14S)-500-25 TM 9-1450-500-20 > TECHNICAL MANUAL UNIVERSITY OF VIRGINIA ALDERMAN LIBRARY DEC 23 1994 ORGANIZATIONAL GOVERNMEN) DOCUMENTS MAINTENANCE MANUAL LOADER-TRANSPORTER, GUIDED MISSILE: XMSO1E3 (HAWK GUIDED MISSILE SYSTEM) » PART NUMBER 11675300 NSN 1450-00-066-8873 This copy is a reprint which includes current pages from Changes 1 through 4. HEADQUARTERS, DEPARTMENT OF THE ARMY JUNE 1979 ) ) Aidit 2 L 004787135 | Gor gleWARNING CARBON MONOXIDE POISONING CAN BE DEADLY Carbon monoxide is_a colorless, odorless, DEADLY POISONOUS gas which, when breathed, deprives the body of oxygen and causes SUFFOCATION. Exposure to air contaminated with carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent BRAIN DAMAGE or DEATH can result from severe exposure. It occurs in the exhaust fumes of internal-combustion engines and becomes DAN- GEROUSLY CONCENTRATED under conditions of INADEQUATE VENTILATION. The following Precautions MUST be observed to insure the safety of personnel whenever the engine of any vehicle is operated for maintenance purposes or tactical use. DO NOT operate engine or vehicle in an enclosed area unless it is ADE- QUATELY ‘LATED. b. BO NOT idle engine for long periods without maintaining ADEQUATE VENTILA~ TION. c- DO NOT drive any vehicle with inspection plates, cover plates, engine com- Partment doors removed unless necessary for maintenance purposes. 4. BE ALERT at all times during vehicle operation for exhaust odors and ex- Posure symptoms. If either are present, IMMEDIATELY VENTILATE the inmediate are, If symptoms persist, remove affected personnel from vehicle and treat as follows expose to fresh air; keep warm; DO NOT PERMIT PHYSICAL EXERCISE; if necessary, administer artificial respiration. THE BEST DEFENSE AGAINST CARBON MONOXIDE POISONING IS ADEQUATE VENTILATION. IOS SSS CARBON MONOXIDE POISONING IS ADEQUATE VENTILATION, Google‘TM 9-1480-800-20 co (CHANGE HEADQUARTERS NO. 4 DEPARTMENT OF THE ARMY Washington D.C., 16 September 1990 ORGANIZATIONAL MAINTENANCE MANUAL LOADER-TRANSPORTER, GUIDED MISSILE: XM501E3 (HAWK GUIDED MISSILE SYSTEM) PART NUMBER 11676300 NSN 1450-00-066-8873 “TM 9-1460-500-20 is changed ws follows: 1. Remove old pages and insert new pages indicated below, ‘2. New or changed material Is indicated by « vertical ber in the margin of the page. '3. Added ilustrations are indicatad by a vertial ber adjacent to the illustration identification number. 4. llustration revisions are indicated by « pointing hand. ‘5. These changes reflect addition of intervehicle power recepticle, provide Loader-Tranaportar Operator with a seet belt, ‘end change to gearshift lever to prevent accidental shifting of transmission If missle support falls. i i ro ighlisse" Syotgeree 38° i 6 = 18 blank) an Bh * File this change sheet in front of the publication for referencs purposes(C4, TM 9-1460-600-20 By Order of the Secretary of the Army: CARL E. VUONO General, United States Army Chief of Staff Official: THOMAS F. SIKORA Brigadier General, United States Army The Adjutant General Distribution: ‘To be distributed in accordance with DA Form 12~32-E, Block 2039, Unit, maintenance requirements for TM9-1450-500-20.TM 9-1450-500-20 c3 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY NO. 3 Washington, D.C., 1 August 1988 ORGANIZATIONAL MAINTENANCE MANUAL LOADER-TRANSPORTER, GUIDED MISSILE: XM501E3 (HAWK GUIDED MISSILE SYSTEM) PART NUMBER 11675300 (NSN 1450-00-066-8873) TM 9-1450-500-20, 29 June 1979 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. 3. Added or revised illustrations are indicated by a vertical bar adjacent to the illustration identification number. Remove Pages Insert Pages 2-15 and 2-16 2-15 and 2-16 File this change sheet in front of the publication for reference purposes.By Order of the Secretary of the Army: CARL E. VUONO General, United States Army Official: Chief of Staff RL. DILWORTH Brigadier General, United States Army The Adjutant General Distribution: To be distributed in accordance with DA Form 12-32, Organizational Main- tenance Manual, Loader-Transporter Guided Missile, XMSO1E3 (Hawk Guided Mis- sile System).CHANGE NO. 2 ‘TM9-1450-500-20 c2 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 1 June 1988 ORGANIZATIONAL MAINTENANCE MANUAL, LOADER-TRANSPORTER, GUIDED MISSILE: XM501E3 (HAWK GUIDED MISSILE SYSTEM) PART NUMBER 11675300 NSN 1450-00-066-8873 TM 9-1450-500-20 is changed as follows: sawn Remove Pages. ‘None ‘None and i 1-1 tu 4 1-7 thew 1-10 2 they 26 ‘None 27 thru 2-10 213 and 2-14 3-27 and 3-28 3-31 and 3-32 ‘None 3-33 and 3-34 ‘None 3.35 theu 3:38 ‘None 3-39 and 3-40 ‘None 3-41 and 3-42 345 thru 3-50 3-61 and 3-62 3-81 and 3-82 3-85 and 3-86 Remove old pages and insert new pages as indicated below. New or changed materia is indicated by a vertical bar in the margin of the page. ‘Added illustrations are indicated by a vertical bar acjacent to the illustration identification number. Mustration revisions are indicated by a pointing hand. ‘These changes reflect addition of a salety strap assembly, 60 amp alternator, and latch load limiter / roll lock-out it Insert Pages ‘Transmittal sheet Warning page a(b blank) Vand i 1d thu 1-4 1-7 thew 1-10 2:1 thru 2-6 246.1/2-62 blank) 2-7 thru 2-10 2.13 and 2-14 3.27 and 3-28, 3-31 and 332 331.1 and 3-322 3.33 and 3-34 334.1 and 3.342 3.35 thu 3-38 3-38.1/(3.38.2 blank) ‘3:39 and 3-40 340.1 and 3.40.2 3-41 and 3-42 3-45 thru 3-50 3-61 and 3-62 3-81 and 3-82, 3-85 and 3-86 File this change sheet in font of the publication for reference purpotes Remove Pages, None 3.99 theu 3-114 None 3-123 thru 3-126 3137 and 3-138 3147 and 3-148 None 3-189 thru 3-162 3167 and 3-168 None 3-169 and 3-170 None 3-173 and 3-174 4:1/4-9 and 4-10 4-11 thu 4-14 4-33 thea 4-36 451 and 4-52 185 and BG FOL None ‘None Insert pages 3-88,173-882 blank) 3.99 thu 3114 3-114.1/8-1142 blank) 3-123 thu 3126 3-137 and 3.138 3-147 and 3.148 3-148.1 ty 3.148.373.1484 lank) 3-159 theu 3-162 3-167 and 3-168 3-168.1 thru 3-168.4 3-169 and 3.170 3-170.1/(-1702 bank) 3.173 and 3174 4.1/4.9 and 4-10 4-11 thu 4-14 4.33 thu 4.36 451 and 4.52 85 and B6 Fo FOIA Fo32, TM 9-1450-500-20 By Order of the Secretary of the Army: CARL E. VUONO General, United States Army Official: Chief of Staff R.L. DILWORTH Brigadier General, United States Army The Adjutant General Distribution: ‘To be distributed in accordance with DA Form 12-32, Organizational Maintenance Manual, Loader ‘Transporter Guided Missile: XM501E3 (Hawk Guided Missile System).TM 9-1450-500-20 a CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY No.1 WASHINGTON, DC, 1 June 1983 ORGANIZATIONAL MAINTENANCE MANUAL LOADER-TRANSPORTER, GUIDED MISSILE: XMS01E3 (HAWK GUIDED MISSILE SYSTEM) PART NUMBER 11675300 (NSN 1450-00-066-8873) Holes rite 29 June is changed as follows: old pages and insert new pages as indicated below. New or changed material is indicated by a vortical bar inthe margin ofthe page oF poatng band appoate the changed material, ASded or rovaed ilustrations are indicated by a vertical bar adjacent to the illustration identification number. 2. File this change in front of the publication for reference purposes.By Order of the Secretary of the Army: E. C. MEYER General, United States Army : Chief of Staff ROBERT M. JOYCE Major General, United States Army The Adjutant General : Distribution: ‘To be distributed in accordance with DA Form 12-82, Organizational Maintenance requirements for Hawi Improved Missile System.‘TM 9-1450-500-20 WARNING DRY CLEANING SOLVENT P-D-680 Dry cleaning solvent (P-D-680), used to clean parts is TOXIC and FLAMMABLE. 1.WEAR protective goggles and gloves and use only in a well ventilated ares. 2.AVOID CONTACT with the skin, eyes, and clothes. Don't breathe vapors, or smoke near this solvent. 3. DONOT USE near open flame or excessive heat. The flash point for Type No.1 is 100 degrees Fahrenheit (38 degrees Celsius), for Type No. 2 it is 138 degrees Fahrenheit (58 degrees Celsius). 4. IF YOU BECOME DIZZY while using cleaning solvent, get fresh air immediately,and if necessary, seek medical aid. 5, IF CONTACT WITH EYES IS MADE wash your eyes with large quantities of water and get medical attention immediately. CHANGE 2 a/(b blank)‘TM 9-1460-600-20 TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY No. 9-1450-500-20 WASHINGTON, DC, 15 June 1986 ORGANIZATIONAL MAINTENANCE MANUAL LOADER-TRANSPORTER, GUIDED MISSILE: XMSO1E3 (HAWK GUIDED MISSILE SYSTEM) PART NUMBER 11675300 NSN 1450-00-066-8873 REPORTING OF ERRORS . You can help improve this publication. If you find any mis- takes, or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recom- mended Changes to Publication and Blank Forms), or DA Form 2028-2 located in the back of this publication direct to: US Army Tank-Automotive Command, ATIN: DRSTA-MBP, Warren, MI 48090. A reply will be furnished to you. Paragraphs Pages 1. INTRODUCTION Section I. General... ee ee eee eee een ae Let 1-1 II, Description and Tabulated Data ........ 1-6 qt 2. SCHEDULED MAINTENANCE AND SERVICES Section I. Service Upon Receipt of Materiel ....... 2-1 2-1 II, Lubrication Instructions»... 2. ee ee 23 2-3 III, Preventive Maintenance Checks and Services (PMCS)... ee ee eee ee eee 24 24 ‘®This manual supersedes TM 9-1450-500-20, 29 June 1979, including all changes. (Change 2TM 9-1450-600-20 CHAPTER Section CHAPTER Section CHAPTER APPENDIX Section APPENDIX Section INDEX . FOLDOUTS 3. Le I. IIl. Iv. v. vi. vil. VIII. III. Change 4 MAINTENANCE Maintenance Maintenance Systems . Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance Maintenance INSTRUCTIONS of of of of of of of of of of Tachometer and Engine-Transmission Assembly . . Fuel, Air Intake and Exhaust Cooling System... ...... Electrical System ...... : Power Train... . ee. eee Tracks and Suspension .... . Controls and Linkage... .. . Chassis... ee. ee eee Hydraulic Syst Superstructure . . (Cable a eee Troubleshooting .. 2... 161 ee eee eee MAINTENANCE OF AUXILIARY EQUIPMENT Hoisting Devices and Fire Extinguisher... . Winterization Kite ..... eae SHIPMENT AND LIMITED STORAGE ......... REFERENCES MAINTENANCE ALLOCATION CHART (MAC) Introduction Maintenance Allocation Chart ........- Tool and Test Equipment Requirements ..... Remarks . . REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) . . EXPENDABLE SUPPLIES AND MATERIALS LIST Introduction Carrier Schematic Diagram (25 Amp Generator). . Carrier Schematic Diagram (60 Amp Alternator) . Superstructure Schematic Diagram ....... Hydraulic System Flow Diagram... . . Pens Paragraphs Pages 3-1 3-15 3-22 3-27 3-52 3-58 3-69 3-76 3-84 3-95 3-96 3499 bel 4-5 5-1 Al Bel 3-1 3-23 3-28.1 3-31 3-67 3-73 3-84 3-92 3-100 3-113 3-114 3-116 bel ana 5-5 A-1 Be1 Bs B-19 cL D4 Index 1 Fo-1 FO-1A Fo-2 FO-3‘TM 9-1450-600-20 CHAPTER 1 INTRODUCTION ‘Section |. GENERAL 1-1, Scope This manual is for your uée in per- forming organizational maintenance on the Loader-Transporter, Guided Missile, XMSO1E3 (HAWK). 1-2, Maintenance Forms and Records Maintenance forms and records which you are required to use are listed and explained in DA PAM 738-750, |-3. Administrative Storage For Administrative storage require- ments, refer to Chapter 5, 1-4, Destruction of Army Materiel to Prevent Enemy Use Refer to TM 750-244-6 for instructions governing destruction of the vehicle and equipment when subject to capture or abandonment in the combat zone. 1-5, Reporting of Equipment improve- ment Recommendations (E1R’S) Equipment improvement recommendations will be prepared on SF 368, Quality Deficiency Report. Instructions for preparing EIR's are provided in DA PAM 738-750, The Army Maintenance Management System. EIR's should be mailed to the Commanding General, U. S. Army Tank-Automotive Command, ATTN: AMSTA-QRT, Warren, MI 48397-5000. A reply will be furnished to you. ‘Section 11, DESCRIPTION AND TABULATED DATA 1-8. Description 4. General. The loader (fig. 1-1) is a self-propelled, full-tracked vehicle used in and around the missile battery. It is designed for transporting one, two or three missiles between pallet and launcher. Automatic line-up features on the superstructure enable the operator to place the missiles on the launcher in a fire-ready position, on slopes up to 10 degrees. The four-cylinder gas- oline engine has a maximum placarded rpm equivalent to 12.7 mph. An M36. 2-1/2 ton cargo truck is used to tran! port the loader when distance is a fai tor. The loader may be converted into a general purpose crane by utilizing one of the transportation vehicle loa ing ramps and assorted crane accessories. ‘An engine-driven hydraulic pump supplies the hydraulic power for operating the superstructure. All the necessary con- trols for maneuvering the superstructure are located on the hydraulic console adjacent to the operator's seat. A com plete operational description of the loader and its characteristics are con- tained in TM 9-1450-500-10. The follow- ing paragraphs describe the major systems employed in the loader. b. Carrier. The carrier is the mobile mounting base for the hydra lically operated superstructure and its supporting subsystems. Loader power is supplied by a four-cylinder internal combustion gasoline engine, coupled to CHANGE 2 WW‘TM 9-1460-500-20 MISSILE YOKE LATCHTEVERS ASSEMBLY MUFFLER [AIR CLEANER FORWARD | MISSILE SUPPORTS FIRE EXTINGUISHER ROLL CYLINDER: AZIMUTH ELEVATION MAIN, EXTENSION Cylinoex “CHUINGeR sUproR “CyLiNoee Figure 1-1. a three-speed automatic transmission through specially designed adapters. Pressure and temperature sensing elements Provide visual indications of engine- transmission status through associated warning Lights mounted on the operator's instrument panel. (1) Power train. Engine power is transmitted to the transfer transmission through the torque converter and trans- mission and redirected to the differen- tial and drive assembly via the main propeller shaft. Double universal 12 ‘Change 2 HOISTING BEAMS REAR MISSILE SUPPORTS ussite SAFETY STRAPS. HOISTING. BEAM PiNTLE HOOK ENGINE STEERING LEVERS ROAD WHEEL TRANSFER ARM ASS EMBLY.—TAQ76SAIA Loader-Transporter, Guided Missile, XM501E3 joints are used at all coupling points. The differential and drive assembly out- put is distributed to the final drives which transmit the power to the drive sprockets. Brake bands in the differen- tial and drive assembly provide steering and braking control. Excessive heat in the differential is indicated by a heat sensing element coupled to a warning light on the operator's instrument panel. (2) Fuel, air intake, and exhaust system. The fuel system consists of awelded steel gas tank, gage and sending unit, an electric fuel pump, sediment bowl, carburetor, fuel quantity trans— mitter, fuel gage, and associated fuel lines. The 13-U.S. gallon fuel tank is mounted on the left side of the loader directly behind the operator's seat. A screen-type sediment strainer in the filler opening reduces the possibility of contaminated fuel entering the tank. Additional filtering is provided by a Sediment bowl trap installed between the tank and the 24-volt electric fuel Pump. When the master switch and the ignition switch are turned on, the fuel Pump is activated. Filtered air for combustion is provided by an oil-bath, reusable element air cleaner. The air cleaner is mounted on the right fender. A flexible duct directs the filtered air from the air cleaner to the carburetor. The exhaust system is composed of the manifold, muffler, and connecting pipes. This system carries away com- bustion products and minimizes engine noise. The muffler is mounted on the right fender and is equipped with an expanded metal shield over the miffler to prevent accidental burns. (3) Cooling system. Engine cool- ing is accomplished by a forced water circulation system and proper air circu- lation. An engine-driven, seven-blade reverse-pitch fan pulls air across the transmission, and out through the radi- ator core, dissipating accumulated en- gine heat. Water circulation is sus- tained by a belt-driven water pump. Additional engine compartment cooling is provided by a door on the side of the engine hood. Normally, this additional cooling feature is not required unless the ambient temperature exceeds 100°F. Transmission oil is circulated through two small radiator units mounted at the rear of the chassis. A hole in the chassis allows sufficient air to flow through the radiators, maintaining the proper oil temperature. (4) Track and suspension. The loader is equipped with a torsion bar TM 9-1450-600-20 suspension system. Momentary overloads are absorbed by four direct-action shock absorbers mounted on the front and rear road wheels. Center guide, double-pin, rubberized chevrons, endless tracks are driven by sprocket wheels and run on six independently suspended road wheels Track tension is adjustable to compen- sate for wear. A road-wheel arm lockout feature is incorporated into the sus- pension system to provide additional stability when the loader is used as a crane, when fitted with the hoist adapter, or when transporting a pallet. The torsion bar lockout control levers are located on the front of the loader, adjacent to the lifting shackles. (5) Chassis. The basic loader chassis construction consists of welded box-type structural members, steel sheet, and steel plate. (6) Controls. All the necessary controls for operating the loader are located in and about the operator's com partment. These controls consist of steering and braking levers, accelerator pedal, gear selector, choke, hand throt- tle, etc. For a complete description and location of all controls, refer to TM 9-1450-500-10. c. Superstructure. The superstruc— ture is the lifting mechanism of the loader. It consists of the main boom support, index boom, link assembly, transfer arm assembly, yoke assembly, and hoisting beams with missile safety straps. The hydraulically operated superstructure performs the complete missile handling operation. A hydraulic console located to the right of the loader operator contains all the con- trols necessary to index and perform missile transfer. Three hoisting beams are bolted to the yoke assembly which is pivoted to the transfer arm assembly. Latching mechanisms in the hoisting beams are manually actuated for missile latching and released by solenoid action instrument panel or manually by depressing the solenoid Change 2 13‘TM 9-1450-500-20 plunger. Manual release is accomplished through the manual latch release cover located at the forward ends of the hoisting beams. 