TM-10-3930-641-34-2
TM 10-3930-641-34-2
This copy is a reprint which includes current
pages from Change 1.
TECHNICAL MANUAL
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
POWER TRAIN MAINTENANCE
INSTRUCTIONS
PAGE 4-1
BRAKE SYSTEM AND WHEEL
MAINTENANCE INSTRUCTIONS
PAGE 5-1
STEERING SYSTEM
STEERING SYSTEMS
MAINTENANCE INSTRUCTIONS
PAGE 6-1
HYDRAULIC SYSTEM
MAINTENANCE INSTRUCTIONS
PAGE 7-1
BODY AND CAB 5
MAINTENANCE INSTRUCTIONS
PAGE 8-2
TOPHANDLER MAINTENANCE
INSTRUCTIONS
PAGE 9-1
APPENDICES
PAGE A-1
INDEX
INDEX 1
TRUCK, CONTAINER HANDLER
ROUGH TERRAIN, 50,000 LB CAPACITY
DED, PT, NSN 3930-01-082-3758
WITH TOPHANDLER(S)
HEADQUARTERS, DEPARTMENT OF THE ARMY
OCTOBER 1981
TM 10-3930-641-34-2
C1
CHANGE
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON D.C., 14 AUGUST 1989
NO. 1
No. 1
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
TRUCK, CONTAINER HANDLER: ROUGH TERRAIN
50,000 LB CAPACITY, DED, PT
NSN 3930-01-082-3758 WITH TOPHANDLER(S)
TM 10-3930-641-34-2, 30 October 1981, is changed as follows:
1. Remove old pages and insert new pages as indicated below.
2. New or changed material is indicated by a vertical bar in the margin of the page and by a vertical bar adjacent to the TA number.
Remove pages
Insert pages
i and "ii"
4-309 and 4-310
5-1 and 5-2
5-79 through 5-92
7-71 and 7-72
7-75 and 7-76
A-1 and A-2
B-31(B-4 Blank)
INDEX-7 and INDEX-8
INDEX-11 through INDEX-14
i/(ii Blank)
4-309 and 4-310
5-1 and 5-2
5-91 and 5-92
7-71 and 7-72
7-75 and 7-76
A-1 and A-2
B-3/(B4 Blank)
INDEX-7 and INDEX-8
INDEX-11 through INDEX-14
3. File this change sheet in front of the publication for reference purposes.
1
TM 10-3930-641-34-2
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 12-25F, Direct Support and General Support maintenance requirements for Truck, Container Handler,
50,000 LB Capacity, Rough Terrain
2
TM 10-3930-641-34-2
Technical Manual
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington, DC, 30 October 1981
No. 10-3930-641-34-2
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
TRUCK, CONTAINER HANDLER: ROUGH TERRAIN 50,000 LB
CAPACITY, DED, PT, NSN 3930-01-082-3758 WITH TOPHANDLER(S)
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
manual, direct to: Commander, U.S. Army Tank-Automotive Command, ATTN: AMSTA-MB, Warren, MI 48397-5000. A reply will be
furnished to you.
VOLUME II
Chapters 1 through 3 contained in Volume I
Page
CHAPTER 7
CHAPTER 4
POWER TRAIN MAINTENANCE
INSTRUCTIONS ................................................4-1
Section I
II
III
IV
V
VI
VII
General..............................................................4-1
Torque Converter...............................................4-6
Transmission......................................................4-42
Oil System .........................................................4-178
Control Valves and Control Locks ......................4-201
Front Axle ..........................................................4-241
Rear Axle...........................................................4-262
CHAPTER 5
BRAKE SYSTEM AND WHEEL BEARING
ADJUSTMENT INSTRUCTIONS .......................5-1
Section I
II
III
IV
V
General..............................................................5-2
Accumulator.......................................................5-4
Brakes and Control Valves .................................5-25
Parking Brake ....................................................5-60
Wheel Bearing Adjustment.................................5-91
CHAPTER 6
STEERING SYSTEM MAINTENANCE
Section I
II
III
CHAPTER 8
BODY AND CAB MAINTENANCE
INSTRUCTIONS................................................ 8-1
Section I
Cab and Rollover Protective
Structure (ROPS)............................................... 8-2
Cab Components ............................................... 8-18
Body and Platform ............................................. 8-38
II
III
CHAPTER 9
Section I
General..............................................................6-1
II
Steering Components .....................................................6-6
Page
HYDRAULIC SYSTEM MAINTENANCE
INSTRUCTIONS................................................ 7-1
General.............................................................. 7-2
Hydraulic Lift system Components ..................... 7-4
Mast Components.............................................. 7-70
TOPHANDLER MAINTENANCE
INSTRUCTIONS................................................ 9-1
APPENDIX A REFERENCES .................................................. A-1
B
EXPENDABLE ITEMS AND
MATERIALS LIST .......................................................... B-1
C
ILLUSTRATED LIST OF MANUFACTURED
ITEMS AND SPECIAL TOOLS .......................... C-1
D
TORQUE VALUES ............................................ D-1
INDEX
.......................................................................... INDEX 1
Change 1 i
TM 10-3930-641-34-2
CHAPTER 4
POWER TRAIN MAINTENANCE INSTRUCTIONS
Page
Page
Section V.
Section I.
General.................................................................... 4-2
Drive System Description......................................... 4-2
Transmission Oil System Description ....................... 4-4
II.
Torque Converter..................................................... 4-6
Torque Converter Removal...................................... 4-7
Torque Converter Installation ................................... 4-12
Torque Converter Disassembly ................................ 4-17
Torque Converter Assembly..................................... 4-27
III.
Transmission............................................................ 4-42
Transmission and Transfer Assembly Removal........ 4-43
Transmission and Transfer Assembly Installation ..... 4-56
Transmission Disassembly ....................................... 4-68
Transmission Assembly............................................ 4-88
Transfer Gear Assembly Removal ........................... 4-119
Transfer Gear Assembly (Input) Disassembly........... 4-124
Transfer Gear Assembly (Input) Assembly ............... 4-129
Transfer Gears Bearing Adjustment (Input) .............. 4-136
Transfer Gear Assembly (Output) Disassembly ........ 4-138
Transfer Gear Assembly (Output) Assembly............. 4-146
Transfer Gear Assembly Bearing Adjustment
Output) .............................................................. 4-155
Transmission Hydraulic Controls Removal/
Installation................................................................ 4-157
Transmission Hydraulic Controls Disassembly ......... 4-164
Transmission Hydraulic Controls Assembly .............. 4-171
IV.
VI.
VII.
Oil System ............................................................... 4-178
Transmission Oil Pump Removal ............................. 4-179
Transmission Oil Pump Installation .......................... 4-184
Transmission Oil Lines Removal/Installation ............ 4-187
Transmission Oil Pump Disassembly ....................... 4-189
Transmission Oil Pump Assembly ............................ 4-192
Transmission Oil Cooler Removal/Installation .......... 4-197
VIII.
4-1
Control Valves and Control Locks ............................ 4-201
Sequence and Pressure Control Valve
Removal/Installation .......................................... 4-202
Sequence and Pressure Control Valve
Disassembly/Assembly ...................................... 4-205
Transmission Control Lock Removal........................ 4-210
Transmission Control Lock Installation ..................... 4-213
Transmission Control Lock Disassembly .................. 4-217
Transmission Control Lock Assembly....................... 4-221
Torque Converter Outlet Relief Valve
Removal/Installation .......................................... 4-225
Torque Converter Outlet Relief Valve
Disassembly/Assembly ...................................... 4-228
Torque Converter Outlet Relief Valve
Adjustment ........................................................ 4-231
Transmission Control Lock Bench Test .................... 4-234
Sequence Valve Test............................................... 4-237
Front Axle ................................................................ 4-241
Front Differential and Bevel Gear Removal ............. 4-242
Front Differential and Bevel Gear Installation........... 4-246
Drive Axles Removal/Installation ............................. 4-250
Final Drive Planet Carriers Removal/
Installation ......................................................... 4-254
Final Drive Planet Carriers Disassembly/
Assembly........................................................... 4-259
Rear Axle................................................................. 4-262
Rear Differential, Bevel Gear, and Front
Support Removal............................................... 4-263
Rear Differential, Bevel Gear, and Front
Support Installation............................................ 4-267
Differential and Bevel Gear Disassembly ................. 4-271
Differential and Bevel Gear Assembly...................... 4-278
Differential and Bevel Gear Adjustment ................... 4-289
Front and Rear Support Disassembly/
Assembly........................................................... 4-296
Drive Shafts............................................................. 4-305
Upper Drive Shaft Disassembly/Assembly ............... 4-306
Lower Drive Shaft Disassembly/Assembly ............... 4-308
Bearing Cage Adjustment ........................................ 4-323
TM 10-3930-641-34-2
Section I. GENERAL
DRIVE SYSTEM DESCRIPTION
(Sheet 1 of 2)
1. DIESEL ENGINE. All power for the various components of the drive
system originates from the engine. The engine, an eight cylinder V four
cycle, is liquid cooled. The electrical system is a 24 volt negative
ground with an alternator for recharging. Lubrication is supplied from a
camshaft driven oil pump. Engine power is transferred from the engine
flywheel to the torque converter.
2. TORQUE CONVERTER. The torque converter hydraulically increases
the torque from the engine. The converter transfers the engine power to
the drive train through a hydraulically activated clutch.
3. UPPER DRIVE SHAFT. Transmits the power from the torque converter
to the input transfer gears. A universal joint is used at both ends of a
short shaft. These universal joints enable slight movements between
the torque converter and the input transfer gears.
4. INPUT TRANSFER GEARS. A system of gears between torque
converter and transmission. The output gear of the transfer gears turns
the input shaft of the transmission.
5. TRANSMISSION. A hydraulically activated (semi-automatic) type. The
transmission has four speed ranges FORWARD and four speed ranges
in REVERSE. Both speed and direction are manually selected. The
transmission output shaft drives the input shaft of the output transfer
gears.
6. OUTPUT TRANSFER GEARS. A system of gears at the output side of
the transmission which transmits power from the transmission to the
drive shafts. Two universal joints connect the output transfer gears to
the front and rear drive shafts.
7. DRIVE SHAFTS. Three are used as a way of transmitting power from
the:
A. Output transfer gears to the rear differential.
B. Output transfer gears to the bearing cage.
C. Bearing cage to the front differential.
Shafts A and B have universals attached on both ends. Shaft B has one
universal on the end that goes to the front differential. On the end
towards the bearing cage is a splined slip joint.
8. BEARING CAGE. Provides support where the two forward drive shafts
are joined together. The universal joint of one shaft and the splined slip
joint of the other shaft are joined and supported here. While this
connection transmits the power between the drive shafts it is also
required for the vehicles articulated steering system.
9. DIFFERENTIAL. A gear arrangement which changes the direction of
power 90°. Transferring the power from the drive shafts to the axle
shafts it can divide the power between the left and the right shafts.
Dividing the power enables the outside wheel to turn faster than the
inside wheel while making a turn. This vehicle is equipped with a front
and rear differential, both functioning in the same way.
10. FINAL DRIVE. A final gear arrangement causing speed reduction and
torque increase in the drive train. The power from the axle shaft is
changed in the final drive through the use of three planetary gears
revolving around a centered drive gear, then transmitted to the road
wheel. The vehicle has four final drives, one in each wheel.
Go on to Sheet 2
4-2
TM 10-3930-641-34-2
DRIVE SYSTEM DESCRIPTION (CONT)
(Sheet 2 of 2)
TA099229
End
4-3
TM 10-3930-641-34-2
TRANSMISSION OIL SYSTEM DESCRIPTION
(Sheet 1 of 2)
3. FILTER BYPASS SWITCH. Activates a warning light informing the
operator the filter is obstructed.
Transmission oil system consists of:
1.
2.
3.
4.
5.
6.
7.
Oil reservoir
Oil filter
Filter bypass switch
Magnetic screen
Oil pump
Oil cooler
Connecting lines
4. MAGNETIC SCREEN. Removes metal particles and other debris before
the oil goes to the oil pump. The screen is fastened to the output
transfer gear case.
5. OIL PUMP. A gear-type pump, driven by the engine. Oil is pulled from
the reservoir, through the magnetic screen and pumped to the oil filter.
6. OIL COOLER. Removes heat from the transmission system oil. High
temperature oil comes from the torque converter and passes through the
oil cooler. The heat of the oil is transferred to the engine cooling
system, and the cooled oil returns to the transmission.
1. OIL RESERVOIR. The lower portion of the output transfer gear case. A
drain plug is located in the bottom of the case for draining transmission
system oil.
2. OIL FILTER. The filter is located in the compartment behind the cab. It
removes debris from the hydraulic oil. A bypass valve allows oil to flow
if the filter becomes obstructed.
7. CONNECTING LINES. Carry oil to and from the oil filter and oil cooler.
Go on to Sheet 2
4-4
TM 10-3930-641-34-2
TRANSMISSION OIL SYSTEM DESCRIPTION (CONT)
1.
2.
3.
4.
5.
6.
7.
(Sheet 2 of 2)
Oil reservoir
Oil filter
Filter bypass switch
Magnetic screen
Oil pump
Oil cooler
Connecting lines
TA099230
End
4-5
TM 10-3930-641-34-2
Section II. TORQUE CONVERTER
TORQUE CONVERTER MAINTENANCE
This section covers maintenance of the torque converter for direct support and general support maintenance personnel:
a. Torque converter
LIST OF TASKS
(Sheet 1 of 1)
TASK NO
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Torque converter removal.
4-7
2-49
2
Torque converter installation.
4-12
None
3
Torque converter disassembly.
4-17
2-49
4
Torque converter assembly.
4-27
None
4-6
TM 10-3930-641-34-2
TORQUE CONVERTER REMOVAL
(Sheet 1 of 5)
This task covers: Removal of torque converter.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Identification tags for hoses.
Page 2-49
Equipment Condition
Engine off.
Torque converter cooled.
Shipping link installed.
Special Tools
Personnel Required
None
Two mechanics.
References
General Safety Instructions
Hood removal/installation,
TM 10-3930-641-20.
Crankcase guard removal/installation,
TM 10-3930-641-20.
Shipping link removal/installation,
TM 10-3930-641-20.
Steering and brake pump removal/
installation, page 6-52
Transmission oil pump removal page 4-179.
Implement pump removal/installation,
page 7-5
Block front and rear tires.
Go on to Sheet 2
4-7
Main disconnect switch OFF
TM 10-3930-641-34-2
TORQUE CONVERTER REMOVAL (CONT)
(Sheet 2 of 5)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Tag all lines, hoses and harnesses before
disconnecting.
1.
Oil line
Disconnect an oil line at bottom of torque converter and drain oil into suitable container.
2.
Precleaner lid
Remove from air cleaner assembly.
3.
Front hood (1)
a. Disconnect latches.
b. Fasten hoist and remove. Hood is 124 lb.
(56 Kg).
4.
Left and right covers (3) at bottom
of roll over protective structure
Remove.
5.
Door and frame assembly (2) capscrews
Remove.
6.
Door and frame assembly (2)
Fasten hoist to unit and remove. Unit is 160
lb. (73 Kg).
7.
Access door assembly (4) capscrews
Remove.
8.
Access door assembly (4)
Fasten hoist to access door assembly and
remove. Assembly is 55 lb. (25 Kg).
4-8
TM 10-3930-641-34-2
TORQUE CONVERTER REMOVAL (CONT)
(Sheet 3 of 5)
LOCATION/ITEM
ACTION
9.
Channel assembly (5) capscrews
Remove.
10.
Channel assembly (5)
Remove.
11.
Steering and brake pump
Remove.
REMARKS
See page 6-52.
12.
Transmission oil pump
Remove.
13.
Implement pump
Remove.
14.
Hose assembly (6)
Remove.
15.
Drive shaft (7)
Remove. (See TM 10-3930-641-20)
See page 4-179.
See page 7-5.
TA0992324-9
Go on to Sheet 4
4-9
TM 10-3930-641-34-2
TORQUE CONVERTER REMOVAL (CONT)
(Sheet 4 of 5)
LOCATION/ITEM
ACTION
REMARKS
16.
Wiring harness (8)
Disconnect.
17.
Capscrews (9) and sequence and
pressure control valve (10)
Remove. (See page 4-202)
18.
Tube assembly (11)
Remove.
19.
Wiring harness (8)
relief valve.
Disconnect from torque converter outlet
20.
Three capscrews that secure outlet
relief valve
Remove. Remove outlet relief valve. (See
page 4-225)
21.
Governor control cable assembly
(12)
a. Disconnect from governor on engine.
b. Move away from engine.
c. Disconnect from transmission housing.
22. Crankcase guards
Remove.
See TM 10-3930-641-20.
See TM 10-3930-641-20,
TA099233
Go on to Sheet 5
4-10
TM 10-3930-641-34-2
TORQUE CONVERTER REMOVAL (CONT)
(Sheet 5 of 5)
LOCATION/ITEM
ACTION
REMARKS
23.
Hose assembly (13)
Disconnect from torque converter.
24.
Four capscrews
Remove from tube assembly (14) at the engine
cooler.
25.
Clamp (15)
Loosen and move tube assembly (14) away
from torque converter.
26.
Two 1/2-13NC forged eyebolts
Install in cover of torque converter, as shown.
27.
Torque converter
Fasten hoist.
28.
11 capscrews (16)
Remove.
29.
Two capscrews
a. Use as forcing screws to loosen the torque
converter from the flywheel housing.
b. Tighten evenly until torque converter is
loose.
30. Sleeve (18)
Remove lock.
31. Torque converter
a. Pull out of the flywheel housing and make
sure the sleeve at location (18) is free.
b. Remove. Converter is 443 lb. (201 Kg).
TA099234
End
4-11
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION(
This task covers: Installation of torque converter.
Sheet (1 of 5)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Engine OFF.
Shipping link installed
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
LO 10-3930-641-12
Block front and rear tires.
Crankcase guard removal/ installation
TM 10-3930-641-20.
Main disconnect switch OFF.
Shipping link removal/installation.
TM 10-3930-641-20.
Transmission oil pump installation, page 4-184.
Steering and brake pump removal/installation,
page 6-52.
Implement sump removal/installation, page 7-5.
Go on to Sheet 2
4-12
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
1.
Torque converter
(Sheet 2 of 5)
ACTION
REMARKS
a. Install two 1/2-13NC eyebolts.
b. Fasten hoist and position torque
converter in the machine.
2.
Sleeve (5)
Make sure sleeve (5) is in alignment with torque converter and flywheel housing before
torque converter is pushed into position in flywheel housing.
3.
Torque converter
Push torque converter into flywheel housing.
4.
Cover
If teeth in flywheel are not in alignment with
teeth on housing for converter, then remove
cover (1) and turn shaft in converter until teeth
are in alignment and converter is in position.
5.
Flywheel housing
Install 11 capscrews that hold torque converter
to flywheel housing.
6.
Sleeve (5)
Install lock, capscrew, and lockwasher to hold
sleeve (5) in place.
7.
Tube assembly (3)
Put tube assembly (3) in position and install
capscrews that hold it at engine cooler.
8. Clamp (2)
Install.
9. Hose assembly (4)
Connect to torque converter.
10. Crankcase guards
Install crankcase guards.
TA099235
See TM 10-3930-641-20.
Go on to Sheet 3
4-13
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 5)
ACTION
REMARKS
11.
Torque converter outlet relief valve
(10)
Install. (See page 4-225)
12.
Tube assembly (3)
Connect to valve.
13.
Tube assembly (9)
Install.
14.
Wiring harness (6)
Connect.
15.
Sequence and pressure control
valve (7)
Install. (See page 4-202)
16.
Wiring harness (6)
Connect to valve.
17.
Cable assembly (8)
Connect to engine governor.
18.
Hose assembly (13)
Install.
19.
Upper drive shaft (12)
Install with capscrews that hold it. Torque
bolts to 90-110 lb. ft. (122-149 N.m).
(See TM 10-3930-641-20.)
Go on to Sheet 4
4-14
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 4 of 5)
ACTION
REMARKS
20.
Implement pump
Install.
21.
Transmission oil pump
Install.
See page 7-5.
22.
Steering and brake pump
Install.
See page 4-184.
23.
Side access panel
Install.
See page 6-52.
24.
Channel assembly (14)
Install and secure with capscrews.
TA099237
Go on to Sheet 5
4-15
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
25.
Frame and door assemblies (15)
(Sheet 5 of 5)
ACTION
REMARKS
a. Fasten hoist and install over transmission.
b. Secure with capscrews.
26.
Right and left covers (16) at bottom
of roll-over protective structure
Install.
27.
Access door assembly (17) over
rear of cab
Install.
28. Hood
Fasten hoist and install.
29. Precleaner lid
Install on air cleaner assembly.
30.
Fill transmission to correct level.
Oil
See TM 10-3930-641-20.
End
4-16
Refer to LO 10-3930-641-12.
TA099238
TM 10-3930-641-34-2
TORQUE CONVERTER DISASSEMBLY
(Sheet 1 of 10)
This task covers: Disassembly of torque converter.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Wood blocking.
Page 2-49
Equipment Condition
Torque converter removed from vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Torque converter removal, page 4-7.
Place piece parts in clean area.
Go on to Sheet 2
4-17
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 5)
ACTION
REMARKS
1.
Torque converter
Set on wood blocks.
2.
Eleven cover capscrews (20) and
lockwashers (21)
Remove.
3.
Two 1/2-13NC forged eyebolts
Install in cover (2).
4.
Cover (2)
Fasten hoist and remove. Cover weighs 160
lbs. (73 Kg.).
5.
Capscrew (10), retainer (9), yoke (8)
Remove from end of shaft.
6.
Two seals (13)
Remove from carrier assembly.
7.
Six capscrews (7) and lockwashers
(6)
Remove.
8.
Shaft (19) and carrier (14)
Remove as unit.
Go on to Sheet 3
4-18
TM 10-3930-641-34-2
TORQUE CONVERTER DISASSEMBLY (CONT)
(Sheet 3 of 10)
1. Torque Converter Group
2. Torque Converter Cover
3. Breather
4. Gasket
5. Cover
6. Lockwasher
7. Capscrew
8. Yoke
9. Retainer
10. Capscrew
11. Ball Bearing
12. Preformed Packing
13. Lip Type Seal
14. Bearing Carrier
15. Preformed Packing
16. Seal Ring Carrier
17. Metal Ring
18. Rear Sleeve
19. Center Shaft
20. Capscrew
21. Lockwasher
22. Capscrew
23. Preformed Packing
24. Capscrew
25. Bearing Carrier Lock
26. Preformed Packing
27. Preformed Packing
Go on to Sheet 4
4-19
TM 10-3930-641-34-2
TORQUE CONVERTER DISASSEMBLY (CONT)
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
Drive Spider
Capscrew
Washer
Rotating Housing Assembly
Bearing
Housing
Thrust Bearing Retainer
Thrust Bearing Retainer
Thrust Bearing Roller
Capscrew
Converter Turbine
Thrust Race Lock Pin
Retaining Ring
Plate
Converter Stator
Stator Carrier Assembly
Sleeve Bearing
Stator Carrier
Capscrew
Washer
Clutch Disc Assembly
Converter Outer Impeller
Reaction Plate
Converter Impeller
Plastic Ring
Pin
Impeller Hub
Sheet 4 of 10)
56. Clutch Housing
Assembly
57. Pin
58. Housing
59. Sleeve Bearing
60. Sleeve Bearing
61. Capscrew
62. Carrier Assembly
63. Ring Carrier
64. Bearing Carrier
65. Cup Plug
67. External Retaining Ring
68. Seal Ring
69. Screw
70. Name Plate
71. Capscrew
72. Washer
73. Capscrew
74. Washer
75. Seal Ring
76. Seal Ring
77. Clutch Piston
Go on to Sheet 5
4-20
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
9.
Preformed packing (12) and (15)
(Sheet 5 of 10)
ACTION
REMARKS
a. Remove from carrier.
b. Replace packing if damaged.
c.
10.
Shaft (19)
Remove from carrier with arbor press.
11.
Seal ring carrier (16) and sleeve (18)
Remove from carrier.
12.
Ring (17)
Remove from carrier (16).
13.
Bearing (11)
Remove from carrier (14).
14.
Lip type seal (13)
Remove from carrier (14).
15.
External retaining ring (67) and
carrier assembly (62)
Remove from torque converter group.
Go on to Sheet 6
4-21
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 6 of 10)
ACTION
REMARKS
16.
Two rings (68)
Remove from carrier assembly (62).
17.
Pin (66) that holds carrier (63) in
position on carrier assembly (62)
Remove.
18.
Carrier (63)
Remove from carrier assembly.
19.
Six capscrews (71) and washers (72),
thirty-six capscrews (73) and
washers (74)
Remove.
CAUTION
Do not let piston fall out of housing assembly
when housing assembly is removed.
20.
Housing assembly (58)
Fasten hoist and remove from converter
group. Housing assembly weighs 72 lb.
(33 Kg).
Go on to Sheet 7
4-22
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 7 OF 10)
ACTION
REMARKS
21.
Piston (77)
Remove from housing assembly.
22.
Ring (75)
Remove from piston (77).
23.
Ring (76)
Remove from housing assembly (58).
24.
Sleeve (59)
Remove from housing assembly (58) with
puller.
25.
Capscrews (47) and washer (48)
Remove.
26. Disc assembly (49) and plate (51)
from converter group.
Remove.
Go on to Sheet 8
4-23
TM 10-3930-641-34-2
(Sheet 8 of 10)
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Keep disc assembly and plate together when
they are removed from torque converter.
27.
Two 3/8-16NC forged eyebolts
a. Install in impeller.
b. Fasten hoist to eyebolts.
28.
Impeller (52) and hub (55)
Remove as a unit. Impeller and hub weigh
22 lb. (10 Kg).
29.
Plastic ring (53)
Remove from impeller.
30.
Two retainers (34) and (35) and
Remove.
roller assembly (36)
31.
Impeller (50)
Remove from housing (33).
Go on to Sheet 9
4-24
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 9 of 10)
ACTION
REMARKS
32.
Stator (46) and carrier assembly (44)
Remove as unit.
33.
Ring (41)
Remove.
34.
Stator (46)
Remove from carrier assembly.
35.
Plate (42)
Remove from stator.
36.
Bearing (45)
Remove from carrier assembly (44).
37.
Two retainers (34) (35) and
roller assembly (36)
Remove from hub (39).
Go on to Sheet 10
4-25
TM 10-3930-641-34-2
TORQUE CONVERTER INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 10 of 10)
ACTION
REMARKS
38.
Turbine (38) and hub (39)
Remove from housing (33) as unit.
39.
Capscrews (37) and washers (30)
Remove.
40.
Turbine (38)
Remove from hub (39).
41.
Two retainers (35) and roller
assembly (36)
Remove from housing (33).
42.
Housing (33)
Turn housing over.
43.
Capscrews (29), washers (30), and
drive spider (28)
Remove from housing.
44.
Bearing (32)
Remove from drive spider.
End
4-26
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY
(Sheet 1 of 15)
This task covers: Assembly of the torque converter.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
None
Equipment Condition
Engine OFF.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
LO 10-3930-641-12
Make sure piece parts are clean
of all grit and dirt.
Torque converter removal, page 4-7.
Torque converter disassembly, page 4-17.
Go on to Sheet 2
4-27
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 2 of 15)
1. Torque Converter Assembly
2. Torque Converter Cover
3. Breather
4. Gasket
5. Cover
6. Lockwasher
7. Capscrew
8. Yoke
9. Retainer
10. Capscrew
11. Ball Bearing
12. Performed Packing
13. Lip Type Seal
14. Bearing Carrier
15. Performed Packing
16. Seal Ring Carrier
17. Metal Ring
18. Wear Sleeve
19. Carrier Shaft
20. Capscrew
21. Lockwasher
22. Capscrew
23. Performed Packing
24. Capscrew
25. Bearing Carrier Lock
26. Performed Packing
27. Performed Packing
TA099241
Go on to Sheet 3
4-28
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT
28. Drive Spider
29. Capscrew
30. Washer
31. Rotating Housing Assembly
32. Bearing
33. Housing
34. Thrust Bearing Retainer
35. Thrust Bearing Retainer
36. Thrust Bearing Roller
37. Capscrew
38. Converter Turbine
39. Turbine Hub
40. Thrust Race Lock Pin
41. Retaining Ring
-42. Plate
43. Converter Stator
44. Stator Carrier Assembly
45. Sleeve Bearing
46. Stator Carrier
47. Capscrew
48. Washer
49. Clutch Disc Assembly
50. Converter Outer Impeller
51. Reaction Plate
52. Converter Impeller
53. Plastic Ring
54. Pin
55. Impeller Hub
(Sheet 3 of 15)
56. Clutch Housing Assembly
57. Pin
58. Housing
59. Sleeve Bearing
60. Cover
61. Capscrew
62. Carrier Assembly
63. Ring Carrier
64. Bearing Carrier
65. Cup Plug
66. Pin
67. External Retaining Ring
68 Seal Ring
69. Screw
70. Name Plate
71. Capscrew
72. Washer
73. Capscrew
74. Washer
75. Seal Ring
76. Seal Ring
77. Clutch Piston
TA099242
Go on to Sheet 4
4-29
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 15)
ACTION
REMARKS
NOTE
Be sure all parts are clean before assembly.
1. Turbine (38) and converter housing Check clearance between turbine and converter
(33)
housing.
NOTE
Difference between inside diameter of housing
(A) and outside diameter of turbine (B) must
be at least .070 - .110 in. (1.78 - 2.80 mm) but
no more than 0.135 in. (3.43 mm). Check in
several locations.
2. Outer impeller (50) and converter
housing (33).
Check clearance between outer impeller and
converter housing.
NOTE
Difference between inside diameter of the
housing (D) and outside diameter of the
outer impeller (C) must be at least .077 - 0.103
in. (1.96 - 2.62 mm) but no more than 0.135
in. (3.43 mm). Check in several locations.
TA099423
Go on to Sheet 5
4-30
TM 10-3930-641-34-2
(Sheet 5 of 15)
TORQUE CONVERTER ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
3. Bearing (32)
Install in cover assembly with driver. Be sure
bearing is flush with outside surface of cover
assembly.
4. Drive spider (28)
a. Install in housing.
REMARKS
b. Secure with capscrews (29) and washers
(30), torqued to 77-85 lb. ft. (11-12.3 N.m).
5. Housing (33)
Turn housing over.
6. Two retainers (35) and roller
assembly (36)
Install.
7. Turbine (38) and stator (43)
a. Check clearance between turbine and
stator.
NOTE
Difference between diameter of turbine (F)
and diameter of stator (E) must be at least
0.022 - 0.042 in. (0.56 - 1.6 mm) but no more
than 0.048 in. (1.22 mm). Check in several
locations.
TA099244
Go on to Sheet 6
4-31
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 6 of 15)
ACTION
8. Turbine (38)
Put in position over hub (39).
9. Twenty capscrews (37) and washers
(30)
Install and tighten to a torque of 34-38 lb. ft.
(45-51 N-m).
10. Turbine (38) and hub (39)
Put in position in housing (33).
11. Two retainers (34) and (35), roller
assembly (36)
Install on hub (39) as shown.
12. Bearing (45)
Install in carrier assembly (46) with driver.
Be sure bearing is flush with counterbore in
carrier assembly.
Go on to Sheet 7
4-32
REMARKS
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
LOCATION/ITEM
13. Carrier (46) hub (39)
(Sheet 7 of 15)
ACTION
REMARKS
Check clearance between carrier and hub.
NOTE
Clearance (G) must be 0.0028 - 0.0068 in.
(0.071 - 0.173 mm). If clearance is not within
limits, then replace bearing between carrier
and hub.
14. Stator (43) and inner impeller (52)
Check clearance between stator and inner
impeller.
NOTE
Difference between diameter of the stator (J)
and diameter of the inner impeller (H) must
be at least 0.022 - 0.042 in. (0.56 - 1.06 mm)
but no more than 0.0048 in. (1.22 mm).
TA099245
Go on to Sheet 8
4-33
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 8 of 15)
LOCATION/ITEM
ACTION
15. Stator (43)
Install in carrier.
16. Stator ring (41)
Install.
17. Carrier (44) and stator (43)
Install in housing (33).
18. Outer impeller (50) and inner
impeller (52)
Check clearance between outer impeller and
inner impeller.
REMARKS
The difference between dimensions (K) and
(L) must be at least 0.035 - 0.055 in.
(0.64 - 1.40 mm), but no more than 0.60 in.
(1.52 mm). Check in several locations.
The difference between the diameter of the
outer impeller (N) and the diameter of the
inner impeller (M) must be at least .049 .065 in. (1.25 - 1.65 mm) but no more than
.086 in. (2.18 mm). Check in several locations.
TA099246
Go on to Sheet 9
4-34
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 9 of 15)
LOCATION/ITEM
ACTION
19. Impeller (50)
Install in housing (33).
20. Two retainers (34) and (35) and roller
assembly (36)
Install.
21. Hub (55)
Install.
22. Ring (53)
Install on impeller (52).
23. Impeller (52)
a. Install in outer impeller (50).
REMARKS
b. Make sure dowel holes of hub aline with
holes in impeller.
24. Plate (51)
a. Install.
b. Make sure holes in plate (51) aline with
holes in impeller (52).
c.Install.
TA099247
Go on to Sheet 10
4-35
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 10 of 15)
LOCATION/ITEM
ACTION
25. Disc assembly (49)
Install.
26. Twelve capscrews (47) and washers
(48).
Install. Tighten bolts to a torque of 19-21 lb.
ft. (26-28 N-m).
27. Teflon seal (75) on piston (77)
a. Install as shown at right.
REMARKS
b. Put piston (77) in position on disc
assembly (49).
NOTE
Be sure holes in piston aline with holes in
disc.
28. Bearing (59)
a. Install in housing (58) using a driver.
b. Bearing (59) must be flush with outside
surface of housing (58).
29. Teflon seals (76)
Install in housing (58).
TA099248
Go on to Sheet 11
4-36
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 11 of 15)
ACTION
30. Two guide pins (66)
Install in housing (58).
31. Housing (58)
a. Fasten to hoist.
REMARKS
b. Put in position on converter.
NOTE
Be sure pins (66) in housing (58) go through
piston plate and into impeller.
32. Six capscrews (71) and washers (72)
that secure clutch housing to
impeller
Install and tighten to a torque of 80-90 lb. ft.
(108-122 N'm).
33. Thirty-six capscrews (73) and
washers (74) that secure clutch
housing to converter housing.
Install and tighten to a torque of 34-38 lb. ft.
(43-49 N-m).
Go on to Sheet 12
4-37
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 12 of 15)
LOCATION/ITEM
34. Ring carrier (63)
ACTION
REMARKS
a. Heat to no more than 2750F (135°C)
b. Install in bearing carrier (64).
35. Pin (66)
Install as shown to secure carrier (63).
36. Two seals (68)
Install on carrier (63).
37. Carrier assembly (62)
Install in torque converter housing (58).
TA099249
Go on to Sheet 13
4-38
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 13 of 15)
LOCATION/ITEM
ACTION
38. Snap ring (67)
Install to secure carrier assembly (62).
39. Lip type seal (13)
a. Install in carrier (14) with driver.
REMARKS
b. Install with lip toward inside of carrier
as shown.
c. Install until it contacts counterbore in
carrier.
40. Bearing (11) and sleeve (18)
Install in carrier (14).
TA099250
Go on to Sheet 14
4-39
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 14 of 15)
LOCATION/ITEM
ACTION
41. Ring (17)
Install in carrier (14).
42. Carrier seal ring (16)
Install in carrier (14).
43. Shaft (19)
Install in carrier (14) with arbor press as
shown at right.
REMARKS
TA099251
Go on to Sheet 15
4-40
TM 10-3930-641-34-2
TORQUE CONVERTER ASSEMBLY (CONT)
(Sheet 15 of 15)
LOCATION/ITEM
ACTION
REMARKS
44. Large preformed packing (12) and
small performed packing (15)
Install in carrier.
45. Shaft (19) and carrier
a. Install in torque converter.
b. Install capscrews (7) and lockwashers (6)
to secure unit.
46. Two performed packing (27)
Install on carrier assembly (62).
47. Yoke (8), retainer (9) and
canscrew (10)
a. Install on end of shaft.
b. Tighten yoke capscrew to a torque of
80-90 lb. ft. (109-121 N-m).
48. Cover (2)
a. Fasten to hoist.
b. Put in position over torque converter.
49. Eleven cover capscrews (22) and
lockwashers (21)
Install.
TA099252
End
4-41
TM 10-3930-641-34-2
Section III. TRANSMISSION
TRANSMISSION MAINTENANCE INSTRUCTIONS
This section covers maintenance of these transmission components for direct support and general support maintenance personnel.
a.
b.
c.
d.
Transmission
Input gears
Output gears
Transmission controls
LIST OF TASKS
(Sheet 1 of 1)
TASK NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TASK
REF (PAGE)
Transmission and transfer assembly removal.
Transmission and transfer assembly installation.
Transmission disassembly.
Transmission assembly.
Transfer gear assembly (input and output)
removal.
Transfer gear assembly (input and output)
installation.
Transfer gear assembly (input) disassembly.
Transfer gear assembly (input) assembly.
Transfer gears bearing adjustment (input).
Transfer gear assembly (output) disassembly.
Transfer gear assembly (output) assembly
Transfer gear assembly bearing adjustment
(output)
Transmission hydraulic controls removal/
installation
Transmission hydraulic controls disassembly.
Transmission hydraulic controls assembly.
4-42
TROUBLESHOOTING
REF (PAGE)
4-43
4-56
4-68
4-88
None
None
2-44, 2-49, 2-50, 2-52
None
4-119
2-42
4-122
4-124
4-129
4-136
4-138
4-146
None
2-42, 2-49
None
2-42
2-44, 2-49
None
4-155
2-44
4-157
4-164
4-171
None
None
None
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
(Sheet 1 of 13)
This task covers: Removal of transmission and transfer assembly.
INITIAL SETUP
Test Equipment
Reference
Materials/Parts
None
Tags for identification.
Troubleshooting
None
Equipment Condition
Engine cooled.
Oil drained from transmission and transfer gears.
Special Tools
Personnel Required.
None
Two mechanics
References
Tires are blocked.
Replacing oil in transmission and
Main disconnect switch
transfer gears, TM10-3930-641-20.
Drive shafts removal/installation,
TM10-3930-641-20.
Transmission control lock, removal/installation,
page 4-210.
General Safety Instructions
LO 10-3930-641-12
OFF.
Hood removal/installation,
TM 10-3930-641-20.
Shipping link installed.
Brake accumulator removal/installation, page 5-5.
Brake control valve group removal/installation,
page 5-26.
Shipping link removal/installation, TM 10-3930-641-20.
Go on to Sheet 2 4-43
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
(Sheet 2 of 13)
ACTION
REMARKS
1. Oil
Drain from transmission and transfer gears at
bottom of output transfer gear case.
Refer to TM 10-3930-641-20.
2. Hydraulic oil
Drain oil from hydraulic tank.
Refer to TM 10-3930-641-20.
3. Precleaner lid
a. Loosen screw.
b. Remove from air cleaner assembly.
4. Engine access panels
Open.
5. Hood
Fasten hoist and remove. Hood weighs 124 lb.
(56 Kg). (See TM 10-3930-641-20.)
6. Access panels (1) at base of
roll-over protective unit
Remove.
7. Capscrews from door and frame
assembly (2)
Remove.
8. Hoist
Attach to door and frame assembly. Weight of
assembly is 160 lb. (72.6 Kg).
9. Door and frame assembly (2)
Remove.
TA099253
Go on to Sheet 3
4-44
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
(Sheet 3 of 13)
ACTION
REMARKS
10. Access door assembly (3) capscrews,
nuts and washers
Remove.
11. Hoist
Attach to door assembly. Weight of door is
55 lb. (25 Kg).
Remove.
12. Access door assembly (3)
13. Channel assembly (4) capscrews
and washers
Remove.
14. Channel assembly (4)
Remove.
NOTE
Tag all hoses and tubes when they are removed. Cap or plug openings. Secure any
hoses disconnected but not removed away
from the transmission.
TA099254
Go on to Sheet 3
4-45
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
(Sheet 4 of 13)
ACTION
REMARKS
15. Hydraulic supply hose (5)
Tag and remove from hydraulic pump and
filter.
16. Three pilot hose assemblies (6, 7
and 8)
Tag and disconnect from steering control
valve.
17. Two steering cylinder hoses (9)
valve.
Tag and disconnect from steering control
18. Oil return tube assembly (10)
Tag and remove.
19. Filter inlet tube (11)
a. Tag and disconnect at both ends
b. Remove.
20. Supplemental steering tube (12)
a. Tag and disconnect at both ends.
b. Remove.
21. Access panel transmission
compartment, right hand side
of vehicle
Remove for access to steering panel mounting
capscrew.
22. Filter assembly (13)
a. Remove capscrews and washers.
b. Remove from panel assembly.
23. Supplemental steering tubes,
(14 and 15) and hose (15A)
Tag and disconnect at lower end of hoses.
TA099255
Go on to Sheet 5
4-46
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
24. Wire to supplemental steering
flow switch (18)
(Sheet 5 of 13)
ACTION
REMARKS
a. Tag.
b. Disconnect.
25. Supplemental steering supply
hose (16)
a. Tag and disconnect from manifold (17).
b. Remove.
26. Handrail assembly
for clearance.
Remove from right side of vehicle if required
27. Hoist
Attach to filter and steering valve panel (20)
assembly. Weight of panel is 185 lb. (84 Kg).
28. Capscrews (21) securing panel
assembly to frame
Remove.
29. Filter and steering valve panel
assembly (20)
a. Lift slowly and carefully to clear frame
and transmission.
b. Lift until supplemental steering hoses (14
and 15) and 15A capscrews can be reached.
See page 4-46 for art illustration.
TA099256
Go on to Sheet 6
4-47
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
(Sheet 6 of 13)
ACTION
REMARKS
30. Supplemental steering hoses (14
and 15) and 15A
Tag and disconnect from diverter valve
31. Filter and steering valve panel
assembly (20)
Remove from vehicle.
32. Access panel at rear of roll-over
structure (21)
Remove.
33. Connectors (22) at back of cab
Tag and disconnect two connectors.
34. Capscrews and clips (23) securing Remove.
wiring harness to frame
TA099257
Go on to Sheet 7
4-48
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
(Sheet 7 of 13)
ACTION
35. Brake accumulator
Remove.
36. Brake control valve group
Remove.
REMARKS
See page 5-5.
See page 5-26.
37. Governor control cable (24)
a. Disconnect from governor.
b. Remove clamp securing cable to engine
bracket and transmission.
c. Move away from transmission.
38. Three capscrews (25) and screen
assembly (26)
Remove.
Go on to Sheet 8
4-49
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
39. Transmission oil filter hose
assembly (27)
(Sheet 8 of 13)
ACTION
REMARKS
a. Tag and disconnect at transmission.
b. Secure away from transmission.
40. Transmission to torque converter
hose assemblies (28 and 29)
a. Tag and disconnect at transmission.
b. Secure away from transmission.
41. Hose assembly (30) from torque
converter to output transfer gear
assembly
Tag and disconnect at output transfer
gear assembly.
NOTE
Access for removal from bottom of vehicle.
42. Hose clamps (31) on transmission Loosen.
oil pump supply line (32)
43. Bracket (33) securing supply line
to transmission
Remove.
44. Supply line (32)
Tag and remove.
TA099259
Go on to Sheet 9
4-50
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
45.
Capscrews (34)
Remove.
46.
Tube assembly (35) (Right side
of vehicle hydraulic tank)
a. Remove bracket clamp and hose clamp.
b. Tag and remove tube.
47.
Upper drive shaft (between
torque converter and transmission)
Remove.
Refer to TM 10-3930-641-20.
48.
Lower rear drive shaft (between
Remove.
transfer gearcase and rear differential)
Refer to TM 10-3930-641-20.
49.
Lower center drive shaft
Refer to TM 10-3930-641-20.
Remove.
TA099260
Go on to Sheet 10
4-51
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
50.
Transmission plunger assembly (36)
(access from under vehicle)
Remove. Remove from bracket securing
to gearcase.
51.
Transmission control lock assembly
Remove.
See page 4-210.
52.
Transmission control cables (37)
a. Remove two capscrews (38).
b. Separate ring on cable from spool in
transmission hydraulic control valve.
53.
Hose assembly 39
Tag and disconnect.
TA099261
Go on to Sheet 11
4-52
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
54.
Guard assembly (40) over parking
brake
ACTION
REMARKS
Remove.
TA099262
Go on to Sheet 12
4-53
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
ACTION
55.
Two 5/8-11NC forged
eyebolts (41)
Install in top of transmission as shown.
56.
Hoist
Attach. Weight of transmission and transfer
assembly is 2836 lb. (1286 Kg).
57.
Capscrews (42) that hold transmission and transfer assembly to
main frame
Remove.
REMARKS
NOTE
Lift transmission and remove remaining
capscrews.
TA099263
Go on to Sheet 13
4-54
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
58.
Transmission
Lift transmission about 2 in. (50.8 mm).
59.
Bracket assemblies that hold transfer
assembly to frame on both sides
Remove from vehicle.
60. Cables, wire harnesses, and hydraulic
lines
Make sure all are out of the way before
removing transmission.
61. Transmission and transfer assembly
(43)
Remove.
TA099264
End
4-55
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION
(Sheet 1 of 12)
This task covers: Installation of transmission and transfer assembly.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required.
None
Equipment Condition
Transmission and transfer gears removed.
Shipping link installed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
LO 10-3930-641-12
Transmission and transfer assembly removal,'
page 4-43.
Block front and rear tires.
Main disconnect switch OFF.
Hood removal/installation,
TM 10-3930-641-20.
Shipping link removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-56
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 12)
ACTION
REMARKS
1. Transmission and transfer
assembly (1)
Fasten hoist.
2.
Hydraulic lines and electric wires
Be sure all are out of the way of
transmission. Lower unit (1) into machine.
3.
Transmission and transfer assembly
Lower until bracket assembly (2) can be installed on transfer gear case.
TA099265
Go on to Sheet 3
4-57
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
4. Capscrews (3) that hold transmission
and transfer gears to main frame
Install.
5.
Guard assembly (4)
Install over parking brake.
6.
Tube assembly (5) that connects
parking brake to parking brake
valve
Install.
7.
Clip (6) that holds tube assembly to
guard assembly
Install.
REMARKS
TA099266
Go on to Sheet 4
4-58
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
8.
Transmission hydraulic control cable
assemblies (7)
9.
Hydraulic hose assembly (8) that
connects transmission oil cooler to
transfer gear case
Install.
10.
Transmission control lock
assembly
Install.
11.
Transmission plunger assembly
(9)
Install. Install bracket securing to
gearcase.
REMARKS
a. Install ring on cable to spool on hydraulic
control valve.
b. Secure with capscrews.
See page 4-213.
TA099267
Go on to Sheet 5
4-59
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
12.
Lower center drive shaft
13.
Lower rear drive shaft (between
transfer gearcase and rear
differential)
Install.
Refer to TM 10-3930-641-20.
14.
Upper drive shaft (between
torque converter and
transmission)
Install.
Refer to TM 10-3930-641-20.
15. Tube assembly (10) (Right side
of vehicle hydraulic tank)
Install.
Refer to TM 10-3930-641-20.
a. Install and secure bracket clamp and
hose clamp.
b. Secure with capscrew (11).
TA099268
Go on to Sheet 6
4-60
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
16.
Supply line (12)
Install.
17.
Bracket (13) securing supply
line to transmission
Install.
18.
Hose clamps (14) on transmission
oil pump supply line (12)
Install.
19.
Hose assembly (15) from torque
converter to output transfer gear
assembly
Connect to output transfer gear assembly.
20.
Transmission to torque converter
hose assemblies (16 and 17)
Connect to transmission.
21.
Transmission oil filter hose
assembly (18)
Connect to transmission.
TA099269
Go on to Sheet 7
4-61
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
22.
Screen assembly (19)
a. Install.
b. Secure with three capscrews (20).
23.
Governor control cable (21)
a. Connect to governor.
b. Secure to engine bracket and transmission
with clamps.
24.
Brake control valve group
Install.
25.
Brake accumulator
Install.
See page 5-26.
See page 5-5.
TA099270
Go on to Sheet 8
4-62
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
26.
Capscrews and clips (22) securing
wiring harness to frame at back of
cab
Install.
27.
Connectors (23)
Connect.
28.
Filter and steering valve panel
assembly (24)
a. Attach hoist.
REMARKS
b. Make sure harnesses and hoses are out
of the way.
c.
Lower into position.
d. Secure with capscrews.
4-63
TA099271
Go on to Sheet 9
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
29.
Supplemental steering supply
hose (25)
Connect to manifold (26).
30.
Wire to supplemental steering
flow switch (27)
Connect.
31.
Supplemental steering tubes
(28 and 29)
Connect at lower ends.
a. Install to panel assembly.
REMARKS
b. Secure with capscrews and washers.
33.
Supplemental steering tube (31)
Install.
34.
Filter inlet tube (32)
Install.
35.
Oil return tube assembly (33)
Install.
TA099272
Go on to Sheet 10
4-64
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
36.
Two steering cylinder hoses (33)
Connect to steering control valve.
37.
Three pilot hose assemblies (34,
35 and 36)
Connect to steering control valve.
38.
Hydraulic supply hose (37)
Install to hydraulic pump and filter.
39.
Channel assembly (38)
a. Install.
b. Secure with capscrews and lockwashers.
40.
Handrail assembly
Install to right side of vehicle, if removed.
TA099273
Go on to Sheet 11
4-65
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
41.
Access door assembly (39)
55 lb. (25 kg).
ACTION
REMARKS
a. Attach hoist. Weight of door is
b. Lower into position.
c.
42.
Door and frame assembly (40)
assembly is 160 lb. (72.6 kg).
Secure with capscrews, nuts and washers.
a. Attach hoist. Weight of door and frame
b. Lower into position.
c.
Secure with capscrews.
43.
Access panels (41) at base of
roll-over protective unit
Install.
44.
Hood
Install.
TA099274
Go on to Sheet 12
4-66
TM 10-3930-641-34-2
TRANSMISSION AND TRANSFER ASSEMBLY INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
45.
Precleaner lid
Install.
Refer to TM 10-3930-641-20.
46.
Oil
Fill transmission and hydraulic tank to
correct level.
Refer to LO 10-3930-641-12.
47.
Access doors and panels
Close.
End
4-67
TM 10-3930-641-34-2
TRANSMISSION DISASSEMBLY
(Sheet 1 of 20)
This task covers: Disassembly of the transmission.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Wood blocking.
Pages 2-44, 2-49, 2-50, 2-52
Equipment Condition
Transmission removed from vehicle.
Transmission hydraulic controls removed
from transmission.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Transmission and transfer assembly
removal; page 4-43.
Transmission on blocks and level
Transmission hydraulic controls
removal/installation, page 4-157.
Go on to Sheet 2
4-68
TM 10-3930-641-34-2
TRANSMISSION DESASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
CAUTION
As transmission is disassembled, use a parts
rack to keep plates and disc assemblies in
same order in which they were removed.
This is necessary because clutch plates or
disc assemblies can be used again only in
their original location. Failure to follow this
practice can cause excessive wear and possible
failure of transmission.
1
Transmission
Put on wood blocks with output end up as
shown.
2.
Planetary group capscrews
a. Remove.
b. Use two of the capscrews as shown to
force the planetary group from the case.
TA099275
Go on to Sheet 3
4-69
TM 10-3930-641-34-2
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
3.
Planetary group
ACTION
REMARKS
a. Attach hoist as shown.
b. Remove and set on wood blocks with
output end up.
NOTE
Planetary group weighs 1100 lbs. (499 Kg).
4. Clutch housings
5.
Using a grease pencil, draw a line across the
four clutch housings. This will make correct
installation of the housings easier.
5. Tooling (sleeve, capscrew, retainer)
Install on end of shaft assembly as shown.
This is to hold parts on the assembly when it is
removed.
TA099276
Go on to Sheet 4
4-70
TM 10-3930-641-34-2
TRANSMISSION DISASSEMBLY (CONT)
(Sheet 4 of 20)
Planetary Group
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25
26.
27
Ring Gear
Plate Assembly
Pin
Ball
Center Plate
Capscrew
Retainer Plate
Spacer
Sun Gear
Metal Seal Ring
Lock Ring
Washer
Caged Roller Bearing Assembly
Planet Gear
Metal Seal Ring
Planet Carrier
Planet Shaft
Carrier Assembly
Pin
Planet Carrier
Metal Seal Ring
Disc Assembly
Clutch Plate
Ring Gear
Washer
Planet Gear
Special Roller Bearing
Assembly
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Spring Pin
Planet Shaft
Internal Retaining Ring
Retaining Ring
Special Ball Bearing
Clutch Housing Assembly
Cup Plug
Clutch Housing No. 1
Metal Seal Ring
Internal Plastic Seal Ring
External Plastic Seal Ring
Clutch Piston
TA099277
Go on to Sheet 5
4-71
TM 10-3930-641-34-2
TRANSMISSION DISASSEMBLY (CONT)
(Sheet 5 of 20)
Planetary Group
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
Sun Gear
Planet Carrier
Lock Ring
Hub Assembly
Hub
Pin
Snap Ring
Washer
Planet Gear
Caged Roller Bearing Assembly
Planet Shaft
Ring Gear
Disc Assembly
Clutch Piston
Metal Seal Ring
Reaction Pin
Bolt Damper
Housing Assembly
Clutch Housing No. 3
Pin
Spring
Ring Gear
Clutch Piston
Capscrew
Clutch Housing No. 2
Reaction Dowel
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
Special Ball Bearing
Internal Retaining Ring
Sun Gear
Spacer
External Retaining Ring
Metal Seal Ring
Output Shaft Assembly
Metal Seal Ring
Input Shaft Assembly
Pin
Transmission Input Shaft
TA099278
Go on to Sheet 6
4-72
TM 10-3930-641-34-2
(Sheet 6 of 20)
TRANSMISSION DISASSEMBLY (CONT)
Planetary Group
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
Clutch Housing No. 6
Washer
Capscrew
Sun Gear
External Retaining Ring
Lock Ring
Slinger
Planet Carrier
Spacer
Retaining-Ring
Planet Shaft
Caged Roller Bearing
Planet Gear
Lockwasher
Capscrew
Reaction Dowel
Preformed Packing
Manifold Assembly
Pin
Cup Plug
Manifold
Pin
Plug
Preformed Packing
Spring
Capscrew
Preformed Packing
Clutch Disc Assembly
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
Clutch Plate
Housing Assembly
Pin
Rotating Housing
Clutch Piston
External Plastic Seal Ring
Internal Plastic Seal Ring
External Retaining Ring
Retainer Plate
Cored Disc Spring
Housing Assembly
Capscrew
Seal Ring
Capscrew
Washer
Ring Gear
Clutch Housing No. 4
4-73
TM 10-3930-641-34-2
(Sheet 7 of 20)
TRANSMISSION DISASSEMBLY (CONT)
6.
LOCATION/ITEM
Twenty capscrews (79) and washers
(119)
ACTION
Remove. (See sheet 8 for illustration)
7.
No. 6 clutch housing (77)
a. Use clamping tools to hold piston in No. 6
clutch housing as shown.
REMARKS
b. Attach hoist as shown.
c. Remove.
NOTE
Housing weighs 68 lb. (31 Kg).
8.
Piston (53)
Remove from housing.
9.
Two seal rings (38) and (54)
Remove from piston (53).
10.
Springs (101)
Remove.
11.
Three disc assemblies (52) and two
plates (23)
Remove from housing.
12.
Pins (98)
Remove from manifold (97).
TA099280
Go on to Sheet 8
4-74
TM 10-3930-641-34-2
(Sheet 8 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
13.
Retaining ring (86)
Remove from shaft assembly.
14.
Ring gear (61)
Remove from carrier.
15.
Manifold assembly (94)
a. Install two eyebolts.
REMARKS
b. Fasten to hoist.
c.
Remove.
d. Set upside down on wood blocks.
16.
Preformed packing (103) and
preformed packing (93)
Remove and discard.
17.
Manifold assembly (94)
Turn over.
18.
Bearing (32) and retaining ring (30)
Remove.
TA099281
Go on to Sheet 9
4-75
TM 10-3930-641-34-2
(Sheet 9 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
19.
No. 4 clutch housing (121)
ACTION
REMARKS
a. Use clamping tools to hold piston (53)
in No. 4 clutch housing as shown.
b. Attach hoist as shown.
c.
Remove.
NOTE
Housing weighs 60 lb. (27 Kg).
20.
Piston (53)
Remove.
21.
Two seal rings (38) and (54)
Remove.
22.
Two disc assemblies (22) and one
plate (23)
Remove.
23.
Lock ring (82)
Remove from input shaft assembly (74).
(See sheet 6 for location.)
TA099282
Go on to Sheet 10
4-76
TM 10-3930-641-34-2
(Sheet 10 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
24.
Twenty capscrews (116 and 118)
and washers (78 and 119)
Remove from housing assembly (115).
25.
Housing assembly (115
a. Attach hoist as shown.
b. Remove.
NOTE
Assembly weighs 44 lb. (20 Kg).
c.
Place in press as shown.
d. Force retainer plate (113) until retainer ring
(112) can be removed.
e. Release plate.
f.
Remove plate and three disc springs (114).
26.
Two seal rings (117)
Remove from housing assembly (115).
27.
Two seal rings (110) and (111)
Remove and discard. (See sheet 6 for
location.)
TA099283
Go on to Sheet 11
4-77
TM 10-3930-641-34-2
(Sheet 11 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
28.
Housing assembly (106) and ring
gear (120)
ACTION
REMARKS
a. Install two 3/8"--16NC x 5" eyebolts
through housing assembly into ring gear as
shown.
b. Attach hoist as shown.
c.
Remove.
NOTE
Unit weighs 60 lb. (27 Kg).
29.
Five discs (104) and four plates
(105)
Remove.
30.
Piston (53)
Use clamping tools to hold piston in No. 3
clutch housing (57).
31.
No. 3 clutch housing (57)
a. Attach hoist.
b. Remove.
NOTE
Housing weighs 89 lb. (40 Kg).
TA099284
Go on to Sheet 12
4-78
TM 10-3930-641-34-2
(Sheet 12 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
32.
Clutch piston (53)
Remove from clutch housing (57).
33.
Two seal rings (54) and (38)
Remove from piston (53).
34.
Springs (60)
Remove from clutch housing (57).
35.
Three disc assemblies (52) and two
plates (23) of No. 3 clutch housing.
Remove from clutch housing (57).
36.
Snap ring (46)
Remove.
37.
Planet carrier (41)
a. Install two 3/8"-16NC forged eyebolts
in carrier as shown.
b. Attach hoist.
c.
Remove.
NOTE
Carrier weighs 62 lb. (28.12 Kg).
TA099285
Go on to Sheet 13
4-79
TM 10-3930-641-34-2
(Sheet 13 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
38.
Ring gear (51) and planet
carrier (41)
ACTION
REMARKS
a. Install three screwdrivers between ring
gear and carrier.
b. Pry lock ring (42) away from ring gear
until ring gear drops off carrier.
39.
Retainer ring (31)
Remove.
10.
Hub assembly (4-3)
Remove.
41.
Bearing (32)
Remove from planet carrier (41).
42.
Spring pins (28)
Remove by driving pins into shaft (50) with
a hammer and punch.
43.
Shafts (50)
Remove.
Remove pins (28) from shafts (50)
TA099286
Go on to Sheet 14
4-80
TM 10-3930-641-34-2
(Sheet 14 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
44.
Planet gears (48) and washers (47)
Remove from planet carrier (41).
45.
Roller bearing (49)
Remove from each planet gear (48).
46.
Sun gear (40)
Remove.
47.
Piston (62)
Use clamping tools to hold piston in No. 2
clutch housing (64).
NOTE
There are two long capscrews on the No. 2
clutch housing that bolt into the forward
clutch housing.
48.
No. 2 clutch housing (64)
a. Attach hoist as shown.
b. Remove.
NOTE
Housing weighs 109') lb. (46 Kg).
TA099287
Go on to Sheet 15
4-81
TM 10-3930-641-34-2
(Sheet 15 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
49.
Piston (62)
Remove.
50.
Two seal rings (54) and (38)
Remove.
51.
Three disc assemblies (22) and two
plates (23) of No. 2 clutch housing
Remove.
52.
Input shaft assembly (74)
a. Install a 1/2"-13NC forged eyebolt in the
end of shaft assembly.
b. Attach hoist as shown.
c.
Remove with carrier (18) and ring gear
(24) attached.
NOTE
Unit weighs 160 lb. (72.57 Kg).
53.
Tooling (sleeve, capscrew, retainer)
installed in Step 5.
Remove.
TA099288
Go on to Sheet 16
4-82
TM 10-3930-641-34-2
(Sheet 16 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
54.
Input shaft assembly (with carrier
Set in horizontal position on wood blocks.
and ring gear attached)
55.
Capscrew (6), retainer plate (7) and
spacer (8)
Remove from end of input shaft assembly (74).
56.
Sun gear (9)
Remove from end of input shaft assembly.
57.
Input shaft assembly (74)
a. Attach hoist.
b. Remove from ring gear and carrier.
NOTE
Assembly weighs 62 lb. (28 Kg).
58.
Retaining ring (67)
Remove.
59.
Input shaft assembly (74)
Remove from output shaft (72).
60.
Retaining ring (70), spacer (69)
and bearing (66)
Remove from input shaft (76).
61.
Two seal rings (71) and (73) on
output shaft carrier
Remove.
TA099289
Go on to Sheet 17
4-83
TM 10-3930-641-34-2
(Sheet 17 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
62.
Planet carrier (16) and ring gear (1)
ACTION
REMARKS
a. Install three 3/8-16NC eyebolts.
b. Attach hoist as shown.
c.
Using two screwdrivers, pry lock ring (11)
away from ring gear (1) until ring gear
drops away from carrier.
63.
Seal rings (15)
Remove from carrier.
64.
Pins (19)
Remove by driving into shafts (17) using a
hammer and punch.
65.
Shafts (17)
Remove. Remove pins (19) from shafts (17).
66.
Planet gears (14) and washers (12)
Remove from carrier (16).
67.
Roller bearings (13)
Remove from gears (14).
68.
Six pins (3)
Remove from plate assembly.
TA099290
Go on to Sheet 18
4-84
TM 10-3930-641-34-2
(Sheet 18 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
69.
Center plate (5)
ACTION
REMARKS
a. Install two 1/2-13NC eyebolts the
plate assembly.
b. Attach hoist.
c.
Remove.
NOTE
Assembly weighs 30 lb. (14 Kg).
70.
Three disc assemblies (22) and two
plates (23)
Remove from No. 1 clutch housing (35).
71.
Piston (39)
Use clamping tools to hold piston in No. 1
clutch housing (35) as shown.
TA099291
Go on to Sheet 19
4-85
TM 10-3930-641-34-2
(Sheet 19 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
72.
No. 1 clutch housing (35)
ACTION
REMARKS
a. Set upside down on wood blocks.
b. Remove retaining ring (31) that secures
housing to its carrier.
c.
Separate No. 1 clutch housing (35) from
its carrier using clamping tools as shown.
Housing weighs 120 lb. (54 Kg).
TA099292
Go on to Sheet 20
4-86
TM 10-3930-641-34-2
(Sheet 20 of 20)
TRANSMISSION DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
73.
Seal ring (36) and bearing (32)
Remove.
74.
No. 1 clutch housing (35)
Turn over.
75.
Piston (39)
Remove from housing (35).
76.
Seal rings (37) and (38)
Remove from piston (39).
77.
Ring gear (24)
Remove from carrier.
78.
Seal rings (21)
Remove from carrier.
79.
Spring pins (28)
Remove by driving into shafts (29) using a
hammer and punch.
80.
Planet shafts (29)
Remove. Remove pins (28) from shafts (29).
81.
Planet gears (26) and washers (25)
Remove.
82.
Roller bearings (27)
Remove from planet gears (26).
REMARKS
TA099293
End
4-87
TM 10-3930-641-34-2
(Sheet 1 of 31)
TRANSMISSION DISASSEMBLY (CONT)
This task covers:
Assembly of the transmission.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Test nozzle and source of air
100-150 psi (690-1035 kPa)
As required.
None
Equipment Condition
Transmission disassembled.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Transmission hydraulic controls removal/
installation, page 4-157.
None
Transmission disassembly, page 4-68.
Go on to Sheet 2
4-88
TM 10-3930-641-34-2
(Sheet 2 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Be sure all transmission parts are clean and
coated with fresh hydraulic oil before
assembly.
1.
Three roller bearings (27)
a. Lubricate with clean hydraulic oil.
b. Install in the three planet gears (26) of No.
1 clutch.
2.
Washer (25)
Install on both sides of each planet gear.
3.
Planet gear assemblies (bearing,
Install in planet carrier (20).
washer, gear)
4.
Planet shafts (29)Install.
NOTE
Be sure pin hole in each shaft aligns with
hole in carrier.
TA099294
Go on to Sheet 3
4-89
TM 10-3930-641-34-2
(Sheet 3 of 31)
TRANSMISSION DISASSEMBLY (CONT)
Planetary Group
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Ring Gear
Plate Assembly
Pin
Ball
Center Plate
Capscrew
Retainer Plate
Spacer
Sun Gear
Metal Seal Ring
Lock Ring
Washer
Caged Roller Bearing Assembly
Planet Gear
Metal Seal Ring
Planet Carrier
Planet Shaft
Carrier Assembly
Pin
Planet Carrier
Metal Seal Ring
Disc Assembly
Clutch Plate
Ring Gear
Washer
Planet Gear
Special Roller Bearing Assembly
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Spring Pin
Planet Shaft
Internal Retaining Ring
Retaining Ring
Special Ball Bearing
Clutch Housing Assembly
Cup Plug
Clutch Housing No. 1
Metal Seal Ring
Internal Plastic Seal Ring
External Plastic Seal Ring
Clutch Piston
TA099295
Go on to Sheet 4
4-90
TM 10-3930-641-34-2
(Sheet 4 of 31)
TRANSMISSION ASSEMBLY (CONT)
Planetary Group
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
Sun Gear
Planet Carrier
Lock Ring
Hub Assembly
Hub
Pin
Snap Ring
Washer
Planet Gear
Caged Roller Bearing
Assembly
Planet Shaft
Ring Gear
Disc Assembly
Clutch Piston
Metal Seal Ring
Reaction Pin
Bolt Damper
Housing Assembly
Clutch Housing No. 3
Pin
Spring
Ring Gear
Clutch Piston
Capscrew
Clutch Housing No. 2
Reaction Dowel
66.
67.
68.
69.
70.
71
72.
73.
74.
75.
76.
Special Ball Bearing
Internal Retaining Ring
Sun Gear
Spacer
External Retaining Ring
Metal Seal Ring
Output Shaft Assembly
Metal Seal Ring
Input Shaft Assembly
Pin
Transmission Input Shaft
TA099296
Go on to Sheet 5
4-91
TM 10-3930-641-34-2
(Sheet 5 of 31)
TRANSMISSION ASSEMBLY (CONT)
Planetary Group
77. Clutch Housing No. 6
78. Washer
79. Capscrew
80. Sun Gear
81. External Retaining Ring
82. Lock Ring
83. Slinger
84. Planet Carrier
85. Spacer
86. Retaining Ring
87. Planet Shaft
88. Caged Roller Bearing
89. Planet Gear
90. Lockwasher
91. Capscrew
92. Reaction Dowel
93. Preformed Packing
94. Manifold Assembly
95. Pin
96. Cup Plug
97. Manifold
98. Pin
99. Plug
100. Preformed Packing
101. Spring
102. Capscrew
103. Preformed Packing
104. Clutch Disc Assembly
105.
106.
107.
108.
109.
110.
111.
112.
113.
114
115.
116.
117.
118.
119.
120.
121.
Clutch Plate
Housing Assembly
Pin
Rotating Housing
Clutch Piston
External Plastic Seal Ring
Internal Plastic Seal Ring
External Retaining Ring
Retainer Plate
Cored Disc Spring
Housing Assembly
Capscrew
Seal Ring
Capscrew
Washer
Ring Gear
Clutch Housing No. 4
4-92
TM 10-3930-641-34-2
(Sheet 6 0f 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
5.
Spring pins (28)
Install each until it is flush with outside
surface of carrier.
6.
Seal rings (36), (15) and (21)
Install.
7.
Ring gear (24)
Install on carrier.
8.
Bearing (32)
Install in No. 1 clutch housing (35).
NOTE
Be sure bearing is in contact with counterbore in clutch housing.
9.
Internal retaining ring (30)
Install.
10.
Seals (37) and (38)
Install in piston (39).
NOTE
Install seals so oil groove and sealing edge
will be toward inside of No. 1 clutch
housing (35).
TA099298
Go on to Sheet 7
4-93
TM 10-3930-641-34-2
(SHEET 7 0F 31)
TRANMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
11.
Clean oil
Put on seals (37) and (38).
12.
Piston (39)
Install in No. 1 clutch housing (35).
NOTE
Be sure oil groove and sealing edge will be
toward inside of No. 1 clutch housing (35).
13.
Clutch housing No. 1 (35)
a. Use suitable clamping tools to hold piston
in clutch housing.
b. Turn housing upside down and attach
hoist.
c.
Put housing in position on planet carrier
(20) as shown at right.
NOTE
Be sure the bearing groove in the clutch
housing aligns with the pin in the carrier.
14.
Retaining ring (31)
15.
Clutch housing/carrier assembly
Install to secure clutch housing (35) to planet
carrier (20).
Turn assembly over and place on wooden
blocks.
TA099299
Go on to Sheet 8
4-94
TM 10-3930-641-34-2
(Sheet 8 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
16.
Six pins (shown at right)
Install in clutch housing (35).
17.
Three disc assemblies (22) and two
a. Lubricate with clean oil.
clutch plates (23)
REMARKS
b. Install as shown, beginning with a disc
assembly (22).
18.
Plate assembly (2)
Install onto clutch housing (35).
NOTE
Be sure oil hole in plate is aligned with oil
hole in clutch housing.
19.
Bearing (66)
Install in carrier of No. 2 clutch housing as
shown.
NOTE
Be sure bearing is installed with groove facing
up.
TA099300
Go on to Sheet 9
4-95
TM 10-3930-641-34-2
(Sheet 9 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
20.
Internal retaining ring (67)
Install.
21.
Roller bearings (13)
a. Lubricate with clean oil.
REMARKS
b. Install in six planet gears (14) of No. 2
clutch housing.
22.
Washer (12)
Install on both sides of each planet gear.
23.
Planet gear assemblies (bearing,
washer, gear)
Install in planet carrier (16).
24.
Planet shafts (17)
Install.
NOTE
Be sure pin hole in each shaft aligns with
hole in carrier.
TA099301
Go on to Sheet 10
4-96
TM 10-3930-641-34-2
(Sheet 10 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
25. Pins (shown at right)
Install each until it is flush with outside
surface of carrier.
26.
Lock ring (11)
Install on planet carrier (16).
27.
Planet carrier (16)
a. Attach hoist as shown.
b. Lift and position on ring gear (1).
c.
Using two screwdrivers, slightly compress
lock ring (11) as shown.
d. Slide carrier into ring gear until lock ring
(11) engages with groove in gear.
28.
