Technical Manual For Crane, Wheel Mounted, Hydraulic, Light, 7 1/2 Ton

CHAPTER 1. GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
GENERAL INFORMATION
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE
LIST OF ABBREVIATIONS/ACRONYMS
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued
Figure 2. Major Components.
Figure 3. Major Components.
Figure 4. Major Components.
EQUIPMENT DATA
EQUIPMENT DATA - Continued
Hydraulic System
EQUIPMENT DATA - Continued
EQUIPMENT DATA - Continued
EQUIPMENT DATA - Continued
EQUIPMENT DATA - Continued
Figure 5. General Dimensions.
Figure 6. General Dimensions.
Figure 7. Radius from Centerline of Rotation.
Figure 8. Crane Working Positions.
Figure 11. Maximum Permissible Hoist Line Load.
THEORY OF OPERATION
AXLES
Chapter 2. TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING SYMPTOM INDEX
TROUBLESHOOTING SYMPTOM INDEX - Continued
TROUBLESHOOTING SYMPTOM INDEX - Continued
TROUBLESHOOTING SYMPTOM INDEX - Continued
TROUBLESHOOTING SYMPTOM INDEX - Continued
TROUBLESHOOTING PROCEDURES - ENGINE
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - ENGINE - Continued
TROUBLESHOOTING PROCEDURES - HYDRAULICS
TROUBLESHOOTING PROCEDURES - HYDRAULICS - Continued
TROUBLESHOOTING PROCEDURES - HYDRAULICS - Continued
TROUBLESHOOTING PROCEDURES - SWING CIRCUIT
TROUBLESHOOTING PROCEDURES - SWING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - SWING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - SWING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - BOOM HOIST CIRCUIT
TROUBLESHOOTING PROCEDURES - BOOM HOIST CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - BOOM HOIST CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - BOOM EXTEND CIRCUIT
TROUBLESHOOTING PROCEDURES - BOOM EXTEND CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - BOOM EXTEND CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - OUTRIGGER CIRCUIT
TROUBLESHOOTING PROCEDURES - OUTRIGGER CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - OUTRIGGER CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - OUTRIGGER CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - STEERING CIRCUIT - Continued
TROUBLESHOOTING PROCEDURES - PUMPS
TROUBLESHOOTING PROCEDURES - PUMPS - Continued
TROUBLESHOOTING PROCEDURES - PUMPS - Continued
TROUBLESHOOTING PROCEDURES - PUMPS - Continued
TROUBLESHOOTING PROCEDURES - PUMPS - Continued
TROUBLESHOOTING PROCEDURES - RELIEF VALVES
TROUBLESHOOTING PROCEDURES - RELIEF VALVES - Continued
'Unknown' by Unknown - Page 173 of 1440
'Unknown' by Unknown - Page 174 of 1440
'Unknown' by Unknown - Page 175 of 1440
'Unknown' by Unknown - Page 176 of 1440
TROUBLESHOOTING PROCEDURES - ELECTRICAL SYSTEM
TROUBLESHOOTING PROCEDURES - ELECTRICAL SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - ELECTRICAL SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - ELECTRICAL SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - ELECTRICAL SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - ELECTRICAL SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - ANTI-TWO BLOCK SYSTEM
TROUBLESHOOTING PROCEDURES - ANTI-TWO BLOCK SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - ANTI-TWO BLOCK SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - ANTI-TWO BLOCK SYSTEM - Continued
TROUBLESHOOTING PROCEDURES - TRANSMISSION
TROUBLESHOOTING PROCEDURES - TRANSMISSION - Continued
TROUBLESHOOTING PROCEDURES - TRANSMISSION - Continued
TROUBLESHOOTING PROCEDURES - TRANSMISSION - Continued
TROUBLESHOOTING PROCEDURES - TRANSMISSION - Continued
TROUBLESHOOTING PROCEDURES - TRANSMISSION - Continued
TROUBLESHOOTING PROCEDURES - TRANSMISSION - Continued
TROUBLESHOOTING PROCEDURES - AXLE ASSEMBLY
TROUBLESHOOTING PROCEDURES - AXLE ASSEMBLY - Continued
TROUBLESHOOTING PROCEDURES - AXLE ASSEMBLY - Continued
TROUBLESHOOTING PROCEDURES - WINCH
TROUBLESHOOTING PROCEDURES - WINCH - Continued
TROUBLESHOOTING PROCEDURES - WINCH - Continued
TROUBLESHOOTING PROCEDURES - WINCH - Continued
TROUBLESHOOTING PROCEDURES - WINCH - Continued
TROUBLESHOOTING PROCEDURES - WINCH - Continued
MSD-ICE TROUBLESHOOTING AND TEST PROCEDURE
CONTROL TESTS
Figure 1. Remove Cap from DCA Receptacle.
MSD-ICE TESTS - Continued
MSD-ICE TESTS - Continued
MSD-ICE TESTS - Continued
Figure 2. Schematics and Diagrams.
Chapter 3. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
Table 1. Preventive Maintenance Checks and Services (PMCS).
Figure 1. Winch Lubrication Level Access Plug.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 2. Air Cleaner Element Maintenance.
Figure 3. Engine Oil and Filter Change.
Figure 4. Fuel Tank Drain Plug.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 5. Hydraulic Suction Filter Removal.
Figure 6. Transmission Fluid Change.
Figure 7. Check Antifreeze Concentration.
Figure 8. Check Axle Differential and Hub Oil Levels.
Figure 10. Check Fan Hub Bearing End Play.
Figure 11. Winch Oil Change.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 12. Add Hydraulic Oil.
Figure 13. Bleed Air from Hydraulic Reservoir.
Figure 14. Swing Reduction Unit Oil Change.
Figure 15. Differential Oil Filter.
Figure 16. Engine Coolant Change.
Figure 17. Engine Coolant Change.
Figure 18. Check Hydraulic Pressure Relief Valves.
Table 1. Preventive Maintenance Checks and Services (PMCS) - Continued.
Figure 19. Relief Valve Adjustment.
Chapter 4. MAINTENANCE INSTRUCTIONS
SERVICE UPON RECEIPT
GENERAL
Figure 1. Vehicle Check Points.
POWER PACK ASSEMBLY MAINTENANCE
Figure 1. Power Pack Removal.
Figure 2. Power Pack Removal.
Figure 3. Power Pack Removal.
Figure 5 Power Pack Removal.
Figure 6. Power Pack Removal.
Figure 7. Power Pack Removal.
Figure 8. Power Pack Removal.
Figure 9. Power Pack Removal.
Figure 11. Power Pack Removal.
Figure 13. Power Pack Removal.
Figure 14. Power Pack Removal.
Figure 15. Power Pack Removal.
Figure 16. Transmission from Engine Removal.
Figure 17. Transmission from Engine Removal.
Figure 18. Transmission from Engine Removal.
Figure 19. Transmission to Engine Installation.
Figure 20. Transmission to Engine Installation.
Figure 21. Transmission to Engine Installation.
Figure 22. Transmission to Engine Installation.
Figure 23. Power Pack Installation.
Figure 24. Power Pack Installation.
Figure 26. Power Pack Installation.
Figure 28. Power Pack Installation.
Figure 30. Power Pack Installation.
Figure 32. Power Pack Installation.
Figure 34. Power Pack Installation.
Figure 36. Power Pack Installation.
ENGINE ASSEMBLY MAINTENANCE
ENGINE ASSEMBLY MAINTENANCE - Continued
ENGINE MOUNT MAINTENANCE
Figure 2. Engine Mount Installation.
CYLINDER HEAD MAINTENANCE
Figure 1. Cylinder Head Removal.
Figure 2. Cylinder Head Removal.
Figure 3. Cylinder Head Installation.
Figure 4. Cylinder Head Installation.
