TM-10-3930-675-24-2 Rough Terrain Container Handler (RTCH): RT 240; 53 000 Lb Capacity; 4x4 Manual

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TM-10-3930-675-24-2

FIELD AND SUSTAINMENT MAINTENANCE MANUAL (Includes Unit, Direct, and General Support) FOR ROUGH TERRAIN CONTAINER HANDLER (RTCH): RT 240; 53,000 LB CAPACITY; 4 X 4
WARNING SUMMARY
HEAVY PARTS
INFORMATION ON FIRST AID
WARNING
DRY CLEANING SOLVENT
HAZARDOUS WASTE DISPOSAL
NBC EXPOSURE
R-134A REFRIGERANT
LIST OF EFFECTIVE PAGES/WORK PACKAGES
LIST OF EFFECTIVE PAGES/WORK PACKAGES-continued
LIST OF EFFECTIVE PAGES/WORK PACKAGES-continued
LIST OF EFFECTIVE PAGES/WORK PACKAGES-continued
Table of Contents
Table of Contents-continued
Table of Contents-continued
Table of Contents-continued
Table of Contents-continued
Table of Contents-continued
Table of Contents-continued
Table of Contents-continued
HOW TO USE THIS MANUAL
FEATURES OF THIS MANUAL
CHAPTER 3. ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
PMCS INITIAL SETUP
GENERAL LUBRICATION PROCEDURES
GENERAL LUBRICATION PROCEDURES-continued
KEY
CHART A--ENGINE.
CHART D--FRONT/REAR AXLE DIFFERENTIALS.
Primary Fuel Filter
Front Brake Cooling Filter
Tophandler Hydraulic Slewing Motors
Tophandler Pinion and Ring Gear
USMC MACHINES
Front Brake Cooling Filter
Tophandler Hydraulic Slewing Motors
Tophandler Pinion and Ring Gear
VIEW A -- ENGINE (LEFT SIDE)
VIEW B -- FRONT/REAR AXLE DIFFERENTIAL HOUSING
VIEW D -- ENGINE (RIGHT SIDE)
VIEW E -- TOPHANDLER HYDRAULIC SLEWING MOTORS
VIEW G -- TOPHANDLER HYDRAULIC SPREADER MOTOR (USMC ONLY)
Hydraulic and Brake System Oil Filters.
Engine Coolant and Filter.
Autolube System (USMC Only).
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Preventive Maintenance Checks and Services (PMCS) for the RT 240 RTCH-continued
Table 1. Preventive Maintenance Checks and Services (PMCS) for the RT 240 RTCH-continued
Table 1. Preventive Maintenance Checks and Services (PMCS) for the RT 240 RTCH-continued
Table 2. PMCS Mandatory Replacement Parts List.
ROCKER ARM COVER AND GASKET REPLACEMENT
INSTALLATION
INSTALLATION-continued
ENGINE OIL AND OIL FILTER REPLACEMENT
REMOVAL-continued
INSTALLATION
ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT
ENGINE OIL DIPSTICK HOSE REMOVAL
OIL FILL HOSE REMOVAL
OIL SAMPLING VALVES AND HOSES REPLACEMENT
OIL SAMPLING VALVE INSTALLATION
ENGINE OIL SAMPLING VALVE HOSE INSTALLATION
TRANSMISSION OIL SAMPLING VALVE HOSE REMOVAL
HYDRAULIC SYSTEM OIL SAMPLING VALVE HOSE REMOVAL
FUEL SOLENOID SHUTOFF VALVE REPLACEMENT
INSTALLATION
ENGINE AIR CLEANER MAINTENANCE
REMOVAL
INSTALLATION
ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT
AIR CLEANER-TO-TURBOCHARGER HOSES AND TUBES REMOVAL
TURBOCHARGER-TO-CHARGE AIR COOLER HOSES AND TUBES REMOVAL
CHARGE AIR COOLER-TO-ENGINE AIR INTAKE MANIFOLD HOSES AND TUBES INSTALLATION
FUEL FILTER/WATER SEPARATOR REPLACEMENT
INSTALLATION
INSTALLATION-continued
FUEL HOSES, LINES, AND FITTINGS REPLACEMENT
COOLING PLATE-TO-CYLINDER HEAD FUEL LINE INSTALLATION
FUEL PUMP-TO-COOLING PLATE FUEL LINE REMOVAL
ENGINE FUEL RETURN LINE REMOVAL
FUEL SUPPLY HOSE REMOVAL
FUEL RETURN HOSE REMOVAL
ETHER COLD START SYSTEM MAINTENANCE
ETHER CANISTER INSTALLATION
ETHER CANISTER INSTALLATION-continued
COLD START ACTIVATION SOLENOID REMOVAL
COLD START ACTIVATION SOLENOID REMOVAL-continued
COLD START ACTIVATION SOLENOID REMOVAL-continued
COLD START ACTIVATION SOLENOID INSTALLATION
COLD START ACTIVATION SOLENOID INSTALLATION-continued
THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
MUFFLER AND EXHAUST PIPE REPLACEMENT
REMOVAL-continued
INSTALLATION
DRAINING AND FILLING RADIATOR ASSEMBLY
FILLING
FILLING-continued
FILLING-continued
COOLING SYSTEM HOSES REPLACEMENT
CAB INTERFACE UNIT-TO-WATER PUMP HOSE REMOVAL
CAB INTERFACE UNIT-TO-ENGINE BLOCK HOSE INSTALLATION
COOLANT RESERVOIR-TO-RADIATOR HOSE REMOVAL
COOLANT RESERVOIR-TO-WATER MANIFOLD HOSE INSTALLATION
COOLANT RESERVOIR-TO-WATER PUMP HOSE REMOVAL
TRANSMISSION OIL COOLER-TO-RADIATOR HOSES REMOVAL
TRANSMISSION OIL COOLER-TO-WATER PUMP HOSES REMOVAL
TRANSMISSION OIL COOLER-TO-WATER PUMP RETURN HOSE REMOVAL
TRANSMISSION OIL COOLER U-HOSE REPLACEMENT
WATER MANIFOLD-TO-RADIATOR HOSES REMOVAL
COOLING SYSTEM EXPANSION TANK MAINTENANCE
REMOVAL
DISASSEMBLY
CLEANING AND INSPECTION
INSTALLATION-continued
THERMOSTAT REPLACEMENT
REMOVAL-continued
INSTALLATION
WATER PUMP REPLACEMENT
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
COOLANT FILTER REPLACEMENT
INSTALLATION