Bearing (66)
Install on shaft (76).
NOTE
Be sure notch in bearing aligns with pin (75)
in shaft assembly.
TA099302
Go on to Sheet 11
4-97
TM 10-3930-641-34-2
(Sheet 11 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
29.
Spacer (69) and snap ring (70)
Install on input shaft (76).
30.
Input shaft (76)
Slide into output shaft (72).
31.
Metal seal ring (71)
Install on output shaft (72).
32.
Sun gear (68)
Install on input shaft (76).
33.
Seal rings (71) and (73)
a. Install.
REMARKS
b. Lubricate with clean hydraulic fluid.
34.
Input shaft assembly (74)
a. Attach hoist as shown.
b.
b. Install in planet carrier (16) of No. 2 clutch
housing.
TA099303
Go on to Sheet 12
4-98
TM 10-3930-641-34-2
(Sheet 12 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
35.
Sun gear (9)
Install on end of input shaft (76).
36.
Spacer (8)
Install.
37.
Tooling (sleeve, retainer,
capscrew)
Install as shown to hold carrier on input
shaft assembly (74).
38.
Input shaft assembly (74) and
planet carrier (16)
Position as shown in No. 1 clutch housing
carrier.
39.
Ring gear (61)
Install on planet carrier (16).
40.
Three disc assemblies (22) and two
clutch plates (23)
a. Lubricate with clean oil.
b. Install, beginning with a disc assembly (22).
TA099304
Go on to Sheet 13
4-99
TM 10-3930-641-34-2
(SHEET 13 0F 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
41.
Twelve springs (shown at right)
Install.
42.
Seal ring (15)
a. Install on carrier.
b. Lubricate with clean oil.
43.
Two seal rings (37) and (38)
a. Install on piston (62) so that oil groove
and sealing edge will face toward inside
of housing.
b. Lubricate with clean hydraulic fluid.
44.
Piston (62)
Install in No. 2 clutch housing (64).
45.
Clutch housing No. 2 (64)
a. Use clamping tools to hold piston in
clutch housing.
b. Attach hoist.
TA099305
Go on to Sheet 14
4-100
TM 10-3930-641-34-2
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
45.
Clutch housing No. 2 (cont)
ACTION
c.
REMARKS
Position housing on dowels, springs and
plate assembly as shown at right.
NOTE
Be sure grease pencil mark on outside of No. 1
housing aligns with mark on outside of No. 2
housing, and the 12 springs are in their bores
in the piston of No. 2 housing.
d. Install long capscrews. Tighten to a torque
of 65-85 lb. ft. (102-115 N-m).
46.
Sun gear (40)
Install onto output shaft (72).
47.
Bearing (32)
Install in No. 5 clutch housing planet carrier
(41).
TA099306
Go on to Sheet 15
4-101
TM 10-3930-641-34-2
(Sheet 15 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
48.
Ring (shown at right)
Install to secure bearing.
49.
Three roller bearings (49)
a. Lubricate with clean oil.
REMARKS
b. Install in planet gears (48) of planet
carrier (41).
50.
Washer (47)
Install on both sides of each planet gear.
51.
Planet gear assemblies (bearing,
washer, gear)
Install in carrier.
52.
Planet shafts (50)
Install.
NOTE
Be sure pin hole in each shaft aligns with
hole in carrier.
53.
Spring pins (28)
Install each until it is flush with outside surface of carrier.
54.
Pin (45)
Install in hub (44).
TA099307
Go on to Sheet 16
4-102
TM 10-3930-641-34-2
(Sheet 16 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
55.
Hub assembly (43)
ACTION
REMARKS
Install on planet carrier (41).
NOTE
Be sure pin in hub assembly engages with
notch in bearing.
56.
Retaining ring (31)
Install to secure hub assembly.
57.
Lock ring (42)
Install on carrier (41).
58.
Carrier
a. Attach hoist as shown.
b. Lower into ring gear (51).
NOTE
Use screwdrivers to compress ring (42) as
carrier is being installed. Be sure ring
engages groove in ring gear.
c.
Install carrier/ring gear assembly in No. 2
clutch housing.
TA099308
Go on to Sheet 17
4-103
TM 10-3930-641-34-2
(Sheet 17 0f 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
59.
Snap ring (46)
Install to secure carrier/ring groove assembly.
60.
Six reaction pins (55)
Install.
61.
Three disc assemblies (52) and two
clutch plates (23)
a. Lubricate with clean oil.
b. Install as shown, beginning with a disc
assembly.
62.
Two seal rings (38) and (54)
a. Install on piston (53) of No. 3 clutch
piston housing (58).
NOTE
Be sure oil groove and sealing edge are
toward inside of housing.
b. Lubricate with clean hydraulic fluid.
TA099309
Go on to Sheet 18
4-104
TM 10-3930-641-34-2
(Sheet 18 0f 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
63.
Clutch piston (53)
ACTION
REMARKS
a. Install in No. 3 clutch housing (58).
b. Using clamping tools hold piston in
clutch housing (58).
64.
Twelve springs (60)
Install in No. 2 clutch housing (64).
65.
No. 3 clutch housing (58)
a. Attach hoist as shown.
b. Lower into position on No. 2 clutch
housing (64) as shown.
NOTE
Be sure the 12 springs slip into the bores of
the piston in the No. 3 clutch housing as
it is lowered.
TA099310
Go on to Sheet 19
4-105
TM 10-3930-641-34-2
(Sheet 19 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
66.
Ring gear (120)
Install.
67.
Five clutch disc assemblies (104)
and four clutch plates (105)
a. Lubricate with clean oil.
REMARKS
b. Install, beginning with a disc assembly.
68.
Housing assembly (106)
Install over disc assemblies and plates.
TA099311
Go on to Sheet 20
4-106
TM 10-3930-641-34-2
(SHEET 20 OF 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
69.
Two seal ring (110) and (111)
ACTION
REMARKS
a. Install on piston (109) No. 5 clutch
piston housing (115).
NOTE
Be sure oil grooves and sealing edges are
toward inside of housing (106).
b. Lubricate with clean oil.
70.
Three disc springs (114)
a. Install first spring with outside diameter
of spring in contact with housing assembly.
b. Install next two springs with outside
diameter of springs in contact with each
other.
71. Retainer plate (113)
the three springs.
Place in position on housing assembly over
TA099312
Go on to Sheet 21
4-107
TM 10-3930-641-34-2
(Sheet 21 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
72.
Three springs (114)
With an arbor press, compress as shown at
right until retaining ring (112) can be installed over retainer plate (113).
73.
Two seal rings (117)
a. Install on carrier of housing assembly
(115) as shown.
b. Lubricate with clean hydraulic fluid.
74.
Housing assembly (115)
a. Attach hoist.
b. Install in housing assembly (106).
75.
Twenty capscrews (118) and
washers (119)
Install as shown on Sheet 22. Tighten to a
torque of 27-37 lb. ft. (36-50 N-m).
TA099313
Go on to Sheet 22
4-108
TM 10-3930-641-34-2
(Sheet 22 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
76.
Lock ring (82)
Install.
77.
Two disc assemblies (52) and one
clutch plate (23)
a. Lubricate with clean oil.
REMARKS
b. Install, beginning with a disc assembly.
78.
Twelve springs (101) (shown
at right)
Install.
79.
Two seal rings (38) and (54).
a. Install on clutch piston (53) of No. 4
clutch housing (121).
NOTE
Be sure to install seals so that oil groove and
sealing edges face toward inside of No. 4
clutch housing.
b. Lubricate with clean hydraulic fluid.
TA099314
Go on to Sheet 23
4-109
TM 10-3930-641-34-2
(Sheet 23 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
80.
Clutch piston (53)
ACTION
REMARKS
a. Install in No. 4 clutch housing (121).
b. Using clamping tools, hold piston in
clutch housing.
81:
No. 4 clutch housing
a. Attach hoist as shown.
b. Install on No. 3 clutch housing
as shown.
NOTE
Be sure grease pencil mark on outside of
No. 3 housing aligns with mark on outside
of No. 4 housing, and the 12 springs are in
their bores in the piston of No. 4 housing.
TA099315
Go on to Sheet 24
4-110
TM 10-3930-641-34-2
(Sheet 24 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
82.
Bearing (32)
ACTION
REMARKS
Install in manifold assembly until it makes
contact with counterbore in manifold
assembly.
NOTE
Notch on inner race must face downward.
83.
Retaining ring (30)
Install.
84.
Small preformed packing (103) and
large preformed packing (93)
a. Install in manifold assembly (97) as
shown.
b. Lubricate with clean oil.
85.
Manifold assembly (97)
a. Attach hoist as shown.
b. Install on No. 4 clutch housing.
NOTE
Be sure notch in bearing aligns with pin in
shaft assembly before manifold assembly is
lowered all the way.
c.
Turn No. 5 clutch housing (115) until two
of the capscrews (118) align with openings
in the manifold assembly.
TA099316
Go on to Sheet 25
4-111
TM 10-3930-641-34-2
(Sheet 25 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
85.
Manifold assembly (cont)
ACTION
REMARKS
d. Remove the two capscrews that are aligned
with the openings.
e. Install two threaded rods (3/8"-16NC
x 8") into the two capscrew holes as
shown at right.
f.
Install two large flat washers and nuts on
the rods.
NOTE
Before the nuts are tightened, be sure the
notch in the bearing aligns with the dowel
in the shaft assembly.
86
Sun gear (80)
Install over shaft.
87.
Snap ring (81)
Install in groove above sun gear on shaft
assembly.
NOTE
It may be necessary to tighten nuts further
(Step 85 f., above) to expose groove.
TA099317
Go on to Sheet 26
4-112
TM 10-3930-641-34-2
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
88.
Rods, flat washers, nuts
(Sheet 26 of 31)
ACTION
REMARKS
a. Replace with the two original capscrews.
b. Tighten the two capscrews to a torque of
27 to 37 lb. ft. (37 to 51 N-m).
89.
Two roller bearings (88)
a. Lubricate with clean hydraulic fluid.
b. Install in each of the four planet gears (89)
of the planet carrier (84).
90.
Washers (47)
Install on both sides of each planet gear (89).
91. Planet gear assemblies (bearing
washer, gear)
Install in planet carrier (84).
92.
Install in planet gears.
Planet shafts (87)
NOTE
Be sure pin hole in each shaft aligns with hole
in carrier.
TA099318
Go on to Sheet 27
4-113
TM 10-3930-641-34-2
(Sheet 27 of 31)
TRANSMISSION ASSEMBLY
LOCATION/ITEM
ACTION
REMARKS
93.
Spring (28)
Install each until it is flush with the outside
surface of the carrier.
94.
Slinger (83)
Position as shown on planet carrier (84) and
secure carrier (84) and secure with the capscrews (91) and lockwashers (90).
95.
Planet carrier (84)
a. Attach hoist.
b. Install in position on the transmission.
96.
Spacer (85) and retaining ring (86)
Install.
97.
Ring gear (61)
Install on carrier (84).
98.
Six reaction dowels (92)
Install in manifold.
Go on to Sheet 28
4-114
TM 10-3930-641-34-2
(Sheet 28 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
99.
Three disc assemblies (52) and two
clutch plates (23)
ACTION
REMARKS
a. Lubricate with clean oil.
b. Install as shown, beginning with a disc
assembly.
100. Two seal rings (38) and (54)
a. Install on clutch piston (53).
NOTE
Be sure oil grooves and sealing edges face
toward inside of housing.
b. Lubricate with clean oil.
Go on to Sheet 29
4-115
TM 10-3930-641-34-2
(Sheet 29 of 31)
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
101. Clutch piston (53)
a. Install in No. 6 clutch housing (77).
b. Use clamping tools to hold piston in
housing.
102. Twelve springs (101)
Install in manifold assembly.
103. Clutch housing No. 6 (77)
a. Attach hoist as shown.
b. Put in position on manifold assembly as
shown at right.
NOTE
Be sure grease pencil mark on outside of No.
6 housing aligns with mark on manifold
assembly and the twelve springs (101) are in
their bores in the piston of No. 6 housing.
Go on to Sheet 30
4-116
TM 10-3930-641-34-2
(Sheet 30 of 31)
TRANSMISSION ASSEMBLY (CONTD)
LOCATION/ITEM
ACTION
REMARKS
104. Capscrews (79) and washers (119)
Install and tighten to a torque of 65-851b. ft.
(88-116 N-m).
105. Tooling (sleeve, retainer,
capscrew)
Remove from end of shaft assembly
(See Step 37).
106. Capscrew (6) and retainer plate
(7)
Install in end of shaft assembly.
107. Pistons
Check for correct operation:
a. Blow air under pressure of 100-150 psi
(690-1035 kPa) into each of the five oil
passages as shown.
b. Check that each piston will move at least
.12 to .15 in. (3.0 to 6.4 mm).
c.
If any of the pistons do not move the
correct distance, insert a small amount of
clean oil into that passage and recheck
with compressed air.
d. If any or all pistons still do not operate
correctly, transmission must be disassembled to check condition of pistons
and seals.
Go on to Sheet 31
Go on to Sheet 31
4-117
TM 10-3930-641-34-2
TRANSMISSION ASSEMBLY (CONT)
LOCATION/ITEM
108. Transmission assembly
ACTION
a. Attach hoist as shown.
REMARKS
b. Lower assembly into transmission case
as shown.
NOTE
Support case on wooden blocks.
c.
Secure assembly to case with the two
capscrews. Tighten the capscrews to a
torque of 65-85 lb. ft. (101.7-115.3
N-m).
d. Turn transmission on its side so that
opening for the transmission hydraulic
controls faces up.
109. Transmission hydraulic controls
Install into transmission case.
4-118
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT AND OUTPUT) REMOVAL
(Sheet 1 of 3)
This task covers: Separation of transfer gear assembly (input and output) from transmission.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Wooden blocking.
Page 2-42
Equipment Condition
Transmission and transfer assembly are
removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transmission and transfer assembly
removal, page 4-43.
Transmission and transfer assembly on
blocks and level.
Go on to Sheet 2
4-119
TM 10-3930-641-34-2
(Sheet 2 of 3)
TRANSFER GEAR ASSEMBLY (INPUT AND OUTPUT) REMOVAL (CONT)
LOCATION/ITEM
1.
Transmission and transfer assembly
ACTION
REMARKS
Put on wood blocks, as shown.
2.
Capscrews (1) that hold output
transfer assembly to transmission
Remove.
3.
Lifting brackets (A)
Attach to bracket assemblies on transfer gear
case assembly, as shown.
4.
5/8-llNC eyebolt
Install in opposite end of transfer gear case
assembly.
5.
Output transfer gear case assembly
(2)
Attach hoist as shown and remove. Unit weighs
1080 lb. (490 Kg).
6.
Preformed packing between output
transfer gear case and transmission
Discard and replace with new packing.
7.
Transmission
Use hoist to turn over. Transmission weighs
1510 lb. (685 Kg).
8.
12 capscrews (4)
Remove from transmission case.
9.
Cover (3)
Remove.
4-120
TM 10-3930-641-34-2
LOCATION/ITEM
ACTION
REMARKS
10.
Capscrews (6) and plate (5) under
cover (3)
Remove.
11.
Lifting brackets (A)
Attach to input transfer gear assembly (7) as
shown.
12.
3/8-16NC eyebolt
Install in input transfer gear case.
13.
Input transfer gear assembly.
Fasten hoist and remove from transmission.
Input gear assembly weighs 246 lb. (112 Kg).
14.
Preformed packing between input
transfer gear case and transmission
Discard and replace with new packing.
4-121
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT AND OUTPUT) INSTALLATION
(Sheet 1 of 2)
This task covers: Installation of transfer gear assembly (input and output) to transmission.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Performed packing.
None
Wooden blocking
Equipment Condition
Transmission and transfer gear assembly
are removed from vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transmission and transfer assembly
removal, page 4-43.
None
Transfer gear assembly removal,
page 4-119.
Transfer gear assembly installation,
page 4-122.
Go on to Sheet 2
4-122
TM 10-3930-641-34-2
LOCATION/ITEM
ACTION
REMARKS
1.
Preformed packing (2)
Install new packing. Put clean oil on seal.
2.
Lifting brackets (A), 3/8-16NC
Attach to input gear assembly (1) as shown.
eyebolt, and hoist
3.
Input gear assembly (1)
Position unit on transmission as shown.
4.
Capscrew and plate
Install in end of input shaft.
5.
12 capscrews that hold input gear
assembly to transmission
Install.
6.
Transmission
Use hoist to turn over. Put on wooden blocks.
7.
Preformed packing between output
transfer gear assembly and transmission
Install new packing. Put clean oil on seal.
8.
Lifting brackets (A), 5/8-11lNC
eyebolt and hoist.
a. Attach to output transfer gear assembly
(3) as shown.
b. Position unit on transmission.
9.
Capscrews that hold output gear
assembly to transmission
Install.
10.
Transmission and transfer gear
assembly
Install.
End
4-123
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT) DISASSEMBLY
This task covers: Disassembly of transfer gear assembly (input).
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Wooden Blocking
Pages 2-42, 2-49
Equipment Condition
Transfer gear assembly (input and output)
removed from transmission.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transfer gear assembly removal,
Page 4-119.
None
Go on to Sheet 2
4-124
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
1.
Input transfer gear assembly (1)
Put on wood blocks.
2.
Yoke assembly (2)
Remove.
3.
Six capscrews (20) and lockwashers
(30) from bearing cage (4)
Remove.
4.
Two capscrews (20)
a. Install in threaded holes in the bearing
cage (4), use as forcing screws to loosen
bearing cage (4).
b. Tighten evenly until cage (4) is loose.
5.
Cage (4) and shims (5)
Remove.
6.
Preformed packing (6)
Discard.
7.
Seal (3)
Remove.
4-125
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT) DISASSEMBLY
(CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
(Sheet 3 of 5)
Input Transfer Case Gear Group
Yoke Assembly
Lip Seal
Cage
Shim Pack
Preformed Packing
Tapered Roller Bearing Cup
Tapered Roller Bearing Cone
Input Transfer Driver Gear
Tapered Roller Bearing Cone
Tapered Roller Bearing Cup
Capscrew
Lockwasher
Input Transfer Case
Tapered Roller Bearing Cup
Tapered Roller Bearing Cone
Transfer Input Driven Gear
Shim Pack
Bearing Cage
Capscrew
Assembly Mounting Bracket
Upper Pad
Lower Plate
Sleeve
Capscrew
Lockwasher
Sleeve
Sleeve
Upper Plate
Lockwasher
Capscrew
Gasket
Plate
Go on to Sheet 4
4-126
TM 10-3930-641-34-2
(Sheet 4 of 5)
TRANSFER GEAR ASSEMBLY (INPUT) DISASSEMBLY (CONT)
8.
LOCATION/ITEM
Bearing cup (7)
ACTION
Remove with bearing puller (A).
9.
Driver gear (9)
Remove from case (14).
10.
Bearing cones (8) and (10)
Remove from drive gear (9) with bearing
puller (B).
11.
Bearing cup (11)
Remove from case (14) with bearing puller.
REMARKS
Go on to Sheet 5
4-127
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
12.
Transfer gear case (14)
Turn case over.
13.
Six capscrews (20)
Remove from bearing cage (19).
14.
Two capscrews (20)
a. Use as forcing screws to loosen cage.
b. Tighten screws evenly until cage is loose.
15.
Cage (19) and shims (18)
Remove.
16.
Bearing cup (15)
Remove from bearing cage (19) with bearing
puller.
17.
Driven gear (17)
Remove from case (14).
18.
Two bearing cones (16)
Remove from driven gear with bearing puller
(C).
19. Driven gear bearing cup (15)
Remove from case with bearing puller.
End
4-128
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT) ASSEMBLY(Sheet 1 of 7)
This task covers: Assembly of transfer gears (input).
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Dial indicator
Shims
None
Feeler gage
Equipment Condition
Input gears disassembled, ready for
reassembly.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Input transfer gears bearing adjustment,
page 4-136.
None
Transfer gear assembly (input) disassembly,
page 4-124.
Go on to Sheet 2
4-129
TM 10-3930-641-34-2
LOCATION/ITEM
1.
Bearing cup (15)
ACTION
REMARKS
Lower temperature and install in center of
case (14).
NOTE
Be sure back of bearing is flush with counterbore in case.
2.
Two bearing cones (16)
a. Heat to maximum of 2750F (1350C).
b. Install on driven gear (17).
3. Driven gear (17)
Install in case (14) as shown.
4.
Lower temperature of cup and install in cage
(19).
Bearing cup (15)
NOTE
Be sure bearing cup bottoms in counterbore in
cage.
TA099331
Go on to Sheet 3
4-130
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (INPUT) ASSEMBLY (CONT)(Sheet 3 of 7)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Input Transfer Case Gear Assembly
Yoke Assembly
Lip Seal
Cage
Shim Pack
Preformed Packing
Tapered Roller Bearing Cup
Tapered Roller Bearing Cone
Input Transfer Driver Gear
Tapered Roller Bearing Cone
Tapered Roller Bearing Cup
Capscrew
Lockwasher
Input Transfer Case
Tapered Roller Bearing Cup
Tapered Roller Bearing Cone
Transfer Input Driven Gear
Shim Pack
Bearing Cage
Capscrew
Assembly Mounting Bracket
Upper Pad
Lower Plate
Sleeve
Capscrew
Lockwasher
Sleeve
Sleeve
Upper Plate
Lockwasher
Capscrew
Gasket
Plate
Go on to Sheet 4
4-131
TM 10-3930-641-34-2
LOCATION/ITEM
5.
Cage (19)
ACTION
REMARKS
a. Install on case (14) and secure with capscrews (20) tightened finger tight.
b. Install dial indicator on cage (19) as shown.
NOTE
Indicator stem should touch surface of driven
gear.
c.
Tighten the six capscrews (20) evenly until
end play of driven gear is .004-.008 in.
(0.10-0.21 mm). (Move driven gear up and
down to check end play.)
d. Measure gap between cage (19) and case
(14) with a feeler gage.
e. Install the correct thickness of shims (18)
under cage (19) that eliminate gaps between case and cage.
f. Recheck end play. Add or remove shims
until end play measures .004 to .008 in.
(0.10 to 0.21 mm).
g. Remove dial indicator.
TA099333
Go on to Sheet 5
4-132
TM 10-3930-641-34-2
(Sheet 5 of 7)
TRANSFER GEAR ASSEMBLY (INPUT) ASSEMBLY (CONT)
LOCATION/ITEM
6.
Bearing cones (16)
ACTION
REMARKS
a. Heat to maximum of 2750F (1350C).
b. Install on drive gear (9).
7.
Case (14)
Turn case over.
8.
Bearing cup (11)
Lower temperature and install in case (14).
9.
Drive gear (9)
Install in case (14) as shown.
10. Bearing cup (7)
Lower temperature and install in case (4).
Go on to Sheet 6
4-133
TM 10-3930-641-34-2
LOCATION/ITEM
11.
Cage (4)
ACTION
REMARKS
a. Install and secure with capscrews (20) and
lockwashers (30).
b. Install dial indicator on case (14) as shown.
NOTE
Indicator stem should contact surface of drive
gear.
c.
Tighten the six capscrews evenly until end
play of the drive gear is .004 to .008 in.
(0.10 to 0.21 mm). (Move the drive gear
up and down to check end play.)
d. Measure gap between cage (4) and case
(14) with a feeler gage.
e. Install the correct thickness of shims (5)
under cage (4) that will eliminate gap
between case and cage.
f. Recheck end play. Add or remove shims
until end play measures .004 to .008 in.
(0.10 to 0.21 mm).
g. Remove dial indicator.
h. Remove cage.
TA099335
Go on to Sheet 7
4-134
TM 10-3930-641-34-2
(Sheet 7 of 7)
TRANSFER GEAR ASSEMBLY (INPUT) ASSEMBLY (CONT)
LOCATION/ITEM
12.
ACTION
REMARKS
Lip type seal (3)Using suitable driver, install in cage as shown.
NOTE
Back of seal must be flush with counterbore
in cage and lip of seal must point away from
cage surface.
13.
Preformed packing (6)
Install on cage (4).
14.
Lip type seal (3)
Coat with clean oil.
15.
Cage (4)
Install and secure with capscrews (20) and
lockwashers (30).
16. Yoke assembly (2)
Install.
End
4-135
TM 10-3930-641-34-2
TRANSFER GEARS BEARING ADJUSTMENT (INPUT)
(Sheet 1 of 2)
This task covers: Adjusting the bearing in the input transfer gears.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Dial indicator
Shims
Page 2-42
Feeler gage
Equipment Condition
Transfer gears (input) assembled.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transfer gears (input) assembly,
page 4-129.
None
Go on to Sheet 2
4-136
TM 10-3930-641-34-2
TRANSFER GEARS BEARING ADJUSTMENT (INPUT) (Cont)
LOCATION/ITEM
ACTION
REMARKS
1.
Shims (1)
Install as many as necessary so that the end
play of the gear (2) is .003 to .006 in. (0.08
to 0.15 mm).
2.
Shims (3)
Install as many as necessary so that the end
play of the gear (4) is 0.003 to 0.006 in. (0.08
to 0.15 mm).
See Assembly of Transfer Gears (input)
page 4-129.
4-137
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY(Sheet 1 of 8)
This task covers: Disassembly of output transfer gears.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Wooden blocking
Pages 2-44, 2-49
Equipment Condition
Transfer gear assembly (output) removed
from vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transfer gears (input and output) removal,
page 4-119.
None
Go on to Sheet 2
4-138
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 8)
ACTION
Output transfer gear assembly
REMARKS
Position on wood blocks.
2.
Yoke assembly (17), bearing cage
(19)
Remove from bottom of output shaft (68).
3.
Eleven capscrews (46) (47) and
washers (22)
Remove.
4.
Yoke (50)
a. Attach hoist.
1.
b. Remove yoke with output shaft (68) and
cage (45) attached.
NOTE
Unit weighs 210 lb. (95 Kg).
6.
Capscrew (53) and retainer (52)
Remove from end of shaft (68).
7.
Preformed packing (51)
Remove.
8.
Yoke (50)
Remove.
TA099338
Go on to Sheet 3
4-139
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY (CONT)
1.
Capscrew
2.
Lock Nut
3.
Bearing Cage
4.
Shim Pack
5.
Capscrew
6.
Lockwasher
7.
Gasket
8.
Bearing Cup
9.
Bearing Cone
10.
Output Gear
11.
Washer
12.
Capscrew
13.
Preformed Packing
14.
Capscrew
15.
Preformed Packing
16.
Lockwasher
17.
Yoke Assembly
18.
Lip Type Seal
19.
Bearing Cage
20.
Housing
21.
Capscrew
22.
Lockwasher
23.
Preformed Packing
24.
Plate Assembly
25.
Self Tapping Screw
26.
Washer
27.
Plate
28.
Lockwasher
29.
Capscrew
30.
Suction Screen
31.
Tube
32.
Magnet
33.
Tube
34.
Preformed Packing
35.
Drain Plug
36.
Gasket
37.
Output Transfer Gear
38.
Spacer
39.
Capscrew
40.
Lockwasher
(Sheet 3 of 8)
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
Retainer
Bearing Cup
Bearing Cone
Preformed Packing
Bearing Cage
Capscrew
Capscrew
Yoke Assembly
Lip Type Seal
Yoke
Preformed Packing
Retainer
Capscrew
Sleeve
Sleeve
Pad
Plate
Capscrew
Lockwasher
Sleeve
Mounting Bracket
Pin
Bracket Assembly
Plate
Capscrew
Bearing and Race
Roller Bearing Race
Transfer Output Shaft
Bearing Cup
Bearing Cone
Transfer Idler Gear
Preformed Packing
Shim Pack
Cover
Hex Nut
Preformed Packing
Bearing Cage Assembly
Stud
Cage
Plate
TA099339
Go on to Sheet 4
4-140
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 8)
ACTION
REMARKS
9.
Output shaft (68)
Press from cage assembly as shown.
10.
Large preformed packing (44)
Remove from cage (45) and discard.
11.
Lip type seal (49)
Remove from cage (45).
12.
Cage (45)
Turn over.
13.
Capscrews (39), lockwasher (40),
and retainer (41)
Remove from cage (45).
14.
Two bearing cones (43) and
bearing cup (42)
Press from cage (45) as shown.
15.
Opposite bearing cup (42)
Remove from cage (45).
16.
Race (67) and roller bearing
Assembly
Remove from output shaft (68).
TA099340
Go on to Sheet 5
4-141
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 5 of 8)
ACTION
REMARKS
17.
Capscrews (1) and lock nuts (2)
that secure cage (3)
Remove.
18.
Two of capscrews (11)
Use as forcing screws to loosen cage (3). Install
screws opposite each other in blind holes in
cage (3). (Tighten evenly until cage is loose.)
19.
Cage (3) and shims (4)
Remove from gear case.
20.
Cup (8)
Remove from cage (3) with puller as shown.
21.
Capscrews (1) and lockwashers
(16) that secure cage (79)
Remove.
22.
Two capscrews (1)
transfer gear case.
Use as forcing screws to loosen cage (79) from
23.
Cage (79) and shims (73)
Remove from gear case.
24.
(16) and cover (74)
Four hex nuts (75), lockwasher
Remove.
25.
Preformed packing (76)
Remove from under cover (74) and discard.
26.
Bearing cup (69)
Remove from cage with puller.
TA099341
Go on to Sheet 6
4-142
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
27.
Remove from gear case.
(Sheet 6 of 8)
ACTION
Capscrews (5) and lockwashers
REMARKS
(16) that hold plate (80) to
transfer gear case
28.
a.
Plate (80)
Attach hoist.
b.
Remove.
NOTE
Plate weighs 97 lb. (44 Kg).
29.
Remove and discard.
Transfer gear case gasket (7)
30.
a.
Gear (71)
Attach hoist as shown.
b.
Remove.
NOTE
Gear weighs 85 lb. (30 Kg).
31.
Two bearing cones (70)
Remove from idler gear (71) with puller.
TA099342
Go on to Sheet 7
4-143
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 7 of 8)
ACTION
32.
Gear (10)
b.
Remove from gear case.
REMARKS
a. Attach hoist.
NOTE
Gear weighs 65 lb. (29 Kg).
33.
Two bearing cones (9)
Remove from gear (10).
34.
Two gear case bearing cups (8)
Remove with puller.
35.
Gear case
Turn over.
36.
Preformed packing (13)
Remove from gear case and discard.
37.
Eight capscrews (1) and
lockwashers (16)
Remove.
38.
Two capscrews (1)
Use as forcing screws to loosen cage (19).
39.
Cage (19)
Remove from gear case.
40.
Preformed packing (15)
Remove from cage (19) and discard.
TA099343
Go on to Sheet 8
4-144
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) DISASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 8 of 8)
ACTION
REMARKS
41.
Lip type seal (18)
Remove from cage (19).
42.
Bearing race (67)
Remove from cage with puller.
43.
Plate assembly (27), preformed
packing (23), screen (30) and
tube assembly (31)
Remove from gear case.
TA099344
End
4-145
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY
(Sheet 1 of 9)
This task covers: Assembly of output transfer gears.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Dial indicator
Feeler gage
GAA grease
None
Equipment Condition
Output transfer gears disassembled.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Transfer gear assembly (output) disassembly, None
page 4-138.
Go on to Sheet 2
4-146
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY (CONT)
LOCATION/ITEM
1.
(Sheet 2 of 9)
ACTION
Tube assembly magnets (32) and
screen (30)
REMARKS
Clean thoroughly.
2.
Tube assembly (31) and screen
(30)
Install in housing (20).
3.
Preformed packing (23) and plate
assembly (24)
Install on housing (20).
4.
Bearing cup (69)
bearing cage (19).
Lower temperature of cup and install in
5.
Lip type seal (18)
a.
Using driver, install in bearing cage (19).
NOTE
Install so back of bearing contacts counterbore and bearing lip points toward inside of
cage.
b.
Coat lip of seal with fresh GAA grease.
TA099345
Go on to Sheet 3
4-147
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY (CONT)
1.
Capscrew
2.
Lock Nut
3.
Bearing Cage
4.
Shim Pack
5.
Capscrew
6.
Lockwasher
7.
Gasket
8.
Bearing Cup
9.
Bearing Cone
10.
Output Gear
11.
Washer
12.
Capscrew
13.
Preformed Packing
14.
Capscrew
15.
Preformed Packing
16.
Lockwasher
17.
Yoke Assembly
18.
Lip Type Seal
19.
Bearing Cage
20.
Housing
21.
Capscrew
22.
Lockwasher
23.
Preformed Packing
24.
Plate Assembly
25.
Self Tapping Screw
26.
Washer
27.
Plate
28.
Lockwasher
29.
Capscrew
30.
Suction Screen
31.
Tube
32.
Magnet
33.
Tube
34.
Preformed Packing
35.
Drain Plug
36.
Gasket
37.
Output Transfer Gear
38.
Spacer
39.
Capscrew
40.
Lockwasher
(Sheet 3 of 9)
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
Retainer
Bearing Cup
Bearing Cone
Preformed Packing
Bearing Cage
Capscrew
Capscrew
Yoke Assembly
Lip Type Seal
Yoke
Preformed Packing
Retainer
Capscrew
Sleeve
Sleeve
Pad
Plate
Capscrew
Lockwasher
Sleeve
Mounting Bracket
Pin
Bracket Assembly
Plate
Capscrew
Bearing and Race
Roller Bearing Race
Transfer Output Shaft
Bearing Cup
Bearing Cone
Transfer Idler Gear
Preformed Packing
Shim Pack
Cover
Hex Nut
Preformed Packing
Bearing Cage Assembly
78.
79. Cage
80. Plate
Go on to Sheet 4
4-148
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 9)
ACTION
REMARKS
6.
Preformed packing (15)
Install on bearing cage (19).
7.
Bearing cage (19)
a. Install in gear case.
b.
Secure with capscrews (1) and lockwashers
(16).
8.
Transfer gear case
Turn over.
9.
Small preformed packing
Install in gear case as shown.
10.
Bearing cups (8) and (69)
case.
Lower temperature of cups and install in gear
11.
Two bearings (9)
a. Heat to maximum of 2750F (1350C).
b.
12.
Gear (10)
a.
Install on gear (10).
Attach hoist.
b.
Install in gear case.
TA099347
Go on to Sheet 5
4-149
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT ASSEMBLY (CONT)
LOCATION/ITEM
13.
(Sheet 5 of 9)
ACTION
REMARKS
Two bearings (70)
a. Heat to maximum of 2750F (1350C).
b.
14.
Install on gear (71).
Gear (71)
a.
b.
Attach hoist as shown.
Install in gear case as shown.
15.
New gasket (7)
Position on gear case.
16.
Plate (80)
a. Attach hoist.
b.
17.
Install on gear case.
Bearing cup (69)
(79).
Lower temperature of cup and install in cage
TA099348
Go on to Sheet 6
4-150
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY (CONT)
LOCATION/ITEM
18.
(Sheet 6 of 9)
ACTION
REMARKS
Cage (79)
a. Install in gear case.
NOTE
For now, do not install shims (73) or preformed packing (72) behind cage.
b.
Secure cage with capscrews (1) and
washers (16).
c.
Using a feeler gage, measure gap between
cage (79) and gear case.
d.
Remove cage and install correct thickness
of shims (73) to take up gap measured in
c above.
e.
Install cage (and capscrews (1) and install
dial indicator to gear case as shown).
NOTE
Indicator stem should contact top surface of
gear (71).
f.
Attach wire to top of gear (71) and move
gear up and down to check end play.
g.
Remove or install shims until end play is
.002-.006 in. (0.05-0.15 mm).
h.
When correct thickness of shims is obtained, install preformed packing (72)
behind cage.
i.
Install cage and secure with the capscrews
(1) and washers (16).
TA099349
Go on to Sheet 7
4-151
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY (CONT)
LOCATION/ITEM
19.
20.
21.
22.
(Sheet 7 of 9)
ACTION
Preformed packing (76)
Cover (74)
Bearing cup (8)
(3).
Cage (3)
REMARKS
Install on cage (79).
Install on cage (79).
Lower temperature of cup and install in cage
a.
Install in gear case.
NOTE
For now, do not install shims (4) behind cage.
b.
Secure cage with capscrews (1).
c.
Using a feeler gage, measure gap between
cage (3) and gear case.
d.
Remove cage and install correct thickness
of shims (4) to take up gap measured in c
above.
e.
Install cage (and capscrews (1)) and install
dial indicator to gear case as shown.
NOTE
Indicator stem should contact top surface of
gear (37).
f.
Attach wire to top of gear and move gear
up and down to check end play.
g.
Remove or install shims until end play is
.002-.006 in. (0.05-0.15 mm).
h.
When correct thickness of shims is obtained, install locks (2) under capscrews
(1).
TA099350
Go on to Sheet 8
4-152
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY (CONT)
LOCATION/ITEM
23.
(Sheet 8 of 9)
ACTION
Roller assembly (66)
a.
b.
REMARKS
Heat to maximum of 2750F (1350C).
Install on shaft (68).
24.
Two bearing cups (42) and cones
(43) install in cage (45).
Lower temperature of cups and cones and
25.
Retainer (41)
of 3545 lb. ft. (48-60 N⋅m).
Install and secure with capscrews to a torque
26.
Lip type seal (18)
Using driver, install in cage (45) as shown.
NOTE
Install so back of bearing contacts counterbore
and bearing lip points forward inside of cage.
27.
Cage (45), spacer (38), gear (37)
Using suitable press, install on shaft as shown.
28.
Dirt guard (49).
Install on yoke (50).
TA099351
Go on to Sheet 9
4-153
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY (OUTPUT) ASSEMBLY (CONT)
LOCATION/ITEM
29.
(Sheet 9 of 9)
ACTION
REMARKS
Yoke (50), preformed packing
(51), retainer (52), capscrew (53)
b.
a. Install on shaft (68).
30.
Large preformed packing (44)
Install on cage.
31.
Lip type seal
Coat with GAA grease.
32.
Yoke (50), cage (45) and output
shaft (68) assembly
a. Attach hoist to yoke (50).
Tighten capscrew to a torque of 315-385
lb. ft. (426-522 N⋅m).
b.
Position assembly in gear case.
c.
Secure assembly with capscrews (46) and
(47), and washers (22).
33.
Yoke (17) Install on shaft (68).
TA099352
End
4-154
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY BEARING ADJUSTMENT (OUTPUT)
(Sheet 1 of 2)
This task covers: Adjusting the bearing of the output transfer gears.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Dial indicator
Shims
Page 2-44
Feeler gage
Equipment Condition
Transfer gears removed.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Transfer gears (output) assembly,
see page 4-146.
None
Go on to Sheet 2
4-155
TM 10-3930-641-34-2
TRANSFER GEAR ASSEMBLY BEARINGS ADJUSTMENT (INPUT) (CONT)
LOCATION/ITEM
(Sheet 2 of 2)
ACTION
REMARKS
1.
Shims (1)
is .002 to .006 in. (0.05 to 0.15 mm)
Install enough so that the end play of gear (2)
2.
Shims (3)
is .002 to .004 in. (0.05 to 0.10 mm)
Install enough so that the end play of gear (4)
3.
Capscrew (5)
(425 to 515 N⋅m).
Tighten to a torque of 315 to 385 lb. ft.
4.
Capscrew (6)
(48 to 62 N⋅m).
Tighten to a torque of 35 to 45 lb. ft.
NOTE
Before oil seal is installed, put Liquid Gasket
Material on seal bore surface in case and let
dry. Do not put Liquid Gasket Material on
seal case.
Put same type lubricant used in gear case on
lip of seal before seal is installed.
TA099353
End
4-156
TM 10-3930-641-34-2
TRANSMISSION HYDRAULIC CONTROLS REMOVAL/INSTALLATION
(Sheet 1 of 7)
This task covers: Removal and installation of transmission hydraulic controls.
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
As required
None
Equipment Condition
Transmission installed or transmission
removed from vehicle and on a rebuild
stand.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Transmission control lock removal,
page 4-210.
Keep dirt out of controls.
Transmission and transfer assembly
removal, page 4-43.
Go on to Sheet 2
4-157
TM 10-3930-641-34-2
TRANSMISSION HYDRAULIC CONTROLS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 7)
ACTION
REMARKS
REMOVAL
1.
Transmission control lock
vehicle).
2.
Remove from case (10).
Capscrews (7), lockwashers
Remove (only if transmission is installed in See page 4-210
(2) and cover assembly (5)
3.
Remove from case (10).
Cover assembly gasket (8)
4.
Remove from manifold (15).
Three manifold capscrews (18)
and lockwasher (2)
5.
Remove from case (10).
Manifold (15)
6.
Remove from valve assembly.
Capscrew (31) and washer (32)
7.
Remove from transmission and valve
Two sleeves (23)
assembly.
8.
Preformed packings (22)
Replace.
TA099354
Go on to Sheet 3
4-158
TM 10-3930-641-34-2
TRANSMISSION HYDRAULIC CONTROLS REMOVAL/INSTALLATION (CONT)
1.
Hex Nut
2.
Lockwasher
3.
Cover
4.
Gasket
5.
Transmission Cover Assembly
6.
Breather
7.
Capscrew
8.
Transmission Cover Gasket
9.
Transmission Case Assembly
10.
Case
11.
Pin
12.
Preformed Packing
13.
Plug
14.
Preformed Packing
15.
Manifold
16.
Preformed Packing
17.
Plug
18.
Capscrew
19.
Preformed Packing
20.
Capscrew
21.
Lockwasher
(Sheet 3 of 7)
TA099355
Go on to Sheet 4
4-159
TM 10-3930-641-34-2
TRANSMISSION HYDRAULIC CONTROLS REMOVAL/INSTALLATION (CONT)
22.
Preformed Packing
23.
Sleeve
24.
Capscrew
25.
Washer
26.
Preformed Packing
27.
Sleeve
28.
Spring
29.
Preformed Packing
30.
Plug
31.
Capscrew
32.
Washer
33.
Identification Plate
(Sheet 4 of 7)
TA099356
Go on to Sheet 5
4-160
TM 10-3930-641-34-2
(Sheet 5 of 7
TRANSMISSION HYDRAULIC CONTROLS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
9. Plug (30), spring (28) and sleeve
(27), preformed packing (26) and
(29)
ACTION
REMARKS
Remove from transmission case.
NOTE
To remove sleeve (27) it may be necessary to
thread in a 3/8 inch eyebolt.
10. Preformed packings (26) and (29)
Replace if necessary.
11. Four hydraulic control capscrews
(24), and washer (25)
Remove.
12. Lifting bracket (A)
Attach to hydraulic controls as shown.
13. Hydraulic controls
Attach hoist as shown and remove from case,
Hydraulic controls are 88 lb. (40 Kg).
TA099357
Go on to Sheet 6
4-161
TM 10-3930-641-34-2
(Sheet 6 of 7
TRANSMISSION HYDRAULIC CONTROLS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1. Lifting bracket (A) and hoist
Attach to transmission hydraulic control as
shown.
2. Transmission hydraulic controls
a. Position in transmission.
b. Secure with capscrews. Tighten to a
torque of 32-38 lb. ft. (44-52 N-m).
3. Preformed packing (26) and (29)
Install on sleeve (27). Lubricate with clean oil.
4. Sleeve (27), spring (28), and plug
(30)
Install in transmission case and transmission
hydraulic controls.
TA099358
Go on to Sheet 7
4-162
TM 10-3930-641-34-2
(Sheet 7 of 7
TRANSMISSION HYDRAULIC CONTROLS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
5. Preformed packing (22)
ACTION
a. Install on sleeves (23).
REMARKS
b. Lubricate with clean oil.
6. Sleeves (23)
into hydraulic controls.
Install through transmission case (10) and
7. Capscrew (31) and washer (32)
Install to hold sleeves.
8. Cover assembly (5)
a. Install with new gasket (8).
b. Secure with capscrews (7) and lockwashers (2).
9. Preformed packing (19)
Install in manifold (15).
10. Manifold (15)
Install on transmission case (10).
TA099359
End
4-163
TM 10-3930-641-34-2
(Sheet 1 of 7
TRANSMISSION HYDRAULIC CONTROLS DISASSEMBLY
This task covers: Disassembly of transmission hydraulic controls.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
None
Equipment Condition
Transmission hydraulic controls removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transmission hydraulic controls removal/
installation, page 4-157.
Be careful when removing retainer (19)
because of spring tension.
Go on to Sheet 2
4-164
TM 10-3930-641-34-2
(Sheet 2 of 7
TRANSMISSION HYDRAULIC CONTROLS DISASSEMBLY (CONT)
LOCATION/ITEM
1. 26 capscrews (44) and washers (45)
Remove.
2.
Manifold (54), valve group (46),
plate (53), and manifold (51)
Separate.
3.
Selector and pressure control valve
group (7)
Disassemble.
4.
Two detent assemblies (9)
Remove.
5.
Preformed packing (8)
Remove from detents.
6.
Pin (2) and stop (43)
Remove from valve body.
7.
Direction selector spool (41)
Remove from valve body.
8.
Two detent assemblies (9)
Remove.
9.
Packing preformed (8)
Remove from detents.
Pin (2) and stop (43)
Remove from valve body.
10.
ACTION
REMARKS
Go on to Sheet 3
4-165
TM 10-3930-641-34-2
(Sheet 3 of 7
TRANSMISSION HYDRAULIC CONTROLS DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Control Valve
Pin
Pin
Pin
Body Assembly
Plug
Pressure Selector Body
Preformed Packing
Detent Assembly
Setscrew
Preformed Packing
Cover
Capscrew
Preformed Packing
Orifice Screen
Speed Selector Spool
Stop
Slug
Relief Spool Assembly
Retainer Ring
Retainer
Spring
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Ball
Relief Spool
Spring
Spring
Spacer
Spacer
Spacer
Piston
Ratio Spool
Slug
Spring
Stop
Safety Spool
Spring
Spring
Retainer
Spring
Retainer Ring
Direction Selector Spool
Cup Plug
Stop
TA099360
Go on to Sheet 4
4-166
TM 10-3930-641-34-2
(Sheet 4 of 7)
TRANSMISSION HYDRAULIC CONTROLS DISASSEMBLY (CONT)
44. Capscrew
45. Washer
46. Neutralizer Valve Group
47. Seal Ring
48. Preformed Packing
49. Spool
50. Spring
51. Manifold
52. Capscrew
53. Divider Plate
54. Manifold
55. Plug
TA099361
Go on to Sheet 5
4-167
TM 10-3930-641-34-2
(Sheet 5 of 7)
TRANSMISSION HYDRAULIC CONTROLS DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
11.
Speed selector spool (16)
Remove from valve body.
12.
Capscrews (13) and cover (12)
Remove.
13.
Preformed packing (11) in cover
Replace.
14.
Piston (30), spring (26), and
spring (25)
Remove from valve body.
15.
Spacers (27), (28), and (29)
Remove from piston (30).
16.
Valve relief spool assembly (19)
Remove from valve body.
17.
Slug (18)
Remove from relief spool assembly.
18.
Retainer ring (20), retainer (21),
spring (22), and ball (23)
Remove from relief spool (24).
Go on to Sheet 6
4-168
TM 10-3930-641-34-2
(Sheet 6 of 7)
TRANSMISSION HYDRAULIC CONTROLS DISASSEMBLY (CONT)
LOCATION/ITEM
19.
Spring (39) and safety spool (35)
ACTION
REMARKS
Remove.
WARNING
Retainer (38) has tension on it from springs
behind it.
Hold retainer in position when removing
ring (40).
20.
Retainer ring (40), retainer (38),
and two springs (36) and (37) from
safety spool (35)
Remove.
21.
Pin (4)
Remove from valve body.
22.
Valve ratio spool (31) and spring
(33)
Remove from valve body.
23.
Slug (32)
Remove from valve spool.
Go on to Sheet 7
4-169
TM 10-3930-641-34-2
(Sheet 7 of 7)
TRANSMISSION HYDRAULIC CONTROLS DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
24.
Two pins (3) and two stops (17)
and (34)
Remove from valve body.
25.
Divider plate (53)
Remove from neutralizer valve.
26.
Neutralizer valve group (46)
Disassemble.
27.
Capscrew (52), spring (50), and
valve spool (49)
Remove from valve body.
28.
Seal ring (47) and preformed
packing (48)
Remove from valve spool.
End
4-170
TM 10-3930-641-34-2
(Sheet 1 of 7)
TRANSMISSION HYDRAULIC CONTROLS ASSEMBLY
This task covers: Assembly of transmission hydraulic controls
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
None
Equipment Condition
Make sure all parts of transmission
hydraulic control valves are clean. Put
clean oil on all parts before valves are
assembled.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transmission hydraulic controls removal/
installation, page 4-157.
Keep dirt and grit away from clean parts.
Go on to Sheet 2
4-171
TM 10-3930-641-34-2
(Sheet 2 of 7)
TRANSMISSION HYDRAULIC CONTROLS ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
1.
Neutralizer valve group (46)
Assemble.
2.
New seal ring (47) and
preformed packing (48)
Install on valve spool (49).
3.
Spring (50) and valve spool (49)
Install in valve body.
4.
Valve spool (49)
Push into valve body until capscrew (52) can
be installed behind and on valve spool.
5.
Capscrew (52)
Tighten to a torque of 19-25 lb. ft. (25-34
N.m).
6.
Divider plate (53)
Position on neutralizer valve.
7.
Selector and pressure control valve
group
Assemble.
Go on to Sheet 3
4-172
TM 10-3930-641-34-2
(Sheet 3 of 7)
TRANSMISSION HYDRAULIC CONTROLS ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Control Valve
Pin
Pin
Pin
Body Assembly
Plug
Pressure Selector Body
Preformed Packing
Detent Assembly
Setscrew
Preformed Packing
Cover
Capscrew
Preformed Packing
Orifice Screen
Speed Selector Spool
Stop
Slug
Relief Spool Assembly
Retainer Ring
Retainer
Spring
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33,
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Ball
Relief Spool
Spring
Spring
Spacer
Spacer
Spacer
Piston
Ratio Spool
Slug
Spring
Stop
Safety Spool
Spring
Spring
Retainer
Spring
Retainer Ring
Direction Selector Spool
Cup Plug
Stop
TA099362
Go on to Sheet 4
4-173
TM 10-3930-641-34-2
(Sheet 4 of 7)
TRANSMISSION HYDRAULIC CONTROLS ASSEMBLY (CONT)
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
Capscrew
Washer
Neutralizer Valve Group
Seal Ring
Preformed Packing
Spool
Spring
Manifold
Capscrew
Divider Plate
Manifold
Plug
TA099363
Go on to Sheet 5
4-174
TM 10-3930-641-34-2
(Sheet 5 of 7)
TRANSMISSION HYDRAULIC CONTROLS ASSEMBLY (CONT)
LOCATION/ITEM
8.
Two stops (17) and (34)
ACTION
REMARKS
a. Install in center parts of valve body.
b. Make sure holes in stops and valve bodies
are aligned.
9.
Two pins (3)
Install to hold stops.
10.
Slug (32)
Install in ratio spool (31).
11.
Spring (33) and safety spool (35)
Install in valve body.
12.
Pin (4)
Install to hold valve spool and spring.
13.
Safety spool (35)
Turn around.
14.
Two springs (36) and (37) and
retainer (38)
Install in safety spool (35).
15.
Retainer (38)
Push into valve spool, and install snap ring.
Go on to Sheet 6
4-175
TM 10-3930-641-34-2
(Sheet 6 of 7)
TRANSMISSION HYDRAULIC CONTROLS ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
16.
Safety spool (35) and spring (39)
Install in valve body.
17.
Ball (23), spring (22), retainer (21),
and retainer ring (20)
Install in spool (24).
18.
Relief spool assembly (19)
Install in valve body.
19.
Spacers (27), (28), and (29)
Install in piston (30).
20.
Spring (25), spring (26), and
piston (30)
Install in valve body.
21.
Cover (12)
Install. Secure with capscrews (13). Tighten
to a torque of 19-25 lb. ft. (26-34 N-m).
22.
Speed selector spool (16)
Install in valve body as shown.
23.
Stop and pin (3)
Install to hold valve spool.
Go on to Sheet 7
4-176
TM 10-3930-641-34-2
(Sheet 7 of 7)
TRANSMISSION HYDRAULIC CONTROLS ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
24.
Detent assembly (9) and preformed
packing (8)
Install in valve body as shown.
25.
Direction selector spool (41)
Install in valve body as shown.
26.
Stop (43) and pin (2)
Install to hold direction selector spool (41).
27.
Detent assembly
Install in bore in valve body.
28.
Selector and pressure control valve
group (7)
Position on divider plate (53).
29.
Transmission hydraulic control valve
capscrews (44) and washers (45)
Tighten capscrews to a torque of 19-25 lb. ft.
(26-34 N m).
3'0.
Transmission hydraulic controls
Install.
See Transmission Hydraulic Controls/Installation
Removal, page 4-157.
End
4-177
TM 10-3930-641-34-2
Section IV. OIL SYSTEM
TRANSMISSION LUBRICATION MAINTENANCE INSTRUCTIONS
This section covers maintenance of these transmission components for direct support and general support.
a. Transmission oil pump
b. Transmission oil cooler
LIST OF TASKS
TASK NO.
(Sheet 1 of 1)
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Transmission oil pump removal.
4-179
2-41
2
Transmission oil pump installation.
4-184
None
3
Transmission oil lines removal/installation.
4-187
2-47
4
Transmission oil pump disassembly.
4-189
2-47, 2-48, 2-49
5
Transmission oil pump assembly.
4-192
None
6
Transmission oil cooler removal/installation.
4-197
2-41
4-178
TM 10-3930-641-34-2
(Sheet 1 of 5)
TRANSMISSION OIL PUMP REMOVAL
This task covers: Removal of transmission oil pump.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-41
Equipment Condition
Engine off and cool.
Shipping link installed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Hood removal/installation,
TM 10-3930-641-20.
Avoid contact with hot oil.
Main disconnect switch OFF.
Shipping link removal/
installation, TM 10-3930-641-20.
Go on to Sheet 2
4-179
TM 10-3930-641-34-2
(Sheet 2 of 5)
TRANSMISSION OIL PUMP REMOVAL (CONT)
LOCATION/ITEM
ACTION
1.
Precleaner lid (1) and hood (2)
Remove. Hood weighs 96 lb. (43.5 Kg).
2.
Door assemblies
Open door assemblies to filters.
3.
Hydraulic lines (3)
a. Put identification on lines for proper
installation.
b. Disconnect from oil filter base and cap.
4.
Harness (4)
Tag and disconnect wires for sending units for
transmission oil filter and pilot systems oil
filter.
4-180
REMARKS
TM 10-3930-641-34-2
(Sheet 3 of 5)
TRANSMISSION OIL PUMP REMOVAL (CONT)
LOCATION/ITEM
5.
Filter bases
ACTION
REMARKS
a. Remove six capscrews that hold transmission and pilot systems oil filter bases
in position.
b. Do not disconnect hydraulic lines from
bases.
c.
Put filters and bases on floor plates.
6. Air cleaner housing
Remove four capscrews (5) that secure
housing to filter base frame.
7.
Air cleaner indicator sending
unit
Disconnect wire (6) from unit.
8.
Clamp (7)
Loosen.
9.
Filter group (8)
a. Remove four capscrews that hold filter
group in position.
b. Remove three capscrews that hold heat
shield to filter group.
c. Attach hoist to group (8) and remove it.
Weight of group is 100 lb. (45.4 Kg).
TA099365
4-181
Go on to Sheet 4
TM 10-3930-641-34-2
(Sheet 4 of 5)
TRANSMISSION OIL PUMP REMOVAL (CONT)
LOCATION/ITEM
10.
Air cleaner housing (9)
ACTION
REMARKS
a. Attach hoist to air cleaner housing
as shown.
b. Remove air cleaner housing. Weight of
housing is 50 lbs. (22.7 Kg).
11.
Heat shield (11)
a. Remove two capscrews (10).
b. Remove shield.
TA099366
Go on to Sheet 5
4-182
TM 10-3930-641-34-2
(Sheet 5 of 5)
TRANSMISSION OIL PUMP REMOVAL (CONT)
LOCATION/ITEM
ACTION
12.
Hose (12)
Tag and disconnect from side of pump.
13.
Tube assembly (14)
Tag and disconnect from pump.
REMARKS
a. Loosen clamp on other end of tube
assembly.
b. Move tube assembly away from pump.
14.
Tube assembly (13)
Tag and disconnect from pump.
15.
Transmission oil pump (16)
a. Remove capscrews (15) that hold pump in
position.
b. Remove transmission oil pump (16).
Discard gasket.
End
4-183
TM 10-3930-641-34-2
(Sheet 1 of 3)
TRANSMISSION OIL PUMP INSTALLATION
This task covers: Installation of transmission oil pump.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
None
Equipment Condition
Engine OFF.
Shipping link installed.
Hood removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Hood removal/installation,
TM 10-3930-641-20.
Keep dirt and grit away from clean parts.
Main disconnect switch OFF.
Air cleaner/precleaner removal/
installation, TM 10-3930-641-20.
Go on to Sheet 2
4-184
TM 10-3930-641-34-2
(Sheet 2 of 3)
TRANSMISSION OIL PUMP INSTALLATION
LOCATION/ITEM
1.
Transmission oil pump
gasket in position in pump drive.
ACTION
REMARKS
a. Put transmission oil pump and new
b. Install capscrews that hold it.
2.
Tube assembly (1)
a. Connect tube assembly (1) to rear of
pump.
b. Tighten clamp on the other end of tube
assembly.
3.
Tube assembly (2)
Connect to pump.
4.
Hose (3)
Connect hose to side of pump.
5.
Heat shield
a. Install.
b. Secure with two capscrews.
Go on to Sheet 3
TA099368
4-185
TM 10-3930-641-34-2
(Sheet 2 of 3)
TRANSMISSION OIL PUMP INSTALLATION
LOCATION/ITEM
ACTION
6.
Air cleaner housing (4)
Attach hoist to air cleaner housing (4) and
install it on the engine.
7.
Filter group (5)
a. Attach hoist to filter group (5) and install
it. Filter group weighs 100 lb. (45 Kg).
REMARKS
b. Install four capscrews that hold filter frame
in position.
c. Install transmission and pilot system oil
filters to filter base frame.
d. Install four capscrews that hold air cleaner
housing to filter base frame.
8.
Air cleaner indicator line
Connect to sending unit on air cleaner
housing.
9.
Two sending unit wires for oil
filters
Connect.
10.
Engine oil filter hydraulic lines
Connect.
11.
Hood
Attach hoist to hood and install it
on machine. Install precleaner lid.
TA099369
4-186
End
TM 10-3930-641-34-2
TRANSMISSION OIL LINES REMOVAL/INSTALLTION
(Sheet 1 of 2)
This task covers: Removal/installation of transmission oil lines group.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Buckets or container to hold oil
Page 2-47
Equipment Condition
Engine OFF
System cooled
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
None
Be sure oil has cooled.
Hot oil causes burns.
Go on to Sheet 2
4-187
TM 10-3930-641-34-2
(Sheet 2 of 2)
TRANSMISSION OIL LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Transmission
Drain.
2.
Capscrews (1) and washers (2)
Remove from both ends of oil line.
3.
Gasket (3)
Discard.
4.
Line (4)
Remove.
INSTALLATION
1.
New gasket (3)
Spread a light layer of transmission oil on
gasket before installing.
2.
Gasket (3) and flange of oil line
Place in position.
3.
Capscrews (1) and washers (2)
Install.
4.
Transmission
Fill.
See LO 10-3930-641-12.
TA172253
End
4-188
TM 10-3930-641-34-2
TRANSMISSION OIL PUMP DISASSEMBLY
(Sheet 1 of 3)
This task covers: Disassembly of transmission oil pump.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Pages 2-47, 2-48, 2-49
Equipment Condition
Transmission oil pump (with adapter)
removed from vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transmission oil pump removal, page 4-179.
hydraulic components.
Use clean area when disassembling
Go on to Sheet 2
4-189
TM 10-3930-641-34-2
(Sheet 2 of 3)
TRANSMISSION OIL PUMP DISASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Basic Oil Pump
Oil Pump Assembly
Oil Pump Drive Gear Assembly
Oil Pump Body Assembly
Pin
Capscrew
Lockwasher
Oil Pump Cover Assembly
Sleeve Bearing
Seal
Preformed Packing
Adapter Assembly
Pin
Body
Gasket
Washer
Capscrew
Capscrew
Preformed Packing,
Oil Pump Idler Gear Assembly
Oil Pump Manifold Assembly
Sleeve Bearing
Washer
Capscrew
Capscrew
Capscrew
TA099371
Go on to Sheet 3
4-190
TM 10-3930-641-34-2
(Sheet 3 of 3)
TRANSMISSION OIL PUMP DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
1.
Four long capscrews (24) and
washers (23)
Remove from pump.
2.
Transmission oil pump group (1)
Set on end with adapter (12) facing up.
3.
Capscrews (6) and lockwashers (7)
Remove from pump.
4.
Adapter assembly (12)
Remove from pump.
5.
Two short capscrews (26) and
washers (23)
Remove from pump.
6.
Cover assembly (8)
Remove.
7.
Preformed packing (11)
Remove from cover assembly (8).
8.
Seal (10) and two bearings (9)
Remove from cover assembly (8).
9.
Drive gear assembly (3)
Remove.
10.
Idler gear assembly (20)
Remove.
11.
Body assembly
Remove from manifold assembly (21).
12.
Preformed packing (19)
Remove from manifold assembly (21).
End
4-191
TM 10-3930-641-34-2
(Sheet 1 of 5)
TRANSMISSION OIL PUMP ASSEMBLY
This task covers: Assembly of transmission oil pump.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
One inch depth micrometer
As required.
None
Equipment Condition
Oil pump disassembled.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Specifications, page 2-69.
Keep dirt and grit away from clean parts.
Go on to Sheet 2
4-192
TM 10-3930-641-34-2
(Sheet 3 of 5
TRANSMISSION OIL PUMP DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Be sure all parts are clean and coated with
SAE 30 oil before assembly.
1.
Two sleeve bearings (22)
a. Install in oil pump manifold (21) until
bearings are 0.062 in. (1.57 mm) below
machined surface of manifold.
NOTE
Bearing seams should be 15° - 450 from
centerline through bearing bores and should
face toward oil outlet port in manifold.
b. Check that bearing bore is within
specifications.
2.
Preformed packing (19)
Install in oil pump manifold (21).
3.
Body assembly (4)
Put in position on manifold assembly (21).
4.
Idler gear assembly (20) and drive
gear assembly (3)
a. Install in manifold and body.
b.
Check gear clearance.
See Specifications, page 2-69.
See Specifications, page 2-69.
Go on to Sheet 3
4-193
TM 10-3930-641-34-2
(Sheet 3 of 5)
TRANSMISSION OIL PUMP DISASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Basic Oil Pump
Oil Pump Assembly
Oil Pump Drive Gear Assembly
Oil Pump Body Assembly
Pin
Capscrew
Lockwasher
Oil Pump Cover Assembly
Sleeve Bearing
Seal
Preformed Packing
Adapter Assembly
Pin
Body
Gasket
Washer
Capscrew
Capscrew
Preformed Packing
Oil Pump Idler Gear Assembly
Oil Pump Manifold Assembly
Sleeve Bearing
Washer
Capscrew
Capscrew
Capscrew
TA099372
Go on to Sheet 4
4-194
TM 10-3930-641-34-2
(Sheet 4 of 5)
TRANSMISSION OIL PUMP DISASSEMBLY (CONT)
LOCATION/ITEM
5.
Two sleeve bearings (9)
ACTION
REMARKS
a. Install in cover (8) until bearings are 0.062
in. (1.57 mm) below machined surface of
cover.
NOTE
Bearing seams should be 150 - 450 from
centerline through bearing bores and should
face toward oil outlet in cover.
b. Check that bearing bore is within
specifications.
6.
Cover (8)
See Specifications, page 2-69.
a. Turn over.
b. Install seal (10).
NOTE
Install seal until it makes contact with
counterbore in cover assembly. Lip of seal
must point toward splined end of drive gear.
c.
7.
Preformed packing (19)
Coat lip of seal with clean SAE 30 oil.
Install in body assembly (4).
Go on to Sheet 5
4-195
TM 10-3930-641-34-2
(Sheet 5 of 5)
TRANSMISSION OIL PUMP DISASSEMBLY (CONT)
LOCATION/ITEM
8.
Cover assembly (8)
ACTION
REMARKS
a. Put in position on body assembly.
b. Install two short capscrews (26) and
washers (23).
c. Install preformed packing (11).
9.
Four long capscrews (24) and
washers (238
Install in pump.
10.
Adaptor assembly (12)
a. Install on cover (8).
b. Secure with capscrews (6) and washer (7).
End
4-196
TM 10-3930-641-34-2
TRANSMISSION OIL COOLER REMOVAL/INSTALLATION
(Sheet 1 of 4)
This task covers: Replacement of transmission oil cooler.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-41
Equipment Condition
Front crankcase guard removed.
Coolant drained from cooling system.
Oil drained from transmission oil cooler.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Crankcase guard removal
TM 10-3930-641-20.
Avoid contact with hot coolant. Hot
coolant will cause burns.
LO 10-3930-641-12.
Cooling system maintenance,
TM 10-3930-641-20.
Transmission maintenance,
TM 10-3930-641-20.
Go on to Sheet 2
4-197
TM 10-3930-641-34-2
(Sheet 2 of 4
TRANSMISSION OIL COOLER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Two heater hoses (1) and (2)
Disconnect from engine.
2.
Two hose assemblies (3)
Disconnect from transmission oil cooler.
3.
Oil lines clamp
Remove.
4.
Oil lines (4) and (5) at bottom of
transmission oil cooler.
Remove.
CAUTION
Weight of transmission oil cooler is 82 lbs. Use
hoist to lift out.
5.
Hoist
Attach to oil cooler. Wrap lifting strap
around cooler as shown.
6.
Six capscrews (7) that hold trans
mission oil cooler to elbow
Remove.
7.
Two bolts (6) that hold elbow to
engine
Remove.
TA099373
Go on to Sheet 3
4-198
TM 10-3930-641-34-2
(Sheet 3 of 4)
TRANSMISSION OIL COOLER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
8.
Transmission oil cooler
Remove.
9.
Water elbow (8)
Remove.
10.
Tube bundles
Clean by passing a .125 in (3.2 mm) rod
through each tube.
INSTALLATION
1.
Water elbow (8)
Install on transmission oil cooler with new
O-ring seal.
2.
Hoist
Attach to transmission oil cooler.
3.
Transmission oil cooler
Put in position and install bolts to hold it to
engine and water cooler.
4.
Oil lines (4) and (5)
Connect to bottom of transmission oil cooler.
5.
Clamp to hold oil lines to engine
Install.
6.
Hose assemblies (3)
Connect to fitting.
TA099374
Go on to sheet 4
4-199
TM 10-3930-641-34-2
(Sheet 4of 4)
TRANSMISSION OIL COOLER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
7.
Two heater hose assemblies (1) and
(2)
Connect.
8.
Cooling system
Fill with coolant to the specified level.
9.
Transmission oil
Fill to specified level.
10.
Front crankcase guard
Install.
TA099375
END
4-200
TM 10-3930-641-34-2
Section V. CONTROL VALVES AND CONTROL LOCKS
TRANSMISSION CONTROL VALVE AND CONTROL LOCKS MANITENANCE INSTRUCTIONS
This section covers maintenance of these transmission components for direct support and general support maintenance personnel:
a. Sequence and pressure control valve
b. Transmission control lock
c. Torque converter outlet relief valve
LIST OF TASKS
TASK NO
(Sheet 1 of 1)
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Sequence and pressure control valve removal
installation.
4-202
2-45, 2-49
2
Sequence and pressure control valve
disassembly/assembly.
4-205
2-47, 2-48, 2-49
3
Transmission control lock removal.
4-210
2-45
4
Transmission control lock installation.
4-213
None
5
Transmission control lock disassembly.
4-217
2-45, 2-46
6
Transmission control lock assembly.
4-221
2-46
7
Torque converter outlet relief valve removal
installation.
4-225
2-41
8
Torque converter outlet relief valve
disassembly/assembly.
4-228
2-49
9
Torque converter outlet relief valve
adjustment.
4-231
2-48, 2-49
10
Transmission control lock bench test.
4-234
2-45
11
Sequence valve test.
4-237
2-47, 2-48
4-201
TM 10-3930-641-34-2
SEQUENCE AND PRESSURE CONTROL VALVE REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal of sequence and pressure control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
None As required
Page 2-49
Troubleshooting Reference
Equipment Condition
Engine OFF.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Shipping link removal/installation,
TM 10-3930-641-20.
Tires blocked.
Main disconnect switch off.
Go on to Sheet 2
4-202
TM 10-3930-641-34-2
(Sheet 2 of 3)
SEQUENCE AND PRESSURE CONTROL VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Two panels (1)
Remove from left side of vehicle.
2.
Hose assembly (2)
Disconnect from sequence and pressure
control valve (3). Cap or plug opening.
3.
Wire (4)
Disconnect from valve (3).
4.
Three capscrews (5) that secure
valve (3)
Remove.
5.
Sequence and pressure control
valve
(3)
Remove.
Go on to Sheet 3
4-203
TM 10-3930-641-34-2
(Sheet 3 of 3)
SEQUENCE AND PRESSURE CONTROL VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
Sequence and pressure control
valve
Put valve (1) in position on rear of torque
converter.
2.
Three capscrews (2)
Install to secure valve.
3.
Wire (3)
Connect to valve.
4.
Hose assembly (4)
Connect to valve.
5.
Two panels (5)
Install.
TA099377
END
4-204
TM 10-3930-641-34-2
SEQUENCE AND PRESSURE CONTROL VALVE DISASSEMBLY/ASSEMBLY
(Sheet 1 of 5)
This task covers: Disassembly and assembly of sequence and pressure control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required.
Pages 2-47, 2-48, 2-49
Equipment Condition
Sequence and pressure control valve
removed from vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Sequence and pressure control
valve removal/installation, page 4-202.
None
Go on to Sheet 2
4-205
TM 10-3930-641-34-2
(Sheet 2 of 5)
SEQUENCE AND PRESSURE CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Capscrews (13), lockwashers (14),
cover (12)
Remove.
2.
Stop assembly (10), spring (7) and
spacers (8, 9)
Remove from valve body.
3.
Plug (3) and preformed packing (2)
Remove.
4.
Capscrews (13 and 18), lockwasher
(14), and cover (19)
Remove from valve body.
5.
Two valve spools (20) and (16)
Remove from valve body (15).
6.
Valve slug (17)
Remove from spool (16).
7.
Preformed packing (11)
Replace.
Go on to Sheet 3
4-206
TM 10-3930-641-34-2
SEQUENCE AND PRESSURE CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 3 of 6)
Power Train Oil Lines Group
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Plug
Preformed Packing
Plug
Preformed Packing
Screw
Identification Plate
Spring
Spacer
Spacer
Stop Assembly
Preformed Packing
Cover
Capscrew
Lockwasher
Control Valve Body
Sequence Spool
Reducing Valve Slug
Capscrew
Cover
Spool
TA099378
Go on to Sheet 4
4-207
TM 10-3930-641-34-2
(Sheet 4 of 5)
SEQUENCE AND PRESSURE CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
1. Sequence and pressure control valve
free of dirt before assembling.
a. Be sure all parts of valve are clean and
b. Put clean oil on all parts.