FOLLOW-ON MAINTENANCE - Continued
CRANKSHAFT PULLEY MAINTENANCE
Figure 2. Crankshaft Pulley Installation.
FLYWHEEL AND FLYWHEEL HOUSING MAINTENANCE
Figure 2. Flywheel Removal.
Figure 3. Flywheel Installation.
Figure 5. Flywheel Installation.
Figure 6. Flywheel Installation.
Figure 7. Flywheel Installation.
FOLLOW-ON MAINTENANCE
REAR CRANKSHAFT SEAL MAINTENANCE
Figure 1. Rear Seal Removal.
Figure 3. Rear Seal Removal.
Figure 4. Rear Seal Installation.
Figure 5. Rear Seal Installation.
ROCKER LEVERS AND PUSH RODS MAINTENANCE
Figure 1. Cylinder Head Removal.
Figure 3. Rocker Lever and Push Rods Disassembly.
Figure 5. Rocker Lever and Push Rods Inspection.
Figure 7. Rocker Lever and Push Rods Inspection.
Figure 9. Rocker Lever and Push Rods Assembly.
Figure 11. Cylinder Head Installation.
ROCKER LEVERS AND PUSH RODS MAINTENANCE - Continued
FRONT GEAR COVER AND GASKET MAINTENANCE
Figure 1. Tachometer Drive Removal.
Figure 2. Front Cover Removal.
Figure 3. Front Gear Train Installation.
Figure 4. Front Cover Installation.
Figure 5. Tachometer Drive Installation.
TIMING PIN ASSEMBLY MAINTENANCE
Figure 2. Timing Pin Assembly Removal.
Figure 3. Timing Pin Assembly Installation.
TAPPET COVER AND GASKET MAINTENANCE
TAPPET COVER AND GASKET MAINTENANCE - Continued
Figure 1. Tappet Cover Installation.
VALVE COVERS AND GASKET MAINTENANCE
Figure 2. Valve Covers Installation.
FRONT CRANKSHAFT SEAL MAINTENANCE
Figure 1. Front Seal Removal.
FRONT CRANKSHAFT SEAL MAINTENANCE - Continued
Figure 2. Front Seal Installation.
LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE
Figure 1. Lube Oil Cooler Removal.
Figure 3. Lube Oil Cooler Removal.
Figure 5. Lube Oil Cooler Disassembly.
Figure 6. Lube Oil Cooler Inspection.
Figure 7. Lube Oil Cooler Assembly.
Figure 9. Lube Oil Cooler Installation.
LUBE OIL COOLER AND FILTER HEAD ASSEMBLY MAINTENANCE - Continued
LUBE OIL PUMP MAINTENANCE
Figure 2. Lube Oil Pump Removal.
Figure 3. Lube Oil Pump Installation.
OIL PAN AND SUCTION TUBE MAINTENANCE
Figure 1. Oil Pan and Suction Tube Removal.
Figure 2. Oil Pan and Suction Tube Removal.
OIL PAN AND SUCTION TUBE MAINTENANCE - Continued
Figure 3. Oil Pan and Suction Tube Installation.
Figure 4. Oil Pan and Suction Tube Installation.
OIL LEVEL GAGE MAINTENANCE
Figure 2. Oil Level Gage Removal.
Figure 3. Oil Level Gage Installation.
OIL LEVEL GAGE MAINTENANCE - Continued
INTAKE MANIFOLD COVER AND GASKET MAINTENANCE
Figure 2. Manifold Cover Plate Installation.
INTAKE MANIFOLD COVER AND GASKET MAINTENANCE - Continued
EXHAUST MANIFOLD AND GASKETS MAINTENANCE
Figure 2. Exhaust Manifold Removal.
EXHAUST MANIFOLD AND GASKETS MAINTENANCE - Continued
FUEL INJECTOR MAINTENANCE
Figure 1. Injector Nozzles Removal.
Figure 3. Lube Oil Injector Nozzles Installation.
Figure 4. Injector Nozzles Installation.
FUEL INJECTION PUMP MAINTENANCE
Figure 1. Injection Pump Removal.
Figure 2. Injection Pump Removal.
Figure 4. Injection Pump Removal.
Figure 6. Injection Pump Removal.
Figure 7. Injection Pump Disassembly.
Figure 8. Injection Pump Disassembly.
Figure 10. Injection Pump Disassembly.
Figure 12. Injection Pump Disassembly.
Figure 14. Injection Pump Disassembly.
Figure 15. Injection Pump Disassembly.
Figure 17. Injection Pump Disassembly.
Figure 18. Injection Pump Assembly.
Figure 19. Injection Pump Assembly.
Figure 20. Injection Pump Assembly.
Figure 22. Injection Pump Assembly.
Figure 24. Injection Pump Assembly.
Figure 26. Injection Pump Assembly.
Figure 28. Injection Pump Assembly.
Figure 30. Injection Pump Installation.
Figure 32. Injection Pump Installation.
Figure 34. Injection Pump Installation.
FUEL LIFT PUMP MAINTENANCE
Figure 1. Lift Pump Removal.
Figure 2. Lift Pump Installation.
AIR CLEANER ASSEMBLY MAINTENANCE
Figure 1. Air Cleaner Removal.
Figure 2. Air Cleaner Removal.
AIR CLEANER ASSEMBLY MAINTENANCE - Continued
Figure 3. Air Cleaner Maintenance.
Figure 5. Air Cleaner Installation.
FUEL TANK MAINTENANCE
Figure 2. Fuel Tank Removal.
Figure 3. Fuel Tank Disassembly.
Figure 5. Fuel Tank Assembly.
Figure 6. Fuel Tank Assembly.
Figure 7. Fuel Tank Installation.
Figure 8. Fuel Tank Installation.
FUEL LINES MAINTENANCE
Figure 2. Fuel Lines Removal.
Figure 3. Fuel Lines Installation.
Figure 5. Fuel Lines Installation.
FUEL INJECTION TUBES MAINTENANCE
Figure 1. High-Pressure Tubes Removal.
Figure 2. High-Pressure Tubes Removal.
Figure 3. High-Pressure Tubes Removal.
Figure 4. Low-Pressure Tubes Removal.
Figure 5. Low-Pressure Tubes Removal.
Figure 6. Low-Pressure Tubes Removal.
Figure 7. Fuel Drain Tubes Removal.
Figure 8. Fuel Drain Tubes Removal.
Figure 9. Fuel Drain Tubes Installation.
Figure 10. Fuel Drain Tubes Installation.
Figure 11. Low-Pressure Tubes Installation.
Figure 12. Low-Pressure Tubes Installation.
Figure 13. Low-Pressure Tubes Installation.
Figure 14. High-Pressure Tubes Installation.
Figure 15. High-Pressure Tubes Installation.
FUEL FILTER HEAD ASSEMBLY MAINTENANCE
Figure 2. Fuel Filters and Head Assembly Maintenance.
Figure 3. Fuel Filters and Head Assembly Installation.
COLD START DEVICE MAINTENANCE
Figure 2. Cold Start Device Removal.
Figure 4. Cold Start Device Removal.
Figure 5. Cold Start Device Installation.
Figure 7. Cold Start Device Installation.
Figure 8. Cold Start Device Installation.
THROTTLE CONTROL MAINTENANCE
Figure 1. Throttle Control Removal.
Figure 3. Throttle Control Removal.
Figure 5. Throttle Control Removal.
Figure 6. Throttle Control Maintenance.
Figure 7. Throttle Control Installation.
Figure 8. Throttle Control Installation.
Figure 10. Throttle Control Installation.
Figure 11. Throttle Control Installation.
Figure 12. Throttle Control Adjustment.
THROTTLE CONTROL MAINTENANCE - Continued
EXHAUST SYSTEM ASSEMBLY MAINTENANCE
Figure 2. Exhaust System Removal.