INSTALLATION-continued
ALTERNATOR REPLACEMENT
INSTALLATION
INSTALLATION-continued
ALTERNATOR DRIVE BELT MAINTENANCE
INSTALLATION
ADJUSTMENT
STARTER REPLACEMENT
REMOVAL-continued
INSTALLATION
INSTRUMENT PANEL SWITCHES, GAGES, AND PANEL LAMPS REPLACEMENT
ROCKER SWITCH REMOVAL-continued
ROCKER SWITCH INSTALLATION
ROTARY SWITCH INSTALLATION
ROTARY SWITCH INSTALLATION-continued
GAGE REMOVAL
INSTRUMENT PANEL LAMP REMOVAL
INSTRUMENT PANEL LAMP INSTALLATION
12/24V CONNECTOR INSTALLATION
CIRCUIT BREAKERS AND RELAYS REPLACEMENT
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL-continued
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL-continued
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS REMOVAL-continued
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION-continued
CAB DISTRIBUTION BOX CIRCUIT BREAKERS AND RELAYS INSTALLATION-continued
50A CIRCUIT BREAKERS REMOVAL
STARTER RELAY REMOVAL
TOPHANDLER PROXIMITY SWITCHES REPLACEMENT
TWISTLOCK PROXIMITY SWITCH REMOVAL-continued
TWISTLOCK PROXIMITY SWITCH INSTALLATION
FORKLIFT INTERLOCK PROXIMITY SWITCH REMOVAL
FORKLIFT INTERLOCK PROXIMITY SWITCH INSTALLATION
SPREADER BEAM PROXIMITY SWITCH REMOVAL
SPREADER BEAM PROXIMITY SWITCH REMOVAL-continued
SPREADER BEAM PROXIMITY SWITCH INSTALLATION
SPREADER BEAM PROXIMITY SWITCH INSTALLATION-continued
CAB POSITION PROXIMITY SWITCHES REPLACEMENT
CAB-MOUNTED PROXIMITY SWITCH REMOVAL-continued
CAB-MOUNTED PROXIMITY SWITCH INSTALLATION
CAB SUPPORT-MOUNTED PROXIMITY SWITCH REMOVAL-continued
CAB SUPPORT-MOUNTED PROXIMITY SWITCH REMOVAL-continued
TOPHANDLER JUNCTION BOX MAINTENANCE
TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) INSTALLATION
RELAY REMOVAL
TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT
REMOVAL-continued
INSTALLATION
ENGINE ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT
INSTALLATION
INSTALLATION-continued
ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) REMOVAL-continued
TRANSMISSION ELECTRONIC CONTROL UNIT (ECU) INSTALLATION
STEERING SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL
STEERING SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION
HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) REMOVAL
HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) INSTALLATION
ECS DISPLAY SCREEN REPLACEMENT
INSTALLATION
INSTALLATION-continued
ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT
INSTALLATION
ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT
REMOVALc-continued
REMOVALc-continued
REMOVALc-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
HEADLIGHT MAINTENANCE
BULB REPLACEMENT-continued
LIGHT REMOVAL
BACKUP LIGHT AND WORK LIGHT MAINTENANCE
BULB REPLACEMENT-continued
LIGHT REMOVAL
DIRECTIONAL AND SIDE MARKER LIGHT MAINTENANCE
DIRECTIONAL LIGHT BULB AND LED REPLACEMENT-continued
DIRECTIONAL LIGHT REMOVAL
SIDE MARKER LIGHT BULB REPLACEMENT
SIDE MARKER LIGHT REMOVAL
BLACKOUT LIGHT MAINTENANCE
BULB/REFLECTOR REPLACEMENT-continued
BLACKOUT LIGHT REMOVAL
TWISTLOCK INDICATOR LIGHTS MAINTENANCE
TWISTLOCK INDICATOR LIGHT BULB REPLACEMENT-continued
TWISTLOCK INDICATOR LIGHT REMOVAL
TWISTLOCK INDICATOR LIGHT INSTALLATION
TWISTLOCK INFRARED (IR) LIGHT INSTALLATION
CAB INTERIOR LIGHT MAINTENANCE
CAB INTERIOR LIGHT REMOVAL
INFRARED (IR) LIGHTS REPLACEMENT
REMOVAL
FORDING WATER LEVEL SENSOR REPLACEMENT
INSTALLATION
AMBIENT TEMPERATURE SENSOR REPLACEMENT
INSTALLATION
WHEEL TEMPERATURE SENSOR REPLACEMENT
ENGINE SENSORS REPLACEMENT
COOLANT TEMPERATURE SENSOR INSTALLATION
ENGINE POSITION SENSOR REMOVAL
INTAKE AIR TEMPERATURE SENSOR REMOVAL
INTAKE MANIFOLD PRESSURE SENSOR INSTALLATION
OIL PRESSURE/TEMPERATURE SENSOR REMOVAL
FUEL LEVEL SENDING UNIT REPLACEMENT
REMOVAL-continued
INSTALLATION
TRANSMISSION SENSORS REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
BRAKE INCHING SWITCH REPLACEMENT
INSTALLATION
INSTALLATION-continued
BRAKE LIGHT AND PRESSURE SWITCHES REPLACEMENT
REMOVAL
INSTALLATION
BOOM ANGLE SENSOR REPLACEMENT
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
BOOM EXTENSION SENSOR REPLACEMENT
REMOVAL-continued
INSTALLATION
TOPHANDLER ANGLE SENSOR REPLACEMENT
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT
TEMPERATURE SENSOR REPLACEMENT
PRESSURE SENSOR REPLACEMENT
LIFT CYLINDER SENSOR REPLACEMENT
HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT
REMOVAL
INSTALLATION
STEERING SYSTEM WHEEL SENSOR REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
INSTALLATION
Table 2. Rear Junction Box X192 Wire Connections.