2.
Valve slug (17)
Install in valve spool.
3.
Valve spools (20) and (16)
Install in valve body.
4.
Preformed packing (11)
Install in valve body.
5.
Cover (19)
and lockwashers (14).
Install and secure with capscrews (13) and (18)
Go on to Sheet 5
4-208
TM 10-3930-641-34-2
(Sheet 5 0f 5)
SEQUENCE AND PRESSURE CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
6.
Spacers (8) and (9)
Install on stop assembly (10).
7.
Spring (7) and stop assembly (10)
Install in valve body (15).
8.
Preformed packing (11)
Install in valve body (15).
9.
Cover (12)
Install and secure with capscrews.
10.
Plug (3) and preformed packing (2)
Install in valve body (15).
11. Sequence and pressure control valve
Install.
See page 4-202.
End
4-209
TM 10-3930-641-34-2
(Sheet 1 of 3)
TRANSMISSION CONTROL LOCK REMOVAL
This task covers: Removal of transmission lock.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Tags for marking lines.
Page 2-45
Equipment Condition
Engine OFF.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Shipping link removal/installation,
TM 10-3930-641-20.
Tires blocked.
Main disconnect switch OFF.
Go on to Sheet 2
4-210
TM 10-3930-641-34-2
(Sheet 2 of 3)
TRANSMISSION CONTROL LOCK REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Door assemblies above transmission
Open.
2.
Floor panel at rear of cab
Remove.
3.
Two tube assemblies (1)
lock (4). Cap or plug opening.
Tag and disconnect from transmission control
4.
Two capscrews (2)
Remove.
5.
Transmission control lever
Put in reverse position.
NOTE
Face of bracket must be vertical to slide.
36.
Bracket (3)
Slide off transmission control lock.
NOTE
Make sure bracket is perfectly vertical when
sliding off.
TA099379
Go on to Sheet 3
4-211
TM 10-3930-641-34-2
(Sheet 3 0f 3)
TRANSMISSION CONTROL LOCK REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
7.
Capscrews that hold transmission
control lock (4) to transmission
Remove.
8.
Transmission control lock (4)
a. Position so wires (5) can be disconnected.
b. Put identification on wires for later installation.
C
Remove.
TA099380
END
4-212
TM 10-3930-641-34-2
TRANSMISSION CONTROL LOCK INSTALLATION
(Sheet 1 of 4)
This task covers: Installation of transmission control lock.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required.
None
Equipment Condition
Transmission control lock removed.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transmission control lock removal,
page 4-210.
Main disconnect switch OFF until wires
are connected.
Speed control linkage adjustment,
TM 10-3930-641-20.
Tires blocked.
Shipping link removal/installations,
TM 10-3930-641-20.
Go on to Sheet 2
4-213
TM 10-3930-641-34-2
(Sheet 2 0f 4)
TRANSMISSION CONTROL LOCK INSTALLATION (CONT)
LOCATION/ITEM
1.
Transmission control lock (2)
ACTION
a
REMARKS
Position on transmission.
b. Make sure rail in control lock engages
direction selector valve spool in
transmission hydraulic controls.
c.
2.
Wires (1)
Secure with capscrews.
Connect to switch on transmission control
lock.
CAUTION
a. Make sure direction selector valve spool in
transmission hydraulic controls moves freely
after transmission control lock is installed.
b. If valve spool does not move freely, remove
cover over transmission hydraulic controls.
c.
Loosen four capscrews that hold transmission hydraulic controls in position.
d. Move valve group until direction selector
valve spool is free to move with the rail in
transmission control lock. Tighten the
valve group capscrews to a torque of
32-38 lb. ft. (44-52 N-m).
TA099381
Go on to Sheet 3
4-214
TM 10-3930-641-34-2
(Sheet 3 of 4)
TRANSMISSION CONTROL LOCK INSTALLATION (CONT)
LOCATION/ITEM
3.
Bracket (3)
ACTION
REMARKS
a. Slide against transmission control lock (2).
b. Secure with capscrews.
c.
Be sure direction selector valve spool
moves freely with rail in transmission
control lock.
4.
Two tube assemblies (4)
Connect to transmission control lock (2).
5.
Speed control linkage
Adjust. See TM10-3930-641-20.
6.
Transmission control lock switch
Adjust. See page 4-216.
7.
Parking brake
Put in engaged position.
8.
Main disconnect switch
Turn to ON position.
9.
Ignition switch
Turn to ON position.
10.
Transmission control lever
Put in REVERSE position.
11.
Locknut on transmission control
lock switch
Loosen.
TA099382
Go on to Sheet 4
4-215
TM 10-3930-641-34-2
(Sheet 4 of 4)
TRANSMISSION CONTROL LOCK INSTALLATION (CONT)
LOCATION/ITEM
12.
Transmission control lock
switch
ACTION
REMARKS
a. Turn in until horn behind seat in
operator's cab makes sound.
b. Turn switch in one more turn and tighten
locknut.
c.
13.
Transmission control lever
must not make sound.
Horn must still make sound.
a. Put in NEUTRAL position. Horn now
b. Put in FORWARD position. Horn must not
make sound.
14.
Ignition switch
Turn OFF.
15.
Floor panel at rear of cab
Install.
End
4-216
TM 10-3930-641-34-2
TRANSMISSION CONTROL LOCK DISASSEMBLY
(Sheet 1 of 4)
This task covers: Disassembly of transmission control lock.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Pages 2-45, 2-46
Equipment Condition
Transmission control lock removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Transmission control lock removal,
see page 4-210.
Keep dirt away from clean parts.
Go on to Sheet 2
4-217
TM 10-3930-641-34-2
(CONT) (sheet 2 of
TRANSMISSION CONTROL LOCK DISASSEMBLY
4)
LOCATION/ITEM
ACTION
REMARKS
1. Switch assembly (19)
Remove from transmission control lock.
2.
Two plugs (1) and (36), and preformed packings (2) and (13)
Remove.
3.
Cylinder (14) and preformed
packing (13)
Remove from housing.
4.
Connector (17), piston (15), and
preformed packing (16)
Remove from cylinder.
5.
Plunger (12)
Position so that detent groove in plunger
appears in center of bore for plug (1) as
shown.
TA099383
Go on to Sheet 3
4-218
TM 10-3930-641-34-2
TRANSMISSION CONTROL LOCK DISASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
(Sheet 3 of 4)
Plug
Preformed Packing
Ring
Plunger Assembly
Spring
Spring
Sleeve
Spring
Housing
Spring
Spring
Plunger
Preformed Packing
Cylinder
Piston
Preformed Packing
Connector
Plug
Switch Assembly
Preformed Packing
Filter
Nut
Sleeve
Spring
Sleeve
Preformed Packing
Rail
Pin
Ring
Preformed Packing
Preformed Packing
Plug
Preformed Packing
Preformed Packing
Preformed Packing
Plug
TA099384
Go on to Sheet 4
4-219
TM 10-3930-641-34-2
(Sheet 4 of 4)
TRANSMISSION CONTROL LOCK DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
6.
Plunger assembly (4)
Push into detent groove of plunger (12) to
allow removal of rail assembly (22 thru 29).
7.
Rail assembly (22 thru 29)
Remove.
8.
Plunger (12), plunger assembly
group (3 thru 8)
Remove.
9.
Ring (29) and pin (28)
Remove from end of rail (27).
10. Springs (24), sleeve (25), sleeve (23),
nut (22)
Remove from rail.
11.
Seal (26) in sleeve (23)
Discard if damaged.
12.
Ring (3)
Remove from sleeve (7).
13.
Two plunger assemblies (4) and
springs (5) and (6)
Remove from sleeve (7).
14.
Preformed packings (2), (13), (16),
(30), (31), (33), (34), (35)
Discard if damaged.
End
4-220
TM10-3930-641-34-2
TRANSMISSION CONTROL LOCK ASSEMBLY
This task covers. Assembly of transmission control lock.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
Refer to page 4-234.
Page 2-46
Equipment Condition
Transmission control lock disassembled.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Transmission control lock disassembly,
page 4-217.
Keep clean parts away from dirt.
Go on to Sheet 2
4-221
TM10-3930-641-34-2
TRANSMISSION CONTROL LOCK ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 4)
ACTION
REMARKS
NOTE
Be sure all parts are clean and coated with
fresh hydraulic oil before assembly.
7.
1.
Ring (3)
Install in sleeve (7).
2.
Plunger assembly (4), spring (6),
spring (5) and plunger assembly
(4)
a. Install in sleeve (7).
b.
Secure with second ring (3).
3.
Seal (26)
Install in sleeve (23).
4.
Spring (24), sleeve (25), spring
(24) and sleeve (23)
Install on rail (27).
5.
Nut (22)
lb. ft. (55-85 N-m).
Install on rail. Tighten to a torque of 41-63
6.
Pin (28) and retaining ring (29)
pliers.
Install in end of rail with retaining ring
Preformed packings (30) and (31)
for rail assembly
Install in housing (9).
Go on to Sheet 3
4-222
TM10-3930-641-34-2
TRANSMISSION CONTROL LOCK ASSEMBLY (CONT)
1.
Plug
2.
Preformed Packing
3.
Ring
4.
Plunger Assembly
5.
Spring
6.
Spring
7.
Sleeve
8.
Spring
9.
Housing
10.
Spring
11.
Spring
12.
Plunger
13.
Preformed Packing
14.
Cylinder
15.
Piston
16.
Preformed Packing
17.
Connector
18.
Plug
19.
Switch Assembly
20.
Preformed Packing
21.
Filter
22.
Nut
23.
Sleeve
24.
Spring
25.
Sleeve
26.
Seal
27.
Rail
28.
Pin
29.
Ring
30.
Preformed Packing
31.
Preformed Packing
32.
Plug
33.
Preformed Packing
34.
Preformed Packing
35.
Preformed Packing
36.
Plug
(Sheet 3 of 4)
TA099385
Go on to Sheet 4
4-223
TM10-3930-641-34-2
TRANSMISSION CONTROL LOCK ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 4)
ACTION
REMARKS
Install in housing (9).
8.
Rail assembly
9.
Spring (8) and sleeve assembly
(7)
Install in housing (9).
10.
Spring (10), spring (11) and
plunger (12)
Install in housing (9).
11.
Piston (15) in cylinder (14)
Install in housing (9).
12.
Cylinder (14)
Install in housing (9).
13.
Connector (17)
Install in cylinder (14).
14.
Two plugs (1) and (36), preformed
packings (2) and (13)
Install in housing (9).
15.
Switch assembly (19)
Install in housing (9).
End
4-224
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE REMOVAL/INSTALLATION
This task covers: Removal and installation of torque converter outlet relief valve.
INITIAL SETUP
Test Equipment
None
Materials/Parts
(Sheet 1 of 3)
Troubleshooting Reference
Tags to mark hoses.
Page 2-41
Equipment Condition
Engine off and cooled.
Shipping link installed.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Shipping link removal/installation,
TM 10-3930-641-20.
Avoid contact with hot oil.
Main disconnect switch OFF
Go on to Sheet 2
4-225
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 3)
ACTION
REMARKS
REMOVAL
1.
Two panels (1)
Remove from left side of vehicle.
2.
Tube assembly at bottom of
relief valve
Tag and disconnect from under outlet relief
valve (5).
3.
Tube assembly (2)
Tag and disconnect from valve (5).
4.
Wire (3)
Disconnect from sending unit on valve (5).
5.
Three capscrews (4) and torque
converter outlet relief valve (5).
Remove.
4-226
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
REMARKS
INSTALLATION
1.
Torque converter outlet relief
valve (2)
b.
a.
Place in position on torque converter
2.
Wire (4)
Connect to sending unit on valve (2).
3.
Tube assembly at bottom of relief
valve.
Connect to valve.
4.
Tube assembly (1)
Connect to valve.
5.
Two panels (5).
Install on left side of vehicle.
Secure with three capscrews (3).
End
4-227
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE DISASSEMBLY/ASSEMBLY
This task covers: Disassembly/assembly of torque converter outlet relief valve.
(Sheet 1 of 3)
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
As required
Page 2-49
Equipment Condition
Torque converter outlet relief
valve removed.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Torque converter outlet relief valve
removal/installation, page 4-225.
None
Go on to Sheet 2
4-228
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE DISASSEMBLY/ASSEMBLY (CONT)
1.
Preformed Packing
2.
Drive Screw
3.
Identification Plate
4.
Body
5.
Plug
6.
Preformed Packing
7.
Spool Assembly
8.
Retaining Ring
9.
Retainer
10.
Spring
11.
Poppet
12.
Spool
13.
Spacer
14.
Blank Washer
15.
Spacer Plate
16.
Spring
17.
Cover
18.
Lockwasher
19.
Capscrew
(Sheet 2 of 3)
TA099388
Go on to Sheet 3
4-229
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
REMARKS
DISASSEMBLY
1.
Capscrew (19) and lockwasher
(18)
Remove from body (4).
2.
Covers (17) and preformed
packing (1)
Remove from both ends of body (4).
3.
Spring (16) and spacers (13), (14),
(15)
Remove.
4.
Spool assembly (7)
Remove.
5.
Retaining ring (8) retainer (9),
spring(10) and poppet (11)
Remove from valve spool (12).
6.
Plug (5) and preformed packing (6)
Remove from body (4).
1.
Plug (5) and preformed packing
(6).
Install in valve body (4).
2.
Poppet (11) spring (10), retainer
(9), and retaining ring (8)
Install in spool (12).
3.
Spool assembly (7)
Install in body (4).
4.
Spacers (13) (14), (15) and spring
(16)
Install.
5.
Covers (17) and preformed
packing (1)
Position on both ends of body (4).
6.
Capscrew (19) and lockwasher
(18)
Install.
ASSEMBLY
End
4-230
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE ADJUSTMENT
This task covers: Adjustment of torque converter outlet relief valve.
(Sheet 1 of 3)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Pressure Gage (0-100 psi)
(0-690 kPa)
Spacers
Pages 2-48, 2-49
Equipment Condition
As stated in procedure
Special Tools
None
Personnel Required
Two mechanics
References
General Safety Instructions
Torque converter outlet relief valve
disassembly/assembly, page 4-228.
Go on to Sheet 2
4-231
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE ADJUSTMENT (CONT)
LOCATION/ITEM
(Sheet 2 of 3)
ACTION
REMARKS
TEST
1.
Gage (0-100 psi - 0-690 kPa)
tap.
Install in torque converter outlet relief valve
2.
Engine
Start.
3.
Brakes
Engage fully.
4.
Speed selection lever
Place in fourth speed.
5.
Engine
Depress throttle until engine is at high idle.
6.
Gage
Observe.
Spacers
correct pressure. (See chart at right.)
Add or remove to adjust outlet relief valve to
ADJUST
1.
TA099389
Go on to Sheet 3
4-232
TM10-3930-641-34-2
TORQUE CONVERTER OUTLET RELIEF VALVE ADJUSTMENT
(Sheet 3 of 3)
TA099390
End
4-233
TM10-3930-641-34-2
TRANSMISSION CONTROL LOCK BENCH TEST
This task covers: Bench testing transmission control lock.
(Sheet 1 of 3)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
One 0-650 psi (45.7 Kg/cm2)
pressure gage
None
Page 2-45
Hydraulic lines and fittings
Equipment Condition
Transmission oil supply
Transmission control lock removed from
vehicle.
Special Tools
Personnel Required
None One mechanic
References
General Safety Instructions
Transmission control lock removal, page 4-210.
Test in a clean area.
Transmission oil pump specifications,
page 2-69.
Go on to Sheet 2
4-234
TM10-3930-641-34-2
TRANSMISSION CONTROL LOCK BENCH TEST
(Sheet 2 of 3)
LOCATION/ITEM
ACTION
1.
Pressure oil
Find a scourse of supply that will provide
2
650 psi (45.7 Kg/cm ). A transmission test
bench is satisfactory.
2.
Connect as shown at right.
REMARKS
Gage, needle valve, and lines
NOTE
Because the flow needed for this test is low,
be sure the length of the lines used is kept to
a minimum so pressure differences (drops)
are kept to a minimum.
3.
Open slowly.
Needle valve
TA099391
Go on to Sheet 3
4-235
TM10-3930-641-34-2
TRANSMISSION CONTROL LOCK BENCH TEST (CONT)
LOCATION/ITEM
4.
(Sheet 3 of 3)
ACTION
Pressure of approximately 650 psi
(45.7 Kg/cm2)
REMARKS
Send into passage (1).
5.
Shift rail (4)
Must move in either direction with a small
amount of resistance and with a pressure of
650 psi (45.7 Kg/cm2) in passage (1). When
the rail is released, it must stay in that
position.
6.
Pressure into passage (1)
cm2)
7.
Shift rail (4)
Must move in either direction against the force
of the springs for detent (5) and sleeve ?2),
with a pressure of 400 psi (28.1 Kg/cm2) in
passage (1). When the shift rail is released, it
must be returned to its NEUTRAL position
by the force of the springs.
Lower to approximately 400 psi (28.1 Kg/
TRANSMISSION CONTROL LOCK
1. Inlet passage for brake pressure oil. 2. Sleeve.
3. Drain passage. 4. Rail (connected to direction selection spool). 5. Detent. 6. Nut (connected to direction cable from cab).
TA099392
End
4-236
TM10-3930-641-34-2
SEQUENCE VALVE TEST
This task covers: Test for sequence and control valve.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
Materials/Parts
Two 0-600 psi (0-42.2 Kg/cm2) pressure gages
Troubleshooting Reference
None
Pages 2-47, 2-48
Needle valve
Hydraulic lines and fittings
Equipment Condition
Transmission oil supply at 400 psi (28.1 Kg/cm2)
Sequence valve removed from vehicle.
Fabricated plate (see Sheet 2)
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Sequence and pressure control valve
removal/installation, page 4-202.
Test in a clean area.
Go on to Sheet 2
4-237
TM10-3930-641-34-2
SEQUENCE VALVE TEST (CONT)
LOCATION/ITEM
(Sheet 2 of 4)
ACTION
Plate like the one shown in the
illustration
REMARKS
Make with a thickness of .25 in. (6.3 mm).
2.
Preformed packings
body.
Install in their correct locations in the valve
3.
Plate, made in Step 1
so the .13 in. (3.2 mm) holes in the plate
align with the two bleed holes in the valve
body. Secure the plate to the valve with
bolts and nuts.
Place in position on the bottom of the valve
4.
Get a supply source of pressure
oil that can give 400 psi
(28.1 Kg/cm2) of pressure
For example, transmission test bench. Make
sure the supply has a reservoir for leakage oil
from the valve.
5.
Two 0 to 600 psi (0 to 42.4 Kg/
cm2) pressure gages, lines,
fittings and needle valve
Install.
1.
FABRICATED PLATE
INCHES (MM)
NOTE
Because the flow needed for this test is nor- See Sheet 3 for connection.
mally low, be sure the length of the lines
used is kept at a minimum so pressure differnces (drops) are kept at a minimum.
TA099393
Go on to Sheet 3
4-238
TM10-3930-641-34-2
SEQUENCE VALVE TEST (CONT)
(Sheet 3 of 4)
LOCATION/ITEM
ACTION
REMARKS
6.
Oil supply
Activate.
7.
Needle valve (2)
Slowly open until the pressure read on gage (5)
is 200 psi (14.1 Kg/cm2). Gage (3) must read
0 psi, (0 Kg/cm2) (0 kPa).
8.
Valve (2)
Continue to open slowly to increase the pressure read on gage (5), at a rate of 10 psi (0.7
Kg/cm2) at a time.
9.
Sequence valve (7)
Will move against the force of its spring (open)
when the pressure gage (5) is 265 to 275 psi
(18.1 to 19.3 Kg/cm2). This will allow
pressure
oil to flow through a passage in valve body
(6)
to gage (3). At this time, gage (3) will indicate
the pressure read on gage (5).
NOTE
If the needles of the pressure gages move back
SCHEMATIC OF TEST PROCEDURE
and forth (flutter) while the test is performed, 1.
loosen the fitting on gage (3) so there is a small
amount of leakage.
3.
4.
5.
6.
Oil Supply
2.
Needle Valve
Gage
Shims
Gage
Body of sequence and
pressure control valve
7. Sequence valve
4-239
TA099394
Go on to Sheet 4
TM10-3930-641-34-2
SEQUENCE VALVE TEST (CONT)
LOCATION/ITEM
9.
(Sheet 4 of 4)
ACTION
REMARKS
Sequence valve (cont)
If sequence valve (7) does not open at 265 to
2
275 psi (18.1 to 19.3 Kg/cm ), add or remove
shims (4) until the pressure is correct. One
shim will change pressure approximately 4 psi
(0.3 Kg/cm2).
TA099395
END
4-240
TM10-3930-641-34-2
Section VI. FRONT AXLE
FRONT AXLE MAINTENANCE INSTRUCTIONS
This section covers maintenance of these front axle components for direct support and general support maintenance personnel:
a.
Front differential and bevel gear
b.
Drive axles
c.
Final drive planet carrier
LIST OF TASKS
(Sheet 1 of 1)
TASK NO.
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Front differential and bevel gear removal.
4-242
2-43, 2-44
2
Front differential and bevel gear installation.
4-246
None
3
Drive axles removal/installation.
4-250
None
4
Final drive planet carriers removal/
installation.
4-254
2-43, 2-44
5
Final drive planet carriers disassembly/assembly
4-259
2-43
4-241
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR REMOVAL
This task covers: Removal of front differential and bevel gear.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
Container to catch oil.
Pages 2-43, 2-44
Wooden blocks.
Equipment Condition
Engine off and cooled.
Shipping link installed.
Special Tools
None
Personnel Required
Two mechanics
References
General Safety Instructions
Drive axles removal/installation, page 4-250. Tires blocked.
Drive shaft removal, TM 10-3930-641-20.
Jack stands must be used.
Shipping link removal/installation,
TM 10-3930-641-20.
Keep clear of mast.
Go on to Sheet 2
4-242
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR REMOVAL (CONT)
LOCATION/ITEM
(Sheet 2 of 4)
ACTION
REMARKS
1.
Drive axles
Remove.
See Drive Axles Removal/Installation, page 4-
2.
Main drive shaft group
Remove.
See TM10-3930-641-20.
3.
Oil Drain from front axle housing.
250.
4. Mast
WARNING
Keep all personnel except operator away from
vehicle when mast is used to lift front end.
a.
Lower until it rests on wood blocks placed
on ground.
b.
Continue lowering mast until vehicle
front wheels are about 9 in. (22.9 cm) off
ground.
c.
Put jack stands under vehicle.
d.
Place wood blocks under front tires.
WARNING I
Block both sides of rear tires to prevent
vehicle movement.
Go on to Sheet 3
4-243
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR REMOVAL (CONT)
LOCATION/ITEM
5.
(Sheet 3 of 4)
ACTION
Brake tube assembly (2)
REMARKS
a. Disconnect from wheel.
b.
Remove clip (1) that holds tube assembly
to axle housing.
6.
Two capscrews (3) that secure
hydraulic lines to differential
Remove.
7.
Differential and bevel gear
Attach transmission floor jack.
NOTE
Put a piece of bar stock between bottom of
carrier assembly and surface of floor jack.
This will keep carrier assembly off floor jack
for easier removal of the differential from the
axle housing.
8.
Capscrews and washers
Remove twenty-four capscrews and washers.
9.
Two 3/4-10NC forcing screws
Tighten evenly to loosen differential.
TA099396
End
4-244
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR REMOVAL (CONT)
LOCATION/ITEM
(Sheet 4 of 4)
ACTION
REMARKS
NOTE
Differential and bevel gear weigh 1180 lb.
(535 Kg).
10.
Differential and bevel gear
a. Pull differential and bevel gear from axle
housing.
b.
Lower unit and remove from under
vehicle.
TA099397
End
4-245
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR INSTALLATION
This task covers: Installation of front differential and bevel gear.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
As required
None
Wooden blocks
Equipment Condition
Front differential and bevel gear removed.
Special Tools
None
Personnel Required
Two mechanics
References
General Safety Instructions
LO 10-3930-641-12.
Tires blocked.
Drive axles removal/installation, page 4-250. Jack stands must be used.
Bleed brake system, TM 10-3930-641-20.
Keep clear of mast.
Drive shafts removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-246
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR INSTALLATION (CONT)
LOCATION/ITEM
1.
(Sheet 2 of 4)
ACTION
Differential and bevel gear (1)
REMARKS
a. Fasten to transmission floor jack (2).
NOTE
Put a piece of bar stock between bottom of
carrier assembly and surface of floor jack.
This
will keep carrier assembly off floor jack for
easier installation on to axle housing.
b.
Install preformed packing in groove on
differential carrier.
c.
Raise differential and bevel gear until the
unit aligns with axle housing as shown.
d.
Make sure that hole in carrier assembly is in
alignment with pin (3).
e.
Push unit into axle housing.
f.
Install the twenty-four capscrews that
secure differential and bevel gear to axle
housing.
g.
Remove floor jack.
TA099398
Go on to Sheet 3
4-247
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR INSTALLATION (CONT)
LOCATION/ITEM
2.
3.
Brake tube assembly (5)
(Sheet 3 of 4)
ACTION
Hydraulic lines and manifold that
attach to differential
b.
Brake system
5.
Mast
Secure with the two capscrews (4).
a. Connect to wheel.
b.
4.
REMARKS
a. Install.
Install clip (6) that holds tube assembly
to axle housing.
Remove air (bleed).
a.
Position flat on wood blocks.
b.
Remove blocks from around rear tires.
WARNING
Keep away from vehicle when mast is used
to raise and/or lower front end.
c.
Lower mast until front end of machine
is raised enough to remove wood blocks
under front tires.
d.
Lower front end back to ground.
TA099399
Go on to Sheet 4
4-248
TM10-3930-641-34-2
FRONT DIFFERENTIAL AND BEVEL GEAR INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 4 of 4)
ACTION
REMARKS
6.
Oil Fill front axle housing to correct level with,
the specified oil.
See LO 10-3930-641-12.
7.
Main drive shaft group
Install. See TM10-3930-641-20.
8.
Drive axles
Install. See Drive Axles Removal/Installation, page 4-250.
End
4-249
TM10-3930-641-34-2
DRIVE AXLES REMOVAL/INSTALLATION
Removal and installation of drive axles.
INITIAL SETUP
Test Equipment
None
(Sheet 1 of 4)
Materials/Parts
Troubleshooting Reference
As required
None
Equipment Condition
Vehicle moved until final drive drain plug
is at the bottom. Oil drained from the
final drive.
Install shipping link.
Special Tools
Personnel Required
Axle installation tool, FT 1280
(See Appendix C)
One mechanic
References
General Safety Instructions
LO 10-3930-641-12.
Tires blocked.
Shipping link removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-250
TM 10-3930-641-34-2
(Sheet 2 of 4)
DRIVE AXLES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1. Capscrew (1)
Remove from cover. Install a 1/2-13NC
4.6 in. (10-14 cm) long guide pin in bolt
hole.
2. Remaining five capscrews (1)
Remove.
3. Three capscrews (2)
Use as forcing bolts to loosen cover (3).
NOTE
Weight of cover is 40 lb. (18 Kg).
4. Cover and seal
Remove.
5. 7/16 NC forged eyebolt (4)
a. Install in end of axle.
b. Pull axle out of housing until a hoist
can be attached.
6. Axle (5)
Remove.
NOTE
Weight of axle is 135 lb. (61.2 Kg).
TA099400
Go on to Sheet 3
4-251
TM 10-3030-641-34-2
(Sheet 3 of 4)
DRIVE AXLES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
7. Retaining ring, gear (6) spacer
ACTION
REMARKS
Remove from axle shaft.
INSTALLATION
NOTE
Clean axles before installation.
1. Drive axle (1)
a. Place in position in final drive.
b. Use axle installation tool to align spline
at bevel gear.
c. Push into place.
2. Spacer (2), gear (3) and retaining
ring
Install on axle.
NOTE
It may be necessary to move the vehicle to
align the drive axle gear with the final drive
gears.
TA099401
Go on to Sheet 4
4-252
TM 10-3930-641-34-2
(Sheet 4 of 4)
DRIVE AXLES REMAOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
3. Two 1/2-3 NC guide pins (4)
Install in carrier.
4. New seal
Install on cover.
5. Cover (5)
Install. Install capscrews.
6. Final drive
Add oil.
REMARKS
See LO 10-3930-641-12.
TA099402
End
4-253
TM 10-3930-641-34-2
(Sheet 1 of 5)
FINAL DRIVE PLANET CARRIERS REMOVAL/INSTALLATION
This task covers: Removal and installation of final drive planet carriers.
INITIAL SETUP
Test Equipment
None
Materials/Parts
As required
Troubleshooting Reference
Pages 2-43, 2-44
Equipment Condition
Drive axles removed.
Shipping link installed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
LO 10-3930-641-20.
Tires blocked.
Drive axles removal/installation, page 4-250.
Shipping link removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-254
TM 10-3930-641-34-2
(Sheet 2 of 5)
FINAL DRIVE PLANET CARRIERS REMOVAL/INSTALLATION(CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1. Bracket (A)
Attach to carrier (4).
2. Thirty-four nuts (1) and washers
Remove.
3. Hoist
Attach to bracket (A) on carrier (4).
4. Drain plug (2)
Remove.
5. Three 1/2-13 NC forcing
screws (3)
Install in carrier. Tighten evenly, one turn
at a time, until carrier is loose. After carrier
is loose, remove forcing screws.
6. Axle
Install gear end of axle in carrier. The axle
will help hold the carrier in position.
7. Carrier (4)
Remove.
NOTE
`
Weight of carrier is 295 lb. (133.8 Kg).
TA099403
Go on to Sheet 3
4-255
TM 10-3930-641-34-2
FINAL DRIVE PLANET CARRIERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
8. Retainers
Bend away from capscrew heads.
9. Capscrews (5)
Remove.
10. Retainers (6)
Remove.
11. Lifting bracket (B)
Place in position with hoist.
NOTE
Weight of ring gear is 110 lb. (50 Kg).
12. Ring gear (7)
Remove using lifting bracket.
TA099404
Go on to Sheet 4
4-256
TM 10-3930-641-34-2
FINAL DRIVE PLANET CARRIERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1. Lifting bracket (B) and hoist
Use to place ring gear (1) in position in wheel.
2. Retainers (2)
Install.
3. Capscrews (3)
Install. Bend locks over to prevent
capscrew heads from turning.
4. Bracket (A)
Attach to carrier (4).
5. Drive axle
Insert gear end into carrier and use to position
carrier when lifting it into position in the ring
gear.
TA099405
Go on to Sheet 5
4-257
TM 10-3930-641-34-2
FINAL DRIVE PLANET CARRIERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
6. Drive axle
Attach hoist and remove after carrier is
installed.
7. Thirty-four nuts and washers
Install.
NOTE
Tighten nuts to a torque of 335 to 445 lb. ft.
(454-607.3 N-m).
8. Drain plug
Install.
9. Drive axles
Install.
See page 4-250.
10. Final drive
Add oil.
See LO10-3930-641-12.
End
4-258
TM 10-3930-641-34-2
FINAL DRIVE PLANET CARRIERS DISASSEMBLY/ASSEMBLY
(Sheet 1 of 3)
This task covers: Disassembly and assembly of final drive planet carriers.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required.
Page 2-43.
Equipment Condition
Final drive planet carriers
removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Final drive planet carriers removal/
installation, page 4-254.
None.
Go on to Sheet 2
4-259
TM 10-3930-641-34-2
(Sheet 2 of 3)
FINAL DRIVE PLANET CARRIERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1. Three planet shafts (6)
Remove from carrier (5).
NOTE
Shafts can be removed from bottom of carrier
by removing retaining rings (7).
2. Three gears (3) and six washers
a. Remove from carrier (5).
(1)
b. Discard washers if damaged.
3. Two bearings (2) and one space
Remove from each gear (3).
(4)
ASSEMBLY
1. Two bearings (2) and spacer (4)
Install in each gear.
NOTE
Spacer goes between bearings.
2.
3.
4.
5.
6.
7.
1. Washer
Roller Bearing Assembly
Planet Gear
Spacer
Planet Carrier
Planet Shaft
Retaining Ring
TA099406
Go on to Sheet 3
4-260
TM 10-3930-641-34-2
FINAL DRIVE PLANET CARRIERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
2. Three gears (3) and six washer
(1)
ACTION
REMARKS
a. Install a washer on both sides of each gear.
b. Install gears (and washers) in carrier (5).
3. Shafts (6) and retaining rings (7)
Install in carrier (5).
4. Shafts (6)
Turn until flat side of shafts are toward outside of carrier.
End
4-261
TM 10-3930-641-34-2
Section VII. REAR AXLE
REAR AXLE MAINTENANCE INSTRUCTIONS
This section covers maintenance of these rear axle components for direct support and general support maintenance personnel:
a. Rear differential, bevel gear, and front support
b. Differential and bevel gear
c. Rear support
LIST OF TASKS
TASK NO.
(Sheet 1 of 1)
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Rear differential, bevel gear, and front
support removal.
4-263
2-43, 2-44
2
Rear differential, bevel gear, and front
support installation.
4-267
None
3
Differential and bevel gear disassembly.
4-271
2-43, 2-44
4
Differential and bevel gear assembly.
4-278
None
5
Differential and bevel gear adjustment.
4-289
2-43
6
Front and rear support disassembly/assembly.
4-296
None
4-262
TM 10-3930-641-34-2
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT REMOVAL
Sheet 1 of 4)
This task covers: Removal of rear differential, bevel gear and front support.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Container to catch oil.
Pages 2-43, 2-44
Equipment Condition
Engine OFF.
Shipping link installed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Crankcase guard removal,
TM 10-3930-641-20
Jack stands must be used and tires
blocked.
Drive axles removal/installation, page 4-250.
Drive shaft removal, TM 10-3930-641-20.
Shipping link removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-263
TM 10-3930-641-34-2
(Sheet 2 of 4)
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT REMOVAL (CONT)
LOCATION/ITEM
1. Hydraulic jacks
ACTION
REMARKS
a. Position under vehicle as shown.
b. Lift vehicle until full weight is just supported by jacks. (But not so much that
wheels are off ground).
2. Crankcase guards
Remove. (See TM 10-3930-641-20.)
3. Drive axles
Remove. (See page 4-250.) -
4. Oil
Drain from rear axle housing.
5. Capscrews (1)
Remove.
6. Drive shaft (2)
Remove. (See TM 10-3930-641-20.)
NOTE
Drive shaft weighs 55 lb. (25 Kg).
TA099407
Go on to Sheet 3
4-264
TM 10-3930-641-34-2
(Sheet 3 of 4)
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
7. Tube assembly (5)
Disconnect from grease fitting on top of
support.
8. Capscrew (3), retainer and yoke
assembly (4)
Remove.
9. Four capscrews (6)
Remove from hydraulic hose junction blocks
on each side of frame. Eight capscrews each.
10. Four capscrews (7) and nuts
Remove.
NOTE
Support assembly weighs 225 lb. (102 Kg).
11. Support assembly (8)
a. Attach floor jack.
b. Remove.
12. Preformed packing
Remove and discard.
13. Bearing
Remove.
TA099408
Go on to Sheet 4
4-265
TM 10-3930-641-34-2
(Sheet 4 of 4)
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
14. Twenty-four capscrews that secure
differential (9)
Remove.
15. Rear differential and bevel gear (10)
shown.
a. Attach transmission floor jack as
b. Install two 3/4-10 NC forcing screws
in differential.
c. Tighten forcing screws evenly until
differential comes loose from axle housing.
d. Pull differential as far as possible from
axle housing and turn it clockwise.
e. Raise the vehicle until the wheels are
about 9 in. (228.6 mm) off the ground.
NOTE
Differential and bevel gear weigh 915 lb.
(415 Kg).
f. Remove differential and bevel gear from
under vehicle.
TA099409
End
4-266
TM 10-3930-641-34-2
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT INSTALLATION
(Sheet 1 of 4)
This task covers: Installation of rear differential, bevel gear and front support installation.
INITIAL SETUP
Test Equipment
Materials/Parts
None
SAE 90 oil.
Troubleshooting Reference
None
Equipment Condition
Support on jacks, 9 in. (228.6 mm)
clearance between tire and ground.
Shipping link installed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
LO 10-3930-641-12.
Jack stands must be used and front tires
blocked.
Drive axles removal/installation, page 4-250.
Crankcase guard removal/installation,
TM 10-3930-641-20.
Shipping link removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-267
TM 10-3930-641-34-2
(Sheet 2 of 4)
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT REMOVAL (CONT)
LOCATION/ITEM
1. Rear differential and bevel gear (1)
shown.
ACTION
REMARKS
a. Attach transmission floor jack as
b. Position differential in axle housing.
2. Twenty-four capscrews that secure
differential to axle housing
Install.
3. Hydraulic jacks
Lower the two hydraulic jacks that support
rear of vehicle just until wheels contact
ground.
4. Preformed packings, bearing
Install in front support (2). Put a light coat of
grease on packings and bearings.
TA099410
Go on to Sheet 3
4-268
TM 10-3930-641-34-2
(Sheet 3 of 4)
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT REMOVAL (CONT)
LOCATION/ITEM
5. Front support (2)
ACTION
REMARKS
a. Attach to floor jack.
b. Place in position on differential as shown.
c. Install four capscrews (4) and nuts that
secure it.
NOTE
Tighten capscrews to a torque of 750-900 lb.
ft. (1007 to 2118 N-m).
6. Two junction blocks (3)
Connect to main frame on machine.
7. Tube assembly
Connect to grease fitting on support.
8. Drive shaft (5) and capscrews
Install shaft (5) and capscrews that hold it.
TA099411
Go on to Sheet 4
4-269
TM 10-3930-641-34-2
(Sheet 4 of 4)
REAR DIFFERENTIAL, BEVEL GEAR AND FRONT SUPPORT REMOVAL (CONT)
LOCATION/ITEM
ACTION
REMARKS
8. Drive shaft and capscrews (cont)
NOTE
Tighten capscrews to a torque of 90-110 lb. ft.
(123 to 148 N-m).
9. Oil
Fill differential to correct level with SAE 90.
See LO 10-3930-741-12.
10. Drive axles
Install.
See Drive Axles Removal/Installation, page 4-250.
11. Crankcase guards
Install.
See Crankcase Guard Installation,
TM 10-3930-641-20.
End
4-270
TM 10-3930-641-34-2
DIFFERENTIAL AND BEVEL GEAR DISASSEMBLY
(Sheet 1 of 7)
This task covers: Disassembly of front or rear differential and bevel gear.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Repair stand as required.
Pages 2-43, 2-44.
Equipment Condition
Differential and bevel gear removed from
vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Differential and bevel gear removal; front,
pages 4-242, rear, page 4-263.
Differential must be set on suitable surface.
Go on to Sheet 2
4-271
TM 10-3930-641-34-2
(Sheet 2 of 7)
DIFFERENTIAL, BEVEL GEAR AND GEAR DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
1. Differential and bevel gear
Position on repair stand as shown.
2. Capscrews (23), washers (5)
Remove.
3. Yoke assembly (31)
a. Fasten to hoist.
NOTE
Unit weighs 280 lb. (127 Kg).
b. Remove with housing (22) attached.
c. Set on suitable work surface.
4. Shims (17) under housing
Remove.
5. Capscrew (28), retainer (29),
preformed packings (30), yoke
assembly (31)
Remove from pinion shaft.
6. Capscrews (35), lockwashers (36)
Remove.
7. Retainer (37), O-ring
Remove.
NOTE
Discard O-ring if damaged.
TA099412
Go on to Sheet 3
4-272
TM 10-3930-641-34-2
DIFFERENTIAL AND BEVEL GEAR DISASSEMBLY (CONT)
1. Ring
2. Tapered Roller Bearing Cone
3. Tapered Roller Bearing Cup
4. Capscrew
5. Washer
6. Differential Ring Gear
7. Tapered Roller Bearing Cup
8. Tapered Roller Bearing Cone
9. Preformed Packing
10. Lock Wire
11. Capscrew
12. Bearing Lock
13. Differential Carrier Assembly
14. Carrier
15. Bearing Cap
16. Capscrew
17. Shim Pack
18. Bevel Pinion Shaft
19. Tapered Roller Bearing Cone
20. Tapered Roller Bearing Cup
21. Preformed Packing
22. Bearing Support Housing
23. Capscrew
24. Cone
25. Tapered Roller Bearing Cup
26. Washer
27. Pin
28. Capscrew
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
(Sheet 3 of 7)
Retainer
Preformed Packing
Yoke Assembly
Yoke
Guard
Lip Type Seal
Capscrew
Lockwasher
Retainer
Packing Preformed
Bearing Lock Nut
Bearing Nut Lock
Capscrew
TA099413
Go on to Sheet 4
4-273
TM 10-3930-641-34-2
(Sheet 4 of 7)
DIFFERENTIAL AND BEVEL GEAR DISASSEMBLY (CONT)
Differential Gear Group
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Differential Bevel Gear
Spider
Washer
Differential Case Assembly
Case Flange Half
Capscrew
Washer
Case Plain Half
Pin
Sleeve Bearing
Differential Bevel Pinion
Washer
TA099414
Go on to Sheet 5
4-274
TM 10-3930-641-34-2
(Sheet 5 of 7)
DIFFERENTIAL AND BEVEL DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
8. Lip type seal (34)
Remove from retainer.
9. Nut (39), lock (40), and washer (26)
Remove.
10. Housing (22)
Place on wood blocks.
11. Pinion shaft (18)
Using suitable press, remove from housing.
12. Bearing cone (24) and two bearing
cups (25)
Remove from housing.
13. Bearing cone (19), bearing cup (20)
Remove from pinion shaft.
14. Differential and bevel gear
Position on repair stand as shown.
15. Lock wire (10)
Remove.
16. Bearing caps (15)
a. Mark with scribe or grease pencil to
insure correct installation later.
NOTE
Bearing caps must be installed in exact
same location.
b. Remove.
TA099415
Go on to Sheet 6
4-275
TM 10-3930-641-34-2
(Sheet 6 of 7)
DIFFERENTIAL AND BEVEL GEAR DISASSEMBLY(CONT)
LOCATION/ITEM
17. Differential
ACTION
REMARKS
a. Install pipe through differential as shown.
b. Attach hoist to pipe.
NOTE
Differential weighs 370 lb. (167.8 Kg).
c. Remove differential from carrier assembly.
18. Bearing cones (2) and (8)
Remove from each side of differential.
19. Capscrews (47) and washers (48)
Remove.
20. Case plain half (49) and case
flange half (46)
pencil.
a. To insure correct alignment later, mark
line across joint with scribe or grease
b. Remove case plain half (49).
TA099416
Go on to Sheet 7
4-276
TM 10-3930-641-34-2
(Sheet 7 of 7)
DIFFERENTIAL AND BEVEL GEAR DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
21. Washer (44), gear (42)
Remove.
22. Spider (43) and bevel pinions (52)
Remove from case assembly.
23. Gear bevel (42) and washer (44)
Remove from case assembly.
24. Washers (53), pinions (52), and
bearings (51)
Remove from spider (43).
25. Capscrews (4), washers (5)
Remove
26. Case flange half (46)
a. Attach hoist.
NOTE
Case assembly weighs 130 lb. (59 Kg).
TA099417
End
4-277
TM 10-3930-641-34-2
(Sheet 1 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
This task covers: Assembly of differential and bevel gear.
NOTE
Adjustments must be made at the same time you perform this procedure. See Differential and Bevel Gear Adjustment, page 4-289.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Dial indicator
None
None
Equipment Condition
Differential and bevel gear disassembled.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Differential and bevel gear disassembly,
page 4-276.
Work must be done on suitable surface.
Adjustment of differential and bevel gear,
page 4-289.
Go on to Sheet 2
4-278
TM 10-3930-641-34-2
(Sheet 2 of 11)
DIFFERENTIAL AND BEVEL GEAR DISASSEMBLY (CONT)
LOCATION/ITEM
1. Two bearing cups (20) and (25)
2. Inner bearing cone (19)
ACTION
REMARKS
Install in housing (22).
Heat cone to maximum of 2750F (1350C)
and install on pinion shaft (18).
CAUTION
Be sure cone is against shoulder of shaft.
3. Housing (22)
Install over pinion shaft (18).
4. Outer bearing cone (24)
install on pinion shaft.
Heat to maximum of 2750F (1350C) and
5. Washer (26), lock (40), and nut (39)
Install as shown.
6. Pinion shaft (18)
Adjust end play.
See Differential and bevel gear adjustment, page 4-289.
TA099418
Go on to Sheet 3
4-279
TM 10-3930-641-34-2
(Sheet 3 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
Differential Gear Group
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Ring
Tapered Roller Bearing Cone
Tapered Roller Bearing Cup
Capscrew
Washer
Differential Ring Gear
Tapered Roller Bearing Cup
Tapered Roller Bearing Cone
Preformed Packing
Lock Wire
Capscrew
Bearing Lock
Differential Carrier Assembly
Carrier
Bearing Cap
Capscrew
Shim Pack
Bevel Pinion Shaft
Tapered Roller Bearing Cone
Tapered Roller Bearing Cup
Preformed Packing
Bearing Support Housing
Capscrew
Cone
Tapered Roller Bearing Cup
Washer
Pin
Capscrew
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
Retainer
Preformed Packing
Yoke Assembly
Yoke
Guard
Lip Type Seal
Capscrew
Lockwasher
Retainer
Packing Preformed
Bearing Lock Nut
Bearing Nut Lock
Capscrew
TA099419
Go on to Sheet 4
4-280
TM 10-3930-641-34-2
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
(Sheet 4 of 11)
Differential Gear Group
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Differential Bevel Gear
Spider
Washer
Differential Case Assembly
Case Flange Half
Capscrew
Washer
Case Plain Half
Pin
Sleeve Bearing
Differential Bevel Pinion
Washer
TA099420
Go on to Sheet 5
4-281
TM 10-3930-641-34-2
(Sheet 5 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
7.
Guard (33), yoke (32), retainer (29),
preformed packing (30), capscrew
(28)
Install and'adjust (page 4-289).
8.
Lock (40)
When end play is set, bend tab on lock (40)
into notch in nut (39).
9.
Guard (33), yoke (32), packing (30),
retainer (29), capscrew (28)
Remove.
10.
Lip type seal
Install in retainer using suitable seal driver.
NOTE
Install seal with lip toward inside of retainer.
Seal should just contact surface of counterbore
in retainer.
TA099421
Go on to Sheet 6
4-282
TM 10-3930-641-34-2
(Sheet 6 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
11.
Preformed packing between housing
(22) and retainer (37)
Install.
12.
Retainer (37)
Install on housing and secure with capscrews
(35).
13.
Guard (33), yoke (32), packing (30)
retainer (29), capscrew (28)
a. Install.
b. Tighten capscrew (28) to a torque of
265 + 35 lb. ft. (359.3 + 47.5 N-m).
14.
Case flange half (46)
a. Fasten to hoist.
b. Put in position on ring gear (6).
15.
Washers (5), capscrews (4)
a. Coat threads of capscrews and face of
washers with clean oil.
b. Install to secure case to ring gear.
c.
Tighten capscrews to a torque of
350 + 35 lb. ft. (474.5 + 47.5 N-m).
Go on to Sheet 7
4-283
TM 10-3930-641-34-2
(Sheet 7 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
LOCATION/ITEM
16.
Bearing cone (2)
ACTION
REMARKS
a. Heat to maximum of 2750F (1350C).
b. Install on case assembly as shown.
17.
Case (45) and gear (6) assembly
Turn assembly over.
18.
Washer (44)
Install in case (46).
NOTE
Washer oil groove should face upward. Holes
in washer must align with pins in case
assembly.
19.
Gear
Install on washer (44).
20.
Four bearings (51), pinions (52) and
washers (53)
Install on spider (43).
Go on to Sheet 8
4-284
TM 10-3930-641-34-2
(Sheet 8 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
LOCATION/ITEM
21.
Washer (44)
ACTION
REMARKS
a. Put GAA general purpose grease on side
of washer without oil groove.
b. Position washer in case plain half (49)
with oil groove side facing up.
22.
Gear (42)
Install on spider assembly.
23.
Case plain half (49)
Install on case assembly as shown.
NOTE
Be sure mark on housing aligns with mark on
case.
24.
Capscrews (47)
Install to secure housing to case assembly.
Tighten each to a torque of 175 to 225 lb. ft.
(238 to 304 N-m).
25.
Bearing cone (8)
a. Heat to maximum of 2750F (1350C).
b. Install on case plain half (49).
Go on to Sheet 9
4-285
TM 10-3930-641-34-2
(Sheet 9 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
LOCATION/ITEM
26.
Carrier assembly (14)
27. Bearing cap (15), adjusting ring (1)
and bearing cup (3)
ACTION
REMARKS
Position on repair stand as shown.
Install.
CAUTION
Be sure cap is in correct position.
28.
Adjusting ring (1)
Turn ring clockwise five turns. That will
provide for initial bearing preload
adjustment. (See Differential and Bevel
Gear Adjustment, page 4-289.)
29.
Differential assembly
a. Attach hoist.
b. Position in carrier assembly (13) as shown.
NOTE
Be sure tapered roller bearing on differential
is properly seated in bearing cup attached to
carrier.
4-286
TM 10-3930-641-34-2
(Sheet 10 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
30. Bearing cup (7) bearing cap (15),
adjusting ring (1)
Install on upper bearing cone of differential.
31.
Two 3/4-10 NC guide pins
Install in housing (22) side of carrier assembly.
32.
Shims (17)
Install.
CAUTION
Use the exact thickness of shims specified on
the bevel pinion shaft. If incorrect shims are
used, differential cannot be adjusted properly.
33.
Preformed packing (21)
Install in housing (22).
34.
Housing (22) assembly
a. Attach hoist.
b. Using the two guide pins for alignment,
install on carrier assembly.
Go on to Sheet 11
4-287
TM 10-3930-641-34-2
(Sheet 11 of 11)
DIFFERENTIAL AND BEVEL GEAR ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
35.
Capscrews (23) and washers (5)
Install to secure housing (22) to carrier
assembly (13).
36.
Differential and bevel gear
Perform adjustments.
37.
Lock wire (10)
a. Install through bolts that hold bearing
caps in position.
See Adjustment of Differential and Bevel Gear,
page 4-289.
b. Install through lock that holds adjusting
rings in position.
End
4-288
TM 10-3930-641-34-2
DIFFERENTIAL AND BEVEL GEAR ADJUSTMENT(Sheet 1 of 7)
This task covers: Adjustment of differential and bevel gears.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Feeler gage
Shims
Page 2-43
Dial indicator
Equipment Condition
Differential and bevel gears assembled
and installed on vehicle or on stand.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Differential and bevel gears assembly,
see page 4-278.
Tires blocked.
Shipping link removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-289
TM 10-3930-641-34-2
(Sheet 2 of 7)
DIFFERENTIAL AND BEVEL GEAR ADJUSTMENT (CONT)
LOCATION/ITEM
1.
Pinion (6)
ACTION
REMARKS
a. Install in housing (5) complete with
bearings.
b. Install washer (4), lock and locknut (3).
c.
Tighten locknut until play of pinion is
approximately .012 in. (0.30 mm).
2.
Yoke assembly (1)
Install against locknut (3).
3.
Retainer and capscrew (2)
Install and torque to 230 to 300 lb. ft.
(315 to 405 N-m).
4.
Bevel pinion shaft (6)
a. Check end play again.NOTE
b. With yoke, retainer, and capscrew (2)
installed end play is .002 to .005 in.
(0.05 to 0.13 mm).
5.
Differential
If end play is not correct, remove yoke assembly and
adjust nut (3). Then repeat steps 2 thru 4.
Assemble with teeth of the ring gear toward
the TOP. (As shown in illustration).
Go on to Sheet 3
4-290
TM 10-3930-641-34-2
DIFFERENTIAL AND BEVEL GEAR ADJUSTMENT (CONT)(Sheet 3 of 7)
1.
2.
3.
4.
5.
6.
Yoke Assembly
Capscrew
Locknut
Washer
Housing
Bevel Pinion Shaft
Go on to Sheet 4
4-291
TM 10-3930-641-34-2
(Sheet 4 of 7)
DIFFERENTIAL AND BEVEL GEAR ADJUSTMENT (CONT)
LOCATION/ITEM
ACTION
REMARKS
6.
Adjustment ring (8)
Do not tighten.
7.
Adjustment ring (11)
Tighten until the amount of backlash (free
movement) between ring gear (7) and
pinion (6) is .014 + .005 in. (0.36 + 0.13 mm).
8.
Adjustment ring (8)
a. Tighten while turning ring gear (7). Tighten
until a small amount of resistance is needed
to turn ring gear.
b. Install a dial indicator so that the tip of the
indicator is in contact with upper bearing
cap.
c.
Tighten adjustment ring (8) until distance
"A" increases by .018 + .002 in.
(0.46 + 0.05 mm).
TA099426
Go on to Sheet 5
4-292
TM 10-3930-641-34-2
(Sheet 5 of 7)
DIFFERENTIAL AND BEVEL GEAR ADJUSTMENT (CONT)
LOCATION/ITEM
9.
Ring Gear (7)
ACTION
REMARKS
a. Measure the backlash between the pinion
and ring gear. The backlash must be .014
± .005 (0.36 ± 0.13 mm).
b. If the backlash is too much, loosen adjustment ring (8) and tighten adjustment
ring (11) the same amount.
c.
If the backlash is not enough, loosen
adjustment ring (11) and tighten adjustment ring (8) the same amount.
D
if
ferential bearing preload will not change if you
loosen one ring and then tighten the other ring the
same amount.
10.
Capscrews (10)
Lubricate threads and tighten to a torque of
315 to 385 lb. ft. (425 to 515 N-m).
TA099427
Go on to Sheet 6
4-293
TM 10-3930-641-34-2
(Sheet 6 of 7)
DIFFERENTIAL AND BEVEL GEAR ADJUSTMENT (CONT)
LOCATION/ITEM
11.
Tooth contact
ACTION
REMARKS
a. After the backlash and preload adjustments
have been made, the tooth contact between pinion (6) and ring gear (7) must be
checked, as follows:
(1) Put a small amount of Prussian blue,
red lead, or paint on the teeth of
ring gear (7).
(2) Turn pinion (6) in both directions.
(3) The correct area of tooth contact
starts near the inside end of the teeth
of ring gear (7) and goes a maximum
of 50 percent down the length of the
teeth. See Illustration A for the correct area of tooth contact.
b. If the area of tooth contact looks like
Illustration B, use the procedure that follows:
(1) Add some of shims (9).
(2) Do Step 6 thru 10 again.
(3) Do Step 11 again to check the area
of tooth contact.
4-294
TM 10-3930-641-34-2
(Sheet 7 of 7)
DIFFERENTIAL AND BEVEL GEAR ADJUSTMENT (CONT)
LOCATION/ITEM
11.
Tooth contact (Cont.)
ACTION
REMARKS
If the area of tooth contact looks like Illustration C, use the procedure that follows:
a. Remove some of shims (9).
b. Do Steps 6 thru 10 again.
c.
12.
Capscrews (12)
Do Step 11 again to check the area of
tooth contact.
Tighten to a torque of 175 to 225 lb. ft.
(235 to 305 N-m).
4-295
Always make sure the backlash adjustment is
correct before an adjustment is made to the area
of tooth contact. Several adjustments to the
backlash and tooth contact may be necessary to
get the correct adjustments.
TM 10-3930-641-34-2
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY
(Sheet 1 of 9)
This task covers: Disassembly and assembly of the front and rear support.
INITIAL SETUP
Test Equipment
None As required
Materials/Parts
None
Troubleshooting Reference
Equipment Condition
Shipping link installed.
Rear crankcase guard removed.
Drive axles removed.
Special Tools
None
Personnel Required
Two mechanics
References
LO 10-3901-641-12.
General Safety Instructions
Tires blocked.
Crankcase guard removal,
TM 10-3930-641-20.
Drive axle removal/installation, page 4-250.
Shipping link removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
4-296
TM 10-3930-641-34-2
(Sheet 2 of 9)
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Wheels
Block both front wheels to prevent vehicle
movement.
2.
Oil
Drain from plug (16).
3.
Hydraulic jacks
a. Place under vehicle.
See LO 10-3930-641-12.
b. Lift rear of vehicle until jacks just support
vehicle weight (but not so much that tires
are lifted off ground).
c.
Install lock pins in jacks.
4.
Engine oil drain hose
Remove.
5.
Capscrew (24), washers (25) and
cover (26) and gasket
Remove from rear support (35).
6.
Bearing (31)
Remove from rear support (35).
7.
Capscrews (27), washers (29) and
plate (30)Go on to Sheet 3
Remove from rear support (35).
Go on to Sheet 3
4-297
TM 10-3930-641-34-2
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Preformed Packing
Capscrew
Gasket
Bearing Retainer
Washer
Capscrew
Fitting
Front Trunnion Support Assembly
Sleeve Bearing
Front Support
Flat Washer
Hex Nut
Axle Housing Assembly
Spring Pin
Preformed Packing
Plug
Plug
Preformed Packing
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
(Sheet 3 of 9)
Cover
Capscrew
Washer
Pressure Relief Fitting
Pipe Reducing Bushing
Capscrew
Washer
Cover
Capscrew
Plug
Washer
Plate
Thrust Bearing
Rear Trunnion Support Assembly
Sleeve Bearing
Pin
Rear Support
Axle Shaft
4-298
TM 10-3930-641-34-2
(Sheet 4 of 9)
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
8.
Bearing (31)
Remove from rear support (35).
9.
Tube assembly
Remove from grease fitting on rear support.
10.
Capscrews (2), washers (11) and
nuts (12) that secure rear support
(35)
Remove from rear support (35).
CAUTION
Do not remove capscrews (2) that secure front
support (10).
11.
Washers (11) and nuts (12) that
secure front support (10)
Remove from front support (10).
Go on to Sheet 5
4-299
TM 10-3930-641-34-2
(Sheet 5 of 9)
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
12.
Rear support (35)
ACTION
REMARKS
a. Attach to a floor jack.
b. Raise rear of vehicle with the two
hydraulic jacks (See Step 3) until pins in
the top of the support are free of vehicle
frame.
c. Remove rear support.
13.
Preformed packing (1)
Replace.
14.
Bearing (33)
Replace if damaged.
15.
Capscrews (20) and washers (21)
Remove from cover (19).
16.
Cover (19)
a. Attach to floor jack.
b. Use two 7/8-9NC capscrews as
forcing screws to loosen cover.
NOTE
Cover weighs 140 lb. (64 Kg).
c.
17.
Preformed packing (18)
Remove cover from axle housing (13).
Replace.
Go on to Sheet 6
4-300
TM 10-3930-641-34-2
Sheet 6 of 9)
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
18.
Yoke
Remove.
19.
Four capscrews (2) and nuts
Remove from front support (10).
NOTE
Support assembly weighs 225 lb. (102 Kg).
20.
Support assembly (10)
a. Attach to floor jack.
b. Remove.
21.
Preformed packing (1)
Discard.
22. Canscrews (6) and washers (5),
bearing retainer (4)
23.
Remove.
Bearing (9)Remove
Go on to Sheet 7
4-301
TM 10-3930-641-34-2
(Sheet 7 of 9)
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
1.
Preformed packings (1), bearing (9),
and bearing retainer (4)
Install in front support (10). Put a light coat
of grease on packings and bearings.
2.
Front support (10)
a. Attach to floor jack.
b. Place in position on differential as shown.
c.
Install four capscrews (2) and nuts that
secure it.
NOTE
Tighten capscrews to a torque of 750-900 lb.
ft. (1007 to 2118 N-m).
3.
Preformed packing (18)
Install. Grease lightly.
4.
Cover (19)
a. Attach to floor jack.
b. Position against rear axle housing.
c.
Secure with capscrews (20) and washers
(21).
d. Tighten capscrews (20) to a torque of
315-385 lb. ft. (425-525 N-m).
5. Bearing (33)
Replace if damaged. Install in rear support (35).
4-302
TM 10-3930-641-34-2
(Sheet 8 of 9)
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
6.
7.
Preformed packing (1)
Rear support (35)
ACTION
REMARKS
Replace.
a. Attach to floor jack.
b. Position against cover (19).
c.
Lower vehicle so that pins in rear support
engage holes in vehicle frame.
8.
Capscrews (2), washers (11) and nuts a. Install.
(12) that secure rear support.
b. Tighten capscrews to a torque of 750 lb. ft.
(1007 to 1218 N-m).
9.
Capscrews (2), washers (11) and
nuts (12) that secure front support
a. Install.
b. Tighten nuts to a torque of 750-900 lb. ft.
(1007-1218 N-m).
10.
Tube assembly
Connect to grease fitting.
11.
Bearing (31)
Install.
12.
13.
14.
Plate (30)
Capscrews (27) and washers (29)
Bearing (31)
Install.
Install.
Install.
TA099433
Go on to Sheet 9
4-303
TM 10-3930-641-34-2
(Sheet 9 of 9)
FRONT AND REAR SUPPORT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
15.
Gasket and cover (26)
Install.
16.
Capscrews (24) and washers (25)
Install.
17.
Oil drain hose
Install.
18.
Oil
Fill rear differential to correct level with oil.
Refer to LO 10-3930-641-12.
19.
Crankcase guard
Install.
See TM 10-3930-641-20.
20.
Drive axles
Install.
See page 4-250.
End
4-304
TM 10-3930-641-34-2
Section VIII. DRIVE SHAFTS
DRIVE SHAFTS MAINTENANCE INSTRUCTIONS
This section covers maintenance of these drive shaft components for direct support maintenance personnel:
a. Drive shaft
b. Bearing cage adjustment
LIST OF TASKS
(Sheet 1 of 1)
TASK NO.
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Upper drive shaft disassembly/assembly.
4-306
2-42
2
Lower drive shaft disassembly/assembly.
4-308
2-42
3
Bearing cage adjustment.
4-323
2-42
4-305
TM 10-3930-641-34-2
UPPER DRIVE SHAFT DISASSEMBLY/ASSEMBLY
(Sheet 1 of 2)
This task covers: Disassembly and assembly of the upper drive shaft.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-42
Equipment Condition
Drive shaft removed
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Drive shaft removal, TM 10-3930-641-20.
None
Go on to Sheet 2
4-306
TM 10-3930-641-34-2
(Sheet 2 of 2)
UPPER DRIVE SHAFT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Capscrews (6), (8) and washers
(5), (7)
Remove.
2.
Spiders (2)
Remove from tube (4).
3.
Lubrication fittings (3)
Remove from spiders (2).
1.
2.
3.
4.
5.
6.
7.
8.
ASSEMBLY
1.
Lubrication fittings (3)
Install in spiders (2).
2.
Spiders (2)
Position on tube (4).
3.
Capscrews (6), (8) and washers
(5), (7)
Install and tighten to a torque of 90 to 110
lb. ft. (122 to 149 N-m).
4-307
Drive shaft assembly
Spider
Fitting
Tube
Washer
Capscrew
Washer
Capscrew
TM 10-3930-641-34-2
LOWER DRIVE SHAFTS DISASSEMBLY/ASSEMBLY
(Sheet 1 of 15)
This task covers: Disassembly and assembly of drive shafts.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Depth micrometer
(20) seal assemblies
(1) seal
(2) seals
(1) seal
(2) shim packs
(1) shim
(1) shim
Page 2-42
Micrometer
Feeler gage
Special Tools
Personnel Required
None
Two mechanics
Equipment Condition
Drive shafts removed from vehicle.
References
General Safety Instructions
Drive shaft removal, TM10-3930-641-20.
None.
Go on to Sheet 2
4-308
TM 10-3930-641-34-2
(Sheet 2 of 15)
LOWER DRIVE SHAFTS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
LOWER FRONT DRIVE
SHAFT DISASSEMBLY
1.
Front shaft group
Block up shaft.
CAUTION
Put a small block under the shaft group. This
will keep the splined shaft from falling out
of the shaft tube during disassembly.
2.
Three capscrews (23) and washers
(15)
Remove.
3.
Retainer (28)
a.Remove.
b. Inspect for damage (cracks, nicks,
warping).
c. Replace if necessary.
Go on to Sheet 3
4-309
TM 10-3930-641-34-2
DRIVE SHAFTS DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 3 of 15)
Main Drive Shaft Group
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Guard
Spacer
Joint Group
Grease Fitting
Spider and Bearing Assembly
Seal Assembly
Capscrew
Grease Fitting
Hex Nut
Washer
Capscrew
Grease Fitting
Lip Type Seal
Hex Nut
Washer
Bearing Cage
Capscrew
Spherical Roller Bearing
Preformed Packing
Shim
Shim
Bearing Retainer
Capscrew
Yoke Assembly
Guard
Preformed Packing
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Shim Pack
Retainer
Universal Joint Group
Capscrew
Spider and Bearing Assembly
Seal Assembly
Washer
Capscrew
Grease Fitting
Grease Fitting
Capscrew
Universal Joint Group
Capscrew
Spider and Bearing Assembly
Seal Assembly
Grease Fitting
Tube
Change 1 4-310
TM 10-3930-641-34-2
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
(Sheet 4 of 15)
LOCATION/ITEM
ACTION
REMARKS
4.
Shim pack (27)
Remove and discard.
5.
Preformed packing (26)
Remove and discard.
6.
Yoke assembly (24) and dirt guard
(25)
a. Remove.
b. Inspect for cracks, bends, warps, etc.
c. Replace if necessary.
7.
Bearing cage (16)
a. Remove capscrews and nuts.
b. Insert 2 guide bolts.
c. Insert forcing screws and pull cage from
shaft.
d. Use hoist to pull cage from shaft. Weight
of cage is 471 lbs. (213.6 Kg).
TA099436
Go on to Sheet 5
4-311
TM 10-3930-641-34-2
(Sheet 5 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
8.
Six capscrews (23) and washers (15)
Remove.
9.
Bearing cage retainer (22)
a. Remove from bearing cage.
b. Inspect for cracks, dents, and distortion.
c. Replace if necessary.
10.
Shims (21) and (20)
a. Inspect for damage.
b. Remove if necessary, discard.
c. Replace if damaged.
11.
Lip type seal (13)
Remove from retainer and discard.
12.
Bearing (18)
a. Remove from cage.
b. Inspect for cracks, nicks, distortion, and
rough turning action.
c. Replace if necessary.
13.
Preformed packing (19)
Remove from cage and discard.
4-312
Go on to Sheet 6
TM 10-3930-641-34-2
(Sheet 6 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
14.
Guard (1) and spacer (2)
ACTION
REMARKS
a. Remove from shaft (use a soft faced
hammer if necessary).
b. Inspect for cracks, nicks, dents, distortion, etc.
c. Replace if necessary.
15.
Four capscrews (7) (on spider of
front shaft)
16. Spider (5)
Remove.
a. Remove from shaft.
b. Inspect spider for cracks, distortion,
sloppy bearing action, etc.
Replace if necessary.
NOTE
Spider must be replaced as unit.
WARNING
Shaft weighs 90 lbs. (40.8 Kg). Use jack.
TA099437
Go on to Sheet 7
4-313
TM 10-3930-641-34-2
(Sheet 7 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
LOWER MIDDLE DRIVE
SHAFT DISASSEMBLY
ACTION
REMARKS
1.
Four capscrews (30) on front spider
of middle shaft piece
Remove.
2.
Front spider (31)
a. Remove from shaft.
b. Inspect spider for cracks, distortion,
sloppy bearing action, etc.
c. Replace if necessary.
NOTE
Spider must be replaced as unit.
3.
Four capscrews (30) on back spider
of middle shaft piece.
4.
Back spider (31)
a. Remove from shaft.
b. Inspect spider for cracks, distortion,
sloppy bearing action, etc.
Replace if necessary.
NOTE
Spider must be replaced as unit.
WARNING
Shaft's weight is 90 lbs. (40.8 Kg). Use jack.
TA099438
Go on to Sheet 8
4-314
TM 10-3930-641-34-2
(Sheet 8 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
LOWER REAR DRIVE
SHAFT DISASSEMBLY
1.
Four capscrews (39) on front spider
of rear shaft piece
2.
Front spider (40)
ACTION
REMARKS
Remove.
a. Remove from shaft.
b. Inspect spider for cracks, distortion,
sloppy bearing action, etc.
c. Replace if necessary.
NOTE
Spider must be replaced as unit.
3.
Four capscrews (39) on back spider
of rear shaft piece.
4.
Back spider (40)
Remove.
a. Remove from shaft.
b. Inspect spider for cracks, distortion,
sloppy bearing action, etc.
c. Replace if necessary.
NOTE
Spider must be replaced as unit.
NOTE
Shaft's weight is 90 lbs. (40.8 Kg). Use jack.
TA099439
Go on to Sheet 9
4-315
TM 10-3930-641-34-2
(Sheet 9 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
1.
LOCATION/ITEM
LOWER FRONT DRIVE
SHAFT ASSEMBLY
Yoke of front shaft
ACTION
REMARKS
Align spider assembly (5) on yoke.
2.
Four capscrews (7)
Install. Tighten to a torque of 90 to 110 lb. ft.
(122 to 149 N-m).
3.
Guard (1)
Install on splined end of front shaft.
4.
Spacer (2)
Install on splined end of front shaft.
5.
Frontshaft
Block up shaft with splined end pointing up.
6.
Bearing cage (16)
Lay on flat surface with flanged opening
face down.
TA099440
Go on to Sheet 10
4-316
TM 10-3930-641-34-2
(Sheet 10 of 15)
DRIVE SHAFTS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
7.
Seal (13)
ACTION
REMARKS
a. Install in cage using suitable seal driver.
Seal must contact counterbore in cage.
Seal lip must face away from cage.
b. Put GAA Grease on lip of seal.
8.
Bearing (18)
Install in flanged side of cage.
9.
Bearing cage retainer (22)
Align on cage without seal or shims.
10.
Three of six capscrews (23)
a. Install, evenly spaced. Tighten evenly to a
torque of 65 to 85 lb. ft. (88 to 115 N'm).
b. Loosen capscrews.
c. Tighten capscrews again, finger tight only.
TA099441
Go on to Sheet 11
4-317
TM 10-3930-641-34-2
(Sheet 11 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
11. Clearance between retainer (22) and
cage (16)
ACTION
REMARKS
a. Measure clearance with feeier gage.
b. Record this measurement.
12. Bearing cage retainer (22)
Remove from cage.
13. Seal (13)
a. Install in retainer with suitable seal driver.
Seal must contact counterbore in retainer.
Seal lip must face away from retainer.
b. Coat lip of seal with GAA grease.
14. Preformed packing (19)
Install in cage.
15. Shim(s) (21) and (20)
a. Recall clearance measured in Step 11.
b. Add shim(s) to measure .002 in. (0.05
mm) less than clearance in Step 11.
c.
Align shim(s) on cage.
d. Align bearing cage retainer on shim(s).
TA099442
Go on to Sheet 12
4-318
TM 10-3930-641-34-2
(Sheet 12 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
16.
Six capscrews (23) and washers (15)
Install. Tighten evenly to a torque of 65 to
85 lb. ft. (88 to 115 N-m).
17.
Bearing cage assembly (16)
Lower bearing cage onto splined end of front
shaft.
18.
Yoke (24)
Install on top of bearing cage.
19.
Retainer (28)
Align on shaft without seal or shims.
20.