Figure 3. Exhaust System Maintenance.
Figure 4. Exhaust System Installation.
Figure 5. Exhaust System Installation.
RADIATOR AND OIL COOLER MAINTENANCE
Figure 1. Radiator and Oil Cooler Removal.
Figure 2. Radiator and Oil Cooler Removal.
Figure 3. Radiator and Oil Cooler Removal.
Figure 4. Radiator and Oil Cooler Removal.
Figure 5. Radiator and Oil Cooler Removal.
Figure 6. Radiator and Oil Cooler Removal.
Figure 8. Radiator and Oil Cooler Removal.
Figure 9. Radiator and Oil Cooler Removal.
RADIATOR AND OIL COOLER MAINTENANCE - Continued
Figure 10. Radiator and Air Cooler Assembly.
Figure 11. Radiator and Air Cooler Installation.
Figure 12. Radiator and Air Cooler Installation.
Figure 13. Radiator and Air Cooler Installation.
Figure 15. Radiator and Air Cooler Installation.
Figure 16. Radiator and Air Cooler Installation.
Figure 17. Radiator and Air Cooler Installation.
Figure 19. Radiator and Air Cooler Installation.
RADIATOR AND OIL COOLER MAINTENANCE - Continued
DEFROSTER FAN MAINTENANCE
DEFROSTER FAN MAINTENANCE - Continued
Figure 1. Defroster Fan Maintenance.
THERMOSTAT MAINTENANCE
Figure 1. Thermostat Removal.
Figure 3. Thermostat Installation.
Figure 4. Thermostat Installation.
WATER INLET CONNECTION MAINTENANCE
Figure 1. Water Inlet Connection Removal.
Figure 2. Water Inlet Connection Installation.
WATER PUMP MAINTENANCE
Figure 2. Water Pump Inspection.
Figure 3. Water Pump Installation.
FAN DRIVE BELT MAINTENANCE
Figure 1. Fan Drive Belt Removal.
Figure 2. Fan Drive Belt Installation.
COOLING FAN AND HUB ASSEMBLY MAINTENANCE
Figure 2. Fan Pulley Removal.
Figure 4. Hub Assembly Disassembly.
Figure 6. Roller Bearing Assembly.
Figure 7. Hub Assembly Assembly.
Figure 9. Fan Pulley Installation.
COOLING FAN AND HUB ASSEMBLY MAINTENANCE - Continued
DRIVE BELT TENSIONER AND IDLER MAINTENANCE
Figure 1. Drive Belt Tensioner Removal.
Figure 2. Drive Belt Tensioner Installation.
ALTERNATOR AND MOUNTING ASSEMBLY BRACKET MAINTENANCE
Figure 2. Alternator and Mounting Bracket Assembly Removal.
Figure 3. Alternator and Mounting Bracket Assembly Installation.
ALTERNATOR AND MOUNTING ASSEMBLY BRACKET MAINTENANCE - Continued
STARTER MOTOR MAINTENANCE
Figure 2. Starter Motor Assembly.
STARTER MOTOR MAINTENANCE - Continued
NEUTRAL SAFETY SWITCH AND BACKUP REVERSE WARNING SWITCH MAINTENANCE
Figure 1. Warning Switches Maintenance.
NEUTRAL SAFETY SWITCH AND BACKUP REVERSE WARNING SWITCH MAINTENANCE - Continued
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE - Continued
Figure 1. Fuel Pressure Switch and Transducer Installation.
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE - Continued
DASH PANEL GAGES AND SWITCHES MAINTENANCE
Figure 1. Dash Panel Removal.
Figure 2. Dash Panel Removal.
Figure 4. Dash Panel Removal.
Figure 5. Dash Panel Removal.
Figure 6. Side Sloping Dash Panel Removal.
Figure 7. Side Sloping Dash Panel Removal.
Figure 8. Side Sloping Dash Panel Removal.
Figure 9. Side Sloping Dash Panel Removal.
Figure 10. Side Sloping Dash Panel Removal.
Figure 11. Circuit Breaker Panel Removal.
Figure 12. Tachometer and Turn Signal Removal.
Figure 13. Right Console Removal.
Figure 14. Right Console Removal.
Figure 15. Right Console Removal.
Figure 16. Tachometer and Turn Signal Installation.
Figure 17. Circuit Breaker Panel Installation.
Figure 18. Side Sloping Dash Panel Installation.
Figure 19. Side Sloping Dash Panel Installation.
Figure 20. Side Sloping Dash Panel Installation.
Figure 21. Side Sloping Dash Panel Installation.
Figure 22. Side Sloping Dash Panel Installation.
Figure 23. Dash Panel Installation.
Figure 25. Dash Panel Installation.
Figure 26. Dash Panel Installation.
Figure 27. Dash Panel Installation.
Figure 28. Right Console Installation.
Figure 29. Right Console Installation.
Figure 30. Right Console Installation.
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE - Continued
ANTI-TWO BLOCK CONTROL PANEL MAINTENANCE
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE - Continued
Figure 1. Control Panel Maintenance.
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE - Continued
FUEL PRESSURE SWITCH AND TRANSDUCER MAINTENANCE - Continued
VEHICLE BUBBLE LEVEL MAINTENANCE
Figure 2. Vehicle Bubble Level Installation.
VEHICLE BUBBLE LEVEL MAINTENANCE - Continued
HORN MAINTENANCE
Figure 2. Horn Installation.
ELECTRICAL COLLECTOR RING MAINTENANCE
Figure 1. Electrical Collector Ring Removal.
Figure 2. Electrical Collector Ring Removal.
Figure 3. Electrical Collector Ring Removal.
Figure 4. Electrical Collector Ring Removal.
Figure 5. Electrical Collector Ring Installation.
Figure 6. Electrical Collector Ring Installation.
Figure 7. Electrical Collector Ring Installation.
Figure 8. Electrical Collector Ring Installation.
ELECTRICAL COLLECTOR RING MAINTENANCE - Continued
REAR LIGHTS MAINTENANCE
REAR LIGHTS MAINTENANCE - Continued
Figure 1. Rear Lights Maintenance.
FRONT LIGHTS AND BRACKETS MAINTENANCE
REAR LIGHTS MAINTENANCE - Continued
Figure 1. Left Front Lights and Bracket Installation.
REAR LIGHTS MAINTENANCE - Continued
Figure 2. Right Front Lights and Bracket Installation.
REAR LIGHTS MAINTENANCE - Continued
WORK LIGHTS MAINTENANCE
REAR LIGHTS MAINTENANCE - Continued
Figure 1. Work Lights Maintenance.
AXLE CENTERING LIGHT SWITCH ASSEMBLY MAINTENANCE
Figure 1. Axle Centering Light Switch Assembly Removal.
Figure 2. Axle Centering Light Switch Assembly Removal.
Figure 3. Axle Centering Light Switch Assembly Installation.
Figure 4. Axle Centering Light Switch Assembly Installation.
Figure 5. Axle Centering Light Switch Assembly Adjustment.
TACHOMETER ADJUSTMENT
Figure 2. Tachometer Drive Removal.
Figure 3. Tachometer Drive Installation.
Figure 4. Tachometer Wiring Harness Installation.
BATTERY ASSEMBLY AND CABLES MAINTENANCE
BATTERY ASSEMBLY AND CABLES MAINTENANCE - Continued
Figure 1. Battery and Cables Assembly Removal.
Figure 2. Battery and Cables Assembly Removal.
Figure 3. Battery and Cables Assembly Removal.
Figure 4. Battery and Cables Assembly Removal.
Figure 5. Battery and Cables Assembly Removal.
Figure 7. Battery and Cables Assembly Removal.
Figure 8. Battery and Cables Assembly Installation.
Figure 9. Battery and Cables Assembly Installation.
Figure 10. Battery and Cables Assembly Installation.