INSTALLATION-continued
ELECTRIC HORN REPLACEMENT
BACKUP ALARM REPLACEMENT
INSTALLATION
SEAT WARNING BUZZER REPLACEMENT
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
BATTERY MAINTENANCE
REMOVAL
SOLAR CHARGER MAINTENANCE (USMC ONLY)
REMOVAL-continued
INSTALLATION
BATTERY CABLES REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
MASTER BATTERY SWITCH REPLACEMENT
REMOVAL
INSTALLATION
SLAVE STARTING RECEPTACLE REPLACEMENT
RIGHT SLAVE STARTING RECEPTACLE INSTALLATION
LEFT SLAVE STARTING RECEPTACLE REMOVAL
LEFT SLAVE STARTING RECEPTACLE INSTALLATION
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS
MULTIPLE-PIN CONNECTOR IDENTIFICATION DIAGRAMS
CONNECTOR REPAIR
SEALED CONNECTOR REPAIR
WATERPROOF CONNECTOR REPAIR
MILITARY CONNECTOR REPAIR
SPLICING WIRES
ELECTRICAL GROUND POINTS
MULTIMETER USAGE-continued
MULTIMETER USAGE-continued
Measuring DC Voltage.
RELAY INSPECTION AND TEST
TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
TRANSMISSION OIL FILTER AND OIL COOLER HOSES AND FITTINGS REPLACEMENT
TRANSMISSION-TO-OIL COOLER HOSES REMOVAL-continued
TRANSMISSION-TO-OIL COOLER HOSES INSTALLATION
TRANSMISSION-TO-OIL FILTER HOSES REMOVAL-continued
TRANSMISSION-TO-OIL FILTER HOSES INSTALLATION
TRANSMISSION ASSEMBLY HYDRAULIC HOSES AND PIPES REPLACEMENT
REMOVAL
INSTALLATION
TRANSMISSION OIL, OIL FILTERS, AND OIL FILTER HEAD REPLACEMENT
TRANSMISSION OIL FILLING
TRANSMISSION OIL FILTERS INSTALLATION
TRANSMISSION OIL FILTER HEAD REMOVAL
TRANSMISSION OIL FILTER HEAD INSTALLATION
TRANSMISSION INTERNAL COARSE OIL FILTER REMOVAL
TRANSMISSION INTERNAL COARSE OIL FILTER INSTALLATION
TRANSMISSION OIL DIPSTICK HOSE AND PIPE REPLACEMENT
REMOVAL
INSTALLATION-continued
TRANSMISSION AND FRONT AND REAR AXLE VENT HOSES REPLACEMENT
FRONT AXLE VENT HOSE REMOVAL-continued
FRONT AXLE VENT HOSE INSTALLATION
REAR AXLE VENT HOSE INSTALLATION
TRANSMISSION VENT HOSE REMOVAL
TRANSMISSION VENT HOSE INSTALLATION
FRONT AND REAR PROPELLER SHAFTS REPLACEMENT
FRONT PROPELLER SHAFT REMOVAL
FRONT PROPELLER SHAFT INSTALLATION
REAR PROPELLER SHAFT INSTALLATION
REAR PROPELLER SHAFT INSTALLATION-continued
PROPELLER SHAFT UNIVERSAL JOINT REPLACEMENT
INSTALLATION
PARKING BRAKE PADS MAINTENANCE
REMOVAL
CLEANING AND INSPECTION
CAGING AND UNCAGING PARKING BRAKE
CAGING-continued
UNCAGING
PARKING BRAKE CONTROL VALVE REPLACEMENT
REMOVAL-continued
INSTALLATION
PARKING BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT
REMOVAL
SERVICE BRAKE CONTROL VALVE REPLACEMENT
REMOVAL
SERVICE BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT
REMOVAL
INSTALLATION
BRAKE COOLING FILTER AND FILTER HEAD REPLACEMENT
BRAKE COOLING FILTER REMOVAL
BRAKE COOLING FILTER HEAD REMOVAL
BRAKE COOLING FILTER HEAD INSTALLATION
BRAKE SYSTEM CHARGING VALVE PRESSURE ADJUSTMENT
ADJUSTMENT, BRAKE CIRCUIT NO. 2
ADJUSTMENT, BRAKE CIRCUIT NO. 2-continued
DOLLY WHEEL MAINTENANCE
CLEANING AND INSPECTION
STEERING WHEEL REPLACEMENT
INSTALLATION
STEERING COLUMN BASE AND BRAKE PEDAL MAINTENANCE
REMOVAL-continued
DISASSEMBLY
DISASSEMBLY-continued
ASSEMBLY
INSTALLATION
INSTALLATION-continued
STEERING COLUMN REPLACEMENT
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
STEERING SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT
REMOVAL
FRONT AND REAR AXLE STEERING CYLINDERS REPLACEMENT
REMOVAL
INSTALLATION-continued
STEERING COLUMN SENSOR REPLACEMENT
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
TOW PINTLE REPLACEMENT
CAB TRANSPORT LIFT MAINTENANCE
CAB TRANSPORT SYSTEM INSPECTION
CAB TRANSPORT SYSTEM INSPECTION-continued
CAB TRANSPORT SYSTEM ADJUSTMENT
CAB ADJUSTMENT: OPERATIONAL POSITION-continued
CAB ADJUSTMENT: OPERATIONAL POSITION-continued
CAB ADJUSTMENT: TRANSPORT POSITION
CAB ADJUSTMENT: TRANSPORT POSITION-continued
CAB ADJUSTMENT: TRANSPORT POSITION-continued
CAB ADJUSTMENT: TRANSPORT POSITION-continued
CAB ADJUSTMENT: TRANSPORT POSITION-continued
CAB TRANSPORT LIFT REMOVAL
CAB TRANSPORT LIFT REMOVAL-continued
CAB TRANSPORT LIFT INSTALLATION
CAB TRANSPORT LIFT INSTALLATION-continued
CAB TRANSPORT LIFT INSTALLATION-continued
CAB TRANSPORT LIFT INSTALLATION-continued