Three capscrews (23)
a. Install without washers. Tighten to a
torque of 50 to 70 lb. (68 to 95 N•m).
b. Remove capscrews and retainer.
21.
Spacing of yoke (24) and splined
shaft
a. Using depth micrometer as shown at
right, measure distance between end of
shaft and inner face of yoke.
b. Record this measurement.
TA099443
Go on to Sheet 13
4-319
TM 10-3930-641-34-2
(Sheet 13 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
22.
Preformed packing (26)
Install in yoke.
23.
Shim(s) (27)
a. Recall thickness measured in Step 21.
b. Install shim(s) to be from .002 to .004
in. (0.05 to 0.11 mm) thinner than the
thickness measured in Step 21.
c.
Place this shim pack on end of front shaft.
Align holes.
24.
Retainer (28)
Place over shim pack. Align holes.
25.
Three capscrews (23) and washers
(15)
Install. Tighten to a torque of 90 to 110 lb. ft.
(122 to 149 N•m).
TA099444
Go on to Sheet 14
4-320
TM 10-3930-641-34-2
(Sheet 14 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
LOWER MIDDLE DRIVE
SHAFT ASSEMBLY
1.
Front yoke of middle shaft and
front spider (31)
Align spider on yoke.
2.
Four capscrews (30)
Install. Tighten to a torque of 90 to 110 lb. ft.
(122 to 149 N•m).
3.
Back yoke of middle shaft and back
spider (31)
Align spider on yoke.
4.
Four capscrews (30)
Install. Tighten to a torque of 90 to 110 lb. ft.
(122 to 149 N•m).
TA099445
Go on to Sheet 15
4-321
TM 10-3930-641-34-2
(Sheet 15 of 15)
DRIVE SHAFTS DISASSEMBLY / ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
LOWER REAR DRIVE
SHAFT ASSEMBLY
1.
Front yoke of rear shaft and front
spider (40)
Align spider on yoke.
2.
Four capscrews (39)
Install. Tighten to a torque of 90 to 110 lb. ft.
(122 to 149 N•m).
3.
Back yoke of rear shaft and back
spider (40)
Align spider on yoke.
4.
Four capscrews (39)
Install. Tighten to a torque of 90 to 110 lb. ft.
(122 to 149 N•m).
TA099446
End
4-322
TM 10-3930-641-34-2
(Sheet 1 of 4)
BEARING CAGE ADJUSTMENT
This task covers: Adjusting the drive shaft bearing cage.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Feeler gage
Shims
Page 2-42
Micrometer
Steel rule
Equipment Condition
None
Engine OFF.
Yoke assembly removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
LO 10-3930-641-12.
Tires blocked.
Drive shaft removal/installation,
TM10-3930-641-20.
Go on to Sheet 2
4-323
TM 10-3930-641-34-2
(Sheet 2 of 4)
BEARING CAGE ADJUSTMENT
LOCATION/ITEM
1.
Seal (7)
ACTION
REMARKS
a. Install in bearing cage (4).
b. Grease seal with a small amount of grease.
c. Put cage (4) in position on frame.
2.
Capscrews (8)
Install, with washers and nuts.
3.
Bearing (6)
Install in cage (4).
4.
Retainer (2)
Put into position on cage (4) without seal (5)
and shims (3).
5.
Capscrews (1)
a. Install three without washers and an equal
distance apart.
b. Tighten evenly to a torque of 65 to 85 lb.
ft. (86 to 114 N-m).
c. Loosen.
d. Tighten again to finger tight.
e. Measure gap between retainer (2) and
cage (4) with a feeler gage. Record the
distance.
TA099447
Go on to Sheet 3
4-324
TM 10-3930-641-34-2
(Sheet 3 of 4)
BEARING CAGE ADJUSTMENT
LOCATION/ITEM
ACTION
REMARKS
6.
Seal (5)
Install in cage (4). Put a small amount of
grease on seal.
7.
Shims (3)
Install enough shims so their thickness is .002.
in. (0.05 mm) less than the gap in Step 5,
Section e.
8.
Retainer (2)
Install with capscrews (1) and washers.
Tighten capscrews (1) to a torque of 65 to
85 lb. ft. (86 to 114 N-m).
9.
Seal (12)
a. Put small amount of grease on the lip.
b. Install.
10.
Yoke assembly (9)
Install on shaft.
11.
Retainer (10)
Install on shaft without seal (11) and shims
(14).
12.
Capscrews (13)
a. Install without washers and tighten to a
torque of 50 to 70 lb. ft. (66 to 94 N-m).
TA099448
Go on to Sheet 4
4-325
TM 10-3930-641-34-2
(Sheet 4 of 4)
BEARING CAGE ADJUSTMENT
LOCATION/ITEM
12.
Capscrews (cont.)
ACTION
REMARKS
b. Remove capscrews.
c.
Measure distance (A). Record distance.
13.
Seal (11)
Install.
14.
Shims (14)
Install enough so that their thickness is .003 +
.001 in. (0.08 + 0.03 mm) less than distance
(A).
15.
Retainer (10)
a. Install using capscrews (13) and washers.
b. Tighten capscrews to a torque of 90 to
110 lb. ft. (121 to 149 N•m).
TA099449
End
4-326
TM 10-3930-641-34-2
CHAPTER 5
BRAKE SYSTEM AND WHEEL BEARING ADJUSTMENT INSTRUCTIONS
Page
Section
I
General .............................................................................5-2
II
Accumulator ......................................................................5-4
Brake Accumulator Removal/Installation............................5-5
Accumulator Disassembly/Assembly..................................5-9
Accumulator Charging Valve Removal/
Disassembly Assembly[Installation ....................................5-14
Accumulator Charging .......................................................5-21
Page
Section V
Wheel Bearing Adjustment ................................................ 5-91
VI
Brake Lines and Fittings .................................................... 5-97
Brake Lines Removal/Installation....................................... 5-98
III Brakes and Control Valves.................................................5-25
Brake Control Valve Group Removal/Installation ...............5-26
Brake Control Valve Disassembly/Assembly......................5-31
Wheel Brake Assemblies Removal/Installation ..................5-38
Wheel and Brake Assemblies Disassembly........................5-44
Wheel and Brake Assemblies Assembly ............................5-51
IV Parking Brake ....................................................................5-60
Parking Brake Control Valve Removal/
Installation .........................................................................5-61
Parking Brake Control Valve Disassemblyl
Assembly...........................................................................5-63
Parking Brake Removal/Installation ...................................5-68
Parking Brake Disassembly ...............................................5-71
Parking Brake Assembly....................................................5-75
Change 1
5-1
TM 10-3930-641-34-2
Section I. GENERAL
BRAKE SYSTEM
1. HYDRAULIC OIL TANK. The storage reservoir for all of the hydraulic oil
used in the machine except for the transmission and torque converter.
An inlet strainer provides filtering when adding or replacing oil to the
tank. Also, a filter is built into the tank for filtering all of the oil returning
from the hydraulic system. Oil is pumped from the tank through the
braking components and re- turned back to the tank.
2. HYDRAULIC OIL LINES. Serve as passages for the pressurized oil to
operate the different braking components.
3. HYDRAULIC PUMP. The hydraulic pump serves two systems, steering
and braking. It is a positive displacement gear type pump driven by the
engine. The smaller section of the pump supplies high pressure oil to
operate the brake system. Oil is pumped from the hydraulic tank to the
accumulator charging valve and distributed to the system.
4. ACCUMULATOR CHARGING VALVE. Distributes flow of oil, from
pump, to brake and hydraulic oil cooler control systems. Contains a
check valve and a pressure relief valve. Check valve keeps pressure in
accumulator in a constant range of 1950 PSI (137.1 kg/cm2) maximum
to 1450 PSI (101.9 kg/cm2) mini- mum. Pressure relief valve controls
maximum oil pressure in accumulator if accumulator charging valve
malfunctions.
5. ACCUMULATOR. Located below the left hand service door. It has a
sealed piston which divides the accumulator into two chambers. The
upper chamber contains dry nitrogen gas. Pumping oil into the lower
chamber moves the piston up compressing the gas. The charging valve
limits the gas compression to 1950 PSI. Pushing either brake pedal
releases the oil under pressure and allows it to activate the brake control
valve.
6. BRAKE CONTROL VALVE. Controls the amount of high pressure oil
from the accumulator to the wheel brakes. Changing the position of
either pedal will increase or decrease the oil pressure at the wheel. As a
brake pedal is applied, oil pressure at each wheel brake is increased,
slowing or stopping the wheel. As the
7.
8.
9.
10.
5-2
(Sheet 1 of 2)
pedal is released the oil pressure at each wheel is released and the oil
is returned to the oil tank.
TRANSMISSION NEUTRALIZER CONTROL VALVE. Controls hydraulic
oil pressure which disengages the transmission as the left brake pedal is
depressed. This provides full engine power to the hydraulic systems as
the vehicle is braking or stopped. The valve is designed so when the
brake pedal is released the transmission engages slightly before the
brakes are released.
SERVICE BRAKES. Oil pressure activated disc-type brakes are at all
four wheels. Operating in the final drive housing oil keeps them cool. As
a brake pedal is applied it allows pressurized oil from the brake control
valve to push a piston against a set of plates and discs. The discs rotate
with the wheel and the plates are stationary. Friction between the plates
and discs slows or stops the turning wheel. Releasing the brake pedal
allows the pressurized oil to return to the oil tank. The friction between
the plates and discs is eliminated and the wheels are permitted to turn
freely.
EMERGENCY AND PARKING BRAKE. Located on the transfer gear
case housing. A disc-type brake with stationary plates and rotating discs.
Spring pressure applies the brake which stops the transfer gear shaft.
The brake is released by oil pressure from the accumulator tank.
NOTE
If, due to a malfunction in accumulator charging circuit, pressure drops
below 700 PSI (49.2 kg/cm2), the emergency brake will automatically
be activated.
EMERGENCY AND PARKING BRAKE CONTROL VALVE. Controls oil
flow to the emergency and parking brake. Valve is normally activated by
the operator. Pulling out on the parking brake control knob releases oil
pressure and activates the brake. Pushing the knob in hydraulically
releases the brake by removing the spring tension holding the plates and
discs together. The parking brake control is on the right side of the
steering column.
Go on to Sheet 2
TM 10-3930-641-34-2
(Sheet 2 of 2)
BRAKE SYSTEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Hydraulic oil tank
Oil lines
Pump
Accumulator control valve with
relief valve
Accumulator
Brake control valve
Transmission neutralizer control
valve
Service brakes
Emergency and parking brake
Emergency and parking brake
control valve
Transmission valve
Left brake pedal
Right brake pedal
Junction block
TA098912
End
5-3
TM 10-3930-641-34-2
Section II. ACCUMULATOR
BRAKE ACCUMULATOR MAINTENANCE INSTRUCTIONS
This section covers maintenance of these brake components for direct support maintenance personnel:
a. Brake accumulator
b. Accumulator charging valve
and also instructions for changing the accumulator
LIST OF TASKS
TASK NO.
TASK
REF (PAGE)
(Sheet 1 of 1)
TROUBLESHOOTING
REF (PAGE)
1
Brake accumulator removal/installation.
5-5
2-59
2
Accumulator disassembly/assembly.
5-9
2-59
3
Accumulator charging valve removal/
disassembly/assembly/installation.
5-14
2-60
4
Accumulator charging
5-21
2-59
End
5-4
TM 10-3930-641-34-2
(Sheet 1 of 4)
BRAKE ACCUMULATOR REMOVAL/INSTALLATION
This task covers: Removal and installation of brake accumulator.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Dry nitrogen gas
Page 2-59
Equipment Condition
Engine cool.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Brake testing, TM 10-3930-641-10
Accumulator charging, page 5-21.
Test brakes before driving.
Relieve all pressure in brake system before
any lines are disconnected from
accumulator.
Go on to Sheet 2
5-5
TM 10-3930-641-34-2
BRAKE ACCUMULATOR REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
REMOVAL
(SHEET 2 of 4)
ACTION
REMARKS
WARNING
Make sure all pressure in brake system is released before any lines are disconnected from
brake accumulator.
1.
Two panels (1)
Remove from left side of machine.
2.
Floor plate above brake accumulator
Open and move away from accumulator.
3.
Charging valve cap nut (2)
a. Remove.
b. Turn valve 1/2 turn to relieve accumulator
pressure.
4.
Three capscrews (3) that secure
Remove.
accumulator bracket at top
5.
Hydraulic line (4)
a. Disconnect from accumulator.
b. Cap or plug opening.
6.
Tube assembly (5)a. Remove.
b. Cap or plug openings.
7.
Three eyebolts
Fasten to bracket at top of accumulator.
TA098913
Go on to Sheet 3
5-6
TM 10-3930-641-34-2
(SHEET 3 of 4)
BRAKE ACCUMULATOR REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
8.
Two capscrews (6) at bottom of
accumulator
Remove.
9.
Clip that secures heater hose on
transmission
Remove.
10.
Hydraulic line (7) on steering and
brake pump
a. Disconnect to allow clearance for removing
accumulator.
b. Cap or plug openings.
11.
Hydraulic line (8) for rear brakes at
brake control valve manifold
a. Disconnect to allow clearance for removing
accumulator.
b. Cap or plug opening.
12.
Brake accumulator (9)
a. Remove.
b. Accumulator is 160 lb. (72 Kg).
c. Accumulator must be moved around
hydraulic lines and other components to
remove.
TA098914
Go on to Sheet 4
5-7
TM 10-3930-641-34-2
(SHEET 4 of 4)
BRAKE ACCUMULATOR REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
2.
3.
Hoist
Holes (10)
Brake accumulator
4.
Two capscrews that secure
accumulator bottom
Three capscrews that secure
accumulator at top
6.
6.
7.
8.
9.
10.
11.
12.
Hydraulic line (4)
Hydraulic line on steering and brake
pump
Hydraulic line for rear brakes at
brake control valve manifold
Clip that secures heater hose on
transmission
Tube assembly (5)
Two panels over left side of machine
Accumulator
Fasten to brake accumulator.
Position as shown.
a. Lower into vehicle.
b. Move some hoses and lines as accumulator
is put into position.
Install.
a. Install.
b. Remove hoist.
Connect to accumulator.
Tighten.
Tighten.
Install.
Install.
Install.
Charge with dry nitrogen gas.
TA098915
See accumulator charging, page 5-21.
End
5-8
TM 10-3930-641-34-2
ACCUMULATOR DISASSEMBLY/ASSEMBLY
This task covers: Repair of brake system pressure accumulator.
(Sheet 1 of 5)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-59
Equipment Condition
Accumulator removed from vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Brake accumulator removal/
installation, page 5-5
Open valve assembly (6)
Slowly to release gas
pressure.
Go on to Sheet 2
5-9
TM 10-3930-641-34-2
(Sheet 2 of 5)
ACCUMULATOR DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Top bracket to hold accumulator in
vehicle.
Remove.
2.
Valve assembly (6)
Open a little at a time to release nitrogen gas
pressure slowly.
3.
Tube assembly (21)
Disconnect at manifold.
4.
Manifold (2)
Remove.
5.
Seal in manifold
Remove.
6.
Capscrews (20) and lockwasher (3)
Remove.
7.
Tube assembly (21)
Remove.
8.
Capscrews (17) and lockwashers (3)
Remove.
9.
Cover assembly (18)
Remove.
10.
Capscrews (13)
Remove.
Go on to Sheet 3
5-10
TM 10-3930-641-34-2
ACCUMULATOR DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
(Sheet 3 of 5)
Accumulator assembly
Manifold
ockwasher
Capscrew
Washer
Valve assembly
Valve core
Cap
Warning plate
Accumulator assembly
Piston
Seal assembly
Capscrew
Head
Preformed packing
Back up ring
Capscrew
Cover assembly
Rectangular seal
Capscrew
Tube assembly
TA098916
Go on to Sheet 4
5-11
TM 10-3930-641-34-2
(Sheet 4 of 5)
ACCUMULATOR DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
11.
Head (14)
Remove.
12.
Preformed packing (15) and
backup ring (16)
Remove from head.
13.
Piston (11)
Remove using a slide hammer puller.
14.
Seal assemblies (12)
Remove from piston.
ASSEMBLY
NOTE
Be sure inside of accumulator and all parts
are clean.
1. Seal assemblies (12)
Install.
2. Piston (11)
Put in position in accumulator.
NOTE
Be sure threaded hole in piston is toward
HEAD end of accumulator.
3.
Piston (11)
Push into bottom of accumulator using a slide
hammer puller.
4.
Preformed packing (15) and
back-up ring (16)
Install on head (14).
Go on to Sheet 5
5-12
TM 10-3930-641-34-2
ACCUMULATOR DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
5.
Head assembly (14)
6. Capscrews (13)
(Sheet 5 of 5)
ACTION
REMARKS
Install two 7/8 NC guide pins in accumulator.
Put hydraulic oil on seals and put head
assembly (14) in position.
Install.
NOTE
Tighten head capscrews (13) to a torque of
675 lb. ft. to 725 lb. ft. (915 N•m to 983 N•m).
7.
Cover assembly (18)
Install.
8.
Manifold (2)
Install.
9.
Tube assembly (21)
Install.
10.
Top bracket that holds accumulator
in vehicle
Install.
End
5-13
ACCUMULATOR CHARGING VALVE REMOVAL/DISASSEMBLY/ASSEMBLY/INSTALLATION
This task covers: Removal, disassembly, assembly and installation of accumulator charging valve.
TM 10-3930-641-34-2
Sheet 1 of 7)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Preformed packing
page 2-60
Equipment Condition
Engine OFF
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Brake valve group removal/
installation, page 5-26.
Housing (5) is under tension from springs
behind it. Do not remove all housing
capscrews at once.
Go on to Sheet 2
5-14
TM 10-3930-641-34-2
(Sheet 2 of 7)
ACCUMULATOR CHARGING VALUE REMOVAL/DISASSEMBLY/ASSEMBLY/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
2.
Brake control valve group
Remove.
Tube assembly (2)
a. Disconnect from manifold on bottom of
accumulator charging valve.
b. Cap or plug openings.
3.
Tube assembly (1)
4.
Three capscrews (3) that secure
accumulator charging valve to plate
assembly
5. Accumulator charging valve (4)
a. Disconnect at tee fitting.
b. Cap or plug openings.
Remove.
Remove from plate assembly.
DISASSEMBLY
1.
Capscrews (6)
WARNING
Housing (5) is under tension from springs
behind it. Do not remove all housing capscrews at once.
a. Remove except for two.
b. Install longer capscrews or two 3/8-16
NC forcing screws with nuts in body.
Do not force screws too far into housing.
c.
Remove two remaining capscrews.
TA098917
Go on to Sheet 3
5-15
TM 10-3930-641-34-2
(Sheet 3 of 7)
ACCUMULATOR CHARGING VALUE REMOVAL/DISASSEMBLY/ASSEMBLY/INSTALLATION (CONT)
LOCATION/ITEM
1.
Capscrews (6) (Cont)
screws
ACTION
REMARKS
d. Loosen longer capscrews or forcing
evenly to relieve spring tension.
e. Housing (5) must be approximately
3.5 in. (8.9 cm) from body to release
tension.
2.
Housing, two springs (7) and
stem (8)
a. Remove from body.
b. Remove plug from stem (8).
3.
Shims
Remove from housing.
4.
Capscrews that secure body
group (9)
Remove.
5.
Body group (9),retainer (10) and
spring (12)
Remove from body.
6.
Shims
Remove from retainer (10).
7. Spacer (11) and spring (13)
Remove from body.
8.
Retainer (14),capscrews (15) and
washers
Remove from body.
9.
Charging valve stem
Remove from body.
TA098918
Go on to Sheet 4
5-16
TM 10-3930-641-34-2
(Sheet 4 of 7)
ACCUMULATOR CHARGING VALUE REMOVAL/DISASSEMBLY/ASSEMBLY/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
10.
Capscrews that secure retainer (20)
Remove.
11.
Retainer preformed packing
Remove.
12.
Shims (16)
Remove from retainer.
13.
Spring (17),rod (18),and valve (19)
Remove from body group.
14.
Plug (22)
a. Remove.
REMARKS
b. Discard seal.
15.
Piston (23)
Remove from body group.
16.
Seat (21)
Discard.
17.
Plug (26)
a. Remove.
b. Discard preformed packing.
18.
Spring (25) and valve (24)
Remove from body.
TA098919
Go on to Sheet 5
5-17
TM 10-3930-641-34-2
(Sheet 5 of 7)
ACCUMULATOR CHARGING VALUE REMOVAL/DISASSEMBLY/ASSEMBLY/INSTALLATION (CONT)
LOCATION/ITEM
ASSEMBLY
1.
Stem (1)
ACTION
REMARKS
NOTE
Make sure all parts of accumulator charging
valve are clean. Lubricate all parts of valve
with clean hydraulic oil.
a. Install plug.
b. Tighten plug to a torque of 18-22 lb. ft.
(24-30 N-m).
2.
Stem (1) and stem (2)
Install in valve body.
3.
Valve (3),spring (4) and plug (5)
a. Install in valve body.
b. Tighten plug to a torque of 47-53 lb. ft.
(64-72 N-m).
4.
Spring (6) and spacer (7)
Install in valve body.
5.
Washer (10),balls (11),retainer (12)
and spring (13)
Install in valve body.
6.
Shims (8)
Install on retainer (9).
7.
Retainer (9)
Install in valve body.
TA098920
Go on to Sheet 6
5-18
TM 10-3930-641-34-2
(Sheet 6 of 7)
ACCUMULATOR CHARGING VALUE REMOVAL/DISASSEMBLY/ASSEMBLY/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
8.
Seat (21)
Replace.
9.
Piston (15) and plug (14)
a. Install in body group.
b. Tighten plug to a torque of 47-53 lb. ft.
(64-72 N-m).
10.
Valve (20),rod (19) and spring (18)
Install in body group.
11.
Shims (17)
Install in retainer (16).
12.
Retainer
Install on body group.
13.
Body group
Position on valve body and fasten with
capscrews.
TA098921
Go on to Sheet 7
5-19
TM 10-3930-641-34-2
(Sheet 7 of 7)
ACCUMULATOR CHARGING VALUE REMOVAL/DISASSEMBLY/ASSEMBLY/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
14.
Shims (23)
Install in housing (22).
16.
Springs (24) and (26)
Slide into housing.
16.
Housing (22)
a. Position on valve body.
REMARKS
b. Install longer capscrews or two 3/8"16 NC forcing screws. Tighten until
original capscrews can be installed.
c.
Secure with capscrews.
INSTALLATION
1.
Accumulator charging valve (26)
a. Position on plate assembly.
b. Secure with three capscrews.
2.
Tube assembly (27)
Connect to manifold on bottom of
accumulator charging valve.
3.
Tube assembly from fitting on body
group of accumulator charging
valve to tee fitting
Install.
4.
Brake control valve group
Install. See page 5-26.
TA098922
End
5-20
TM 10-3930-641-34-2
ACCUMULATOR CHARGING
(Sheet 1 of 4)
This task covers: Charging the brake accumulator.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Nitrogen charging equipment
Source of dry nitrogen
Page 2-59
Equipment Condition
Engine OFF.
Accumulator may be either in or out of
vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Accumulator removal/installation, page 5-5.
Proceed with caution at all times when
using pressurized gas.
Be sure hoses are firmly attached to valve
connections.
Go on to Sheet 2
5-21
TM 10-3930-641-34-2
(Sheet 2 of 4)
ACCUMULATOR CHARGING (CONT)
LOCATION/ITEM
ACTION
REMARKS
WARNING
Proceed with caution at all times when using
pressurized gas.
1.
Cap
Remove from accumulator valve assembly.
2
Chuck (8)
Install on accumulator valve (see Sheet 4).
3.
Accumulator valve
Open.
4.
Gage (5)
Use to check the nitrogen pressure in accumulators.
NOTE
Check ambient temperature and use chart at
right to determine true pressure in accumulator.
5. Valve (7)
Turn clockwise to end of travel. Check
ambient temperature and gage (5) pressure.
Use chart at right to determine actual accumulator pressure.
CHARGING PRESSURE AND TEMPERATURE
RELATIONSHIP FOR THE ACCUMULATOR
Ambient
Temperature
800 psi (5500 kPa) Pressure*
°F
°C
psi
kPa
20
-7
725
5000
30
-1
740
5105
40
4
755
5235
50
10
770
5340
60
16
785
5420
70
21
800
5500
80
27
815
5605
90
32
830
5735
100
38
845
5840
110
43
860
5920
120
49
875
6000
*+ 10 psi (70 kPa) allowable tolerance on normal pressure.
Every 100F (12.20C) equals 15 psi (105 kPa) change.
TA098923
Go on to Sheet 3
5-22
TM 10-3930-641-34-2
(Sheet 3 of 4)
ACCUMULATOR CHARGING (CONT)
LOCATION/ITEM
6.
Connection (2)
ACTION
REMARKS
Attach to nitrogen tanks.
WARNING
Be sure hose is firmly attached to valve (4).
7.
Valve (4)
Close.
8.
Valve on nitrogen tank
Open.
9.
Adjustment screw (6) on regulator
Turn until gage (1) reads 800 psi.
NOTE
Be sure to adjust for ambient temperature,
using chart on sheet 2.
10.
Valve (4)
Open slowly. Leave valve open and charge
accumulator until gage (5) reads 800 psi.
NOTE
Correct pressure of nitrogen charge in accumulator is
800 psi (5500 kPa) at 70°F (21°C).
TA098924
Go on to Sheet 4
5-23
TM 10-3930-641-34-2
(Sheet 4 of 4)
ACCUMULATOR CHARGING (CONT)
LOCATION/ITEM
ACTION
REMARKS
11.
Valve (4)
Close. Check adjusted pressure on gage (5).
12.
Valve (4)
Be certain valve is closed.
13.
Valve on nitrogen tank
Close.
14.
Valve (7)
Turn counterclockwise to end of travel.
15.
Accumulator valve
Close.
16.
Chuck (8)
Remove.
NOTE
Open and close valve (4) at least two more times to be
certain you have charged the accumulator to the correct adjusted pressure.
CAUTION
A low nitrogen charge can cause early pump
failure because of short cycle times between
the cut-in and cut-out operations of the accumulator charging valve.
End
5-24
TM 10-3930-641-34-2
Section III. BRAKES AND CONTROL VALVES
BRAKE MAINTENANCE INSTRUCTIONS
This section covers maintenance of these brake components for direct support maintenance personnel:
a.
Brake control valve group
b.
Wheel brake assemblies
c.
Brake control valve
LIST OF TASKS
TASK NO.
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Brake control valve group removal/installation.
5-26
2-60
2
Brake control valve disassembly/assembly
5-31
2-60
3
Wheel brake assemblies removal/installation.
5-38
2-59
4
Wheel and brake assemblies disassembly
5-44
2-59
5
Wheel and brake assemblies assembly
5-51
2-59
5-25
TM 10-3930-641-34-2
BRAKE CONTROL VALVE GROUP REMOVAL/INSTALLATION
(Sheet 1 of 5)
This task covers: Removal and installation of brake control valve group.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Brake control valve group
Page 2-60
Equipment Condition
Brake pressure relieved.
Engine OFF.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Shipping Link Removal/
Installation, TM 10-3930-641-20
Make sure all pressure in brake system
is released before any lines are disconnected.
Go on to Sheet 2
5-26
TM 10-3930-641-34-2
(Sheet 2 of 5)
BRAKE CONTROL VALUE GROUP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMOVAL
REMARKS
NOTE
Valves for brake system can be removed
separately or as a unit.
1.
Door assembly over brake control
valve group.
Open.
WARNING
2.
Two clips (2) from plate assembly
3.
Wire harness (3)
Make sure all pressure in brake system is released before any lines are disconnected.
Remove.
a. Disconnect at low brake pressure switch,
stop light switch and parking brake switch.
b. Tag wires for identification later.
CAUTION
Put identification on all hydraulic lines for correct installation of lines for brake control valve
group. Cap or plug all openings and lines to
keep dirt out of the system.
4.
Line (1)
Disconnect from manifold.
5.
6.
Tube assembly (4) and line (5)
Two brake control cables (6)
Disconnect from neutralizer valve.
a. Remove cotter pin and clevis pin.
b. Disconnect from levers.
NOTE
It may be necessary to press the brake pedal
to allow removal of the clevis pin.
c.
Disconnect from mounting bracket.
TA098925
Go on to Sheet 3
5-27
TM 10-3930-641-34-2
(Sheet 3 of 5)
BRAKE CONTROL VALUE GROUP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
7.
Tube assembly (7)
Disconnect from manifold.
8.
Oil inlet line (9) and oil outlet line
(8)
Disconnect from accumulator charging valve.
9.
Tube assembly (10) and line (11)
Disconnect from parking brake valve.
10.
Left side access panel
Remove.
11.
Brake accumulator
Relieve pressure:
a. Remove valve nut.
b. Turn valve 1/2 turn to allow pressure to
escape.
12.
Line (12)
Disconnect from brake accumulator.
13.
Tube assemblies (13)
Remove.
14.
Parking brake cable (14)
a. Remove cotter pin and clevis pin to disconnect from parking brake valve.
b. Remove from bracket.
TA098926
Go on to Sheet 4
5-28
TM 10-3930-641-34-2
(Sheet 4 of 5)
BRAKE CONTROL VALUE GROUP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
15.
Hoist
Fasten to brake control valve group.
16.
Brake control valve mounting
capscrews
Remove.
17.
Brake control valve group (15)
a. Remove from vehicle.
b. Group is 160 lb. (73 Kg).
INSTALLATION
1.
Hoist
a. Fasten to brake control valve group.
b. Lower unit until cable assembly can be
connected to parking brake valve.
c. Lower unit into position and secure with
four capscrews.
CAUTION
Make sure all hydraulic lines and tube assemblies can be moved into position at brake
control valve group.
TA098927
Go on to Sheet 5
5-29
TM 10-3930-641-34-2
(Sheet 5 of 5)
BRAKE CONTROL VALUE GROUP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
2.
Tube assembly (4) and line (5)
Connect to neutralizer valve.
3.
Line (1) for rear brakes
Connect to manifold.
4.
Tube assembly (7) for front brakes
Connect to manifold.
5.
Line (12)
Connect to brake accumulator.
6
.Left guard panel
Install.
7.
Tube assembly (10) and line (11)
Connect to parking brake valve.
8.
Two cable assemblies (6) for brakes
Connect to two levers and plate assembly.
9.
Oil inlet line (9) and oil
outlet line (8)
Connect to accumulator charging valve.
10.
Wire harness (3)
a. Connect to sending units under brake control valve and on upper manifold.
b. Position on plate assembly and secure with
clips.
11.
Brake accumulator
Charge with dry nitrogen gas.
See page 5-21.
12.
All valves and cable assemblies in
brake control valve group
Adjust.
See TM 10-3930-641-20
End
5-30
TM 10-3930-641-34-2
BRAKE CONTROL VALVE DISASSEMBLY/ASSEMBLY
(Sheet 1 of 7)
This task covers: Disassembly and assembly of brake control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-60
Equipment Condition
Brake control valve group removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Brake control valve group removal/
installation, page 5-26
None
Go on to Sheet 2
5-31
TM 10-3930-641-34-2
(Sheet 2 of 7)
BRAKE CONTROL VALUE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
DISASSEMBLY
ACTION
REMARKS
1.
Tube assemblies (1 and 2)
Disconnect from manifolds on brake
control valve.
2.
Tube assembly (3)
Disconnect from upper manifold on
brake control valve.
3.
Tube assembly (4)
Remove.
4.
Brake control valve
5.
Capscrews (13) and washers (14)
that secure brake control valve
Remove cotter pin and clevis pin (5) from
cable assembly.
Remove. See sheet 3 for art.
6.
Capscrews (27) that secure upper
and lower manifold
Remove. See sheet 3 for art.
7.
Manifolds (6 and 7)
Remove.
TA098928
Go on to Sheet 3
5-32
TM 10-3930-641-34-2
(Sheet 3 of 7)
BRAKE CONTROL VALUE DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5
6
7
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26
27.
28
Capscrew
Lockwasher
Plug
Packing
Cover
Spring
Orifice
Packing
Packing
Piston
Spring
Retainer
Capscrew
Washer
Retainer
Spring
Spring
Seal
Retainer
Packing
Stem
Retainer
Nut
Shim
Capscrew
Flange
Capscrew
Washer
29.
30.
31.
32.
33.
Valve group
Packing
Plug
Packing
Plug
TA098929
Go on to Sheet 4
5-33
TM 10-3930-641-34-2
(Sheet 4 of 7)
BRAKE CONTROL VALUE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
8.
Four capscrews (13) washers (14),
and retainer (19)
Remove from valve group.
9.
Shims (24)
Remove from retainer (19).
10.
Nut (23),retainer (22) and valve
stem (21)
Remove from retainer (19).
11.
Packing (20)
Replace.
12.
Seal (18)
Remove from retainer (19).
13.
Springs (16) and (17)
Remove from valve body.
14.
Retainer (15)
Remove from valve body.
15.
Four capscrews (1),washers (2)
that secure cover (5)
Remove.
16.
Cover (5)
Remove.
17.
Piston (10)
Remove from cover (5).
REMARKS
Go on to Sheet 5
5-34
TM 10-3930-641-34-2
(Sheet 5 of 7)
BRAKE CONTROL VALUE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
18.
Spring (6),orifice (7) and
packing (8)
Remove from cover (5).
19.
Spring (11),retainer (12),stem (29),
packing (9)
Remove.
ASSEMBLY
REMARKS
NOTE
Be sure all parts are clean and coated with
fresh hydraulic oil before assembly.
1.
Stem (29),retainer (12) and
spring (11)
Install in valve body (29).
2.
Piston (10)
Install in cover (5).
3.
Spring (6),orifice (7) and
packing (8)
Install in cover (5).
4
Cover (5),and packing (9)
a. Position on valve body.
b. Secure with four capscrews (1),and
lockwashers (2).
5
Retainer (15),large spring (16) and
small spring (17)
Install in valve body.
Go on to Sheet 6
5-35
TM 10-3930-641-34-2
(Sheet 6 of 7)
BRAKE CONTROL VALUE DISSAMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
6.
Lip type seal (18)
ACTION
REMARKS
Install on retainer (19) with suitable driver.
NOTE
Lip of seal must face inside of retainer.
7.
Valve stem (21)
Install in retainer (19).
8.
Retainer (22)
Install on valve stem (21).
9.
Nut (23)
Install on valve stem and tighten to a torque
32-38 lb. ft. (44-52 N-m).
10.
Shims (24)
Install.
11
Packing (20)
Replace.
12.
Retainer (19),four capscrews (13),
and washers (14)
Install on valve body.
13.
Upper and lower manifolds
(6 and 7)
Install on brake control valve.
See sheet 2 for art.
Go on to Sheet 7
5-36
TM 10-3930-641-34-2
(Sheet 7 of 7)
BRAKE CONTROL VALUE DISSAMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
14.
Brake control valve
Position on plate and secure with capscrews.
15.
Tube assembly (4)
Connect to manifold.
16.
Stem of control valve
Position in rod end and install clevis pin and
cotter pin (5).
17.
Tube assembly (3)
Connect to upper manifold.
18.
Tube assemblies (1 and 2)
Install.
19.
Brake control valve group
Install.
See page 5-26.
End
5-37
TM 10-3930-641-34-2
(Sheet 1 of 6)
WHEEL BRAKE ASSEMBLIES REMOVAL/INSTALLATION
This task covers: Removal and installation of wheel brake assemblies.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-59
Equipment Condition
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Shipping link installation/removal,
TM 10-3930-641-20
None
Tire and rim removal/installation,
pages 5-80 and 5-82.
Crankcase guard removal/installation,
TM 10-3930-641-20
Go on to Sheet 2
5-38
TM 10-3930-641-34-2
(Sheet 2 of 6)
WHEEL BRAKE ASSEMBLIES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
See TM 10-3930-641-20
See page 4-254
1.
Crankcase guards
Remove.
2.
Final drive planet carriers
Remove.
NOTE
Removal procedures for front and back assemblies are basically the same. The only difference is in the tooling used to lift the vehicle.
3.
Parking brake
Engage.
4.
Wood blocks
Place in front of front tires.
5.
Lifting rear of machine
a. Put jacks under rear main frame as shown.
b. Lift machine until tires are off floor.
6.
Lift front of machine
a. Put wood block behind rear tires.
See Remove Tires and rims, Page 5-80.
b. Put jacks under front main frame.
c.
Lift machine until tires are off floor.
TA098930
Go on to Sheet 3
5-39
TM 10-3930-641-34-2
(Sheet 3 of 6)
WHEEL BRAKE ASSEMBLIES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
7.
Nuts (1) and washers
Remove those holding tire and rim to wheel
assembly.
8.
Tire and rim
a. Remove using lift truck.
b. Put forks under tire (2) and rim.
c.
Fasten chain to tire and rim and remove
(3000 lb.-1361 Kg.).
TA098931
Go on to Sheet 4
5-40
TM 10-3930-641-34-2
(Sheet 4 of 6)
WHEEL BRAKE ASSEMBLIES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
10.
Tube assembly (4)
ACTION
REMARKS
Remove.
11. Brake oil supply tube assembly (5)
Disconnect.
12. Wheel and wheel brake assembly
a. Fasten hoist to wheel assembly and
wheel brake assembly.
b. Remove nuts (3) and washers that hold
unit in place.
13.
Wheel and wheel brake assembly
Remove as a unit (6) (1500 Ib.-680.4 Kg.).
TA098932
Go on to Sheet 5
5-41
TM 10-3930-641-34-2
(Sheet 5 of 6)
WHEEL BRAKE ASSEMBLIES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
Wheel assembly and wheel brake
assembly
Fasten hoist to assemblies. Put unit (1) into
position on axle housing. Make sure brake
tube assemblies aline with each other.
2.
Washers and nuts
Install.
3.
Brake supply tube assembly
Install tube assembly to remove air (bleed)
from brake system.
4.
Tire (2) and rim
a. Install on wheel assembly with a lift truck.
b. Install nuts and washers holding unit in
place. Tighten nuts to a torque of
315-385 lb. ft. (425-515 N-).
TA098933
Go on to Sheet 6
5-42
TM 10-3930-641-34-2
(Sheet 6 of 6)
WHEEL BRAKE ASSEMBLIES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
5.
Lower machine to floor
Use hydraulic jacks.
6.
Final drive planet carriers
Install.
See page 4-254.
7.
Crankcase guards
Install.
See TM 10-3930-641-20.
End
5-43
TM 10-3930-641-34-2
(Sheet 1 of 7)
WHEEL AND BRAKE ASSEMBLIES DISASSEMBLY
This task covers: Disassembly of wheel and brake assemblies.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
Page 2-59
Equipment Condition
Wheel brake assemblies removed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Wheel brake assemblies removal/
Installation, page 5-38.
None
Go on to Sheet 2
5-44
TM 10-3930-641-34-2
(Sheet 2 0f 7)
WHEEL AND BRAKE ASSEMBLIES DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
1.
Wheel and brake assemblies
Position as unit on large end of spindle (1).
2.
Capscrews (48), ring (47) and shims
(46)
Remove from small end of spindle (1).
3.
Hub assembly (28)
a. Fasten to hoist as shown.
b. Remove from spindle (1).
NOTE
Hub assembly weighs 100 lb. (45.4 kg).
4.
Bearing (42) and bushing (30)
Remove from hub (29).
5.
Wheel assembly (34)
a. Fasten to hoist as shown.
b. Remove from spindle (1).
NOTE
Wheel assembly weighs 590 lb. (267.6 kg).
TA09834
Go on to Sheet 3
5-45
TM 10-3930-641-34-2
(Sheet 3 of 7)
WHEEL AND BRAKE ASSEMBLY DISASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Wheel spindle
Outer plate
Friction disc
Preformed packing
Pin
Capscrew
Washer
Brake disc housing
Preformed packing
Piston
D-ring packing
D-ring packing
Duo cone seal group
Toric sealing ring
Ring seal
Tapered roller bearing cup
Tapered roller bearing cone
Plug
Preformed packing
Spring guide
Pin
Piston return spring
Brake piston housing
Preformed packing
Capscrew
Sleeve
Capscrew
Hub assembly
Intermediate gear hub
Bushing
Hex nut
Washer
Preformed packing
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
Wheel assembly
Stud
Wheel
Stud
Dowel
Preformed packing
Plug
Tapered roller bearing cup
Tapered roller bearing cone
Retainer
Nut lock
Capscrew
Shim
Ring
Capscrew
Spacer
Ring gear
Cover
Preformed packing
Plug
Lockwasher
Capscrew
Preformed packing
Plate
Capscrew
Retaining ring
Planet shaft
Planet carrier
Washer
Roller bearing assembly
Spacer
Planet gear
TA098935
Go on to sheet 4
5-46
TM 10-3930-641-34-2
(Sheet 40f 7)
WHEEL AND BRAKE ASSEMBLIES DISASSEMBLY (CONT)
LOCATION/ITEM
6.
Duo-cone seals (13)
ACTION
REMARKS
a. Remove from wheel assembly.
b. Put identification on seals for correct
installation later.
7.
Two bearing cups (41)
Remove from wheel assembly (34).
8.
Capscrews (48) that hold brake to
spindle
Remove.
9.
Capscrews that hold housing (23)
to housing (8)
Remove.
10.
Brake line (tube assembly)
Remove.
11.
Housing assembly (23)
a. Fasten to hoist.
b. Remove from spindle (1).
NOTE
Housing weighs 180 lb. (81.6 kg).
Go on to Sheet 5
5-47
TM 10-3930-641-34-2
(Sheet 5 0f 7)
WHEEL AND BRAKE ASSEMBLIES DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
12.
Six plugs (18) and preformed
packings (19)
Remove from housing (23).
13.
Housing assembly (23)
Turn over and put on wood blocks.
14.
Six guides (20), pins (21), return
springs (22)
a. Install a 2" x .75" (50.8 mm long x
19.1 mm dia.) piece of bar stock in
guide bore.
b. Install valve compressor around bore.
c.
Compress spring (22) until pin (21) can be
removed.
d. Remove valve compressor.
e. Remove guide (20) and spring (22) from
guide bore.
TA098936
Go on to Sheet 6
5-48
TM 10-3930-641-34-2
(Sheet 6 0f 7)
WHEEL AND BRAKE ASSEMBLIES DISASSEMBLY (CONT)
LOCATION/ITEM
15.
Piston (10)
ACTION
REMARKS
a. Install three 3/8"-16 NC forcing
screws in piston (10).
b. Tighten screws evenly until piston is
loose in housing.
c.
Remove piston.
NOTE
Piston weighs 49 lb. (22 kg).
16.
Preformed packings (11) and (12)
Replace.
17.
Eight capscrews (25) and sleeve (26)
Remove from housing.
18.
Preformed packing (24)
Remove and discard.
19.
Bearing (17) and spacer (49)
Remove from spindle (1).
Go on to Sheet 7
5-49
TM 10-3930-641-34-2
(Sheet 70f 7)
WHEEL AND BRAKE ASSEMBLIES DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
20.
Eight plates (2) and seven discs (3)
Remove from housing (8)
21.
Housing (8)
a. Fasten to hoist.
REMARKS
b. Remove from spindle.
NOTE
Housing weighs 144 lb. (65.3 kg).
22.
Preformed packing (4)
Remove and discard.
End
5-50
TM 10-3930-641-34-2
(Sheet 1 of 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY
This task covers: Assembly of wheel and brake assemblies.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-59
Equipment Condition
Wheel brake assemblies removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Wheel brake assemblies removal/
installation, Page 5-38.
None
Wheel bearing adjustment, page 5-91.
Go on to Sheet 2
5-51
TM 10-3930-641-34-2
(Sheet 2 0f 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
LOCATION/ITEM
1.
Bearing (42)
ACTION
REMARKS
a. Heat to maximum temperature of 275°F
(135°C).
b. Install on hub (29).
NOTE
Be sure bearing contacts shoulder of hub.
2.
Hub (29)
Turn over.
3.
Bushing (30)
a. Lower temperature of bushing.
b. Install in hub (29).
NOTE
Be sure edge of bushing lies flush or below.
top of bushing bore.
Go on to Sheet 3
5-52
TM 10-3930-641-34-2
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28
29.
30.
31.
32.
33.
Wheel spindle
Outer plate
friction disc
Preformed packing
Pin
Capscrew
Washer
Brake disc housing
Preformed packing
Piston
Preformed packing
Preformed packing
Duo cone seal group
Toric sealing ring
Ring seal
Tapered roller bearing cup
Tapered roller bearing cone
Plug
Preformed packing
Spring guide
Pin
Piston return spring
Brake piston housing
Preformed packing
Capscrew
Sleeve
Capscrew
.Hub assembly
Intermediate gear hub
Bushing
Hex nut
Washer
Preformed packing
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
46.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56
57.
58.
59.
60.
61.
62.
63.
64.
65.
(Sheet 3 of 9)
Wheel assembly
Stud
Wheel
Stud
Dowel
Preformed packing
Plug
Tapered roller bearing cup
Tapered roller bearing cone
Retainer
Nut lock
Capscrew
Shim
Ring
Capscrew
Spacer
Ring gear
Cover
Preformed packing
Plug
Lockwasher
Capscrew
Preformed packing
Plate
Capscrew
Retaining ring
Planet shaft
Planet carrier
Washer
Roller bearing assembly
Spacer
Planet gear
TA098937
Go on to sheet 4
5-53
TM 10-3930-641-34-2
(Sheet 4 of 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
4.
Wheel assembly (34)
Turn over.
5.
Bearing cup (16)
Lower temperature of cup and install in wheel
assembly (34).
NOTE
Be sure bottom of cup is flush with counterbore in assembly.
6.
Hub assembly (28)
Fasten to repair stand as shown.
7.
Wheel assembly (34)
a. Fasten to hoist.
b. Position over hub assembly.
TA098938
Go on to Sheet 5
5-54
TM 10-3930-641-34-2
(Sheet 5 0f 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
LOCATION/ITEM
8.
Preformed packing (12)
ACTION
REMARKS
a. Install in sleeve (26).
b. Coat with clean oil.
9.
Sleeve (26)
a. Install.
b. Secure with eight capscrews (25).
10.
Preformed packing (11)
a. Install in piston (10).
b. Coat with clean oil.
11.
Piston (10)
Install.
NOTE
Using soft faced hammer, tap piston to be
sure it is completely installed in housing.
12.
Spring (22)
Slide over guide (20).
Go on to Sheet 6
5-55
TM 10-3930-641-34-2
(Sheet 6 0f 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
LOCATION/ITEM
13.
Each spring (22) and guide (20)
ACTION
REMARKS
a. Install in housing (23).
b. Using a valve compressor and piece of bar
stock 2" long x .75" dia. (50.8 mm x
19.1 mm), compress guide until pin (21)
can be installed.
14.
Preformed packing (24)
Install in housing (23).
15.
Housing (23)
Turn over.
16.
Six plugs (18)
Install.
17.
Duo-cone seals (13)
a. Thoroughly clean and dry all seals and seal
contact surfaces in housing (23) and wheel
assembly (34).
b. Coat seals with clean. SAE 30 oil.
c. Using suitable tooling install seal in
housing (23).
TA098939
Go on to Sheet 7
5-56
TM 10-3930-641-34-2
(Sheet 7 of 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
d. Use same tool to install seal in wheel
assembly (34).
18.
Brake housing (23)
a. Fasten to hoist.
b. Put in position on wheel assembly (34).
NOTE
Do not damage Duo-Cone seals when brake
housing is put into position.
19.
Eight plates (2) and seven discs (3)
Install.
NOTE
Start with a plate and end with a plate.
20,
Two 1/2-13 NC x 10 guide pins
Install in housing (23).
Go on to Sheet 8
5-57
TM 10-3930-641-34-2
(Sheet 8 of 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
LOCATION/ITEM
21.
ACTION
REMARKS
Housing (16)
a. Fasten to hoist.
b.
Lower housing over guide pins, plates and
discs.
NOTE
Be sure tabs in plates engage with grooves in
housing.
22.
Two guide pins
Remove from housing (23).
23.
Two capscrews that secure housing
(8) to housing (23)
Install.
24.
Spacer (49) and bearing (17)
Install on spindle.
Go on to Sheet 9
5-58
TM 10-3930-641-34-2
(Sheet 9 of 9)
WHEEL AND BRAKE ASSEMBLIES ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
25.
Preformed packing (4)
Install on spindle (1).
'26.
Spindle (1)
a. Fasten to hoist.
REMARKS
b. Lower into position in wheel and brake
assembly.
27.
Capscrews (6) that secure
spindle (1) to housing (8)
Install.
28.
Ring (47) and six capscrews (48)
Install.
29.
Wheel and brake assemblies
a. Fasten to hoist.
b. Remove from repair stand.
30.
Wheel bearings
Adjust.
See page 5-91.
End
5-59
TM 10-3930-641-34-2
Section IV. PARKING BRAKE:
PARKING BRAKE MAINTENANCE INSTRUCTIONS
This section covers maintenance of these brake components for direct support maintenance personnel:
a. Parking brake control valve
b. Parking brake
LIST OF TASKS
TASK NO
(Sheet 1 of 1)
TROUBLESHOOTING
REF (PAGE)
TASK
REF (PAGE)
1
Parking brake control valve removal
installation.
5-61
2-62
2
Parking brake control valve disassembly
assembly.
5-63
2-62
3
Parking brake removal/installation.
5-68
2-63
4
Parking brake disassembly.
5-71
2-63
5
Parking brake assembly.
5-75
2-63
5-60
TM 10-3930-641-34-2
PARKING BRAKE CONTROL VALVE REMOVAL/INSTALLATION
(Sheet 1 of 2)
This task covers: Removal/installation of parking brake control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-62
Equipment Condition
Brake control valve group removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Brake control valve group removal/
installation, page 5-26.
None
Go on to Sheet 2
5-61
TM 10-3930-641-34-2
(Sheet 2 of 2)
PARKING BRAKE CONTROL VALVE REMOVAL/INSTRUCTION
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Brake control valve group
Remove.
See page 5-26.
2.
Cotter pin and clevis pin (1)
a. Remove.
b. Disconnect parking brake linkage from
control valve.
3.
Brake lines (2, 3 and 4)
a. Disconnect from control valve.
b. Cap or plug opening.
4.
Capscrews (5)
a. Remove.
b. Remove control valve from bracket.
INSTALLATION
1.
Parking brake control valve
Position on bracket.
2.
Capscrews (5)
Install to secure control valve.
3.
Brake lines (2, 3.and 4)
Connect.
4.
Parking brake linkage
a. Position on control valve.
b. Secure with cotter pin and clevis pin (1).
5.
Brake control valve group
Install.
See page 5-26.
TA098940
END
5-62
TM 10-3930-641-34-2
(Sheet 1 of 5)
PARKING BRAKE CONTROL VALVE DISASSEMBLY/ASSEMBLY
This task covers: Disassembly/assembly of parking brake control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-62
Equipment Condition
Brake control valve group removed.
Parking brake control valve removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Brake control valve group removal/
installation, page 5-26.
None
Go on to Sheet 2
5-63
TM 10-3930-641-34-2
(Sheet2 of 5)
PARKING BRAKE CONTROL VALVE DISASSEMBLY/ASSEMBLY(CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1. Three capscrews that secure parking
brake valve to bracket
Remove.
2.
Parking brake valve
Remove from bracket.
3.
Switch and adapter
Remove from parking brake valve.
4.
Nut and eye
Remove from valve stem (10).
5.
Two capscrews (1)
Remove.
6.
Cover (3) and body (9)
Remove.
7.
Teflon seal (7) and preformed
packing (8) behind it
Remove and discard.
8.
Preformed packings (5) and (4)
Remove and discard
9.
Stem (10) and cover (17)
Remove.
10. Plug (12) and preformed packing
Remove from end of stem (10)
Go on to Sheet 3
5-64
TM 10-3930-641-34-2
PARKING BRAKE CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
(Sheet 3 of 5)
Capscrew
Lockwasher
Cover
Preformed packing
Preformed packing
Valve group
Teflon seal
Preformed packing
Body
Stem
Preformed packing
Plug
Tube
Snap ring
Seal
Preformed packing
Cover
Packing
Plug
TA098941
Go on to sheet 4
5-65
TM 10-3930-641-34-2
(Sheet 4 of 5)
PARKING BRAKE CONTROL VALVE DISASSEMBLY/ASSEMBLY(CONT)
LOCATION/ITEM
ACTION
11.
Snap ring (14) and seal (15)
Remove from cover.
12.
Preformed packing (16) in cover
Remove and discard.
13.
Plug (19), spring and plunger
Remove from cover.
14.
Preformed packing (18) on plug
Remove and discard.
ASSEMBLY
REMARKS
NOTE
Be sure all parts of parking brake valve are
clean. Lubricate all parts with clean hydraulic
oil.
1.
Preformed packing (16) inside of
cover (17)
Replace.
2.
Lip type seal (15)
Install in cover with tooling until seal contacts
counterbore. Lip is toward inside of cover.
3.
Snap ring (14)
Install over seal.
Go on to Sheet 5
5-66
TM 10-3930-641-34-2
(Sheet 5 of 5)
PARKING BRAKE CONTROL VALVE DISASSEMBLY/ASSEMBLY(CONT)
LOCATION/ITEM
ACTION
4.
Preformed packing (8) and teflon
seal (7)
Install in valve body (9).
5.
Preformed packing (5)
Install.
6.
Plug (12) and seal (11)
a. Install in end of stem (10).
REMARKS
b. Tighten plug to a torque of 7-11 lb. ft.
(9-15 N-m).
7.
Stem (10)
Install in cover (17).
8.
Valve body (9) and cover (3)
a. Position on cover (17).
b. Secure with two capscrews.
9.
Switch and adapter
Install on parking brake valve.
10.
Locknut and eye
Install on stem.
11.
Plunger, spring and plug (19)
Install in cover.
12.
Parking brake valve
a. Position on bracket.
b. Secure with capscrews.
13.
Brake valve and bracket
a. Position on plate assembly.
b. Secure with nuts.
End
5-67
TM 10-3930-641-34-2
PARKING BRAKE REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal of parking brake.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
Page 2-63
Equipment Condition
Transmission and transfer gears removed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Transmission and transfer assembly
removal/installation, pages 4-43 and 4-56.
Block wheels.
Go on to Sheet 2
5-68
TM 10-3930-641-34-2
(Sheet 2 of 3)
PARKING BRAKE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Transmission and transfer gears
Remove.
See page 4-43.
NOTE
It is necessary to remove the transmission and
transfer gears for the removal of the parking
brake.
2.
Parking brake guard
Remove.
3.
Capscrews (1) securing parking brake
to transfer gear case
Remove.
4.
Parking brake (2)
Fasten hoist and remove. Parking brake weighs
200 lb. (91 Kg).
5.
Preformed packing in parking
brake cage
Replace if damaged.
TA098942
Go on to Sheet 3
5-69
TM 10-3930-641-34-2
(Sheet3 of 3)
PARKING BRAKE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
Parking brake (2)
Fasten hoist and put in position on transfer
gear case.
2.
Capscrews (1) securing parking
brake to transfer gear case
Install.
3. Transmission and transfer gears
Install.
See page 4-56.
END
5-70
TM 10-3930-641-34-2
(Sheet 1 of 4)
PARKING BRAKE DISASSEMBLY
This task covers: Disassembly of parking brake components.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
Page 2-63.
Equipment Condition
Parking brake removed from vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Removal of parking brake, page 5-68
Remove housing capscrews slowly and
evenly to release spring tension.
Go on to Sheet 2
5-71
TM 10-3930-641-34-2
(Sheet 2 of 4)
PARKING BRAKE DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
1.
Parking brake
a. Remove.
b. Place on two wood blocks.
See page 5-68.
2.
Six capscrews (2), washers and
plate (6)
Remove from housing assembly (15).
3.
3/8-16 NC forged eyebolt
Install in piston (32).
4.
Piston (32)
Pull out of bore in housing assembly.
5.
Spring (31) and preformed
packing (33)
Remove from bore.
6.
Other two pistons, springs, and
preformed packings
Remove from housing assembly.
7.
Spacer (10)
Remove from housing assembly.
WARNING
Remove capscrews (28) slowly and evenly to
release tension from springs behind housing
assembly (15).
8.
Housing assembly (15)
Remove from parking brake.
NOTE
Mark top side of parking brake.
Go on to Sheet 3
5-72
TM 10-3930-641-34-2
PARKING BRAKE DISASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
(Sheet 3 of 4)
Washer
Capscrew
Screw
Warning plate
Capscrew
Retaining plate
Capscrew
Retainer
Preformed packing
Spacer
Spring
Ball
Bleeder screw
Grease fitting
Housing assembly
Pressure plate
Brake disc assembly
Clutch plate
Hub
Bearing cage
Preformed packing
Brake shaft
Lip type seal
Ball bearing
Retaining ring
Capscrew
Capscrew
Capscrew
Plug
Preformed packing
Spring
Piston
Preformed packing
TA098943
Go on to Sheet 4
5-73
TM 10-3930-641-34-2
(Sheet 4 of 4)
PARKING BRAKE DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
9.
Springs (11)
Remove from plate.
10.
Plate (16)
Remove.
11.
Three plates (18) and four disc
assemblies (17)
Remove.
12.
Capscrew (7) and retainer (8)
Remove from shaft.
13.
Hub (19)
Remove from shaft.
14.
Shaft (22)
Remove from bottom side of cage (20).
15.
Seal (23), ring (25), and
bearing (24)
Remove from cage (20).
End
5-74
TM10-3930-641-34-2
PARKING BRAKE ASSEMBLY
This task covers: Assembly of parking brake.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-63
Wooden blocks
Equipment Condition
Parking brake disassembled;
components clean and dry.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Parking brake disassembly, page 5-71
None
Go on to Sheet 2
5-75
TM10-3930-641-34-2
PARKING BRAKE ASSEMBLY (CONT)
(Sheet 2 of 4)
1.
LOCATION/ITEM
Parking brake cage (20)
ACTION
Place on two wood blocks.
REMARKS
2.
Bearing (24)
Install in cage (20) until it makes contact with
counterbore.
3.
Ring (25)
Install ring that holds bearing in position.
4.
Lip type seal (23)
a.
Install in cage.
b. Install seal until it makes contact with
counterbore and with lip as shown.
5. Shaft (22) Install from bottom of cage.
8.
6.
Hub (19)
Install over shaft.
7.
Preformed packing (9)
Install in end of shaft.
Retainer (8)
Install capscrew that holds it. Tighten to a
torque of 80-90 lb. ft. (109-121 N-m).
9. Four disc assemblies (17) and
three plates (18)
Install. Start with disc assembly and alternate
a plate with a disc.
TA098944
Go on to Sheet 3
5-76
TM10-3930-641-34-2
PARKING BRAKE ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
(Sheet 3 of 4)
Washer
Capscrew
Screw
Warning plate
Capscrew
Retaining plate
Capscrew
Retainer
Preformed packing
Spacer
Spring
Ball
Bleeder screw
Grease fitting
Housing assembly
Pressure plate
Brake disc assembly
Clutch plate
Hub
Bearing cage
Preformed packing
Brake shaft
Lip type seal
Ball bearing
Retaining ring
Capscrew
Capscrew
Capscrew
Plug
Preformed packing
Spring
Piston
Preformed packing
TA098945
Go on to Sheet 4
5-77
TM10-3930-641-34-2
PARKING BRAKE ASSEMBLY (CONT)
(Sheet 4 of 4)
LOCATION/ITEM
ACTION
REMARKS
10. Large plate (16) and springs (11)
Install.
11. Housing assembly (15)
Install with capscrews (28) and washers (1).
12. Preformed packing (33)
Install in bores of housing assembly (15).
13. Spring (31) and piston (32)
Install.
14. Remaining two pistons, springs and
preformed packing
15. Plate (6)
Install in bores of housing assembly.
a. Install on housing assembly.
b. Secure with capscrews (2).
16.
Parking brake
Install.
See page 5-68.
End
5-78
TM10-3930-641-34-2
(Pages 5-79 through 5-90 rescinded.)
Section V. WHEEL BEARING ADJUSTMENT|
WHEEL BEARINGS ADJUSTMENT
This task covers: Adjusting the wheel bearings both on and off the vehicle.
(Sheet 1 of 6)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Micrometer
Shims
Page 2-59.
Depth micrometer
Equipment Condition
Wheel assembly either on or off the
vehicle.
Shipping link installed
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Wheel brake assemblies removal/
installation, page 5-38.
Tires blocked.
Go on to Sheet 2
Change 1 5-91
TM10-3930-641-34-2
WHEEL BEARINGS ADJUSTMENT (CONT)
(Sheet 2 of6)
LOCATION/ITEM
ACTION
REMARKS
NOTE
ADJUSTMENT PROCEDURE
(OFF THE VEHICLE)
These adjustments start with sections of the
equipment off the vehicle.
1.
Spindle housing (7)
Place on a support with small end up.
2.
Brake group (6), bearings, wheel
assembly (1), and hub (5)
Assemble on spindle housing (7).
3.
Ring (3)
Install without shims (4).
4.
Capscrews (2)
Install five so that there are even spaces
between them.
5.
Wheel assembly (1)
to 55 to 75 lb.
While turning by hand torque capscrews (2)
ft. (76 to 104 N-m).
6.
Capscrews (2) and ring (3)
Remove.
7.
Distance between end of spindle
housing (7) and hub (5).
Measure at three different locations and find
the average.
To find average add the three distances and divide the
sum by three.
Go on to Sheet 3
5-92
TM 10-3930-641-34-2
WHEEL BEARINGS ADJUSTMENT (CONT)
(Sheet 3 of 6)
TA098951
Go on to Sheet 4
5-93
TM 10-3930-641-34-2
WHEEL BEARINGS ADJUSTMENT (CONT)
(Sheet 4 of 6)
LOCATION/ITEM
ACTION
REMARKS
8.
Shims (4)
Install enough so that the thickness is .005 in.
(0.13 mm) less than the distance in step no. 7.
9.
Ring (3)
a. Install with capscrews (2).
b. Tighten capscrews evenly to a torque of
180 to 220 lb. ft. (245 to 305 N-m).
NOTE
ADJUSTMENT PROCEDURE
(ON THE VEHICLE)
These adjustments start with sections of the
equipment on the vehicle.
1.
Wheel assembly (1) and bearings Put on spindle housing (7).
2.
Hub (5) and ring gear (8)
Install.
3.
Ring (3) without shims
Install.
4.
Two capscrews
a. Install so that they are opposite each other.
b. While turning wheel by hand, tighten
evenly to a torque of 35 to 45 lb. ft.
(48 to 62 N·m).
Go on to Sheet 5
5-94
TM 10-3930-641-34-2
WHEEL BEARINGS ADJUSTMENT (CONT)
LOCATION/ITEM
(Sheet 5 of 6)
ACTION
REMARKS
5.
Depth micrometer (9)
Measure through the small holes in ring (3).
Find the average depth.
6.
Outside micrometer (10)
a. Measure through the small holes in ring (3).
Find the average depth.
Average depth equals the sum of the three
measurements divided by three.
b. Find the difference of the two average
measurements. The difference is the gap
between the end of the spindle housing
(7) and the ring (3).
7.
Ring (3)
Remove. Install enough shims (4) to be .001 in.
(0.03 mm) less than the gap found in step 6.
8.
Ring (3) and capscrews (2)
Install. Tighten capscrews evenly to a torque of
180 to 220 lb. ft. (245 to 295 N-m).
Go on to Sheet 6
5-95
TM 10-3930-641-34-2
WHEEL BEARINGS ADJUSTMENT (CONT)
(Sheet 6 of 6)
TA098952
End
5-96
TM 10-3930-641-34-2
Section VI. BRAKE LINES AND FITTINGS
BRAKE LINES MAINTENANCE INSTRUCTIONS
This section covers maintenance of brake lines and parking brake lines for direct support and general support maintenance personnel.
LIST OF TASKS
(Sheet 1 of 1)
TASK NO.
1
TASK
REF (PAGE)
Brake lines removal/installation.
5-98
5-97
TROUBLESHOOTING
REF (PAGE)
2-59
TM 10-3930-641-34-2
BRAKE LINES REMOVAL/INSTALLATION
This task covers: Removal/installation of brake lines.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Containers to catch oil
Page 2-59
Equipment Condition
Engine OFF
Wheels blocked
System cooled
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
None
Allow system to cool.
Hot oil causes burns.
Go on to Sheet 2
5-98
TM 10-3930-641-34-2
BRAKE LINES REMOVAL/INSTALLATION (CONT)
(Sheet 2 of 4)
5-99
TM 10-3930-641-34-2
BRAKE LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 4)
ACTION
REMOVAL
REMARKS
NOTE
NOTE
Cap or plug openings as lines are removed. Tag
to identify location.
See page 5-99 for illustration.
See TM 10-3930-641-20.
1.
Transmission
Drain.
2.
Capscrews and washers
Remove at both ends of line.
3.
Preformed packing
Remove and discard.
NOTE
Some of the hoses and tubing have brackets
and clips supporting them. Remove capscrews,
washers and nuts and remove.
4.
Tube fittings
Disconnect and remove line.
Go on to Sheet 4
5-100
TM 10-3930-641-34-2
BRAKE LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 4 of 4)
ACTION
REMARKS
INSTALLATION
1.
Metal tube lines
Install new preformed packing. Reconnect
fittings.
2.
Preformed packings in hose
flanges
Use new preformed packings. Coat with oil and
place into flange.
3.
Flanges
Place into position and secure with capscrews
and washers.
NOTE
If any brackets or clips were removed, reinstall
in the correct location.
End
5-101
TM 10-3930-641-34-2
CHAPTER 6
STEERING SYSTEM MAINTENANCE INSTRUCTION
Page
Section I
General ..........................................................................
6-2
II
Steering Components....................................................
Neutralizer Valve Removal/Installation..........................
Neutralizer Valve Disassembly/Assembly .....................
Hand Metering Unit Removal/Installation ......................
Hand Metering Unit Disassembly/Assembly..................
Steering Control Valve Removal/Installation .................
Steering Control Valve Disassembly/Assembly.............
Articulated Hitch Disassembly/Assembly ......................
Hydraulic (Steering and Brake) Pump
Removal/Installation ......................................................
Hydraulic (Steering and Brake) Pump
Disassembly/Assembly..................................................
Supplemental Steering Pump
Removal/Installation ......................................................
Supplemental Steering Pump
Disassembly/Assembly..................................................
Steering Cylinders Removal/Installation ........................
Steering Cylinders Disassembly/Assembly ..................
Steering Lines Removal/Installation ..............................
Supplemental Steering Lines
Removal/Installation .....................................................
Tee Test Procedure for Steering System ......................
6-6
6-7
6-10
6-14
6-18
6-24
6-28
6-36
6-52
6-61
6-71
6-74
6-79
6-85
6-91
6-94
6-97
6-1
TM 10-3930-641-34-2
Section I. GENERAL
STEERING SYSTEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
(Sheet 1 of 4)
Hydraulic oil tank
Hydraulic oil lines
Hydraulic pump
Filter
Steering control valve
Steering cylinders
Steering wheel and column
Hand metering unit
Neutralizer valves
TA098953
Go on to Sheet 2
6-2
TM 10-3930-641-34-2
STEERING SYSTEM (CONT)
(Sheet 2 of 4)
Steering system can be divided into two groups: steering group and
supplemental steering group.
1.
2.
3.
4.
5.
STEERING CONTROL VALVE. Directs high pressure oil to the front
of one cylinder and to the rear of the opposite cylinder. Direction of the
steering wheel will determine which cylinder is pressurized in the front
or rear. The control valve is hydraulically activated by the hand
metering unit.
6.
STEERING CYLINDERS (2). Are activated by the high pressure oil
from the control valve. A left turn will cause the left cylinder to shorten
and the right cylinder to lengthen. The changing lengths of these
cylinder causes the vehicle to turn.
HYDRAULIC OIL LINES. Serves as passages for the pressurized oil
to operate the different steering components.
7.
HYDRAULIC PUMP. The hydraulic pump serves two systems, steering
and braking. A positive displacement gear type pump driven by the
engine. The larger section of the pump supplies high pressure oil to
operate the steering system. The oil is drawn from the oil tank and
pumped through the steering system and returned to the tank.
STEERING WHEEL AND COLUMN. Adjustable to eight different
positions. Seven of the positions are for operator comfort, while the
eighth and most forward is for storing and locking the wheel when not in
use. Pushing the wheel into the store position also moves the
transmission control lever to NEUTRAL.
8.
HAND METERING UNIT (HMU). Attached to the steering wheel with a
shaft. It is a small hydraulic pump which meters and directs oil into the
steering control valve as the wheel is turned.
FILTER. Protects the system in the event of a pump failure. It is a
replaceable screen type.
9.
NEUTRALIZER VALVES (2). Stops the flow of pilot oil to the steering
control valve at the end of a complete turn in either direction. This
stops the steering action before the machine turns against the frame
stops. The valves are normally open, allowing flow through them.
HYDRAULIC OIL TANK. The storage reservoir for all of the hydraulic
oil used in the machine except for the transmission and torque
converter. An inlet strainer provides filtering when adding or replacing
oil to the tank. Also, a filter is built into the tank for filtering all of the oil
returning from the hydraulic system. Oil is pumped from the tank
through the steering components and re- turned back to the tank.
Go on to Sheet 3
6-3
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING SYSTEM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
(Sheet 3 of 4)
Hydraulic pump (large
section is primary
steering pump)
Flow switch
Left neutralizer valve
Hand metering unit
(HMU)
Right neutralizer valve
Steering control valve
Hydraulic tank
Left steering cylinder
Filter
Supplemental steering
pump
Diverter valve
Right steering cylinder
Go on to Sheet 4
6-4
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING SYSTEM (CONT)
(Sheet 4 of 4)
11. DIVERTER VALVE. Senses the pressure and controls the flow direction
of the oil from the primary and supplemental pumps.
The supplemental steering system has two purposes:
To give an oil supply for the steering system if there is a failure of the
primary system or if the engine stops when the machine is moving.
12. FLOW SWITCH. Electrically operates an instrument light to warn the
operator the primary pump system has failed.
To add oil to the primary oil flow when the engine rpm is less than 1170 to
1300 rpm and the machine is moving.
10. SUPPLEMENTAL STEERING PUMP. A ground driven, gear type
pump. Ground driven means that the pump turns as long as the
machine moves. The pump gets its power from the output transfer
gears of the transmission. Its function is to supply oil to the steering
system when there is a failure of the primary pump or when the engine
stops and the machine is still moving. It also adds oil to the primary oil
flow when the engine is turning at less than 1170 to 1300 rpm and the
machine is moving. The oil sup- ply is from the same tank as the
primary pump.
End
6-5
TM 10-3930-641-34-2
Section II. STEERING COMPONENTS
STEERING MAINTENANCE INSTRUCTIONS
This section covers maintenance of these steering components for direct support and general support maintenance personnel:
a.
b.
Neutralizer valve
Hand metering unit
c.
d.
Steering control valve
Articulated hitch
e.
f.
Steering and brake pump
Steering cylinders
LIST OF TASKS
(Sheet 1 of 1)
TASK NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TASK
REF (PAGE)
Neutralizer valve removal/installation.
Neutralizer valve disassembly/assembly.
Hand metering unit removal/installation.
Hand metering unit disassembly/assembly.
Steering control valve removal/installation.
Steering control valve disassembly/assembly.