4. Hydraulic Systems. Power for perstructure operation is provided by an engine-driven hydraulic pump, hydrau- lic cylinders, and associated hydraulic fluid reservoir, filters, valves swivels, lines, fittings, and hoses. The main ofl filter and all manual con- trols and associated components are mounted on a single, hinged cover form ing the hydraulic console. Flexible hoses leading from the console are dis— tributed to the various cylinders. Hy- draulic ofl pressure is registered on the operator's instrument panel and oil quantity is visually monitored through a transparent sight indicator on the out- board side of the fluid reservoir. e. Electrical Systems. A 24-volt, d.c. system supplies electrical current for the loader. Two 12-volt batteries, connected in series, supply electrical energy for the ignition, fuel pump, and starting motor. The major components of the electrical system are the batteries, 14 2 distributor and ignition coil, starting motor, generator/alternator, spark plugs, voltage regulator (with generator only), missile release solenoids, sole- noid valves (hydraulic), switches, accessory equipment, and necessary wir- ing. Electrical accessories consist of headlights, blackout marker lights, stop and tail lights, gages and sending units. Two limit switches and one cut- out switch are mounted on the super- structure to prevent equipment damage and inadvertent release of the missile. f£. Accessories and Auxiliary Equip- ment. A shatter-proof, carbon dioxide fire extinguisher is mounted on top of the right fender. A quick release clamp secures the extinguisher to its mounting bracket. Two ramp assemblies are pro- vided for loading the loader on an M36 cargo truck. (Refer to TM 9-1450- 500-10.) 1-7. Tabulated Data Figure 1-3 shows identification plates and their location. For oper: ting instruction plates and decals refer to TM 9-1450-500-10.Figure 1-2, ‘TM 9-1460-600-20 Loader in Crane Configuration with Hoisting Beam XM15 Attached. (Deleted)‘TM 9-1450-500-20 CYLINDER ASSEMBLY ~ EXTENSION part. CIO semiaLno. Cure ORDNANCE PART NO. CJ ORDER Ho. STOCK No, WeioHT Css PART NAME. PART NO. SERAL NO, DATE OPES HYDRAULIC CYLINDER, ‘AZIMUTH vanteso7 Figure 1-3. Name, Caution and Instruction Plates (Sheet 1 of 5) 16 Change 1‘TM 9-1460-600-20 PART NAME FINAL DRIVE, NAME PLATE LOADER TRANSPORT NAME PLATE. 3702 INSTRUCTION PLATE Figure 1-3. Name, Caution, and Instruction Plates (Sheet 2 of 5)‘TM 9-1450-600-20 REMOVE THIS COVER TO INSPECT AND SERVICE UNIVERSAL JOINTS. aS mars ese ‘TA0RS7O7A, Figure 1-3. Name, Caution, and Instruction Plates (Sheet 3 of 5) 18 Change 4 Google‘TM 9-1450-500-20 ign ace seruc no [ ‘ono PART NO. [ = - : CONTRACT NO. ‘GENERATOR 24 VOLT D.C. RATING TYPE CLASS: re Se AUTO-LITE Seen es Figure 1-3. Name, Caution, and Instruction Plates (Sheet 4 of 5) ‘Change 2 19‘TM 9-1450-600-20 | BRAKE BAND ADJUSTMENT | Use AD UsTING HUTS ee TO COMPENSATE FOR LINING NEAR ‘BRAKES ust Be riba wien CEVERS ARE IN TH NOTCH WARNING DISCONNECT LEADS AT BATTERY ‘BEFORE SERVICING THIS UNIT lO Generaroe recutator 9] VOLT D.C. SPEC.NO, _ORON. NO. REMOVE COVER BRAKE BANDS DIFFERENTIAL ASSY ‘ORD PART NO. #17140 MFG PART NO. 106215 no. 7 TATNG_ MEPS WO, “SERIAL NO. Coo oO NOTE THIS NAME PLATE (S NOT USED (ON LOADER-TRANSPORTERS WITH ALTERNATOR ASSEMBLIES TAORSTI9A Figure 1-3. Name, Caution, and Instruction Plates (Sheet 5 of 5) 1-10 Change 2(2) horsepower.....72 at 4200 rpm Net horsepower. .62.7 at 3600 rpm Compression ratio... : 17.5021 Compression at cranking speed.. 135 to 145 psi Gross torque (max) .124.5 £t-1b at 1800 rpm Displacement....141.5 cu. in. Spark plug gap......0.030 in. Firing order.........1-3-4-2 Distributor point gap...........0.020 in. Timing..6° before top dead center @ 500-550 rpm Exhaust valve clearance (hot)..... 0.015 in. Intake valve clearance (hot)... -0.015 in, 041 system. Type - pressure-fed ‘TM 9-1460-600-20 Pressure (700-800 rpm).......15-30 psi Pressure (1000-1200) rpm)....35-45 psi Filter...disposable cartridge (3) Cooling system. Water type with radiator and fan- Radiator pressure.......7 pei (4) Hydraulic system. Rated flow..3 gpm at 1500 rpm 1-8. Spares, Repair Parts, Special Toots, Special Test, Maintenance and Diagnostic Equip- ment and Other Special Support Equipment Special Tools and Equipment Special tools and equipment especially designed for organizational maintenance, repair and general use with the materiel are illustrated in figure 1-4 and listed in table 1-1. Special tools and equip- ment authorized for organizational main- tenance are listed in TM 9-1450-500-24P which is the authority for requistioning replacements. bd. Spares and Repair Parts. Repair parts authorized to organizational main- tenance for the loader are listed in TH 9-1450-500-24P which is the authority for requisitioning replacements. watTM 9-1450-600-20 MRCTNicAL run CLAMP ASSEMBLY: MOUNTING REMOVER AND REPLACER WRENCH Figure 1-4. Special Tools and Equipment SLING, ENGINE AND TRANSMISSION MOTOR VEHICLE ‘TAM»S000‘TM 9-1460-600-20 Table 1-1. Special Tools and Bquipment 5120-00-708-3254 (7083254) Adapter, mechanical puller To remove torsion bar; used with puller NSN 5120-00-423-1596 in the common mechanic tool kit To install bushings, housing 2. Driver, oil and water line| 5120-00-473-7025 ferrule (7079403) mounting, differential and transfer 3. Gage 5220-00-443-0529 | To check wear limits of drive (11626018) sprocket 4, Remover and replacer 5120-00-991-3150 (10892939) 3940-00-692-9112 To remove or install differential, transfer case or mounts 5. Sling, engine and trans- To replace engine transmission I on motor vehicle (7345279) mount insulators 6. Clamp assembly: 4910-00-799-0018 | To install track track mounting (10943651) 7. Wrench 5120-00-337-9134 | To remove or install cylinder (7084207) head holddown bolts Change 1 1-13/(1-14 blank)Google‘TM 9-1450-500-20 CHAPTER 2 SCHEDULED MAINTENANCE AND SERVICES Section |. SERVICE UPON RECEIPT OF MATERIEL 2-1. Inspecting, Servicing, Installing, Setting Up Instructions a. General Procedures. (1) Lf any exterior surfaces are coated with rust preventive compound, remove it with dry- cleaning solvent, item 19, App. D or mineral spirits paint thinner, item 23, App. D. (2) Read the Processing and Depro- cessing Record for Shipment, Storage and Issue of Vehicles and Spare Engines Tag (DD Form 1397) and follow all precau- tions checked thereon. This tag should be attached to a steering lev.r, the shift lever, or the ignition switch in the operator's compartment. (3) Before starting engine, turn MASTER SWITCH ON and leave IGNITION switch in OFF posi- tion. Turn engine over at least two revolutions with starter to test for hydrosta~ tic lock. This precaution is taken because there may be an excess of preservative oil or other fluids in the cylin der chamber. (4) Follow the general procedures given in paragraph 2-7. b. Specific Procedures. Refer to table 2-1. TM 9-1450-500-10 contains daily preventive maintenance checks and services (PMCS) performed by the operator. 2-2. Equipment Conversion Refer to chapter 4 of this manual for procedures for adapting the loader to crane configuration and installing winterization kits. Table 2-1. Service Upon Receipt Reference Remove Basic Issue Item boxes 2 Restore tension to all drive belts. 3 Remove tape and protective paper from operator's seat. 4 Remove tape and protective paper from instrument panel and hydraulic console. 5 Open Basic Issue Item boxes and inventory con- tents with packing list furnished with each con- tainer. Record missing items. a. Open inner packs and remove packaging material. b. Degrease equipment such as tools, hardware, beam cable, sheaves, and missile handling beam. 24‘TM 9-1450-500-20 Table 2-1. Service Upon Receipt - Continued Action Reference 5 ¢. Stow Basic Issue Items which are not Cont to be installed on the vehicle, in their respective stowage facility. 6 Check radiator coolant. If cooling system has | TM 9-1450-500-10 been drained, fill with proper coolant. 7 Install drive shaft, using hardware in bag Para 3-57 attached to starter. 8 Unpack batteries, add electrolyte, and install, } Para 3-51 noting polarity. 9 Gasoline engines not processed or reprocessed within the time limitation established in the block titled "Reprocessing Cycle on the face of DD Form 1397 will be serviced prior to use as outlined in reference as follows: a. Remove spark plugs from each cylinder. b. Atomize-spray 2 ounces of lubricating oil, item 14, App. D, into each cylinder through the spark plug opening. c. After an interval of 15 minutes, rotate engine with starter for 30 seconds. 10 Install spark plugs, Para 3-6 NOTE If the vehicle has been driven to the using organization, most or all of the foregoing pro- cedures should have been per- formed. oy Tighten cylinder head bolts before starting Para 3-8 engine. See reference for correct procedure. 12 Perform the semiannual preventative mainten- ance service (every 6 months or 150 hours, whichever occurs first) using Equipment In- spection and Maintenance Worksheet, DA Form 2404, as a worksheet. 22 CHANGE2‘TM 9-1450-500-20 Table 2-1. Service Upon Receipt - Continued Reference NOTE Due to internal processing, engine may start hard, smoke excessively, and run errati- cally. However, conditions should greatly improve after five minutes of running time. Failure to obtain full engine power will necessitate per- forming troubleshooting pro- cedure outlined in Chapter 3, section XII. Record all de- ficiencies on DA Form 2404. 13 Lubricate all points of vehicle in accordance with reference regardless of interval. Check processing tag (DD Form 1397) for gearcase (transfer, differential, and transmission) and engine oil. If tag in- LO 9-1450-500-12 dicates oil is of correct viscosity for local operation, check level but do not change engine or gearcase oils. ‘Section Il. LUBRICATION INSTRUCTIONS 3. General Lubricating Instructions c- Reports and Records. @. General. Any special lubricat- ing instructions required for specific mechanisms or parts are covered in the pertinent section. (1) Report unsatisfactory perfor- mance of prescribed petroleum fuels, lubricants, or preserving materials, . using SF 368, Quality Deficiency Report, be ee ees. Service and prepared in accordance with intervals specified on the lubrication DA PAM 738-750. order are for normal operation and where moderate temperature, humidity, and at- mospheric conditions prevail. For lubri- cation procedures and instructions under (2) Maintain a lubrication record unusual conditions, refer to para 2-6. of the loader on DD Form 314, Preventa. tive Maintenance Schedule and Record, I in accordance with DA PAM 738-750.TM 9-1450-600-20 4. Lubrication Order (10). The pertinent Lubrication Order, LO 9-1450- 500-12, prescribes cleaning and lubri- cating procedures according to location, intervals, and the proper materials for the loader. Lubrication will be per- formed in accordance with the lubrica- tion order. Whenever necessary, the operator or user will assist organiza- tional maintenance personnel in lubri- cating the loader. Section III, PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 2.4. General Preventive maintenance is the 8; tematic care, inspection, and service of equipment to maintain it in service- able condition, and to detect fauli and failures before extensive and time- consuming repairs or replacements are required. Before and during the opera- tion of the vehicle, always keep in mind all of the CAUTIONS and WARNINGS. If the equipment fails to operate, troubleshoot with proper equipment and report any deficiencies using the pro- per forms(DA PAM 738-750), The following paragraphs describe the two types of Army preventive maintenance services. @. Daily (Operator). TH-9-1450- 500-10 describes the preventive mainten- ance services performed by the loader operator each day the loader is operated. b. Semiannual (Organizational). This section contains the procedures and instructions necessary to perform semiannual services. These services are performed by organizational main- tenance personnel with the assistance of the loader operator every 6 months or 150 hours, whichever occurs first. 2-5. Intervals Operation under adverse conditions, such as extreme temperature, dust, or mud, may require servicing more frequen- tly. Commanders are authorized to re~ duce the intervals between preventive maintenance services whenever conditions indicate the need. After operation in 2-4 — Change2 water, mud, or loose sand, the loader must be cleaned and lubricated as soon as possible without waiting for the next scheduled service. 2-6. Special Instructions a. Automatically Applied. All of the operating procedures in T™ 9-1450— 500-10 will be followed. Organization- al mechanics must be so thoroughly trained in these procedures that they apply them automatically at all tines in the performance of their dutie: b. Vehicle Cleanliness. The driver should present the vehicle for a sched- uled preventive maintenance service in a clean condition; that is, it should be dry and not caked with mud to such an extent as to seriously hamper inspec- tion and services. However, washing of the vehicle should be avoided inmedi- ately prior to an inspection, since cer- tain types of defects such as loose parts and oil leaks may not be evident immediately after washing. CAUTION Water may enter engine exhaust system when washing vehicle. To prevent this occurrence, tape exhaust outlet before washing vehicle. While wash- ing, do not direct any stream of water into muffler, air cleaner, or engine compartment. c. Plates. Nameplates, caution plates, and instruction plates found in a corroded condition should be thor-oughly cleaned and coated with clea lacquer, item 7, App. D. 4. Services. Organizational main- tenance services are defined by, and restricted to, the following general procedures unless approval to perform services of a higher category of main- tenance has been given by the direct support maintenance unit. (1) Adjust. Make all necessary adjustments in accordance with instructions contained herein. (2) Clean. Clean the unit to remove old lubricant, dirt, and other foreign matter. Special cleaning instructions are given, when necessary, in the pertinent sections. (3) Special lubrication. Perform all special lubrication in connection with the maintenance operations, even though it does not appear in LO 9-1450- 500-12. (4) Service. Servicing usually consists of performing special operations, such as replenish- ing battery water, draining and refilling units with oil, and changing or cleaning the fuel filters, oil filters air cleaner, and elements (S) Tighten. All units should be tightened to torque spec- ified herein, or if not speci- fied, to accepted practice. Use a torque-indicating wrench where specified. Do not over- tighten, as this may strip threads or cause distortion. Tightening includes the cor- rect installation of lock- washers, nuts, lockwire, or cotter pins to secure the tightened nut or bolt in place. (6) Repair. To restore an item to serviceable condition ‘TM 9-1450-500-20 through correction of a spe- cific failure or the unservice- able condition. This includes, but is not limited to, inspec~ tion, cleaning, preserving, adjusting, replacing, welding, riveting, and strengthening. NOTE Welding repairs to superstruc- ture components will be accom- plished only by direct support maintenance personnel . (7) Modification work order ap- plication. Enter all modifica- tion work orders (MWO) appli cable to the equipment on DA Form 2408-5. e. jal Condition: When con- ditions hake Tt -GFFieule to perform the complete preventive maintenance pro- cedures on the vehicle at one time, the procedures can be handled in sections. Plan to complete all operations within, a given week, if possible. All avail- able time at halts and in bivouac areas must be utilized, if necessary, to as- sure that maintenance operations are completed. 2.7. Special Procedures for Semiannual a Preventive Maintenance Services The S preventive main- tenance services insure the correct ad- justment, securing, and assembly of all components of the vehicle. Necessary replacements, cleaning, lubrication, and protection of parts and/or assem blies will be accomplished, as required, to give reasonable assurance of trouble- free operation until the next preventive maintenance service is performed. To insure complete maintenance of the ve hicle, many procedures which are normal operator functions are also included in the S services because of varying con- ditions, such as climate, terrain, and changing assignments of personnel. DA Form 2404, Equipment Inspection and Maintenance Worksheet, Change2 2.5TM 9-1450-500-20 is used by the organizational . 