CAB TRANSPORT LIFT STRUCTURE REMOVAL
CAB TRANSPORT LIFT STRUCTURE REMOVAL-continued
CAB TRANSPORT LIFT STRUCTURE REMOVAL-continued
CAB TRANSPORT LIFT STRUCTURE INSTALLATION
CAB TRANSPORT LIFT STRUCTURE INSTALLATION-continued
CAB TRANSPORT LIFT STRUCTURE INSTALLATION-continued
RIGHT-SIDE STEP ASSEMBLY REPLACEMENT
INSTALLATION
LEFT-SIDE STAIR ASSEMBLY MAINTENANCE
STAIR ASSEMBLY REMOVAL
STAIR ASSEMBLY INSTALLATION
AUTOLUBE SYSTEM MAINTENANCE
AUTOLUBE TUBE REMOVAL
AUTOLUBE PUMP REMOVAL
AUTOLUBE DISTRIBUTION VALVE REMOVAL
TRANSMISSION SKID PLATE AND ACCESS COVERS REPLACEMENT
SKID PLATE REMOVAL
FRONT ACCESS COVER REMOVAL
MIDDLE ACCESS COVER AND CAB SUPPORT REMOVAL
REAR ACCESS COVER REMOVAL
RADIATOR SPLASH SHIELD REPLACEMENT
RADIATOR TOP GRATING REPLACEMENT
RADIATOR FILL COVER PLATE REPLACEMENT
BOOM ASSEMBLY WEAR PLATES REPLACEMENT
GENERAL
STYLE A WEAR PLATE REMOVAL
STYLE A WEAR PLATE INSTALLATION
STYLE A WEAR PLATE INSTALLATION-continued
STYLE B WEAR PLATE REMOVAL
STYLE B WEAR PLATE REMOVAL-continued
STYLE B WEAR PLATE REMOVAL-continued
STYLE B WEAR PLATE INSTALLATION
STYLE B WEAR PLATE INSTALLATION-continued
STYLE B WEAR PLATE INSTALLATION-continued
STYLE C (ARMY AND RESET) WEAR PLATE REMOVAL
STYLE D (USMC ONLY) WEAR PLATE REMOVAL
TOPHANDLER WEAR PLATES REPLACEMENT
WEAR PLATE LOCATOR DIAGRAM
WEAR PLATE LOCATOR DIAGRAM
STYLE A WEAR PLATE REMOVAL
STYLE A WEAR PLATE INSTALLATION
STYLE B WEAR PLATE REMOVAL
STYLE B WEAR PLATE REMOVAL-continued
STYLE B WEAR PLATE INSTALLATION
STYLE B WEAR PLATE INSTALLATION-continued
STYLE C WEAR PLATE REMOVAL
STYLE C WEAR PLATE INSTALLATION
STYLE D WEAR PLATE REMOVAL
STYLE E WEAR PLATE REMOVAL
ENGINE COVER MAINTENANCE
DISASSEMBLY
ASSEMBLY
INSTALLATION
FENDER ASSEMBLY REPLACEMENT (ARMY, RESET, AND USMC)
FENDERS AND FENDER BRACKETS REMOVAL (ARMY)
FENDERS AND FENDER BRACKETS REMOVAL (ARMY)-continued
FENDERS AND FENDER BRACKETS INSTALLATION (ARMY)
FRONT FENDERS AND FENDER BRACKETS INSTALLATION (RESET)
REAR FENDERS AND FENDER BRACKETS REMOVAL (USMC)
REAR FENDERS AND FENDER BRACKETS INSTALLATION (USMC)
FRONT FENDERS AND FENDER BRACKETS REMOVAL (USMC)
FRONT FENDERS AND FENDER BRACKETS INSTALLATION (USMC)
MUDGUARD REPLACEMENT
SEAT BELT REPLACEMENT
SEAT ASSEMBLY MAINTENANCE
DISASSEMBLY
ASSEMBLY
INSTALLATION
CAB DOOR WEATHERSEAL REPLACEMENT
REMOVAL-continued
INSTALLATION
STORAGE COMPARTMENT DOORS AND LATCHES REPLACEMENT
INSTALLATION
INSTALLATION-continued
BATTERY AND DOLLY WHEELS STORAGE COMPARTMENT REPLACEMENT
REMOVAL
INSTALLATION-continued
REMOTE HYDRAULIC CONTROL COMPARTMENT REPLACEMENT
REMOVAL
REARVIEW MIRRORS REPLACEMENT
EXTERIOR REARVIEW MIRROR REMOVAL
EXTERIOR REARVIEW MIRROR INSTALLATION
WINDSHIELD WIPER MAINTENANCE
FRONT WINDSHIELD WIPER AND MOTOR REMOVAL
FRONT WINDSHIELD WIPER AND MOTOR REMOVAL-continued
FRONT WINDSHIELD WIPER AND MOTOR INSTALLATION
FRONT WINDSHIELD WIPER AND MOTOR INSTALLATION-continued
REAR WINDOW WINDSHIELD WIPER AND MOTOR REMOVAL
REAR WINDOW WINDSHIELD WIPER AND MOTOR INSTALLATION
ROOF WINDOW WINDSHIELD WIPER AND MOTOR REMOVAL
ROOF WINDOW WINDSHIELD WIPER AND MOTOR INSTALLATION
WINDSHIELD WASHER RESERVOIR AND PUMP REPLACEMENT
WINDSHIELD WASHER RESERVOIR REMOVAL
WINDSHIELD WASHER RESERVOIR INSTALLATION
WINDSHIELD WASHER PUMP INSTALLATION
WINDSHIELD WASHER PUMP REMOVAL-continued
DATA PLATE REPLACEMENT
FIRE EXTINGUISHER BRACKET REPLACEMENT
RIFLE MOUNTING BRACKET REPLACEMENT
INSTALLATION
BOOM-TO-BOOM EXTENSION FLEXIBLE CONVEYER MAINTENANCE
REMOVAL
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
RELIEVING HYDRAULIC SYSTEM PRESSURE
RELIEVING HYDRAULIC SYSTEM PRESSURE-continued
RELIEVING HYDRAULIC SYSTEM PRESSURE-continued
AUXILIARY HYDRAULIC PUMP REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
TOPHANDLER HYDRAULIC SLEWING MOTORS REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
TOPHANDLER HYDRAULIC SPREADER MOTOR REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
SPREADER CHAIN REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
CHAIN TENSION MEASUREMENT
CHAIN ADJUSTER VERTICAL ADJUSTMENT (ARMY AND RESET ONLY)