Figure 11. Battery and Cables Assembly Installation.
Figure 12. Battery and Cables Assembly Installation.
Figure 13. Battery and Cables Assembly Installation.
Figure 14. Battery and Cables Assembly Installation.
BATTERY BOX AND TOOLBOX WITH COVERS MAINTENANCE
Figure 2. Battery Box and Toolbox Removal.
Figure 3. Battery Box and Toolbox Installation.
Figure 4. Battery Box and Toolbox Cover Installation.
MAIN ENGINE WIRING HARNESS MAINTENANCE
Figure 1. Main Engine Wiring Harness Removal.
Figure 2. Main Engine Wiring Harness Installation.
MAIN ENGINE WIRING HARNESS MAINTENANCE - Continued
CAB MAIN HARNESS MAINTENANCE
MAIN ENGINE WIRING HARNESS MAINTENANCE - Continued
Figure 1. Cab Main Harness Maintenance.
MAIN ENGINE WIRING HARNESS MAINTENANCE - Continued
BACKUP ALARM MAINTENANCE
Figure 1. Back Up Alarm Removal.
Figure 2. Back Up Alarm Installation.
MSD-ICE WIRING HARNESS MAINTENANCE
Figure 2. Main MSD-ICE Harness Installation.
MSD-ICE WIRING HARNESS MAINTENANCE - Continued
BOOM WIRING HARNESS MAINTENANCE
Figure 1. Boom Wiring Harness Removal.
Figure 2. Boom Wiring Harness Removal.
Figure 3. Boom Wiring Harness Removal.
Figure 4. Boom Wiring Harness Removal.
Figure 5. Boom Wiring Harness Removal.
Figure 6. Boom Wiring Harness Removal.
Figure 7. Boom Wiring Harness Removal.
Figure 8. Boom Wiring Harness Removal.
Figure 10. Boom Wiring Harness Installation.
Figure 11. Boom Wiring Harness Installation.
Figure 13. Boom Wiring Harness Installation.
Figure 14. Boom Wiring Harness Installation.
Figure 15. Boom Wiring Harness Installation.
Figure 17. Boom Wiring Harness Installation.
BOOM WIRING HARNESS MAINTENANCE - Continued
MSD-ICE DCA CONNECTOR/RESISTOR MODULE MAINTENANCE
Figure 1. MSD-ICE DCA Connector Resistor/Module Removal.
Figure 2. MSD-ICE DCA Connector Resistor/Module Installation.
TRANSMISSION DIPSTICK TUBE ASSEMBLY MAINTENANCE
Figure 1. Transmission Dipstick Tube Removal.
Figure 2. Transmission Dipstick Tube Installation.
TRANSMISSION SHIFT CONTROLS MAINTENANCE
TRANSMISSION SHIFT CONTROLS MAINTENANCE - Continued
Figure 1. Transmission Shift Controls Removal.
TRANSMISSION SHIFT CONTROLS MAINTENANCE - Continued
Figure 2. Transmission Shift Controls Installation.
TRANSMISSION CABLES MAINTENANCE
Figure 1. Transmission Cable Removal.
Figure 2. Transmission Cable Removal.
Figure 4. Transmission Cable Removal.
Figure 6. Transmission Cable Removal.
Figure 7. Transmission Cable Installation.
Figure 8. Transmission Cable Installation.
Figure 10. Transmission Cable Installation.
Figure 12. Transmission Cable Installation.
TRANSMISSION CABLES MAINTENANCE - Continued
TRANSMISSION CONTROLS MAINTENANCE
Figure 1. Transmission Controls Maintenance.
Figure 2. Transmission Controls Maintenance.
Figure 3. Transmission Controls Maintenance.
TRANSMISSION ASSEMBLY MAINTENANCE
TRANSMISSION ASSEMBLY MAINTENANCE - Continued
CHARGE PUMP MAINTENANCE
Figure 1. Charge Pump Removal.
Figure 2. Charge Pump Installation.
CONTROL VALVE MAINTENANCE
Figure 1. Control Valve Disassembly.
Figure 2. Control Valve Disassembly.
Figure 3. Control Valve Disassembly.
Figure 4. Control Valve Disassembly.
Figure 5. Control Valve Disassembly.
Figure 7. Control Valve Disassembly.
CONTROL VALVE MAINTENANCE - Continued
CONTROL VALVE MAINTENANCE - Continued
Figure 9. Control Valve Assembly.
Figure 11. Control Valve Assembly.
Figure 12. Control Valve Assembly.
Figure 14. Control Valve Assembly.
Figure 16. Control Valve Assembly.
Figure 17. Control Valve Assembly.
TRANSMISSION OIL AND FILTER ELEMENT MAINTENANCE
Figure 1. Transmission Oil and Filter Element Removal.
Figure 2. Transmission Oil and Filter Element Removal.
Figure 3. Transmission Oil and Filter Element Installation.
Figure 4. Transmission Oil and Filter Element Installation.
PUMP ADAPTER MAINTENANCE
Figure 1. Pump Adapter Removal.
PUMP ADAPTER MAINTENANCE - Continued
Figure 2. Pump Adapter Installation.
FRONT AND REAR DRIVESHAFT MAINTENANCE
Figure 2. Front Driveshaft Removal.
Figure 4. Front Driveshaft Disassembly.
Figure 5. Front Driveshaft Assembly.
Figure 7. Front Driveshaft Installation.
Figure 9. Rear Driveshaft Removal.
Figure 10. Rear Driveshaft Disassembly.
Figure 11. Rear Driveshaft Assembly.
Figure 12. Rear Driveshaft Installation.
FRONT AXLE MAINTENANCE
FRONT AND REAR DRIVESHAFT MAINTENANCE - Continued
Figure 1. Front Axle Removal.
FRONT AND REAR DRIVESHAFT MAINTENANCE - Continued
Figure 2. Front Axle Installation.
FRONT AND REAR DRIVESHAFT MAINTENANCE - Continued
FRONT DIFFERENTIAL ASSEMBLY MAINTENANCE
FRONT AND REAR DRIVESHAFT MAINTENANCE - Continued
Figure 1. Front Differential Removal.
Figure 2. Front Differential Removal.
Figure 3. Front Differential Installation.
Figure 4. Front Differential Installation.
Figure 5. Front Differential Installation.
PLANETARY WHEEL END MAINTENANCE
Figure 1. Planetary Wheel End Removal.
Figure 2. Planetary Wheel End Removal.
Figure 3. Planetary Wheel End Removal.
Figure 5. Planetary Wheel End Removal.
PLANETARY WHEEL END MAINTENANCE - Continued
Figure 7. Planetary Wheel End Maintenance.
Figure 8. Planetary Wheel End Assembly.
Figure 9. Planetary Wheel End Installation.
Figure 11. Planetary Wheel End Installation.
Figure 13. Planetary Wheel End Installation.
PIVOT AND SPINDLE ASSEMBLY MAINTENANCE
Figure 1. Pivot and Spindle Assembly Removal.
Figure 2. Pivot and Spindle Assembly Removal.
PIVOT AND SPINDLE ASSEMBLY MAINTENANCE - Continued
Figure 3. Pivot and Spindle Assembly Installation.
Figure 4. Pivot and Spindle Assembly Installation.
Figure 5. Pivot and Spindle Assembly Installation.
PIVOT AND SPINDLE ASSEMBLY MAINTENANCE - Continued
Figure 6. Pivot and Spindle Assembly Installation.
PIVOT BEARINGS (TYPE II) MAINTENANCE
PIVOT BEARINGS (TYPE II) MAINTENANCE - Continued
Figure 1. Pivot Bearings (Type II) Installation.
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE
Figure 1. Constant-Velocity Joint and Axle Shaft Removal.
Figure 2. Constant-Velocity Joint and Axle Shaft Removal.