4. mechanic to record periodic inspections and maintenance services performed, faults corrected, and faults which beyond the particular category of m tenance to correct. The item numbers recorded on DA Form 2404 must correspond to the item numbers on the preventive maintenance table. A DA Form 2407 (Main- tenance Request) shall be initiated for repairs required by a repair maintenance category and forwarded with the equip- ment to the supporting maintenance ac- tivity. a) @) G3) b. Vehicle Checks and Service: The organizational preventive mainte- nance checks and services for the vehi- cle are listed in table 2-2, items 1 through 37. Detailed procedures to be followed and certain specific items to be checked are included for each item. ¢. Inspection and Road Test. The driver of the vehicle is often un- avare of defects that have developed gradually in the vehicle. It is, there~ fore, desirable for organizational mail tenance personnel to road test the veh cle as part of the semiannual preventive maintenance service, performing the in- spection and road test specified as items 30 through 32. During and. after road test of the vehicle, any repairs or adjustments necessary to assure operation should be made. Any defect of an item that does not require immedi- ate correction should be noted in DA Form 2404. The defect should be cor- rected later during the after-road-test services. When the tactical situation does not permit a complete road test, perform those services which require little or no movement of the vehicle. When a road test can be performed, the distance should be limited to sufficient length to completely check vehicle oper- tion. Perform the before-operation service specified in TM 9-1450-500-10 and correct any deficiencies to insure that the vehicle is in a safe operating condition for road testing. During road test, listen for unusual noises from components of the vehicle. fe 26 Change? After-Road-Test Services. Maintenance services. Per- form after-road-test services listed as items 33 through 37. Correct any defects noted during road test and inspec- tion. Lubrication. Inspect and lubricate if necessary, in accordance with LO 9-1450-500- 12. Final road test. After all services and inspections on the vehicle have been com pleted, take the vehicle on @ road test of sufficient length to insure that opera- tional difficulties have been corrected. Pay particular attention to those items which were found defective initially Correct any remaining prob- lems noted during this test run. e. Vehicle Corrosio (1) During normal semiannual in- spection, check all parts and surrounding areas inspected for corrosion. Corrosion damage is divided into the following stages. Stage 1. Red, black, or white corrosion deposits on surface, etching pitting. Base metal is sound. Stage 2. Powdered, granular or scaled condition. Base metal is sound. Stage 3. Surface condition and corrosion deposits are similar to Stage 2, except that metal in the corroded area is unsound and small pin holes may be present.Stage 4. No metal remains at point of severest corrosion. Corrosion holes in the area, or metal is com- pletely missing. (2) Corrosion areas in Stages 1 and 2 shall be cleaned, primed, and painted with required final top coat (in accordance with TB 43-0213). In the areas where Stages 3 and 4 are, the corrosion must be completely removed or parts/assemblies replaced with new parts/assemblies if repair is not economical. f. Hoisting Beam Missile Latches Preventive maintenance checks and services on these _latches (Sequence number 34a) must still be done on a 75-hour/90 day basis. 2-8. Painting, Spot Painting and Marking (stencilling) 4, General. Instructions for the preparation of the materiel for paint- ing, method of painting, and material to ‘TM 9-1450-600-20 be used are contained in TM 43-0139. Instructions for camouflage painting are contained in FM 5-20. b. Spot Painting. Spot painting and marking (stencilling) of tactical vehi- cles will be performed under the control of the organizational maintenance per- sonnel except’ in cases where the driver is also a mechanic or mechanic's helper. c. Painting of Vehicle. Painting of a complete vehicle will be performed by direct support maintenance units. d. Stencilling Vehicle Markings. Stencilled markings must be renewed per— iodically because of weathering or repainting. To stencil markings use black (flat) on contrasting background. The legend "U.S. Army" and vehicular registration numbers shall be of a size to fit the vehicle (1, 2, 3, or 4& inches). Change 4 2-6.1/(2.6.2 blank)LL —- _—_S——t—“‘_‘_OCS~S*s ‘TM 9-1450-500-20 Table 2-2. Preventive Maintenance Checks and Services Oe Organizational Maintenance Semiannual Schedule] Vehicle Table Item to be inspected Sequence number Paragraph Procedure reference Lubrication Lubricate loader. 10 9-1450-500-12 for interval and grade of lubricant NOTE Lubrication should be per- formed in sequence and in conjunction with checks and services listed below. Check engine and transmis sion oil levels, and cool- ant level prior to first item requiring engine operation. Road vheels Replace wheels that show evidence of | Para 3-63 tire separation, or if damage is sufficient to cause thumping during use. Tighten loose road wheel re- taining nuts to 75-80 ft-1b torque. Check for leaks. At each semiannual service or whenever the track is removed, check the wheel bearings for looseness and end play. Replace shock absorbers that have severe fluid leaks or damage suf- ficient to impair operation. In- spect shock absorber bushings by shaking shock absorber; defective shock absorber will rattle or have excessive play. Replace bumper stops that have gouges, cuts or excessive wear. Pry up each road wheel to detect broken torsion bars. If road wheel can be lifted easily, the torsion bar is broken. Replace sprockets that have bent ‘or broken teeth. Inspect sprocket hubs for cracks and if detected replace sprocket. No welding re- pairs are authorized. Axle and hub assembly Para 3-67 Shock absorbers, Para 3-66 bushings, and bumper stops Torsion bars Para 3-64 Drive sprocket Para 3-59‘TM 9-1450-500-20 Prevent ive Maintenance Checks and Services - Continued Table 2-: Item to be inspected Paragraph reference Sequence number Procedure Replace track sections having less | Para 3-60 than 1/8 inch of rubber chevron re- maining. Inspect track for worn bushings or damaged links which allow free play. Inspect track sections for missing center guide caps and replace sections as ap- plicable. Replace worn or damaged track blocks and connectors. Tighten loose wedge-nut bolts. With vehicle in unloaded condition, have operator move vehicle approx- imately 15 feet and coast to a stop on a smooth level surface with gear shift lever in neutral. Do not apply brakes. Measure clearance between upper track and top of cen- ter road wheel. Adjust track if clearance is less than 1/2 inch or more than 3/4 inch. With loader on relatively level ground and superstructure in transport position, operate lock- out levers to be sure the front stop levers move over the suspen- sion arms of the forward road wheels. The rear stop lever hooks should engage the underside of the suspension arms of the center road wheels. Readjust rear stop lever hooks or replace missing or dam- aged components as necessary. Secure and/or replace loose or miss- ing access covers. Remove boom support access cover and water drain covers to drain any accumu- lated water. Track tension Para 3-61 Suspension lock- Para 3-68 out mechanism 10 ‘Access covers (under hull) Fig. 3-78 NOTE If water or contaminants’ are present, clean and dry lower support area and check for excessive play. If excessive play is found, notify Direct Support Maintenance. ul Towing pintle | Check towing pintle and towing hooks | Para 3-82 and towing for secureness of mounting. Ob- hooks serve if pintle jaws lock satisfactorily. 2-8 CHANGE 2Table 2-2. TM 9-1450-500-20 Preventive Maintenance Checks and Services - Continued Item to be inspected Headlights, taillight stoplights, blackout drive lights, and blackout markers Fire extinguisher Hydraulic reservoir Differential and final drives Batteries Procedure With the driver assisting, test operation of lights. Repair and/ or replace broken, cracked, and discolored lens and lamps. Adjust headlights if not correctly aligned. WARNING Handle charged cylinders with care. Do not bump, jar or drop. Remove and weigh portable fire ex- tinguisher. The cylinder must be recharged or replaced if the weight loss exceeds 10 percent of the dif- ference between the full and empty weight marked on the cylinder. Record the weight and date. Clean and service hydraulic reser voir filter and air filter. Fill reservoir to FULL level mark on sight indicator. Check oil levels. Fill different and final drives. Tighten final drive mounting bolts (two places), if loose, to 175 - 200 ft-1b torque Replace leaking seals and/or gas~ kets on differential and final drives. Make sure that jack screw through final drive clip contacts chassis side rails (tighten to 1 - 2 ft-1b torque). Clean batteries, supports, and retainers. Repaint with either epoxy coating kit (NSN 8010-00-959-4661) or Bituminous Coating Compound (NSN 8030-00-290-5141). Repair bent or broken supports and retainers. Replace batteries that leak or have cracked cases. Remove caps and clean the vents. Elec- trolyte level should be up to split ring as indicated on filler plugs. Test specific gravity with hydro- meter. Clean cable terminals, bolts and posts. Tighten terminal clamps and hold-downs carefully to avoid damage to batteries. Grease terminals lightly. Paragraph reference Para 4-4 Refer to TM 9-1450-500-10 page 1-7 Para 3-91. Refer to 10 9-1450-500 w12 for grade of lubricant. Refer to 10 9-1450-500 -12 for grade of lubricant. Para 3-56 and 3-57. Para 3-49 CHANGE 2 29‘TM 9-1450-500-20 Table 2-2. Preventive Maintenance Checks and Services - Continued Sequence number 17 Oil levels, engine and transmission 18 Engine Cooling system 20 Antifreeze 2-10 CHANGE 2 NOTE If engine and transmission are scheduled for oil change, drain only when hot after operation. Engine. Assure vehicle is on level ground and check engine oil. Iflevel is below FULL mark, add oil until level is at FULL mark. ‘Transmission Check transmission oil level with engine running and shift lever in N (neutral). Oil -must be at operating temperature. NOTE With engine at operating temperature the fluid should not exceed “F" (FULL) mark. ‘When fluid exceeds “F” mark ,it will foam and form bubbles. ‘Tighten loose connections and mounting bolts. Replace cracked or frayed engine belts. Place a straightedge over the fan/water pump to generator drive belts (between the fan/water pump pulley end the generator drive pulley). Move generator until both drive belts have a measured deflection of 1/2 inch at the midpoint between the fan/water pump pulley and the generator pulley. Have driver start engine Observe if it develops adequate cranking speed and starts without excessive noise. Listen for unusual noises thet might indicate improper operation or lack of lubrication Look for excessive exhaust smoke. Every other 6-Month service perform complete engine tune-up. Record ‘each cylinder’s compression reading on DA Form 2404. ‘Tighten hose clamps and loose mounting bolts. Replace hoses that are cut, cracked, ot deteriorated. Inspect cooling system for leaks. Check coolant level Test radiator antifreeze coolant for proper engine protection. Paragraph reference WO 9-1450-500-12 Oil level should be Just below or at the “Fr mark on the dipstick Table 3-5 for troubleshooting. Para 3-6 for tune-up. Para 3-2 for removal, and installation of fan belts. Para 3-25 for adjustment of fan belts, Para 3-23. Refer to: TM 9-1450-500-10TM. 9-1450-500-20 Table 2-2. Preventive Maintenance Checks and Services - Continued Paragraph reference Sequence number Exhaust system Tighten connections and clamps if there are indications of exhaust leaks. Replace damaged or deteri- orated exhaust system components. Tighten connections that show evi- dence of leaks. Check operation of fuel shutoff valve. Clean fuel sediment bowl. Clean and service air cleaner and air duct. Make sure that all joints, seals, and connections are tight and not leaking. Replace air intake hoses that are cut or cracked. Tighten loose mounting bolts Check for leaks. Repair and/or adjust as required, shift linkage that is bent or improperly adjust- ed. Look for oil cooler hoses that are split, cracked or deteriorated. Replace transfer transmission case seals that are leaking. Fill with oil to check plug level. Tighten loose mounting bolts. Replace worn universal joints and broken locking plates. Tighten all bolts which secure universal joints to yokes Tape frayed insulation. Replace de- fective connectors and missing chassis gromments or clamps. Repair and/or replace torn seat cushion, back rest and replaceable seat pad. Inspect seat pad elastic cord for elasticity. Check seat adjusting mechanism. Start engine and allow to warm up for several minutes. Check for smooth operation of throttle, choke, and accelerator. 22 Fuel system Para 3-16 - 3-19 23 Para 3-20 and LO 9-1450-500- 12 Air cleaner 24 Transmission Para 3-2 - 3-4 25 Para 3-53 - 3-55 Transfer trans- mission, un: versal joints, and propeller shafts. 26 Wiring Para 3-50 harness 27 Seat Para 3-81 28 Para 3-70 - 3-75 Controls, throttle, choke, and accelerator ROAD TEST NOTE Road test should be suf- ficient length to bring loader components to normal operating temperatures 2‘TM 9-1450-500-20 Table 2-2. Sequence Item to be number inspected 29 Instruments, gages, and warning lights Prevent ive Maintenance Checks and Services - Continued Paragraph Procedure reference ROAD TEST - Continued Tighten loose electrical connections | Para 3-40 and mountings. Repair or replace broken or inoperative instruments, gages, and warning lights. Check instruments, gages, and warning lights for normal indication. a. Battery -~ generator indicator. Tn green zone. b. Hydraulic oil pressure gage. 2,900 to 3,200 psi. NOTE The pressure and tempera~ ture warning lights are not illuminated during normal operation. Press TEST push- button on instrument panel to test lamps. Engine low oil pressure warning light comes on when engine oil| pressure is below 8 psi. . Transmission low oil pressure warning light comes on hen transmission oil pressure is below 32 psi. Transmission high temperature warning light comes on when the transmission oil tempera~ ture reaches 285°F. Differential high temperature warning light comes on when the differential oil tempera- ture reaches 285°F. . Hydraulic oil high temperature warning light comes on when the hydraulic oil temperature reaches 165°F. Engine coolant high temperature warning light comes on when the engine coolant temperature reaches 245°F. Tachometer and hourmeter should operate without fluctuation or| unusual noises.TM 9-1450-600-20 Table 2-2. Preventive Maintenance Checks and Services - Continued Item to be inspected ROAD TEST Paragraph reference Sequence number Continued 30 Operate steering levers and observe | Para 3-70 if steering response is satisfac- tory. With loader operating at a moderate speed and the steering levers released, note if there is any tendency to drift or pull to one side. Release accelerator and apply brakes, observing if the loader stops effectively without pulling to one side. With the loader stopped on an incline, pull back on steering levers and de- press lock buttons. Brakes must lock securely and hold loader in place. With brake levers fully locked there must be 2 minimum of two notches of travel remaining. Shift through full range of the transmission to see that the link- age does not bind and the loader responds satisfactorily. Examine all visible controls for correct |justment and any restriction or binding action. Test engine for normal acceleration and power in each transmission range. While testing in H (hilly) range, accelerate rapidly noting any tendency for the engine to mis- fire or stall. Listen for unusual noises or vibrations that might in- dicate loose, damaged, or worn parts. Steering and brakes a1 Table 3-5 (Troubleshoot- ing) Transmission 32 Engine performance Table 3-5 (Troubleshoot- ing) AFTER ROAD TEST 33 | Wheel hubs and shock absorbers tely after road test, feel all wheel hubs cautiously for noticeable variation of tempera- ture between like components. An overheated hub indicates a mal- adjusted, inadequately lubricated, or damaged bearing. Shock absorber! may feel warmer than the hull. 243TM 9-1450-600-20 Sequence number 24 34 3ha 35 Table 2-2. Preventive Naintenance Checks and Services - Continued Item to be Paragraph inspected reference Superstructure Hydraulic controls and cylinders AFTER ROAD TEST - Continued Replace limit switches that are Para 3-48 damaged or inoperative. Tighten loose connections. Replace mis- sile support pads that are damaged Check condition and of extension cylinder gimbal fitting. Check rubber boot for cracks, cuts or deterioration. NOTE Distance between missile latches on hoisting beams must be checked and adjusted after 75 hours of operation, or every 90 days, whichever occurs first. NOTE Coordinate with di- rect support maintenance per- onnel for measurement, ad- justment and replacement of latches. Coordinate with direct support maintenance personnel for yearly aline- ment and proof-loading tests to determine if the equip- went is properly alined, structurally adequate and satisfactory for field use. CAUTION Para 3-84 - 3-94 Do not actuate roll control when extension cylinder is in fully extended position. Operate hydraulic levers to activate extension, azimuth, elevation, and roll cylinders to extreme positions Check for smooth operation. Tight- en, repair, or replace connections where leaks are evident. If hy- draulic cylinders and hoses are damaged or leaking fluid, notify direct support maintenance.