using 12" adjustable wrench.

194. Position protective sleeve (item 55, C5131118-2) over A/C pump high pressure line (item 109, C5111011-1).




195. Connect A/C pump high pressure line (item 109, C5111011-1) onto flex hose

(item 96, C5122509-1) and tighten using 1" combination wrench while holding A/C pump high pressure flex hose (item 96, C5122509-1) using 12" adjustable wrench.

196. Connect union (item 113, AN815-12D) to generator pump high pressure flex hose (item 99, C5122512-1) and tighten using 12" adjustable wrench while holding flex hose (item 99, C5122512-1) using 1-1/4" combination wrench.

51

TB 5-2520-551-24


197. Position protective sleeve (item 56, C5131118-3) over generator pump high pressure line (item 108, C511101O-1).




198. Connect generator pump high pressure line (item 108, C511101O-1) onto union

(item 113, AN815-12D) and tighten using 1-1/4" combination wrench while holding union (item 113, AN815-12D) connected to generator pump high pressure flex hose (item 99, C5122512-1) using 12" adjustable wrench.

199. Position protective sleeve (item 55, C5131118-2) over A/C pump suction hose

(M6000HO0304).


Using 1/4" flat tip screwdriver, tighten hose clamp (item 59, AN737TW30) securing protective sleeve (item 55, C5131118-2).

200. Slide hose clamp (item 112, AN737TW46) onto A/C pump suction hose

(M6000HO0304).

Push hose onto union of tandem pump (C5122498-1). Using

1/4" flat tip screwdriver, tighten hose clamp (item 112, AN737TW46).

201. Position protective sleeve (item 55, C5131118-2) over generator pump suction hose (M6000DO0307).


Using 1/4" flat tip screwdriver, tighten hose clamp (item 59,

AN737TW30) securing protective sleeve (item 70, C5131118-2).

202. Slide hose clamp (item 59, AN737TW30) onto generator pump suction hose

(M6000DO0307).

Push hose onto union of tandem pump (C5122498-1). Using

1/4" flat tip screwdriver, tighten hose clamp (item 59, AN737TW30).

203. In truck bed, connect union to A/C sense line (item 110, C5111012-1).

Tighten union (item 114, AN815-4D) using 12" adjustable wrench while holding A/C sense line (item 110, C5111012-1) using 9/16" combination wrench.

204. Connect A/C sense flex hose (item 95, C5122508-1) onto union (item 114,

AN815-4D) and tighten using 9/16" combination wrench. Hold union (item

114, AN815-4D) using 12" adjustable wrench.

205. Position protective sleeve (item 54, C5131118-1) over A/C sense line flex hose (item 95, C5122508-1).

Slide sleeve down flex hose (item 95,

C5122508-1).

Using 9/16" combination wrench, hold A/C sense flex hose

(item 95, C5122508-1).

Using 12" adjustable wrench, tighten quick disconnect (item 101, C5131409-1) to flex hose (item 95, C5122508-1). Trim sleeve as necessary, and secure with tiedown strap (item 73, MS3367-2-0).

52

TB 5-2520-551-24


206.

Using 1" combination wrench, hold A/C high pressure line (item 109,

C5111011-1).

Using 12" adjustable wrench, tighten A/C high pressure flex hose (item 96, C5122509-1) to A/C high pressure line (item 109,

C5111011-1).

207.

Position protective sleeve (item 55, C5131118-2) over A/C high pressure flex hose (item 96, C5122509-1). Slide sleeve down flex hose. Using 1" combination wrench, hold A/C high pressure line flex hose (item 96,

C5122509-1).

Using 12" adjustable wrench, tighten quick disconnect (item

103, C5131409-3) to flex hose (item 96, C5122509-1). Trim sleeve as necessary, and secure with tiedown strap (item 73, MS3367-2-0).

208.

Using 1-1/4" combination wrench, hold generator pump high pressure line

(item 108, C511101O-1).

Using 12" adjustable wrench, tighten union (item

113, AN815-12D) to generator pump high pressure line (item 108,

C511101O-1).

209.

Using 12" adjustable wrench, hold union (item 113, AN815-12D). Using

1-1/4" combination wrench, tighten generator pump high pressure flex hose

(item 99, C5122512-1) onto union (item 113, AN815-12D).

210.

Position protective sleeve (item 56, C5131118-3) over generator pump high pressure flex hose (item 99, C5122512-1). Slide sleeve down flex hose

(item 99, C5122512-1).