CHAIN ADJUSTER VERTICAL ADJUSTMENT (ARMY AND RESET ONLY)-continued
SPREADER 20 AND 40 FOOT ADJUSTMENT
MEASUREMENT AND ADJUSTMENT - 20 FT-continued
MEASUREMENT AND ADJUSTMENT - 40 FT
MEASUREMENT AND ADJUSTMENT - 40 FT-continued
MEASUREMENT AND ADJUSTMENT - 40 FT-continued
CAB TRANSPORT CONTROL VALVE REPLACEMENT
REMOVAL
CONTROL VALVE SOLENOIDS REPLACEMENT
TYPE A SOLENOID REMOVAL
TYPE A SOLENOID INSTALLATION
TYPE C SOLENOID REMOVAL
TYPE D SOLENOID REMOVAL
BOOM FOLDING CONTROL VALVE REPLACEMENT
REMOVAL
CAB LIFTING CYLINDER REPLACEMENT
REMOVAL
INSTALLATION-continued
CAB SLIDING CYLINDER REPLACEMENT
REMOVAL
TOPHANDLER TWISTLOCK CYLINDER REPLACEMENT
REMOVAL
HYDRAULIC SYSTEM COOLING HOSES AND FITTINGS REPLACEMENT
REMOVAL
CAB PARKING AND SERVICE BRAKE HYDRAULIC HOSES AND FITTINGS REPLACEMENT
REMOVAL
MAIN HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT
REMOVAL
HYDRAULIC SERVO SYSTEM HOSES AND FITTINGS REPLACEMENT
REMOVAL
HYDRAULIC SYSTEM TEST POINT HOSES AND FITTINGS REPLACEMENT
REMOVAL
CAB TRANSPORT HYDRAULIC HOSES AND FITTINGS REPLACEMENT
REMOVAL
BOOM HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT
REMOVAL
TOPHANDLER HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT
REMOVAL
FORKLIFT KIT HYDRAULIC HOSES AND FITTINGS REPLACEMENT
REMOVAL
HYDRAULIC SYSTEM OIL FILTERS REPLACEMENT
HYDRAULIC RESERVOIR RETURN OIL FILTER REMOVAL
HYDRAULIC RESERVOIR RETURN OIL FILTER INSTALLATION
HYDRAULIC RESERVOIR BREATHER FILTER REMOVAL
HYDRAULIC SYSTEM IN-LINE FILTERS AND FILTER HEAD INSTALLATION
DRAINING AND FILLING HYDRAULIC RESERVOIR
DRAINING
FILLING-continued
HYDRAULIC RESERVOIR SIGHT GAGE REPLACEMENT
INSTALLATION
HYDRAULIC SYSTEM TEST POINT PROCEDURES
GENERAL
TEST POINT NO. 1: BRAKE ACCUMULATOR NO. 1
TEST POINT NO. 3: STEERING SYSTEM MAIN VALVE
TEST POINT NO. 5: BRAKE CIRCUIT NO. 1
TEST POINT NO. 9: SERVO SYSTEM
TEST POINT NO. 12: ENGINE DRIVEN PUMP/FAN HYDRAULIC SYSTEM-continued
TOPHANDLER REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
CERTIFICATION OF INSPECTION
HEATER HOSES REPLACEMENT
ENGINE HEATER HOSES REMOVAL-continued
ENGINE HEATER HOSES REMOVAL-continued
ENGINE HEATER HOSES INSTALLATION
ENGINE HEATER HOSES INSTALLATION-continued
CAB HEATER HOSES REMOVAL
CAB HEATER HOSES REMOVAL-continued
CAB HEATER HOSES REMOVAL-continued
CAB HEATER HOSES REMOVAL-continued
CAB HEATER HOSES INSTALLATION
CAB HEATER HOSES INSTALLATION-continued
CAB HEATER HOSES INSTALLATION-continued
CAB HEATER/AIR CONDITIONING BLOWER MOTOR AND FAN REPLACEMENT
REMOVAL-continued
INSTALLATION
CAB AIR FILTERS REPLACEMENT
CAB SIDE AIR FILTER REMOVAL
CAB SIDE AIR FILTER CLEANING AND INSPECTION
CAB SIDE AIR FILTER INSTALLATION-continued
CAB INTERIOR AIR FILTER REMOVAL
CAB INTERIOR AIR FILTER CLEANING AND INSPECTION
CAB INTERIOR AIR FILTER INSTALLATION
CAB INTERIOR AIR FILTER INSTALLATION-continued
CAB AUXILIARY FAN REPLACEMENT
INSTALLATION
AIR CONDITIONER LEAK TEST
AIR CONDITIONING COMPRESSOR DRIVE BELTS REPLACEMENT
INSTALLATION
AIR CONDITIONER FANS MAINTENANCE
AIR CONDITIONER FANS INSTALLATION
RELAYS AND RESISTORS REMOVAL
RELAYS AND RESISTORS REMOVAL-continued
RELAYS AND RESISTORS INSTALLATION
CHAPTER 4. DIRECT SUPPORT MAINTENANCE INSTRUCTIONS
ENGINE ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT
LIFTING BRACKETS INSTALLATION
FRONT ENGINE MOUNT INSTALLATION
REAR ENGINE MOUNT REMOVAL
REAR ENGINE MOUNT INSTALLATION
CYLINDER HEAD REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
CLEANING
INSPECTION
INSPECTION-continued
Table 1. Cylinder Head Flatness Measurements.
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
CYLINDER HEAD REPAIR
DISASSEMBLY
DISASSEMBLY-continued
DISASSEMBLY-continued
CLEANING
INSPECTION
INSPECTION
INSPECTION
INSPECTION
INSPECTION
INSPECTION
ASSEMBLY
ASSEMBLY-continued
ASSEMBLY-continued
ASSEMBLY-continued
ASSEMBLY-continued
FRONT MAIN OIL SEAL REPLACEMENT
INSTALLATION
INSTALLATION-continued
REAR MAIN OIL SEAL REPLACEMENT
INSTALLATION
INSTALLATION-continued
VIBRATION DAMPER REPLACEMENT
INSPECTION
INSPECTION-continued
INSTALLATION
FLYWHEEL ASSEMBLY REPLACEMENT
REMOVAL-continued
INSPECTION
Table 1. Flywheel Face Runout.