‘TM 9-1450-600-20 Table 2-2. Preventive Maintenance Checks and Services - Continued Sequence number 35 (Cont) 36 37 Item to be inspected | Decals, instruction plates, sten- cile markings, and paint Hoisting beam M15 Procedure WARNING © Hydraulic system must be checked semianually by a superstructure settlement (droppage test). a. Load three dummy missiles in transport position, six to twelve inches off the missile support arm pads. b. Place hydraulic control levers in neutral (centered). c. Turn engine off. Superstructure must not settle (drop) more than two inches in 1 minute. If superstructure set- tlement exceeds this allowance, notify direct support maintenance. Elevation cylinder assemblies must be inspected semi-annually by direct support maintenance per- sonnel. This inspection prevents these assemblies from failing prematurely, Premature failure of an elevation cylinder assembly can be extremely hazardous, damag- ing equipment or injuring person- nel. Coordinate with direct sup- port maintenance personnel for this important inspection. Replace decals and instruction plates: restencile markings that are not legible. Clean and paint bare spots in the painted surface that might permit reflection, rust or corrosion. Before attching to missile, examine assembly for worn, damage, or missing components and replace as required. Change 4 z Paragraph reference Refer to TH-9- 1450-500-10 and para 1-7 for correct data plate locations. Para 4-3 2-16/(2-16 blenk) ff‘TM 9-1460-500-20 CHAPTER 3 MAINTENANCE INSTRUCTIONS ‘Section |. MAINTENANCE OF ENGINE-TRANSMISSION ASSEMBLY 3-1. General a. The engis (fig. 3-1) consists of a four-cylinder gasoline engine, fluid coupled to a three-speed automatic trat A functional description TH 9-1450-500-10. b. Deleted. s given in 3-2, Engine~Transmission Assembly (Deleted) Transmission and Torque Converter Replacement (Engine-Transmission Assembly Removed) (Deleted) Figures 3-1 through 3-6 are deleted. 1-4. Transmission and Torque Converter a. Removal, Deleted. | b. Installation. Deleted. c. Adjustment (fig. 3-7). (1) Intermediate band adjustment. (a) Clean band adjusting screw area. Loosen locknut which secures intermediate band adjusting screw. (b) Using a torque wrench, tight- en adjusting screw to 10 ft-1b torque. 301/3-9TM 9-1450-500-20 ‘VACUUM LINE TYPICAL VACUUM TEST ‘SET UP VACUUM UNIT LOW-REVERSE BAND ‘ADJUSTMENT LOW-REVERSE BAND ADJUSTING SCREW INTERMEDIATE BAND. ‘ADJUSTING SCREW LINKAGE ‘SPRING ADJUSTING SEAT ‘SCREW Oh ‘THIS CLEARANCE CHANGED BY ADJUSTING SCREW (CUTAWAY VIEW OF VACUUM UNIT TT TT Figure 3-7. Transmission Band Adjustments 310 Change 1(c) Back off adjusting screw (a) exactly 1-3/4 turns. (4) Hold adjusting screw from (e) turning and tighten locknut to 35-45 ft-1b torque. (2) Low-reverse band adjustment. (a) Clean band adjusting screw area. Loosen locknut which secures low-reverse band adjusting screw. (b) Using torque wrench, tighten adjusting screw to 10 ft Ib torque. ‘TM 9-1450-500-20 Adjust engine idle speed to 700-750 rpm. If engine idle speed cannot be adjusted to specified rpm by adjustment at idle adjustment screw on carbu- retor, check throttle and downshift linkages for bind- ing. If linkages are sati factory, check for vacuum leaks in transmission dia- phragm unit (step (4)) and its connecting tubes and hoses. Check all other vac~ uum lines for leaks. (4) Vacuum diaphragm leakage (c) Back off adjusting screw exactly three full turns. (a) (4) Hold adjusting screw from turning and tighten locknut to 35-45 ft-1b torque. @) (3) Control pressure check and vacuum diaphragm unit adjust- ment. When the vacuum di phragm unit is operating prop- erly and the downshift linkage is properly adjusted, trans- mission shifts should be posi- tive and without excessive slippage. If the shifts are excessively harsh or the trans- mission slips during shift points, use the following pro- cedure to determine if engine, transmission, linkage, or dia~ phragm unit is at fault. (c) (a) test. Remove vacuum unit from transmission. Using a vacuum pump and vac- uum gage, adjust vacuum reg- ulator control until vacuum gage indicates 18 inches with end of vacuum hose blocked off. Connect vacuum hose to vac~ uum unit. If gage indicates 18 inches, vacuum diaphragm is not leaking and unit is satisfactory for reinstal- lation. As vacuum hose is removed from vacuum unit, hold fin- ger over end of vacuum unit control rod. When hose is (a) Connect a vacuum gage to disconnected, the internal transmission at vacuum unit spring of vacuum unit should (fig. 3-7). push control rod outward. (b) Connect a pressure gage to control pressure outlet at (5) Control pressure check at transmission sending unit. engine idle. (c) Apply and lock brakes, place (a) Install pressure gage and shift lever in N (neutral), and start engine. vacuum gage as specified in (3) (a) and (b). 311‘TM 9-1450-500-20 (b) Place shift lever in N (neu- tral) and adjust engine idle speed to 700-750 rpm. Vac- uum gage should indicate a minimum of 18 inches at sea level. NOTE If vacuum reading is lower than 18 inches, engine malfunction is indicated or there is leak- age in vacuum line. Refer to table 3-5 and correct malfunc tion before continuing. At altitudes above sea level, it may not be possible to obtain 18 inches of vacuum at engine idle. At these altitudes with idle vacuum less than 18 inches, refer to table 3-2 to determine idle speed control pressure in forward driving ranges D (drive) or H (hilly). (c) Transmission control pres- sure gage readings should be as specified when the shift lever position and vacuum readings are as spe- sified in table 3-1. Table 3-1. Table 3-2. Engine Vacuum/Control Pressure Control pressure (psi) Engine vacuum (inches) (at idle) 17 55 to 62 16 55 to 68 15 55 to 74 14 . 55 to 80 13 55 to 87 12 55 to 93 ir 55 to 99 CAUTION While making following pressure tests, do not hold throttle open for more than five seconds in each detent position. Be- tween each test, move shift lever to N (neutral) and run engine at 1000 rpm for fifteen seconds to cool the converter. (4) With engine idling, depress and release accelerator pedal quickly and observe vacuum gage. Amount of vacuum should decrease and increase with changes in throttle openings. If vacuum response to changes in openings is Transmission Control Pressure/Manifold Vacuum (Zero Output Shaft Speed) Engine speed or Throttle Control Test no. manifold vacuum position |Shift lever| pressure (psi) 1 Idle - above 18 inches | Closed N,D, H |55 to 62 of vacuum R 55 to 84 2 17.5 to 16.5 inches of | As required | D, H pressure increase vacuum over idle 3 10 inches of vacuum | As required | D, H 93 to 110 4 3 inches of vacuum As required | D, H 138 to 166 R 213 to 242 3-12(6) too slow, the vacuum line to diaphragm unit may be restricted. Vacuum diaphragm adjustment. The vacuum diaphragm has an adjusting screw in the vacuum hose connecting tube. The ‘TM 9-1450-500-20 35. Replacement of Engine-Transmission Mount Insulators NOTE The following special tool is re~ quired to perform the removal and installation procedures: inner end of the screw/bears Part against a plate which in turn Special tool NSN number bears against the vacuum dia — phragm spring. All control Sling, engine 3940-00-692-9112 7345279 pressure readings if slightly high or low, may indicate the need of adjustment to correct a particular shift condition. For example, if the pressure a nd trans mission mo- t or vehicle Remove engine hood cover and pro- peller shaft rear access cover. jebnLOdaneheslochvscuum|us2) 120) Remove carburetor air-intake psi_and the pressure at 3 in- sleeve fron carburetor. ches of vacuum was 170 psi, and upshifts and downshifts were harsh, a diaphragm adjust- ment to reduce the diaphragm spring force would be required. Conversely, if pressure read- ings are low, the line pres- sure does not start to build up until vacuum drops to 15 inches, an adjustment to in- crease diaphragm spring force is required. To increase control pressure, turn the adjusting screw in (clockwise) and out (counterclockwise) to decrease control pressure. One com- plete turn of the adjusting screw will change idle line control pressure approximately 2to 3 psi. After adjustment is made, install vacuum line and recheck the pressures, particularly the pressure at ce. NOTE ‘The engine-transmission assem- bly is supported by two insula~ tor assemblies and chassis mounts for the engine and one insulator assembly and chassis mount for the transmission (fig. 3-8). Disconnect the transmission yoke from universal joint. CAUTION Use sling to be sure engine does not shift when removing bolts from mounts. Remove bolts and replace an insu- lator assembly under engine. Re- place bolts. Remove nut and washer from center bolt under transmission. 10 inches of vacuum. Do not f. Elevate transmission to raise adjust the diaphragm to pro~ bolt to provide clearance and vide pressures below those remove insulator assembly. given in table 3-1 in order g. Remove four nuts, washers and to change shift feel. This could result in soft or slip- ping shifts and damage to the transmission. screws. assembly. Replace insulator assembly and attaching hardware. Lower engine-transmission assem- bly and install washer and nut. Install removed parts in the re- verse order of removal. Remove insulator Change 1 313Insulators Transmission Mount 11 Figure 3-8. Replacement of Engine - 3143-6. Engine Tune-Up General. Minor engine tune- up consists of services to the engjne electrical and fuel sys~ tems as outlined in steps b through i. Perform air-cleaner service, battery service and lubrication in accordance with TM 9-1450-500-10 before proceed- ing with engine tune-up. Major tune-up consists of these serv- ices and the services outlined in paragraphs 3-7, 3-8, and 3-9. Spark Plug Service. (1) Remove engine hood cover, en- gine hood assembly, and radia- tor grille (fig. 3-54). (2) Remove engine side panel (fig. 3-54). (3) Warm up engine to normal oper- ating temperature to facili- tate compression testing. (4) Remove spark plugs and inspect for general condition and gap setting. If general condition of electrode is good and is not burned or pitted, clean plugs and re-gap to 0.030 inch. If electrode is burned or pitted, obtain new plug(s), check gap setting, and proceed to paragraph c. Compression Test. Perform the compression test (para 3-7) before installing spark plugs. Spark Plug Wiring. Inspect spark plug cables for cracked or oil-soaked insulation. Inspect connectors for corrosion. Replace if required. Install spark plug cable nuts finger tight on elec~ tronic ignitor (distributor) cover and tighten 1/4-turn with a wrench. Connect cables to spark plugs. e £ TM 9-1450-600-20 Electronic Ignitor (Distributor) Component Inspection. Inspect cap and cover, ignitor module, or capacitor and breaker points, for general condition, cracks, corrosion or foreign matter. Breaker points surfaces should be clean, flat and alined. Clean and replace components as necessary. NOTE An interchangeable electronic ignitor may be provided in place of the distributor points, rotor, cap, condenser, coil, and cam. If so, delete step f. Breaker Point Adjustment. (1) Remove cover, cap and rotor. (2) Manually, crank engine until breaker points are open with breaker lever on high point of cam. (3) Loosen locking bolt and turn adjusting screw until gap is 0.020 inch; tighten bolt and recheck gap. Readjust if required. Ignition Timing Adjustment. Ignition timing is accomplished by three separate and consecutive procedures; breaker point adjust- ment (step f preceding), approxi- mate timing by electronic ignitor (distributor) positioning (fig. 3-9), and precise timing by using an adapter, timing light, and a tachometer (fig. 3-10). (1) Approximate timing by elec- tronic ignitor (distributor) positioning. (a) Set electronic ignitor (dis- tributor) to approximate timing as shown in figure 3-9. 315TM 9-1450-500-20 Figure Distributor Positioning 12 vout 3-16 Figure 3-10. Ignition Timing Using Timing Light and Adapter |. Approximate Timing by Hookup for Precise (b) (ec) (a) (e) (£) Mark the position of the No. 1 spark plug cable on electronic ignitor (distrib- utor) base. Accomplish the breaker point adjustment as specified in step f (1) through (3) pre- ceding, if applicable. Do not install cap and cover after adjusting breaker points. Rotate crankshaft until rotor is positioned toward No. 1 spark plug cable mark and pointer on timing gear cover and notch on crankshaft pul- ley are alined. (Refer to fig. 3-9.) Slowly rotate distributor counterclockwise until breaker points just start to open, if applicable. Tighten electronic ignitor (distributor) to adapter mounting screw to a snug fit. Install cap and cover assem- bly. This procedure alone is not adequate for good engine performance. Perform the precise timing procedure following. (2) Precise timing. Refer to figure (a) (b) 3-10 for correct hook-up for ignition timing. Remove No. 1 spark plug cable from spark plug; place timing light adapter on spark plug, and attach spark plug cable to timing light adapter. Connect timing light leads to timing light adapter, ground, and battery.h. (c) Attach tachometer to primary connector and ground. Start engine and adjust engine idle speed to 450 to 500 rpa. (d) With engine idling, direct timing light at timing pointer on timing gear cover. (e) Slowly rotate electronic ignitor (distributor) until timing pointer and crank- shaft pulley notch are alined. When timing marks are alined, firing will take place at 6 degrees before top dead center of piston travel. When this alinement obtained, tighten elec- tronic #gnitor (distributor)- to-adapter mounting screw. (£) After tightening mounting screw, check timing to deter- mine that tightening has not disturbed alinement. Increase engine speed while directing timing light to notch and pointer. Notch should move away from pointer if centrifugal advance is functioning. Disconnect all timing devices and in- stall spark plug cable. Fuel System Check (fig. 3-11). (1) Install pressure gage at fuel pump outlet. (2) Turn MASTER SWITCH to ON, then turn IGNITION switch to ON and check pressure indication on pressure gage. Pressure must be 4 psi minimum. Check system for leaks. Carburetor Adjustment (fig. 3-12). Adjustment of the carbu- retor is accomplished by means of the idle mixture adjusting TM 9-1450-600-20 PRESSURE GAGE "AND LINE Figure 3-11. Fuel System Pressure Test MIXTURE ‘ADJUSTMENT rte seco ADJUSTMENT Tanes10 Figure 3-12. Carburetor Adjustment 317‘TM 9-1450-500-20 screw and idle speed adjusting screw. Make all carburetor ad- justments with engine running at normal operating temperature: (1) Idle mixture. Turn idle mixture adjusting screw in (clockwise) until it just touches needle seat or engine begins to lag; then turn out (counterclockwise) until en- gine operates smoothly (ap- proximately one full turn). (2) Idle speed. The idle speed adjusting screw on the throttle lever should be set to idle engine at 700 to 750 rpm. 3-7. Cylinder Compression Test 318 Start engine and run for a mini- mum of 1/2 hour at 1200 rpm. Turn IGNITION switch OFF. NOTE Before making compression test, adjust valve-stem-to-rocker- arm clearance to 0.015 inch. Remove spark plugs. Pull throttle control out to wide open position. Make sure choke control is pushed in all the way against panel. Insert compression gage into spark plug holes, beginning with No. 1 cylinder, and crank engine with starter. Record highest compression reading from each cylinder on DA Form 2404. Repeat test on each cylinder, cranking engine same number of times for each cylinder as was required to obtain highest read- ing on the No. 1 cylinder. Compare the compression pressures of the cylinders. Normal com- pression pressure is from 135 Change 1 Figure 3-13. to 145 psi at a starter speed of 185 rpm. The minimum compres- ion allowable is 90 p: ings of cylinder pressure should be uniform within 10 pounds A low compression reading on two adjacent cylinders indicates the possibility of a leak from one cylinder to the other at the cyl- inder head gasket. The leakage may be caused by improperly tight- ened cylinder head bolts or a faulty cylinder head gasket. Tighten the cylinder head bolts to 60-65 ft-lb torque in the sequence shown in figure 3-13. Adjust valve-to-rocker-arm clear- ance and check cylinder compres~ sion again. If compression is still low on adjacent cylinders, there may be leakage because of a faulty cylinder head gasket. If leakage is present, install new cylinder head gasket. TIGHTENING SEQUENCE OF BOLTS Taowse14 Cylinder Head Bolt Tightening Sequence If compression readings are uni- formly low, the low compression may be due either to leakage at the valves or piston rings, or incorrect valve timing. If these faults are suspected, notify di- rect support maintenance person- nel. If compression pressures of cyl- inders vary more than +10 psi, or are lower than 90 psi (after corrections indicated by the vac~TM 9-1450-600-20 uum test have been made), notify (1) Tighten bolts to 10 ft-1b direct support maintenance per- torque. sonnel. (2) Tighten bolts to 45-50 ft-lb i. If any cylinder reads over 145 torque. psi, excessive cylinder deposits may be present. Notify direct (3) Tighten bolts to 60-65 £t-1b support maintenance personnel. torque. j. If any cylinder reads less than (4) Recheck bolts to 60-65 £t-1b 90 psi, insert engine oil into torque. spark plug hole and crank engine one revolution. Repeat compres- b. When replacing rocker arm cover, sion test. If reading does not use new gasket. increase, valve trouble is indi- cated. If reading increases, 3.9, Manifold Vacuum Test piston rings may be defective. Notify direct support maintenance a. Remove the pipe plug installed personnel. in the top rear of the intake manifold. Insert adapter on end k. Using new gasket, reinstall of vacuum gage hose. Be sure spark plugs and tighten to 27- all connections are tight, as 30 £t-1b torque. even a slight leak will result in a false reading. 