Using 1-1/4" combination wrench, hold generator pump high pressure flex hose (item 99, C5122512-1). Using 12" adjustable wrench, tighten quick disconnect (item 105, C5131409-4) to generator pump high pressure flex hose (item 99, C5122512-1). Trim sleeve as necessary, and secure with tiedown strap (item 73, MS3367-2-0).

211.

Using 7/8" combination wrench, hold HG/AC case drain line (item 111,

C5111013-1).

Using 12" adjustable wrench, tighten union (item 115,

AN815-8D) to HG/AC case drain line (item 111, C5111013-1).

212.

Using 12" adjustable wrench, hold union (item 115, AN815-8D). Using 7/8" combination wrench, tighten HG/AC case drain flex hose (item 98,

C5122511-1) onto union (item 115, AN815-8D).

213.

Position protective sleeve (item 55, C5131118-2) over HG/AC case drain flex hose (item 98, C5122511-1).

Slide sleeve down flex hose (item 98,

C5122511-1).

Using 7/8" combination wrench, hold HG/AC case drain flex hose (item 98, C5122511-1). Using 12" adjustable wrench, tighten quick disconnect (item 102, C5131409-2) to HG/AC case drain flex hose (item 98,

C5122511-1).

Trim sleeve as necessary, and secure with tiedown strap (item

73, MS3367-2-0).

214.

Position protective sleeve (item 56, C5131118-3) over HG/AC return (item

97, C512251O-1).

Slide sleeve down HG/AC return line (item 97,

C512251O-1).

Using 1-1/2" combination wrench, hold HG/AC return line (item

97, C512251O-1).

Using 15" adjustable wrench, tighten quick disconnect

(item 104, C5131409-5) to HG/AC return line (item 97, C512251O-1). Trim sleeve as necessary, and secure with tiedown strap (item 73, MS3367-2-0).

53

TB 5-2520-551-24

SKID PLATE

215.

Using 16 oz hammer and center punch, mark center of four holes on transmission mounting crossmember in accordance with skid plate mounting modifications on Figure 4.

Using electric drill with 1/8" drill bit drill four pilot holes.

Enlarge the four holes with .406" drill bit.

216.

Install roadside skid plate bracket (item 5, C5118948-1) on left frame rail with two bolts (item 37, MS90725-8), nuts (item 43, MS51971-1), flat washers (item 45, AN960C416) and lock washers (item 47, NAS1640-416).

Install bolts in available hole of frame rail.

Using 3/8" drive ratchet handle, 7/16" socket, and 7/16” combination wrench, tighten bolts (item 37,

MS90725-8).

N O T E

If vehicle to remodified is a 1985 M-1028A1, proceed to step 219.

217.

Install curbside skid plate bracket (item 4, C5118947-1) to fuel and brake line crossmember with two bolts (item 37, MS90725-8), nuts (item 43,

MS51971-1), flat washers (item 45, AN960C416) and lock washers (item 47,

NAS1640-416). Use two holes available in bottom of crossmember. Using 3/8” drive ratchet handle, 7/16" socket, and 7/16" combination wrench, tighten bolts (item 37, MS90725-8). Proceed to step 220.

54

TB 5-2520-551-24

SKID PLATE (cont.)

218.

Using 3/8" drive ratchet handle, and 7/16" socket, secure spacer plate

(C5132683-1) onto curbside skid plate bracket (item 4, C5118947-1) with two bolts (MS35200-74), flat washers (item 45, AN960C416), lock washers (item

47, NAS1640-416), and nuts (item 43, MS51971-1).

219.

Secure spacer plate (C5132683-1) and skid plate bracket (item 4,

C5118947-1) to fuel and brakeline crossmember using two available holes.

Using 3/8" drive ratchet handle, and 1/2" socket, tighten two bolts

(MS35307-338), flat washers (AN960C516), lock washers (item 63,

NAS1640-516), and nuts (item 64, MS51971-2).

220.

Position skid plate (item 3, C5118946-1) under tandem pump assembly

(C5122498-1).

Secure skid plate (item 3, C5118946-1) with six bolts (item

38, MS90725-62), nuts (item 44, MS51971-3), flat (item 46, AN960C616) and lock washers (item 48, NAS1640-616).

Using 3/8" drive ratchet handle,

9/16" socket, and 9/16" combination wrench, tighten bolts (item 38,

MS90725-62).

221.