Articulated hitch disassembly/assembly.
Hydraulic (steering and brake) pump removal/
installation.
Hydraulic (steering and brake) pump
disassembly/assembly.
Supplemental steering pump removal/installation.
Supplemental steering pump disassembly/assembly.
Steering cylinders removal/installation.
Steering cylinders disassembly/assembly.
Steering lines removal/installation.
Supplemental steering lines removal/installation.
Tee test procedures for steering system.
6-6
TROUBLESHOOTING
REF (PAGE)
6-7
6-10
6-14
6-18
6-24
6-28
6-36
2-55
2-55
2-53
2-53
2-54
2-53
None
6-52
2-54
6-61
6-71
6-74
6-79
6-85
6-91
6-94
6-97
2-54
None
None
2-56
2-56
2-53
2-53
2-56
TM 10-3930-641-34-2
NEUTRALIZER VALVE REMOVAL/INSTALLATION
This task covers: Replacement of neutralizer valve.
(Sheet 1 of 3)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Tags
Page 2-55
Equipment Condition
Pressure relieved on hydraulic system.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Shipping Link
Removal/Installation,
TM 10-3930-641-20
Tires blocked.
Go on to Sheet 2
6-7
TM10-3930-641-34-2
NEUTRALIZER VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 3)
ACTION
REMOVAL
REMARKS
NOTE
Right side neutralizer valve has two lines at
drain port. Left side neutralizer valve has one
line at drain port.
1.
Oil outlet line (1)
Tag and disconnect.
2.
Oil inlet line (2)
Tag and disconnect.
3.
Lines (3) and (6) on drain port
(right side only)
Tag and disconnect.
4.
Four capscrews (4) that hold
neutralizer valve (5) in position
Remove.
5.
Neutralizer valve (5)
Remove.
TA098956
End
6-8
TM10-3930-641-34-2
NEUTRALIZER VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
REMARKS
INSTALLATION
1.
Neutralizer valve (6)
Place in position on bracket and install capscrew (4).
2.
Lines (3) and (6) (right side only)
Connect to drain port.
3.
Oil inlet line (2)
Connect.
4.
Oil outlet line (1)
Connect.
5.
Striker (7)
Adjust.
See TM10-3930-641-20
TA098956
End
6-9
TM 10-3930-641-34-2
NEUTRALIZER VALVE DISASSEMBLY/ASSEMBLY
This task covers: Repair of neutralizer valve.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
Page 2-55
Equipment Condition
Neutralizer valve removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Neutralizer Valve Removal/Installation,
page 6-7
Put parts in a clean area.
Go on to Sheet 2
6-10
TM 10-3930-641-34-2
NEUTRALIZER VALVE DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
(Sheet 2 of 4)
Plug Assembly
Preformed Packing
Spring
Ball
Plug
Preformed Packing
Spring
Valve Group
Capscrew
Lockwasher
Washer
Valve Body
Lip Type Seal
Valve Stem
Boot
TA098957
Go on to Sheet 3
6-11
TM 10-3930-641-34-2
NEUTRALIZER VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 3 of 4)
ACTION
REMARKS
DISASSEMBLY
1.
Plug assembly (1)
Remove from body (12).
2.
Spring (3)
Remove.
3.
Ball (4)
Remove.
4.
Preformed packing (2)
Remove from plug assembly (1).
5.
Boot (15)
Remove.
6.
Plug (S)
Remove.
7.
Preformed packing (6)
Remove from plug assembly (5).
8.
Spring (7)
Remove from body (12).
9.
Stem (14)
Remove.
10. Lip seal (13)
Remove from body (12).
Go on to Sheet 4
6-12
TM 10-3930-641-34-2
NEUTRALIZER VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 4)
ACTION
REMARKS
ASSEMBLY
1.
Lip seal (13)
Install using a seal driver.
NOTE
Install seal until it makes contact with counterbore in body. Lip of seal must be toward inside
of body.
2.
Stem (14)
Install in body.
3.
Spring (7)
Install.
4.
Plug (5)
Install.
5.
Boot (15)
Install.
6.
Ball (4)
Install.
7.
Spring (3)
Install.
8.
Plug assembly (1) and preformed Install.
packing (2)
End
6-13
TM 10-3930-641-34-2
HAND METERING UNIT REMOVAL/INSTALLATION
This task covers: Replacement of hand metering unit.
(Sheet 1 of 4)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Tags.
Page 2-53
Equipment Condition
Pressure relieved from hydraulic system.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Shipping Link
Removal/Installation,
TM 10-3930-641-20
Tires blocked.
Go on to Sheet 2
6-14
TM 10-3930-641-34-2
(Sheet 2 of 4)
HAND MEETING UNIT REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Plates (1) and (2)
Remove.
2.
Detent block (3)
a. Remove by removing four detent block
capscrews and washers.
Remove shims.
b.
3.
4.
Nuts (5)
a. Remove outer nuts.
b.
Loosen inner nuts to end of threads.
c.
Slide pins (4) out.
Four hydraulic lines (6)
Disconnect and identify.
TA098958
Go on to Sheet 3
6-15
TM 10-3930-641-34-2
(Sheet 3 of 4)
HAND METERING UNIT REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
5.
Four capscrews (7)
Remove.
6.
Hand metering unit (8)
Remove.
REMARKS
INSTALLATION
1.
Hand metering unit (8)
Place in position.
NOTE
Engage splines of drive with shaft assembly.
2.
Four capscrews (7)
Install.
3.
Four hydraulic lines (2)
Connect.
TA098959
Go on to Sheet 4
6-16
TM 10-3930-641-34-2
(Sheet 4 of 4)
HAND METERING UNIT REMOVAL/INSTALLATION ( CONT)
LOCATION/ITEM
ACTION
REMARKS
4.
Pins (4)
washers.
Install in steering column with nuts (4) and
5.
Detent block (3)
a. Install shims.
b.
6.
Plates (1) and (2)
Install four capscrews and washers.
Install.
END
6-17
TM 10-3930-641-34-2
HAND METERING UNIT DISASSEMBLY/ASSEMBLY
(Sheet 1 of 6)
This task covers: Repair of hand metering unit.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-53
None
Troubleshooting Reference
Equipment Condition
Hand metering unit removed from
steering column.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Hand Metering Unit Removal/Installation,
page 6-14
Release hydraulic oil pressure.
Go on to Sheet 2
6-18
TM 10-3930-641-34-2
(Sheet 2 of 6)
HAND METERING UNIT DISASSEMBLY/ASSEBLY (C0NT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Retaining ring (4)
Remove from body assembly.
2.
Bushing (6)
Remove from body assembly.
3.
Seals (5) and (7)
Remove from bushing (2).
4.
Two races (1) and bearing (2)
Remove from body.
5.
Preformed packing seal (3)
Remove from body.
6.
Seven capscrews (16)
Remove.
7.
Cap (17)
Remove.
8.
Gerotor assembly (15)
Remove.
9.
Spacer (14)
Remove.
10.
Spacer (12)
Remove.
11.
Drive (13)
Remove.
Go on to Sheet 3
6-19
TM 10-3930-641-34-2
(Sheet 3 of 6)
HAND METERING UNIT DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Race
Needle Thrust Bearing
Preformed Packing
Internal Retaining Ring
Lip Type Seal
Seal Gland Bushing
Quad Ring Seal
Body Assembly
Centering Springs
Pin
Preformed Packing
Spacer
Control End Drive (Spool)
Spacer
Gerotor Assembly
Capscrew
Cap
Check Ball Retainer (Clip)
Ball
Preformed Packing
Seat (Sleeve)
Preformed Packing
Socket Set Screw
TA098960
Go on to Sheet 4
6-20
TM 10-3930-641-34-2
(Sheet 4 of 6 )
HAND METERING UNIT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
12.
Sleeve and spool assembly
Remove.
13.
Pin (10)
Remove from sleeve and spool assembly.
14.
Spool (13)
Remove from sleeve.
15.
Six springs (9)
Remove from spool (13).
16.
Hydraulic connection
Remove from right port of body assembly.
17.
Clip (18) and ball (19)
Remove from right port.
Go on to Sheet 5
6-21
TM 10-3930-641-34-2
(Sheet 5 of 6 )
HAND METERING UNIT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
Ball (19) and clip (18)
Install in body assembly.
2.
Hydraulic connection
Install in right port.
3.
Six springs (9)
Install in spool (13).
4.
Sleeve
Slide in position over spool (13).
5.
Pin (10) that holds spool (13) to
sleeve
Install.
6.
Sleeve and spool assembly
Install in body.
7.
Spacer (12)
Put in position on body.
8.
Drive assembly
Install in body.
9.
Gerotor assembly (15)
Install.
NOTE
Be sure gear in the gerotor assembly is alined
with pin (10) of sleeve assembly as shown.
TA172243
Go on to Sheet 6
6-22
TM 10-3930-641-34-2
(Sheet 6 of 6 )
HAND STEERING UNIT DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
10.
Spacer (14)
Install.
11.
Cap (17)
Install using seven capscrews (16).
NOTE
Tighten capscrews to a torque of 18-24 lb. ft.
(24-33 N.m).
12.
Preformed packing (3)
Install in body.
13.
Two races (1) and bearing (2)
Install.
14.
Lip seal (7)
Install in bushing (6) with a seal driver.
NOTE
Seal must make contact with counterbore in
bushing and lip must be toward outside of
hand metering unit.
15.
Bushing (6)
Install.
16.
Retaining ring (4)
Install.
End
6-23
TM 10-3930-641-34-2
STEERING CONTROL VALVE REMOVAL/INSTALLATION
(Sheet 1 of 4)
This task covers: Replacement of steering control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-54
Tags and caps for hydraulic lines
Troubleshooting Reference
Equipment Condition
Hydraulic system pressure relieved.
Panels opened.
Special Tools
None
Shipping link installed.
Personnel Required
One mechanic
References
General Safety Instructions
Shipping Link
Removal/Installation,
TM 10-3930-641-20
Tires blocked.
Go on to Sheet 2
6-24
TM 10-3930-641-34-2
(Sheet 2 of 4)
STEERING CONTROL VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMOVAL
REMARKS
NOTE
Tag and cap hydraulic lines as they are
removed.
1.
Oil return tube assembly (1)
Disconnect from steering control valve.
2.
Oil supply hose (2) for hand
metering unit
Disconnect.
3.
Hose (3) from right turn pilot port
Disconnect.
4.
Tube assembly (4)
Disconnect.
5.
Hose (6) from left turn pilot port
Disconnect.
6.
Hose (8) for left turn port
Disconnect.
_
TA098962
Go on to Sheet 3
6-25
TM 10-3930-641-34-2
(Sheet 3of 4 )
STEERING CONTROL VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
7.
Hose (9) for left hand port
Disconnect at lower end of hose.
8.
Steering valve (7)
Fasten hoist.
9.
Three capscrews (5)
Remove.
10.
Steering valve (7)
Remove from vehicle.
NOTE
Steering valve weighs 85 lb (38.6 Kg).
11.
Hose (9)
of valve.
Disconnect at steering valve to allow removal
INSTALLATION I
1.
2.
Steering valve (7)
Capscrews (5)
Fasten hoist and put in position.
Install.
Go on to Sheet 4
6-26
TM 10-3930-641-34-2
(Sheet 4 of 4 )
STEERING CONTROL VALVE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
3.
Hose (8)
Connect to left turn port.
4.
Hose (9)
Connect to right turn port.
5.
Hose (6)
Connect to left turn pilot port.
6.
Tube assembly (4)
Connect.
7.
Hose (3)
Connect to right turn pilot port.
8.
Oil return tube assembly (1)
Connect.
9.
Oil supply hose (2)
Connect.
REMARKS
End
6-27
TM 10-3930-641-34-2
(Sheet 1 of 8)
STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY
This task covers: Disassembly/assembly of steering control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-53
None
Troubleshooting Reference
Equipment Condition
Steering control valve removed from
vehicle.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Steering Control Valve Removal/Installation,
page 6-24
None
Go on to Sheet 2
6-28
TM 10-3930-641-34-2
(Sheet 2 of 8 )
STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Plug (15)
Remove from cover (11).
2.
Packing (14) and shims (13) and (16)
Remove from plug (15).
3.
Spring (12)
Remove from cover (11).
4.
Valve (7)
Remove from pilot seat (6).
5.
Capscrew (17) that holds cover (11)
in position.
Remove.
6.
Seat (6)
Remove from cover.
7.
Packings (22)
Remove from cover.
8.
Spring (19)
Remove from body (35).
9.
Spring (20)
Remove.
10.
Valve (45)
Remove.
11.
Valve stem assembly (48 thru 56)
Remove.
Go on to Sheet 3
6-29
TM 10-3930-641-34-2
(5 STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
(Sheet 3 of 8)
Plug
Packing
Identification Plate
Machine Screw
Valve Assembly
Pilot Seat
Valve
Packing
Plug
Packing
Cover
Spring
Shim
Packing
Plug
Shim
Capscrew
Lockwasher
Spring
Spring
Packing
Packing
Half Flange
Washer
Capscrew
Cover
Capscrew
Stop Assembly
Packing
Packing
Ball
Spring
Packing
Plug Assembly
TA098963
Go on to Sheet 4
6-30
TM 10-3930-641-34-2
(Sheet 4 of 8)
STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
Steering Valve Body
Packing
Plug
Ball
Packing
Plug
Packing
Seat
Seat
Packing
Valve
Spacer
Spacer
Valve Stem
Shim
Retainer
Spacer
Socket Head Screw
Lockwasher
Washer
Retainer
Spring
Seat
TA098964
Go on to Sheet 5
6-31
TM 10-3930-641-34-2
(Sheet 5 of 8 )
STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
12.
ACTION
Valve stem assembly (48 thru 56)
Disassemble as follows:
a. Screw (52), lockwasher (53),
washer (54)
Remove.
b. Retainer (55), spring (56), and
spacer (51)
Remove.
c. Retainer (50) and shims (49)
Remove from valve stem (48).
13.
Plug (40) and packing (41)
Remove from valve body (35).
14.
Ball resolver valve (38, 39, 42, 43, 44) Remove.
15.
Stop assembly (28)
Remove from valve body (35).
16.
Plug assembly (34)
Remove.
17.
Check valve (31 thru 33)
Remove.
18.
Capscrews (27)
Remove.
19.
Cover (26)
Remove.
20.
Plug (9) and preformed packing (10)
Remove from cover (26).
REMARKS
Go on to Sheet 6
6-32
TM 10-3930-641-34-2
(Sheet 6 of 8 )
STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
NOTE
Clean all parts.
1.
Check valve; ball (31), spring (32)
plug assembly (33) and (34)
Install in valve body (35).
2.
Stop assembly (28) and packing (29)
Install in valve body (35).
3.
Preformed packing (10) and plug (9)
Install in cover (26).
4.
Cover (26)
Place on body (36).
5.
Capscrews (27) and lockwashers (18)
Install.
6.
Ball resolver valve assembly (38, 39,
42, 43, 44)
Install.
7.
Plug (40) and preformed packing
(41)
Install.
Go on to Sheet 7
6-33
TM 10-3930-641-34-2
(Sheet 7 of 8 )
STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
8.
ACTION
REMARKS
Valve stem assembly
Assemble as follows:
a. Shims (49)
Put in valve stem (48).
b. Retainer (50), spacer (51), spring
(56), and retainer (55)
Assemble and put in position.
c. Washer (54), lockwasher (53), and
screw (52)
Assemble and install in valve stem (48).
9.
Valve stem assembly
Install in body (35).
10.
Valve (45)
Install.
11.
Spacers (46)
Install.
12.
Spring (20)
Install.
13.
Spring (19)
Install.
14.
Preformed packings (22) and (21)
Install in cover (11).
15.
Seat (6)
Install.
16. Cover (11)
Place in position on valve body (35).
Go on to Sheet
6-34
TM 10-3930-641-34-2
(Sheet 8 of 8 )
STEERING CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
17.
Capscrews (T7) and lockwashers (18)
Install.
18.
Valve (7)
Install.
19.
Spring (12) and shims (13) and (16)
Install.
20.
Plug (15) and packing (14)
Install.
REMARKS
End
6-35
TM 10-3930-641-34-2
(Sheet 1 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY
This task covers: Disassembly and assembly of articulated hitch component.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Feeler gage
Tags and wires
None
Equipment Condition
Relieve pressure in hydraulic system.
Vehicle must be on a level smooth surface,
preferably concrete.
Special Tools
None
Tilt cylinders fully extended.
Personnel Required
Mast lowered.
Four mechanics
References
General Safety Instructions
Driveshaft Removal, page 4-305
Put wood blocks in front of and behind all
four tires.
Steering Cylinder Removal, page 6-79
Go on to Sheet 2
6-36
TM 10-3930-641-34-2
(Sheet 2 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Shipping link
Install.
2.
Lower middle drive shaft
Remove.
See TM 10-3930-641-20
3.
Rod ends of steering cylinder
Disconnect.
See page 6-79.
4.
Wiring harness (A)
Remove clip, disconnect and identify
5.
Hydraulic oil return line (B)
Tag, disconnect, and cap.
6.
Front brake hydraulic line (C)
Tag, disconnect, and cap.
TA098965
Go on to Sheet 3
6-37
TM 10-3930-641-34-2
(Sheet 3 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Washer
Capscrew
Capscrew
Cover Assembly
Pin
Collar
Grease Fitting
Cap
Tapered Roller Bearing Cone
Tapered Roller Bearing Cup
Lip Type Seal
Cap
Shim Pack
Pressure Relief Fitting
Capscrew
Capscrew
Pin
Spacer
Cap
Tapered Roller Bearing Cone
Tapered Roller Bearing Cup
Lip Type Seal
Cap
Spacer
Shim Pack
Lockplate
Hardened lockwasher
Capscrew
Capscrew
Shim
TA098966
Go on to Sheet 4
6-38
TM 10-3930-641-34-2
(Sheet 4 of 16 )
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
7.
Eight hydraulic lines (D) for brake
control valve
ACTION
REMARKS
Tag, disconnect, and cap.
NOTE
Tag and disconnect lines at valves.
8.
Two capscrews (3), and washers (1)
that hold upper pin (5)
Remove.
WARNING
Do not remove cover until pin is loose.
9.
Four capscrews (2) and washers (1)
that hold cover assembly (4) in
position
Loosen, but do not remove. Do not exceed
1/4 inch.
10.
Steering neutralizer valve hydraulic
lines (E)
Tag, disconnect, and cap.
NOTE
If necessary, tag and remove any additional
lines that block access to hoses.
TA098967
Go on to Sheet 5
6-39
TM 10-3930-641-34-2
(Sheet 5 of 16 )
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
11.
Capscrews (29) and capscrews (28)
Remove.
12.
Lower lock plate (26)
Remove.
13.
Rear main frame
Put vehicle jacks, of sufficient capacity to lift
vehicle, in position under forward extreme
points of vehicle rear main frame.
NOTE
Mast should be tilted forward, in lowest position and immobilized.
14.
Rear main frame
Fasten and immobilize to a suitable vehicle.
(No less than 10,000 lbs. lifting capacity.)
NOTE
Vehicle should be of sufficient size for lifting,
pulling, and pushing front assembly of RTCH.
15.
Front main frame
shown.
Put jacks under rear of front main frame as
TA098968
Go on to Sheet 6
6-40
TM 10-3930-641-34-2
(Sheet 6 of 16 )
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
16. Rear of RTCH
jacks. This will help loosen top pivot pin.
ACTION
REMARKS
Move up and down with vehicle and floor
WARNING
Do not remove cover assembly of top pivot pin
until pivot pin is loosened.
17.
Top pivot pin (5)
Loosen with a hydraulic jack.
18.
Cover assembly (4) and pivot pin (5)
Remove.
NOTE
Pin weighs 35 lbs (14 kg).
19.
Lower pivot pin (17)
Remove using a hydraulic puller.
NOTE
Weight of pin is 48 lbs. (22 kg).
20
Spacer (24)
Remove, using puller.
Go on to Sheet 7
6-41
TM 10-3930-641-34-2
(Sheet 7 of 16 )
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
CAUTION
You must disconnect shipping link at this time.
21.
Front main frame and supports
Move away from rear frame using suitable
vehicle. Move supports and floor jack at same
time.
22.
Capscrews (15), bearing cap (8),
lower bearing cap (12) and shim
pack (13)
Remove from upper pivot joint.
23.
Seals (11)
Remove from upper and lower bearing caps.
24.
Lower top center joint
Put hydraulic puller in position as shown. Both
sets of bearing cups and cones will be removed
at same time.
25.
Adapter (38)
Install step.
26
Bearing cups (21) and cones (20) on
front frame
Fasten hoist and remove.
TA098969
Go on to Sheet 8
6-42
TM 10-3930-641-34-2
(Sheet 8 of 16 )
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
27.
Collar (6)
frame. Use a hydraulic puller.
Remove from upper pivot joint of rear main
28.
Spacer (18)
Remove from lower pivot joint.
29.
Capscrews (16)
Remove from lower pivot joint.
30.
Upper bearing cap (19)
Remove.
31.
Lower bearing cap (23)
Remove.
32.
Shim pack (25)
Remove.
33.
Lip seals (22)
Remove from bearing cap (19) and (23).
34.
Lower bearing cone (20), and upper
bearing cone (20), and upper bearing
cup (21).
Using hydraulic puller, remove as one unit.
35.
Lower bearing cup (21)
hydraulic puller as shown.
Remove through top of lower pivot joint with
TA098970
Go on to Sheet 9
6-43
TM 10-3930-641-34-2
(Sheet 9 of 16 )
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
1.
Seal (22)
Install in upper bearing cup (21) of lower pivot
joint using a seal installation tool and hammer
as shown.
NOTE
Install seal so lip is toward outside of bearing
cap and makes contact with counterbore.
2.
Other seal (22)
joint.
Install in lower bearing cup (21) of lower pivot
NOTE
Install seal until it makes contact with counterbore. Lip of seal must be toward inside of cap.
3.
Lower cap (23)
Install in lower pivot joint.
4.
Lower bearing cup (21)
Lower temperature to -900 to -110°F
(-32.1 to -430C) and install in the bore.
5.
Installation sleeve
Use to make bearing cup contact lower cap.
6.
Two bearing cones (20)
Install in bore of lower pivot joint.
TA098671
Go on to Sheet 10
6-44
TM 10-3930-641-34-2
(Sheet 10 of 16)
ARTICULTED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
7.
Upper bearing cup (21)
(-32 to -430C) and install in bore.
Lower temperature to -900 to -110°F
8.
Bearing driver
Use to make bearing cup contact bearing cone.
9.
Shims (25)
Install original amount.
10.
Upper cap (19)
Install.
11. Six capscrews (16)
evenly.
12.
Install an equal distance apart and tighten
Stud, nut and adapter
Connect to bearing cones as shown. Use a
torque wrench to check amount of torque
needed to turn bearing cones.
NOTE
The amount of torque must not be less than
80 lb. in. (9 N-m) or more than 400 lb. in.
(45 N-m). Remove or install shims (25) until
you have the correct amount of torque.
Go on to Sheet 11
6-45
TM 10-3930-641-34-2
(Sheet 11 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
13.
Spacer (18)
the joint.
Install in lower pivot joint from the bottom of
14.
Upper collar (6)
(-32 to -430C) and install.
Lower temperature to -900F to -1100F
15.
Lower cap (26)
Install in bore of front upper pivot joint.
16.
Three capscrews (29)
and tighten evenly.
Install in lower cap an equal distance apart
17.
Bearing cup (21)
(-32 to -430C) and install in bore.
Lower temperature to -900F to -110°F
18.
Bearing driver
Use to make bearing cup (8) contact cap.
19.
Two bearing cones (20)
Install in bore.
Go on to Sheet 12
6-46
TM 10-3930-641-34-2
(Sheet 12 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
20.
Upper bearing cup (10)
Lower temperature to -900F to -110°F
(-32.1 to -430C) and install in upper pivot
joint.
21.
Bearing driver
cone.
Use to make bearing cup (10) contact bearing
22.
Shims (13)
Install original amount.
23.
Cap (8)
Install.
24.
Three capscrews (15)
and tighten evenly.
Install in upper cap an equal distance apart
25.
Caps (12) and (8)
bearing cones.
Remove. Install nuts and sleeve, as shown, on
26.
Caps (12) and (8)
Install.
27.
Capscrews (15)
Install.
28.
Bearing cones (20)
Check amount of torque needed to turn
bearings using a torque wrench as shown.
Go on to Sheet 13
6-47
TM 10-3980-641-34-2
(Sheet 13 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
The amount of torque must not be less than
80 lb. in. (9 N-m) or more than 400 lb.
(45 N-m). Remove or install shims until you
have the correct amount of torque.
29.
Two caps (8) and (12) and
installation tooling
30.
Seals (11)Install in caps (8) and (12).
Remove.
NOTE
c
Install seal until it makes contact with
counterbore. Lips of seals must be toward
inside of caps.
31.
Caps (9) and (11)
Install again.
32.
Capscrews (15)
Install all capscrews and tighten evenly.
Go on to Sheet 14
6-48
TM 10-3930-641-34-2
(Sheet 14 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
33.
Hydraulic jack
Put in position under rear of front main frame.
34.
Front main frame
Position in articulated joint.
35.
Pin (17)
Install in lower pivot.
36.
Pin (5)
Place in position in upper pivot joint.
37.
Retainer (4)
Place into position one pin (5). Using three
2-1/2 inch long capscrews align holes in retainer with holes in top of pin (5).
38.
Pin (5)
Install.
39.
Shipping link
Connect.
NOTE
Vehicle used for positioning front main frame
may be removed at this time.
See TM 10-3930-641-20.
40.
Long capscrews (installed in step 37)
Remove and install original capscrews (2).
41.
Capscrews (2)
Torque in sequence:
a.
Tighten to a torque of 65 lb. ft. to 85 lb.
ft. (88-115.2 N-m).
b.
Hit joint until torque is less than 40 lb. ft.
(54.2 N.m).
c.
Tighten to a torque of 65 lb. ft. to 85 lb.
ft. (88-115.2 N.m).
d.
Hit joint until torque is less than 60 lb. ft.
81.3 N.m).
e.
Tighten to a torque of 65 lb. ft. to 85 lb.
ft. (88-115.2 N.m).
Go on to Sheet 15
6-49
TM 10-3930-641-34-2
(Sheet 15 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
42.
Spacer (24)
Install in lower pivot joint with bevel up.
43.
Pin (17)
holes in frame.
Use jacks to align holes in bottom of pin with
44.
Plate (26)
Put in position under rear of front main frame.
45.
Four capscrews (28)
Install.
46.
Plate (26)
Measure distance between plate and frame with
feeler gage. Remove plate and install same
thickness of shims.
47.
Plate (26) and four capscrews (28)
Install.
48.
Pin (17)
aligned with holes in frame.
Turn with hydraulic jack until four holes are
49.
Four capscrews (29)
Install.
50.
Hydraulic line (E)
Connect to neutralizer valve.
51.
Eight hydraulic lines (D)
Connect to pilot control valve.
Go on to Sheet 16
6-50
TM 10-3930-641-34-2
(Sheet 16 of 16)
ARTICULATED HITCH DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
52.
Wiring harness (A)
Connect.
53.
Hydraulic oil return line (B)
Connect.
54.
Hydraulic brake line (C)
Connect.
55.
Steering cylinders rod ends
Install.
56.
Lower middle driveshaft
Install.
REMARKS
NOTE
Tighten capscrews to a torque of 90 lb. ft. to
110 lb. ft. (122-149 N.m).
57. Brake system
Bleed air.
See TM 10-3930-641-20
TA098975
End
6-51
TM 10-3930-641-34-2
HYDRAULIC (STEERING AND BRAKE) PUMP REMOVAL/INSTALLATION
(Sheet 1 of 9)
This task covers: Replacement of steering and brake pump
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-54
Tags
Troubleshooting Reference
Equipment Condition
Engine off
Hydraulic oil cooled
Shipping link installed
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Shipping link removal/installation, None
TM 10-3930-641-20
Go on to Sheet 2
6-52
TM 10-3930-641-34-2
(Sheet 2 of 9)
HYDRAULIC (STEERING AND BRAKE) PUMP REMONAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Precleaner (1)
Remove.
2.
Hood (2)
Attach hoist as shown and remove.
NOTE
Weight of hood is 96 lb. (43.5 Kg).
3. Door assemblies at rear of engine
Open.
6-53
TM 10-3930-641-34-2
(Sheet 3 of 9)
HYDRAULIC (STEERING AND BRAKE) PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
4.
Hydraulic lines (3)
Tag and disconnect from oil filter base.
5.
Wire harness (4)
Disconnect from sending unit.
6.
Six capscrews (5)
Remove from filter bases.
NOTE
Do not disconnect hydraulic lines from the
bases. Place the filters and bases on the floor
plates.
7.
Wire (6)
8. Clamp (7)
Disconnect from sending unit.
Loosen.
6-54
TM 10-3930-641-34-'
(Sheet 4 of 9)
HYDRAULIC (STEERING AND BRAKE) PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
9.
Four capscrews that secure filter
group (8) and three capscrews for
heat shield.
Remove.
10.
Filter group (8)
Attach hoist as shown and remove.
NOTE
Weight of filter group is 100 lb. (45.4 Kg).
11.
Air cleaner housing
Attach hoist and remove.
NOTE
Weight of housing is 50 lb. (22.7 Kg).
12. Heat shield (11)
Remove two capscrews (10).
6-55
TM 10-3930-641-34-2
(Sheet 5 of 9)
HYDRAULIC (STEERING AND BRAKE) PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
13.
Two panels on left side of engine
Remove.
14.
Hydraulic lines (12) and (13)
Remove from bottom of pump.
15.
Clamp (14)
Loosen.
16.
Four capscrews (16)
Remove from pump.
17. Tube assembly (15)
REMARKS
Remove from pump.
6-56
TM 10-3930-641-34-2
(Sheet 6 of 9)
HYDRAULIC (STEERING AND BRAKE) PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
18.
ACTION
REMARKS
Pump (17)
Attach hoist as shown. Remove four capscrews
securing pump and remove pump (17).
CAUTION
Be careful not to damage the splined drive
shaft when pump is removed.
INSTALLATION
1. Pump (1)
rear of engine.
Attach hoist and place into position in the
CAUTION
Be careful not to damage the splined drive
shaft of pump when installing pump.
6-57
TM 10-3930-641-34-2
(Sheet 7 of 9)
HYDRAULIC (STEERING AND BAKE) PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
2.
Tube (2)
(4).
Reinstall on pump and secure with capscrews
3.
Clamps (3)
Tighten.
4.
Hydraulic lines (5)
Install.
5.
Upper and lower left side panels
and heat shield
Install.
6-58
TM 10-3930-641-34-2
(Sheet 8 of 9)
HYDRAULIC (STEERING AND BRAKE) PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
6.
Air cleaner housing
Attach hoist and install.
7.
Filter group (6)
Attach hoist and install.
8.
Transmission and pilot system
filters
Install.
9.
Air cleaner housing
Install four capscrews.
10.
Air cleaner indicator
Reconnect wire to sending unit.
11.
Transmission and pilot system oil
filter indicator.
Reconnect wire to sending unit.
REMARKS
TA173019
Go on to Sheet 9
6-59
TM 10-39803)41-34-2
(Sheet 9 of 9)
HYDRAULIC (STEERING AND BRAKE) PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
12.
Engine oil filters
Reconnect the two hydraulic lines.
13.
Hood (7)
Attach hoist and reinstall.
14.
Precleaner
Install.
TA173020
End
6-60
TM 10-3930-641-34-2
HYDRAULIC (STERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY(Sheet 1 of 10)
This task covers: Repair of steering and brake hydraulic pump.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-54
None
Troubleshooting Reference
Equipment Condition
Hydraulic pump removed.
Shipping link installed.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Hydraulic pump removal/installation,
page 6-52
None
Shipping link removal/installation,
TM 10-3930-641-20
Go on to Sheet 2
6-61
TM 10-3930-641-34-2
(Sheet 2 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
DISASSEMBLY
REMARKS
CAUTION
Lay out parts in the order of disassembly. Do
not mix parts.
Clean outside of pump.
1.
Capscrew (40) and washer (41) that
hold steering section to brake section
Remove.
2.
Packing (37) in steering section
Remove.
3.
Isolation plate (44)
Remove.
4.
Retaining ring (29)
Remove.
5.
Packing (31)
Remove.
6.
Back-up ring (30)
Remove.
7.
Drive gear (33)
Remove with pressure plate (32).
8.
Pressure plate (32)
Remove from drive gear.
9.
Idler gear (34)
Remove.
Go on to Sheet 3
6-62
TM 10-3930-641-34-2
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Lip type seal
Spacer
Lip type seal
Washer
Capscrew
Pump assembly
Nut 42.
Washer
Stud 44.
Ball
Body assembly
Bushing
Bushing
Relief valve
Guide pin
Preformed packing
Retaining ring
Back-up ring
Preformed packing
Pressure plate
Idler gear
Snap ring
Splined coupling
Drive gear
Isolation plate
Capscrew
Body assembly
Bushings
Retaining ring
Back-up ring
Preformed packing
Pressure plates
Drive gear
Idler gear
Isolation plate
(Sheet 3 of 10)
36. Isolation plate
37. Preformed packing
38. Body assembly
39. Bushing
40. Capscrew
41. Washer
Body assembly
43. Bushing
Isolation plate
Go on to Sheet 4
6-63
TM 10-3930-641-34-2
(Sheet 4 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
10.
Pressure plate (32)
Remove.
11.
Isolation plate (35)
Remove.
12.
Retaining ring (29)
Remove.
13.
Packing (31)
Remove.
14.
Back-up ring (30)
Remove.
15.
Nuts that hold body assembly (11)
in plate
Remove.
16.
Body assembly (11)
Remove.
17.
Packing (16) in body assembly (11)
Remove.
18.
Two lip seals (1) and (3) and spacer
(2)
Remove from seal retainer.
19.
Isolation plate (25)
Remove from brake pump body.
20.
Retaining ring (17)
Remove.
21.
Packing (19)
Remove.
Go on to Sheet 5
6-64
TM 10-3930-641-34-2
(Sheet 5 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
22.
Back-up ring (18)
Remove.
23.
Drive gear (24)
Remove with pressure plate (20).
24.
Pressure plate (20)
Remove from drive gear.
25.
Idler gear (21)
Remove.
26.
Pressure plate (20)
Remove from pump.
27.
Isolation plate (36)
Remove.
28.
Retaining ring (17)
Remove.
29.
Packing (19)
Remove.
30.
Back-up ring (18)
Remove.
31.
Body (27)
Remove from housing. Reinstall one nut flush
to end of stud. With mallet tap stud. Remove
nut and slide body out.
Go on to Sheet 6
6-65
TM 10-3930-641-34-2
(Sheet 6 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
32. Preformed packing (16)
Remove from housing.
33. Splined coupling (23)
Remove from housing.
ASSEMBLY
REMARKS
NOTE
Clean all parts.
If grooves in the bore are deeper than 0.015 in.
(0.381 mm), in either the steering or brake
pump, replace the body and gears.
1.
Splined coupling (23)
Install in housing.
NOTE
Replace snap ring (22) if necessary.
2.
Preformed packing (16)
3. Body assembly (27)
Install.
Place in position.
TA098977
Go on to Sheet 7
6-66
TM 10-3930-641-34-2
(Sheet 7 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
4.Isolation plate (36)
ACTION
REMARKS
Install into body (27).
NOTE
Isolation plate must be installed on inlet side
of pump with trap slot (machined notch)
toward the outlet of pump body.
5.
Back-up ring (18)
Install.
6.
Packing (19)
Install.
7.
Ring retainer (17)
Install.
NOTE
Ring retainer must be installed on inlet side of
pump body.
Seals must be installed on pressure side of
pump.
8.
Pressure plate (20)
Install.
NOTE
Install pressure plate with machined notch
(trap slot) toward outlet side of pump and
bronze side toward the gears.
9.
Drive gear (24)
Install in pump body.
10.
Idler gear (21)
Install.
Go on to Sheet 8
6-67
TM 10-3930-641-34-2
(Sheet 8 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
11.
Pressure plate (20)
ACTION
REMARKS
Install on gears.
NOTE
Pressure plate must be installed with machined
notch (trap slot) toward outlet side of pump
and bronze side toward gears.
12.
Isolation plate (25)
Install on inlet side of pump.
13.
Back-up ring (18)
Install.
14.
Packing (19)
Install.
15.
Ring retainer (17)
Install beveled side up.
16.
O-ring (16)
Install in flange (6).
17.
Body assembly (11)
Position on pump body and install nuts.
NOTE
Tighten nuts to a torque of 165 lb. ft. to 185
lb. ft. (223.7-250.8 N.m).
18.
Lip seals (3) and (1) and spacer (2)
Install in flange with a seal driver.
NOTE
Install outside seal with lip toward outside of
pump.
TA098978
Go on to Sheet 9
6-68
TM 10-3930-641-34-2
(Sheet 9 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
19.
20.
Isolation plate (35)
Back-up ring (30)
Install on inlet side of pump body (38).
Install.
21.
22.
Packing (31)
Ring retainer (29)
Install.
Install.
NOTE
23.
Radius of ring retainer (9) must be toward
bottom of pump body.
Pressure plate (32)Put in position.
NOTE
24.
Install pressure plate with bronze side toward
gears. Machined notch (trap slot) must be
toward outlet side of pump.
Drive gear (33)Install in pump body.
NOTE
Outlet side of pump body facing away. Drive
gear goes in left side.
25.
Idler gear (34)
Install.
26.
Isolation plate (32)
Install.
27.
Back-up ring (30)
Install in pump body.
TA098979
Go on to Sheet 10
6-69
TM 10-3930-641-34-2
(Sheet 10 of 10)
HYDRAULIC (STEERING AND BRAKE) PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
28.
Packing (31)
Install.
29.
Ring retainer (44)
Install.
30.
Packing (37)
Install in pump housing.
31.
Brake pump
Place in position on steering pump (27).
NOTE
Turning spline will align both drive gears.
32.
Nuts (7) and studs (9), capscrews
(40) and washers
Install.
NOTE
Tighten capscrews to a torque of 80 lb. ft. to
90 lb. ft. (108.5-122 N.m).
End
6-70
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING PUMP REMOVAL/INSTALLATION(Sheet 1 of 3)
This task covers: Removal/installation of supplemental steering pump.
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
As required
Troubleshooting Reference
Equipment Condition
Engine OFF
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Lower driveshaft, middle piece
Main disconnect switch OFF
removal/installation, TM 10-3930-641-20.
Shipping link installed
Go on to Sheet 2
6-71
TM 10-3930-641-34-2
(Sheet 2 of 3)
SUPPLLEMENTAL STEERING PUMP REMAVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMOVAL
REMARKS
NOTE
It is necessary to remove the lower driveshaft
middle piece for better access to the
supplemental steering pump.
1.
Lower driveshaft, middle piece
Remove
2.
Inlet and outlet lines
openings.
Disconnect. Tag lines and cap or plug
3.
Capscrews (1) and washers securing
supplemental steering pump (2)
to output transfer gear case (3)
Remove.
4. Supplemental steering pump (2)
See TM 10-3930-641-20
Remove.
6-72
TM 10-3930-641-34-2
(Sheet 3 of 3)
SUPPLEMENTAL STEERING PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1. Supplemental steering pump (2)
Place in position on output transfer case (3).
CAUTION
Be careful lining up the splines on the driveBe careful lining up the splines on the driveshaft with the pump drive.
2.
Capscrews (1) and washers
Install.
3.
Inlet and outlet lines
Install.
4.
Lower driveshaft, middle piece
Install.
See TM 10-3930-641-20.
End
6-73
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING PUMP DISASSEMBLY/ASSEMBLY
(Sheet 1 of 5)
This task covers: Disassembly/assembly of supplemental steering pump.
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
As required
Troubleshooting Reference
Equipment Condition
Supplemental steering pump removed
from vehicle.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Supplemental steering pump removal/ None
installation, page 6-71.
Go on to Sheet 2
6-74
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 5)
ACTION
DISASSEMBLY
REMARKS
CAUTION
Lay out parts in the order of disassembly. Do
not mix parts.
1.
Capscrews (15) and washers (14)
Remove.
2.
Body assembly (1)
Separate from housing (20).
3.
Preformed packing (3)
Remove.
4.
Spacers (7) and retainer (5)
Remove.
5.
Retainer (8) and spacers (4)
Remove.
6.
Seals (6) and preformed packing (12)
Slip off end of shafts (10) and (11).
7.
Drive gear (10)
Remove with pressure plate (9).
8.
Pressure plate (9)
Remove from drive gear (10).
9.
Idler gear (11)
Remove from housing.
10.
Pressure plate (9)
Remove from housing.
Go on to Sheet 3
6-75
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING PUMP DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
(Sheet 3 of 5)
Body assembly
Bushing
Preformed packing
Spacer
Retainer
Seal
Spacer
Retainer
Pressure plate
Drive gear
Idler gear
Preformed packing
Ball
Washer
Capscrew
Spacer
Dowel
Preformed packing
Plug
Housing
Bushing
TA 172240
Go on to Sheet 4
6-76
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 5)
ACTION
11.
Spacers (7) and retainers (5)
Remove.
12.
Retainers (8) and spacers (4)
Remove.
13.
Seals (6) and preformed packing (12)
Remove.
ASSEMBLY
REMARKS
NOTE
Clean all parts.
If grooves in the bore are deeper than 0.015 in.
(0.381 mm), replace the body and gears.
1.
Seals (6) and preformed packing (12)
Assemble and install in bottom of housing.
2.
Spacers (7, 4) and retainers (5, 8)
Assemble around seals in bottom of housing.
3.
Pressure plate (9)
Install.
NOTE
Install pressure plate with machined notch
(trap slot) toward outlet side of pump and
bronze side toward the gears.
4.
Idler gear (11) and drive gear (10)
Install.
NOTE
Outlet side of pump body facing away. Drive
gear goes in left side.
5.
Pressure plate (9)
Install.
NOTE
Pressure plate must be installed with machined
notch (trap slot) toward outlet side of pump
and bronze side toward gears.
TA 172241
Go on to Sheet 5
6-77
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING PUMP DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 5 of 5)
ACTION
REMARKS
6.
Seals (6) and preformed packing (12)
Slip over ends of shafts (10) and (11).
7.
Drive gear (10)
turn freely.
Turn by hand a few rotations to be sure gears
8.
Preformed packing (3)
Install in groove in body assembly (1).
9.
Body assembly (1)
Position on housing (20).
10.
Capscrews (15) and washers (14)
Install.
NOTE
Tighten capscrews to a torque of 80 lb. ft. to
90 lb. ft. (108.5-122 N-m).
End
6-78
TM 10-3930-641-34-2
STEERING CYLINDERS REMOVAL/INSTALLATION
(Sheet 1 of 6)
This task covers: Replacement of steering cylinders.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-56
None
Troubleshooting Reference
Equipment Condition
Engine off.
Hydraulic oil cooled.
Shipping link installed.
Special Tools
None
Personnel Required
Two mechanics
References
General Safety Instructions
Shipping link removal/installation, Tires blocked.
TM 10-3930-641-20
Go on to Sheet 2
6-79
TM 10-3930-641-34-2
STEERING CYLINDERS REMOVAL/INSTALLATION (CONT)
(Sheet 2 of 6)
LOCATION/ITEM
ACTION
REMOVAL
REMARKS
WARNING
Shipping link must be connected before working at center of machine.
1.
Shipping link
Install. See TM 10-3930-641-20.
2.
Capscrew (2)
Remove.
3.
Washer (1)
Remove.
4.
Tool Install as follows:
5.
a. Washer (A)
a. Place on pin.
b. Capscrew (2)
b. Install in pin (3).
c. Jacking cylinder (B)
c. Install under pin, against capscrew.
Steering cylinder rod end retaining
pin
Force out, using jacking cylinder.
TA098981
6-80
TM 10-3930-641-34-2
STEERING CYLINDERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
6.
Vehicle
b.
(Sheet 3 of 6)
ACTION
REMARKS
a. Start engine and turn steering wheel until
rod is positioned all the way into cylinder.
Shut off engine.
7.
Hydraulic lines at steering cylinder
keep dirt out.
Tag and disconnect. Use plugs in openings to
8.
Steering cylinder
Fasten hoist and sling.
9.
Lubrication line (4)
Disconnect from steering cylinder.
10.
Capscrew and washer installed in
step 4
Remove from cylinder end retaining pin.
11.
Tool Install as follows:
a. Washer (A)
b. Capscrews (2)
c. Jacking cylinder (B)
a. Place on pin.
b. Install in pin (3).
c. Install under pin, against capscrew.
TA098981
Go on to Sheet 4
6-81
TM 10-3930-641-34-2
STEERING CYLINDERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 4 of 6)
ACTION
REMARKS
12.
Cylinder end retaining pin
Force out, using jacking cylinder.
13.
Steering cylinder (5)
Remove.
NOTE
Weight of cylinder is 168 lb. (76.2 kg).
INSTALLATION
1.
Steering cylinder (5)
Fasten hoist and move into position.
2.
Ratchet puller (C)
Fasten to rod end of steering cylinder. Pull
cylinder forward until cylinder end retaining
pin can be installed.
TA098992
Go on to Sheet 5
6-82
TM 10-3930-641-34-2
STEERING CYLINDERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 5 of 6)
ACTION
REMARKS
3.
Washer and capscrew
not tighten.
Install in retaining pin at cylinder end, but d
4.
Lubrication line (4)
Install. See sheet 3.
5.
Hydraulic lines at steering cylinder
Connect.
6.
Vehicle
end pin can be installed.
Start engine and turn steering wheel until roc
7.
Washer (1) and capscrew (2)
Install in retaining pin at rod end.
8.
Capscrews at rod end and cylinder
Tighten as follows:
end
a. Tighten to a torque of 230 lb. ft. to 300
lb. ft. (311.8-406.7 N-m).
b. Hit tapered ends of pins with a hammer
until torque is less than 140 lb. ft.
(189.8 N•m).
Go on to Sheet 6
6-83
TM 10-3930-641-34-2
STEERING CYLINDERS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
8.
Capscrews (cont)
(Sheet 6 of 6)
ACTION
REMARKS
c. Tighten again to 230 lb. ft. to 300 lb. ft.
(311.8-406.7 N•m) of torque.
d. Hit tapered end of pins with a hammer
until torque is less than 210 lb. ft.
(284.7 N•m).
e. Tighten again to a torque of 230 lb. ft. to
300 lb. ft. (311.8-406.7 N•m).
End
6-84
TM 10-3930-641-34-2
STEERING CYLINDERS DISASSEMBLY/ASSEMBLY
(Sheet 1 of 6)
This task covers: Repair of steering cylinders.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-56
Teflon seal
Troubleshooting Reference
Equipment Condition
Steering cylinder removed from vehicle.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Steering Cylinder Removal/Installation, Place parts in a clean area.
page 6-79.
Go on to Sheet 2
6-85
TM 10-3930-641-34-2
STEERING CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 6)
ACTION
REMARKS
DISASSEMBLY
1.
Cylinder (1)
Put in position on repair stand.
2.
Cylinder (1)
Move piston rod (6) to fully extended position.
3.
Piston rod (6)
Support rod (6) securely.
NOTE
Eye of rod should be held rigid.
4.
Four capscrews (18) and washer (17)
Remove.
5.
Rod (6) and piston assembly (16)
Pull out of cylinder (11).
6.
Nut (13)
socket.
Remove from rod using torque multiplier and
7.
Piston (16)
Remove from rod.
Go on to Sheet 3
6-86
TM 103930-641-34-2
STEERING CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
(Sheet 3 of 6)
Cylinder group
Ring seal
U cup seal
Lip type seal
Rod assembly
Piston rod
Sleeve bearing
Head
Backup ring
Preformed packing
Cylinder assembly
Sleeve bearing
Self-locking nut
Wear ring
Seal assembly
Piston
Hardened washer
Capscrew
Lip type seal
Pin
Hydraulic grease fitting
Washer
Hardened washer
Capscrew
Capscrew
Go on to Sheet 4
6-87
TM 10-3930-641-34-2
STEERING CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 6)
ACTION
REMARKS
8.
Ring (14)
Remove from piston (16).
9.
Seal assembly (15)
Remove.
10.
Head (8)
Pull off rod (6).
11.
Packing (10)
Remove from head.
12.
Ring (9)
Remove from head.
13.
Seals (2), (3) and (4)
Remove from head.
14.
Seals (19)
Remove from cylinder and rod ends.
15.
Bearings (12) and (7)
Remove from cylinder using bearing puller.
Go on to Sheet 5
6-88
TM 10-3930-641-34-2
STEERING CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 5 of 6)
ACTION
REMARKS
ASSEMBLY
1.
Three seals (2), (3), and (4)
Install in head (8), position inside seal. Center
seal must have lip toward inside of cylinder.
Outside seal must have lip toward outside of
cylinder. Install outside seal with seal driver
until it makes contact with counterbore in
head.
2.
Ring (9)
Install on head.
3.
Packing (10)
Install on head.
4.
Cylinder (11)
Install four 3/4-10 NC guide bolts in cylinder.
5.
Head (8)
Install on rod.
6.
Seal guide
Install on rod.
7.
Head (8)
rod (6).
Put clean hydraulic oil on seal lips. Push onto
8.
Ring (14)
Install on piston (16).
9.
Seal assembly (15)
Install.
Go on to Sheet 6
6-89
TM 10-3930-641-34-2
STEERING CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 6 of 6)
ACTION
10.
Piston (16)
Install on rod (6).
11.
Nut (13)
a. Install.
REMARKS
b. Tighten using a torque multiplier.
NOTE
Torque nut to 1440 lb. ft. to 1760 lb. ft.
(1950 to 2390 N-m).
12.
Piston (16)
cylinder.
Use a piston compressor to push piston into
13.
Capscrews (18)
head and cylinder.
Remove guide bolts. Install four capscrews in
14.
Cylinder end bearings (12) and (7)
Install, using a hydraulic press.
NOTE
Bearing must be 0.32 in. (8.13 mm) below outside surface of cylinder. Inside diameter of
bearings must be 2.2523 to 2.2583 in.
(57.21-57.36 mm) after installation.
15.
Two seals (19)
Install one seal on each side of cylinder bearing, using a seal driver. Install seals 0.06 in.
(1.52 mm) below surface of cylinder, with lip
of seal toward outside.
End
6-90
TM 10-3930-641-34-2
STEERING LINES REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal and installation of steering lines.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-53
Container to drain oil into
Troubleshooting Reference
Equipment Condition
Engine OFF.
All electrical accessories off.
Steering system drained.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
None
None
Go on to Sheet 2
6-91
TM 10-3930-641-34
STEERING LINES REMOVAL/INSTALLATION (CONT)
(Sheet 2 of 3)
Go on to Sheet 3
6-92
TM 10-3930-641-34-2
STEERING LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
REMARKS
REMOVAL
1.
Capscrews and washers securing
flanges
2.
Preformed packing
3.
Clips and brackets
Remove.
NOTE
Tag hoses and lines to identify location. Cap or plug
Remove and discard.
openings.
a. Remove capscrews, washers and nuts.
b. Remove brackets and clips.
4.
Hose and tube assemblies
Remove.
INSTALLATION
1.
Preformed packing
Oil new packing and position into flanges.
2.
Hose and tube assemblies
Place in correct position on vehicle.
3.
Capscrews and washers
and washers.
Secure flanges and assemblies with capscrews
4.
Clips and brackets
Reinstall in correct position.
End
6-93
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING LINES REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal and installation of supplemental steering lines.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-53
Container to drain oil into
Troubleshooting Reference
Equipment Condition
Engine OFF.
All electrical accessories off.
Steering system drained.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
None
None
Go on to Sheet 2
6-94
TM 10-3930-641-34
SUPPLEMENTAL STEERING LINES REMOVAL/INSTALLATION (CONT)
(Sheet 2 of 3)
Go on to Sheet 3
6-95
TM 10-3930-641-34-2
SUPPLEMENTAL STEERING LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
REMARKS
REMOVAL
1.
Capscrews and washers securing
flanges
Remove.
NOTE
Tag lines to identify location on the vehicle. Cap or
plug openings.
2.
Preformed packing
Remove and discard.
3.
Clips and brackets
a. Remove capscrews, washers and nuts.
b. Remove brackets and clips.
4.
Hose and tube assemblies
Remove.
INSTALLATION
1.
Preformed packing
Oil new packing and position into flanges.
2.
Hose and tube assemblies
Place in correct position on vehicle.
3.
Capscrews and washers
and washers.
Secure flanges and assemblies with capscrews
4.
Clips and brackets
Reinstall in correct position.
End
6-96
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM
(Sheet 1 of 24)
This task covers: Tee test procedure for steering system.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Flow meter assembly equipped with
manual load valve
Hydraulic lines and fittings
Page 2-56
Tachometer
Equipment Condition
Shipping link installed
Special Tools
None
Personnel Required
Two mechanics
References
Shipping Link Removal/Installation,
TM 10-3930-641-20
General Safety Instructions
Make sure that all connections are tight.
Test equipment must be capable of withstanding pressures higher than 3000 psi
(20,700 kPa).
Go on to Sheet 2
6-97
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
(Sheet 2 of 24)
TA098985
SCHEMATIC OF STEERING SYSTEM WITH FLOW METER INSTALLED
1. Pump (large section is steering pump). 2. Combination Tee Tap and Pressure Tap. 3. Flow Meter. 4. Neutral valve (left side). 5. Hand Metering Unit
(HMU). 6 Neutralizer valve (right side). 7. Steering control valve. 8. Hydraulic tank. 9. Flow switch. 10. Steering cylinder (left side). 11. Filter. 12. Pump
for Supplemental Steering. 13. Diverter valve. 14. Steering cylinder (right side).
Go on to Sheet 3
6-98
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
TEST
4
15
27
35
(Sheet 3 of 24)
STEERING SYSTEM TESTS
COMPONENTS IN EACH TEST
Steering System test
Pump (Steering, Pilot and Brakes, Large Section)
Pump 9Steering, Pilot and Brakes, Large Section) and
Steering Valve
Pump (Steering, Pilot and Brakes, Large Section)
Steering Valve and Left Cylinder
DESIRED FLOW
77 U.S. gpm
81 U.S. gpm
78 U.S. gpm
77 to 78 U.S. gpm
TA098986
6-99
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
(Sheet 4 of 24)
CHART A. SYSTEM TEST
Test
Name
Test
Number
Control
Lever
Position
Mast
Position
Engine
Speed
System
Test
Pressure
Test
Data
Maximum
Pressure
Relief Valve
Setting
System
Oil
Temperature
(Start)
System
Base
Flow
Rate
Lift
LOWER
Flow
Rate
Lift
RAISE
Flow
Rate
1
2
3
4
5
6
Steer
Right
Steer
Right
Steer
Right
Steer
Right
Steer
Left
Steer
Right
Fully
Lowered
2000
RPM
Fully
Lowered
2000
RPM
100
PSI
Fully
Lowered
2000
RPM
1000
PSI
Fully
Lowered
2000
RPM
1000
PSI
Fully
Maximum
Fully
Lowered
Any
Speed
0-100
PSI
Any
Speed
0-100
PSI
2500
±75
PSI
150
±6
OF
90.0
GPM
77.0
GPM
77.0
GPM
150
±5
0
F
(3-4)
13.0
GPM
(3-4) x 100
3
15%
(3-5)
13.0
GPM
(3-5) x 100
3
15%
Flow
Differential
Percent
Flow Loss
NOTE: Connect shipping link before tests are made.
System
Oil
Temperature
(End)
Go on to Sheet 5
6-100
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 5 of 24)
ACTION
REMARKS
EQUIPMENT INSTALLATION
1.
Engine
Remove to relieve pressure. Install cap.
2.
MastStart.
3.
Engine
Lower completely.
4.
Hydraulic tank cap
Stop.
WARNING
Do not install adapter in pump supply line
with engine running. Injury to personnel can
result.
5.
Plug (A) for tee test in pump supply
line.
Remove and install correct adapter.
See diagram on sheet 2.
NOTE
Install adapter as quickly as possible to prevent
oil loss.
Go on to Sheet 6
6-101
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 6 of 24)
ACTION
REMARKS
6.
Return line assembly (D) and pump
supply line adapter (C)
Connect to flow meter (B).
7.
a. Tachometer generator
Install.
b. Tachometer drive
Install.
c. Cable
for tachometer on flow meter.
Install between generator and input connection
Shipping link
Install. See TM 10-3930-641-20.
8.
PREPARATION OF SYSTEM
FOR TEST
1.
Manual load valve on the flow meter
Open fully.
2.
Steering wheel
Turn continuously.
3.
Engine
Run at test rpm. See chart on sheet 4.
TA098987
Go on to Sheet 7
6-102
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
4.
Manual load valve on flow meter
1000 psi (703 kgs/sq. meter).
(Sheet 7 of 24)
ACTION
Close valve slowly until pressure goes up to
REMARKS
5.
Oil temperature
Observe. When oil temperature reaches 100°F
(37.70C), close load valve slowly until pressure
is 1500 psi (1054.5 kgs/sq. meter).
6.
Shipping link
(71.50C).
7.
Steering cylinders
Move several times through full cylinder travel
until oil is 1500F (660C) throughout system.
8.
Shipping link
Remove when oil temperature is 1600F
Install.
Refer to TM 10-3930-641-20.
Refer to TM 10-3930-641-20.
Go on to Sheet 8
6-103
TM 10-3930-641-34
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 8 of 24)
ACTION
REMARKS
TEST 1 |
MAXIMUM PRESSURE
RELIEF VALVE SETTING
NOTE
Turn steering wheel continuously through the
test. Record all test data.
1. Manual load valve on flow meter
Open all the way.
2. Engine
Maintain at 2000 rpm.
3. Manual load valve
Slowly close until oil flow through meter
stops. Record the pressure.
4. Steering relief valve
Maximum pressure must be no higher than
2575 lb. psi (1810 kgs/sq. meter).
See page 6-28.
CAUTION
Manual load valve must be opened slowly before turning steering wheel back to center.
This will prevent damage to the pressure gage.
Go on to Sheet 9
6-104
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 9 of 24)
ACTION
REMARKS
TEST 2
TEMPERATURE
1.
Manual load valve on flow meter
Open all the way.
2.
Steering wheel
Turn continuously.
3.
Engine
Run at any speed.
4.
Oil temperature
Record. You will compare this temperature
with a temperature reading taken at the end
of this series of tests.
Go on to Sheet 10
6-105
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 10 of 24)
ACTION
REMARKS
TEST 3
SYSTEM BASE FLOW RATE
1.
Manual load valve
Open all the way.
2.
Steering wheel
Turn continuously.
3.
Engine
Run at 2000 rpm.
4.
System pressure
Should be approximately 100 psi (70.3 kgs/sq.
meter).
6.
Flow rate
Record. You will use this figure to compare
tests 4 and 5.
Go on to Sheet 11
6-106
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 11 of 24)
ACTION
REMARKS
TEST 4
LEAKAGE RATES
1.
Steering wheel
Turn continuously to the right.
2.
Engine
Run at 2000 rpm.
3.
Manual load on flow meter
Close valve slowly clockwise until you have a
pressure of 1000 psi (703 kgs/sq. meter).
4.
Flow rate
Record.
5.
Flow differential
Calculate. Find the flow differential by subtracting the flow rate for this test from the
base flow rate, (test 3). Find the percentage
of flow loss by dividing the base flow rate
(test 3) by the flow differential of this test.
Go on to Sheet 12
6-107
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 12 of 24)
ACTION
REMARKS
TEST 5
LEAKAGE RATES
1.
Steering wheel
Turn continuously to the left.
2.
Engine
Run at 2000 rpm.
3.
Manual load valve on flow meter
Close valve slowly clockwise until you have a
pressure of 1000 psi (703 kgs/sq. meter).
4.
Flow rate
Record.
5.
Flow differential
Calculate. Find the flow differential by subtracting the flow rate for this test from the
base flow rate, (test 3). Find the percentage
of flow loss by dividing the base flow rate
(test 3) by the flow differential of this test.
Go on to Sheet 13
6-108
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 13 of 24)
ACTION
REMARKS
TEST 6
SYSTEM OIL TEMPERATURE
1.
Manual load valve on flow meter
Open all the way.
2.
Steering wheel
Turn continuously.
3.
Engine
Run at any speed.
4.
Oil temperature
Record. Compare oil temperatures from test 2
and this test. Temperature from test 2 must
be 145°F to 1550F (63°-69°C). Test 6 results
must be within 100F (12.2°C) of test 2.
5.
Temperature difference:
a.
b.
Test 6 is higher
Test 6 is lower
For each 100F (12.2°C) difference, subtract
0.5 gallons per pump cartridge from leakage
rate.
For each 100F (12.2°C) difference add 0.5
gallons per pump cartridge to leakage rate.
Go on to Sheet 14
6-109
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
(Sheet 14 of 24)
Compare the data from tests 7, 8, 9, 10, with this chart. The figures given on the chart represent maximum performance.
CHART B. PUMP TEST
Test
Name
Test
Number
Engine
Speed
Pump Test
Pressure
Oil
Temperature
Test
Data
Flow
Differential
Percent
Flow Loss
Full Speed
Pump Flow
Low
High
Pressure Pressure
7
8
2000
RPM
100
PSI
150
±5
ºF
90.0
GPM
2000
RPM
1000
PSI
150
±5
ºF
81.0
GPM
(7-8)
9.0*
GPM
(14-15)x100
14
Half Speed
Pump Flow
Low
High
Pressure Pressure
9
10
1000
RPM
100
PSI
150
±5
ºF
45.0
GPM
1000
RPM
1000
PSI
150
±5
ºF
35.0
GPM
(9-10)
10.0*
GPM
Pump Test For Aeration And/Or Cavitation
11
12
Varied Speeds — Constant Pressure
13
14
15
16
17
600
800
1000
1200
1400
1600
1800
RPM
RPM
RPM
RPM
RPM
RPM
RPM
1000
1000
1000
1000
1000
1000
1000
PSI
PSI
PSI
PSI
PSI
PSI
PSI
150
150
150
150
150
150
150
±5
±5
±5
±5
±5
±5
±5
ºF
ºF
ºF
ºF
ºF
ºF
ºF
17.0
26.0
35.0
44.0
54.0
63.0
72.0
GPM
GPM
GPM
GPM
GPM
GPM
GPM
(11-12) (12-13) (13-14) (14-15) (15-16) (16-17) (17-18)
9.0
GPM
9.0
GPM
9.0
GPM
10.0
GPM
9.0
GPM
9.0
GPM
18
2000
RPM
1000
PSI
150
±5
ºF
81.0
GPM
9.0
GPM
10%
* Flow differential for Test 10 is normally more than the flow differential for Test 8 on gear-type pumps.
NOTE: Block steering valve return line to tank to do pump tests.
Go on to Sheet 15
6-110
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 15 of 24)
ACTION
REMARKS
This test is used to find the efficiency of the
hydraulic pump. Install a Blocking Plate Assembly in the pressure line from the hydraulic
pump, or in the return line on the control
valve. This prevents oil from going through the
system. All pump flow now goes through the
flow meter.
WARNING
Open the manual load valve on the flow meter
fully before starting the diesel engine. The
relief valve is not part of the circuit for the
Pump Test. If the pressure gets too high, it is
possible to cause injury to personnel or damage
to equipment.
CAUTION
Immediately after stopping the diesel engine,
remove the Blocking Plate Assembly from the
pressure line for the pump or the return line on
the control valve on larger machines. This will
prevent any possible damage later.
TA098988
Go on to Sheet 16
6-111
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 16 of 24)
ACTION
REMARKS
TEST 7
PUMP FLOW AT LOW PRESSURE
1.
Manual load valve on flow meter
Open all the way.
2.
Engine
Start and run at 2000 rpm.
3.
Manual load valve
Open slowly until you get 100 psi (70.3 kgs/
sq. meter).
4.
Oil temperature
Record.
5.
Flow rate (gpm)
Record.
TEST 8
PUMP FLOW AT HIGH PRESSURE
1.
Engine
Run at 2000 rpm.
2.
Manual load valve on flow meter
sq.
Close slowly to get 1000 psi (703 kgs/
meter).
3.
Oil temperature
Record.
4.
Flow rate (gpm)
Record.
Go on to Sheet 17
6-112
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 17 of 24)
ACTION
REMARKS
TEST 9
PUMP FLOW AT LOW PRESSURE
(1/2 TEST RPM)
1.
Engine
Run at 1000 rpm.
2.
Manual load valve on flow meter
Open slowly to get 100 psi (70.3 kgs/
sq. meter).
3.
Oil temperature
Record.
4.
Flow rate (gpm)
Record.
TEST 10
PUMP FLOW AT HIGH PRESSURE
(1/2 TEST RPM)
1.
Engine
Run at 1000 rpm.
2.
Manual load valve on flow meter
Close slowly to get 1000 psi (703 kgs/
sq. meter).
3.
Oil temperature
Record.
4.
Flow rate (gpm)
Record.
Go on to Sheet 18
6-113
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
TESTS 11 THRU 18
PUMP AERATION AND CAVITATION
(Sheet 18 of 24)
ACTION
REMARKS
NOTE
These eight (8) tests are similar, except for the
engine rpms. Run the engine (step 2) according
to the list under REMARKS.
1.
Manual load valve on flow meter
Open all the way before starting engine.
2.
Engine
Start and run at (see list).
3.
Oil temperature
Record for each test.
4.
Flow rate (gpm)
Record for each test.
TEST 11 — 1600 rpm
TEST 12 — 800 rpm
TEST 13 — 1000 rpm
TEST 14 — 1200 rpm
TEST 15 — 1400 rpm
TEST 16 — 1600 rpm
TEST 17 — 1800 rpm
TEST 18 — 2000 rpm
NOTE
Chart B also gives the data for each test.
Go on to Sheet 19
6-114
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
(Sheet 19 of 24)
Make a comparison of the test data with the
data on Chart C for the specific test. The
information on Chart C is the maximum
for best performance.
Blocking Plate Assemblies or Caps and Plugs can be put
in each of the cylinders lines. For best accuracy, do these
tests with the oil temperature approximately 150ºF
(66ºC) (near the oil temperature for the System Tests
and pump Test).
CHART C. BLOCKED CYLINDER TESTS
System
Oil
Test Temperature
Name
(Start)
Test
19
Number
Control
Steer
Lever
Right
Position
Engine
Any
Speed
Speed
System
0-100
Test
PSI
Pressure
150
Test
±5
Data
°F
Cylinder
Leakage
Rate
Control
Valve
Group
Steer
Right
Flow
Rate
20
Steer
System
System
Left
Oil
Oil
Flow Temperature Temperature
Rate
(End)
(Start)
21
22
23
Steer
Right
Flow
Rate
24
System
Oil
Temperature
(End)
25
Steer
Right
Steer
Left
Steer
Left
Steer
Right
Steer
Right
Steer
Right
2000
RPM
1000
PSI
2000
RPM
1000
PSI
Any
Speed
0-100
PSI
Any
Speed
0-100
PSI
2000
RPM
1000
PSI
Any
Speed
0-100
PSI
150
±5
°F
150
±5
°F
Right
Cylinder
Leakage
WARNING
78.0
GPM
(20-4)
78.0
GPM
(21-5)
1.0
1.0
GPM
GPM
(15-20) (15-21)
3.0
GPM
3.0
GPM
Left
Cylinder
Leakage
77.0-78.0
GPM
(24-4)
0-1.0
GPM
(20-24)
1.0-0
GPM
NOTE: Install shipping link before tests are made.
6-115
150
±5
°F
Install the shipping link. Lower the mast to the ground.
Move the steering wheel from RIGHT TURN to LEFT
TURN several times to release any pressure oil in the
cylinder lines. All pressure in the lines must me released
or injury to personnel and damage to equipment can
result while loosening the lines to install or remove the
plate assemblies.
TA098989
Go on to Sheet 20
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 20 of 24)
ACTION
REMARKS
TEST 19
TEMPERATURE
1.
Steering wheel
Turn to. right continuously.
2.
Engine
Run at any rpm.
3.
Oil temperature
Record.
TESTS 20 AND 21
LEAKAGE RATES
NOTE
Tests 20 and 21 are the same except one is for
left turn and the other for right turn.
1.
Manual load valve on flow meter
Open all the way.
2.
Steering wheel
Turn to the right (or left).
3.
Engine
Run at 2000 rpm.
4.
Manual load valve
5.
Flow rate (gpm)
Close slowly until you get 1000 psi (703 kgs/
sq. meter).
Record. Do this for both tests.
Go on to Sheet 21
See chart C, page 6-115.
Go on to Sheet 22
6-116
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 21 of 24)
ACTION
REMARKS
TEST 22
TEMPERATURE
1.
Steering wheel
Turn to right.
2.
Engine
Run at any rpm with system pressure at 0 to
100 psi (70.3 kgs/sq. meter).
3.
Oil temperature
Record.
NOTE
Find the leakage rate of the cylinders and the
leakage rate of the control valves. Use the test
information from the System Tests, Pump Test
and Blocked Cylinder Tests.
Example: Find the leakage rates in the RIGHT
TURN position.
Test 8: flow rate of the pump only.
Test 20: flow rate of pump and control valve.
Test 4: flow rate of pump, control valve and
cylinders.
The system components tested in Tests 8 and
20 are the same except for the control valve.
Then the difference in flow rates must be the
leakage in the control valve. (Subtract the information for Test 20 from the test information
for Test 8.
Go on to Sheet 22
6-117
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 22 of 24)
ACTION
REMARKS
The system components tested in Tests 20 and
4 are, the same except for the cylinders. Then
the difference in flow rates must be the leakage
in the cylinders. (Subtract the test information
for Test 4 from the test information for Test
20).
NOTE
If the Blocked Cylinder Tests give an indication
of leakage that is too high in one or more of
the cylinders, do the Blocked Cylinder Tests
for the Right Side. For best accuracy, turn the
steering wheel through several cycles to get the
temperature of the oil in the cylinders the
same as the temperature of the oil in the hydraulic tank. Make the temperature of the complete system 1500F (660C). Put a Blocking
Plate Assembly in the rod end of the right
steering cylinder.
TEST 23
TEMPERATURE
1.
Manual load valve on flow meter
Open all the way.
2.
Engine
Start and run at any rpm.
3.
Oil temperature
Record.
Go on to Sheet 23
6-118
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 23 of 24)
ACTION
REMARKS
TEST 24
STEER RIGHT FLOW RATE
1.
Manual load valve on flow meter
Open all the way.
2.
Engine
Run at 2000 rpm.
3.
Manual load valve
Close slowly until you get 1000 psi (703 kgs/
sq. meter).
4.
Flow rate (gpm)
Record.
TEST 25
TEMPERATURE
1.
Manual load valve on flow meter
Open all the way.
2.
Engine
Run at any rpm.
3.
Steering wheel
Turn to the right.
4.
Oil temperature
Record.
Go on to Sheet 24
6-119
TM10-3930-641-34-2
TEE TEST PROCEDURE FOR STEERING SYSTEM (CONT)
LOCATION/ITEM
(Sheet 24 of 24)
ACTION
REMARKS
NOTE
Find the leakage rates for the right and left
cylinders. Use the test information from System
Test, Pump Test and Blocked Cylinder Tests.
Example: Find the leakage rate for the steering
cylinders.
Test 20: flow rate of pump and control valve.