1, Remove rocker arm cover and tight- en cylinder head bolts as speci b. Start engine and run at idling fied in paragraph 3-8. Replace speed until minimum operating rocker arm cover. temperature (160°F) is reached. Check carburetor adjustments as NOTE specified in paragraph 3-6. When cylinder head bolts are c. With the engine idling at 600 tightened, valve-stem-to- rpm, vacuum gage should show a rocker-arm clearance must be steady reading of from 17 to 21 adjusted to 0.015 inch. inches of mercury. As a further check, open and close the throt- 3-8. Cylinder Head Bolt Tightening tle quickly. If the engine is in good condition, vacuum should The following special tool is required drop to 2 inches at wide open to remove, install or tighten cylinder throttle and quickly return to head bolts. approximately 25 inches at closed throttle. If this action Special Part is not obtained, worn piston tool NSN number rings, or an abnormal restriction in the carburetor, air cleaner, Wrench — 5120-00-337-9134 7084207 or exhaust system is indicated. a. Cylinder head bolt tightening d. Incorrect valve timing is indi- cated by a steady reading of ap- ek ecCOne Lt sues Rim ne Cucaste De proximately 10 inches of mercury. Using wrench, special tool (7, fig. 1-4), tighten head bolts in sequence shown in figure 3-13. Weak valve springs are indicated by a rapid fluctuation of the Change 1 319‘TM 9-1450-600-20 3-10, gage hand when the engine is ac- celerated. If a valve sticks at times only, the vacuum drops 4 or 5 inches momentarily when the valve sticks. Fluctuation of the gage hand between 15 and 19 inches indicates that the valve guides are worn. A slow movement of the gage hand between 12 and 16 inches indicates poor carburetion. Leakage at the carburetor gasket is indicated by a low steady read~ ing. Leakage of compression be- tween the cylinders is indicated by the gage hand drifting regu- larly between 5 and 19 inches. Worn or poorly fitted piston rings or scored pistons and cylinder walls are indicated by the gage hand remaining lower than normal, at approximately 15 inches. NOTE The above readings are for sea level operations. At higher elevations, the vacuum gage readings are lowered approxi- mately 1 inch of mercury for each 1000 feet increase in altitude. After performing manifold vacuum test, reinstall 1/4-inch pipe plug into the intake manifold. Tighten plug. Valve Adjustment Operate engine for a minimum of 30 minutes at 1200 rpm to warm engine to normal operating tem- perature. Allow engine to idle and remove rocker arm cover. Insert feeler gage between valve stem and rocker arm pad and ad- just to 0.015 inch. NOTE If torque required to turn an adjusting screw is less than 3 Et-1b, notify direct support maintenance personnel. d. Coat one side of valve rocker arm cover gasket with oil-re ant cement and lay cemented side of gasket in cover. Install cov- er, seating gasket evenly. In- stall two rubber seals, seal re- tainers, and nuts on studs and tighten to 3/4 ft-lb torque. 3-11. Oil Filter Replacement a. Using a strap wrench, turn oil filter assembly counterclockwise to remove. Discard old oil fil- ter assembly. NOTE If a strap wrench is not avail- able, fabricate one from a piece of belting and other com mon materials. b. Coat seal on new filter element assembly with engine oil, turn filter assembly clockwise until hand tight, then, using a strap wrench, advance an additional 1/2 turn. Add engine oil, start engine and check for oil leaks from sealing surface or line. 3-12, Oil Pressure Indicator Line Replacement a. Remove pressure indicator line and cap ports. Remove caps, and install new pressure indicator line. Add engine oil if necessary, start engine and check for oil leaks3-13. Intake Manifold a. Removal (fi qa) (2) 3) (4) (5) (6) q@ (8) (9) qo) any (12) 3) 14). Remove engine hood cover and engine hood and grille. Disconnect exhaust pipe from plenum and muffler. Remove hose and carburetor-to-air- cleaner elbow. Remove engine side panel (fig. 3-54). Disconnect choke cable from carburetor. Remove throttle control return spring. Remove carburetor connecting link. Disconnect fuel line from carburetor. Disconnect distributor vent line and carburetor vent line from carburetor fitting. Remove two nuts, washers, and lockwashers which secure car- buretor to intake manifold. Remove return spring bracket, carburetor and gasket. Bend up tab locks on two bolts which secure intake manifold center to cylinder head; remove bolts and tab Lockwasher. Disconnect vacuum line from forward end of manifold (fig. 3-14). Disconnect line and remove metering valve (fig. 3-14). Disconnect ventilation lines and unscrew ventilation fitting (fig. 3-14), qa) as) TM 9-1450-500-20 Remove four bolts and washers which secure intake-manifold upper flanges to cylinder head and remove intake manifold. Remove intake manifold gaskets. b. Installation. NOTE Clean all gasket mounting surface! qa) (2) (3) (4) (5) (6) @ (8) (9) Install new intake manifold gaskets. Position intake manifold and install four bolts and washers to secure upper flanges to cylinder head. Do not tighten bolts. Install two center bolts and tab lockwashers. Tighten cen- ter bolts to 12-16 ft-lb torque. Tighten four intake manifold bolts to 23-28 ft-1b torque. Install ventilation fitting, connect vacuum line, metering valve, and ventilation lines (fig. 3-14). Using a new carburetor gasket, position carburetor and return spring bracket on the intake manifold and secure in place with two each washers, lock- washers, and nuts. Connect distributor and car- buretor vent lines to carbure- tor fittings. Connect fuel line to carbu- retor. Install carburetor connecting link, throttle control return spring, and choke cable. 321‘TM 9-1450-500-20 VENTILATION INTAKE 2 VENTILATI LUNES Figure 3-14. Intake Manifold Replacement (10) Install engine side panel (fig. 3-54). (11) Install carburetor-to-air- cleaner elbow and hosi (12) Connect exhaust pipe to plenum and muffler. (13) Install engine hood and grille, and engine hood cover (fig. 3-54). 3-14, Exhaust Manifold a 1 (Fig. 3-15). Figure 3-15. Exhaust Manifold Replacement (1) Remove grille, engine hood cover, and hood (fig. 3-54). (4) Remove engine side panel and (2) Disconnect exhaust pipe from exhaust pipe (fig. 3-18). plenum and muffler (fig. 3-18). (5) Remove plenum and gasket. (3) Remove engine side panel (fig. 3-15) and exhaust pipe. (6) Remove alining bolt and washer.(7) Remove four bolts and lock- washers which secure mounting clamps; remove clamps. (8) Remove exhaust manifold. tion. NOTE Clean all mating surfaces to make sure of adequate sealing. (1) Place exhaust manifold on mounting saddles and aline bolt hole on outlet flange bracket with tapped hole in cylinder block. NOTE A gasket between manifold and cylinder block is not required. (2) Install lining bolt and wash- er finger-tight. ‘TM 9-1450-500-20 (3) Install two exhaust manifold retaining clamps, one on each end of manifold. Install two bolts and tab lockwashers on each clamp and tighten to 10- 16 ft-1b torque. Tighten ex- haust and outlet flange alin- ing bolt to 20-30 ft-1b torque. Bend tabs on each of four tab lockwashers against bolt heads to secure bolts. (4) Install plenum and new gasket (fig. 3-18). (5) Install intake manifold (fig. 3-14) and carburetor (fig. 3-16). (6) Install engine side panel (fig. 3-54). (7) Install exhaust pipe to plenum chamber and muffler. (8) Install engine hood, cover and grille (fig. 3-54). ‘Section II. MAINTENANCE OF FUEL, AIR-INTAKE, AND EXHAUST SYSTEMS 3-15. General a. This section contains removal and installation procedures for compo- nents of the fuel system, air-intake system and exhaust system (fig. 3-16). b. Fuel System (fig. 3-17). The components making up the fuel system include the carburetor and carburetor controls, fuel tank, fuel pump, sedi- ment bowl, fuel gage, fuel gage sending unit, fuel lines, and associated elec- trical connections. c. Air-Intake System. The air- intake system consists of the air clean- er air-intake sleeve and hose. d. Exhaust System (fig. 3-18). The exhaust system consists of the muf- fler, exhaust pipe, plenum and shields. 3-16. Carburetor a. Removal (fig. 3-16). (1) Remove engine hood cover and engine hood and grille. (2) Disconnect exhaust pipe from plenum and muffler. (3) Remove hose and carburetor- to-air-cleaner elbow. (4) Remove engine side panel (fig. 3-54). (5) Disconnect choke cable from carburetor. (6) Remove throttle control return spring. 323TM 9-1450-500-20 ¢ 324 AIR CLEANER Figure 3-16. (7) Remove throttle connecting link. (8) Disconnect fuel line from carburetor. (9) Disconnect distributor vent line and carburetor vent line from carburetor fitting. 10) Remove two nuts, washers, and lockwashers which secure carbu- retor to intake manifold. Remove return spring bracket, carburetor, and gasket. Dis card old gasket. Installation. Install carbu- retor by reversing the sequence of the removal procedure. Fuel, Air-Intake, and Exhaust System Components 3-17, Fuel Pump a. Removal (fig. 3-17). qa) (2) (3) @) Remove battery cover (fig. 3-55) and disconnect battery ground (negative) cable (lead) at battery negative post (fig. 3-2). Remove propeller shaft rear cover (fig. 3-55). Disconnect electrical connec~ tor (circuit 77) from fuel pump. Disconnect fuel lines. In- stall protective caps on lines and open ports.‘TM 9-1450-500.20 screw 9 crowno iso JL nse ® TA0%5818 Figure 3-17. Fuel System Component Replacement 3-25jl ‘TM 9-1450-600-20 (5) Remove two screws and flat 3-19, Fuel Tank washers which secure fuel pump, filter, and mounting bracket a. Removal (fig. 3-17). to fuel tank. Remove pump. WARNING NOTE Verify that ché is free of { If a new pump is not to be in~ fuel vapor. stalled immediately, replace filter and bracket assembly (1) Drain fuel tank through bottom using same attaching hardware. access opening, after removing plate (fig. 3-55). b. Installation. Install the fuel pump by reversing the se- (2) Remove propeller shaft rear quence of the removal procedure. cover (fig. 3-55). ¢. Testing. Refer to paragraph 3-6h. (3) Remove battery cover and dis- connect battery ground (nega- tive) cable (lead). Sh? (4) Remove fuel pump and fuel fil- ,—. ter bracket (para 3-17 and a. Removal (fig. 3-17). batty WARNIN( (5) Disconnect electrical leads Verify that chassis is free of from fuel gage sending unit. GO (6) Remove three bolts and flat washers which secure tank to (1) Verify that MASTER SWITCH is mounting bracket. in OFF position. (7) Remove fuel tank. CAUTION Handle tank carefully so as not to damage sending unit Nore installed in tank. (2) Remove propeller shaft rear cover (fig. 3-55). (3) Disconnect inlet and outlet fuel lines at fuel filter. b. Installation. Install the fuel tank by reversing the se- quence of the removal procedure. After tank installation i pleted, install dr: check operation of sending unit and fuel gage. It will be necessary to remove two capscrews, fuel pump and mounting bracket for filter removal. (4) Unscrew filter from mounting bracket. b. Installation, Install the fuel 3-20. Air Cleaner filter by reversing the sequence of the removal procedure. After installation, pressurize fuel a. Removal (fig. 3-16). system and check for leal (1) Loosen hose clamp which securesTM 9-1450500-20 hose assembly to air cleaner, (a) Saw off the 5/8-inch tube flush and disconnect hose. (2) Remove four screws and lock- washers which secure air cleaner to mounting bracket. Remove air cleaner. with the air bonnet extension (fig. 3-17.1, view a). (b) With fingers, gently remove the remaining tubing from inside the extension without damaging the b. Modification of New Air Cleaner eresreso NOTE (c) Using hand file, remove all burrs from around the hole ‘Air cleaner, NSN 2940-00-678-4253 where the tube was located. must be modified per procedure listed below before installing (a) Remove the paint from area around the hole in the ex- ‘The following tools and materials tension; then clean the are required to modify the air extension. cleaner: (e) Place the I-inch by 1 1/2- Part Anches 20 gauge sheet steel Tools NSH number plate over the hole and solder to the extension. (fig. 3-17.1, File, Hand 5110-00-241-9152 view B). Make certain the seal Frame, Rand does not leak. Hacksaw 5110-00-289-9657 Blade, Hacksaw 5110-00-237-8107 Soldering Iron Materiole ‘Acid Core Solder 3439-00-184-8960 Plate, 1 inch by 1 1/2 inches Manufactured from 20 gauge sheet steel 9515-00-230-6650 Plug, Pipe . 1/8 inch 4730-00-788-5959 Primer 8010-00-161-7425 Enamel, Non 8010-00-080-2173 Bake Dry, Black (1) Remove the air cleaner top and the air bonnet: (2) Alter air bonnet extension at GGG-F-451 (3) Alter air cleaner cover as follow (a) Saw 1 inch off the 3/4-inch tube that extends from the air cleaner top (fig. 317.1, view C). @Q-S-571 (b) Clean the area around the 3/4- inch tube; then solder shut the hole (fig. 317.1, view D). (4) Install the 1/8-inch pipe plug in Q-8-698 tapped hole (fig. 3-17.1, view E). (5) Install air cleaner cover and air bonnet (fig. 317.1, view E). TT-P-636 (6) Paint soldered areas with primer and then with black enamel. ‘TT-£-529 or qiie-gg5 + ‘Installation. Install the air cleaner by reversing the sequence of the removal procedure. d. Servicing. Service the air cleaner in accordance with TH 9-1450-500-10. Change2 3.27‘TM 9-1450-500-20 AIR CLEANER ‘AIR CLEANER A smsonter exrension Baca stvawen use 3/4INCH TUBE ‘AIR CLEANER COVER ‘VBANCH PIPE PLUG ‘AIR CLEANER COVER 3:28 Change 2 ‘TARC08A Figure 3-17.1. Modification of New Air Cleaner3-21, Muffler and Exhaust System Components a. Removal (fig. 3-18). (1) Remove muffler guard. (2) Remove engine hood cover (fig. 3-54). (3) Remove four locknuts and four flat washers which secure both retaining strips of the muf- fler. Remove retaining strips. (4) Remove clamps which secure muffler assembly to flexible pipe. Remove muffler assembly and gasket. (5) Remove four screws and flat washers which secure plate ‘TM 9-1450-500-20 and gasket to side panel assem- bly. Remove plate and gasket. (6) Remove clamps retaining flex- ible pipe to plenum assembly. (7) Remove flexible pipe and gasket. Installation. Install muffler and exhai t system components by reversing the sequence of the removal procedure. NOTE Use new gaskets and make sure that all gasket mounting sur- faces are clean before insta: lation. Section Ill, MAINTENANCE OF COOLING SYSTEM 3-22. General This section contains the removal and installation procedures for all the components in the loader cooling system (fig. 3-19). The cooling system consists of a radiator, water pump, fan, two fan belts, thermostat, hoses and clamps. 3-23. Redistor a. Removal. (1) -Remove engine hood cover (fig. 3-54). (2) Remove right drive shaft cover (fig. 3-55) and radiator grille (fig. 3-54). 3) (4) (5) (6) a) Remove propeller shaft rear cover (fig. 3-55). Remove engine hood (fig. 3-54). Remove engine hood support frame (fig. 3-54). Remove engine access cover (fig. 3-55) and drain radiator and engine. (Engine drain cock is located on left side of engine.) Loosen hose clamps which secure upper and lower hoses to radi- ator. Slide clamps back and remove hoses from radiator. ‘Change 1 328.1TM 9-1450-600-20 ~y BEER TY LW a pmsnenca NTO S Tamnssi9 Figure 3-18. Exhaust System Component Replacement 3-28.2 ‘Change 1(8) (9) (10) When installing hose, make sure pump drive belt waswes 2) uray Pigure 3-19. Remove hex nut, flat washer, and lockwasher which secure top of radiator to insulator assembly. Remove two nuts, two flat washers, two spacers, four insulators and two bolts which secure bottom of radiator to support brackets. Remove ra- diator and shroud assembly. Remove six capscrews and lock- washers to separate shroud from radiator and remove shroud. NOTE lower radiator hydraulic oil is not in con- tact with hose. nose FAN BOUT 4) be 1A095820 Cooling System Component Replacement Installation. Install the radiator by reversing the sequence of the removal procedure. After installation is complete, close radiator and engine drain cocks and fill cooling system in accord- ance with TM 9-1450-500-10. Start the engine and check cooling sys- tem for leaks. Check coolant level and add coolant as required. 3-24, Thermostat qa) (2) Removal (fi 19). Remove engine hood cover and engine hood and grille (fig. 3-54). Remove engine access cover (fig. 3-55).‘TM 9-1450-500-20 (3) Drain radiator. Loosen upper hose clamps and remove hose. (4) Remove cable clamp which se- cures fuel line to electronic ignitor(distributor) vacuum line cable clamp (if neces- sary). (5) Disconnect fuel line at carbu- retor to provide access to thermostat housing bolts (if necessary). (6) Remove two bolts and lockwash- ers which secure thermostat housing to engine block. Re~ move housing, gasket and thermostat. b. Installation. Install the ther- mostat by reversing the sequence of the removal procedure. After installation, operate engine to warm engine coolant and check thermostat operation. Check cool- ant system for leaks. NOTE Use new gaskets and clean all gasket mounting surfaces before installation. 