Fill hydraulic reservoir with approximately 8 gallons of Mil-F-17111.

Recheck fluid level after running the hydraulic system.

55

TB 5-2520-551-24

TEST AND ADJUSTMENT

SPEED CONTROL RPM ADJUSTMENT

56

1.

Ensure that attachments all electrical connections are tight, and that all hardware are secure.

2.

Place cable on front battery negative (-) terminal, tighten nut, and place protective cover over terminal.

3 Place cable on rear battery negative (-) terminal, tighten nut, and place protective cover over terminal.

4.

Place gear shift lever in PARK (P) and set EMERGENCY BRAKE.

5.

Start vehicle engine and allow to idle.

6.

Move speed control toggle switch to RUN.

7.

Move speed increase.

control toggle switch to START and hold. Engine speed should not

8.

Move speed control toggle switch to OFF.

TB 5-2520-551-24

SPEED CONTROL RPM ADJUSTMENT (cont.)

9. Set transfer case control lever to NEUTRAL (N) and engage transfer case lockout.

57

TB 5-2520-551-24


10. Move speed control toggle switch to RUN.

11. Move speed control toggle switch to START and hold. Engine speed should increase to 2000 RPM.

12. If engine speed does not increase from idle, check for defective transfer case lockout switch.

13. If 2000 RPM is not obtained, but engine speed increases above 1400 RPM, release speed control toggle switch to RUN.

14. Using NO.2 cross tip screwdriver, remove and retain two screws securing RPM regulator assembly (item 32, C5122557-1) to instrument panel.

Pull RPM regulator assembly out and position to allow access to "R1" control .

58

TB 5-2520-551-24


15. Using 1/8" flat tip screwdriver, adjust "R1" control on RPM regulator assembly (item 32, C5122557-1) for a 2000 RPM reading when holding speed control toggle switch in START position.

16. Release speed control toggle switch to RUN. Engine speed should decrease to 1400 RPM +/- 10 RPM.

17. Reinstall RPM regulator assembly (item 32, C5122557-1) and secure with two screws (item 50, MS51959-70B).

Using a NO.2 cross tip screwdriver, tighten screws.

59

TB 5-2520-551-24


WARNING

If transfer case is not in NEUTRAL, vehicle will attempt to move forward when gear shift lever is set to DRIVE.

Repeat setting transfer case control lever to NEUTRAL.

60

18. Set transmission gear shift lever to DRIVE (D).

19. Move speed control toggle switch to RUN.

20. Move speed control toggle switch to START and hold for about two seconds to assure that transmission has shifted to third gear. Engine speed should increase to 2000 RPM.

21. Release speed control toggle switch to RUN. Engine speed should drop to

1400 RPM.

22. Move speed control toggle switch to OFF.

TB 5-2520-551-24


23.

With engine running at operating temperature, check for contact between upper radiator hose and W-65 cable. If no contact is made, turn vehicle engine off, then place gear shift lever to PARK, and transfer case lever to

2H.

24.

If contact is made, and allow engine to securing hose clamp

1/4 turn clockwise.

between radiator hose and W-65 cable, turn engine off cool.

Using a 1/4" flat tip screwdriver, loosen screw at upper end of radiator hose. Twist radiator hose

Using same tool tighten screw securing hose clamp.

61

TB 5-2520-551-24

By Order of the Secretary of the Army:

CARL E. VUONO

General, United States Army

Chief of Staff

Official:

WILLIAM J. MEEHAN, II

Brigadier General, United States Army

The Adjutant General

DISTRIBUTION:

To be distributed in accordance with DA Form 12-36, Unit, Direct Support and

General Support and General Support Maintenance requirements for AN/TRQ-30(V);

AN/TRQ-30(V) 1-2; AN/TRQ-30(V)4.

PIN: 065278 000

TB 5-2520-551

INSTALLATION INSTRUCTIONS

FOR

TRUCK INSTALLATION KIT

Approved for public release. Distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

12 JANUARY 1989

SPEED CONTROL GROUP

By Order of the Secretary of the Army:

CARL E. VUONO

General, United States Army

Chief of Staff

Official:

WILLIAM J. MEEHAN, II

Brigadier General, United States Army

The Adjutant General

DISTRIBUTION:

To be distributed in accordance with DA Form 12-36, Unit, Direct Support and

General Support and General Support Maintenance requirements for AN/TRQ-30(V);

AN/TRQ-30(V) 1-2; AN/TRQ-30(V)4.

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