Test 24: flow rate of pump, control valve and
left side cylinder.
Test 4: flow rate of pump, control valve and
both cylinders.
The system components tested in Tests 20 and
24 are the same except for the left side cylinder.
The difference in flow rates must be the leakage
in the left side cylinder (subtract the test information for Test 24 from the test information
for Test 20).
The system components tested in Tests 24 and
4 are the same except for the right side cylinder.
The difference in flow rates must be the leakage
in the right side cylinder (subtract the test information for Test 4 from the test information
for Test 24). Make a comparison of the test
values with the values on Chart C.
End
6-120
TM10-3930-641-34-2
CHAPTER 7
HYDRAULIC SYSTEM MAINTENANCE
Page
Section I
II.
General .................................................................... 7-2
Hydraulic Lift System Components...........................
Hydraulic Pump Removal/Installation.......................
Hydraulic Pump Disassembly/Assembly...................
Hydraulic Oil Cooler Oil Lines Removal/
Installation................................................................
Hydraulic Oil Cooler Removal/Installation ................
Hydraulic Tank Removal/Installation ........................
Hydraulic Tank Disassembly/Assembly ....................
Hydraulic Control Lines and Fittings
Removal/Installation.................................................
Hydraulic Control Valve Disassembly/
Assembly .................................................................
Tilt Cylinder Removal/Installation .............................
Tilt Cylinder Disassembly/Assembly .........................
Tilt Cylinder Bearings Removal/Installation ..............
Lift Cylinder Removal/Installation .............................
Lift Cylinder Disassembly/Assembly .........................
Page
Section III
7-4
7-5
7-13
7-20
7-22
7-27
7-29
7-42
7-44
7-50
7-54
7-61
7-63
7-66
7-1
Mast Components ....................................................
Mast Removal/Installation ........................................
Mast Disassembly/Assembly ....................................
Fork Assembly Removal/Installation.........................
Carriage Removal/Installation ..................................
Carriage Assembly Disassembly/Assembly ..............
Side Tilt Cylinder Removal/installation .....................
Side Shift Cylinder Removal/Installation...................
Side Shift/Tilt Cylinders Disassembly/Assembly .......
Mast Hydraulic Lines Removal/Installation ...............
Mast Lift Chains Removal/installation.......................
Tee Test Procedure for Hydraulic System ................
7-70
7-71
7-76
7-87
7-91
7-94
7-101
7-104
7-107
7-111
7-118
7-124
TM10-3930-641-34-2
Section I. GENERAL
HYDRAULIC SYSTEM
(Sheet 1 of 2)
TA099151
Go on to Sheet 2
7-2
TM10-3930-641-34-2
MAST HYDRAULIC SYSTEM
(Sheet 2 of 2)
5.
LIFT CYLINDER. A ram type which moves up by hydraulic oil
pressure and moves down by gravity. The extended part of the cylinder is
completely filled with oil. As the lift cylinder is ex- tended it pushes up on a
crosshead. This crosshead is connected to the mast with a set of wheels and
chains. The chains lift the mast at twice the lift cylinder rate.
High pressure mast hydraulic system consists of:
1.
Hydraulic tank
2.
Hydraulic pump
3.
Filter
4.
Control valves
5.
Lift cylinder
6.
Tilt cylinders
7.
Side shift cylinder
8.
Side tilt cylinders
9.
Container lock cylinder(s)
6.
TILT CYLINDERS (2). Double acting cylinders which extend by
hydraulic pressure and retract by hydraulic pressure. Control the forwardbackward tilt angle of the mast. Total movement is 17 degrees;
7.
SIDE SHIFT CYLINDER. A double acting cylinder which controls the
side shift of the forks and tophandler with respect to the center line of the
vehicle. Total movement from left to right is 24 inches.
Oil flows from hydraulic tank (1) to hydraulic pump (2) then to control valve
(4). The control levers are moved to let oil go through the control valve to lift
cylinder (5), tilt cylinders (6), side shift cylinder (7), side tilt cylinder (8) or
container lock cylinders (9). Oil returns from the cylinders through the control
valve and back to the tank.
8.
SIDE TILT CYLINDER. A double acting cylinder which rotates the
forks and tophandler. Total movement is 10 degrees.
9.
CONTAINER LOCK CYLINDERS. Double acting cylinders which lock
or unlock the container. On the 20 ft tophandler there is one cylinder; on the
35 ft and 40 ft there are two.
1.
HYDRAULIC TANK. The storage reservoir for all of the hydraulic oil
used in the machine except for the transmission and torque converter.
Equipped with an inlet strainer for filtering oil when added. A filter is built into
the tank for filtering oil returning from the hydraulic system. A sensor is also
in the tank to monitor the oil temperature.
2.
HYDRAULIC PUMP. A gear type, driven by the engine. Supplies oil to
the control valve for distribution to the hydraulic system.
3.
FILTER. Protects the system in the event of a pump failure. It is a
replaceable screen type.
4.
CONTROL VALVE. Directs high pressure oil to hydraulic
cylinders, depending on the position of one of the five control
handles. The five control valves activate the mast up and down,
tilt forward and back, slide shift left and right, slide tilt, and the
container locks. All valves contain an oil pressure relief valve to
return extra oil pressure back to the hydraulic tank when the
mast is fully tilted, fully raised, fully shifted or fully rotated.
End
7-3
TM10-3930-641-34-2
Section II. HYDRAULIC LIFT SYSTEM COMPONENTS
HYDRAULIC LIFT COMPONENTS MAINTENANCE INSTRUCTIONS
This section covers maintenance of these hydraulic components for direct support and general support maintenance personnel:
a.
b.
c.
d.
Hydraulic pump
Hydraulic cooler
Hydraulic tank
Hydraulic control valve
e. Tilt cylinders
f. Lift cylinder
LIST OF TASKS
TASK NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
TASK
REF (PAGE)
Hydraulic pump removal/installation.
Hydraulic pump assembly/disassembly.
Hydraulic oil cooler oil lines removal/installation.
Hydraulic oil cooler removal/installation.
Hydraulic tank removal/installation.
Hydraulic tank disassembly/assembly.
Hydraulic control lines and fittings removal/installation.
Hydraulic control valve disassembly/assembly.
Tilt cylinder removal/installation.
Tilt cylinder assembly/disassembly.
Tilt cylinder bearings removal/installation.
Lift cylinder removal/installation.
Lift cylinder disassembly/assembly.
7-4
7-5
7-13
7-20
7-22
7-27
7-29
7-42
7-44
7-50
7-54
7-61
7-63
7-66
TROUBLESHOOTING
REF (PAGE)
2-28, 2-29
2-28, 2-29, 2-30, 2-32
2-26
None
None
None
None
2-28, 2-29, 2-30, 2-31, 2-33
None
2-29, 2-30, 2-35
None
None
2-29, 2-30
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION
This task covers: Replacement of hydraulic implement pump.
(Sheet 1 of 8)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
Page 2-28, 2-29
Equipment Condition
Relieve pressure on hydraulic tank.
Oil cooled.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Precleaner Lid and Hood Removal/
Installation, TM 10-3930-641-20.
Shipping Link Removal/Installation,
TM 10-3930-641-20.
Air Cleaner Removal/Installation,
TM 10-3930-641-20.
Hot oil causes burns.
Go on to Sheet 2
7-5
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 8)
ACTION
REMARKS
REMOVAL
1.
Precleaner lid (1) and hood (2)
Remove. See TM 10-3930-641-20.
2.
Door assemblies at rear of engine Open.
3.
Hydraulic lines (3)
Tag and disconnect from oil filter base
and cap.
4.
Wires for sending units of transmission and brake system oil
filters.
Disconnect from harness (4) and identify.
5. Six capscrews (5) that hold bases Remove.
for brake and transmission oil filters
NOTE
Do not disconnect hydraulic lines from the
filter bases. Place filters and bases on floor
plates.
TA099153
Go on to Sheet 4
7-6
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 8)
ACTION
6.
Four capscrews (6) that hold air
cleaner housing to filter base
frame
Remove.
7.
Wire (7) for sending unit of air
cleaner indicator.
Disconnect and identify.
8.
Clamp (8)
Loosen.
9.
Filter group (9)
Remove by following:
a.
Four position capscrews
Remove.
b.
Three heatshield capscrews
Remove.
c.
Filter group
Fasten hoist and remove.
REMARKS
NOTE
Filter group assembly weighs 100 lbs. (45.4
(kg).
TA099153
Go on to Sheet 4
7-7
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 4-of 8)
ACTION
REMARKS
10. Air cleaner housing
Fasten hoist and remove.
11. Two capscrews (10)
Remove.
12. Heat shield (11)
Remove.
13. Panels from right side of engine
Remove.
14. Hydraulic line (12)
Disconnect from pump and identify.
TA099155
Go on to Sheet 5
7-8
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 5 of 8)
ACTION
REMARKS
15. Lower right side panel.
Remove.
16. Four capscrews (13)
Remove.
17. Oil supply line (pump discharge
line)
Disconnect.
18. Clamp (14)
Loosen.
19. Hydraulic pump
Fasten hoist.
20. Capscrews that hold pump to
rear of engine
Remove.
21. Clamp below elbow on supply
line
Tighten.
22. Pump (16)
Pull away from engine and remove.
NOTE
Pump weighs 110 lbs. (49.9 kg).
TA099155
Go on to Sheet 6
7-9
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 6 of 8)
ACTION
REMARKS
INSTALLATION
1.
Pump (15)
Fasten hoist and place in position at rear of
engine.
CAUTION
Be careful not to damage the splines on shaft.
2.
Capscrews that hold pump to
rear of engine
Install.
3.
Clamp (14)
Tighten.
4. Four capscrews (13) that hold
supply line (pump discharge line)
to bottom of pump.
Install.
TA099156
Go on to Sheet 7
7-10
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 7 of 8)
ACTION
5.
Clamp below elbow on supply line Tighten.
6.
Hydraulic line (12)
Connect to rear of pump.
7.
Heat shield (11)
Place in position.
8.
Cal)screws (10) to hold heat shield Install.
9.
Air cleaner housing
10. Filter group (9)
REMARKS
Fasten hoist and install.
Install by following:
a.
Filter group (9)
Fasten hoist and place in position.
b.
Three heat shield capscrews Install.
c.
Four position capscrews
Install.
11. Transmission and pilot filter
systems filters
Install in filter base.
12. Four capscrews (6) that hold air
cleaner housing to filter base frame
Install.
TA099157
Go on to Sheet 8
7-11
TM10-3930-641-34-2
HYDRAULIC PUMP REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 8 of 8)
ACTION
13. Clamp (8)
Tighten.
14. Wire (7) for sending unit of air
cleaner indicator.
Connect.
REMARKS
15. Six capscrews that hold bases for Install.
pilot and transmission oil filters
16. Wires for sending units of trans- Connect.
mission and pilot system oil filters
17. Hydraulic lines (3)
Connect to oil filter base.
18. Precleaner lid (1) and hood (2)
Install. (See TM 10-3930-641-20.)
] 9. Engine side panels
Install.
20. Door assemblies at rear of engine Close.
TA099152
End
7-12
TM10-3930-641-34-2
HYDRAULIC PUMP ASSEMBLY/DISASSEMBLY
This task covers: Repair of hydraulic implement pumps.
(Sheet 1 of 7)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
Page 2-28, 2-29, 2-30, 2-32
Equipment Condition
Hydraulic pump removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Hydraulic Pump Removal/Installation, page 7-5.
Place parts in a clean area.
Go on to Sheet 2
7-13
TM10-3930-641-34-2
HYDRAULIC PUMP ASSEMBLY/DISASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 7)
ACTION
DISASSEMBLY
REMARKS
NOTE
Clean outside of pump before disassembly.
1.
Eight nuts (1)
Remove four (2), loosen four (1).
2.
Pump
Place on end opposite the drive shaft.
3.
Four Nuts (1)
Remove.
4.
Casting (3)
Remove.
5.
O-ring seal (6)
Remove from casting.
6.
Two lip seals (15) and
spacer ring (16)
Remove from casting.
7.
Ring retainer (8)
Remove.
8.
Back-up ring (7)
Remove.
9.
Packing (9)
Remove.
10. Isolation plate (6)
Remove.
Go on to Sheet 3
7-14
TM 10-3930-641-34-2
(Sheet 3 of 7)
HYDRAULIC PUMP ASSEMBLY/DISASSEMBLY (CONT)
1.
2.
3.
4.
B.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Nut
Stud
Casting
Dowel
O-ring seal
Isolation plate
Backup ring
Ring retainer
Preformed packing
Pressure plate
Drive gear
Idler gear
Cover plate
Gear plate (pump body)
Lip type seal
Spacer
TA099158
Go on to Sheet 4
7-15
TM 10-3930-641-34-2
(Sheet 4 of 7)
HYDRAULIC PUMP ASSEMBLY/DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
11.
Body (14) and pressure plate
Remove as a unit from cover plate..
12.
Pressure plate (10)
Remove from gear plate.
13.
Drive gear (11)
Remove from cover plate.
14.
Idler Fear (12)
Remove from cover plate.
15.
O-ring seal (5)
Remove from cover plate.
16.
Pressure plate (10)
Remove from cover plate.
17.
Isolation plate (6)
Remove.
18.
Back-up ring (7)
Remove.
19.
O-ring seal (5)
Remove.
20.
Ring retainer (8)
Remove.
ASSEMBLY
NOTE
Clean all parts before assembly.
If grooves (4) in the bore are deeper than .015
in. (0.381 mm), replace body (5), and gears.
1.
O-ring (6)
Install In cover plate.
TA098977
Go on to Sheet 5
7-16
TM 10-3930-641-34-2
(Sheet 5 of 7)
HYDRAULIC PUMP ASSEMBLY/DISASSEMBLY (CONT)
LOCATION/ITEM
2.
Body (14)
ACTION
REMARKS
Install on cover plate.
NOTE
Make sure you place wide opening over the
inlet port in cover plate.
3.
Isolation plate (6)
Install on inlet side of pump.
4.
Back-up ring (7)
Install.
5.
Packing (9)
Install.
6.
Ring retainer (8)
Install.
7.
Pressure plate (10)
Install.
NOTE
Pressure plate must be installed with the
notch up. Bronze surface must be toward
gears.
8.
Drive gear (11)
Install.
9.
Idler gear (12)
Install.
10.
Pressure plate (10)
Install.
NOTE
Pressure plate must be installed with notch
down. Bronze surface must be toward gears.
Go on to Sheet 6
7-17
TM 10-3930-641-34-2
(Sheet 3 of 7)
HYDRAULIC PUMP ASSEMBLY/DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
11.
Isolation plate (6)
Install.
12.
Back-up ring (7)
Install.
13.
Packing (9)
Install.
14.
Ring retainer (8)
Install.
15.
Seal (15)
Install.
REMARKS
NOTE
Using suitable drive plate and handle, install
seal until it makes contact with counterbore
in casting. Lip of seal must be toward inside
of pump.
16.
Spacer ring (16)
Install.
17.
Seal (15)
Install.
Go on to Sheet 7
7-18
TM 10-3930-641-34-2
(Sheet 7 of 7)
HYDRAULIC PUMP ASSEMBLY/DISASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Using suitable drive plate and handle, install
seal until it makes contact with spacer ring.
Lip of seal must be toward inside of pump.
18.
Casting (3)
Place in position on gear plate housing.
19.
Four nuts (1)
Install.
NOTE
Place pump on small wooden blocks to allow
the studs in the casting to go through cover
plate without moving inside parts of pump
out of position.
20.
Four nuts (1)
Install.
NOTE
Use an arbor press to hold pump in position
while torquing nuts.
Tighten nuts to a torque of 280 to 320 lb. ft.
(379.6-433.9 N-m).
End
7-19
TM 10-3930-641-34-2
HYDRAULIC OIL COOLER OIL LINES REMOVAL/INSTALLATION
(Sheet 1 of 2)
This task covers: Removal and installation of hydraulic oil cooler oil lines.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-26
Container to catch
oil remaining in lines
Troubleshooting Reference
Equipment Condition
Engine shut off
Hydraulic oil cooler drained
Special Tools
None
Personnel Required
One mechanic
References
None
General Safety Instructions
None
Go on to Sheet 2
7-20
TM 10-3930-641-34-2
(Sheet 2 of 2)
HYDRAULIC OIL COOLER OIL LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Capscrews and washers securing
flanges
Remove.
2.
Hose assemblies
Remove and discard preformed packing.
3.
Tube assemblies
Disconnect connectors. Loosen hose clamps.
4.
Clips and brackets
brackets. Remove tube assemblies.
Remove capscrews and nuts securing clips and
INSTALLATION
1.
Clips and brackets and tube
assemblies
Position clips and brackets onto tube
assemblies. Position tube assemblies.
2.
Tube connectors
clamps.
Connect tube connectors and secure hose
3.
Hose assemblies
position into flanges. Position hose assemblies
and secure with capscrews and washers.
Lubricate new preformed packing with oil and
TA172254
END
7-21
TM 10-3930-641-34-2
(Sheet 1 of 5)
HYDRAULIC OIL COOLER REMOVAL/INSTALLATION
This task covers: Replacement of hydraulic oil cooler.
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
None
Troubleshooting Reference
Equipment Condition
Rear hood and crankcase guard removed.
Oil drained from hydraulic tank and
system.
Special Tools
None
Coolant drained from system.
Personnel Required
One mechanic
References
General Safety Instructions
LO 10-3930-641-12
Be careful not to damage radiator when
moving cooler.
Rear hood removal/installation,
TM 10-3930-641-20.
Crankcase guard removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
7-22
TM 10-3930-641-34-2
(Sheet 2 of 5)
HYDRAULIC OIL COOLER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
CAUTION
Hydraulic oil cooler weighs 134 lbs. Use hoist
of suitable lifting capacity to lift it.
Do not cause damage to hydraulic oil cooler or
radiator core assembly when replacing.
1.
Channel assembly (2)
Remove.
2.
Tube assemblies (1) and (3)
Remove.
3.
Bolts (4) and shield assembly (5)
Remove.
4.
Hydraulic hoses (6)
Disconnect from oil cooler bypass valve.
Go on to Sheet 3
TA099159
7-23
TM 10-3930-641-34-2
(Sheet 3 of 5)
HYDRAULIC OIL COOLER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
5.
Two shield assemblies (7)
Remove from bottom of radiator.
6.
Hydraulic hose (8)
cooler.
Disconnect from bottom of hydraulic oil
7.
Four capscrews (9) that hold top
of oil cooler in position.
Remove from supports.
8.
Hydraulic oil cooler lift handles
Fasten hoist
TA099160
Go on to Sheet 4
7-24
TM 10-3930-641-34-2
(Sheet 4 of 5)
HYDRAULIC OIL COOLER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
9.
Four capscrews (10) that hold
bottom of hydraulic oil cooler in
position
Remove.
10.
Hydraulic oil cooler
Remove.
REMARKS
INSTALLATION
1.
Hydraulic oil cooler
Fasten hoist and put in position.
2.
Four capscrews (10) that hold
bottom of cooler in position.
Install.
3.
Hydraulic hose (8)
Install at bottom of hydraulic oil cooler.
4.
Four capscrews (9) that hold top of
cooler in position.
Install.
TA099161
Go on to Sheet 5
7-25
TM 10-3930-641-34-2
(Sheet 5 of 5)
HYDRAULIC OIL COOLER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
5.
Two hydraulic hoses (6)
Install in oil cooler bypass line.
6.
Two shield assemblies (7)
Install at bottom of radiator.
7.
Shield assembly (5) and bolts (4)
Install.
8.
Two tube assemblies (1) and (3)
Install.
A9.
Channel assembly (2)
Install.
10.
Cooling system
Fill with coolant.
11.
Rear hood and crankcase guard
Install.
REMARKS
TA099162
END
7-26
TM 10-3930-641-34-2
(Sheet 1 of 2)
HYDRAULIC TANK REMOVAL/INSTALLATION
This task covers: The removal and installation of the hydraulic tank.
INITIAL SETUP
Test Equipment
Materials/Parts
None None
None
Troubleshooting Reference
Equipment Condition
Engine OFF
Hydraulic tank drained.
Hydraulic tank shield removed.
Special Tools
None
Remove right side platform.
Shipping link installed.
Personnel Required
Two mechanics
References
General Safety Instructions
Replacing hydraulic oil, LO 10-3930-641-12.
Tires blocked.
Platform removal/installation, page 8-39.
(shield and platform).
Shipping Link Removal/Installation,
TM 10-3930-641-20.
Go on to Sheet 2
7-27
TM 10-3930-641-34-2
(Sheet 2 of 2)
HYDRAULIC TANK REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Strap
b.
a. Loop around hydraulic tank.
Fasten to hoist.
2.
Capscrews (1), washers (2) and
spacers (3)
Remove from brackets (4).
3.
Hydraulic tank
Lower to ground.
NOTE
INSTALLATION
1.
Strap
b.
Hydraulic tank weighs 750 lbs. (239 kg)
a. Loop around hydraulic tank.
Fasten to hoist.
2.
Hydraulic tank
Lift into position.
3.
Capscrews (1), washers (2) and
spacers (3)
Use to fasten hydraulic tank brackets (4) to
frame.
See Torque Limits Chart, page D-1
TA099163
END
7-28
TM 10-3930-641-34-2
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY
(Sheet 1 of 13)
This task covers: Disassembly and assembly of the hydraulic tank.
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
As required
Troubleshooting Reference
Equipment Condition
Hydraulic tank removed from vehicle.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Hydraulic tank removal/installation, page 7-27.
None
Go on to Sheet 2
7-29
TM 10-3930-641-34-2
(Sheet 2 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Capscrew (17) and lockwasher (16)
Remove from access cover (1).
2.
Access cover (1)
Remove.
3.
Access cover (1)
a. Plug (2) and preformed packing
(3)
Disassemble.
Remove.
b. Pin (13)
Remove from shaft (14). Then remove retainer
(10), spring (9), housing (11), capscrew (15)
and washer (12).
c. Capscrew (7)
and ball (5) from cover (4).
Remove and remove retainer (8), spring (6),
4.
Filter element (28)
Remove.
5.
Preformed packing (26)
Remove.
6.
Cap (20)
Remove.
7.
Cap (20)
Disassemble.
Go on to Sheet 3
7-30
TM 10-3930-641-34-2
(Sheet 3 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
7.
Cap (20 (Cont)
a. Retaining ring (24)
ACTION
REMARKS
Remove.
b. Ball (21), plate (22), and
gasket (23)
Will come out.
8.
Strainer assembly (25)
Remove.
9.
Coupling (31)
Remove.
10.
Head assembly (27) and preformed
packing (32)
Remove.
11.
Elbows (60) and (59)
Remove by:
a.
Loosen and remove retaining nuts on tubes
(61) and (62).
b.
Unscrew elbows.
12.
Capscrew (83) and lockwasher (51)
Remove.
13.
Tube assembly (82) and preformed
packing (84)
Remove.
Go on to Sheet 4
7-31
TM 10-3930-641-34-2
(Sheet 4 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Access cover
19. Preformed packing
Plug 20.
Cap
56. Preformed packing
Preformed packing 21. Ball 57.
Cover
22. Plate 58. Preformed packing
Ball 23.
Gasket 59. Elbow
Spring
24. Retaining ring
Capscrew
25. Strainer assembly
Retainer
26. Preformed packing
Spring
27. Head assembly
Retainer
28. Filter element
Housing
29. Screen assembly
Washer
30. Rod 66. Lockwasher
Pin 31.
Coupling 67. Tube assembly
Shaft
32. Preformed packing
Capscrew
33. Tank assembly
Washer
34. Switch assembly
Capscrew
35. Elbow
71.
Plug 36.
Nipple
72. Preformed packing
37.
Flange 73. Cover assembly
38.
Switch assembly
39.
Sensing unit 75.
40.
Nipple
76. Preformed packing
41.
Wire
77. Flange
42.
Gasket 78. Preformed packing
43.
Cover
79. Plug, drain
44.
Washer 80. Valve
45.
Capscrew81. Nut
46.
Plug
82. Tube assembly
47.
Capscrew83. Capscrew
48.
Washer 84. Preformed packing
49.
Cover
85. Tube assembly
50.
Capscrew86. Joint assembly
51.
Lockwasher 87.
52.
Preformed packing
53.
Cover
89. Washer
54. Plate
90. Capscrew
55. Glass, sight
57. Capscrew
60.
61.
62.
63.
64.
65.
Elbow
Tube
Tube
Tube assembly
Preformed packing
Capscrew
68. Capscrew
69. Gasket
70. Preformed packing
Tube assembly
74. Guide
Spring
Clamps
88. Tube
TA099164
Go on to Sheet 5
7-32
TM 10-3930-641-34-2
(Sheet 5 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
14.
Clamps (87) on joint assembly (86)
Loosen.
15.
Capscrews securing tube assembly
(85) to bottom of screen assembly
(29)
Remove.
16.
Tube assembly (85) and preformed
packing (84)
17.
Capscrew (90) and lockwasher (89)
Remove.
18.
Tube (88) and preformed packing
(84) (87), as a unit.
Remove with joint assembly (86) and clamps
19.
Capscrews (68) and washers (44) at
bottom of hydraulic tank
Remove.
20.
Cover assembly (73) and preformed
packing (72)
Remove.
Remove.
Go on to Sheet 6
7-33
TM 10-3930-641-34-2
(Sheet 6 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
21.
ACTION
REMARKS
Cover assembly (73)
Disassemble.
a. Plug (79) and valve (80)
Unscrew and remove.
b. Preformed packing (78)
Remove.
c. Nuts (81)
Remove.
d. Flange (77) and preformed
packing (76)
Remove.
e. Spring (75) and guide (74)
Will come out.
22.
Tube assembly (71) and preformed
packing (70)
Remove retaining capscrews (not shown) and
remove.
23.
Capscrew (68) and washer (44)
Remove.
24.
Tube assembly (67) and gasket (69)
Remove.
25.
Capscrews (65) and lockwashers
(66)
Remove.
Go on to Sheet 7
7-34
TM 10-3930-641-34-2
(Sheet 7 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
26.
Tube assembly (63) and preformed
packing (64)
Remove.
27.
Elbows (60) and (59) at bottom of
screen assembly (29)
Remove by:
REMARKS
a.
(61) and (62).
Loosen and remove retaining nuts on tubes
b.
Unscrew elbows.
28.
Capscrew (57) and preformed
packing (58)
Remove.
29.
Cover (53)
Remove.
30.
Plate (54), sight glass (55), and
preformed packing (56)
Remove from cover (53).
31.
Capscrew (50) and lockwasher (51)
Remove.
32.
Cover (49) and preformed packing
(52)
Remove.
33.
Capscrew (47) and washer (48)
Remove.
34.
Switch assembly (34)
Remove.
Go on to Sheet 8
7-35
TM 10-3930-641-34-2
(Sheet 8 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
35.
ACTION
REMARKS
Switch assembly (34)
Disassemble.
a. Capscrew (45) and washer (44)
Remove.
b. Cover (43) and gasket (42)
be removed.)
Remove from flange (37). (Plug (46) may also
c. Nipple (36)
Unscrew from flange (37).
d. Elbow (35)
Unscrew from nipple (36).
e. Switch assembly (38)
Unscrew from elbow (35).
f. Switch assembly (38)
May be disassembled further by unscrewing
nipple (40) from sensing unit (39) and
separating from wire (41).
ASSEMBLY
1.
Wire (41)
Insert into nipple (40).
a.
Screw nipple (41) into sensing unit (39).
b.
Switch assembly (38) is screwed into
elbow (35).
Go on to Sheet 9
7-36
TM 10-3930-641-34-2
(Sheet 9 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
2. Switch assembly (34)
ACTION
REMARKS
Assemble.
a. Elbow (35)
Screw onto nipple (36).
b. Nipple (36)
Screw into flange (37).
c. Cover (43) and gasket (42)
Place in position on switch assembly (34).
d. Capscrews (45) with washers
(44)
Install.
3.
Switch assembly (34)
Place in position on tank assembly (33).
4.
Capscrews (47) and washers (48)
Install.
5.
Cover (49) and preformed packing
(52)
Place in position on tank assembly (33).
6.
Capscrews (50) and washers (51)
Install.
7.
Plate (54), sight glass (55), and
preformed packing (56)
Install in cover (53).
8.
Cover (53)
Place in position on tank assembly (33).
Go on to Sheet 10
7-37
TM 10-3930-641-34-2
(Sheet 10 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
9.
Capscrews (57) and preformed
packings (58)
Install.
10.
Elbows (60) and (59)
Install at bottom of screen assembly by:
a.
Screw elbows into screen assembly.
b.
Use retaining nuts and fasten tubes (61)
and (62) to elbows (60) and (59).
11.
Tube assembly (63) and preformed
packing (64)
Place in position.
12.
Capscrews (65) and lockwashers
(66)
Install.
13.
Tube assembly (67) and gasket (69)
Place in position.
14.
Capscrew (68) and washer (44)
Install.
15.
Tube assembly (71) and preformed
packing (70)
Place in position and install retaining capscrews
(not shown).
Go on to Sheet 11
7-38
TM 10-3930-641-34-2
(Sheet 11 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
16.
ACTION
REMARKS
Cover assembly (73)
Assemble.
a. Spring (75) and guide (74)
Place in position.
b. Flange (77) and preformed
packing (76)
Place in position and secure with nuts (81).
c. Cover assembly (73) and
preformed packing (72)
(44).
Place in position on bottom of tank and
secure with capscrews (68) and lockwashers
d.
Plug (79) with preformed
packing (78) and valve (80)
Screw into bottom of cover assembly (73).
17.
Tube (88) and preformed packing
(84) lockwasher (89).
Install on cover (27) using capscrew (90) and
18.
Joint assembly (86) and clamps (87)
Install on tube (88).
19.
Tube assembly (85)
Place in position in joint assembly (86) and on
screen assembly (29) with preformed packing
(84).
20.
Capscrews securing tube assembly
(85) to bottom of screen assembly
Install and tighten.
Go on to Sheet 12
7-39
TM 10-3930-641-34-2
(Sheet 12 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
21.
Clamps (87)
Tighten.
22.
Tube assembly (82) and preformed
packing (84)
Place in position on bottom of screen
assembly.
23.
Capscrews (83) and lockwasher (51)
Install.
24
Elbows (60) and (59)
a.
assembly (27).
Install by:
Screw elbows into fitting in head
b.
Screw retaining nuts on tubes (61) and
(62) onto elbows.
25.
Head assembly (27) and preformed
packing (32)
Place in position on tank assembly (33).
26.
Coupling (31)
Install.
27.
Strainer assembly (25)
Install.
28.
Cap (20)
Assemble.
a. Ball (21), plate (22), and
gasket (23)
Place in position in cap (20).
b. Retaining ring (24)
Install.
Go on to Sheet 13
7-40
TM 10-3930-641-34-2
(Sheet 13 of 13)
HYDRAULIC TANK DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
29.
Cap (20)
Install in head assembly (27).
30.
Access cover (1)
Assemble.
a. Retainer (8), spring (6) and
ball (5)
Install in cover (4) and secure with capscrew
(7).
b. Washer (12), capscrew (15),
housing (11), spring (9) and
retainer (10)
Assemble on shaft (14) and secure with pin
(13) in cover assembly (4).
31.
Access cover (1) and preformed
packing (26)
Place in position on head assembly (27).
32.
Capscrew (17) and lockwasher (16)
Install.
33
Plug (2) and preformed packing (3)
Install in access cover (1).
End
7-41
TM 10-3930-641-34-2
HYDRAULIC LINES AND FITTINGS REMOVAL/INSTALLATION
(Sheet 1 of 2)
This task covers: Removal/installation of hydraulic lines and fittings.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-30'
Containers to catch oil
Troubleshooting Reference
Equipment Condition
Engine OFF
System cooled
Special Tools
None
Mast lowered to end of travel
Personnel Required
One mechanic
References
General Safety Instructions
None
Hot oil causes burns.
Allow system to cool.
Go on to Sheet 2
7-42
TM 10-3930-641-34-2
(Sheet 2 of 2)
HYDRAULIC LINES AND FITTING REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Hydraulic tank
Drain.
See TM 10-3930-641-20
NOTE
Tag hydraulic lines to identify location. Cap
or plug all openings to prevent dirt from
entering hydraulic system.
2.
Fitting (1)
Loosen and unscrew from nipple (2).
3.
Line (3)
Remove.
I INSTALLATION I
1. Line (3) Place in position.
2. Fitting (1)
Install on nipple (2).
3. Hydraulic tank
Fill.
4.
See LO 10-3930-614-12
MastBleed.
See LO 10-3930-614-12.
TA172242
END
See TM 10-3930-641-20.
7-43
TM 10-3930-641-34-2
(Sheet 1 of 6)
HYDRAULIC CONTROL VALVE DISASSEMBLY/ASSEMBLY
This task covers: Disassembly/assembly of the hydraulic control valve.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-28, 2-29, 2-30, 2-31, 2-33
None
Troubleshooting Reference
Equipment Condition
Hydraulic valve removed
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Hydraulic Control
Valve Removal/Installation,
TM 10-3930-641-20.
Place parts in a clean area.
Go on to Sheet 2
7-44
TM 10-3930-641-34-2
(Sheet 2 of 6)
HYDRAULIC CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
NOTE
The disassembly/assembly procedure for
each of the five valves is identical.
1. Elbows and o-ring seals
Mark, identify and remove.
2. Four nuts (10)
Remove. Separate valve bodies.
3. Preformed packing (8) and
(9) and shim (1)
Remove.
4. Cap (27)
Remove.
5. Valve plunger
Remove.
Go on to Sheet 3
7-45
TM 10-3930-641-34-2
HYDRAULIC CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
(Sheet 3 of 6)
Shim
Body
Ball
Guide
Spring
Preformed packing
Plug
Preformed packing
Preformed packing
Nut
Stud
Plug
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
7-46
O-ring seal
Capscrew
Shims
Plunger
Spring
Body
Body
Plunger
O-ring seal
Retainer
Retainer
Spring
Guide
Screw
Cover
Capscrew
TA099165
Go on to Sheet 4
TM 10-3930-641-34-2
HYDRAULIC CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Keep valve plunger assemblies with the valve
bodies they were in.
NOTE
Spring is compressed.
6. Screw (26)
Remove.
7. Guide (25), spring retainer (23),
spring (24), spring retainer (23),
retainer (22), O-ring seal (21)
Remove from plunger (20).
8. O-ring seal at opposite end of valve
body.
Remove and replace, if damaged.
9. Plug (12)
Remove.
10. Capscrew (14), shims (15),
plunger (16), spring (17)
Remove from valve body (18).
Go on to Sheet 5
7-47
TM 10-3930-641-34-2
HYDRAULIC CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
11. Plug (7)
Remove.
12. Preformed packing (6), spring (5),
guide (4), and ball (3)
Remove.
REMARKS
ASSEMBLY
1. Ball (3), guide (4), and spring (5)
Install.
2. Plug (7)
Install.
3. Spring (17), plunger (16),
shims (15), and capscrew (14)
Install in relief valve body (18).
4. Relief valve assembly
Install.
Go on to Sheet 6
7-48
TM 10-3930-641-34-2
(Sheet 6 of 6)
HYDRAULIC CONTROL VALVE DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
5. O-ring seal (6)
Install on plug (7).
6. Plug (7)
Install.
7. O-ring seal (21)
Install on plunger (20).
8. Retainer (22)
Install on plunger (20).
9. Spring retainer (23), spring (24),
spring retainer (23), guide (25),
screw (26)
Install on plunger (20).
10. Plunger assembly (20)
Install.
11. Cover (27)
Install.
12. Preformed packing (8) and (9)
Install.
13. Shim (1)
Install.
14. Four nuts (10)
Install.
REMARKS
End
7-49
TM 10-3930-641-34-2
(Sheet 1 of 3)
TILT CYLINDER REMOVAL/INSTALLATION
This task covers: Replacement of tilt cylinders.
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
None
None
Equipment Condition
Relieve pressure on hydraulic tank.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
None
Care should be taken so cylinder doesn't
fall.
Go on to Sheet 2
7-50
TM 10-3930-641-34-2
(Sheet 2 of 3)
TILT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMOVAL
REMARKS
WARNING
Do not remove both cylinders at one time
unless the mast is properly blocked and held
stationary.
1. Two hydraulic lines (3)
Disconnect, cap and identify.
2. Tilt cylinder (4)
Fasten hoist.
3. Two capscrews
Remove.
4. Retainer (6)
Remove.
5. Pin (5)
Remove.
6. Retainer (7)
Remove.
7. Two capscrews
Remove.
8. Pin (8)
Remove.
9. Tilt cylinder (4)
Remove.
TA099166
Go on to Sheet 3
7-51
TM 10-3930-641-34-2
(Sheet 3 of 3)
TILT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1. Tilt cylinder (4)
Fasten hoist and lift into position.
2. Pin (8)
Install.
3. Retainer (7)
Install.
4. Two capscrews
Install.
5. Pin (5)
Install.
6.Retainer (6)
Install.
7. Two capscrews
Install.
8. Two hydraulic lines (3)
Uncap and connect.
TA099167
End
7-52
TM 10-3930-641-34-2
THIS PAGE INTENTIONALLY LEFT BLANK
7-53
TM 10-3930-641-34-2
TILT CYLINDER DISASSEMBLY/ASSEMBLY
(Sheet 1 of 7)
This task covers: Disassembly and assembly of the tilt cylinder.
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
None
Page 2-29, 2-30, 2-35.
Equipment Condition
Tilt cylinder removed.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Tilt Cylinder Removal/Installation, page 7-50.
Place parts in a clean area.
Go on to Sheet 2
7-54
TM 10-3930-641-34-2
(Sheet 2 of 7)
TILT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1. Tilt cylinder
Secure to repair stand.
2. Tilt cylinder
Move rod (8) to fully extended position.
3. Rod (8)
Put support under rod and fasten strap.
4. Nut (10)
Loosen.
5. Cap (12)
Loosen.
6. Cylinder
Pull away from rod assembly with repair stand.
7. Piston nut (3)
socket.
Remove, using torque multiplier, adapter, and
NOTE
Hold rod (8) stationary with tool while removing piston nut (3).
Go on to Sheet 3
7-55
TM 10-3930-641-34-2
(Sheet 3 of 7)
TILT CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Cylinder group
Cylinder
Piston lock nut
Piston
Packing ring
Spacer
Preformed packing
Cylinder piston rod
Wiper ring
Packing guide nut
Packing
End cap
Back-up ring
Preformed packing
Bearing
Retaining ring
Pin
Gease fitting
Capscrew
Washer
Pin retainer
Locknut
Tilt cylinder washer
Clevis
TA099168
Go on to Sheet 4
7-56
TM10 3930-641-34-2
(Sheet 4 of 7)
TILT CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
8. Piston (4)
Remove.
9. Spacer (6)
Remove.
10. Cap (12)
Remove.
11. Nut (10)
Remove.
12. Preformed packing (7)
Remove.
13. Three packing rings (5)
Remove.
14. Packing (11)
Remove from inside cap (12).
15. Preformed packing (14) and
back-up ring (13)
Remove from cap.
16. Wiper ring (9)
Remove from nut (10).
REMARKS
Go on to Sheet 5
7-57
TM10 3930-641-34-2
(Sheet 5 of 7)
TILT CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
ASSEMBLY
REMARKS
NOTE
Clean all parts.
1. Wiper ring (9)
Install in nut (10).
2. Back-up ring (13)
Install on cap (12).
NOTE
Back-up ring (13) must be installed with curved
(concave) surface toward the preformed
packing (14).
3. Preformed packing (14)
Install on cap (12).
4. Packing (11)
Install in cap (12).
5. Preformed packing (7)
Install on piston (4).
6. Three packing rings (5)
Install on piston (4).
Go on to Sheet 6
7-58
TM10 3930-641-34-2
(Sheet 6 of 7)
TILT CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
7. Nut (10)
Put on rod.4
8. Cap (12)
Put on rod.
9. Spacer (6)
Put on rod.
10. Piston (4)
REMARKS
Put on rod.
11. Nut (3)
Install and tighten with torque multiplier,
adapter and socket. Use tool to hold rod.
NOTE
Tighten nut to a torque of 2225 lb. ft. to 2275
lb. ft. (3016.7-3084.5 N-m).
12. Cylinder (2)
Install over rod assembly.
NOTE
Grease piston, spacer, and cap with general
purpose grease before installation.
Go on to Sheet 7
7-59
TM10 3930-641-34-2
TILT CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
13. Cap (12)
ACTION
REMARKS
Place in position and tighten, using tooling.
NOTE
Extend rod when installing cap.
14. Nut (10)
Install, using tool.
15. Tilt cylinder
Remove from repair stand.
End
7-60
TM 10-3930-641-34-2
TILT CYLINDER BEARINGS REMOVAL/INSTALLATION
(Sheet 1 of 2)
This task covers: Replacement of tilt cylinder bearings.
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
None
None
Equipment Condition
Tilt cylinder removed.
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Tilt Cylinder Removal/Installation, page 7-50.
Wear eye protection.
Go on to Sheet 2
7-61
TM10 3930-641-34-2
(Sheet 2 of 2)
TILT CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
I
1. Retaining ring (1)
Remove from mast/vehicle frame.
2. Bearing (2)
a bearing driver.
Remove from mast/vehicle frame, using
INSTALLATION
NOTE
Clean all parts.
1. Bearing (2)
frame, using suitable driver.
Install against counterbore in mast/vehicle
2. Retaining ring (1)
Install in mast/vehicle frame.
TA099169
End
7-62
TM 10-3930-641-34-2
LIFT CYLINDER REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Replacement of the lift cylinder.
INITIAL SETUP
Test Equipment
None
Caps for hydraulic lines
Materials/Parts
Troubleshooting Reference
None
Equipment Condition
Carriage and lift chains removed.
Special Tools
None
Personnel Required
Two mechanics
References
General Safety Instructions
Mast Lift Chains Removal/Installation, Tires blocked.
page 7-118.
Cylinder may swing when removed.
Carriage Removal/Installation,
page 7-91.
Go on to Sheet 2
7-63
TM10 3930-641-34-2
(Sheet 2 of 3)
LIFT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1. Hydraulic oil line (1)
Disconnect at coupling and cap.
2. Lift cylinder (2)
Fasten hoist.
3. Four capscrews (3)
Remove.
4. Lift cylinder (2)
Remove.
NOTE
Lift cylinder weighs 2400 lbs. (1088.6 kg).
Watch out for any swing.
5. Pad (4)
Remove.
TA099170
Go on to Sheet 3
7-64
TM10 3930-641-34-2
(Sheet 3 of 3)
LIFT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1. Pad (4)
Place in position.
2. Lift cylinder (2)
a. Fasten hoist.
b. Place cylinder in position.
3. Base (5)
Push into position.
4. Four capscrews (3)
Install.
5. Hydraulic oil line (1)
Uncap and connect.
TA099171
End
7-65
TM 10-3930-641-34-2
LIFT CYLINDER DISASSEMBLY/ASSEMBLY
(Sheet 1 of 4)
This task covers: The disassembly and assembly of the lift cylinder.
INITIAL SETUP
Test Equipment
None
As required
Materials/Parts
Troubleshooting Reference
Page 2-29, 2-30
Equipment Condition
Lift cylinder removed.
Special Tools
None
Personnel Required
One mechanic.
References
General Safety Instructions
Lift Cylinder Removal/Installation, None
page 7-63.
Go on to Sheet 2
7-66
TM10 3930-641-34-2
(Sheet 2 of 4)
LIFT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1. Rod head (18)
Remove.
2. Preformed packing (15), seals (1) (2)
and rings (16) (17)
Remove from rod head (18).
3. Rod assembly (14)
Remove from tube assembly (4).
4. Ring (12) and seal (13)
Remove from rod assembly (14).
5. Clip (11)
Remove.
6. Strap (9) and spacer (10)
Remove.
7. Hose (8), clamp (7) and adapter (6)
Remove from tube assembly (4).
Go on to Sheet 3
7-67
TM 10-3930-641-34-2
(Sheet 3 of 4)
LIFT CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Seal, rod packing
Seal, rod wiper
Chain assembly
Tube assembly
Overflow hose
Hose adapter
Hose clamp
Hose
Strap
Spacer
Clip
Rod wear ring
Seal assembly
Rod assembly
Preformed packing
Ring
Rod wear ring
Go on to Sheet 4
7-68
TM10 3930-641-34-2
(Sheet 4 of 4)
LIFT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
1. Adapter (6), clamp (7) and hose (8)
Install on tube assembly (4).
2. Spacer (10) and strap (9)
Install.
3. Clip (11)
Install.
4. Ring (12) and seal (13)
Install on rod assembly (14).
5. Rod assembly (14)
Install in tube assembly (4).
6. Rings (16) (17), seals (1) (2) and
preformed packing (15)
Install on rod head (18).
7. Rod head (18)
Install in tube assembly (4).
End
7-69
TM 10-3930-641-34-2
Section III. MAST COMPONENTS
MAST COMPONENTS MAINTENANCE INSTRUCTIONS
This section covers maintenance of these mast components for direct support maintenance personnel:
a. Mast
b. Fork assembly
c. Carriage
d. Side tilt cylinder
e. Side shift cylinder
f. Mast hydraulic lines
g. Mast lift lines
In addition, this section contains the hydraulic system TEE TESTS.
LIST OF TASKS
(Sheet 1 of 1)
TROUBLESHOOTING
TASK NO.
(PAGE)
TASK
REF (PAGE)
REF
1
Mast removal/installation.
7-71
None
2
Mast disassembly/assembly.
7-76
2-28, 2-
3
Fork assembly removal/installation.
7-87
None
4
Carriage removal/installation.
7-91
None
5
Carriage assembly disassembly/assembly
7-94
2-28, 2-
6
Side tilt cylinder removal/installation.
7-101
None
7
Side shift cylinder removal/installation.
7-104
None
8
Side shift/tilt cylinders disassembly/assembly.
7-107
2-40
9
Mast hydraulic lines removal/installation.
7-111
None
10
Mast lift chains removal/installation.
7-118
None
11
Tee test procedure for hydraulic system.
7-124
2-36
29
29
7-70
TM 10-3930-641..34-2
MAST REMOVAL/INSTALLATION
(Sheet 1 of 5)
This task covers: Removal and installation of the mast.
INITIAL SETUP
Test Equipment
Materials/Parts
None Tags and wire
None
Troubleshooting Reference
Equipment Condition
Fork assembly removed.
Side tilt cylinder removed.
Side shift cylinder removed.
Mast lowered.
Vehicle on level ground with brake set.
Shipping link installed.
Special Tools
Personnel Requited
Wrench, Torque, 3/4" Sq. Drive,
NSN 5120-00-221-7983
Wrench, Torque,
NSN 5120-00-008-3632
References
Two mechanics.
General Safety Instructions
Fork Assembly Removal/Installation, page 7-87
Side Tilt Cylinder Removal/Installation,
page 7-101.
Side Shift Cylinder Removal/Installation,
page 7-104.
Shipping Link Removal/Installation,
TM 10-3930-641-20.
Never use fingers to push pins out.
Persons should NEVER be under mast.
Tires blocked.
Go on to Sheet 2
Change 1
7-71
TM10 3930-641-34-2
MAST REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1. Hose assemblies
Tag and disconnect.
2. Mast assembly
a. Secure hoist to lifting eyes with chains.
b. Pull chains tight but do not lift.
c. Under vehicle, remove capscrews (1)
that secure eyes (retaining) on each
side of mast.
NOTE
At this point mast is resting on "J" hooks (3).
TA099173
Go on to sheet 3
7-72
TM10 3930-641-34-2
(Sheet 3 of 5)
MAST REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
WARNING
Hoist must be secured to mast. Use appropriate
equipment to keep mast from falling forward.
3. Tilt cylinders
a. Install shipping support (2).
b. Remove two capscrews.
c. Remove retaining plate.
WARNING
Use appropriate tool to remove pins. Never use
fingers.
d. Remove pin.
4. Mast assembly
Lift up and off "J" hooks (3) and place on
proper blocking. Mast should lie down flat.
TA099174
Go on to Sheet 4
7-73
TM10 3930-641-34-2
(Sheet 4 of 5)
MAST REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION I
1. Shims, wear pads, and sliding blocks
Check for wear and replace if worn thin.
2. Mast
a. Lift to upright position.
b. Guide to "J" hooks (3) and have eyes (4)
on either side of "J" hooks.
c. Lift mast up onto "J" hooks.
WARNING
Use appropriate safety equipment to secure
mast from falling forward
WARNING
Never place any part of your body under mast.
TA099175
Go on go sheet 4 of 5
7-74
TM 10-3930-641-34-2
MAST REMOVAL/INSTALLATION (CONT)
(Sheet 5 of 5)
LOCATION/ITEM
d.
3.
Tilt cylinder (6)
b.
ACTION
REMARKS
Install two capscrews (6) and retainer plate
(5) onto eyes (4) and torque capscrews.
Tighten capscrews to a torque of 1000 ± 130 ft. lbs.
(1356 ± 176 N•m).
a. Align bearing and install pin.
Do the same for other side.
NOTE
Groove in pin is for retainer plate to fit into.
4.
c.
Install two capscrews and retainer plate.
Do the same for each side.
d.
Remove shipping support (2).
Hose assemblies
Connect.
TA099176
End
7-75
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY
(Sheet 1 of 11)
This task covers: The disassembly and assembly of the mast.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-28, 2-29
Wooden blocks
Troubleshooting Reference
Equipment Condition
Mast removed and laid flat on
level surface.
Lift cylinder removed.
Special Tools
None
Personnel Required
Two mechanics.
References
General Safety Instructions
Mast Removal/Installation, page 7-71 None
Lift Cylinder Removal/Installation,
page 7-63.
Go on to Sheet 2
7-76
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 2 of 11)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Inner mast
extended.
Pull with lift truck and chain until fully
2.
Capscrews (46) and washers (47)
that secure upper side roller
assemblies (1) and shims (67) (68)
(70)
Remove.
3.
Upper side roller assemblies (1)
a. Remove pin (7).
4.
b.
Remove shaft (2) and roller assembly (4).
c.
Remove fitting (8) from block (3).
d.
Remove bearings (5) from roller (6).
Capscrews (60) and washers (58)
Remove.
Go on to Sheet 3
7-77
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 3 of 11)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Upper side roller assembly
Shaft
Block
Roller assembly
Bearing
Roller
Pin 27.
Fitting
Sheave assembly
Crosshead
Ring 31.
Spacer
Ball bearing
Cup 34.
Spacer'
Seal 36.
Cap 37.
Retainer
Sheave
Nut 40.
21. Washer, spherical
22. Pin
23. Cotter pin
24. Anchor screw
25. Capscrew
26. Washer
Nut
28. Washer
29. Stud
30. Wear pad
Shim
32. Ring
33. Bushing
Eye
35. Pin
Bushing
Bar
38. Shim
39. Capscrew
Fitting
TA099177
Go on to Sheet 4
7-78
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 4 of 11)
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
Lower guide roller assembly
Roller
Bearing
Ring
Ring
Capscrew
Washer
Lower side roller assembly
Bearing
Roller
Shaft
Pillow block
Pin
Pillow block
Shim
Fitting
Plate
Washer
Capscrew
Capscrew
Upper guide roller assembly
Shaft
Roller assembly
Roller
Bearing
Ring
Shim
Shim
Capscrew
Shim
Capscrew
TA099178
Go on to Sheet 5
7-79
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 5 of 11)
LOCATION/ITEM
5.
Upper guide roller assemblies (61)
ACTION
REMARKS
a. Remove from outer mast.
b.
Remove ring (66).
c.
Remove roller assembly (63) from shaft
(62).
d.
Press bearing (65) from roller (64).
6.
Wooden blocks
Put in position to support inner mast.
7.
Inner mast
Pull from outer mast.
8.
Rings (45)
Remove.
9.
Lower guide roller assemblies (41)
a. Remove.
b.
c.
10.
Capscrews (46) and washers (47)
Use 7 in. (17.8 cm) diameter plate.
Remove ring (44).
Press bearing (43) from roller (42).
Remove.
Go on to Sheet 6
7-80
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 6 of 11)
LOCATION/ITEM
11.
Lower side roller assemblies (48)
and shims (55)
b.
c.
ACTION
REMARKS
a. Remove from inner mast.
Remove block (54), bearings (49) and
roller (50) from shaft (51).
Remove block (52) and fitting (56) from
shaft (51).
12.
Ring (32)
Remove.
13.
Bushing (33)
Remove.
14.
Fitting (40)
Remove.
15.
Nuts (27) and washers (28)
Remove.
16.
Sheave assembly (9)
Remove from lift cylinder.
17.
Capscrews (25) and washers (26)
Remove.
18.
Retainer (18), sheaves (19) and
outer bearing (13)
Remove from crosshead (10).
Go on to Sheet 7
7-81
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 7 of 11)
LOCATION/ITEM
ACTION
REMARKS
19.
Cups (14), spacer (15), seal (16)
and cap (17)
Remove from sheaves, if necessary.
20.
Inner bearing (12) and ring (11)
Remove.
ASSEMBLY
1.
Inner bearing (12) and ring (11)
Install.
2.
Cups (14), spacer (15), seal (16)
and cap (17)
Install.
3.
Outer bearing (13), sheaves (19)
and retainer (18)
Install on crosshead.
4.
Washers (26) and capscrews (25)
Install.
5.
Sheave assembly (9)
washers (58).
Secure to lift cylinder with capscrews (71) and
Go on to Sheet 8
7-82
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 8 of 11)
LOCATION/ITEM
ACTION
REMARKS
6. Fitting (40)
Install.
7. Bushing (33)
Install.
8.
Ring (32)
Install.
9.
Lower side roller assemblies (48)
a. Install block (52) and fitting (56) on
shaft (51).
10.
b.
Install bearings (49), roller (50) and
block (54) on shaft (51).
c.
Loosely secure assemblies (48) to inner
mast. Use no shims (55).
Outer mast
side rails.
Measure narrowest distance (A) between
TA099179
Go on to Sheet 9
7-83
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 9 of 11)
LOCATION/ITEM
11.
Inner mast
b.
12. Shims (55)
is between .010 and .062 in. (0.25 to 1.57
mm).
ACTION
REMARKS
a. Measure distance (B) between lower side
rollers (where rollers contact side rails of
outer mast).
Subtract distance B from distance A.
Install under blocks (52) (54) until B minus A
NOTE
The shims should be divided so there is an
equal thickness on either side of the mast.
13.
Bearing (43)
Install in roller (42).
14.
Ring (44)
Install.
15.
Lower guide roller assembly (41)
(45).
Install on inner mast and secure with ring
16.
Inner mast
a. Fasten strap and hoist to lower end and
put lift truck in position under upper end.
b.
Install in outer mast.
TA099180
Go on to Sheet 10
7-84
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 10 of 11)
LOCATION/ITEM
ACTION
REMARKS
17.
Bearing (65)
Press into roller (64).
Use 7 in. (17.8 cm ) diameter plate.
18.
Roller assembly (63)
Install on shaft (62).
19.
Ring (66)
Install.
20.
Upper guide roller assemblies (61)
Install on outer mast.
21.
Capscrews (60) and washers (58)
Install.
22.
Shims (31) and wear pads (30)
a. Install on both sides of mast.
b.
Check clearance between inner mast and
wear pad.
c.
Add or remove shims to get clearance of
.00 to .06 in. (0.0 to 1.5 mm).
23.
Washers (28) and nut (27)
Install.
24.
Bearings (5)
Install in rollers (6).
25.
Fittings (8)
Install in blocks (3).
TA099181
Go on to Sheet 11
7-85
TM 10-3930-641-34-2
MAST DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 11 of 11)
LOCATION/ITEM
ACTION
REMARKS
26.
Shafts (2) and roller assemblies (4)
Install in blocks (3).
27.
Pin (7)
Install.
28.
Upper side roller assemblies (1)
(67) (68) (70).
Install on outer mast without the shims
29.
Inner mast
a. Move over to one side of outer mast.
b.
30. Shim (67) (68) (70)
clearance between inner mast and side rollers
is .010 to .062 in. (0.25 to 1.57 mm).
Measure clearance between mast and
rollers.
Install behind upper side rollers (1) until
NOTE
The shims should be divided so there is an
equal thickness on either side of the mast.
TA099182
End
7-86
TM 10-3930-641-34-2
FORK ASSEMBLY REMOVAL/INSTALLATION
(Sheet 1 of 4)
This task covers: Removal and installation of the fork assembly.
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
None
Troubleshooting Reference
Equipment Condition
Engine off
Mast blocked
Special Tools
Personnel Required
None
One mechanic.
References
General Safety Instructions
None
Do not stand under forks.
Go on to Sheet 2
7-87
TM 10-3930-641-34-2
FORK ASSEMBLY REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 4)
ACTION
REMARKS
REMOVAL
1.
Side shift cylinder
a. Remove capscrews (1) that secure rod end
retainer plate (2).
b.
Remove retainer plate (2).
c.
Lash cylinder to carriage.
WARNING
Use a drift to push pins out. Never use your
fingers.
d. Remove pin (3).
TA099183
Go on to Sheet 3
7-88
TM 10-3930-641-34-2
FORK ASSEMBLY REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
2.
Fork assembly (4)
(Sheet 3 of 4)
ACTION
REMARKS
a. Attach hoist at four lift points.
b.
Remove the five capscrews (6) and washers
(7)that secure right and left bar assemblies
(8) and shims (9).
c.
Remove each bar assembly and shim.
d.
Hoist fork assembly up and away from
carriage tilt assembly (10).
e.
Remove "L" shaped plastic wear pads (11).
TA099184
Go on to Sheet 4
7-89
TM 10-3930-641-34-2
FORK ASSEMBLY REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 4 of 4)
ACTION
REMARKS
INSTALLATION
1.
Five "L" shaped plastic wear pads
(11)
Install on carriage tilt assembly (10).
2.
Fork assembly (4)
a. Attach to hoist.
b.
Put into position on wear pads (11).
3.
Right and left bar assemblies (8)
and shims (9)
Attach each to carriage tilt assembly (10),
the five capscrews (6) and washers (7).
4.
Side shift cylinder
a. Position rod end in fork assembly retainer
and install pin (3).
b.
Install retainer plate (2).
c.
Install two capscrews (1).
TA099185
End
7-90
TM 10-3930-641-34-2
CARRIAGE REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal and installation of the carriage.
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
None
Troubleshooting Reference
Equipment Condition
Fork assembly removed.
Side shift cylinder removed.
Side tilt cylinder removed.
Shipping link installed.
Special Tools
None
Personnel Required
One mechanic.
References
General Safety Instructions
Fork Assembly Removal/Installation, page 7-87
Side Shift Cylinder Removal/Installation,
page 7-104.
Side Tilt Cylinder Removal/Installation,
page 7-101.
Tires blocked.
Go on to Sheet 2
7-91
TM 10-3930-641-34-2
CARRIAGE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 3)
ACTION
REMARKS
REMOVAL
1.
2.
Carriage assembly
a. Raise 1-2 feet.
b.
Position wood block (1) under each end.
c.
Lower onto blocks.
Lift chains (2)
b.
a. Remove two nuts (3) and washers.
Separate from carriage assembly.
3.
Carriage assembly
4.
MastRaise until carriage assembly can be removed.
5. Carriage assembly
Fasten securely to hoist.
Remove.
TA099186
Go on to Sheet 3
7-92
TM 10-3930-641-34-2
CARRIAGE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
REMARKS
INSTALLATION
1.
Carriage assembly
b.
wood blocks).
a. Fasten securely to hoist.
Put in position inside inner mast (and on
2.
MastLower over carriage.
3.
Lift chains (2)
washers.
Attach to carriage with the two nuts and
4.
Wood blocks
Remove.
TA099187
End
7-93
TM 10-3930-641-34-2
CARRIAGE ASSEMBLY DISASSEMBLY/ASSEMBLY
(Sheet 1 of 7)
This task covers: Disassembly and assembly of the carriage.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Pages 2-28, 2-29
As required
Troubleshooting Reference
Equipment Condition
Carriage assembly removed from mast.
Special Tools
None
Personnel Required
One mechanic.
References
General Safety Instructions
Carriage Removal/Installation, page 7-91.
None
Go on to Sheet 2
7-94
TM 10-3930-641-34-2
CARRIAGE ASSEMBLY DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 7)
ACTION
REMARKS
DISASSEMBLY
1.
Bolts (16) and washers (4)
Remove.
2.
Bar (21) and shims (22) (23)
Remove from bracket assembly (25).
3.
Two capscrews (13)
Remove from shaft assembly (12).
4.
Shaft assembly (12), bearing (9) and
rings (8)
Remove.
5.
Tilt assembly (24)
Remove.
6.
Wear plate (15)
Remove from tilt assembly (24).
7.
Wear plate (20)
Remove from bracket assembly (25).
Go on to Sheet 3
7-95
TM 10-3930-641-34-2
CARRIAGE ASSEMBLY DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Fork Assembly
Attachment Mounting Group
Bolt 34.
Washer
Bar 36.
Fitting
Shim
Ring 39.
Bearing
Bar 41.
Slide Block
Shaft Assembly
Capscrew
Fitting
Plate
Bolt
Bar Assembly, LH
Bar Assembly, RH
Shim
Plate
Bar
Shim
Shim
Tilt Assembly
Roller Bracket Assembly
Carriage Mounting Group
Side Roller Assembly
Pillow Block
Spring Pin
Shaft
Roller Assembly
(Sheet 3 of 7)
32. Roller Bearing
33. Carriage Guide Roller
Pillow Block
35. Capscrew
Lockwasher
37. Fitting
38. Elbow
Shim
40. Ring
Roller Assembly
42. Roller
43. Ball Bearing
44. Ring
TA099188
Go on to Sheet 4
7-96
TM 10-3930-641-34-2
CARRIAGE ASSEMBLY DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
8.
Four guide roller assemblies (41)
(Sheet 4 of 7)
ACTION
REMARKS
a. Remove ring (40).
b.
Remove from bracket assembly (25).
c.
Remove ring (44).
d.
Press bearing (43) from each roller (42).
9.
Capscrews (35) and lockwashers (36)
Remove.
10.
Four side roller assemblies (27)
a. Remove from bracket assembly (25).
11.
b.
Remove fitting (37) and elbow (38) from
shaft (30).
c.
Remove pillow block (34) and roller
assembly (31) from shaft (30).
d.
If necessary, remove bearing (32) from
roller (33).
e.
Remove pillow block (28) from shaft (30).
Bars (5) and (10)
Use 7 in. (17.8 cm) diameter plate.
Remove from bracket assembly (25).
Go on to Sheet 5
7-97
TM 10-3930-641-34-2
CARRIAGE ASSEMBLY DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 5 of 7)
ACTION
REMARKS
ASSEMBLY
1.
Bars (5) and (10)
Install on bracket assembly (25).
2.
Bearing (43)
Install in each roller (42).
3.
Ring (44)
Install in each roller assembly (41).
4.
Four roller assemblies (41)
Install on bracket assembly (25).
5.
Ring (40)
Install in each roller assembly (41).
6.
Wear plate (20)
Install on bracket assembly (25).
7.
Bearing (32)
Install in each roller (33).
8.
Pillow block (28)
Install on each roller shaft (30).
Go on to Sheet 6
7-98
TM 10-3930-641-34-2
CARRIAGE ASSEMBLY DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 6 of 7)
ACTION
REMARKS
9.
Roller assembly (31) and pillow
block (34)
Install on each roller shaft (30).
10.
Fitting (37) and elbow (34)
Install on each roller shaft (30).
11.
Capscrews (35) and lockwashers (36)
Install through pillow blocks (28) (34).
12.
Inner mast
surface of side rails.
Measure narrowest distance (A) between inside
TA099189
Go on to Sheet 7
7-99
TM 10-3930-641-34-2
CARRIAGE ASSEMBLY DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
13.
14.
Side roller assemblies (27)
(Sheet 7 of 7)
ACTION
REMARKS
a. Install without shims on inner mast.
b.
Measure distance (B) between outside
surface of each pair of side rollers.
c.
Subtract distance B from A.
Shims (39)
Add under each pair of roller assemblies until
B minus A is between .010 to .059 in. (0.25
to 1.50 mm).
NOTE
Divide shims so that an equal thickness is
installed on each side of carriage.
TA099190
End
7-100
TM 10-3930-641-34-2
SIDE TILT CYLINDER REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal and installation of side tilt cylinder.
INITIAL SETUP
Test Equipment
None
None
Materials/Parts
None
Troubleshooting Reference
Equipment Condition
Engine off
Shipping link installed
Mast lowered
Special Tools
None
Personnel Required
One mechanic
References
General Safety Instructions
Shipping Link Removal/Installation,
Tires blocked.
TM 10-3930-641-20.
Go on to Sheet 2
7-101
TM 10-3930-641-34-2
(Sheet 2 of 3)
SIDE TILT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Side tilt cylinder (1)
b.
2.
Two hydraulic lines (2)
b.
3.
Two capscrews (3) and washers (4)
that secure each retainer (5)
a. Fully retract rod.
Fasten to hoist.
a. Tag and disconnect.
Cap open ends.
Remove.
WARNING
Use proper tools, never use fingers to push pins
out.
4. Pins (6)
Remove.
TA099191
Go on to Sheet 3
7-102
TM 10-3930-641-34-2
SIDE TILT CYLINDER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
INSTALLATION
REMARKS
NOTE
The rod end of the tilt cylinder attaches to the
carriage bracket assembly. The barrel end
attaches to the carriage tilt assembly.
1.
Side tilt cylinder (1)
b.
a. Fasten to hoist.
Put in position.
2.
Two hydraulic lines (2)
Remove caps and connect.
3.
Pins (6)
Install.
4.
Capscrews (3), washers (4), and
retainers (5)
Install.
End
7-103
TM 10-3930-641-34-2
SIDE SHIFT CYLINDER REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal and installation of the side shift cylinder.
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
None
Troubleshooting Reference
Equipment Condition
Engine off
Shipping link installed
Mast lowered
Special Tools
None
Personnel Required
One mechanic.
References
General Safety Instructions
Shipping Link Removal/Installation,
Use proper tools, never use fingers to
TM 10-3930-641-20.
push pins out.
Tires blocked
Go on to Sheet 2
7-104
TM 10-3930-641-34-2
(Sheet 2 of 3)
SIDE SHIFT CYLINDER REMOVAL/INSTALLATIN (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Side shift cylinder (1)
b.
2.
Two hydraulic lines (2)
b.
3.
Two capscrews (3) and washers (4)
that secure each retainer (5)
a. Fully retract rod.
Fasten to hoist.
a. Tag and disconnect.
Cap or plug open lines.
Remove.
WARNING
Use proper tools, never use fingers to push
pins out.
TA099192
Go on to Sheet 3
7-105
TM 10-3930-641-34-2
(Sheet 3 of 3)
SIDE SHIFT/TILT CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
4.
Pins (6)
ACTION
REMARKS
Remove.
INSTALLATION
NOTE
The rod end of the shift cylinder attaches to
the fork assembly. The barrel end attaches to
the carriage tilt assembly.
1.
Side shift cylinder (1)
b.
a. Fasten to hoist.
Put in position.
2.
Two hydraulic lines (2)
Remove caps and connect.
3.
Pins (6)
Install.
4.
Capscrews (3), washers (4),
retainers (5)
Install.
End
7-106
TM 10-3930-641-34-2
(Sheet 1 of 4)
SIDE SHIFT/TILT CYLINDERS DISASSEMBLY/ASSEMBLY
This task covers: The disassembly and assembly of the side shift and side tilt cylinders.
INITIAL SETUP
Test Equipment
Materials/Parts
None
Page 2-40
None
Troubleshooting Reference
Equipment Condition
Side shift cylinder removed.
Side tilt cylinder removed.
Special Tools
None
Personnel Required
One mechanic.
References
General Safety Instructions
Side Tilt Cylinder Removal/Installation, page 7-101.
Side Shift Cylinder Removal/Installation,
page 7-104.
None
Go on to Sheet 2
7-107
TM 10-3930-641-34-2
(Sheet 2 of 4)
SIDE SHIFT/TILT CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
DISASSEMBLY
REMARKS
NOTE
The following is disassembly/assembly of the
side shift cylinder. This procedure is identical
to that for the side tilt cylinder.
1.
Side shift cylinder (7)
b.
2.
Rod (13)
b.
a. Put in position on repair stand.
Fully extend rod (13).
a. Place support under rod.
Secure rod to stand.
3.
Collar (12)
Remove.
4.
Rod (13)
Pull from barrel assembly (8).
5.
Nut (9)
multiplier.
Remove from rod (13) using torque
6.
Piston (10), gland-(11)
Remove from rod (13).
7.
Elbows (5), preformed packings (6)
Remove from barrel assembly (8).
Go on to Sheet 3
7-108
TM 10-3930-641-34-2
(Sheet 3 of 4)
SIDE SHIFT/TILT CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26
Liner, attachment secondary
Coupling
Hose
Fitting
Elbow
Preformed packing
Cylinder group (side shift)
Barrel assembly
Nut
Piston
Gland
Collar
Rod
Retainer
Pin
Washer
Capscrew
Cylinder group (side tilt)
Rod assembly
Collar
Gland
Piston
Nut
Barrel assembly
Elbow
Tie
7-109
TM 10-3930-641-34-2
(Sheet 4 of 4)
SIDE SHIFT/TILT CYLINDERS DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
1.
Elbows (5), preformed packings (6)
Install on barrel assembly (8).
2.
Collar (12), gland (11), piston (10)
Install on rod (13).
3.
Nut (9)
Install on rod.
4.
Rod (13) and attached parts
Install in barrel assembly (8).
5.
Collar (12)
securely.
Thread onto barrel assembly (8) and tighten
End
7-110
TM 10-3930-641-34-2
(Sheet 1 of 7)
MAST HYDRAULIC LINES REMOVAL/INSTALLATION
This task covers: The removal and installation of the mast hydraulic lines.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Hydraulic lines disconnected and
capped at side shift, side tilt and
container lock cylinders.
Special Tools
Personnel Required
None
One mechanic.
References
General Safety Instructions
Side Shift Cylinder Removal/Installation
page 7-104.
Side Tilt Cylinder Removal/Installation,
page 7-101.
Container Cylinder, page 9-4
None
Go on to Sheet 2
7-111
TM 10-3930-641-34-2
(Sheet 2 of 7)
MAST HYDRAULLIC LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Lift cylinder hydraulic line (A) at
base of mast
Disconnect and cap.
2.
Side shift cylinder hydraulic lines at
vehicle (B)
Disconnect and cap.
3.
Side tilt cylinder hydraulic lines at
vehicle (C)
Disconnect and cap.
4.
Container lock cylinder hydraulic
lines at vehicle (D)
Disconnect and cap.
5.
Eight nuts (3) and washers (4) that
secure brackets (17)
Remove.
6.
Brackets (17)
Remove.
7.
Nuts (3) and washers (4) that
secure brackets (36) (50) and
clamps (5) (34)
Remove.
8.
Brackets (36) (50) and clamps
(5) (34)
Remove.
TA099194
Go on to Sheet 3
7-112
TM 10-3930-641-34-2
(Sheet 3 of 7)
MAST HYDRAULLIC LINES REMOVAL/INSTALLATION (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Fitting
Hose
Nut 34.
Washer
Clamp
Stud 37.
Spring
Spring
Collar
Clamp
Bolt42.