3-25, Fan Belts Removi (1) Remove hydraulic pump belt (para 3-92). (2) Loosen generator belt tension adjustment nut (fig. 3-22); pivot generator toward engine and remove fan belts. Installation. Install the fan belts by reversing the sequence of the removal procedure. ¢. Belt Tension Adjustment. Pivot 326. generator back from engine allow- ing 3/8-inch to 1/4-inch deflec- tion in fan belts (fig. 3-22). Tighten generator belt tension adjustment nut. Fan Blade and Water Pump Removal (fig. 3-19). (1) Remove radiator (para 3-23). (2) Remove fan belts (para 3-25). (3) Remove four screw and washer mblies which attach fan blade and water pump pulley to water pump. Remove fan blade and water pump pulley. (4) Remove radiator lower hose from pump. (5) Remove three bolts and lock- washers which attach water pump to cylinder block. Re- move water pump and gasket. Installation. Install the fan blade and water pump by reversing the sequence of the removal pro- cedure. NOTE Use new water pump gasket and make sure that all gasket mounting surfaces are clean before installation.‘TM 9-1450-500-20 Section IV. MAINTENANCE OF ELECTRICAL SYSTEM 3-27. General This section describes and illus- trates the cable assemblies, components and circuits used in the loader. Each major circuit or wire is physically identified by a metal band at its func— tional or terminal end. Tables 3-3 and 3-4 are numbered listings of all the circuits, plus origination and termina— tion point for each circuit. For a detail tracking of each lead, refer to figures FO-1 and FO-2. This section pertains to removal and installation Procedures for major electrical compo- nents. Repair of components at the direct support level of maintenance is indicated, where applicable. 3-28. Electrical Circuits a. General. Pin-to-pin routing of electrical wiring is illustrated in fig- ures FO-1/FO-1A and FO-2 in schematic form. Figures 3-20, 3-20A, and 3-21 locate and identify (by reference designator) the wiring harnesses, cable Brief functional descriptions of the loader electrical circuits are given in the following Paragraphs. FO-1 and FO-2, located in the back of this manual, show the electrical sche- matic diagrams of the carrier and super- structure. b. Starter Circuit. The starter circuit consists of the starter motor, starter solenoid, starter relay, two 12-volt batteries, master switch, starter switch, and neutral start switch. The circuit is completed and power will flow from the batteries to energize the starter relay when the following conditions exist: Shift lever N (neutral) MASTER SWITCH ON Starter switch Energized ¢. Generator/Alternator Cire: The generator/alternator circuit con— sists of two 12-volt batteries, gener- ator/alternator, separate voltage regu- lator used with generator only, master switch, coil, battery-generator/alter- nator indicator, circuit breaker, igni- tion switch, and interconnecting wir- ing. The engine-driven generator/alter- nator converts mechanical energy into electrical energy. Output current is controlled by a voltage regulator and registers on the indicator. The voltage regulator is a separate assembly with the use of a generator. The alternator has a built-in voltage regulator com- bined as one assembly. The circuit is energized simultaneously with engine operation. The battery-generator/alter- nator indicator registers in the green area if the battery voltage is up to specifications with the IGNITION switch ON and engine not operating. After the engine is started, the indicator pointer should remain in the green area, thus indicating the generator/alternator is operating properly. If the battery- generator/alternator indication is in the red area with the IGNITION switch ON and engine not operating, the batteries are not up to their specified voltage. If the battery-generator/alternator indicator pointer is in the red area with engine operating, check the generator/alternator belt for slippage. 4. Engine and Transmission Warning Indicator Circuits. The warning indi- cator circuits consist of pressure switches, indicator lights, high temper ature sending units, and interconnecting wiring. When the MASTER and IGNITION switches are ON, circuits to the TRANS and ENG LOW OIL PRESS indicators are completed. The indicator lamps remain on until the engine is operating and oil pressures build high enough to actuate the pressure switches and turn off the associated warning lamp. The engine must not be operated with a warning Light on. Change 2 331‘TM 9-1450-500-20 e. Differential and Hydraulic Fluid Warning and Indicator Circuits. The warning indicator circuits consist of temperature-sensitive sending units, indicator lights, and interconnecting wiring. The indicator lights in the warning circuits will not come on unless the fluid temperatures rise above normal and actuate the associated sending unit. Do not operate the engine with a high temperature warning indication. f£, Fuel Level Indicator Circui The fuel level indicator circuit con- sists of the ignition switch, fuel gage, sending unit, circuit breaker, and interconnecting wiring. A float- controlled sending unit in the fuel tank varies its resistance depending on the fuel level in the tank. The resultant voltage is applied to the fuel gage, thus indicating the actual fuel level. g- Lighting Circuits. The service Light circuits consist of the light selector switch, dimmer switch, two stoplight switches, taillights, drive lights, blackout light, marker Lamps and interconnecting wiring. Power is distributed to the various lights, via the light selector switch. The dimmer switch is used to select the headlight filaments, providing high and low beams. Two series-connected, normally open, switches are used in the stoplight cir- cuit. When both braking levers are pulled full back, the switches are closed, completing a circuit to the stop lights. h. Missile Latch and Release Cir- cuits. The missile latch and release circuits consist of solenoids, indicator lights, a relay switch, circuit 332 Change 2 limit switches, a latch release switch, and interconnecting cabling and wiring. The missiles are latched to the hoisting beams manually. Operating the latch lever on the hoist- ing beams to the latched position closes a switch and completes a circuit to the MISSILE LATCHED indicator lights. When the missile(s) are released from the hoisting beams, another switch is closed completing a circuit to the MISSILE RELEASED indicator lights. The missiles may be released individually or collec- tively by actuating one, two, or three of the CIRCUIT BREAKER switches and tripping the MISSILE LATCH RELEASE switch. Limit switches are incorporated in the circuits to prevent accidental or premature release of the missiles until the superstructure and missiles are properly positioned on launcher or pallet. i. Reduced Pressure, Azimuth and Roll, and Starter Dump Valve Solenoid Circuits. The hydraulic system uses seven valves which are operated by elec~ trical solenoids. The reduced pressure control solenoid circuit consists of five solenoids, two series-connected limit switches, circuit breaker, relay, latch release switch, reduced pressure indicator light, reduced pressure switch, and interconnecting wiring. The azimuth and roll control solenoid cir- cuit consists of a solenoid, limit switch, circuit breaker, ignition switch, and interconnecting wiring. hydraulic dump valve solenoid circuit consists of a solenoid, starter relay, neutral start switch, starter switch, and interconnecting wiring. For a func~ tional description of the above cir- cuits, refer to Chapter 3, section IX. The‘TM 9-1450-500-20 ble 3-3. Carrier Electrical Circuits Circuit number Description 1 Generator connector 10A3A3P2 pin B to voltage regulator connector 10A3A2P1 pin B. 1X Alternator IGN connector 10A3A3P2 to connector 10A3A3J1 pin B through I ‘10A3A3P2. 2 Generator connector 10A3A3P2 pin A to voltage regulator connector 10A3A2P1 pin A. x Alternator POS terminal to alternator connector 10A3A3J1 pin A. ' 28 Generator connector 10A3A3P2 pin C to voltage regulator connector 10A3A2P1 pin C. 2x Alternator POS terminal to alternator connector 10A3A3J1 pin C. t 5 Voltage regulator connector 10A3A2P1 pin A to battery positive terminal lead (circuit 6). 6 Battery positive terminal to starter terminal 10A3A2E2. 7 Battery negative terminal to master switch 1QA3A6P1. 8 Voltage regulator connector 10A3A2P1 pin B to distribution box connector 10A3A5P28 pin S. ax Alternator connector 10A3A2P1 pin B to distribution box connector 10A3A5P28 fl pin S through 10A3A2P2/10A3ASP11. 8A Distribution box connector 10A3A1J1 pin § to battery-generator indicator, Post A. 8B Junction of circuit 8A with circuits 8C, 8D, and 8E. 8c Distribution box connector 10A3Al1J1 pin S$ circuit 8A to 10A3A1J1 pin cir- cuit 12. 8D Distribution box connector 10A3A1J1 pin S$ circuit 8A to ignition switch 10A3A1S1 pin A. 8E Junction of circuit 8B to BAT-GEN IND 10A3A1M2. 10 Voltage regulator connector 10A3A2P1 pin C to distribution box connector 10A3A5P28 pin 0. 10X Alternator connector 10A3A2P1 pin C to distribution box connector 10a3a5P28 pin 0 through 10A3A2P3/10A3A5P12. 10A, Distribution box connector 10A3AlJ1 pin O to main power feed circuit breaker 10A3A1CB2. 10B Main power feed circuit breaker 10A3A1CB2 to ignition switch 10A3A1S1 terminal B. 11A Ignition switch 10A3A1S1 terminal C to main power feed circuit breaker 1OA3A1CB2. 12 Ignition coil 10A3L& to ignition ewitch 10A3A1S1 terminal A. a Starter switch 10A3S2 connector 10A3A5P30 to neutral start switch 10A3S11, connector 10A3A5P4. 15 Distribution box main power feed circuit breaker 10A3A1CB2 to light switch 10A3A1S4 pin F. 16 Light switch 10A3A1S4 pin M to dimmer switch 10A3S1 pin G. wv Dimmer switch 10A3S1 pin F to high beam terminals of right (10A3ASP3) and left (10A3A5P22) service headlights. 18 Dimmer switch 10A3S1 pin E to low beam terminals of right (10A3A5P2) and left (10A3A5P23) service headlights. 19 Light switch 10A3A1S4 pin D to blackout drive light terminal 10A3ASP24. Change 2 332.1‘TM 9-1450-500-20 Table 3-3. Carrier Electrical Circuits - Continued Circuit number Description 20 Light switch 1OA3A1S4 pins T and U to marker lamps 10A3A5P1 and 1OA3ASP25. 208 | Jumper from connector 10A3A1J1 pin T to pin U. 21 Light switch 1OA3AIS4 pin H to left tail, stop, and marker light con- nector 10A3ASP15. 22 Light switch 10A3A1S4 pin C to left tail, stop, and marker light con— nector 10A3A5P13. 23 Light switch 1OA3A1S4 pin N to left tail, stop, and marker Light con- nector LOA3ASP9. 2m Circuit 20 and 24 junction 10A3A1J1 pin V and pin T. Pin V and pin Z to left and right tail light connectors 10A3A5P14 and 10A3A5P10. 24B | Jumper from connector LOA3A1J1 pin Z to pin V. 27 Fuel gage to indicator lights and azimuth circuit breaker 10A3ALCB3 (circuits 76 and 77A junction). 274 | Indicator lights and azimuth circuit breaker 10A3A1CB3 (circuit 505 junction) to DIN-BRT control 10A3A1R1 pin 1. 27D | Distribution box TB1 terminal opposite terminal 6 to DIFF HI TEMP indicator lamp DS8. 27 | Distribution box TB1 terminal opposite terminal 6 or 11 to TRANS HIGH TEMP indicator lamp DSS. 27G | Distribution box TB1 terminal opposite terminal 11 to TRANS LOW OIL PRESS indicator lamp DS4. 27H | Distribution box TB1 terminal opposite terminal 11 to ENG LOW OIL PRESS indicator lamp DS1. 273 | Distribution box TB1 terminal opposite terminal 6 to HYD HIGH TEMP indi- cator lamp DS9. 27K —_| Distribution box 7Bl terminal opposite terminal 6 to WATER HIGH TEMP indicator lamp DS12. 27L | Test light switch 10A3A1S3 terminal 2 to distribution box TB1 terminal opposite terminal 6. 28 Fuel gage sending unit connector 10A3A5P20 to distribution box connector 10A3A5P28 pin R. 284 | Distribution box connector LOA3AIJ1 pin R to fuel gage 10A3AIML. 33 Engine water temperature sending unit 10A3S9 to distribution box connector 10A3A5P28 pin J. 33A | Distribution box connector 1OA3A1J1 pin J to 33B circuit opposite ter- minal 2. 33B | Distribution box terminal opposite terminal 2 to WATER HIGH TEMP indicator lamp DS12. 34 Engine low oil pressure sending unit 10A3S7 to distribution box connector 10A3A5P28 pin E. 34A | Distribution box connector 1OA3A1J1 pin E to 34B circuit opposite ter- minal 15. 34B | Distribution box terminal opposite terminal 15 to ENG LOW OIL PRESS indi- cator lamp 10A3A1DS1. 37 Main power feed circuit breaker 10A3AICB2 to auxiliary power output re- ceptacle 10A3A1J4. 3322 ‘Change 2‘TM 9-1450-500-20 Table 3-3. Carrier Electrical Circuits - Continued Circuit number Description 40 Light switch 10A3A1S4 pin B to instrument panel light 10A31DS13. 57 Distribution box to ground. 68 Battery jumper cable. 72 Transmission low oil pressure sending unit 10A3S8 to distribution box connector 10A3A5P28 pin F. 724 | Distribution box connector 10A3AlJ1 pin F to 72B circuit opposite ter- minal 12. 728 | Distribution box TBI terminal opposite terminal 12 to TRANS LOW OIL PRESS indicator lamp 10A3A1DS4. 7m Starter dump valve connector 10A3A5P21 pin B to neutral start switch connector 10A3A5P33. 744 | Starter dump valve connector 10A3A5P21 pin A to starter terminal 10A3ASES. 75 Light switch 10A3A1S4 pin A to connectors 10A3A1J1 and 10A3ASP28, pin X to 10A3A5P17 and 10A3ASP18, back to connector 10A3A5P28 pin Y. 75D | Light switch 10A3A1S4 pin K to distribution box connector 10A3A1J1 pin Y. 76 Ignition switch 10A3A1S1 terminal D to indicator lights and azimuth circuit breaker LOA3AICB3. 7 Fuel pump 10A3A7 to distribution box connector LOA3A5P28 pin D. 774 | Distribution box connector 10A3A1J1 pin D to indicator lights and azi- muth circuit breaker 10A3A1CB3. 79 Fuel tank to ground. 80 Master switch 10A3S3 to starter switch 10A3S2. 81 Starter terminal 10A3ASE3 to neutral start switch, connector 10A3A5P32. 100A | Circuit 459P junction connector 10A3A5P8 to distribution box connector 10A3A5P27. 100B | Distribution box connector 10A3A1J3 to missile release relay terminal Cl. 327 | Transmission oil temperature sending unit 10A3S6 to distribution box con- nector 10A3A5P28 pin G. 327A | Distribution box connector 10A3A1J1 pin G to distribution box TB1 327B circuit opposite terminal 10. 3278 | Distribution box TB1 terminal opposite terminal 12 to TRANS HIGH TEMP indicator lamp DS5. 327H | Hydraulic oil high temperature sending unit 10A3S10 to distibution box 327J circuit opposite terminal 5. 3275 | Distribution box TBl pin opposite terminal 5 to HYD TEMP HIGH indicator lamp DS9. 328 | Differential oil high temperature sending unit 10A3S12 to distribution box connector 10A3A5P28 pin H. 328A | Distribution box connector 10A3A1J1 pin H to distribution box TBl 3288 circuit opposite terminal 7. 3288 | Distribution box TB1 terminal opposite terminal 7 to DIFF HIGH TEMP indicator lamp Ds8. 459P | Junction of circuit 5 and circuit 6 to connector 10A3A2P4. 