Figure 3. Constant-Velocity Joint and Axle Shaft Maintenance.
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE - Continued
Figure 5. Constant-Velocity Joint and Axle Shaft Installation.
REAR AXLE MAINTENANCE
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE - Continued
Figure 1. Rear Axle Removal.
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE - Continued
Figure 2. Rear Axle Installation.
REAR DIFFERENTIAL ASSEMBLY MAINTENANCE
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE - Continued
Figure 1. Rear Differential Assembly Removal.
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE - Continued
Figure 2. Rear Differential Assembly Installation.
CONSTANT-VELOCITY JOINT AND AXLE SHAFT MAINTENANCE - Continued
Figure 4. Rear Differential Assembly Installation.
PARKING BRAKE MAINTENANCE
Figure 1. Parking Brake Removal.
Figure 3. Parking Brake Removal.
Figure 5. Parking Brake Removal.
Figure 6. Parking Brake Disassembly.
Figure 7. Parking Brake Assembly.
Figure 8. Parking Brake Installation.
Figure 10. Parking Brake Installation.
Figure 12. Parking Brake Installation.
Figure 14. Parking Brake Installation.
BRAKE ASSEMBLY MAINTENANCE
Figure 1. Brake Assembly Removal.
Figure 2. Brake Assembly Removal.
BRAKE ASSEMBLY MAINTENANCE - Continued
Figure 4. Brake Assembly Installation.
Figure 6. Brake Assembly Installation.
Figure 7. Brake Assembly Installation.
BRAKE ASSEMBLY MAINTENANCE - Continued
BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE
BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE - Continued
Figure 1. Brake Booster Valve/Master Cylinder Removal.
Figure 3. Brake Booster Valve/Master Cylinder Removal.
Figure 4. Brake Booster Valve/Master Cylinder Disassembly.
Figure 6. Brake Booster Disassembly.
Figure 8. Brake Booster Disassembly.
BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE - Continued
Figure 11. Brake Booster Assembly.
Figure 13. Brake Booster Assembly.
Figure 15. Brake Booster Assembly.
Figure 17. Master Cylinder Installation.
Figure 18. Master Cylinder Installation.
BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE - Continued
HYDRAULIC BRAKE LINES AND FITTINGS MAINTENANCE
BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE - Continued
Figure 1. Hydraulic Brake Lines and Fittings Removal.
Figure 2. Hydraulic Brake Lines and Fittings Removal.
Figure 3. Hydraulic Brake Lines and Fittings Removal.
Figure 4. Hydraulic Brake Lines and Fittings Removal.
Figure 5. Hydraulic Brake Lines and Fittings Removal.
Figure 7. Hydraulic Brake Lines and Fittings Removal.
Figure 8. Hydraulic Brake Lines and Fittings Removal.
Figure 9. Hydraulic Brake Lines and Fittings Installation.
Figure 10. Hydraulic Brake Lines and Fittings Installation.
Figure 11. Hydraulic Brake Lines and Fittings Installation.
Figure 12. Hydraulic Brake Lines and Fittings Installation.
Figure 14. Hydraulic Brake Lines and Fittings Installation.
Figure 15. Hydraulic Brake Lines and Fittings Installation.
Figure 16. Hydraulic Brake Lines and Fittings Installation.
BRAKE BOOSTER VALVE/MASTER CYLINDER MAINTENANCE - Continued
BRAKE PEDAL AND LINKAGE MAINTENANCE
Figure 2. Brake Pedal and Linkage Removal.
Figure 3. Brake Pedal and Linkage Installation.
Figure 4. Brake Pedal and Linkage Installation.
TIRES AND WHEELS MAINTENANCE
Figure 1. Tires and Wheels Removal.
Figure 2. Tires and Wheels Disassembly.
Figure 3. Tires and Wheels Assembly.
Figure 4. Tires and Wheels Assembly.
Figure 6. Tires and Wheels Installation.
TIE ROD ASSEMBLY MAINTENANCE
Figure 1. Tie Rod Assembly Removal.
Figure 2. Tie Rod Assembly Installation.
Figure 3. Tie Rod Assembly Adjustment.
GROUND DRIVEN STEERING PUMP MAINTENANCE
Figure 1. Ground Driven Steering Pump Removal.
Figure 2. Ground Driven Steering Pump Disassembly.
Figure 4. Ground Driven Steering Pump Disassembly.
Figure 6. Ground Driven Steering Pump Disassembly.
Figure 8. Ground Driven Steering Pump Disassembly.
GROUND DRIVEN STEERING PUMP MAINTENANCE - Continued
Figure 9. Ground Driven Steering Pump Assembly.
Figure 10. Ground Driven Steering Pump Assembly.
Figure 12. Ground Driven Steering Pump Assembly.
Figure 14. Ground Driven Steering Pump Assembly.
Figure 15. Ground Driven Steering Pump Assembly.
Figure 16. Ground Driven Steering Pump Installation.
STEERING CONTROL UNIT MAINTENANCE
Figure 1. Steering Control Removal.
Figure 2. Steering Control Disassembly.
STEERING CONTROL UNIT MAINTENANCE - Continued
Figure 3. Steering Control Assembly.
Figure 4. Steering Control Installation.
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
Figure 1. Steering System Hydraulic Hoses Removal.
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
Figure 2. Steering System Hydraulic Hoses Installation.
STEERING CYLINDERS MAINTENANCE
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
Figure 1. Steering Cylinders Removal.
Figure 2. Steering Cylinders Installation.
STEERING SELECTOR VALVE MAINTENANCE
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
Figure 1. Steering Selector Valve Removal.
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
Figure 2. Steering Selector Valve Installation.
Figure 3. Steering Selector Valve Installation.
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
FLOW DIVIDER AND STEERING VALVE MAINTENANCE
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
Figure 1. Flow Divider and Steering Valve Removal.
Figure 2. Flow Divider and Steering Valve Installation.
STEERING SYSTEM HYDRAULIC HOSES MAINTENANCE - Continued
HOOK BLOCK TIEBACK MAINTENANCE
Figure 1. Hook Block Tieback Removal.
Figure 2. Hook Block Tieback Installation.
HOOK BLOCK TIEBACK MAINTENANCE - Continued
PINTLE HOOK MAINTENANCE
HOOK BLOCK TIEBACK MAINTENANCE - Continued
Figure 1. Pintle Hook Maintenance.
CAB DOOR MAINTENANCE
Figure 1. Cab Door Removal.
Figure 2. Cab Door Removal.
Figure 4. Cab Door Removal.
Figure 6. Cab Door Removal.
Figure 8. Cab Door Installation.
Figure 9. Cab Door Installation.
Figure 11. Cab Door Installation.
Figure 12. Cab Door Installation.
ENGINE HOOD AND GRILLE GUARD MAINTENANCE
Figure 1. Grille Guard Removal.
Figure 2. Engine Hood Removal.
Figure 3. Engine Hood Disassembly.
Figure 4. Engine Hood Assembly.
Figure 5. Engine Hood Installation.
Figure 6. Grille Guard Installation.
CAB ASSEMBLY MAINTENANCE
Figure 1. Cab Assembly Removal.
Figure 2. Fire Extinguisher Removal.
Figure 3. Floormats Removal.
Figure 4. Cab Assembly Disassembly.
CAB ASSEMBLY MAINTENANCE - Continued
Figure 5. Cab Assembly Assembly.
Figure 6. Floormats Installation.
Figure 7. Fire Extinguisher Installation.
Figure 8. Cab Assembly Installation.
CAB ASSEMBLY MAINTENANCE - Continued
HOOD SUPPORT MAINTENANCE
Figure 1. Hood Support Removal.
Figure 2. Hood Support Installation.
Figure 3. Hood Support Installation.