INSTALLATION
INSTALLATION-continued
FLYWHEEL HOUSING REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
ALIGNMENT
Table 2. Flywheel Housing Bore Alignment Maximum TIR.
Table 3. Flywheel Housing Face Alignment Maximum TIR.
ALIGNMENT-continued
ALIGNMENT-continued
ROCKER ARM ASSEMBLY MAINTENANCE
DISASSEMBLY
DISASSEMBLY-continued
INSPECTION
ASSEMBLY
ASSEMBLY-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
VALVE AND INJECTOR ADJUSTMENTS
VALVE LASH CHECK
Table 1. Injector and Valve Measurement Sequence.
INJECTOR LASH CHECK
INJECTOR ADJUSTMENT
INJECTOR ADJUSTMENT-continued
VALVE ADJUSTMENT
VALVE ADJUSTMENT-continued
VALVE ADJUSTMENT-continued
VALVE ADJUSTMENT-continued
OIL PAN REPLACEMENT
INSTALLATION
INSTALLATION-continued
OIL FILTER HEAD AND OIL COOLER MAINTENANCE
REMOVAL
REMOVAL-continued
DISASSEMBLY
CLEANING
TEST
ASSEMBLY
INSTALLATION
Schematic Drawing
INSTALLATION-continued
INSTALLATION-continued
EXHAUST MANIFOLD REPLACEMENT
INSTALLATION
INSTALLATION-continued
INTAKE MANIFOLD REPLACEMENT
INSTALLATION
FRONT GEAR COVER REPLACEMENT
REMOVAL
CLEANING-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
ACCESSORY DRIVE ASSEMBLY MAINTENANCE
REMOVAL
REMOVAL-continued
DISASSEMBLY
DISASSEMBLY-continued
DISASSEMBLY-continued
INSPECTION
INSPECTION-continued
ASSEMBLY
ASSEMBLY-continued
ASSEMBLY-continued
ASSEMBLY-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
COOLING FAN HYDRAULIC PUMP DRIVE GEAR REPLACEMENT
REMOVAL
REMOVAL-continued
INSPECTION
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
FUEL INJECTOR REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION-continued
FUEL PUMP ASSEMBLY REPLACEMENT
REMOVAL
INSTALLATION
TURBOCHARGER REPLACEMENT
REMOVAL
REMOVAL-continued
INSPECTION
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
FUEL TANK REPLACEMENT
REMOVAL
INSTALLATION
RADIATOR ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
BOOM WIRING HARNESSES REPLACEMENT
INSTALLATION
Schematic Drawing
TOPHANDLER WIRING HARNESSES REPLACEMENT
WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182: REMOVAL
WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182: INSTALLATION
WIRING HARNESS A, TOPHANDLER JUNCTION BOX-TO-JUNCTION BOX 182: INSTALLATION-continued
WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE: REMOVAL
WIRING HARNESS B, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE: INSTALLATION
WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE: REMOVAL
WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE: REMOVAL-continued
WIRING HARNESS C, TOPHANDLER JUNCTION BOX-TO-CONTROL VALVE: INSTALLATION
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183: REMOVAL
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183: REMOVAL-continued
WIRING HARNESS D, JUNCTION BOX 182-TO-JUNCTION BOX 183: INSTALLATION
WIRING HARNESS D, JUNCTION BOX 182 -TO-JUNCTION BOX 183: INSTALLATION-continued
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184: REMOVAL
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184: REMOVAL-continued
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184: INSTALLATION
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184: INSTALLATION-continued
WIRING HARNESS E, JUNCTION BOX 182-TO-JUNCTION BOX 184: INSTALLATION-continued
TOPHANDLER JUNCTION BOX REPLACEMENT
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
TRANSMISSION TORQUE CONVERTER REPLACEMENT
REMOVAL-continued
INSTALLATION
TRANSMISSION ASSEMBLY REPLACEMENT
REMOVAL
Schematic Drawing
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
Schematic Drawing
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
TRANSMISSION CALIBRATION
CALIBRATION-continued
Table 1. Main Code Identification.
Table 2. Sub Code Identification.
TRANSMISSION OIL COOLER REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
FRONT AXLE ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
REAR AXLE ASSEMBLY REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
PARKING BRAKE CYLINDER MAINTENANCE
PARKING BRAKE CYLINDER REMOVAL
Schematic Drawing
PARKING BRAKE CYLINDER DISASSEMBLY
PARKING BRAKE CYLINDER ASSEMBLY
PARKING BRAKE CYLINDER INSTALLATION
PARKING BRAKE ROTOR REMOVAL
PARKING BRAKE BRACKET REMOVAL
BRAKE ACCUMULATOR REPLACEMENT
REMOVAL
BRAKE AND STEERING ACCUMULATOR SERVICE
CHECKING BRAKE ACCUMULATOR PRE-CHARGE PRESSURE-continued
BRAKE ACCUMULATOR CHARGING
CHECKING STEERING ACCUMULATOR PRE-CHARGE PRESSURE
STEERING ACCUMULATOR CHARGING
WHEEL AND TIRE REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
BOGIE WHEEL ASSEMBLY MAINTENANCE
BOGIE WHEEL INSTALLATION
HYDRAULIC CYLINDERS REMOVAL
HYDRAULIC CYLINDERS REMOVAL-continued
HYDRAULIC CYLINDERS INSTALLATION
SCREW ASSEMBLY REMOVAL
BOGIE WHEEL FRAME REMOVAL
STEERING COLUMN REPAIR
ASSEMBLY
EMERGENCY STEERING PUMP REPLACEMENT
REMOVAL
STEERING CONTROL VALVE REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION-continued
STEERING ACCUMULATOR REPLACEMENT
REMOVAL
STEERING CALIBRATION
CALIBRATION-continued
Steering Cylinder No. 2 Calibration (Menu 5 of 10).
Steering System Hydraulic and Electrical Connections Check (Menu 8 of 10).