500AB | Roll lock-out relay 10A3A1K2 pin Xl to missile latch release switch 10A3A182; junction to circuits 500V and 577A. Change 2 333TM 9-1450-500-20 Table 3-3. Carrier Electrical Circuits - Continued Circuit number Description S00AC | Roll lock-out relay 10A3A1K2 pin Bl junctions with circuit 500B, and 500AD 500K 500W 500X S00¥ 500z 505 505K sil 521 531 550 550A, 550L 551 556 560 572 573 573A 574 574A 575 576 576A 5768 34 missile release and hydraulic actuator circuit breaker 10A3A1CB1 to the index boom limit ewitch 10A3S14 NC pin through connector 10A3AL0P1, pin B of the distribution box, connector 10A3A10P2 and 10A3411J1 pin 8, and connector 10A3A11J3 and 10A3A12P1 pin A. Roll lock-out relay 10A3A1K2 juiper from pin Bl to pin Al Jumper from distribution box connector 10A3A1J2 pin A to pin C. Jumper from distribution box connector 10A3A1J1 pin A to 10A3A1J2 pin M. Jumper from distribution box connector 10A3A1J1 pin B to pin A. Reduced pressure control valve connector 10A3A5P29 pin B to distribu- tion box connector 10A3A5P28 pin A. Distribution box connector 10A3A5P28 pin B to reduced pressure switch connector 10A3A5P34 pin B. Indicator lights and azimuth circuit breaker 10A3A1CB3 to distribution box connector 1OA3A1J2 pin R. Jumper from distribution box connector 10A3A1J1 pin C to connector 10A3A1J2 pin P. Distribution box connector 10A3A1J2 pin N to ground. Distribution box connector 10A3A1J2 pin S to ground. Distribution box connector 10A3A1J2 pin E to ground. Distribution box connector 10A3A1J1 pin h to ground. Reduced pressure control valve connector 10A3A5P29 pin A to distribu- tion box connector 10A3A5P28 pin h. Azimuth and roll control valve connector 10A3A5P5 pin to distribution box connector LOA3ASP28 pin C. Distribution box connector 1OA2A1J1 pin j to ground. Battery-generated/alternator indicator to ground. Azimuth and roll control valve connector 10A3A5P5 pin B, through con- nector 10A3A5P28 and 10A3A1J1 pin k, to ground. Instrument panel light TEST switch 10A3A1S3 pin 3 to ground Distribution box TB1 terminal opposite terminal 1 to distribution box connector 10A2A1J1 pin c. Distribution box connector 10A3A5P28 pin c to reduced pre connector 10A3A5P34 pin C. Distribution box TB1 terminal 1 to TEST light switch 10A3A1S3 terminal 7. Distribution box TB1 terminal 1 to HYD SYSTEM REDUCED PRESSURE indicator lamp DS14. HYD SYSTEM REDUCED PRESSURE indicator lamp DS14 to ground. Roll lock-out relay 10A3A1K2 pin X2 to ground Junctions with ground circuit 576 of the roll lock-out relay 10A3A1K2 pin X2, and through distribution box connector 10A3A1J5 pin E. Junctions with ground circuit 576A, through distribution box connector 10A3A1J5 pin G. ure switch Change 2‘TM 9-1450-600-20 Table 3-3. Carrier Electrical Circuits - Continued Circuit number Description 576¢ | Roll lock-out valve 10A3L6 connector 10A3ASP37 pin A and roll lock-out valve 10A3L7 connector 10A3A5P38 pin A, to distribution box connector 10A3A5P39 pin EB. 576D | Elevation lock-out valve 10A3L4 connector 10A3ASP35 pin A and elevation lock-out valve 10A3L5 connector 10A3ASP36 pin A, to distribution box connector 10A3A5P39 pin G. 577 | Roll lock-out relay 10A3A1K2 pin B2, to distribution box connector 10A3A1J5 pin D. 577A | Missile latch release switch terminal junctions with circuits 5O0AB and 500V and connects to distribution box connector 10A3A1J5 pin F. 5778 | Roll lock-out valve 10A3L6 connector 10A3A5P37 pin B and roll lock-out valve 10A3L7 connector 10A3A5P38 pin B to distribution box connector 10A3A5P39 pin D. 577¢ | Jumper circuit between Elevation lock-out valve 10A3L4 connector 10A3A5P35 pin B and Elevation lock-out valve 10A3L5 connector 10A3A5P36 pin B, to distribution box connector 1OA3A5P39 pin F. 577BX | Roll lock-out relay 10A3A1K2 jumper circuit from pin B2 to A2. ‘Change 2 3-34.1/(3-34.2 blank)‘TM 9-1450-500-20 Table 3-4, Superstructure Electrical Circuits Circuit number 1006 1016 1026 103-1 104-1 105-1 201-16 203-16 205-16 207-16 209-16 211-16 Description Right latch release solenoid 10A3A20L1 to distribution box connector 10A3A10P1 pin L Center latch release solenoid LOA3AI9LI to distribution box connector 10A3A10P1 pin T. Left latch release solenoid 10A3A18L1 to distribution box connector 10A3A10P1 pin Right latch release solenoid 10A3A20L1 (opposite circuit 100G junction) to distribution box connector 10A3A10P1 pin N. Genter latch release solenoid 1OA3A19L1 (opposite circuit 101G junction) to distribution box connector 10A3AL0P1 pin S. Right latch release solenoid 10A3A18L1 (opposite circuit 102G junction) to distribution box connector 10A3A10P1 pin F. Right latch release terminal board 10A3A20TB1 terminal 1 to distribution box connector 10A3AL0P1 pin U. Center latch release terminal board 10A3A19TB1 terminal 1 to distribution ‘box connector 10A3ALOP1 pin G. Left latch release terminal board 10A3A18TB1 terminal 1 to distribution box connector 10A3A10P1 pin J. Right latch release terminal board 10A3A20TB1 terminal 2 to distribution ‘box connector 10A3A10P1 pin D. Center latch release terminal board 10A3A19TB1 terminal 2 to distribution box connector 10A3A10P1 pin H. Left latch release terminal board 10A3A18TB1 terminal 2 to distribution box connector 10A3A10P1 pin K. NOTE The following circuits are located in the carrier but functionally complete the superstructure circuits.Superstructure Blectrical Circuits - Continued Circuit number 500A SO0AA, 5008 soov 501 510 510A 5136 5138 514 515¢ 51SH 516 520 520A 5236 5238 524 5256 525H 526 530 530A 5336 5338 534 5356 535H 536 Description Missile release relay 10A3AIK1 terminal Al to missile release relay and hydraulic actuator circuit breaker 10A3A1CBI Missile release relay 10A3AIKI terminal Xl to MISSILE LATCH RELEASE switch 10A3A1S2. Missile release relay and hydraulic actuator circuit breaker 10A3AICB to distribution box connector 10A3A1J2 pin B. MISSILE LATCH RELEASE switch 10A3A1S2 to circuit 500W junction Missile release relay 10A3AIKI terminal X2 to ground Missile release relay 10A3AIKI terminal A2 to missile release manual CIRCUIT BREAKER 10A3A1CB6. Missile release manual CIRCUIT BREAKER 10A3A1CB6 to distribution box connector 10A3A1J2 pin L. Distribution box connector 10A3A1J2 pin U to circuit 513H junction Circuit 513G junction to RIGHT MISSILE RELEASED indicator lamp, DS11. Instrument panel DIM BRT CONTROL rheostat 10A3AIRI pin 2 to RIGHT MISSILE RELEASED indicator lamp, DS11 Distribution box connector 10A3A1J2 pin D to circuit 515H junction Circuit 515G junction to RIGHT MISSILE LATCHED indicator lamp, DS10. Instrument panel DIM BRT CONTROL rheostat 10A3AIRI pin 2 to RIGHT MISSILE LATCHED indicator lamp, DS10 Missile release relay 10A3A1K1 terminal B2 to missile release manual CIRCUIT BREAKER 10A3A1CB5. Missile release manual CIRCUIT BREAKER 10A3AICB5 to distribution box connector 10A3A1J2 pin T Distribution box connector 10A3A1J2 pin G to circuit 523K junction. Circuit 523G junction to CENTER MISSILE RELEASED indicator lamp, DS7 Instrument panel DIM BRT CONTROL rheostat 10A3AIR1 pin 2 to CENTER MISSILE RELEASED indicator lamp, DS7 Distribution box connector 10A3A1J2 pin H to circuit 525H junction Circuit 525G junction to CENTER MISSILE LATCHED indicator lamp, DS6. Instrument panel DIM BRT CONTROL rheostat 10A3AIR1 pin 2 CENTER MISSILE LATCHED indicator lamp, DS6. Missile release relay 10A3A1K1 t&rminal C2 to missile release manual CIRCUIT BREAKER 10A3A1CB4. Missile release manual CIRCUIT BREAKERS 10A3AICB4 to distribution box connector 10A3A1J2 pin F Distribution box connector 10A3A1J2 pin J to circuit 533H junction Circuit 533G junction to LEFT MISSILE RELEASED indicator lamp, DS3. Instrument panel DIM BRT CONTROL rheostat 10A3AIR1 pin 2 to LEFT MIS- SILE RELEASED indicator lamp, DS3. Distribution box connector 10A3A1J2 pin K to circuit 535H junction. Circuit 535G junction to LEFT MISSILE LATCHED indicator lamp, DS2 Instrument panel DIM BRT CONTROL rheostat 10A3AIR1 pin 2 to LEFT MIS- SILE LATCHED indicator lamp, DS2.TM 9-1450-500-20 Figure 3-20. Wiring Harness and Cabling Installation (Carrier) with Generator and Voltage Regulator‘TM 9-1450-500-20 Figure 3-20A, Wiring Harness and Cabling Installation (Carrier) with Alternator 338 Change 2 GoogleTM 9-1450-500-20 Figure 3-21. Wiring Harness and Cabling Installation (Carrier) (Superstructure) Change 2 3-38. 1/(3-38.2 blank) t Google‘TM 9-1450-500-20 j. Transfer Arm and Index Boom Light ground cable lead first and Switch Circuit. The transfer arm and then disconnect the positive index boom limit switch circuits consist cable lead. of limit ewitches, relay, circuit break- ers, latch release switch, and inter- (2) Remove engine hood cover, connecting wiring. The contacts of one radiator grille and engine or the other normally closed limit hood (fig. 3-54). switches are mechanically held open un- til the superstructure is in the proper position to release the missile(s). At (3) Remove air cleaner hose. Dis- this point, the switches return to the connect air cleaner elbow from normally closed position, completing the carburetor. circuits to the missile latch release switch and the hydraulic solenoid valve (4) Disconnect flexible pipe from for reduced pressure. muffler and plenum assembly (Eig. 3-18). 3-29. Generator/Alternator a. Removal (fig. 3-22)/(fig. 3-22A) (5) Remove engine side panel assembly by removing seven (1) Remove battery cover and dii screws, fourteen washers, and connect battery negative seven locknuts. INWARD DEFLECTION. V2 INCH BELT TENSION ADJUSTMENT BELT TENSION. ADJUSTMENT BOLT Bvor gout @ FLAP WAsHEd toy LOCKNUT @) MOUNTING GENERATOR ‘BRACKET acne Figure 3-22. Generator Replacement Change 2 339BELT TENSION ADJUSTMENT TM 9-1450-500-20 INWARD DEFLECTION. V2 INCH BELT TENSION ADJUSTMENT BOLT MOUNTING BRACKET EN oUe. a) FLAY WASHER (2), LOcKNUT @) \ ALTERNATOR Figure 3-22A. Alternator Replacement (6) Disconnect electrical cable from generator/alternator receptacle. (7) Remove belt tension adjusting bolt, washer, and nut. (8) Push generator/alternator towards engine and slip fan belts off generator/alternator pulley. (9) Remove locknuts and flat washers which secure pivot bolts to mounting bracket. CAUTION The generator/alternator weighs approximately 4% pounds. Use caution when removing support- ing hardwai Change 2 (10) Support generator/alternator and remove pivot bolts. Remove generator/elternator. Do not tighten adjustment bolt or pivot locknuts b. Installation. Install the gener- ator/alternator by reversing the sequence of the removal procedure. ¢, Belt_Tension Adjustment. Pull ‘generator/alternator away from engine. Tighten adjustment bolt to allow for 1/2-inch deflection of belts (Fig 3-22/3-22A). d. Tighten pivot locknuts. 3-30. Generator Regulator NOTE Generator regulators are not used on vehicles equipped with alternators.a b. Installation. Removal (fi qa) 3-20 Remove right drive shaft access cover (fig. 3-55). NOTE Fabricate a suitable protective covering and place over the transmission oil cooler to pre- vent damage to the cooling fins. Remove protective cover~ ing before installing access cover; otherwise, cooling will be impaired. (2) Remove battery cover (fig. 3-55). (3) Disconnect battery negative ground cable lead. (4) Disconnect both electrical connectors from generator regulator. (5) Remove four nuts and washers which secure generator regu- lator to mounting bracket and remove regulator. ‘TM 9-1450-500-20 NOTE Fabricate a suitable protective covering and place over the transmission oil cooler to pre~ vent damage to the cooling fins. Remove protective cover- ing before installing access cover; otherwise, cooling will be impaired. (3) Remove engine bottom access cover (if necessary). (4) Remove three clamps which retain cable assembly. (5) Disconnect cable connectors at generator and generator regu- lator using a suitable spanner wrench. (6) Remove cable from vehicle. b. Installation. Install the gener- ator-to-generator-regulator cable by reversing the sequence of the removal procedure. 331.1 Alternator Cable Install the gener- ator regulator by reversing the sequence of the remove procedure. 3-31. Generator to Generator-Regulator Cable a. Removal qa) (2) NOTE Generator to generator-regul. tor cables are not used on vehi- cle equipped with alternator: 3) Remove battery cover (fig. 3-55) and disconnect battery negative ground cable lead. Remove differential (para 3-56). a. Removal (fig. 3-234). (1) Remove battery cover (fig. 3-55) and disconnect battery negative ground cable lead. (2) Disconnect battery positive cable lead. NOTE Fabricate a suitable protective covering and place over the transmission oil cooler to pre- vent damage to the cooling fins. Remove protective cover- ing before installing access door; otherwise, cooling action will be impaired. 340.1‘TM 9-1450-600-20 GENERATOR GENERATOR-REGULATOR CLAMP @) | WASHER Figure 3-23. Generator to Regulator Cable Replacement (3) Remove engine bottom access bd. Installation. Install the alter- cover (if necessary). nator cable by reversing the sequence of the removal procedure. (4) Remove cable clamps which retain cable assembly. 3-32, Starter a. Removal (fig. 3-24). (5) Disconnect cable leads at alternator. (1) Make sure that the MASTER SWITCH is in OFF position. (6) Disconnect cable connector (2) Remove battery cover and dis- using a suitable spanner connect battery negative wrench. ground cable lead. (3) Remove quick release pin which (7) Remove screws attaching con- secures operator's protective nector to bracket. device to rear missile sup- port. Pivot protective device (8) Remove cable from vehicle. and lay on fender (fig. 1-2). 340.2 Change 2‘TM 9-1450-500-20 Cable Replacement Figure 3-23A. Alternator 341 Change 2@ (8) (9) (ORD E 71485 b. Installation. 1 starter by reversing the sequence of the removal procedure. Loosen four turnlock fasteners which secure starter access panel to angle frame and con- sole frame. Remove panel. Disconnect circuit leads 81, 74A, and 6 from the starter solenoid. Remove two bolts which secure starter to adapter. Remove starter and solenoid assembly. tall the 3-33. Starter Switch Figure 3-24. Starter Replacement a. Removal. (4) Remove engine hood cover, ra- (1) Remove battery access cover diator grille, and engine hood (fig. 3-54). (5) Remove propeller shaft front and rear access covers (fig. @) 3-55). (6) Loosen three turnlock fasten- ers which secure master switch @) to starter access panel (fig. 3-25). (fig. 3-55) and disconnect battery negative ground cable lead at battery. Release turnlock fasteners and raise hydraulic console cover. Tag starter switch electrical leads for identification and disconnect electrical leads Figure 3-25. Master Switch Replacement‘TM 9-1450-600-20 (circuits 14 and 80) from 3-35. Electronic Ignitor (Distributor) starter switch terminals. and Goil Assembly (4) Remove mounting hardware which a. Removal (fig. 3-27). secures switch to side of con- sole and remove switch. (1) Remove engine hood cover, ra- diator grille, and engine hood b. Installati Install the (fig. 3-56). starter switch by reversing the sequence of the removal procedure. (2) Tag spark plug leads for iden- tification. Loosen four ter- 3.34. Master Switch minal nuts which secure leads to electronic ignitor (dis- a. Removal (fig. 3-25). tributor) cover. Remove leads. (1) Remove engine hood cover, ré (3) Remove ventilation line and diator grille, hood, and bat- vacuum line. Disconnect elec~ tery cover (fig. 3-54 and trical connector (circuit 12) 3-55). from electronic ignitor (dis- tributor) receptacle. (2) Disconnect battery negative ground cable lead at battery. (4) Remove screw, lockwasher, and flat washer which secure dis: (3) Remove circuit lead 80, ground tributor to adapter. Remove lead, and connector (circuit 7) electronic ignitor (distribu- from switch. tor). Remove seal. (4) Remove screw which secures b. Installation. control knob to switch and remove knob. (1) Install new seal on electronic ignitor (distributor) and turn (5) Loosen three turnlock fasten- electronic ignitor (distribu- ers which secure switch assem- tor) shaft to aline offset bly to starter access panel. tang with offset slot in inter mediate drive shaft. Insert (6) Remove two screws, flat washers, electronic ignitor (distribu- and locknuts which secure tor) in adapter on cylinder switch to switch plate. block. (2) Install hex-head screw, lock washer and flat washer through slot in adapter into tapped hole in electronic ignitor (distributor) housing. Do >. Installation. Install the mas- BOE NeAe etka Da Sea cao ter switch by reversing the se- timing is completed. quence of the removal procedure. (7) Pass switch through master switch plate. Retain hardware and master switch identifi- cation plate. (3) Install ventilation and vac~ ¢. Installation Test. Turn MASTER jemi ines Pa cELace ne eccticel ‘GHITGH to ON position. Turn connector (circuit 12). IGNITION switch to ON position (4) Install spark plug leads. to assure that power is available at the STARTER switch. (5) Set ignition timing (para 3-6). 3-43‘TM 9-1450-500-20 NOTE When installing electronic ig- nitor (distributor), make sure distributor t bottoms in drive slot in intermediate shaft before tightening mount- ing screw. 3-36. Electronic Ignitor (Distributor) Cap and Cover Assembly Removal (fig. 3-26. 7a) Remove engine hood cover, ra~ diator grille, and engine hood (fig. 3-54). (2) Tag spark plug leads for iden- tification. Remove leads from electronic ignitor (dis- tributor). (3) Remove six fillister-head screws which secure cover as- sembly to electronic ignitor (distributor). (4) Remove three screws and lock- washers which secure cap to cover. Remove cap. Installation. Inspect the seals for evidence of wear or damage. If damage or wear is indicated, replace with new seals. Install the distributor cap and cover assembly by reversing the se~ quence of the removal procedure. 3-37. Electronic Ignitor Module or Distributor Capacitor Removal{fig. 3-26). (1) Remove engine hood cover, ra- diator grille, and engine hood (fig. 3-54). (2) Tag spark plug leads for iden- tification and remove leads from distributor. (3) Remove six screws which secure cover to electronic ignitor (distributor). Remove cover and cap assembly. NOTE If the interchangeable elec- tronic ignitor is provided, omit steps (4), (5), and (6) and proceed to step (7). (4) Remove rotor from cam shaft (if applicable). (5) Loosen terminal screw which secures breaker lever spring to breaker lever terminal. Remove capacitor lead from terminal screw. (6) Remove screw and washer which secure capacitor to breaker plate. Remove capacitor. (7) Bend down clamp tabs and re- move two screws and clamp which hold lip of ignitor mod- ule. When installed, those screws are torqued to 40-50 in-1b. (8) Disconnect module red, green, and black wires from coil and ground. (Black ground wire is not provided with all units.) Remove module. Installation. Install the ig- nitor module or capacitor by reversing the sequence of the removal procedure. Replace seals if worn or damaged. Distributor Breaker Points NOTE This paragraph applies only to vehicles not furnished with electronic ignition.‘TM 9-1460-600-20 * ants REPLACED BY ELECTRONIC IGNITOR Ionitoy ~ = CLAMP RED gue \ perro RousiNG Figure 3-26. Electronic Ignitor (Distributor) Components and Coil Replacement‘TM 9-1450-500-20 DISTRIBUTION BOX INSULATOR (4 Figure 3-27. Distribution Box Replacement GoogleTM 9-1450-600-20 a. Removal (fig. 3-26, tronic ignitor (distributor). Remove cover and cap assembly. (1) Remove engine hood cover, radiator grille and engine (4) Remove two nuts, washers, and hood (fig. 3-54). electrical leads from coil terminal studs. Tag leads (2) Tag spark plug leads for iden- before removal tification and remove from distributor. (5) Remove two screws, lockwashers and clips which secure coil (3) Remove six screws and lock- to electronic ignitor (dis- washers which secure cover tributor). Remove coil and cap assembly to distribu- tor. Remove cover and cap b. Installation. Install the ig- assembly. nition coil by reversing the se- quence of the removal procedure. (4) Remove rotor from camshaft. 