HOOD SUPPORT MAINTENANCE - Continued
FENDERS MAINTENANCE
HOOD SUPPORT MAINTENANCE - Continued
Figure 1. Fender Maintenance.
DECK PLATES MAINTENANCE
HOOD SUPPORT MAINTENANCE - Continued
Figure 1. Deck Plates Maintenance.
OUTRIGGER ASSEMBLY MAINTENANCE
OUTRIGGER ASSEMBLY MAINTENANCE - Continued
Figure 1. Outrigger Assembly Removal.
Figure 2. Outrigger Assembly Assembly.
Figure 3. Outrigger Assembly Assembly.
Figure 4. Outrigger Assembly Installation.
OUTRIGGER ASSEMBLY MAINTENANCE - Continued
SEAT AND SEAT BELT MAINTENANCE
Figure 1. Seat Belt Removal.
Figure 2. Seat Removal.
Figure 3. Seat Installation.
Figure 4. Seat Belt Installation.
WINCH ASSEMBLY MAINTENANCE
Figure 1. Winch Removal.
Figure 2. Winch Disassembly.
Figure 3. Hydraulic Hose Disassembly.
Figure 6. Sun Primary Gear Disassembly.
Figure 7. Seal and Ball Bearing Disassembly.
Figure 9. Sun Output Gear Disassembly.
Figure 11. Snap Ring Disassembly.
Figure 12. Drum Disassembly.
Figure 13. Seal and Bearing Disassembly.
Figure 14. Base Positioning Assembly.
Figure 15. Drum Assembly.
Figure 16. Drum Assembly.
Figure 18. Bearing Support Fasteners Assembly.
Figure 19. Snap Ring Assembly.
Figure 21. Output Planet Carrier Assembly.
Figure 23. Bearing and Seal Assembly.
Figure 25. Sun Primary Gear Assembly.
Figure 26. Brake Cylinder Assembly Assembly.
Figure 28. Brake Clutch Assembly Assembly.
Figure 29. Motor Installation Assembly.
Figure 30. Oil Fill Assembly.
Figure 31. Winch Installation.
WINCH MOTOR MAINTENANCE
Figure 1. Winch Motor Disassembly.
Figure 3. Winch Motor Disassembly.
Figure 5. Winch Motor Disassembly.
Figure 7. Winch Motor Disassembly.
Figure 9. Winch Motor Disassembly.
Figure 11. Winch Motor Disassembly.
Figure 13. Winch Motor Disassembly.
Figure 15. Winch Motor Disassembly.
Figure 16. Winch Motor Assembly.
Figure 18. Winch Motor Assembly.
Figure 20. Winch Motor Assembly.
Figure 22. Winch Motor Assembly.
Figure 24. Winch Motor Assembly.
Figure 26. Winch Motor Assembly.
Figure 28. Winch Motor Assembly.
Figure 30. Winch Motor Assembly.
WINCH BRAKE VALVE MAINTENANCE
WINCH BRAKE VALVE MAINTENANCE - Continued
Figure 1. Winch Brake Valve Maintenance.
WINCH BRAKE VALVE MAINTENANCE - Continued
Figure 2. Winch Brake Valve Maintenance.
WINCH BRAKE VALVE MAINTENANCE - Continued
WINCH CONTROL VALVE AND FITTINGS MAINTENANCE
WINCH CONTROL VALVE AND FITTINGS MAINTENANCE - Continued
Figure 1. Winch Control Valve Installation.
Figure 2. Winch Control Valve Test and Adjustment.
Figure 3. Winch Control Valve Test and Adjustment.
Figure 4. Winch Control Valve Test and Adjustment.
Figure 5. Winch Control Valve Test and Adjustment.
WINCH CONTROL VALVE AND FITTINGS MAINTENANCE - Continued
VALVE CONTROL, BOOM HOIST, EXTEND, AND WINCH CABLES MAINTENANCE
Figure 1. Valve Control Cable Removal.
Figure 2. Valve Control Cable Removal.
Figure 3. Valve Control Cable Removal.
Figure 4. Swing and Outrigger Cable Removal.
Boom Hoist, Extend, And Winch Cable
Figure 5. Boom Hoist, Extend, and Winch Cable Removal.
Figure 6. Boom Hoist, Extend, and Winch Cable Installation.
Figure 7. Swing and Outrigger Cable Installation.
Figure 8. Valve Control Cables Installation.
Figure 9. Valve Control Cables Installation.
Figure 10. Valve Control Cables Installation.
Figure 11. Cables Adjustment.
MIRROR MAINTENANCE
Valve Control Cables
Figure 1. Mirror Maintenance.
WINDSHIELD WIPER ASSEMBLY MAINTENANCE
Figure 1. Windshield Wiper Removal.
Figure 2. Windshield Wiper Removal.
Figure 3. Windshield Wiper Removal.
Figure 4. Windshield Wiper Removal.
WINDSHIELD WIPER ASSEMBLY MAINTENANCE - Continued
Figure 5. Windshield Wiper Removal and Installation.
Figure 6. Windshield Wiper Installation.
Figure 7. Windshield Wiper Installation.
Figure 8. Windshield Wiper Installation.
Figure 9. Windshield Wiper Installation.
HEATER MAINTENANCE
HEATER MAINTENANCE - Continued
Figure 1. Heater Removal.
Figure 3. Heater Removal.
Figure 5. Heater Removal.
Figure 7. Heater Disassembly.
Figure 8. Heater Disassembly.
Figure 9. Heater Disassembly.
Figure 10. Heater Assembly.
Figure 11. Heater Assembly.
Figure 13. Heater Installation.
Figure 15. Heater Installation.
Figure 17. Heater Installation.
MARKING DECALS MAINTENANCE
MARKING DECALS MAINTENANCE - Continued
MAIN HYDRAULIC PUMP MAINTENANCE
Figure 1. Main Hydraulic Pump Removal.
MAIN HYDRAULIC PUMP MAINTENANCE - Continued
Figure 2. Main Hydraulic Pump Installation.
MAIN HYDRAULIC PUMP MAINTENANCE - Continued
ROTARY MANIFOLD MAINTENANCE
ROTARY MANIFOLD MAINTENANCE - Continued
Figure 1. Rotary Manifold Removal.
Figure 2. Rotary Manifold Removal.
Figure 3. Rotary Manifold Removal.
Figure 4. Rotary Manifold Removal.
Figure 5. Rotary Manifold Disassembly.
ROTARY MANIFOLD MAINTENANCE - Continued
Figure 6. Rotary Manifold Assembly.
Figure 7. Rotary Manifold Installation.
Figure 8. Rotary Manifold Installation.
Figure 9. Rotary Manifold Installation.
Figure 10. Rotary Manifold Installation.
Figure 11. Rotary Manifold Installation.
ROTARY MANIFOLD MAINTENANCE - Continued
OUTRIGGER SOLENOID VALVE MAINTENANCE
OUTRIGGER SOLENOID VALVE MAINTENANCE - Continued
Figure 1. Outrigger Solenoid Valve Removal.
Figure 3. Outrigger Solenoid Valve Disassembly.
Figure 5. Outrigger Solenoid Valve Disassembly.
Figure 6. Outrigger Solenoid Valve Assembly.
Figure 7. Outrigger Solenoid Valve Assembly.
Figure 9. Outrigger Solenoid Valve Assembly.
Figure 10. Outrigger Solenoid Valve Installation.
AXLE LOCKOUT VALVE MAINTENANCE
Figure 1. Axle Lockout Valve Removal.
AXLE LOCKOUT VALVE MAINTENANCE - Continued
Figure 2. Axle Lockout Valve Installation.
Figure 3. Axle Lockout Valve Adjustment.
BOOM HOIST, WINCH, AND OUTRIGGER VALVE CONTROLS MAINTENANCE
Figure 2. Boom Hoist, Winch, and Outrigger Valve Controls Removal.