LOCKING PIN BUSHING REPLACEMENT
FRAME BUSHINGS REMOVAL
FRAME BUSHINGS INSTALLATION
BOOM SUPPORT BUSHINGS REMOVAL
BOOM SUPPORT BUSHINGS REMOVAL-continued
BOOM SUPPORT BUSHINGS INSTALLATION
BOOM SUPPORT BUSHINGS INSTALLATION-continued
BOOM SUPPORT BUSHINGS INSTALLATION-continued
CAB DOOR ASSEMBLY MAINTENANCE
DISASSEMBLY
ASSEMBLY
INSTALLATION
INSTALLATION-continued
WINDSHIELD AND WINDOW GLASS REPLACEMENT
REMOVAL
INSTALLATION
TOPHANDLER AND STEERING HYDRAULIC PUMP ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
TOPHANDLER AND STEERING HYDRAULIC PUMPS ADJUSTMENT
TOPHANDLER PUMP STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT
TOPHANDLER PUMP STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT-continued
STEERING PUMPS NOS. 1 AND 2 STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT
STEERING PUMPS NOS. 1 AND 2 STANDBY AND OPERATING HYDRAULIC PRESSURE ADJUSTMENT-continued
SLEWING MOTOR BRAKE REPLACEMENT
SLEWING MOTOR BRAKE REMOVAL
SLEWING MOTOR GEAR REMOVAL
SPREADER MAINTENANCE
HYDRAULIC MOTOR REMOVAL
GEAR INSTALLATION
BOOM AND BRAKE SYSTEM HYDRAULIC PUMP REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION-continued
COOLING FAN HYDRAULIC PUMP REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION-continued
HYDRAULIC COOLING FAN MAINTENANCE
DISASSEMBLY
INSTALLATION-continued
MAIN CONTROL VALVE REPLACEMENT
REMOVAL
Schematic Drawing
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
SERVO CONTROL VALVE REPLACEMENT
REMOVAL
INSTALLATION-continued
TOPHANDLER CONTROL VALVE REPLACEMENT
REMOVAL
INSTALLATION
BOOM LIFT CYLINDER REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
BOOM FOLDING CYLINDER REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
Procedure for USMC Vehicle
Procedure for USMC Vehicle-continued
BOOM SUPPORT LOCKING PIN CYLINDER AND LOCKING PIN REPLACEMENT
LOCKING PIN CYLINDER REMOVAL
LOCKING PIN REMOVAL
LOCKING PIN CYLINDER INSTALLATION
LOCKING PIN CYLINDER INSTALLATION-continued
TOPHANDLER TILT CYLINDER REPLACEMENT
REMOVAL
INSTALLATION
TOPHANDLER SIDESHIFTING CYLINDER REPLACEMENT
REMOVAL
INSTALLATION
TOPHANDLER LEVELING CYLINDER REPLACEMENT
REMOVAL
INSTALLATION
BOOM ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
BOOM AND TOPHANDLER CALIBRATION
Boom Calibration, Boom Angle, Lowered Position (Menu 1 of 10).
Boom Calibration, Tophandler Tilt Angle (Boom in Raised Position) (Menu 4 of 10).
Boom Calibration, Boom Cylinders (Retracted) (Menu 7 of 10).
Boom Calibration Completed (Menu 10 of 10).
TOPHANDLER TWISTLOCK REPLACEMENT
INSTALLATION
INSTALLATION-continued
FORKLIFT CYLINDER REPLACEMENT
REMOVAL
HYDRAULIC RESERVOIR REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
HYDRAULIC SYSTEM VALVE MAINTENANCE
PUMP SHUT-OFF VALVE (611) REMOVAL
PUMP SHUT-OFF VALVE (611) INSTALLATION
SHIFT VALVE (6041) REMOVAL
BOOM SUPPORT/BOGIE SUPPLY VALVE (6043) REMOVAL
BOOM SUPPORT/BOGIE SUPPLY VALVE (6043) INSTALLATION
SERVO PRESSURE REGULATOR VALVE (6043) INSTALLATION
BOGIE/BOOM SUPPORT FLOW CONTROL VALVE REMOVAL
BOGIE/BOOM SUPPORT FLOW CONTROL VALVE INSTALLATION
BOOM SUPPORT LOCKING PIN DOUBLE PILOT OPERATED CHECK VALVE INSTALLATION
BOGIE PRESSURE BALL VALVE REMOVAL
EXTENSION CYLINDER OVER-CENTER VALVE REMOVAL
PARKING BRAKE HOLD FLOW CONTROL VALVE REMOVAL
PARKING BRAKE HOLD FLOW CONTROL VALVE INSTALLATION
BRAKE CHARGING VALVE REMOVAL
BRAKE DRAIN SHUT-OFF VALVE REMOVAL
BRAKE CIRCUIT SAFETY REGULATING VALVE REMOVAL
FRONT BRAKE COOLING BYPASS VALVE (6049-1) REMOVAL
REAR BRAKE COOLING BYPASS VALVE (6049-2) REMOVAL
COOLING FAN FLOW CONTROL VALVE (6037) REMOVAL
EMERGENCY STEERING PRESSURE BALANCING VALVE REMOVAL
EMERGENCY STEERING PRESSURE BALANCING VALVE INSTALLATION
MODERATION AND TILT MANIFOLD VALVE INSTALLATION
TILT OVER-CENTER VALVE INSTALLATION
OSCILLATION OVER-CENTER VALVE REMOVAL
OSCILLATION FLOAT LOCK FLOW CONTROL VALVE REMOVAL
TWISTLOCK DOUBLE PILOT OPERATED CHECK VALVE REMOVAL
CAB HEATER/AIR CONDITIONING UNIT REPLACEMENT
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
AIR CONDITIONING SYSTEM MAINTENANCE
RECOVERY
EVACUATING/RECYCLING
PURGING
FLUSHING
CHARGING-continued
AIR CONDITIONER COMPRESSOR REPLACEMENT
REMOVAL-continued
INSTALLATION
AIR CONDITIONER HOSES REPLACEMENT
CHASSIS A/C HOSES REMOVAL-continued
CHASSIS A/C HOSES INSTALLATION
CAB REAR A/C HOSE REMOVAL
CAB REAR A/C HOSE INSTALLATION
CAB INTERIOR A/C HOSES REMOVAL
CAB INTERIOR A/C HOSES REMOVAL-continued
CAB INTERIOR A/C HOSES REMOVAL-continued
CAB INTERIOR A/C HOSES INSTALLATION
CAB INTERIOR A/C HOSES INSTALLATION-continued
CAB INTERIOR A/C HOSES INSTALLATION-continued
AIR CONDITIONER CONDENSER REPLACEMENT
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
AIR CONDITIONER RECEIVER/DRYER REPLACEMENT
INSTALLATION
Schematic Drawing
CHAPTER 5. GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
MOUNTING ENGINE ON REBUILD STAND
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
CYLINDER BLOCK REPAIR
DISASSEMBLY-continued
DISASSEMBLY-continued