Idler pulley
Washer
Spacer
Nut 46.
Stud 47.
Bracket
Washer
Guard
Bolt51.
Bolt
Hose assembly
Hose
Coupling
Union, bulkhead
Tag
Tag
Tag
Tag
Locknut
Hose assembly
32. Coupling
33. Hose
Clamp
35. Stud
36. Bracket
Plug
38. Tag
39. Tag
40. Fitting
41. Preformed packing
Fitting
43. Fitting
44. Hose
assembly
45. Coupling
Hose
Capscrew
48. Capscrew
49. Nut
50. Bracket
Nut
TA099195
Go on to Sheet 4
7-113
TM 10-3930-641-34-2
(Sheet 4 of 7)
MAST HYDRAULLIC LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
9.
Nut (49) and capscrew (48) that
secure clamp (5)
Remove.
10.
Capscrews (20)
Remove.
11.
Guards (19)
Remove.
12.
Capscrews (21) (11) and nuts (15)
Remove.
13.
Pulleys (12) and spacers (14)
Remove.
14.
Hose assemblies (22) (31) (44)
Disassemble as necessary.
REMARKS
Go on to Sheet 5
7-114
TM 10-3930-641-34-2
(Sheet 5 of 7)
MAST HYDRAULLIC LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
Hose assemblies (22) (31) (44)
Assemble.
2.
Pulleys (12), spacers (14) and
capscrews (11) (21)
Install on brackets (17).
3.
Nuts (15)
Install.
4.
Brackets (17)
a. Position on studs (16).
b.
Secure with washers (4) and nuts (3).
Go on to Sheet 6
7-115
TM 10-3930-641-34-2
(Sheet 6 of 7)
MAST HYDRAULLIC LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
5.
Guards (19)
Install and secure with capscrews (20).
6.
Brackets (36) (50) and clamps
(5) (34)
a. Insert hydraulic lines.
b.
7.
Clamp (5)
b.
8.
Container lock cylinder hydraulic
lines (D)
Secure to mast with nuts (3) and
washers (4).
a. Insert hydraulic line.
Secure to mast with capscrew (48) and
nut (49).
Remove cap and connect.
Go on to Sheet 7
7-116
TM 10-3930-641-34-2
(Sheet 7 of 7)
MAST HYDRAULLIC LINES REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
9.
Side tilt cylinder hydraulic
lines (C)
Remove cap and connect.
10.
Side shift cylinder hydraulic
lines (B)
Remove cap and connect.
11.
Lift cylinder hydraulic line (A) at
base of mast
Remove cap and connect.
REMARKS
End
7-117
TM 10-3930-641-34-2
(Sheet 2 of 7)
MAST LIFT CHAINS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
This task covers: Replacement of mast lift chains.
ACTION
REMARKS
INITIAL SETUP
Test Equipment
Materials/Parts
None
None
None
Troubleshooting Reference
Equipment Condition
Mast lowered.
Special Tools
None
Personnel Required
Two mechanics
References
General Safety Instructions
None
Chains should be properly secured from
dropping.
Go on to Sheet 2
7-118
TM 10-3930-641-34-2
(Sheet 2 of 6)
MAST LIFT CHAINS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Carriage (1)
end.
Lower until it rests on wood blocks at each
NOTE
This is to relieve tension on both chains. Check
by wiggling chains.
2.
Two nuts (3), spacers and washers
Remove.
3.
Chains (2)
Pull up to remove from carriage.
4.
Masta.
Raise approximately 6.0 in. (15.2 cm).
b.
Insert wood block to support inner mast.
c.
Lower mast.
TA099196
Go on to Sheet 3
7-119
TM 10-3930-641-34-2
(Sheet 3 of 6)
MAST LIFT CHAINS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
The weight of the crosshead will not permit
removal of all eight of the mounting capscrews
at one time.
5.
Capscrews (4)
of access hole.
Remove six of eight, leaving one on each side
6.
Two 3/4"-10 NC capscrews and
washers (5)
Install.
7.
Capscrews (6)
Remove.
8.
Capscrews and washers (5)
Remove.
9.
Crosshead (7)
Lower with lift cylinder.
TA099197
Go on to Sheet 4
7-120
TM 10-3930-641-34-2
(Sheet 4 of 6)
MAST LIFT CHAINS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
10.
Lifting straps
Fasten to lift chains near top front of mast.
11.
Nuts (8)
Remove.
NOTE
Lift chain weighs 130 lb. (59 kg).
12.
Lift chains
Remove.
TA099198
Go on to Sheet 5
7-121
TM 10-3930-641-34-2
(Sheet 5 of 6)
MAST LIFT CHAINS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
Lifting straps (1)
Fasten to chains.
2.
Lift chains (2)
a. Lift up to crosshead (3) with a hoist.
b.
Put over sheaves (4) from front of mast.
c.
Insert chain ends (5) in mast.
3.
Nuts Install on chain ends at mast.
4.
Crosshead
Raise up to top of inner mast.
5.
Flat head screws (6)
Install in top of mast.
Go on to Sheet 6
7-122
TM 10-3930-641-34-2
(Sheet 6 of 6)
MAST LIFT CHAINS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
6.
Lift chains (7)
Install ends in carriage (8).
7.
Retainers, washers and nuts (9)
Install on chain ends.
8.
Carriage
Lift and remove wood blocks.
REMARKS
TA099200
End
7-123
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM
This task covers: Tee test procedure for hydraulic system.
(Sheet 1 of 27)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Flow meter assembly equipped
with manual load valve
Tachometer drive
Hydraulic lines and fittings
Page 2-36
Equipment Condition
Follow test procedure.
Special Tools
None
Personnel Required
Two mechanics
References
General Safety Instructions
None
Test equipment must be capable of
withstanding pressures higher than
3000 psi (20,700 kPa).
Go on to Sheet 2
7-124
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
(Sheet 2 of 27)
SCHEMATIC OF HYDRAULIC SYSTEM WITH FLOW METER INSTALLED
TA099201
Go on to Sheet 3
7-125
TM 10-3930-641-34-2
(Sheet 3 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
REMARKS
EQUIPMENT INSTALLATION
1.
Engine
Stop.
2.
Hydraulic tank cap
Open to release pressure. Install.
3.
MastLift approximately 5 ft. Tilt all the way forward. Lower to ground.
4.
Pump suction line (A)
Remove plug for tee test and install adapter.
See diagram on sheet 2.
WARNING
Do not install adapter with engine running.
NOTE
Install adapter as quickly as possible to
prevent oil loss.
5.
Return line assembly
Connect to return line (B).
6.
Adapter and return line assembly
Connect to flow meter.
See diagram on sheet 2.
Go on to Sheet 4
7-126
TM 10-3930-641-34-2
(Sheet 4 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
7.
8.
LOCATION/ITEM
Tachometer generator
ACTION
Install. Use correct drive.
REMARKS
Cable
Install between tachometer generator and the
input connection for the tachometer, on the
flow meter.
PREPARATION OF SYSTEM FOR
TEST
1.
Manual load valve on the flow
meter
Open all the way.
2.
Engine
Start.
3.
Lift control lever
Move to lower position.
TA099202
Go on to Sheet 5
7-127
TM 10-3930-641-34-2
(Sheet 3 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
REMARKS
4.
Engine
Run at 2000 rpm.
5.
Manual load valve
1000 psi (703 kgs/sq. meter).
Close slowly until system pressure rises to
6. Manual load valve
When oil temperature reaches 1000F (37.70C),
close load valve slowly, until system pressure
rises to 1500 psi (1054.5 kgs/sq. meter).
7.
Oil temperature
When temperature reaches 1600F (710C),
cycle the mast through lift and tilt cycles until
the system oil goes down to 150°F (660C).
Go on to Sheet 6
7-128
TM 10-3930-641-34-2
(Sheet 6 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
CHART A
SYSTEM TEST 2000 RPM
Maximum
Pressure
Test
Relief Valve
Name
Setting
Test
1
Number
Control
Lift
Lever
LOWER
Position
Mast
Position
Engine
Speed
System
Test
Pressure
Test
Data
Flow
Differential
Percent
Flow Loss
System
Oil
Temperature
(Start)
2
System
Base
Flow
Rate
3
Lift
LOWER
Flow
Rate
4
Lift
RAISE
Flow
Rate
5
Tilt
TILTBACK
Flow
Rate
6
Tilt
FORWARD
Flow
Rate
7
System
Oil
Temperature
(End)
8
Lift
Circuit
Drift
Comparison
9
Tilt
Circuit
Drift
Comparison
10
Lift
LOWER
Lift
LOWER
Lift
LOWER
Lift
RAISE
Tilt
TILTBACK
Tilt
FORWARD
Lift
RAISE
Lift
1. HOLD
2. RAISE
Tilt
1. HOLD
2. TILTBACK
Fully
Lowered
2000
RPM
100
PSI
Fully
Lowered
2000
RPM
1000
PSI
Fully
Raised
2000
RPM
1000
PSI
Full
Tiltback
2000
RPM
1000
PSI
Full
Forward
2000
RPM
1000
PSI
Forks
Horizontal
Any
Speed
0-100
Maximum
Fully
Lowered
Any
Speed
0-100
PSI
Mast Level
Low Idle
or Stopped
0
PSI
Mast Level
Low Idle
or Stopped
0
PSI
3000
+50_
150
+5_
126
107
107
107
107
PSI
°F
GPM
GPM
(3-4)
GPM
(3-5)
GPM
(3-6)
GPM
(3-7)
RAISE Drift
M
S
Than HOLD
Drift Rate
TILTBACK
M
S
Than HOLD
Drift Rate
19
GPM
(3-4) x 100
3
19
GPM
(3-5) x 100
3
19
GPM
(3-6) x 100
3
19
GPM
(3-7) x 100
3
15%
15%
15%
15%
Fully
Lowered
2000
RPM
SYSTEM TEST
7-129
150
+5_
°F
Go on to Sheet 7
TM 10-3930-641-34-2
(Sheet 7 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT
SYSTEM TEST 700 RPM
Test
Name
Test
Number
Control
Lever
Position
Mast
Position
Engine
Speed
System
Test
Pressure
Test
Data
Flow
Differential
Percent
Flow Loss
CHART A-1
Maximum
Pressure
Relief Valve
Setting
1
System
Oil
Temperature
(Start)
2
System
Base
Flow
Rate
3
Lift
LOWER
Flow
Rate
4
Lift
RAISE
Flow
Rate
5
Tilt
TILTBACK
Flow
Rate
6
Tilt
FORWARD
Flow
Rate
7
System
Oil
Temperature
(End)
8
Lift
Circuit
Drift
Comparison
9
Tilt
Circuit
Drift
Comparison
10
Lift
LOWER
Lift
LOWER
Lift
LOWER
Lift
LOWER
Lift
RAISE
Tilt
TILTBACK
Tilt
FORWARD
Lift
RAISE
Lift
1. HOLD
2. RAISE
Tilt
1. HOLD
2. TILTBACK
Fully
Lowered
700
RPM
Fully
Lowered
700
RPM
100
PSI
Fully
Lowered
700
RPM
1000
PSI
Fully
Raised
700
RPM
1000
PSI
Full
Tiltback
700
RPM
1000
PSI
Full
Forward
700
RPM
1000
PSI
Forks
Horizontal
Any
Speed
0-100
Maximum
Fully
Lowered
Any
Speed
0-100
PSI
Mast Level
Low Idle
or Stopped
0
PSI
Mast Level
Low Idle
or Stopped
0
PSI
2600
+200
150
+5_
42
22
22
22
22
150
+5_
RAISE DRIFT
M
S
RAISE DRIFT
M
S
PSI
°F
GPM
GPM
(3-4)
GPM
(3-5)
GPM
(3-6)
GPM
(3-7)
°F
Than HOLD
Drift Rate
Than HOLD
Drift Rate
20
GPM
(3-4) x 100
3
20
GPM
(3-5) x 100
3
20
GPM
(3-6) x 100
3
20
GPM
(3-7) x 100
3
____%
____%
____%
____%
NOTE: Flow differential on gear pump is normally higher at low pump speed. Test data readings shown are minimum expected on worn system.
SYSTEM TEST
7-130
Go on to Sheet 8
TM 10-3930-641-34-2
(Sheet 8 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
SYSTEM TEST
REMARKS
NOTE
These tests must be done in two steps: one
time at 2000 rpm (Chart A) and once at 700
rpm (Chart A-1).
Best test results happen when system oil
temperature is 1450F to 1550F (630C to 690C).
TEST 1
MAXIMUM PRESSURE
RELIEF VALVE SETTING
1.
Manual load valve
Open all the way.
2.
Lift control lever
Put in lower position.
3.
Engine
Run at 2000 (700) rpm.
4.
Manual load valve
Close slowly until oil flow through meter stops.
5.
System pressure
Record. Relief valve maximum pressure must
be approximately 3000 psi (2109 kgs/sq.
meter).
To change relief valve setting, see TM 10-3930-641-20.
Go on to Sheet 9
7-131
TM 10-3930-641-34-2
(Sheet 9 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
REMARKS
CAUTION
Open load valve slowly before control lever is
moved to HOLD, to prevent damage to the
equipment.
TEST 2
SYSTEM OIL TEMPERATURE
1.
Manual load valve
Open all the way.
2.
Lift control lever
Put in LOWER position.
3.
Oil temperature
Record.
TEST 3
SYSTEM BASE FLOW RATE
1.
Manual load valve
Open all the way.
2.
Lift control lever
Put in LOWER position.
3.
Engine
Run at 2000 (700) rpm.
Go on to Sheet 10
7-132
TM 10-3930-641-34-2
(Sheet 10 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
4.
Oil pressure
meter).
5. Oil flow rate (gpm)
ACTION
REMARKS
Must be down to at least 100 psi (70.3 kgs/sq.
Record.
NOTE
The base flow rate of the system must be the
same as the low pressure flow of the hydraulic
pump. Because there will be minimum leakage
in the control valves, lines and cylinder
packings at 100 psi (70.3 kgs/sq. meter), the
base flow rate can be used to find the flow
differential (flow loss) in Tests 4 through 7.
Keep system constant under each test
condition.
TESTS 4 THRU 7
LEAKAGE RATES
1.
Control levers
Operate in each position.
2.
Engine
Run at 2000 (700) rpm.
3.
Manual control valve
kgs/sq. meter).
Close until system pressure is 1000 psi (703
4.
Oil flow rate
Record for each test.
Go on to Sheet 11
7-133
TM 10-3930-641-34-2
(Sheet 11 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
The flow differential for each test (4 through 7)
is found by subtracting the flow rate for each
test from the base flow rate (Test 3). The percent of flow loss for each test (4 through 7) is
found by dividing the flow differential for each
test by the base flow rate (Test 3) and
multiplying by 100.
TEST 8
TEMPERATURE
1.
Manual load valve
Open all the way.
2.
Lift control lever
Put in RAISE position.
3.
Oil temperature
Record.
NOTE
Make a comparison of the oil temperatures
from Tests 2 and 8. Test 2 must be 1450 to
1550F (710C to 660C) and Test 8 must be
within 100F (12.20C) of Test 2. For each
100F higher difference (Test 8 higher than
Test 2), subtract .5 gallon per pump cartridge from the leakage rate. For each 10°F
(12.20C) lower difference, add .5 gallon per
pump cartridge to the leakage rate.
Go on to Sheet 12
7-134
TM 10-3930-641-34-2
(Sheet 12 of 27)
TEE TEST PROCEDURE FOR DYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
REMARKS
TEST 9
VISUAL DRIFT TEST LIFT CIRCUIT
1.
Fork assembly
Raise bottom of assembly 5 ft. off ground.
2.
Lift control lever
Place in HOLD position.
3.
Manual load valve
Open all the way.
4.
Engine
Stop.
5.
Mast
Watch for downward drift.
6.
Lift control lever
Place in RAISE position.
7.
Mast
Watch for downward drift.
NOTE
If the drift in the RAISE position is more than
the drift in the HOLD position circle the "M"
in the Test Data Box. If the drift in the RAISE
position is the same or less than in the HOLD
position circle the "S" in the Test Data Box.
Go on to Sheet 13
7-135
TM 10-3930-641-34-2
(Sheet 13 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
REMARKS
TEST 10
VISUAL DRIFT TEST TILT CIRCUIT
1.
Fork assembly
Raise bottom of assembly 6 ft. off ground.
2.
Mast
Tilt back all the way.
3.
Tilt lever
Place in HOLD position.
4.
Manual load valve
Open all the way.
5.
Engine
Stop.
6.
Mast
Watch for forward drift.
7.
Tilt lever
Put in TILTBACK position.
8.
Mast
Watch for forward drift.
NOTE
If the drift in the TILTBACK position is more
than the drift in the HOLD position circle the
"M" in the Test Data Box. If the drift in the
TILTBACK position is the same or less than in
the HOLD position circle the "S" in the Test
Data Box.
Go on to Sheet 14
7-136
TM 10-3930-641-34-2
(Sheet 14 of 27)
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Make a comparison of the test data on Charts
A and A-1. The percent of flow loss on Chart
A-1 is the maximum for best performance.
Components that are worn, or do not work
correctly, are found by their flow differential
(loss) and percent of flow loss or lower system
efficiency. System values for new and rebuilt
machines must not be more than shown in the
system tests shown on Charts A and A-1.
If the flow loss is acceptable in one or more
circuits, the tests for the pump and/or the
blocked cylinders must be done.
PUMP TESTS
These tests are used to find the efficiency of
the hydraulic pump. Install a Blocking Plate
Assembly in the pressure line from the hydraulic pump. This prevents the oil from
going through the system. All of the pump
flow now goes through the flow meter.
WARNING
Open the load valve on the flow meter fully
before engine is started. The main relief
valve is not a part of the circuit for the pump
test. If the pressure gets too high, it is
possible to cause injury to personnel or
damage to equipment.
Go on to Sheet 15
7-137
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
(Sheet 15 of 27)
CHART B
Test
Name
Full Speed
Pump Flow
Low
High
Pressure Pressure
Half Speed
Pump Flow
Low
High
Pressure Pressure
Pump Test For Aeration And/Or Cavitation
Varied Speeds — Constant Pressure
Test
Number
11
12
13
14
15
16
17
18
19
20
21
22
Engine
Speed
2000
RPM
2000
RPM
1000
RPM
1000
RPM
600
RPM
800
RPM
1000
RPM
1200
RPM
1400
RPM
1600
RPM
1800
RPM
2000
RPM
Pump Test
Pressure
100
PSI
1000
PSI
100
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
150
±5
150
±5
150
±5
150
±5
150
±5
150
±5
150
±5
150
±5
150
±5
150
±5
150
±5
150
±5
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
°F
126
GPM
113
GPM
63
GPM
48
GPM
22
GPM
35
GPM
48
GPM
61
GPM
74
GPM
87
GPM
100
GPM
113
GPM
15*
GPM
13
GPM
13
GPM
13
GPM
13
GPM
13
GPM
13
GPM
13
GPM
Oil
Temperature
Test
Data
Flow
Differential
13*
GPM
Percent
Flow Loss
10%
*Flow differential for Test 14 is normally more than the flow differential for Test 12 on gear type pump.
PUMP TEST
Go on to Sheet 16
7-138
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
(Sheet 16 of 27)
ACTION
REMARKS
PUMP TEST
TEST 11
PUMP FLOW AT LOW PRESSURE
1.
Manual load valve
Open all the way.
2.
Engine
Start and run at 2000 rpm.
3.
Manual load valve
Close slowly to get 100 psi (70.3 kgs/sq. meter)
system pressure.
4.
Oil temperature
Record.
5.
Flow rate (gpm)
Record.
TEST 12
PUMP FLOW AT HIGH PRESSURE
1.
Engine
Run at 2000 rpm.
2.
Manual load valve
Close slowly until you get 1000 psi (703 kgs/
sq. meter) system pressure.
7-139
Go on to Sheet 17
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
(Sheet 17 of 27)
ACTION
3.
Oil temperature
Record.
4.
Flow rate (gpm)
Record.
REMARKS
TEST 13
PUMP FLOW AT LOW PRESSURE
1.
Engine
Run at 1000 rpm.
2.
Manual load valve
Open slowly until you get 100 psi (70.3 kgs/
sq. meter).
3.
Oil temperature
Record.
4.
Flow rate (gpm)
Record.
TEST 14
PUMP FLOW AT HIGHI PRESSURE
1.
Engine
Run at 1000 rpm.
2.
Manual load valve
Close slowly to get 1000 psi (703 kgs/sq.
meter.
3.
Oil temperature
Record.
Go on to Sheet 18
7-140
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
4.
Flow rate (gpm)
(Sheet 18 of 27)
ACTION
REMARKS
Record.
NOTE
Make a comparison of the test data with the
data on Chart B. The information on Chart B
is the maximum for best performance.
NOTE
Tests 15 thru 22 are the same except for the
engine rpms. Follow the procedure, changing
the engine rpms for each test, according to the
list under REMARKS and Chart B. Record the
data for each test.
Test 15 - 600 rpm
Test 16 - 800 rpm
Test 17 - 1000 rpm
Test 18 - 1200 rpm
Test 19 - 1400 rpm
Test 20 - 1600 rpm
Test 21 - 1800 rpm
Test 22 - 2000 rpm
TESTS 15 THRU 22
PUMP TEST FOR AERATION
AND CAVITATION
1.
Manual load valve
Open fully.
2.
Engine
Start and run at 600 rpm.
Go on to Sheet 19
7-141
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
3.
Manual load valve
(Sheet 19 of 27)
ACTION
REMARKS
Close valve slowly until you get 1000 psi
(703 kgs/sq. meter).
NOTE
At each rpm change you will need to adjust the
manual control valve.
4.
Oil temperature
Record.
5.
Flow rate (gpm)
Record.
CAUTION
Immediately after the engine is stopped, remove
the Blocking Plate Assembly from the pressure
line for the pump to prevent any possible
damage later.
Go on to Sheet 20
7-142
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
(Sheet 20 of 27)
CHART C
All Cylinders Blocked
Right Cylinder Blocked
System
Oil
Temperature
(Start)
Lift
LOWER
Flow
Rate
Lift
RAISE
Flow
Rate
Tilt
TILTBACK
Flow
Rate
Tilt
FORWARD
Flow
Rate
Auxiliary
Circuits
Test
Number
23
24
25
26
27
28
29
30
31
Control
Lever
Position
Lift
LOWER
Lift
LOWER
Lift
RAISE
Tilt
TILTBACK
Tilt
FORWARD
All
Movements
Lift
LOWER
Lift
LOWER
Tilt
TILTBACK
Lift
LOWER
Engine
Speed
Any
Speed
2000
RPM
2000
RPM
2000
RPM
2000
RPM
2000
RPM
Any
Speed
Any
Speed
2000
RPM
Any
Speed
System
Test
Pressure
0-100
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
1000
PSI
0-100
PSI
0-100
PSI
1000
PSI
0-100
PSI
150
+5
°F
108
108
108
108
108
GPM
GPM
GPM
GPM
150
±5
°F
107-108
GPM
150
+5
°F
150
±5
°F
1.0
1.0
1.0
1.0
1.0
0-1.0
GPM
GPM
GPM
GPM
GPM
Right
Cylinder
Leakage
5.0
5.0
5.0
5.0
5.0
GPM
GPM
GPM
GPM
GPM
Test
Name
Test
Data
Cylinder
Leakage
Rate
Control
Valve
Group
Leakage
System
System
Oil
Oil
TemperatureTemperature
(End)
(Start)
Left
Cylinder
Leakage
Tilt
TILTBACK
Flow
Rate
GPM
System
Oil
Temperature
(End)
32
GPM
1.0-0
GPM
BLOCKED CYLINDERS
TEST
Go on to Sheet 21
7-143
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
(Sheet 21 of 27)
LOCATION/ITEM
ACTION
BLOCKED CYLINDERS TESTS
REMARKS
NOTE
If the System Tests and Pump Test give an indication of leakage in the control valves and/or
cylinders that is not acceptable, do the Blocke(
Cylinder Tests.
Blocking Plate Assemblies can be put in each
of the cylinder lines. For best accuracy, do
these tests with the oil temperature approximately 1500F (660C) (near the oil temperature for the System Tests and Pump Test).
WARNING
Lower all implements to the ground. Move the
control levers through OPERATE and HOLD
positions to release any pressure oil in the cylinder lines. All pressure in the lines must be
released or injury to personnel and damage to
equipment can result when the lines are
loosened to install or remove the plate assemblies. The implements can move and pressure
oil can be released.
TEST 23
1.
Control levers
Put in HOLD position.
2.
Manual load valve
Open all the way.
Go on to Sheet 22
7-144
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
(Sheet 22 of 27)
LOCATION/ITEM
ACTION
3.
Engine
Start and run at any rpm.
4.
Control lever
Put in LOWER position.
5.
Oil temperature
Record.
TESTS 24 TIHRU 28
LEAKAGE RATES
REMARKS
NOTE
All these tests are the same except for the position of the control levers. Run these tests
following the same procedure for each of the
control lever positions.
1.
Cylinder lines
Block as needed.
2.
Manual load valve
Open all the way.
3.
Control lever
Move to position.
4.
Engine
Run at 2000 rpm.
5.
Manual load valve
Slowly close to get 1000 psi (703 kgs/sq.
meter).
6.
Flow rate (gpm)
Record for each test.
Go on to Sheet 23
7-145
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
(Sheet 23 of 27)
ACTION
REMARKS
TEST 29
TEMPERATURE
1.
Forks
Lower.
2.
Engine
Run at any rpm.
3.
Manual load valve
Open until you get 100 psi (70.3 kgs/sq.
meter) to 0 psi pressure.
4.
Oil temperature
Record.
NOTE
Find the leakage rate of the cylinders and the
leakage rate of the control valves. Use the test
information from the System Tests, Pump
Test and Blocked Cylinder Tests.
Example: Find the leakage rates of the lift circuit in the LOWER position.
Test 12: flow rate of the pump only.
Test 24: flow rate of pump and control
valves.
Test 4: flow rate of pump, control valve
and cylinders.
7-146
Go on to Sheet 24
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
(Sheet 24 of 27)
ACTION
REMARKS
The system components tested in Tests 12 and
24 are the same except for the control valves.
So the difference in flow rates must be the
leakage in the control valves in the circuit.
Subtract the test information for Test 24 from
the test information for Test 12.
The system components tested in Tests 24 and
4 are the same except for the cylinders. So the
difference in flow rates must be the leakage in
the cylinders in the circuit. Subtract the test
information for Test 4 from the test information for Test 24.
Compare the test data with the data on Chart C
for the specific test. The information on
Chart C is the maximum for best performance.
NOTE
Right Side Cylinders Blocked
If the Blocked Cylinder tests give an indication
of leakage that is too high in one or more of
the cylinders, do the Blocked Cylinder Tests
for the Right Side. For best accuracy, operate
all controls through several cycles to get the
temperature of the oil in the cylinders the
same as the temperature of the oil in the hydraulic tank. Make the temperature of the complete system 1500F (660C).
Lower all implements to the ground. Stop the
engine. Move the control levers through
OPERATE and HOLD positions to release any
7-147
Go on to Sheet 25
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
(Sheet 25 of 27)
ACTION
REMARKS
oil pressure. Put the control levers in HOLD
position. Open the filler cap for the hydraulic
tank to release any tank pressure and close the
cap. Use the Blocking Plate Assemblies, to
block the head end of the right tilt cylinder and
the rod end of each auxiliary cylinder as
needed.
TEST 30
TEMPERATURE
1.
Manual load valve
Open fully.
2.
Engine
Start and run at any rpm.
3.
Control lever
Move to LOWER position.
4.
Oil temperature
Record.
TEST 31
TILT TILTBACK FLOW RATE
1.
Control lever
Move to TILTBACK position
2.
Engine
Run at 2000 rpm.
Go on to Sheet 26
7-148
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
(Sheet 26 of 27)
ACTION
REMARKS
3.
Manual control valve
Close slowly until you get 1000 psi (703 kgs/
sq. meter).
4.
Flow rate (gpm)
Record.
TEST 32
TEMPERATURE
1.
Manual load valve
Open fully.
2.
Engine
Run at any rpm.
3.
Control lever
Move to LOWER position.
4.
Oil temperature
Record.
WARNING
All pressure in the lines must be released or
injury to personnel and damage to equipment
can result when the lines are loosened to install
or remove plate assemblies. The implements
can move and pressure oil can be released.
Go on to Sheet 27
7-149
TM 10-3930-641-34-2
TEE TEST PROCEDURE FOR HYDRAULIC SYSTEM (CONT)
LOCATION/ITEM
(Sheet 27 of 27)
ACTION
REMARKS
NOTE
Find the leakage rates for the right and left
cylinders. Use the test information from System
Test, Pump Test and Blocked Cylinder Tests.
Example: Find the leakage rate for the lift
cylinders.
Test 24: flow rate of pump and control
valves.
Test 31: flow rate of pump, control valves,
and left side cylinder.
Test 4:
flow rate of pump, control valves,
and both cylinders.
The system components tested in Tests 24 and
81 are the same except for the left side cylinder. So the difference in flow rates must be the
leakage in the left side cylinder. Subtract the
test information for Test 31, from the test information for Test 24.
The system components tested in Tests 31 and
4 are the same except for the right side cylinder. So the difference in flow rates must be the
leakage in the right side cylinder. Subtract the
test information for Test 4 from the test information for Test 31. Make a comparison of the
test values with the values on Chart C.
7-150
End
TM 10-3930-641-34-2
CHAPTER 8
BODY AND CAB MAINTENANCE INSTRUCTIONS
Page
Section I
Cab and Rollover Protective Structure (ROPS) ........................8-2
Cab Removal/Installation .........................................................8-3
Rollover Protective Structure Removal/
Installation................................................................................8-11
II
Cab Components .....................................................................8-18
Cab Heater Disassembly/Assembly..........................................8-19
Cab Window, Right Side, Removal/Installation.......................8-28
Cab Window Glass removal/Installation ...................................8-31
Cab Door Disassembly/Assembly.............................................8-34
III
Body and Platform ...................................................................8-38
Right Platform Removal/Installation .........................................8-39
Rear Bumper Removal/Installation...........................................8-42
Fuel Tank Removal/Installation ................................................8-48
Fuel Tank Disassembly/Assembly ............................................8-51
Battery Box Removal/Installation .............................................8-54
General Metal Repair ...............................................................8-58
8-1
TM 10-3930-641-34-2
Section I. CAB AND ROLLOVER PROTECTIVE STRUCTURE (ROPS)
CAB AND ROPS MAINTENANCE INSTRUCTIONS
This section covers maintenance of these components for direct support and general support maintenance personnel:
a. Cab
b. ROPS
LIST OF TASKS
TASK NO.
1
2
(Sheet 1 of 1)
TASK
REF (PAGE)
Cab removal/installation.
Rollover protective structure removal/installation
8-2
8-3
8-11
TROUBLESHOOTING
REF (PAGE)
None
None
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION
(Sheet 1 of 8)
This task covers: Removing and installing the cab.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
Tags and wires
None
Equipment Condition
Engine off.
Shipping link installed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
ROPS Removal/Installation, page 8-11
Shipping Link Removal/Installation,
TM 10-3930-641-20.
Seat Removal/Installation, TM 103930-641-20
Windshield Wiper Removal/Installation,
TM 10-3930-641-20
Tires blocked.
Go on to Sheet 2
8-3
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION (CONT)
(Sheet 2 of 8)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Roll-over protection structure
Remove ROPS.
2.
Heater lines
a. Remove upper panel (1) inside cab and
panel below it.
b. Disconnect and tag heater lines (2).
8-4
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION (CONT)
(Sheet 3 of 8)
LOCATION/ITEM
3.
Capscrews
ACTION
REMARKS
a. Remove capscrews (3) and panel (4).
b. Remove 12 caps (5) from around ledges of
cab.
c.
Remove capscrews, nuts, and washers that
are under the caps.
d. Open window on right side of cab and
remove cap.
e. Remove capscrew, nut, and washer from
under cap.
f.
Open cab door and remove two caps (6).
g. Remove capscrews from underneath caps.
Go on to Sheet 4
8-5
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION (CONT)
(Sheet 4 of 8)
LOCATION/ITEM
3.
Capscrews (cont)
ACTION
REMARKS
h. Remove three capscrews and cover (7).
i.
Remove capscrews and washers from
underneath cover (7).
j.
Remove capscrews that hold seat down.
Move seat forward. Find the wiring harnes
underneath the seat. Disconnect harness at
connector (8). (Refer to TM 10-3930641-20 for seat removal.)
4.
Front windshield wiper
Remove wiper arm and blade. (See TM 103930-641-20.)
5.
Cab
a. Install four 1/2-13NC forged eyebolts on
top of cab.
8-6
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION (CONT)
(Sheet 5 of 8)
LOCATION/ITEM
5.
Cab (cont)
ACTION
REMARKS
b. Fasten sling to eyebolts and lift cab. Be
sure cab clears steering wheel.
c.
Move cab away from the vehicle and place
on ground.
NOTE
Cab weighs 750 lb. (343 kg).
INSTALLATION I
1.
Cab
a. Install four 1/2-13NC forged eyebolts on
top of cab. Fasten a hoist to eyebolts.
b. Lift the cab over the steering wheel and
into position. Lower cab on to three guide
pins.
Go on to Sheet 6
8-7
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION (CONT)
(Sheet 6 of 8)
LOCATION/ITEM
1.
Cab (Cont)
ACTION
c.
REMARKS
Install one capscrew and washer at bottom
and inside of door frame (4).
d. Install two capscrews (2) and washers in the
back panel on the outside of door frame.
e. Using three screws, install plate at bottom
of door frame (4). Install caps over two
holes (3) in door frame.
f.
Install capscrew and lockwasher in hole
under window. Install cap (5) in hole.
8-8
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION (CONT)
(Sheet 7 of 8)
LOCATION/ITEM
1.
Cab (Cont)
ACTION
REMARKS
g. Install ten capscrews (6), lockwashers and
nuts (7) in front and rear ledges of cab.
h. Move seat into position. Install capscrews
and washers.
2.
Wire harness
3. Seat
i.
Install caps (8) over all capscrews
j.
Using five capscrews, install panel below
front window.
Pull wire harness through seat platform opening and connect the connectors (9).
Install. (See TM 10-3930-641-20.)
8-9
TM 10-3930-641-34-2
CAB REMOVAL/INSTALLATION (CONT)
Sheet 8 of 8)
LOCATION/ITEM
4.
Heater lines
ACTION
REMARKS
a. Connect heater lines (10) to the correct
fittings.
b. Install panels (11).
5.
Front windshield wiper
Install wiper arm and blade.
NOTE
ROPS weighs 2500 lb. (1125 kg).
6.
ROPS
Install ROPS.
See page 8-11
8-10
End
TM 10-3930-641-34-2
ROLL-OVER PROTECTIVE STRUCTURE REMOVAL/INSTALLATION
(Sheet 1 of 7)
This task covers: Removal and installation of Roll-Over Protective Structure (ROPS).
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Engine OFF
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
None
Hold steel plates when the support
assembly capscrews are removed.
Shipping Link Removal/Installation,
TM 10-3930-641-20
Tires blocked.
Go on to Sheet 2
8-11
TM 10-3930-641-34-2
ROLL-OVER PROTECTIVE STRUCTURE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
REMOVAL
REMARKS
CAUTION
When capscrews are removed, steel plates will
fall.
1.
Covers and panels
a. Remove capscrews (1) and rear panel (2).
b. Remove capscrews (3) and cover (4).
c.
2.
Supports (10)
Remove nine capscrews (5) and right side
panel (6).
a. Holding steel plate in location (7), remove
capscrews (8).
b. Remove steel plate.
c.
Remove capscrews (11) at bottom of
supports (10).
d. Remove cable held in place with capscrews
(8) at both the bottom and top of right
support (10).
e. Remove support (10).
f.
(Sheet 2 of 7)
Disconnect wiring harness at terminals (9).
8-12
TM 10-3930-641-34-2
ROLL-OVER PROTECTIVE STRUCTURE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
3.
Handrail (12)
ACTION
REMARKS
a. Remove capscrews (14).
b. Remove handrail (12, 13).
4.
Roll-Over protection system (ROPS)
a. Install three 5/8-11lNC forged eyebolts in
top holes of the ROPS.
b. Attach ratchet assembly to front eyebolt and a chain to the rear two eyebolts.
c.
5.
Capscrews (15) and spacers
(Sheet 3 of 7)
Fasten a ratchet assembly and chain to
a hoist.
Remove ten (20 total) from each side of
ROPS.
8-13
TM 10-3930-641-34-2
ROLL-OVER PROTECTIVE STRUCTURE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
(Sheet 4 of 7)
REMARKS
NOTE
Make sure cab door is open before ROPS is
removed.
6.
ROPS
a. Lift slowly so ROPS (18) will clear the
plenum chamber (17) and rear platform (16).
b. Pull ROPS (18) back so it will clear cab.
Move ROPS sideways until it may be
lowered to ground.
NOTE
ROPS weighs 2500 lb. (1125 kg).
INSTALLATION
1.
ROPS
a. Install three 5/8-11NC forged eyebolts in
top of ROPS.
b. Attach ratchet assembly to front eyebolt and
a chain to the rear eyebolt.
Go on to Sheet 5
8-14
TM 10-3930-641-34-2
ROLL-OVER PROTECTIVE STRUCTURE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
ACTION
c.
(Sheet 5 of 7)
REMARKS
Fasten ratchet assembly and chain to
a hoist.
NOTE
Make sure cab door is in the open position.
d. Lift ROPS (18) into position. Make sure
that there is enough clearance between
ROPS (18) and the plenum chamber (17).
2.
Capscrews (15)
Install capscrews (15) and spacers (19).
Tighten capscrews and remove ratchet
assembly chain, and hoist.
TA099215
Go on to Sheet 6
8-15
TM 10-3930-641-34-2
ROLL-OVER PROTECTIVE STRUCTURE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
3.
Support assemblies
ACTION
(Sheet 6 of 7)
REMARKS
a. Install support assemblies (10).
b.
Install capscrews, lockwashers, and
spacers (15).
c.
Install plate (7) behind support (10) in
grooved slot behind cab.
d. Install capscrew (8) and lockwasher to hold
plate in place.
4.
Ground wire
Install at top and bottom of support (10).
5.
Capscrews (8 and 15)
a. Torque the 1 inch capscrews to 560 to 720
lb. ft. (775 to 975 N m).
b. Torque 1-1/8 inch capscrews to 700 to 900)
lb. ft. (950 to 1250 N m).
NOTE
Terminals are color coded and must be connected to the proper color.
6.
Wiring harness
Connect wiring harness to the back of cab.
TA099216
Go on to Sheet 7
8-16
TM 10-3930-641-34-2
ROLL-OVER PROTECTIVE STRUCTURE REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
7.
Panels and covers
ACTION
(Sheet 7 of 7)
REMARKS
a. Install right side panel (6) and rear
panel (2)
b. Install capscrews (1, 6).
c.
8.
Handrail
Install cover (4) with capscrews (3).
Install handrails (12, 13).
TA099217
End
8-17
TM 10-3930-641-34-2
Section II. CAB COMPONENTS
MAINTENANCE INSTRUCTIONS
This task covers: Maintenance of operator comfort item components for direct support maintenance personnel:
a. Cab heater
b. Cab windows and glass
c. Cab door
LIST OF TASKS
TASK NO.
(Sheet 1 of 1)
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Cab heater disassembly/assembly.
8-19
None
2
Cab window, right side, removal/installation.
8-28
None
3
Cab window glass removal/installation.
8-31
None
4
Cab door disassembly/assembly.
8-34
None
8-18
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ASSEMBLY
This task covers: Disassembly and assembly of the cab heater.
(Sheet 1 of 9)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
Ohmmeter
None
None
Equipment Condition
Heater removed from cab.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
None
Heater should be cooled.
Heater Removal/Installation,
TM 10-3930-641-20
Go on to Sheet 2
8-19
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 19)
ACTION
REMARKS
DISASSEMBLY I
1.
Two small capscrews and bracket
Remove.
2.
Three nuts, (55) washers, (57),
and
lockwashers (56)
Remove.
Plate assembly (36)
a. Remove.
3.
b. Check for cracks, dents, distortion.
c.
Replace as needed.
4.
Three washers behind bracket (not
pictured)
Remove.
5.
Valve with elbow (5)
a. Remove from heater core.
b. Remove valve from elbow.
c.
Check for plugged orifices, cracks, and
distortion.
d. Replace all seals.
e. Replace valve or elbow as needed.
Go on to Sheet 3
8-20
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ASSEMBLY (CONT)
(Sheet 3 of 9)
Heater Lines
1.
Heater lines group
2.
Tube assembly.
3.
Tag
4.
Elbow
5.
Valve
6.
Coupling
7.
Nipple
8.
Clip
9.
Tube
10. Elbow
11. Clamp
12. Connector
Cab Heater Group
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Gasket
Plate assembly
Capscrew
Washer
Capscrew
Bushing
Fitting
Hose
Tee
Plate assembly
Gasket
Clip
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Cab heater group
Heater switch
Wire assembly
Connector
Wire
Terminal
Washer
Lockwasher
Capscrew
Plate
35
36.
37.
38.
39.
40.
41.
42.
43.
Heater group
Plate assembly
Washer
Washer
Washer
Capscrew
Plate
Switch
Lockwasher
TA099218
Go on to Sheet 4
8-21
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 4 of 9)
ACTION
REMARKS
Heater Group
44.
45.
46.
47.
48.
49.
50.
51.
Heater group
Bracket
Spacer
Grommet
Washer
Nut
Channel
Motor
52.
53.
54.
55.
56.
57.
58.
Fan
Channel
Plate assembly
Nut
Lockwasher
Washer
Core
TA099219
Go on to Sheet 5
8-22
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 5 of 9)
ACTION
6.
Fitting (7)
Remove from heater core.
7.
Four sheet metal screws
Remove.
8.
Ground wire
a. Disconnect.
REMARKS
b. Check for breaks in the wire, also for
frayed or broken insulation.
c.
9.
Plate assembly (54)
Replace as needed.
a. Remove.
b. Check for cracks, dents, distortion.
c.
Replace as needed.
10.
Four sheet metal screws
Remove.
11.
heater core (58)
a. Remove.
b. Check for crushed fins, cracks, and
distortion.
c.
Replace as needed.
Go on to Sheet 6
8-23
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
12.
Channel (53)
(Sheet 6 of 9)
ACTION
REMARKS
a. Remove from housing.
b. Check for cracks, dents, distortion.
c.
Replace as needed.
13. Set screw
Remove from fan (52).
14.
a
Fan (52)
Remove from motor shaft.
b. Check for cracks, dents, distortion.
c.
Replace as needed.
15.
Two nuts and washers
Remove from motor screw posts.
16.
Motor (51)
a. Remove from housing.
b. Check shaft for smooth turning action
with hand.
c.
Check motor for cracks, dents, nicks or
burs on shaft, distortion, etc.
d. Check continuity of windings with an
ohm meter. Connect meter probes to
the two motor lead wires. Meter should
register near zero resistance.
e. Replace as needed.
Go on to Sheet 7
8-24
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
17.
Washers (48), grommet (47),
spacers
(46) and one bracket (45)
(Sheet 7 of 9)
ACTION
REMARKS
Remove from motor.
ASSEMBLY
1.
Bracket (45)
Install on screw posts of heater motor.
2.
'Two spacers (46)
Install on screw posts.
3.
Two washers (48) and
grommets (47)
Install on screw posts.
4.
Motor assembly
Position inside heater group (35) with
screw posts through holes.
5.
Two nuts (49)
Install on screw posts.
6.
Wires from motor
Push through hole in top of housing (35).
Go on to Sheet 8
8-25
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 8 of 9)
ACTION
REMARKS
7.
Fan (52)
Install on motor shaft.
8.
Setscrew
Tighten.
9.
Channel (53)
Install in housing (35).
10.
Heater core (58)
Install in housing (365).
11.
Four screws that secure fan shroud
and heater core to housing
Install in housing (35).
12.
Mounting plate (54)
Position on housing.
13.
Four screws that secure mounting
plate to housing
Install. (Connect ground wire with one
of these screws).
Go on to Sheet 9
8-26
TM 10-3930-641-34-2
CAB HEATER DISASSEMBLY/ ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 9 of 9)
ACTION
REMARKS
14.
Elbow (4)
Install on inlet opening.
15.
Fitting (7)
Install on outlet opening.
16.
Valve (5)
Install on elbow.
17.
Three washers
plate (54),
Install one washer on each post of mounting
18.
Plate assembly (36)
Install on mounting plate.
19.
Three flat washers (57), lockwashers (56), and nuts (55)
Install.
20.
Base plate (34)
Position over heater assembly.
21.
Two capscrews (33) and
washers (31 and 32)
Install in base plate.
End
8-27
TM 10-3930-641-34-2
CAB WINDOW, RIGHT SIDE, REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal and installation of right side window.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Window open.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Handrail Removal/Installation,
TM 10-3930-641-20
Don't use hoist for window.
Go on to Sheet 2
8-28
TM 10-3930-641-34-2
CAB WINDOW, RIGHT SIDE, REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 3)
ACTION
REMARKS
REMOVAL
1.
Handle arm (2)
a. Remove nut (1) from top and bottom of
handle arms (2).
b. Remove handle arms (2) from brackets (3).
2.
Handrail (4)
Remove handrail (4) on right side of the
vehicle. (See TM 10-3930-641-20.)
TA099220
Go on to Sheet 3
8-29
TM 10-3930-641-34-2
CAB WINDOW, RIGHT SIDE, REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
3.
Window frame (6)
(Sheet 3 of 3)
ACTION
REMARKS
a. Remove nut (5) from stud on hinge
in middle of window.
b. Push window out to 900 angle with
the cab.
c.
Lift window frame up and out of the
hinges on the cab.
INSTALLATION
1.
Window frame (6)
a. Slide frame down into hinges.
b. Install nut (5) on stud of middle hinge.
2.
Handle arms (2)
a. Install top and bottom handle arms (2) into
window brackets (3).
b. Install nuts (1).
3.
Handrail (4)
Install on right side of body.
See TM 10-3930-641-20
TA099221
End
8-30
TM 10-3930-641-34-2
CAB WINDOW GLASS REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removing and installing all cab window glass.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Engine off.
Sliding window glass assemblies are
removed.
Shipping link installed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Shipping Link Removal/Installation,
TM 10-3930-641-20.
Windshield Wiper Removal/Installation,
TM 10-3930-641-20.
Use thick gloves to remove damaged glass.
Go on to Sheet 2
8-31
TM 10-3930-641-34-2
CAB WINDOW CLASS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 3)
ACTION
REMARKS
REMOVAL
1.
Seal
NOTE
Remove windshield wiper and arm. See
TM 10-3930-641-20.
a. Place seal installation tool (A) between two
locking lips (6) of seal (1).
b. Move tool (A) along seal pulling locking lip
out and away from cab.
c.
Move the tool (A) completely around seal.
2.
Glass (2)
Remove glass from seal.
3.
Seal (1)
Remove seal from opening in panel.
INSTALLATION
1.
Seal (1)
a. Install groove (4) of seal (1) over edge of
panel (5) with locking lip (6) toward outside of cab and nearer the glass (7) than
the panel.
b. Install seal (1) all around edge of opening.
Cut seal so end will extend past the starting
point by .125 in. (3.18 mm) per foot. This
will make a tight waterproof seal.
c.
Push ends together.
TA099222
Go on to Sheet 3
8-32
TM 10-3930-641-34-2
CAB WINDOW GLASS REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
2.
Glass (2)
(Sheet 3 of 3)
ACTION
REMARKS
a. Place glass down into groove (3) as far as
possible without forcing.
b. Adjust glass into place.
3.
Seal
a. Place soap and water solution on locking
lip (6).
b. Place curved end of seal insertion tool (A)
into groove (8) at some point opposite the
starting point.
c.
Move tool (A) along groove (8) all around
edge of window. Glass is now in place.
TA099223
End
8-33
TM 10-3930-641-34-2
CAB DOOR DISASSEMBLY/ASSEMBLY
(Sheet 1 of 4)
This task covers: Disassembly and assembly for cab door.
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
None
None
Equipment Condition
Engine off.
Door on or off vehicle.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Cab Window Glass Removal/Installation,
page 8-31.
None
Go on to Sheet 2
8-34
TM 10-3930-641-34-2
CAB DOOR DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
(Sheet 2 of 4)
ACTION
REMARKS
DISASSEMBLY
1. Panels (1), (2), (3)
a. Remove from inside of door, and
disconnect rod (8) behind panel
from lever (15).
b. Remove insulation from bottom of door.
2.
a. Remove hex nut (6).
b. Slide bracket (4) off panel (3).
Handle assembly (5)
c.
Remove handle assembly (5).
d. Loosen clips on outside door handle.
Remove rods (7) and (8).
TA099224
Go on to Sheet 3
8-35
TM 10-3930-641-34-2
(Sheet 3 of 4)
CAB DOOR DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
e.
Remove nut (9) from outside handle
assembly (12).
f.
Remove retaining bracket (11).
g. Remove handle assembly from outside of
door.
3. Door latch (10)
a. Remove four capscrews and lockwashers
(14).
b. Remove latch (10).
NOTE
To remove glass from door, see page 8-31,
Cab Window Glass Removal and Installation.
ASSEMBLY
1.
Door latch
a. Install door latch (10), with lever (13)
installed through hole.
b. Install four bolts and lockwashers (14).
TA099225
Go on to Sheet 4
8-36
TM 10-3930-641-34-2
CAB DOOR DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
2.
Handle assembly
(Sheet 4 of 4)
ACTION
REMARKS
a. Install outside handle assembly (12) from
outside.
b. Install retaining bracket (11).
c.
Install nut (9) to hold retaining bracket.
d. Install two rods (7) and (8) with clips.
e. Install inside door handle (5) to panel (3).
f.
Install retaining bracket (4) with nut (6).
g. Connect rod (8) to lever (15). Install inside
panel (3) with seven screws.
3.
Panel
a. Install upper panel (1).
b. Install insulation and lower panel (2).
NOTE
To install glass, see page 8-31, Cab Window
Glass Removal and Installation.
TA099226
End
8-37
TM 10-3930-641-34-2
Section III. BODY AND PLATFORM
BODY MAINTENANCE INSTRUCTIONS
(Sheet 1 of 1)
This task covers repair of body components and general metal repair.
LIST OF TASKS
TASK NO.
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Right platform removal/installation.
8-39
None
2
Rear bumper removal/installation.
8-42
None
3
Fuel tank removal/installation.
8-48
None
4
Fuel tank disassembly/assembly.
8-51
None
5
Battery box removal/installation
8-54
None
6
General metal repair.
8-58
None
8-38
TM 10-3930-641-34-2
RIGHT PLATFORM REMOVAL/INSTALLATION
(Sheet 1 of 3)
This task covers: Removal and installation of the platform and guard over the hydraulic tank.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Ladders and grabirons removed.
Platform hand rails removed.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Ladder and grabiron removal/installation,
TM 10-3930-641-20.
None
Platform hand rails removal/installation,
TM 10-3930-641-20.
Go on to Sheet 2
8-39
TM 10-3930-641-34-2
RIGHT PLATFORM REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 3)
ACTION
REMARKS
REMOVAL
1.
Platform tread (2)
Remove capscrews (1) washers (3) and
plate (5).
2.
Capscrews (15) and washers (14)
Remove.
3.
Hydraulic tank shield (13)
Remove.
NOTE
Weight of shield is 110 pounds (50 kg).
4.
Hoist
Fasten to right side platform (10).
5.
Capscrews holding platform (10) to
support channels
Remove.
6. Platform (10)
Lift free of support channels and remove.
TA099227
Go on to Sheet 3
8-40
TM 10-3930-641-34-2
RIGHT PLATFORM REMOVAL/INSTALLION (CONT)
LOCATION/ITEM
(Sheet 3 of 3)
ACTION
REMARKS
INSTALLATION
1.
Platform (10)
Lift into position.
2.
Capscrews for platform
Install.
3.
Hydraulic tank shield (13)
Lift into position.
4.
Capscrews (15) for shield
Install.
5.
Platform treads (2)
Install.
End
8-41
TM 10-3930-641-34-2
REAR BUMPER REMOVAL/INSTALLATION
(Sheet 1 of 6)
This task covers: Removal and installation of the rear bumper.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Engine OFF
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
Battery removal/installation, TM 10-3930-641-20
Main disconnect switch OFF.
Battery cable removal/repair/installation,
TM 10-3930-641-20
Go on to Sheet 2
8-42
TM 10-3930-641-34-2
REAR BUMPER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
(Sheet 2 of 6)
ACTION
REMARKS
REMOVAL
1.
Capscrews holding grab irons rear
fender and steps
Remove.
2.
Batteries
Disconnect cables and remove. See
TM 10-3930-641-20.
3.
Battery box
Remove retaining capscrews and remove
battery box.
4.
Nut (1) and plate
Remove three, each set of weights.
5.
Threaded rod (2), nut and plate
Remove three, each set of weights.
6.
Hoist
Fasten to pin (3) and lift counterweight from
vehicle.
NOTE
There are four (4) counterweights on the top
of the bumper. Each counterweight weighs
3600 pounds (1633 kg).
TA098789
Go on to Sheet 3
8-43
TM 10-3930-641-34-2
REAR BUMPER REMOVAL/INSTALLATION (CONT)
LOCATION/ITEM
7.
Bottom counterweights
(Sheet 3 of 6)
ACTION
REMARKS
Support with jacks.
NOTE
Bottom counterweight set weighs 5700 pounds
(2586 kg).
8.
Capscrews (4) nuts and washers
Remove. Use jacks to lower counterweight.
9.
Capscrews and spacers (5) for
bumper platforms (6)
Remove.
NOTE
When capscrews are removed, lift platform
free of lug (7).
TOP VIEW
TA098790
Go on to Sheet 4
8-44
TM 10-3930-641-34-2
(Sheet 4 of
REAR BUMPER REMOVAL/INSTALLATION (CONT)
6)
LOCATION/ITEM
10.
Rear bumper
ACTION
REMARKS
Support with jacks
NOTE
Bumper weighs 2550 pounds (1159 kg).
11.
Capscrews (8) and pins (9) attaching
bumper assembly to vehicle
Remove.
12.
Bumper
Lower to ground.
TA098791
Go on to Sheet 5
8-45
TM 10-3930-641-34-2
(Sheet 5 of
REAR BUMPER REMOVAL/INSTALLATION (CONT)
6)
LOCATION/ITEM
ACTION
REMARKS
1.
INSTALLATION
Rear bumper
Lift into position, using jacks.
2.
Capscrews (8) and pins (9)
Install.
3.
Bumper platforms (6)
Place in position.
4.
Capscrews and spacers (5)
Install.
5.
Bottom counterweights
Lift into position, using jacks.
6.
Capscrews (4) and nuts and washers
Install.
7.
Top counterweights
Place in position on the bumper platforms.
8.
Nuts (1), plates and threaded rods
(2)
Install.
Go on to Sheet 6
8-46
TM 10-3930-641-34-2
(Sheet 6 of
REAR BUMPER REMOVAL/INSTALLATION (CONT)
6)
LOCATION/ITEM
ACTION
REMARKS
9.
Battery box
Put in position and install capscrews and
washers.
10.
Batteries
Install.
See TM 10-3930-641-20.
11.
Battery cables
Install.
See TM 10-3930-641-20.
12.
Grab irons, rear fenders and steps
Install using capscrews and washers.
See TM 10-3930-641-20.
End
8-47
TM 10-3930-641-34-2
(Sheet 1 of
FUEL TANK REMOVAL/INSTALLATION
3)
This task covers: Removal and installation of fuel tank.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
None
Equipment Condition
Fuel tank drained
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
None
None
Go on to Sheet 2
8-48
TM 10-3930-641-34-2
(Sheet 2 of
FUEL TANK REMOVAL/INSTALLATION (CONT)
3)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Handrails
Remove.
2.
Left rear fender (1)
a. Remove four capscrews (2) and spacers (3).
b. Remove fender (1).
3.
Hoist
Attach slings to tank (4) and hoist. Put a
slight strain on hoist.
4.
Tank mounting bolts.
Remove capscrews (5), washers (6), (7) and
nuts (8). Remove tank.
5.
Ladder
a. Remove capscrews securing ladder.
b. Remove ladder.
TA172244
Go on to Sheet 3
8-49
TM 10-3930-641-34-2
(Sheet 3 of
FUEL TANK REMOVAL/INSTALLATION (CONT)
3)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATIONI
1.
Hoist
a.
b.
Attach slings to tank and hoist.
Position tank onto vehicle.
2.
Tank mounting bolts
Secure with capscrews (5), washers (6), (7) and
nuts (8).
3.
Ladder
Reinstall.
4.
Left rear fender
Reinstall.
5.
Handrails
Reinstall.
TA172245
End
8-50
TM 10-3930-641-34-2
(Sheet 1 of
FUEL TANK REMOVAL/INSTALLATION
3)
This task covers: The disassembly and assembly of fuel tank.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
None
Equipment Condition
Fuel tank drained and removed
from vehicle
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
General metal repair, page 8-58
None
Go on to Sheet 2
8-51
TM 10-3930-641-34-2
(Sheet 2 of
FUEL TANK DISASSEMBLY/ASSEMBLY (CONT)
3)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Bracket (2)
a. Remove capscrews (5) washers (3) and (4).
b. Remove bracket.
2.
Wire harness (6)
3.
Tube (7)
Disconnect from switches (17) and remove.
a. Remove capscrews (8) and lock
washers (9).
b. Remove tube.
4.
Switch assemblies (17)
a. Remove six nuts (11) and washers (12).
b. Remove switch assemblies (17).
5.
Cap assembly (21)
Remove.
6.
Strainer (20)
Remove.
TA172246
Go on to Sheet 3
8-52
TM 10-3930-641-34-2
(Sheet 3 of
FUEL TANK REMOVAL/INSTALLATION (CONT)
3)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
1.
Strainer (20)
Install.
2.
Cap assembly (21)
Install.
3.
Switch assemblies (17).
Install. Use new preformed packing and
gasket.
4.
Tube (7)
a. Position on tank.
b. Secure with capscrew (8), washer (9) and
clip (10).
5.
Wire harness (6)
a. Install into tube (7).
b. Connect to switch assemblies (17).
6.
Bracket (2)
Install.
TA172247
End
8-53
TM 10-3930-641-34-2
(Sheet 1 of
BATTERY BOX REMOVAL/INSTALLATION
4)
This task covers: Removal and installation of battery boxes.
INITIAL SETUP
Test Equipment
None
Materials/Parts
Troubleshooting Reference
As required
Page 2-3
Equipment Condition
Engine off, key switch off and all
electrical accessories off.
Special Tools
Personnel Required
None
Two mechanics
References
General Safety Instructions
None
Be careful not to cause an arc or
spark near the battery.
Go on to Sheet 2
8-54
TM 10-3930-641-34-2
(Sheet 2 of
BATTERY BOX REMOVAL/INSTALLATION (CONT)
4)
LOCATION/ITEM
ACTION
REMARKS
REMOVAL
1.
Battery box
Open cover (4).
2.
Battery cable (1)
Remove cable (1) from negative (-) post first.
3.
Battery cable (2)
Remove cable (2) from negative (-) post first
and positive (+) post second.
4.
Battery cable (3)
Remove cable (3) from positive (+) post last.
5.
Battery hold down (8)
Remove nut (5) and washer (6) from hold
down bolt (7). Remove hold down (8).
6.
Batteries (9)
Remove.
7.
Tray assembly (12)
Remove capscrew (10) and washer (11).
Remove tray assembly.
8.
Battery box (13)
Remove.
TA172248
Go on to Sheet 3
8-55
TM 10-3930-641-34-2
(Sheet 3 of
BATTERY BOX REMOVAL/INSTALLATION (CONT)
4)
LOCATION/ITEM
ACTION
REMARKS
INSTALLATION
1.
Battery box (13)
a. Position battery box onto rear bumper.
b. Aline holes in bottom of box with holes in
top of bumper.
2.
Tray assembly (12)
a. Position tray into battery box.
b. Aline holes in tray assembly with holes
in box and bumper.
c.
Secure with capscrews (10) and
washers (11).
3.
Batteries (9)
Position batteries into tray assemblies.
4.
Battery hold down (8)
a. Engage hook of hold down bolt (7) into
tray assembly.
b. Place the hold down assembly (8) over
battery and hold down bolt.
c.
Secure with nut (5) and washer (6).
TA172249
Go on to Sheet 4
8-56
TM 10-3930-641-34-2
(Sheet 4 of
BATTERY BOX REMOVAL/INSTALLATION (CONT)
4)
LOCATION/ITEM
ACTION
REMARKS
NOTE
Do not over tighten hold down bolts.
Damage to the battery could result.
5.
Battery cable (3)
Install cable onto positive (+) post.
NOTE
Do not pound terminals onto terminal
posts, this would damage the battery.
6.
Battery cable (2)
Install onto positive (+) post first and
negative (-) post second.
7.
Battery cable (1)
Install onto negative (-) post.
8.
Battery box (13)
Close cover and secure with latches.
TA172250
End
8-57
TM 10-3930-641-34-2
(Sheet 1 of
GENERAL METAL REPAIR
2)
This task covers: All metal repair.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
See FM 43-2
None
Equipment Condition
See FM 43-2.
Special Tools
Personnel Required
See FM 43-2
One mechanic
References
General Safety Instructions
FM 43-2
See FM 43-2
Go on to Sheet 2
8-58
TM 10-3930-641-34-2
(Sheet 2 of
GENERAL METAL REPAIR (CONT)
2)
LOCATION/ITEM
1.
Body
ACTION
Repair.
REMARKS
All repair work shall be done per FM 43-2.
End
8-59/ (8-60)
TM 10-3930-641-34-2
CHAPTER 9
TOPHANDLER
MAINTENANCE INSTRUCTIONS
Page
Tophandler ...............................................................................9-3
Container lock cylinder........................................................... 9-16
Force limiter ........................................................................... 9-21
Twistlock adjustment .............................................................. 9-24
9-1
TM 10-3930-641-34-2
TOPHANDLER MAINTENANCE INSTRUCTIONS
This section covers maintenance of these tophandler components for direct support and general support personnel:
a. Tophandler
b. Container Lock Cylinder
c. Twistlock
LIST OF TASKS
TASK NO.
(Sheet 1 of 1)
TASK
REF (PAGE)
TROUBLESHOOTING
REF (PAGE)
1
Tophandler disassembly/assembly
9-3
None
2
Container lock cylinder disassembly/assembly
9-16
None
3
Force limiter disassembly/assembly
9-21
None
4
Twistlock adjustment
9-24
None
End
9-2
TM 10-3930-641-34-2
TOPHANDLER DISASSEMBLY/ASSEMBLY(Sheet 1 of 13)
This task covers: Disassembly and assembly of tophandler.
NOTE
This procedure applies to the 40 ft, 35 ft and 20 ft tophandlers. The only difference is that the 20 ft tophandler has only one
container lock cylinder while the 35 ft and 40 ft tophandlers have two.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Tophandler removed from vehicle
Special Tools
Personnel Required
None
One mechanic.
References
General Safety Instructions
Removing and Installing the
Tophandler, TM10-3930-641-10.
None
Go on to Sheet 2
9-3
TM 10-3930-641-34-2
(Sheet 2 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Container lock cylinder (78)
a. Tag and remove hydraulic lines.
b. Plug open lines.
c.
Remove front and rear clevis pins (39).
d. Remove cylinder.
2.
Force limiter assembly
a. Remove capscrews (12) and nuts (38).
b. Remove force limiter assembly from
frame assembly (3).
3.
Control rod limit switch (69)
a. Disconnect wiring at limit switch.
b. Remove capscrews (70) and lockwashers
(56).
c.
Remove limit switch.
Go on to Sheet 3
9-4
TM 10-3930-641-34-2
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
(Sheet 3 of 13)
Tophandler assembly
Capscrew
Frame assembly
Nut
Capscrew
Bracket
Rubber bushing
Rubber bushing
Plate
Bearing
Control rod
Capscrew
Lockwasher
Grommet
Twistlock assembly
Cotter pin
Clevis pin
Nut, slotted
Cotter pin
Connecting lever
Washer
Key
Fitting
Nut
Plunger bracket
Spring
Bushing
Socket set screw
Plunger
Screw
Plate
Slide block
Bayonet
Capscrew, socket head
Switch
Clevis
Jam nut
TA173011
Go on to Sheet 4
9-5
TM 10-3930-641-34-2
(Sheet 4 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
Nut
Clevis pin
Capscrew
Twistlock actuator
Cotter pin
Actuator rod
Decal
Lever
Decal
Decal
Decal
Decal
Decal
Decal
Shackle assembly
Chain
Shackle
Master link
Lockwasher
Bolt
Nut
Bolt
Decal
Capscrew
Guide arm
Control arm
Capscrew
Nut
Lever
Key
Capscrew
Limit switch
Capscrew, socket head
Capscrew
Capscrew
Junction box assembly
Junction box
75.
76.
77.
78.
Electrical socket
Capscrew
Stop nut
Lever
TA173012
Go on to Sheet 5
9-6
TM 10-3930-641-34-2
(Sheet 5 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
4.
Capscrews (2) and nuts (4) that
Remove.
secure junction box (74)
5.
Junction box (74)
a. Disconnect wiring.
b. Remove.
6.
Capscrews (5) and nuts (4) that
Remove.
secure brackets (6)
7.
Brackets (6) and bushings (7) (8)
Remove.
8.
Electrical cable and hydraulic lines
Remove.
9.
Capscrews (12) and lockwashers
(13) that secure bearings (10)
Remove.
10.
Bearings (10)
Pull away from frame assembly.
11.
Capscrews (40) and nuts (38) that
secure control rod (11) to twistlock
actuators (41)
Remove.
REMARKS
Go on to Sheet 6
9-7
TM 10-3930-641-34-2
(Sheet 6 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
REMARKS
12.
Capscrews (40) and nuts (38) that
secure control rod (11) to control
arm (63)
Remove.
13.
Capscrews (68) and nuts (65) that
secure control rod (11) to lever
(66)
Remove.
14.
Lever (66)
Move to side to uncover key (67).
15.
Cotter pins (42) (16) that secure
actuator rod clevis pins (39) (17)
Remove.
16.
Clevis pins (39) (17)
Remove.
17.
Actuator rod (43)
Remove.
Go on to Sheet 7
9-8
TM 10-3930-641-34-2
(Sheet 7 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
REMARKS
NOTE
As control rod is pulled from frame assembly,
be sure to remove loose bearings (10), lever
(66) and control arm (62).
18. Control rod (11)
Remove from frame assembly (3).
19. Capscrews (61) and lockwashers (13)
that secure guide bars (62)
Remove.
20. Guide bars (62)
Remove.
Go on to Sheet 8
9-9
TM 10-3930-641-34-2
(Sheet 8 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
21.
Capscrews (34) that secure bayonet
limit switches (35)
Remove.
22.
Bayonet limit switches (35)
a. Disconnect wiring.
REMARKS
b. Remove switches.
23.
Cotter pin (19) that secures slotted
nut (18)
Remove.
24.
Slotted nut (18)
Remove.
Go on to Sheet 9
9-10
TM 10-3930-641-34-2
(Sheet 9 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
25.
Bayonet (33), washer (21) and
connecting lever (20)
Remove.
26.
Nut (24) that secures plunger (29)
Remove.
27.
Plunger (29) and spring (26)
Remove.
28.
Bushing (27)
Remove.
29.
Bracket (25)
Remove.
30.
Screw (30), plate (31) and slide
block (32)
Remove.
REMARKS
ASSEMBLY
1.
Slide block (32), plate (31) and
screw (30)
Install.
2.
Bracket (25)
Install.
3.
Bushing (27)
Install.
Go on to Sheet 10
9-11
TM 10-3930-641-34-2
(Sheet 10 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
REMARKS
4.
Spring (26) and plunger (29)
Install.
5.
Nut (24) that secures plunger (29)
Install.
6.
Bayonet (33), washer (21) and
connecting lever (20)
Install.
7.
Slotted nut (18)
Install.
8.
Cotter pin (19) that secures slotted
nut (18)
Install.
9.
Guide bars (62)
Fasten to frame assembly with capscrews (61)
and lockwashers (13).
NOTE
Leave bearings (10), control arm (63) and lever
(66) loose until control rod (11) is fully
installed.
10.
Control rod (11)
a. Insert rod tip into inboard side of frame
assembly (3).
b. Install bearings (10), control arm (63) and
lever (66) on rod.
c.
Insert rod into other half of frame
assembly (3).
d. Install bearings (10) on rod.
e. Fully install rod.
Go on to Sheet 11
9-12
TM 10-3930-641-34-2
(Sheet 11 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
REMARKS
11.
Twistlock actuators (41)
Install on each end of control rod (11) and
secure with capscrews (40) and nuts (38).
12.
Bearings (10)
Secure to frame assembly (3) with capscrews
(12) and lockwashers (13).
13.
Lever (66)
Secure to control rod (11) with capscrews
(68) and nuts (65).
14.
Control arm (63)
Secure to control rod (11) with capscrew (40)
and nut (38).
15.
Force limiter assembly
Secure to frame assembly with capscrews
(12) and nuts (38).
16.
Container lock cylinder
a. Position cylinder between force limiter
and control arm (63).
b. Insert clevis pins (39) and secure with
cotter pins (42).
c.
Unplug and connect the two hydraulic
lines.
Go on to Sheet 12
9-13
TM 10-3930-641-34-2
(Sheet 12 of
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
13)
LOCATION/ITEM
ACTION
REMARKS
17.
Clevis (36)
Install in each end of actuator rods (43).
18.
Actuator rods (43)
Position between connecting levers (20) and
twistlock actuators (41) and insert clevis pins
(39) (17).
19.
Cotter pins (16) (42)
Install.
20.
Lever (66)
Secure to control rod (11) with capscrews
(68) and nuts (65).
21.
Control rod limit switch (69)
a. Secure to frame assembly (3) with
capscrews (70) and lockwashers (56).
b. Connect wiring.
Go on to Sheet 13
9-14
TM 10-3930-641-34-2
TOPHANDLER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
22.
Bayonet limit switches (35)
(Sheet 13 of 13)
ACTION
REMARKS
a. Secure to frame assembly (3) with
capscrews (34).
b. Connect wiring.
23.
Junction boxes (74)
Secure to frame assembly with capscrews
(2) and nuts (4).
24.
Electrical cable and hydraulic lines
Insert in bushings (7) (8).
25.
Bushings (7) (8)
Install in bracket (6) and secure with
capscrews (5).
End
9-15
TM 10-3930-641-34-2
CONTAINER LOCK CYLINDER DISASSEMBLY/ASSEMBLY
This task covers: Disassembly and assembly of container lock cylinder.
(Sheet 1 of 5)
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Container lock cylinder removed.
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Tophandler disassembly,
page 9-3.
None
Go on to Sheet 2
9-16
TM 10-3930-641-34-2
(Sheet 2 of 5)
CONTAINER LOCK CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
DISASSEMBLY
1.
Cylinder body assembly (2)
Secure to repair stand.
2.
Ring (15)
Remove from cylinder body.
3.
Rod (8) and attached parts
Pull from cylinder body assembly (2).
4.
Clevis (16), ring (15) and cylinder
head (13)
Remove from rod (8).