Figure 3. Boom Hoist, Winch, and Outrigger Valve Controls Disassembly.
BOOM HOIST, WINCH, AND OUTRIGGER VALVE CONTROLS MAINTENANCE - Continued
Figure 4. Boom Hoist, Winch, and Outrigger Valve Controls Assembly.
Figure 5. Boom Hoist, Winch, and Outrigger Valve Controls Installation.
Figure 6. Boom Hoist, Winch, and Outrigger Valve Controls Installation.
SWING/TELESCOPE VALVE CONTROLS MAINTENANCE
Figure 1. Swing/Telescope Valve Controls Removal.
Figure 2. Swing/Telescope Valve Controls Removal.
Figure 3. Swing/Telescope Valve Controls Disassembly.
Figure 4. Swing/Telescope Valve Controls Assembly.
Figure 5. Swing/Telescope Valve Controls Installation.
Figure 6. Swing/Telescope Valve Controls Installation.
UPPER HYDRAULICS LINE MAINTENANCE
UPPER HYDRAULICS LINE MAINTENANCE - Continued
Figure 1. Upper Hydraulics Line Removal.
UPPER HYDRAULICS LINE MAINTENANCE - Continued
Figure 2. Upper Hydraulics Line Installation.
LOWER BOOM, SWING, AND WINCH HYDRAULIC LINES MAINTENANCE
LOWER BOOM, SWING, AND WINCH HYDRAULIC LINES MAINTENANCE - Continued
Figure 1. Lower Boom, Swing, and Winch Hydraulic Lines Removal.
LOWER BOOM, SWING, AND WINCH HYDRAULIC LINES MAINTENANCE - Continued
Figure 2. Lower Boom, Swing, and Winch Hydraulic Lines Installation.
RETURN AND PRESSURE HYDRAULICS MAINTENANCE
RETURN AND PRESSURE HYDRAULICS MAINTENANCE - Continued
Figure 1. Return and Pressure Hydraulics Removal.
Figure 2. Return and Pressure Hydraulics Installation.
RETURN AND PRESSURE HYDRAULICS MAINTENANCE - Continued
OUTRIGGER HYDRAULICS MAINTENANCE
OUTRIGGER HYDRAULICS MAINTENANCE - Continued
Figure 1. Outrigger Hydraulics Removal.
OUTRIGGER HYDRAULICS MAINTENANCE - Continued
Figure 2. Outrigger Hydraulics Installation.
SUCTION HYDRAULICS MAINTENANCE
SUCTION HYDRAULICS MAINTENANCE - Continued
Figure 1. Suction Hydraulics Removal.
SUCTION HYDRAULICS MAINTENANCE - Continued
Figure 2. Suction Hydraulics Installation.
ROTARY MANIFOLD QUICK DISCONNECTS (TYPE II) MAINTENANCE
ROTARY MANIFOLD QUICK DISCONNECTS (TYPE II) MAINTENANCE - Continued
Figure 1. Rotary Manifold Quick Disconnects (Type II) Removal.
Figure 2. Rotary Manifold Quick Disconnects (Type II) Removal.
Figure 3. Rotary Manifold Quick Disconnects (Type II) Removal.
Figure 4. Rotary Manifold Quick Disconnects (Type II) Removal.
Figure 5. Rotary Manifold Quick Disconnects (Type II) Installation.
Figure 6. Rotary Manifold Quick Disconnects (Type II) Installation.
Figure 7. Rotary Manifold Quick Disconnects (Type II) Installation.
Figure 8. Rotary Manifold Quick Disconnects (Type II) Installation.
ROTARY MANIFOLD QUICK DISCONNECTS (TYPE II) MAINTENANCE - Continued
HYDRAULIC SYSTEM VALVE BANK MAINTENANCE
Figure 1. Hydraulic System Valve Bank Removal.
Figure 2. Hydraulic System Valve Bank Installation.
OTHER MAINTENANCE
Figure 3. Hydraulic System Valve Bank Adjustment.
RELIEF VALVE MAINTENANCE
Figure 1. Relief Valve Removal.
Figure 2. Relief Valve Installation.
Figure 3. Relief Valve Adjustment.
Figure 4. Relief Valve Adjustment.
RETURN FILTER MAINTENANCE
RETURN FILTER MAINTENANCE - Continued
Figure 1. Return Filter Removal.
Figure 2. Return Filter Installation.
RETURN FILTER MAINTENANCE - Continued
BOOM HOIST CYLINDER MAINTENANCE
Figure 1. Boom Hoist Cylinder Removal.
Figure 2. Boom Hoist Cylinder Removal.
Figure 3. Boom Hoist Cylinder Disassembly.
Figure 5. Boom Hoist Cylinder Disassembly.
Figure 6. Boom Hoist Cylinder Disassembly.
Figure 7. Boom Hoist Cylinder Disassembly.
Figure 8. Boom Hoist Cylinder Disassembly.
Figure 9. Boom Hoist Cylinder Assembly.
Figure 10. Boom Hoist Cylinder Assembly.
Figure 11. Boom Hoist Cylinder Assembly.
BOOM HOIST CYLINDER MAINTENANCE - Continued
Figure 13. Boom Hoist Cylinder Installation.
Figure 14. Boom Hoist Cylinder Installation.
BOOM HOIST CYLINDER MAINTENANCE - Continued
BOOM EXTEND CYLINDER MAINTENANCE
Figure 2. Boom Extend Cylinder Disassembly.
Figure 3. Boom Extend Cylinder Disassembly.
Figure 4. Boom Extend Cylinder Disassembly.
Figure 5. Boom Extend Cylinder Disassembly.
Figure 6. Boom Extend Cylinder Disassembly.
Figure 8. Boom Extend Cylinder Disassembly.
Figure 10. Boom Extend Cylinder Disassembly.
Figure 11. Boom Extend Cylinder Assembly.
Figure 12. Boom Extend Cylinder Assembly.
Figure 14. Boom Extend Cylinder Assembly.
Figure 15. Boom Extend Cylinder Assembly.
Figure 16. Boom Extend Cylinder Assembly.
Figure 17. Boom Extend Cylinder Assembly.
BOOM EXTEND CYLINDER MAINTENANCE - Continued
OUTRIGGER CYLINDER ASSEMBLY MAINTENANCE
Figure 1. Outrigger Cylinder Removal.
Figure 2. Outrigger Cylinder Removal.
Figure 3. Outrigger Cylinder Removal.
Figure 4. Outrigger Cylinder Disassembly.
Figure 5. Outrigger Cylinder Disassembly.
Figure 6. Outrigger Cylinder Disassembly.
Figure 8. Outrigger Cylinder Disassembly.
Figure 9. Outrigger Cylinder Assembly.
Figure 10. Outrigger Cylinder Assembly.
Figure 11. Outrigger Cylinder Assembly.
Figure 13. Outrigger Cylinder Assembly.
Figure 14. Outrigger Cylinder Installation.
Figure 15. Outrigger Cylinder Installation.
Figure 16. Outrigger Cylinder Installation.
AXLE LOCKOUT CYLINDER MAINTENANCE
AXLE LOCKOUT CYLINDER MAINTENANCE - Continued
Figure 1. Axle Lockout Cylinder Removal.
Figure 2. Axle Lockout Cylinder Removal.
Figure 3. Axle Lockout Cylinder Installation.
Figure 4. Axle Lockout Cylinder Installation.
AXLE LOCKOUT CYLINDER MAINTENANCE - Continued
HYDRAULIC RESERVOIR MAINTENANCE
Figure 1. Hydraulic Reservoir Removal.
Figure 2. Hydraulic Reservoir Removal.
Figure 4. Hydraulic Reservoir Removal.
Figure 5. Hydraulic Reservoir Installation.
Figure 6. Hydraulic Reservoir Installation.