DISASSEMBLY-continued
CLEANING
CLEANING-continued
INSPECTION
INSPECTION-continued
INSPECTION-continued
ASSEMBLY
ASSEMBLY-continued
ASSEMBLY-continued
ASSEMBLY-continued
ASSEMBLY-continued
CRANKSHAFT REPLACEMENT
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
CLEANING
INSPECTION
INSPECTION-continued
INSPECTION-continued
INSPECTION-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
PISTON AND CONNECTING ROD MAINTENANCE
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
DISASSEMBLY
DISASSEMBLY-continued
CLEANING
INSPECTION-continued
INSPECTION-continued
INSPECTION-continued
INSPECTION-continued
ASSEMBLY
ASSEMBLY-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
CAMSHAFT AND DRIVE GEAR REPLACEMENT
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
CLEANING
INSPECTION-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
CAM FOLLOWER ASSEMBLY MAINTENANCE
REMOVAL-continued
DISASSEMBLY
CLEANING
ASSEMBLY
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
IDLER GEARS AND CAMSHAFT DRIVE GEAR REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
CLEANING
INSPECTION-continued
INSPECTION-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
OIL PUMP ASSEMBLY MAINTENANCE
REMOVAL
INSPECTION
INSPECTION-continued
DISASSEMBLY
ASSEMBLY
ASSEMBLY-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
FRONT GEAR HOUSING REPLACEMENT
REMOVAL-continued
CLEANING
INSPECTION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
HYDRAULIC CYLINDER REPAIR (CAB LIFT AND SIDESHIFT)
DISASSEMBLY-continued
INSPECTION
HYDRAULIC CYLINDER REPAIR (TOPHANDLER, SIDESHIFT, LEVELING, LOCKING PIN, AND FORKLIFT KIT)
INSPECTION
ASSEMBLY
BOOM SUPPORT REPLACEMENT
REMOVAL
REMOVAL-continued
REMOVAL-continued
REMOVAL-continued
INSTALLATION
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
INSTALLATION-continued
PREPARATION FOR ARCTIC OPERATION
PREPARATION FOR ARCTIC OPERATION-continued
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION FOR LONG-TERM STORAGE
PREPARATION FOR SHIPMENT
GENERAL MAINTENANCE INSTRUCTIONS
CLEANING INSTRUCTIONS
INSPECTION INSTRUCTIONS
LUBRICATION INSTRUCTIONS
LINES AND PORTS
Table 2. Flat-Face Type O-rings.
Table 5. Hydraulic Hose Torque Chart
ILLUSTRATED LIST OF MANUFACTURED ITEMS
TORQUE LIMITS
Table 1. Torque Limits.
CHAPTER 6. SUPPORTING INFORMATION
REFERENCES
TECHNICAL MANUALS-continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1
EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS, TABLE 2
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 1. MAC for the RT 240 RTCH-continued
Table 2. Tools and Test Equipment Requirements for the RT 240 RTCH.
Table 2. Tools and Test Equipment Requirements for the RT 240 RTCH-continued
Table 2. Tools and Test Equipment Requirements for the RT 240 RTCH-continued
Table 2. Tools and Test Equipment Requirements for the RT 240 RTCH-continued
Table 2. Tools and Test Equipment Requirements for the RT 240 RTCH-continued
Table 2. Tools and Test Equipment Requirements for the RT 240 RTCH-continued
Table 3. Remarks for the RT 240 RTCH.
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable List for the RT 240 RTCH.
Table 1. Expendable and Durable List for the RT 240 RTCH-continued
Table 1. Expendable and Durable List for the RT 240 RTCH-continued
Table 1. Expendable and Durable List for the RT 240 RTCH-continued
Table 1. Expendable and Durable List for the RT 240 RTCH-continued
LOAD TESTING PROCEDURE
BOOM CYLINDER DRIFT TEST-continued
BOOM CYLINDER DRIFT TEST-continued
EXTENSION CYLINDER DRIFT TEST
EXTENSION CYLINDER DRIFT TEST-continued
INDEX
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
INDEX-continued
Figure 1. Parking Brake System Hydraulic Hoses and Fittings.
Figure 2. Service Brake System Hydraulic Hoses and Fittings.
Figure 3. Steering System Hydraulic Hoses and Fittings.
Figure 4. Hydraulic System Cooling Hoses and Fittings.
Figure 4. Hydraulic System Cooling Hoses and Fittings - Continued.
Figure 5. Cab Parking and Service Brake Hydraulic Hoses and Fittings.
Figure 6. Main Hydraulic System Hoses and Fittings.
Figure 7. Hydraulic Servo System Hoses and Fittings.
Figure 8. Hydraulic System Test Point Hoses and Fittings.
Figure 9. Cab Transport Hydraulic Hoses and Fittings.
Figure 10. Boom Lifting Hydraulic System.
Figure 11. Boom Extension Hydraulic System.
Figure 12. Tophandler Tilt Hydraulic System.
Figure 13. Boom Support Folding and Bogie Hydraulic System.
Figure 14. Tophandler Hydraulic System Hoses and Fittings.
Figure 14. Tophandler Hydraulic System Hoses and Fittings - Continued.
Figure 14. Tophandler Hydraulic System Hoses and Fittings - Continued.
Figure 14. Tophandler Hydraulic System Hoses and Fittings - Continued.
Figure 15. Forklift Kit Hydraulic Hoses and Fittings.
THE METRIC SYSTEM AND EQUIVALENTS
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ARMY DISTRIBUTION
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DISTRIBUTION
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