5.
Preformed packings (9) (11) and
backup rings (10) (12)
Remove from cylinder head (13).
Go on to Sheet 3
9-17
TM 10-3930-641-4-2
CONTAINER LOCK CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
(Sheet 3 of 5)
Container lock cylinder assembly
Cylinder body assembly
Locknut
Piston
Preformed packing
Preformed packing
Backup ring
Rod
Preformed packing
Backup ring
Preformed packing
Backup ring
Cylinder head
Rod wiper
Ring
Clevis
Setscrew
Clevis pin assembly
Go on to Sheet 4
9-18
TM 10-3930-641-34-2
(Sheet 4 of 5)
CONTAINER LOCK CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
6.
Locknut (3)
Remove from rod (8).
7.
Piston (4)
Remove from rod (8).
8.
Preformed packings (5) (6) and
backup ring (7)
Remove from piston (4).
REMARKS
ASSEMBLY
1.
Backup ring (7) and preformed
packings (5) (6)
Install on piston (4).
2. Piston (4)
Install on rod (8).
3. Locknut (3)
Install.
See Torque limits chart, page D-1
Go on to Sheet 5
9-19
TM 10-3930-641-34-2
(Sheet 5 of 5)
CONTAINER LOCK CYLINDER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
4.
Backup rings (10) (12) and
preformed packings (9) (11)
Install on cylinder head (13).
5.
Cylinder head (13), ring (15) and
clevis (16)
Install on rod (8).
REMARKS
NOTE
Lubricate packings (6) (7) (9) (10) on cylinder
head (13) and piston (4) with hydraulic oil
before installing in cylinder body.
6.
Rod (8) and attached parts
Install in cylinder body assembly (2).
7.
Ring (15)
Install in cylinder body.
NOTE
Make sure that ring (15) is seated in the
groove in cylinder body.
End
9-20
TM 10-3930-641-34-2
FORCE LIMITER DISASSEMBLY/ASSEMBLY
(Sheet 1 of 3)
This task covers: Disassembly/assembly of the force limiter.
NOTE
This procedure applies to force limiter on 40 ft, 35 ft and 20 ft tophandlers.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
As required
None
Equipment Condition
Force limiter removed from tophandler
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Tophandler disassembly/assembly,
page 9-3.
None
Go on to Sheet 2
9-21
TM 10-3930-641-34-2
(Sheet 2 of 3)
FORCE LIMITER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
ACTION
REMARKS
ASSEMBLY
1.
Cover (3)
washers (4).
a. Remove four capscrews (5) and lock-
b. Remove cover.
2.
Clevis (11)
a. Remove nuts (14) and (13) rod holder
(12) and one spacer (9).
b. Remove clevis (11).
NOTE
Other spacer (9), washers (6) and springs (7)
will also be removed at the same time.
3.
Guide rods (2)
a. Drive pins (10) out of clevis (11).
b. Remove guide rods.
INSTALLATION
1.
Guide rods(2)
a. Install in clevis (11).
b. Align holes in rods and clevis.
c.
Secure with pins (10).
TA172236
Go on to Sheet 3
9-22
TM 10-3930-641-34-2
FORCE LIMITER DISASSEMBLY/ASSEMBLY (CONT)
LOCATION/ITEM
2.
Clevis (11)
(Sheet 3 of 3)
ACTION
REMARKS
a. Place one spacer (9) onto clevis rod.
b. Install clevis (11) into spring mount (8).
3.
Rod holder (12)
c.
Place one washer (6), four springs (7)
and other washer (6) onto clevis rod.
a.
Place other spacer (9) and rod holder
(12) onto clevis rod.
b. Secure with nuts (13) and (14).
NOTE
Tighten nut (13) just enough to remove all
lengthwise slack in the assembly, grease
guide rods (2) and sliding parts for 6 inches of
travel on either side of rod guides.
TA172237
End
9-23
TM 10-3930-641-34-2
TWISTLOCK ADJUSTMENT
(Sheet 1 of 2)
This task covers: Adjustment of twistlock.
NOTE
This procedure applies to the 40 ft, 35 ft and 20 ft tophandlers.
INITIAL SETUP
Test Equipment
Materials/Parts
Troubleshooting Reference
None
None
None
Equipment Condition
Twistlock assembled into tophandler
Special Tools
Personnel Required
None
One mechanic
References
General Safety Instructions
Tophandler disassembly, page 9-3.
None
Go on to Sheet 2
9-24
TM 10-3930-641-34-2
TWISTLOCK ADJUSTMENT (CONT)
(Sheet 2 of 2)
LOCATION/ITEM
Adjust bayonet (33)
ACTION
REMARKS
a. Remove cotter pin (19).
b. Adjust nut (18) to achieve 4-1/8"
(101.7 mm) to 4-5/8" (102.2 mm) at "A."
c.
Align nearest slot in nut (18) with hole in
bayonet (33).
d. Install new cotter pin (19).
NOTE
Always use a new cotter pin when replacing.
For best operation all four bayonets on top
handler should be adjusted to the same
dimension at "A."
TA172238
End
9-25 / (9-26 Blank)
TM 10-3930-641-34-2
APPENDIX A
REFERENCES
A-1.
PUBLICATION INDEXES AND GENERAL REFERENCES
Indexes should be consulted frequently for latest changes or revisions of references given in this appendix and for new publications relating to material covered in
this publication.
a.
Military Publication Indexes
Consolidated Index of Army Publication and Forms ......................................................................................................DA PAM 25-30
Index of Graphic Training Aids and Devices .............................................................................................................................. DAM 310-5
b.
A-2.
General References
First Aid for Soldiers............................................................................................................................................................. FM 21-11
FORMS
Refer to DA PAM 738-750, The Army Maintenance Management System (TAMMS), for instructions on the use of maintenance forms pertaining to the
material.
A-3.
OTHER PUBLICATIONS
The following publications contain information pertinent to the major item material and associated equipment.
a.
Vehicle
Lubrication Order, Truck, Container Handler: Rough Terrain, 50,000 lb. Capacity ..................................................LO 10-3930-641-12
Operator's Manual, Truck, Container Handler: Rough Terrain, 50,000 lb. Capacity................................................ TM 10-3930-641-10
Organizational Maintenance Manual, Truck, Container Handler: Rough Terrain, 50,000 lb. Capacity .................... TM 10-3930-641-20
Organizational Maintenance Repair Parts and Special Tools List for Truck, Container
Handler: Rough Terrain, 50,000 lb. Capacity .................................................................................................TM 10-3930-641-20P
Direct Support and General Support Maintenance Repair Parts and Special Tools List for Truck,
Container Handler: Rough Terrain, 50,000 lb. Capacity......................................................................................TM 10-3930-641-34P
b.
Camouflage
Camouflage ............................................................................................................................................................................FM 5-20
Color, Marking and Camouflage Painting of Military Vehicles, Construction Equipment and
Materials Handling Equipment.......................................................................................................................................TB 43-0209
Change 1 A-1
TM 10-3930-641-34-2
APPENDIX A
REFERENCES (CONT)
A-3.
OTHER PUBLICATIONS (CONT)
c.
Decontamination
Chemical, Biological, and Radiological (CBR) Decontamination.................................................................................................. TM 3-220
d.
General
Basic Cold Weather Manual........................................................................................................................................................ FM 31-70
Manual for Wheeled Vehicle Driver .......................................................................................................................................... FM 21-305
Northern Operations.................................................................................................................................................................... FM 31-71
Operation and Maintenance of Ordnance Material in Cold Weather (0°F to -65°F) FM 9-207
Procedures for Destruction of Equipment to Prevent Enemy Use ......................................................................................... TM 750-244-3
Military Traffic Management Command's Transportability Review.......................................................................................... TR 80-1-19A
e.
Maintenance and Repair
Organizational Care, Maintenance and Repair of Pneumatic Tires and Inner Tubes...................................................... TM 9-2610-200-20
Operator's, Organizational, Direct Support and General Support Maintenance Manual for Lead-Acid Storage Batteries TM 9-6140-200-14
Description, Use, Bonding Techniques, and Properties of Adhesives ................................................................................... TB ORD 1032
Inspection, Care, Maintenance of Antifriction Bearings................................................................................................................ TM 9-214
Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling Systems .................................................................. TB 750-651
Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance Material and Related Materials
Including Chemicals ............................................................................................................................................................... TM 9-247
Welding Theory and Application.................................................................................................................................................. TM 9-237
Non-Aeronautical Equipment Army Oil Analysis Program (AOAP)............................................................................................ TB 43-0210
f.
Administrative Storage
Administrative Storage of Equipment .................................................................................................................................... TM 740-90-1
Change 1 A-2
TM 10-3930-641-34-2
APPENDIX B
EXPENDABLE SUPPLIES AND MATERIALS LIST
Section I. INTRODUCTION
SCOPE
This appendix lists expendable supplies and materials you will need to operate and maintain the Rough Terrain Container Handler. These items are authorized to
you by CTA 50-970, Expendable Items (Except Medical, Class V, Repair Parts, and Heraldic Items).
EXPLANATION OF COLUMNS
(1)
ITEM NUMBER
This number is assigned to the entry in the listing and is referenced in the narrative instructions to identify the material (e.g.,
"Use cleaning compound, item 2, App. C").
(2)
LEVEL
This column identifies the lowest level of maintenance that requires the listed item.
C - Operator/Crew
O - Organizational Maintenance
F - Direct Support Maintenance
H - General Support Maintenance
(3)
NATIONAL STOCK
NUMBER
This is the National stock number assigned to the item; use it to request or requisition the item.
(4)
DESCRIPTION
Indicates the Federal item name and, if required, a description to identify the item. The last line for each item indicates the part
number followed by the Federal Supply Code for Manufacturer (FSCM) in parentheses, if applicable.
(5)
U/M (Unit of Measure)
Indicates the measure used in performing the actual maintenance function. This measure is expressed by a two-character
alphabetical abbreviation (e.g., ea, in, pr). If the unit of measure differs from the unit of issue, requisition the lowest unit of issue
that will satisfy your requirements.
B-1
TM 10-3930-641-34-2
Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST
(1)
ITEM
NUMBER
(2)
(3)
(4)
(5)
LEVEL
NATIONAL
STOCK
NUMBER
DESCRIPTION
U/M
1
O,F,H
6850-00-181-7929
Antifreeze, Type I
MIL-A-46153 (81349)
gal
2
O,F,H
6850-00-941-5054
Cleaning Compound, Solvent
FED SPEC O-C-1889, 5 gal can
gal
3
O,F,H
9150-00-935-1017
GAA Grease, Auto/Artillery (4 oz cartridge)
MIL-G-10924 (81349)
ea
4
O,F,H
9150-00-190-0904
GAA Grease, Auto/Artillery
MIL-G-10924 (81349)
lb
5
O,F,H
9150-00-905-9100
GO Lubricating Oil, Grade 80
MIL-L-2105 (81349)
gal
6
O,F,H
9150-00-257-5440
GO Lubricating Oil, Subzero
MILL-10324 (81349)
gal
7
O,F,H
9150-00-181-9858
Lubricating Oil, Engine OE 30
MIL-L-2104 (81349)
gal
8
O,F,H
9150-00-404-2372
Lubricating Oil, Engine OE 5
MIL-L-2104 (81349)
gal
8
O,F,H
9150-00-186-6668
Lubricating Oil, Engine OE 10
MIL-12104 (81349)
gal
9
O,F,H
9150-00-935-9807
OH T, Hydraulic Fluid, Petroleum Base
MIL-H-6083 (81349)
qt
B-2
TM 10-3930-641-34-2
Section II. EXPENDABLE SUPPLIES AND MATERIALS LIST
(1)
ITEM
NUMBER
(2)
(3)
(4)
(5)
LEVEL
NATIONAL
STOCK
NUMBER
DESCRIPTION
U/M
10
O,F,H
8030-00-965-2438
Sealing Compound, Paste, 60 ft roll
MILS-11030 (81349)
ft
11
O,F,H
8135-00-551-1245
Tape, Adhesive
PPPT60 (81348)
yd
12
O,F,H
8010-00-297-0560
Enamel, Alkyd, Lusterless OD
MIL-E-5556 (81349)
gal
13
O,F,H
8010-00-598-5936
Enamel, Semigloss OD, 12 oz can (pressurized)
TTE8485 (81348)
ea
14
O,F,H
9140-00-180-6084
Fuel Oil, Diesel: DF2
VV-F-80D (81348)
gal
15
O,F,H
6810-00-356-4936
Distilled Water, Technical: 5 gal bottle
gal
16
C,O,F,H
7920-00-205-1711
Rag, Wiping: Cotton, Class 2. Grade B, 50 lb bundle
DDD-R-30 (81348)
lb
17
O,F,H
6850-00-281-1985
Dry Cleaning Solvent (SD-2), 1 gal can
P-D-680 (81348)
gal
18
O,F,H
7930-00-249-8036
P-D-220 (81348)
Detergent, General Purpose: 5 lb box
lb
19
O,F,H
6810-00-264-6618
Sodium Bicarbonate, Technical: 1 lb box
lb
20
F
--
Antiseize Compound
5P3931 (11083)
Change 1 B-3/(B-4 Blank)
TM 10-3930-641-34-2
APPENDIX C
ILLUSTRATED LIST OF MANUFACTURED ITEMS
MANUFACTURED HOSES
(Sheet 1 of 5)
A.
Stem Assy - Assembly may have nuts on the ends or may be attached with flanges. Stem assemblies will be listed as one per end.
B.
Sleeve Assy - Sleeves will be listed as one per end.
C.
Hose - Hoses listed are in bulk length.
Hose Assy No.
Bulk Hose No.
Hose Length
Sleeve No (Qty)
3V0188
5P0181
22 in. (0.56 m)
3S7252 (2)
3V0189
5P0181
25 in. (0.64 m)
3S7252 (2)
2V3785
5P0180
35 in. (0.89 m)
3S7166 (2)
Stem Assy No. (Qty)
3S8503 (1)
8S3918 (1)
3S8503 (1)
8S3918 (1)
5S3049 (1)
9S9724 (1)
TA1 72255
Go on to Sheet 2
C-1
TM 10-3930-641-34-2
MANUFACTURED HOSES (CONT)
(Sheet 2 of 5)
Hose Assy No.
Bulk Hose No.
Hose Length
Sleeve No. (Qty)
2V5040
5P0182
43 in. (1.1 m)
3S7116 (2)
2V2934
5P0181
22 in. (0.56 m)
3S7252 (2)
2V5043
3V0730
5P0181
5P0178
44 in. (1.12 m)
25 in. (0.64 m)
3S7252 (2)
4S5414 (2)
2V5038
5P0182
17 in. (0.43 m)
3S7116 (2)
2V2931
5P0182
43 in. (1.1 m)
3S7116 (2)
3V0849
5P0178
19.7 in. (0.5 m)
4S5414 (2)
4V8370
3V7899
5P0180
5P0180
32.31 in. (0.82 m)
53.15 in. (1.4 m)
3S7166 (2)
3S7166 (2)
2V7967
5P0178
12 in. (0.3 m)
4S5414 (2)
2V2180
5P0181
28.35 in. (0.72 m)
3S7252 (2)
2V2176
5P0180
39.76 in. (1.01 m)
3S7166 (2)
Stem Assy No. (Qty)
5S3779 (1)
3S8570 (1)
7S0570 (1)
7S0575 (1)
7S0570 (1)
7S0575 (1)
8S6417 (2)
5S3779 (1)
3S8570 (1)
5S3777 (1)
3S8568 (1)
8S6393 (1)
1P9919 (1)
3S8360 (1)
7S1712 (1)
3S8363 (2)
8S6393 (1)
8S6417 (1)
7S0570 (1)
7S0574 (1)
8S4591 (1)
3S8360 (1)
Go on to Sheet 3
C-2
TM 10-3930-641-34-2
MANUFACTURED HOSES-(CONT)
(Sheet 3 of 5)
Hose Assy No.
Bulk Hose No.
Hose Length
Sleeve No. (Qty)
2V2179
5P0180
37.01 in. (0.94 m)
3S7166 (2)
2V2178
5P0180
64.17 in. (1.63 m)
3S7166 (2)
2V7966
5P0180
53.98 in. (1.37 m)
3S7166 (2)
2V9298
5P0178
69.68 in. (1.77 m)
4S5414 (2)
2V9301
2V9302
2V9299
2V6758
5P0178
5P0178
5P0178
5P0181
28 in. (0.7 m)
36 in. (0.9 m)
75.2 in. (1.91 m)
4S5414 (2)
4S5414 (2)
4S5414 (2)
42.5 in. (1.08 m)
3S7252 (2)
2V2109
5P0182
30 in. (0.76 m)
3S7116 (2)
2V6760
5P0181
32 in. (0.81 m)
3S7252 (2)
2V2986
5P0183
18.5 in. (0.4 7 m)
3S8330 (2)
Stem Assy No. (Qty)
3S8363 (1)
3S8360 (1)
3S8363 (1)
7S1712 (1)
5S3049 (1)
5S5287 (1)
8S6417(1)
8S6393 (1)
8S6393 (1)
8S6417 (1)
3S8496 (1)
8S6417 (2)
3S8496 (1)
7S0570 (1)
7S1707 (1)
5S3777 (1)
3S8498 (1)
7S0570 (1)
7S9370 (1)
7S8439 (1)
Go on to Sheet 4
C-3
TM 10-3930-641-34-2
MANUFACTURED HOSES (CONT)
(Sheet 4 of 5)
Hose Assy No.
Bulk Hose No.
Hose Length
Sleeve No. (Qty)
3V2660
5P0183
17.3 in. (0.44 m)
3S8330 (2)
3V2661
5P0183
11.8 in. (0.3 m)
3S8330 (2)
2V2979
5P0183
55.9 in. (1.42 m)
3S8330 (2)
2V2988
538128
538129
538127
5P0182
5P6624
5P6624
5P6624
57.5 in. (1.46 m)
92 in. (2.34 m)
90 in. (2.29 m)
76 in. (1.93 m)
3S7116 (2)
5R4516
5P0180
28 in. (0.71 m)
3S7166 (2)
5R4545
5P0180
25 in. (0.64 m)
8 in. (2.24 m)
3S7166 (2)
5R4514
5R4532
5P0180
5P0181
89.4 in. (2.27 m)
3S7166 (2)
3S7252 (2)
5R4508
5P0181
25.6 in. (0.65 m)
3S7252 (2)
Stem Assy No. (Qty)
3S9331 (1)
3S9329 (1)
3S9331 (1)
3S9330 (1)
3S9327 (1)
5P3229 (1)
7S1074 (1)
8S8957 (1)
690478 (2)
690478 (2)
690478 (2)
8S6389 (1)
8S3759 (1)
8S6389 (1)
8S3759 (1)
8S6389 (1)
8S3759 (1)
8S3918 (2)
8S3918 (1)
8K5114 (1)
Go on to Sheet 5
C-4
TM 10-3930-641-34-2
MANUFACTURED HOSES (CONT
(Sheet 5 of 5)
Hose Assy No.
5R4511
5R4509
Bulk Hose No.
5P0179
5P0179
5R4512
5P0179
Hose Length
100 in. (2.54 m)
Sleeve No. (Qty)
3S8606 (2)
3S8606 (2)
100 in. (2.54 m)
3S8606 (2)
100 in. (2.54 m)
5R4523
5R4497
5R4501
5P0181
5P0740
5P0180
3S7252 (2)
42.5 in. (1.08 m)
193 in. (4.9 m)
24 in. (0.61 m)
3S7116 (2)
3S7166 (2)
Stem Assy No. (Qty)
8S4055 (2)
8S6391 (1)
8S4055 (1)
8S6391 (1)
8S4055 (1)
2P1411 (1)
8S3918 (1)
2P0988 (2)
8S6389 (2)
End
C-5
TM 10-3930-641-34-2
FT834 - NOZZLE
(Sheet 1 of 1)
TA172256
End
C-6
TM 10-3930-641-34-2
FT1280-AXLE INSTALLATION TOOL
(Sheet 1 of 1)
TA172257
End
C-7
TM 10-3930-641-34-2
FT1322 - LEVER ASSEMBLY
(Sheet 1 of 1)
TA172258
End
C-8
APPENDIX D. TORQUE VALUES TM 10-3930-641-34-2
CAPSCREWS, NUTS, TAPERLOCK STUDS TORQUE
TM 10-3930-641-34-2
(Sheet 1 of 11)
*1 newton meter (N-m) is approximately the same as 0.1 mkg.
Go on to Sheet 2
D-1
TM 10-3930-641-34-2
CAPSCREWS, NUTS, TAPERLOCK STUDS TORQUE (CONT)
(Sheet 2 of 11)
*1 newton meter (N-m) is approximately the same as 0.1 mkg.
Go on to Sheet 3
D-2
TM 10-3930-641-34-2
LINES, PLUGS, FITTINGS TORQUE
(Sheet 3 of 11)
Ermeto Tube Fittings
Put nut and sleeve over the tube with head or shoulder end of sleeve next
to nut. Push tube into counterbore of fitting body as far as possible. Turn nut
clockwise until sleeve holds tube and prevents movement. Tighten the nut
11/4 turns more to seat sleeve and give a locking action. When necessary to
assemble again, put sleeve over tube and tighten nut until a sudden increase
in torque is felt. Then tighten 1/6 to 1/3 turn more to seat the sleeve.
Flex Fittings
Put nut and sleeve over tubing and push tube into counterbore of fitting
body as far as possible. Tighten the nut until it is against 'he hex part of the
fitting body.
Hi Duty (shear sleeve)
Tube Fittings
After tube has been put through the nut and makes contact against the
tube shoulder in the fitting body, turn the nut with a wrench until a small
decrease in torque is felt. This is an indication that the sleeve has been
broken off of the nut. Hold the tube to prevent turning and tighten the nut I
and 1/2 turns.
Hi Seal Fittings
Put nut and sleeve over the tubing with the short heavy end of the sleeve
facing the end of tubing. Put the tube end against the counterbore in the body
of the fitting and tighten until nut is over the last thread on the body. The
remainder of space is used whenever the fitting is removed and installed
again.
Go on to Sheet 4
D-3
TM 10-3930-641-34-2
LINES, PLUGS, FITTINGS TORQUE (CONT
(Sheet 4 of 11)
NOTE
The torques shown in the chart that follows are to be used on the nut part of 370 Flared, 450 Flared and Inverted Flared fittings
(when used with steel tubing), O-ring plugs, O-ring fittings and swivel nuts when used in applications to 3000 psi (210.9 kg/cm2)
(20700 kPa).
Go on to Sheet 5
D-4
TM 10-3930-641-34-2
ENGINE SPECIAL TORQUE VALUES
(Sheet 5 of 11)
1. Upper drive shaft at torque converter - capscrews
90-110 lb. ft. (122-150 N m)
2. Fan belt adjustment rod nuts
95-125 lb. ft. (129-169 N-m)
3. Engine oil pump drive gear capscrew
35-45 lb. ft. (47-61 N m)
4. Cylinder head capscrews
315-345 lb. ft. (427-467 N m)
5. Rocker shaft capscrews
315-345 lb. ft. (427-467 N m)
6. Cylinder head housing capscrew
27-37 lb. ft. (36-50 N m)
7. Cylinder head 3/8" capscrews
27-37 lb. ft. (36-50 N m)
8. Exhaust manifold capscrews
17-23 lb. ft. (23-31 N m)
9. Valve cover base capscrews
13-23 lb. ft. (17-31 N m)
10. Fuel line nuts
25-35 lb. ft. (34-48 N m)
11. Cylinder lines crossbar capscrews
65-75 lb. ft. (85-105 N m)
12. Connecting rod nuts
54-66 lb. ft. (73-89 N m)
13. Crankshaft main bearing cap capscrews
180-200 lb. ft. (244-272 N m)
Go on to Sheet 6
D-5
TM 10-3930-641-34-2
FUEL SYSTEM SPECIAL TORQUE VALUES
(Sheet 6 of 11)
1. Fuel injection pump bushing
140-160 lb. ft. (190-218 N m)
2. Fuel lines nuts
25-35 lb. ft. (32-48 N-m)
3. Fuel injection valve nut
50-60 lb. ft. (34-46 N m)
4. Fuel transfer pump driveshaft gear nut
17-27 lb. ft. (24-36 N m)
5. Fuel transfer pump plug
24-30 lb. ft. (32-40 N m)
6. Turbocharger capscrew
36-44 lb. ft. (44-49 N m)
COOLING SYSTEM SPECIAL TORQUE VALUES
1. Water pump impeller nut
26-30 lb. ft. (36-42 N m)
DRIVE SHAFT SPECIAL TORQUE VALUES
1. Drive shaft spider capscrews
90-110 lb. ft. (122-149 N m)
2. Yoke retainer capscrews
65-85 lb. ft. (88-115 N m)
Go on to Sheet 7
D-6
TM 10-3930-641-34-2
DIFFERENTIAL AND BEVEL GEAR SPECIAL TORQUE VALUES
(Sheet 7 of 11)
1. Differential yoke retaining capscrew
230-300 lb. ft. (312-407 N m)
2. Differential case flange capscrews
315-385 lb. ft. (427-523 N m)
3. Differential housing and case assembly capscrews
175-225 lb. ft. (238-304 N m)
4. Rear axle support cover capscrews
315-385 lb. ft. (425-525 N m)
5 .Rear and front support main capscrews
750-900 lb. ft. (1007-1218 N m)
BRAKE ASSEMBLIES SPECIAL TORQUE VALUES
1. Parking brake control valve plug
7-11 lb. ft. (9-15 N m)
2. Accumulator head capscrews
675-725 lb. ft. (915-983 N m)
3. Parking brake retainer capscrew
80-90 lb. ft. (109-121 N m)
4. Control valve stem nut
32-38 lb. ft. (44-52 N m)
5. Accumulator charging valve stem plug
18-22 lb. ft. (24-30 N m)
Go on to Sheet 8
D-7
TM 10-3930-641-34-2
BRAKE ASSEMBLIES SPECIAL TORQUE VALUES (CONT)
(Sheet 8 of 11)
6. Accumulator charging valve plug
47-53 lb. ft. (64-72 N m)
7. Accumulator charging valve piston plug
47-53 lb. ft. (64-72 N m)
WHEELS SPECIAL TORQUE VALUES
1. Tire and rim nuts
340-440 lb. ft. (460-596 N m)
2. Wheel assembly capscrews
55-75 lb. ft. (74-102 N m)
STEERING SYSTEM SPECIAL TORQUE VALUES
1. Hand metering unit cap capscrews
18-24 lb. ft. (24.4-32.5 N m)
2. Steering cylinder retaining pin capscrews
230-300 lb. ft. (311.8-406.7 N m)
3. Articulated hitch cover assembly capscrews
65-85 lb. ft. (88.1-115.2 N m)
4. Hydraulic pump nuts
165-185 lb. ft. (223.7-250.8 N m)
5. Hydraulic pump seal retainer screws
13 lb. ft. (16.3 N m)
6. Hydraulic pump capscrews
80-90 lb. ft. (108.5-122 N m)
7. Steering cylinder piston nut
1440-1760 lb. ft. (1952.4-2386.2 N m)
Go on to Sheet 9
D-8
TM 10-3930-641-34-2
BODY, CAP, HOOD AND HULL SPECIAL TORQUE VALUES
(Sheet 9 of 11)
1. ROPS one inch capscrews
560-720 lb. ft. (775-975 N m)
2. ROPS one and one-eighth inch capscrews
400-700 lb. ft. (950-1250 N m)
HYDRAULIC SYSTEM SPECIAL TORQUE VALUES
1. Hydraulic pump nuts
280-320 lb. ft. (379.6-426.9 N m)
2. Tilt cylinder piston nut
2225-2275 lb. ft. (3016.7-3084.5 N m)
TRANSMISSION SPECIAL TORQUE VALUES
1. Torque converter drive spider capscrews
77-85 lb. ft. (106-116 N m)
2. Turbine capscrews
77-85 lb. ft. (106-116 N m)
3. Disc assembly capscrews
19-21 lb. ft. (26-28 N m)
4. Clutch housing capscrews
34-38 lb. ft. (43-49 N m)
Go on to Sheet 10
D-9
TM 10-3930-641-34-2
TRANSMISSION SPECIAL TORQUE VALUES (CONT)
(Sheet 10 of 11)
5. Torque converter yoke capscrew
80-90 lb. ft. (109-121 N m)
6. Transmission carrier housing assembly capscrews
27-37 lb. ft. (36-50 N m)
7. Planet carrier capscrews
27-37 lb. ft. (37-51 N m)
8. Clutch housing capscrews
65-85 lb. ft. (88-116 N m)
9. Transmission housing capscrews
65-85 lb. ft. (88-116 N m)
10. Transmission hydraulic controls capscrews
32-38 lb. ft. (44-52 Nom)
11. Transmission controls manifold capscrew
19-25 lb. ft. (25-34 N m)
12. Transmission controls cover capscrews
19-25 lb. ft. (26-34 N m)
13. Transmission control valve capscrews
19-25 lb. ft. (26-34 N m)
14. Drive shaft capscrews
90-110 lb. ft. (128-149 N m)
15. Bearing cage retainer capscrews
35-45 lb. ft. (48-60 N m)
16. Output transfer gears yoke capscrew
315-385 lb. ft. (426-522 N m)
Go on to Sheet 11
D-10
TM 10-3930-641-34-2
TRANSMISSION SPECIAL TORQUE VALUES (CONT)
(Sheet 11 of 11)
17. Final drive planet carrier cover nuts
335-445 lb. ft. (454.2-603.3 N m)
18. Transmission control lock rail nut
41-63 lb. ft. (55-85 N m)
19. Transmission control-cap capscrews
32-38 lb. ft. (44-52 N m)
20. Sequence and pressure control valve control cable capscrew
19-25 lb. ft. (36-44 N m)
End
D-11
TM 10-3930-641-34-2
INDEX
Page
Page
Accessory Drive Gears and Housings................................. 3-296
Accumulator Charging Valve Specifications ...................... .2-150
Accumulator Charging Valve, Brake,
Disassembly/Assembly.................................................... 5-14
Accumulator Specifications ................................................ 2-151
Accumulator, Brake, Disassembly/Assembly ..........................5-9
Accumulator, Brake, Removal/Installation ..............................5-4
Adapters, Gears and Rear Accessory Drive........................ 3-296
Air Induction....................................................................... 3-106
Air Inlet and Exhaust System ............................................. 3-105
Air Lines Inspection, Turbocharger ..................................... 3-128
Air Lines, Turbocharger Removal/
Installation..................................................................... 3-124
Air-Fuel Ratio Control Specifications.................................. 2-118
Alternator Disassembly/Assembly ...................................... 3-176
Alternator Specifications ...................................................... 2-97
Alternator Test ................................................................... 3-183
Articulated Hitch Disassembly/Assembly .............................. 6-36
Axle Specifications............................................................. 4-241
Axle, Front ......................................................................... 4-262
Axle, Rear.......................................................................... 4-262
Axles, Drive, Removal/Installation...................................... 4-250
Auxiliary Cooler, Hydraulic Oil.............................................. 7-22
Bearings (Cleaning) ....................................................... 2-68
Bearings, Camshaft, Removal/Installation................... .3-280
Bearings, Connecting Rod, Removal/
Installation............................................................... 3-347
Bearings, Crankshaft Main, Inspection ......................... 3-333
Bearings, Crankshaft Main, Removal/
Installation............................................................... 3-326
Belt Tightener Specifications........................................ 2-100
Belts, Wiring, Hoses and Lines Replacement................. 2-65
Block Inspection, Cylinder........................................... .3-250
Block, Short, Engine Removal/Installation.................... 3-216
Body .............................................................................. 8-38
Body and Cab ..................................................................8-1
Brake Accumulator Charging Valve,
Disassembly/Assembly.............................................. 5-14
Brake Accumulator Disassembly/Assembly......................5-9
Brake Accumulator Removal/Installation..........................5-4
Brake and Steering Pump, Hydraulic,
Disassembly/Assembly.............................................. 6-61
Brake and Wheel Assemblies Assembly ........................ 5-51
Brake and Wheel Assemblies Disassembly.................... 5-44
Brake Control Valve Disassembly/Assembly .................. 5-31
Brake Control Valve Group Removal/
Installation................................................................. 5-26
Brake Control Valve Parking, Removal/
Installation................................................................. 5-61
Brake Control Valve Specifications .............................. 2-149
Brake Control Valve, Parking,
Disassembly/Assembly.............................................. 5-63
Brake Filter Specifications ........................................... 2-129
Brake Lines and Fittings Removal/
Installation................................................................. 5-97
Brake Pump Specifications .......................................... 2-131
A
B
Battery Box Removal/Installation .......................................... 854
Bearing Adjustment, Input Transfer Gears.......................... 4-136
Bearing Adjustment, Wheel.................................................. 5-91
Bearing Cage, Drive Shaft, Adjustment .............................. 4-323
Bearing Replacement........................................................... 2-65
Bearing, Connecting Rod, Inspection.................................. 3-357
Bearing, Main..................................................................... 3-326
INDEX-1
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Brake Special Torque Valves ........................................... App. D
Brake System.........................................................................5-1
Brake, Parking, Assembly .................................................... 5-75
Brake, Parking, Disassembly................................................ 5-71
Brake, Parking, Removal/Installation.................................... 5-68
Brakes....................................................................................5-1
Brakes, Troubleshooting....................................................... 2-59
Brakes, Wheel, Removal/Installation.................................... 5-38
Bridge Specifications............................................................ 2-78
Bumper, Rear....................................................................... 8-42
Clutch Combinations, Transmission Speed .................... 2-45
Connecting Rod and Piston Disassembly/
Assembly ................................................................ 3-355
Connecting Rod and Piston Inspection......................... 3-365
Connecting Rod and Piston Removal/
Installation............................................................... 3-350
Connecting Rod Bearings Inspection............................ 3-369
Connecting Rod Bearings Removal/
Installation............................................................... 3-359
Connecting Rod Specifications ...................................... 2-90
Control Lock Bench Test, Transmission ....................... 4-234
Control Lock, Transmission, Assembly......................... 4-221
Control Lock, Transmission, Disassembly .................... 4-217
Control Lock, Transmission, Installation ....................... 4-213
Control Lock, Transmission, Removal.......................... 4-210
Control Valve Group, Brake, Removal/
Installation................................................................. 5-26
Control Valve, Brake, Disassembly/Assembly ................ 5-31
Control Valve, Pressure and Sequence,
Disassembly/Assembly ................................................ 4-205
Control Valve, Pressure and Sequence,
Removal/Installation .................................................... 4-202
Control Valve, Steering, Disassembly/
Assembly ....................................................................... 6-28
Control Valve, Steering, Removal/
Installation................................................................. 6-24
Control Valves, Transmission....................................... 4-201
Controls, Governor Removal/Installation........................ 3-95
Converter Outlet Relief Valve
Specifications.......................................................... 2-140
Cooling System............................................................ 3-151
Cooling System Pressure Cap Specifications 2-101
Cooling System Special Torque Valves ..................... App. D
Counterweight................................................................ 8-42
Cover, Timing Gear, Removal/Installation ................... 3-288
B (cont)
C
Cab ........................................................................................8-2
Cab and Body ........................................................................8-1
Cab Components ................................................................. 8-18
Cab Door Disassembly/Assembly......................................... 8-34
Cab Heater Disassembly/Assembly...................................... 8-19
Cab Removal/Installation .......................................................8-3
Cab Window Glass Removal/Installation.............................. 8-31
Cab Window, Right Side, Removal/
Installation....................................................................... 8-28
Camshaft ........................................................................... 3-272
Camshaft Bearings Removal/Installation ........................... 3-280
Camshaft Inspection .......................................................... 3-283
Camshaft Removal/Installation........................................... 3-273
Camshaft Specifications....................................................... 2-82
Capabilities, Equipment .........................................................1-3
Carriage Disassembly/Assembly .......................................... 7-94
Carriage Removal/Installation .............................................. 7-91
Carrier Assembly Removal/Installation............................... 4-254
Charging Valve, Brake Accumulator,
Disassembly/Assembly.................................................... 5-14
Cleaning...................................................................... 2-64, 2-68
Clearance Setting, Valve ............................................... 3-268
INDEX-2
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Crankcase Guard Removal/Installation ................................ 8-43
Crankshaft ......................................................................... 3-330
Crankshaft Inspection......................................................... 3-347
Crankshaft Main Bearings Inspection ................................. 3-345
Crankshaft Main Bearings Removal/
Installation..................................................................... 3-330
Crankshaft Removal/Installation......................................... 3-321
Crankshaft Seals Replacement .......................................... 3-331
Crankshaft Specifications..................................................... 2-91
Cylinder Block Inspection ................................................... 3-250
Cylinder Block Specifications ............................................... 2-86
Cylinder Head Spacer Plates Removal/
Installation..................................................................... 3-246
Cylinder Head Specifications................................................ 2-81
Cylinder Heads................................................................... 3-216
Cylinder Heads Disassembly./Assembly............................. 3-231
Cylinder Heads Removal/Installation.................................. 3-217
Cylinder Liner Inspection.................................................... 3-252
Cylinder Liner Projection Specifications ............................... 2-88
Cylinder Liner Removal/Installation .................................... 3-239
Cylinder Liner Specifications ................................................ 2-87
Cylinders, Steering, Disassembly/Assembly ......................... 6-85
Cylinders, Steering, Removal/Installation ............................. 6-79
Differential Troubleshooting ........................................... 2-42
Differential, Front, and Bevel Gear
Installation............................................................... 4-246
Differential, Front, and Bevel Gear Removal .............. .4-242
Differential, Rear, Bevel Gear and Front
Support Installation ................................................. 4-267
Differential, Rear, Bevel Gear and Front
Support Removal .................................................... 4-263
Disassembly and Assembly............................................ 2-64
Diverter Valve Specifications ....................................... 2-135
Door, Cab, Disassembly/Assembly ................................ 8-34
Drive Axles Removal/Installation ................................. 4-250
Drive Line Components Troubleshooting........................ 2-42
Drive Shaft Bearing Cage Adjustment.......................... 4-323
Drive Shaft Special Torque Valves ............................ App. D
Drive Shaft Specifications............................................ 2-102
Drive Shafts................................................................. 4-305
Drive Shafts Disassembly/Assembly ............................ 4-306
Drive System ...................................................................4-2
C (cont)
D
Description and Data, Equipment ...........................................1-3
Differential and Bevel Gear Adjustment ............................. 4-289
Differential and Bevel Gear Special Torque
Valves ......................................................................... App. D
Differential and Bevel Gear, Front or Rear,
Assembly ........................................................................... 4-278
Differential and Bevel Gear, Front or Rear,
Disassembly .................................................................. 4-271
Differential Rear Support, Disassembly/
Assembly....................................................................... 4-296
E
Electrical System ......................................................... 3-175
Emergency and Parking Brake
Specifications.......................................................... 2-152
Engine Front Support Removal/Installation ......................3-3
Engine Installation ......................................................... 3-17
Engine Lubrication System ......................................... .3-133
Engine Maintenance Instructions......................................3-2
Engine Oil Cooler Removal/Installation........................ 3-152
Engine Oil Filter and Cooler Bypass Valves
Removal/Installation................................................ 3-285
Engine Oil Pump Removal/Installation......................... 3-143
Engine Removal ..............................................................3-6
Engine Short Block ...................................................... 3-216
INDEX-3
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Engine Special Torque, Values ........................................ App. D
Engine Supports Removal/Installation.................................. 3-17
Engine Table of Contents.......................................................3-1
Engine Troubleshooting..........................................................2-8
Engine Trunnion Removal/Installation ....................................3-3
Engine Valve Components................................................. 3-254
Equipment Description and Data ............................................1-3
Equipment Improvement Recommendations..........................1-2
Equipment Purpose, Capabilities and
Features ............................................................................1-3
Exhaust Manifold Removal/Installation............................... 3-131
Exhaust Manifold Specifications........................................... 2-82
Exhaust System, Air Inlet and ............................................ 3-105
Exhaust Valve Clearance Setting ....................................... 3-268
Exhaust Valve Removal/Installation ................................... 3-255
Front Axle .................................................................... 4-241
Front Differential and Bevel Gear
Installation ................................................................... 4-246
Front Differential and Bevel Gear Removal . ............... 4-242
Fuel Filter Specifications, Primary ............................... 2-112
Fuel Injection Nozzle Removal/Installation..................... 3-29
Fuel Injection Pump Disassembly/Assembly . ................ 3-36
Fuel Injection Pump Drive Specifications ..................... 2-119
Fuel Injection Pump Housing Disassembly/
Assembly .................................................................. 3-47
Fuel Injection Pump Housing Removal/
Installation................................................................. 3-41
Fuel Injection Pump Housing
Specifications .............................................................. 2-110
Fuel Injection Pump Removal/Installation ...................... 3-32
Fuel Injection Specifications ........................................ 2-108
Fuel Ratio Control Adjustment ....................................... 3-75
Fuel Ratio Control Disassembly/Assembly ..................... 3-70
Fuel Ratio Control Removal/Installation ......................... 3-67
Fuel Shutoff Solenoid Removal/Installation ................... 3-64
Fuel Shutoff Solenoid Adjust.......................................... 3-64
Fuel System................................................................... 3-26
Fuel System Special Torque Valves .......................... App. D
Fuel Tank Removal/Installation...................................... 8-48
Fuel Tank Disassembly/Assembly.................................. 8-51
Fuel Transfer Pump Disassembly/Assembly .................. 3-58
Fuel Transfer Pump Drive Specification....................... 2-115
Fuel Transfer Pump Specifications .............................. 2-114
E (cont)
F
Fan Drive Mechanism ........................................................ 2-100
Final Drive Planet Carriers Disassembly/
Assembly....................................................................... 4-259
Final Drive Planet Carriers Removal/
Installation..................................................................... 4-254
Fittings, Lines, Plugs Installation ...................................... App. D
Flywheel............................................................................. 3-308
Flywheel Housing Bore Specifications.................................. 2-95
Flywheel Housing Covers................................................... 3-305
Flywheel Housing Removal/Installation .............................. 3-309
Flywheel Housing Specifications .......................................... 2-94
Flywheel Removal/Installation............................................ 3-315
Flywheel Ring Gear............................................................ 3-310
Flywheel Specifications........................................................ 2-96
Forge Limiter Disassembly/Assembly................................... 9-21
Fork Assembly Removal/Installation .................................... 7-87
Forms, Maintenance..........................................................1-2
G
Gage Replacement ........................................................ 2-65
Gasket Replacement ..................................................... 2-66
Gear Cover, Timing, Removal/Installation ................... 3-288
Gear Replacement......................................................... 2-67
INDEX-4
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Gear, Bevel and Differential, Adjustment ........................... 4-289
Gear, Bevel, and Differential Front or Rear,
Disassembly .................................................................. 4-271
Gear, Bevel, and Differential, Front or Rear,
Assembly....................................................................... 4-278
Gear, Bevel, and Front Differential,
Installation..................................................................... 4-246
Gear, Bevel, and Front Differential,
Removal........................................................................ 4-242
Gear, Bevel, and Front Support, Rear
Differential, Installation.................................................. 4-267
Gear, Bevel, and Front Support, Rear
Differential, Removal..................................................... 4-263
Gears, Timing .................................................................... 3-287
Gears, Timing, Removal/Installation .................................. 3-291
Gears, Transfer, Input Bearing Adjustment........................ .4-136
Gears, Transfer, Input, Assembly ....................................... 4-129
Gears, Transfer, Input, Disassembly .................................. 4-124
Gears, Transfer, Installation ............................................... 4-122
Gears, Transfer, Output, Assembly .................................... 4-146
Gears, Transfer, Output, Bearing
Adjustment .................................................................... 4-155
Gears, Transfer, Output, Disassembly................................ 4-138
Gears, Transfer, Removal.................................................. 4-119
General Maintenance Practices............................................ 2-64
General Metal Repair ........................................................... 8-58
Glass, Cab Window, Removal/ Installation........................... 8-31
Governor Adjustments ....................................................... 3-102
Governor Disassembly/Assembly......................................... 3-83
Governor Drive Specifications............................................ 2-120
Governor Oil Pump Specifications ..................................... 2-120
Governor Pedal Removal/Installation ................................... 3-95
Governor Removal/Installation............................................. 3-79
Governor Specifications ..................................................... 2-116
Guard, Crankcase, Removal/Installation .............................. 8-43
Guides, Valve, Removal/Installation ............................ 3-262
G (cont)
H
Hand Brake Assembly Removal/Installation................... 5-68
Hand Metering Unit, Steering Removal/
Installation................................................................. 6-14
Hand Metering Unit, Steering, Disassembly/
Assembly .................................................................. 6-18
Hardware Replacement.................................................. 2-65
Heads, Cylinder ........................................................... 3-216
Heater, Cab, Disassembly/Assembly.............................. 8-19
Hitch, Articulated, Disassembly/Assembly...................... 6-36
Hose Replacement ........................................................ 2-65
Hydraulic Components.....................................................7-1
Hydraulic Control Valve Disassembly/
Assembly .................................................................. 7-44
Hydraulic Cylinder Disassembly/Assembly..................... 9-16
Hydraulic Filter Specifications...................................... 2-128
Hydraulic Lift System Components ..................................7-4
Hydraulic Oil Cooler Oil Lines Removal/
Installation................................................................. 7-20
Hydraulic Oil Cooler Removal/Installation ...................... 7-22
Hydraulic Pump Disassembly/Assembly......................... 7-13
Hydraulic Pump Removal/Installation...............................7-5
Hydraulic Pump Specifications..................................... 2-126
Hydraulic Steering and Brake Pump
Disassembly/Assembly.............................................. 6-61
Hydraulic System Special Torque Valves .................. App. D
Hydraulic System Troubleshooting................................. 2-26
Hydraulic System, Transmission ......................................4-4
Hydraulic Tank Disassembly/Assembly .......................... 7-29
Hydraulic Tank Removal/Installation .............................. 7-27
Hydraulic Valve, Brake Control Removal/
Installation................................................................. 5-61
INDEX-5
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
I
M
Injection Nozzle, Fuel Removal/
Installation....................................................................... 3-29
Injection Pump, Fuel Disassembly/Assembly ...................... .3-36
Injection Pump, Fuel Removal/
Installation....................................................................... 3-32
Injection Pump Housing, Fuel Disassembly/
Assembly......................................................................... 3-47
Injection Pump Housing, Fuel Removal/
Installation....................................................................... 3-41
Input Gears, Transfer, Assembly ........................................ 4-129
Input Gears, Transfer, Disassembly ................................... 4-124
Input Gears, Transfer, Installation ...................................... 4-122
Input Gears, Transfer, Removal ......................................... 4-119
Input Transfer Gears, Input Bearing
Adjustment .................................................................... 4-136
Instruments and Gages Replacement................................... 2-65
Intake Valve Clearance Setting .......................................... 3-268
Intake Valve Removal/Installation ...................................... 3-255
Main Bearing ............................................................... 3-338
Main Bearings, Crankshaft, Inspection ......................... 3-345
Main Bearings, Crankshaft, Removal/
Installation............................................................... 3-338
Maintenance Forms, Records and Reports.......................1-2
Manifold, Exhaust, Removal/Installation ...................... 3-131
Manufactured Items ................................................... App. C
Mast Components.......................................................... 7-70
Mast Disassembly/Assembly.......................................... 7-76
Mast Hydraulic Lines Removal/
Installation............................................................... 7-111
Mast Lift Chains Removal/Installation .......................... 7-118
Mast Removal/Installation.............................................. 7-71
Mechanical Brake Pedal Linkage Removal/
Installation................................................................. 5-68
Metal Repair, General.................................................... 8-42
Metering Unit, Hand, Steering, Disassembly/
Assembly .................................................................. 6-18
Metering Unit, Hand, Steering, Removal/
Installation................................................................. 6-14
L
Lift Cylinder Disassembly/Assembly..................................... 7-66
Lift Cylinder Removal/Installation......................................... 7-63
Lifter Specifications.............................................................. 2-78
Lifters, Valve, Removal/Installation .................................... 3-264
Line Replacement ................................................................ 2-65
Liner Inspection, Cylinder................................................... 3-252
Lines Fittings and Hoses Removal/
Installation....................................................................... 5-97
Lines, Plugs, Fittings Installation ...................................... App. D
Lip Type Seal Replacement ................................................. 2-66
Lower Drive Shaft Disassembly/Assembly.......................... 4-308
Lubrication System, Engine................................................ 3-133
Lubrication System, Transmission ................................. 4-178
N
Neutralizer Valve, Steering, Disassembly/
Assembly .................................................................. 6-10
Neutralizer Valve, Steering, Removal/
Installation...................................................................6-7
Neutralizer Valves Specifications................................. 2-134
Nozzle, Fuel Injection, Removal/Installation .................. 3-29
O
Oil Bypass Valves Specifications ................................... 2-85
Oil Cooler, Transmission, Removal/
Installation............................................................... 4-197
INDEX-6
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Oil Filter Adapter Removal/Installation ............................... 3-136
Oil Filter Flange Removal/Installation................................. 3-136
Oil Filter Specifications ........................................................ 2-84
Oil Filter Support Removal/Installation ............................... 3-136
Oil Lines, Hydraulic Oil Cooler Removal/
Installation....................................................................... 7-20
Oil Lines, Transmission Removal/
Installation..................................................................... 4-187
Oil Lines, Turbocharger, Removal/
Installation.......................................................................... 3-117
Oil Pan Removal/Installation ............................................. .3-140
Oil Pump Disassembly/Assembly ....................................... 3-146
Oil Pump Removal/Installation .......................................... .3-143
Oil Pump Specifications ....................................................... 2-83
Oil Pump, Transmission, Assembly .................................... 4-192
Oil Pump, Transmission, Disassembly ............................... 4-188
Oil Pump, Transmission, Installation .................................. 4-184
Oil Pump, Transmission, Removal ..................................... 4-179
Oil Return Line, Turbocharger Removal/
Installation..................................................................... 3-122
Oil Supply Line Turbocharger, Removal/
Installation..................................................................... 3-120
Outlet Relief Valve, Torque Converter,
Removal/Installation...................................................... 4-225
Output Gears, Transfer, Assembly ..................................... 4-146
Output Gears, Transfer, Bearing
Adjustment .................................................................... 4-155
Output Gears, Transfer, Disassembly................................. 4-138
Output Gears, Transfer, Installation.................................... 4-122
Output Gears, Transfer, Removal ...................................... 4-119
Parking Brake Assembly ................................................ 5-75
Parking Brake Control Valve Disassembly/
Assembly .................................................................. 5-63
Parking Brake Control Valve Removal/
Installation................................................................. 5-61
Parking Brake Control Valve
Specifications.......................................................... 2-151
Parking Brake, Disassembly .......................................... 5-71
Parking Brake, Removal/Installation .............................. 5-68
Parts Protection ............................................................. 2-68
Parts Removal ............................................................... 2-64
Pilot Control Valve Specifications ................................ 2-127
Piston and Connecting Rod Disassembly/
Assembly ................................................................ 3-355
Piston and Connecting Rod Inspection......................... 3-365
Piston and Connecting Rod Removal/
Installation............................................................... 3-350
Piston and Rings Specifications ..................................... 2-89
Piston Assembly .......................................................... 3-349
Piston Top Center Piston ............................................. 3-371
Planet Carriers, Final Drive, Disassembly/
Assembly ................................................................ 4-259
Planet Carriers, Final Drive, Removal/
Installation............................................................... 4-254
Planetary Assembly Removal/
Installation............................................................... 4-254
Platform Removal/Installation ........................................ 8-39
Plugs, Fittings, Lines Installation ................................ App. D
Power Train .....................................................................4-1
Power Train Components.................................................4-3
Pressure Cap Specifications, Cooling
System.................................................................... 2-101
Pressure Control Valve Disassembly/
Assembly ................................................................ 4-205
O (cont)
P
Packing Replacement .......................................................... 2-67
Pan, Oil Removal/Installation ........................................ 3-140
INDEX-7
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Pressure Control Valve Removal/
Installation..................................................................... 4-202
Pressure Control Valve Specifications................................ 2-142
Pressure Relief Valve Specifications.................................. 2-125
Propeller Shaft Specifications ............................................ 2-102
Propeller Shafts ................................................................. 4-305
Pump Housing, Fuel Injection Disassembly/
Assembly......................................................................... 3-47
Pump Housing, Fuel Injection, Removal/
Installation....................................................................... 3-41
Pump, Fuel Injection, Disassembly/
Assembly......................................................................... 3-36
Pump, Fuel Injection, Removal/
Installation....................................................................... 3-32
Pump, Fuel Transfer, Disassembly/
Assembly......................................................................... 3-58
Pump, Oil Removal/Installation .......................................... 3-143
Pump, Oil, Disassembly/Assembly ..................................... 3-146
Pump, Steering and Brake, Hydraulic,
Disassembly/Assembly.................................................... 6-61
Pump, Transmission Oil, Assembly .................................... 4-192
Pump, Transmission Oil, Disassembly ............................... 4-188
Pump, Transmission Oil, Installation .................................. 4-184
Pump, Transmission Oil, Removal ..................................... 4-179
Pump, Water, Disassembly/Assembly................................ 3-168
Purpose, Equipment...............................................................1-3
Push Rods Removal/Installation......................................... 3-264
Rear Bumper ................................................................. 8-42
Rear Differential, Bevel Gear and Front
Support Installation ................................................. 4-267
Rear Differential, Bevel Gear and Front
Support Removal .................................................... 4-263
Rear Gear Group Specifications .................................. 2-121
Rear Support, Differential, Disassembly/
Assembly ................................................................ 4-296
References ................................................................ App. A
Repair and Replacement Rules...................................... 2-65
Repair Parts.....................................................................2-2
Reports, Maintenance ......................................................1-2
Rocker Arm Assembly Removal/
Installation............................................................... 3-208
Rocker Arm Specifications............................................. 2-78
Rocker Shaft Assembly Disassembly/
Assembly ................................................................ 3-211
Rocker Shaft Components ........................................... 3-206
Rocker Shaft Removal/Installation ............................... 3-207
Rod Bearings, Connecting, Inspection.......................... 3-369
Rod, Connecting, and Piston, Disassembly/
Assembly ................................................................ 3-355
Rod, Connecting, and Piston, Inspection...................... 3-365
Rod, Connecting, and Piston, Removal/
Installation............................................................... 3-350
Rods, Push, Removal/Installation ................................ 3-264
Rollover Protective Structure Removal/
Installation................................................................. 8-11
Rops Special Torque Valves ...................................... App. D
Rotocoil Assembly Replace.......................................... 3-255
Rust or Corrosion Removal............................................ 2-68
P (cont)
R
Radiator and Shroud Assembly Removal/
Installation.......................................................................... 3-162
Radiator Removal/Installation ............................................ 3-155
Radiator Specifications ...................................................... 2-101
Rear Axle ...................................................................... 4-262
Change 1 INDEX-8
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Safety .................................................................................. 2-64
Seals, Oil, Replacement..................................................... 3-319
Seat Inserts, Valve, Removal/Installation ........................... 3-260
Sequence and Pressure Control Valve
Disassembly/Assembly.................................................. 4-205
Sequence and Pressure Control Valve
Removal/Installation...................................................... 4-202
Sequence Valve Specifications .......................................... 2-142
Sequence Valve Test ......................................................... 4-237
Service Brake Assembly Removal/
Installation....................................................................... 5-38
Service Meter Specifications................................................ 2-75
Shaft Replacement .............................................................. 2-67
Shaft, Drive, Bearing Cage Adjustment .............................. 4-323
Shaft, Drive, Lower Disassembly/
Assembly....................................................................... 4-308
Shafts, Drive ...................................................................... 4-305
Shafts, Drive, Disassembly/Assembly ................................ 4-306
Shafts, Propeller ................................................................ 4-305
Shroud and Radiator Assembly Removal/
Installation..................................................................... 3-162
Side Shift Cylinder Removal/Installation............................. 7-104
Side Shift/Tilt Cylinders Disassembly/
Assembly....................................................................... 7-107
Side Tilt Cylinder Removal/Installation............................... 7-101
Sleeve Bearings................................................................... 2-66
Solenoid, Fuel Shutoff, Removal/
Installation....................................................................... 3-64
Spacer Plates Removal/Installation.................................... 3-246
Special Tools, TMDE and Support
Equipment.........................................................................2-2
Specifications
Accumulator .................................................................. 2-151
Accumulator Charging Valve ......................................... 2-150
Air-Fuel Ratio Control.................................................... 2-118
Alternator....................................................................... 2-97
Axle ............................................................................. 2-106
Belt Tightener .............................................................. 2-100
Brake Control Valve..................................................... 2-149
Brake Pump................................................................. 2-131
Bridge ............................................................................ 2-78
Camshaft ....................................................................... 2-82
Connecting Rod ............................................................. 2-90
Converter Outlet Relief Valve ...................................... 2-140
Cooling System Pressure Cap ..................................... 2-101
Crankshaft ..................................................................... 2-91
Cylinder Block................................................................ 2-86
Cylinder Head ................................................................ 2-81
Cylinder Liner ................................................................ 2-87
Cylinder Liner Projection................................................ 2-88
Diverter Valve.............................................................. 2-135
Drive Shaft .................................................................. 2-102
Emergency and Parking Brake..................................... 2-152
Exhaust Manifold ........................................................... 2-82
Flywheel ........................................................................ 2-96
Flywheel Housing........................................................... 2-94
Flywheel Housing Bore .................................................. 2-95
Fuel Filter, Primary ...................................................... 2-112
Fuel Injection ............................................................... 2-108
Fuel Injection Pump Housing ....................................... 2-110
Fuel Injection Pump Drive............................................ 2-119
Fuel Transfer Pump ..................................................... 2-114
Fuel Transfer Pump Drive............................................ 2-115
Governor ..................................................................... 2-116
Governor Drive ............................................................ 2-120
Governor Oil Pump...................................................... 2-120
Hydraulic Pump ........................................................... 2-126
Hydraulic Filter............................................................. 2-128
Lifter .............................................................................. 2-78
Neutralizer Valves........................................................ 2-134
S
INDEX-9
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Oil Bypass Valves ................................................................ 2-85
Oil Cooler........................................................................... 3-152
Oil Filter ............................................................................... 2-84
Oil Filter Bypass Valves ..................................................... 3-285
Oil Pump.............................................................................. 2-83
Parking Brake Control Valve .............................................. 2-151
Pilot Control Valve ............................................................. 2-127
Piston and Rings .................................................................. 2-89
Pressure Cap, Cooling System........................................... 2-101
Pressure Control Valve ...................................................... 2-142
Pressure Relief Valve......................................................... 2-125
Propeller Shaft ................................................................... 2-102
Radiator ............................................................................. 2-101
Rear Gear Group ............................................................... 2-121
Rocker Arm.......................................................................... 2-78
Sequence Valve................................................................. 2-142
Service Meter....................................................................... 2-75
Starter Solenoid ................................................................. 2-122
Starting Motor .................................................................... 2-122
Steering Control Group ...................................................... 2-133
Steering Control Valve ....................................................... 2-130
Steering Cylinder ............................................................... 2-132
Steering Hydraulic Pump.................................................... 2-131
Supplemental Steering Flow Switch ................................... 2-137
Supplemental Steering Pump............................................. 2-136
Tachometer Drive ................................................................ 2-75
Tilt Circuit Relief Valve ...................................................... 2-123
Tilt Cylinder........................................................................ 2-124
Timing Gear......................................................................... 2-74
Timing Gear Housing ........................................................... 2-93
Torque Converter............................................................... 2-138
Transmission...................................................................... 2-143
Transmission Control Lock ................................................. 2-144
Transmission Hydraulic Controls ........................................ 2-148
Transmission Neutralizer Valve.......................................... 2-148
Transmission Oil Filter ............................................ 2-145
Transmission Oil Pump ........................................... 2-141
Transmission Pressure Control Valve...................... 2-146
Turbocharger........................................................... 2-107
Valve ........................................................................ 2-76
Valve Cover .............................................................. 2-80
Water Pump.............................................................. 2-98
Water Temperature Regulator................................... 2-99
Wheel ..................................................................... 2-104
Wheel Brake ........................................................... 2-153
Specifications, Vehicle................................................... 2-69
Starter Solenoid Specifications .................................... 2-122
Starting Motor Disassembly/Assembly ......................... 3-186
Starting Motor Specifications ....................................... 2-122
Starting Motor Test ...................................................... 3-200
Steering ................................................................ 6-27, 6-58
Steering and Brake Pump, Hydraulic,
Disassembly/Assembly.............................................. 6-61
Steering and Brake Pump Removal/
Installation................................................................. 6-52
Steering Components ......................................................6-6
Steering Control Group Specifications ......................... 2-133
Steering Control Valve Disassembly/
Assembly .................................................................. 6-28
Steering Control Valve Removal/
Installation................................................................. 6-24
Steering Control Valve Specifications .......................... 2-130
Steering Cylinder Specifications................................... 2-132
Steering Cylinders Disassembly/Assembly..................... 6-85
Steering Cylinders Removal/Installation......................... 6-79
Steering Hand Metering Unit, Disassembly/
Assembly .................................................................. 6-18
Steering Hand Metering Unit Removal/
Installation................................................................. 6-14
Steering Hydraulic Pump Specifications....................... 2-131
S (cont)
INDEX-10
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Steering Limit Valve Removal/
Installation.........................................................................6-7
Steering Lines Removal/Installation ..................................... 6-91
Steering Neutralizer Valve Disassembly/
Assembly......................................................................... 6-10
Steering Neutralizer Valve Removal/
Installation..............................................................................6-7
Steering System.....................................................................6-1
Steering System Diverter Valve Removal/
Installation....................................................................... 6-24
Steering System Special Torque Valves........................... App. D
Steering System, Supplemental .............................................6-5
Steering System Tee Tests .................................................. 6-97
Steering System Troubleshooting......................................... 2-53
Supplemental Steering Flow Switch
Specifications ................................................................ 2-137
Supplemental Steering Lines Removal/
Installation....................................................................... 6-94
Supplemental Steering Pump Disassembly/
Assembly......................................................................... 6-74
Supplemental Steering Pump Removal/
Installation....................................................................... 6-71
Supplemental Steering Pump Specifications .2-136
Supplemental Steering System..........................................6-5
Support, Rear Differential, Disassembly/
Assembly....................................................................... 4-296
Supports, Engine Removal/Installation................................. 3-17
Symptoms Index ....................................................................2-4
Tilt Circuit Relief Valve Specifications.......................... 2-123
Tilt Cylinder Bearings Removal/Installation .................... 7-61
Tilt Cylinder Disassembly/Assembly............................... 7-54
Tilt Cylinder Removal/Installation................................... 7-50
Tilt Cylinder Specifications........................................... 2-124
Timing Gear Cover Removal/Installation ..................... 3-288
Timing Gear Housing Specifications .............................. 2-93
Timing Gear Specifications ............................................ 2-74
Timing Gears .............................................................. .3-287
Timing Gears Removal/Installation .............................. 3-291
Top Center Piston, No.1 Piston .................................... 3-371
Top Handler Disassembly/Assembly ................................9-2
Top Handlers ...................................................................9-1
Torque Converter Assembly........................................... 4-27
Torque Converter Cooler Lines .................................... 4-197
Torque Converter Disassembly ...................................... 4-17
Torque Converter Installation......................................... 4-12
Torque Converter Outlet Relief Valve
Removal/Installation................................................ 4-225
Torque Converter Removal..............................................4-7
Torque Converter Specifications .................................. 2-138
Torque Converter Troubleshooting................................. 2-41
Torque Valves ........................................................... App. D
Torque Valves, Brake, Special................................... App. D
Torque Valves, Cooling System, Special ................... App. D
Torque Valves, Differential and Bevel Gear,
Special.................................................................. App. D
Torque Valves, Drive Shaft, Special .......................... App. D
Torque Valves, Engine, Special ................................. App. D
Torque Valves, Fuel System, Special ........................ App. D
Torque Valves, Hydraulic System, Special................ .App. D
Torque Valves, Rops, Special .................................... App. D
S (cont)
T
Tachometer Drive Specifications.......................................... 2-75
Tee Test Procedure for Hydraulic System .......................... 7-124
Tests, Tee, Steering System ................................................ 6-83
Throttle Control Removal/Installation ................................... 3-95
Change 1 INDEX-11
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Torque Valves, Special .................................................... App. D
Torque Valves, Steering System, Special........................ .App. D
Torque Valves, Transmission, Special.............................. App. D
Torque Valves, Wheels, Special ...................................... App. D
Transfer Gear Case Troubleshooting.................................... 2-42
Transfer Gears Bearing Adjustment, Input.......................... 4-136
Transfer Gears Bearing Adjustment,
Output ........................................................................... 4-155
Transfer Gears Installation ................................................. 4-122
Transfer Gears Removal.................................................... 4-119
Transfer Gears, Input, Assembly ........................................ 4-129
Transfer Gears, Input, Disassembly ................................... 4-124
Transfer Gears, Output, Assembly ..................................... 4-146
Transfer Gears, Output, Disassembly................................. 4-138
Transfer Pump, Fuel, Disassembly/
Assembly......................................................................... 3-58
Transmission........................................................................ 4-42
Transmission Assembly........................................................ 4-88
Transmission Control Lock Assembly ................................. 4-221
Transmission Control Lock Bench Test .............................. 4-234
Transmission Control Lock Disassembly ............................ 4-217
Transmission Control Lock Installation ............................... 4-213
Transmission Control Lock Removal .................................. 4-210
Transmission Control Lock Specifications .......................... 2-144
Transmission Control Valves.............................................. 4-201
Transmission Disassembly ................................................... 4-68
Transmission Drive ................................................................4-6
Transmission Hydraulic Controls
Assembly....................................................................... 4-171
Transmission Hydraulic Controls
Disassembly .................................................................. 4-164
Transmission Hydraulic Controls Removal/
Installation..................................................................... 4-157
Transmission Hydraulic Controls
Specifications ................................................................ 2-148
Transmission Hydraulic System .......................................4-4
Transmission Lubrication System................................. 4-178
Transmission Neutralizer Valve
Specifications.......................................................... 2-148
Transmission Oil Cooler Removal/
Installation............................................................... 4-197
Transmission Oil Filter Specifications .......................... 2-145
Transmission Oil Lines Removal/
Installation............................................................... 4-187
Transmission Oil Pump Assembly................................ 4-192
Transmission Oil Pump Disassembly ........................... 4-188
Transmission Oil Pump Installation .............................. 4-184
Transmission Oil Pump Removal................................. 4-179
Transmission Oil Pump Specifications ......................... 2-141
Transmission Pressure Control Valve
Specifications.......................................................... 2-146
Transmission Special Torque Valves ......................... App. D
Transmission Specifications......................................... 2-143
Transmission Speed Clutch Combinations ..................... 2-45
Transmission and Transfer Assembly
Installation................................................................. 4-56
Transmission and Transfer Assembly
Removal ........................................................................ 4-43
Transmission Troubleshooting ....................................... 2-44
Troubleshooting ...............................................................2-3
Troubleshooting Steering System .................................. 2-53
Troubleshooting Warning Alarm..................................... 2-45
Troubleshooting, Brakes ................................................ 2-59
Troubleshooting, Differential .......................................... 2-42
Troubleshooting, Drive Line Components....................... 2-42
Troubleshooting, Engine ..................................................2-8
Troubleshooting, Hydraulic System................................ 2-26
Troubleshooting, Torque Converter................................ 2-41
Troubleshooting, Transfer Gear Case ............................ 2-42
Troubleshooting, Transmission ...................................... 2-44
T (cont)
INDEX-12
TM 10-3930-641-34-2
INDEX (cont)
Page
Page
Trunnion, Engine Removal/Installation ...................................3-3
Trunnion Support Assembly Removal ................................ 4-296
Turbocharger Air Lines Inspection ...................................... 3-128
Turbocharger Air Lines Removal/
Installation..................................................................... 3-124
Turbocharger Disassembly/Assembly................................. 3-112
Turbocharger Oil Lines Removal/
Installation..................................................................... 3-117
Turbocharger Oil Return Line Removal/
Installation..................................................................... 3-122
Turbocharger Oil Supply Line Removal/
Installation..................................................................... 3-120
Turbocharger Removal/Installation..................................... 3-107
Turbocharger Specifications............................................... 2-107
Twistlock Adjustment ........................................................... 9-24
Valve, Charging, Brake Accumulator,
Disassembly/Assembly.............................................. 5-14
Valve, Control, Brake, Disassembly/
Assembly .................................................................. 5-31
Valve, Neutralizer, Steering, Disassembly/
Assembly ....................................................................... 6-10
Valve, Neutralizer, Steering, Removal/
Installation...................................................................6-7
Valve, Outlet Relief, Torque Converter,
Removal/Installation................................................ 4-225
Valve, Parking Brake Control, Disassembly/
Assembly .................................................................. 5-63
Valve, Parking Brake Control, Removal/
Installation................................................................. 5-61
Valve, Sequence, Test................................................. 4-237
Valve, Steering Control, Disassembly/
Assembly .................................................................. 6-28
Valve, Steering Control, Removal/
Installation................................................................. 6-24
Valves, Removal/Installation........................................ 3-255
Valves, Sequence and Pressure Control,
Disassembly/Assembly............................................ 4-205
Valves, Sequence and Pressure Control,
Removal/Installation................................................ 4-202
Valves, Transmission Control....................................... 4-201
Vehicle Specifications.................................................... 2-69
T (cont)
U
Universal Joint/Spider and Bearing Assembly
Removal/Installation...................................................... 4-305
Upper Drive Shaft Disassembly/Assembly.......................... 4-306
Upper Shaft, Drive, Disassembly/
Assembly ........................................................................... 4-306
V
Valve Clearance Setting..................................................... 3-268
Valve Components, Engine................................................ 3-254
Valve Cover Specifications .................................................. 2-80
Valve Group, Control, Brake, Removal/
Installation............................................................................ 5-26
Valve Guides Removal/Installation..................................... 3-262
Valve Lifters Removal/Installation ...................................... 3-264
Valve Seat Inserts Removal/Installation ............................. 3-260
Valve Specifications............................................................. 2-76
W
Warning Alarm Troubleshooting..................................... 2-45
Warranty..........................................................................1-3
Water Pump Disassembly/Assembly............................ 3-168
Water Pump Specifications............................................ 2-98
Water Temperature Regulator
Specifications............................................................ 2-99
INDEX-13
TM 10-3930-641-34-2
INDEX (cont)
Page
W (cont)
Wheel Bearing Adjustment................................................... 5-91
Wheel and Brake Assemblies Assembly............................... 5-51
Wheel and Brake Assemblies Disassembly .......................... 5-44
Wheel Brake Specifications ............................................... 2-153
Wheel Brakes Removal/Installation...................................... 5-38
Wheel Special Torque Valves .......................................... App. D
Wheel Specifications.......................................................... 2-104
Window Glass, Cab, Removal/Installation............................ 8-31
Window, Cab, Right Side, Removal/
Installation....................................................................... 8-28
Wiring Replacement............................................................. 2-65
Change 1 INDEX-14
TM 10-3930-641-34-2
By Order of the Secretary of the Army:
E. C. MEYER
General, United, States Army
Chief of Staff
Official:
ROBERT M. JOYCE
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-38, Direct and General Support maintenance requirements for Truck, Container Handler, 50, 000
lb. capacity.
*U.S. GOVERNMENT PRINTING OFFICE: 1994 - 300-421/82307
PIN: 049849-000
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