Figure 7. Hydraulic Reservoir Installation.
HYDRAULIC RESERVOIR MAINTENANCE - Continued
BOOM ANGLE INDICATOR MAINTENANCE
Figure 1. Boom Angle Indicator Removal.
Figure 2. Boom Angle Indicator Installation.
HOOK BLOCK MAINTENANCE
Figure 1. Hook Block Disassembly.
Figure 2. Hook Block Disassembly.
HOOK BLOCK MAINTENANCE - Continued
Figure 3. Hook Block Assembly.
Figure 4. Hook Block Assembly.
BOOM ASSEMBLY MAINTENANCE
Figure 1. Boom Assembly Removal.
Figure 2. Boom Assembly Removal.
Figure 3. Boom Assembly Removal.
Figure 4. Boom Assembly Removal.
Figure 5. Boom Assembly Removal.
Figure 6. Boom Assembly Disassembly.
Figure 8. Boom Assembly Disassembly.
Figure 10. Boom Assembly Disassembly.
Figure 11. Boom Assembly Disassembly.
Figure 12. Boom Assembly Disassembly.
Figure 14. Boom Assembly Disassembly.
Figure 16. Boom Assembly Disassembly.
BOOM ASSEMBLY MAINTENANCE - Continued
Figure 17. Boom Assembly Assembly.
Figure 19. Boom Assembly Assembly.
Figure 20. Boom Assembly Assembly.
Figure 21. Boom Assembly Assembly.
Figure 22. Boom Assembly Assembly.
Figure 23. Boom Assembly Assembly.
Figure 24. Boom Assembly Assembly.
Figure 26. Boom Assembly Assembly.
Figure 28. Boom Assembly Installation.
Figure 29. Boom Assembly Installation.
Figure 30. Boom Assembly Installation.
Figure 31. Boom Assembly Installation.
Figure 32. Boom Assembly Installation.
BOOM ASSEMBLY MAINTENANCE - Continued
BOOM WORK LIGHT BRACKET MAINTENANCE
UPPERSTRUCTURE MAINTENANCE
Figure 1. Upperstructure Removal.
Figure 2. Upperstructure Removal.
UPPERSTRUCTURE MAINTENANCE - Continued
Figure 3. Upperstructure Removal.
Figure 4. Swing Bearing Assembly Removal.
UPPERSTRUCTURE MAINTENANCE - Continued
Figure 5. Swing Bearing Assembly Installation.
Figure 6. Upperstructure Installation.
Figure 7. Upperstructure Installation.
Figure 8. Upperstructure Installation.
Figure 9. Upperstructure Installation.
MAST ASSEMBLY (TYPE II) MAINTENANCE
MAST ASSEMBLY (TYPE II) MAINTENANCE - Continued
Figure 1. Mast Assembly Maintenance.
SWING MOTOR MAINTENANCE
Figure 1. Swing Motor Removal.
Figure 2. Swing Motor Disassembly.
Figure 4. Swing Motor Disassembly.
Figure 6. Swing Motor Disassembly.
Figure 8. Swing Motor Disassembly.
Figure 9. Swing Motor Assembly.
Figure 10. Swing Motor Assembly.
Figure 12. Swing Motor Assembly.
Figure 13. Swing Motor Assembly.
Figure 14. Swing Motor Assembly.
Figure 15. Swing Motor Installation.
SWING GEARBOX MAINTENANCE
Figure 1. Swing Gearbox Removal.
Figure 2. Swing Gearbox Disassembly.
Figure 3. Swing Gearbox Cover Disassembly.
Figure 5. Swing Gearbox Bearing Retainer Disassembly.
Figure 6. Swing Gearbox Disassembly.
Figure 7. Swing Gearbox Disassembly.
Figure 8. Swing Gearbox Output Shaft Disassembly.
Figure 9. Swing Gearbox Bearing Cups Disassembly.
Figure 11. Swing Gearbox Vent Plug and Grease Fitting Assembly.
Figure 12. Swing Gearbox Bearing Cups Assembly.
Figure 13. Swing Gearbox Assembly.
Figure 15. Swing Gearbox Assembly.
Figure 16. Swing Gearbox Assembly.
Figure 17. Swing Gearbox Bearing Retainer Assembly.
Figure 18. Swing Gearbox Bearing Retainer Assembly.
Figure 20. Swing Gearbox Drain Plugs Assembly.
Figure 22. Swing Gearbox Installation.
SWING GEARBOX MAINTENANCE - Continued
GENERAL MAINTENANCE INSTRUCTIONS
GENERAL MAINTENANCE INSTRUCTIONS - Continued
GENERAL MAINTENANCE INSTRUCTIONS - Continued
GENERAL MAINTENANCE INSTRUCTIONS - Continued
GENERAL MAINTENANCE INSTRUCTIONS - Continued
GENERAL MAINTENANCE INSTRUCTIONS - Continued
GENERAL MAINTENANCE INSTRUCTIONS - Continued
GENERAL MAINTENANCE INSTRUCTIONS - Continued
GENERAL MAINTENANCE INSTRUCTIONS - Continued
FLUID DISPOSAL
GENERAL WIRING HARNESS AND CABLE MAINTENANCE
Figure 1. Electrical Harness Identification.
Figure 2. Electrical Harness Identification.
Figure 3. Electrical Harness Disassembly.
Figure 4. Electrical Harness Disassembly.
Figure 5. Electrical Harness Disassembly.
Figure 6. Electrical Harness Disassembly.
Figure 7. Electrical Harness Disassembly.
Figure 8. Electrical Harness Disassembly.
Figure 9. Electrical Harness Assembly.
Figure 10. Electrical Harness Assembly.
Figure 12. Electrical Harness Assembly.
Figure 13. Electrical Harness Assembly.
Figure 14. Electrical Harness Assembly.
Figure 15. Electrical Harness Assembly.
Figure 16. Electrical Harness Assembly.
Figure 17. Electrical Harness Assembly.
Figure 18. Electrical Harness Assembly.
PREPARATION FOR SHIPMENT AND STORAGE
SHORT TERM STORAGE (30 DAYS OR LESS)
LONG TERM STORAGE (MORE THAN 30 DAYS) - Continued
LONG TERM STORAGE (MORE THAN 30 DAYS) - Continued
RESTORING ENGINE TO SERVICE
RESTORING TRANSMISSION TO SERVICE - Continued
TORQUE LIMITS
HOW TO USE TORQUE LIMIT TABLES
Figure 1. English Capscrew Heads.
Figure 3. Metric Fastener Markings.
How Adapters Affect Torque Limits
Figure 5. Fastener Indented Markings.
Table 1. Engine Fastener Torque Values.
Table 2. Transmission Fastener Torque Values.
Table 2. Transmission Fastener Torque Values. - Continued
Table 3. All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values
Table 3. All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values - Continued
Table 4. All Other Fasteners Except Engine and Transmission English (in.) Measurement Torque Values
Table 5. Torque Limits for Dry Fasteners.
Table 6. Torque Limits for Wet Fasteners.
Table 6. Torque Limits for Wet Fasteners. - Continued
DIAGRAMS
Chapter 5. SUPPORTING INFORMATION
REFERENCES
REFERENCES - Continued
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - Continued
EXPLANATION OF COLUMNS IN THE MAC
EXPLANATION OF COLUMNS IN THE REMARKS
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 1. Maintenance Allocation Chart (MAC) - Continued.
Table 2. Tools and Test Equipment.
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
TOOL IDENTIFICATION LIST
Table 1. Tool Identification List - Continued.
Table 1. Tool Identification List - Continued.
Table 1. Tool Identification List - Continued.
MANDATORY REPLACEMENT PARTS LIST
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued
Table 1. Mandatory Replacement Parts List for the Crane, Wheel Mounted 7.5 Ton - Continued

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