3-40. Distribution Box and Instrument (5) Loosen breaker lever spring Panel Components terminal screw and lift out breaker lever. a. Instrument Panel (6) Remove screw which secures (1) Removal stationary contact to breaker plate. Remove stationary (a) Remove battery cover and contact. disconnect battery negative ground lead at the battery. b. Installation. Install the dis- tributor breaker points by revers- (b) With superstructure in trans- ing the sequence of the removal port position, cycle the procedure. hydraulic control levers several times to relieve ¢. Breaker Point Gap Setting. system pressure. HYD OIL ‘Adjust the gap as specified in pars PRESS gage must read 0. graph 3-6f and tighten screw which secures stationary contact to (ce) Disconnect ground strap be- breaker plate. tween bottom of distribution box and chassis. 38. Ignition Coil NOTE a. Removal (fig. 3-26). If removal of the distribution (1) Remove engine hood cover, box is not to be accomplished, radiator grille, and engine disregard step (c) hood (fig. 3-54). (4) Remove six screws, flat (2) Tag spark plug leads for iden- washers, and lockwashers tification and remove from from the front of the in- electronic ignitor (disteibu- strument panel and move the tor). panel to one side sufficient- ly to gain access to the (3) Remove six screws which secure interior of the distribution cover and cap assembly to elec- box.‘TM 9-1450-500-20 fe) (£) (e) (h) (2) b. Dist Disconnect electrical con- nectors 10A3A10P1, 10A3A5P27, 10A3AP28, and 10A3AP29 from rear (interior) of distribu- tion box. Disconnect hydraulic hose from rear (interior) of dis- tribution box. Cap port and hose. Disconnect tachometer cable. Remove instrument panel with cable assemblies and hy- draulic hose attached. Installation. Install the instrument panel by reversing the sequence of the remove procedure. tribution Box. qa) (a) (ob) (ce) (a) (e) (f) 348 Removal. Verify that MASTER SWITCE is in OFF position. Disconnect distribution box grounding strap from chassis. Disconnect electrical con- nectors 10A3A10P1, 10A3A5P27, 10A3A5P28, and 10A3A5P39 from rear of distribution box. With superstructure in trans- port position, operate EXTEN- SION lever several times to relieve pressure in hydraulic system. HYD OIL PRESS gage must read 0. Disconnect hydraulic hose from distribution box. Cap hose and port. Loosen six screws and washers which retain instrument panel to distribution box. Lift panel away from box to gain access to tachometer cable Change 2 connection. Remove grommet and tachometer cable. (g) Loosen locknut which secures throttle control handle to mounting bracket. Remove throttle control. (h) Remove four locknuts and flat washers which secure distribution box to mounting bracket. Remove distribu- tion box and flat washers. (2) Installation. Install the distribution box by reversing the sequence of the removal procedure. After installa- tion, start loader and check that HYD OIL PRESS gage reads 2900 to 3200 psi. Operate all systems to be sure gages and indicators are functioning correctly. ¢.Distribution-Box-to-Instrument-Panel Wiring Harness. (1) Removal. (a) Remove instrument panel (para 3-40a). (b) Disconnect electrical con- nector from driving light selector switch. (c) Tag all wires for identifi- cation and disconnect from switches, indicator lights, instruments, and diode board assembly on instrument panel. NOTE Some of the wires must be un- soldered. Others are secured by terminal screws. (a) Remove wiring harness. (2) Installation. Install the wiring harness by reversingthe sequence of the removal procedure. d. Driving Light Selector Switch. (1) Removal. (a) Remove instrument panel (para 3-40a) sufficiently to dis- connect electrical connector at rear of selector switch. (b) Remove four screws and lock- washers which secure switch to instrument panel. Remove switch. (2) Installation. Install the driving light selector switch by reversing the sequence of the removal procedure. e. Tachometer. (1) Removal. (a) Remove instrument panel (para 3-40a) sufficiently to gain access to the tach- ometer cable connection on the tachometer. (b) Disconnect tachometer cable from tachometer. (ec) Remove two nuts and lock- washers which secure tachom- eter ‘to removable bracket on rear side of instrument panel. (4) Remove tachometer and bracket. (2) Installation. Install the tachometer by reversing the sequence of the removal pro- cedure. f. Battery-Cenerator/Alternator Indicator. (1) Removal. (a) Remove instrument panel (para 3-40a) sufficiently to ‘TM 9-1450-500-20 jain access to the electri- cal wiring connection at the rear of the indicator. Tag wiring for identification and disconnect. Remove two nuts and lock- ers which secure indi- cator to removable bracket on rear side of instrument panel. Remove indicator and bracket from instrument panel. Installation. Install the battery-generator/alternator indicator by reversing the sequence of the removal pro- cedure. Fuel Quantity Indicator. The fuel quantity indicator may be removed and installed by using the same procedures specified for the battery-generator/alternator indicator (para 3-40f). Hydraulic Oil Pressure Indicator. WARNING Oil pressure must be relieved before disconnecting hose to avoid possible injury. This is done by cycling hydraulic control levers until HYD OIL PRESSURE GAGE reads “O" (b) (ce) @) (1) Removal. (2) Inst. 4 (a) Remove instrument panel suf- ficiently to disconnect hydraulic fluid hose from elbow at rear of indicator. Remove four screws and lock- vashers which secure indica- tor to instrument panel. Remove gasket, window, spacer, and indicator from instrument panel. lation, Install the hydraulic oil pressure indica- tor by reversing the sequence of the removal procedure. Refill reservoir in accordance with LO 9-1450-500-12. Diode Board Assembly. (1) Removal. (a) Remove instrument panel (para 3-40a). (b) (ec) Change 2‘TM 9-1450-500-20 k 3-50 (b) Tag wires for identification and unsolder wiring from terminals of the diode board assembly. (c) Remove four screws and lock- washers which secure diode board assembly to instrument -panel. Remove diode assem- bly. (2) Installation. Install the diode board assembly by re- versing the sequence of the removal procedure. Indicator Lights, Switches, and Circuit Breakers. (1) Removal. Removal of these components is relatively straightforward. The instru- ment panel must be removed sufficiently (para 3-40a) to gain access to the wiring con- nections at the rear of the item being removed. Tag wir- ing for identification and disconnect wiring. Remove the mounting hardware and re- move the component. (2) Installation. Install the component by reversing the sequence of the removal procedure. Distribution Box Armature Relay. (1) Removal. (a) Remove instrument panel (para 3-40a) sufficiently to gain access to interior of dis- tribution box. It may be necessary to completely re- move the instrument panel. (bo) Tag wiring for identifica tion and disconnect wiring from terminals of the arma- ture relay, (c) Remove four screws, nuts, and lockwashers which secure relay to interior of dis- tribution box. Remove relay. (2) Installation. Install the relay by reversing the sequence of the removal procedure. Distribution Box Resilient Mount. (1) Removal. (a) Remove distribution box (para 3-40b). (b) Remove nut and washer from threaded post of mount in interior of distribution box. Remove mount. (2) Installation, Install the mount by reversing the sequence ‘of the removal procedure. 3-41. Dimmer Switch Removal (fig. 3-28). (1) Disconnect electrical connec~ tor (P26) from switch. (2) Remove two screws and lock- washers which secure switch to mounting bracket. Remove switch. Installation. (1) Install switch to mounting bracket. Secure with two screws and lockwashers. (2) Install electrical connector (P26) to switch receptacle. (3) Turn MASTER SWITCH to ON position. (4) Place light selector switch lever in SER. DRIVE position.Figure 3-28. Dimmer Switch Replacement (5) Operate dimmer switch to be sure of correct operation of the high and low beams. (6) Turn light selector switch and MASTER SWITCH to OFF position. 342. Stoplight Switches a. Removal (fig. 3-29). (1) Remove engine hood cover, hood, and radiator grille (fig. 3-54). (2) Remove propeller shaft rear access cover, and battery box cover (fig. 3-55). (3) Disconnect battery negative ground cable at battery. (4) Remove electrical connectors (circuit 75) from stoplight switch. (5) Remove nut and lockwasher which secure each switch to Figure 3-29. BRE ST OPL GH FR switch CUM Stoplight Switch Replacement each mounting bracket. Remove switches and flat washers. b. Installation. qa) (2) Install switches and flat washers through mounting bracket and secure switches with lockwashers and nut. Connect electrical connectors (circuit 75) to stoplight switches. c. Testing. a) (2) (3) (4) Turn MASTER SWITCH to ON position, Place light selector switch lever in stoplight position. Pull both steering levers full back to make sure that stop- Lights operate. Turn light selector switch and MASTER SWITCH to OFF position.‘TM 9-1450-500-20 3-43. Service Headlights (2) qa) (2) (4) (s) Removal (fig. 3-30). NOTE Replacement procedures are identical for right and left headlights. (1) Disconnect electrical connec- tors (circuits 17 and 18) from headlight. Remove nut, flat washer, and pherical washer from head- light mounting stud. Remove light from fender mounting bracket. Installation. Install service headlight by reversing the se- quence of the removal procedure. Replacement of Lamp Unit. Remove four screws which se- cure door assembly to light body and remove door assembly. Remove preformed gasket and lens. CAUTION Handle carefully so lens does not break. (3) Remove three screws which se- cure lamp unit retaining plates, and remove plates. Replace lamp unit by pulling gently and disconnecting it from its connector. Install removed items in re- verse order of disassembly. NOTE Replace preformed packing if worn, damaged, or deteriorated. 3-44, Blackout Drive Headlight b. a) (2) (2) (3) (4) (s) qa) (2) Removal (fig. 3-30). Disconnect electrical connec- tor (circuit49). Remove nut, flat washer, spherical washer from drive Light mounting stud. Remove light from mounting bracket. Installation. Install blackout flight by reversing the sequence of the removal procedure. Replacement of Lamp Unit (fig. 3530): Remove three screws which se- cure door assembly and Lamp unit to lamp body assembly. Remove slotted-terminal retain- ing washers from electrical terminals and disconnect leads from connectors. Remove spring retainer which secures lamp unit in lamp body. Remove lamp unit. Guide wir- ing through rubber grommet in lamp body as lamp unit is being removed. Install new lamp unit and re- moved items by reversing the order of removal. 3-46. Blackout Marker Light Removal (fig. 3-30). Disconnect electrical connec- tor (circuit 20) from marker Light. Remove ‘nut and flat washer which secures marker to mounting bracket. Light.TM 9-1450-500-20 SPRING WASHER ELECTRICAL CONNECTOR Ne pe orapw + ZS voor - SPRING GROMMET -" ve emg 9 0S) accion moun suo ®& < weston ‘SCREW @) olor BLACKOUT MARKER LIGHT DISSASSEMBLY BLACKOUT DRIVE HEADLIGHT DISSASSEMBLY TAORSESI Figure 3-30. Service Headlight, Blackout Drive, and Blackout Marker Light Removal and Component Replacement 353‘TM 9-1450-500-20 Installation. Install blackout marker light by reversing the sequence of the removal procedure. Replacement of Lamp. (1) Remove two screws which secure door lamp body. (2) Replace lamp. (3) Position door and gasket on lamp body and secure in place with two screws. NOTE If gasket is broken, cracked or deteriorated, replace with new gasket. 3-46. Taillights b. q@) 3) Removal (fig. 3-31). NOTE Replacement procedures for left and right taillights are identical except as noted. a) Remove screw, flat washer, and locknut which secure cable to taillight mounting bracket. Remove clamp. Disconnect electrical connec- tors (circuits 23 and 24 on right taillight; circuits 21, 22, and 24 on left taillight). Remove two bolts and lockwash- ere which secure taillight to mounting bracket. Remove taillight. Installation. Install the tail- ight by reversing the sequence of the removal procedure. ce. 347. Lamp Replacement. (1) Remove six screws which secure door assembly and preformed packing to light body. (2) Remove lamp by pushing in and turning counterclockwise. Install new lamp. (3) Install door assembly to light by securing with six screws. NOTE Replace preformed packing if worn, damaged, or deteriorated. Sending Units Fuel Gage Sending Unit (fig. 217). (1) Removal. (a) Remove battery cover and disconnect battery negative ground cable at battery. (b) Disconnect electrical con- nector (circuit 28) from sending unit. (ce) Remove five screws and lock- washers which secure sending unit to fuel tank. NOTE One screw serves as a termi: nal for the ground lead (cir- cuit 79). (4) Remove sending unit and gasket. (2) Installation. Clean gasket mounting surfaces prior to installation of the sending unit. Install the sending‘TM 9-1450-500-20 RH. TAIL LIGHT TAIL LIGHT (LH) ‘SCREW ‘Tagp5832 Figure 3-31. Taillight Removal and Component Replacement 3-55‘TM 9-1450-500-20 ce. (3) (a) (b) unit by reversing the sequence of the removal procedure. Testing. Turn MASTER and IGNITION switches to ON position. Observe indication on fuel quantity gage. It should indicate a fuel quantity corresponding to the level of fuel in the tank. Transmission High Temperature Sending Unit. (1) Removal (fig. 3-6). (a) (b) (ec) (a) (2) (a) (b) Remove transmission access plate. Drain transmission fluid. (Refer to LO 9-1450-500-12.) Install transmission drain plug. Disconnect electrical con- nector (circuit 327) from transmission high tempera- ture sending unit. Remove sending unit. Installation. Install sending unit by re- versing the sequence of the removal procedure. Remove engine hood cover and fill transmission as specified in LO 9-1450-500- 12. Hydraulic Oil Temperature Send- ing Unit. qa) (a) Removal (fig. 3-32). Remove propeller shaft rear cover (fig. 3-55). HYDRAULIC OIL HIGH TEMPERATURE] SENDING UNIT Pigure 3-32, Hydraulic Oil High Temperature Sending Unit Replacement (b) Remove engine hood cover and radiator grille (fig. 3-54). (c) Remove engine hood (fig. 3-54). (4) Disconnect electrical con- nector (circuit 327H) from hydraulic high temperature sending unit. NOTE A omall amount of hydraulic fluid will be lost in the process of removing the send- ing unit and capping the open- ing. A container or rag should be placed under the unit to catch the runoff. Unnecessary draining of the reservoir is discouraged to minimize the in- troduction of contaminants into the hydraulic system.' (e) Slowly back out the tempera- ture sending unit and imme- diately plug the opening. Wipe up any spillage. (2) Installation. Install the sending unit by reversing the sequence of the removal pro- cedure. Prior to installing engine hood, energize loader and check for leaks. d. Engine Coolant Sending Unit. (1) Removal’ (fig. 3-33). (a) Remove engine hood cover, hood and rad (fig. 3-54), tor grille (b) Disconnect electrical con- nector (circuit 33) from sending unit. (c) Remove sending unit. Obtain a suitable plug and install plug to retain engine cool- ant. (2) Installation. Install the temperature sending unit by reversing the sequence of the removal procedure. Check cool- ant level before installing engine hood and cover. e. Transmission Low Oil Pressure ‘Switch. (1) Removal (fig. 3-33). (a) Remove engine hood cover, radiator grille, and engine hood (fig. 3-54). (b) Disconnect electrical con- nector (circuit 72) from the transmission low oil Pressure switch. (c) Remove switch and cap port. (2) Installation. Install pres- sure switch on the bracket ‘TM 9-1450-600-20 none count scones JENGINE LOW OL PRESSURE SWITCH! CONNECTOR -ToAIAAP4) A Twos f Figure 3-33. Bngine-Transmission Sending Units Replacement assembly by reversing the se- quence of the removal proce- dure. £. Bngine Low Oil Pressure Switch. (1) Removal (fig. 3-33). (a) Remove engine hood cover, radiator grille, and hood (£ig. 3-54). (b) Disconnect electrical con- nector (circuit 34) from engine low oil pressure switch. (c) Remove pressure switch. Obtain a suitable cap and cap port. (2) Installation. Install switch to bracket assembly by revers- ing the sequence of the removal procedure. g. Differential Oil High Tempera- Eure Sending Unit. (1) Removal (fig. 3-42). (a) Remove left drive shaft cover (fig. 3-55).‘TM 9-1450-500-20 (b) Disconnect electrical con- connector (circuit 5002, nector (circuit 328) from 573A) from reduced pressure differential sending unit. switch. (c) Remove differential access (b) Disconnect tube assembly cover and drain plug. Re- from reduced pressure switch. place drain plug after oil has been drained. (c) Remove nut, washer, screw and clamp thereby releasing (d) Remove sending unit. switch. (2) Installation. Install send- (2) Installation. Install the ing unit by reversing the se- reduced pressure switch by quence of the removal proce- reversing the sequence of the dure. Fill differential with removal procedure. oil in accordance with LO 9- 1450-500-12. 3-48, Superstructure Limit Switches hh. Extension System Reduced Pres- a. Azimuth and Roll Control Limit sure Switch Switch (1) Removal (fig. 3-66). (1) Removal (fig. 3-34). (a) Lift hydraulic console cover (a) Position superstructure in and disconnect electrical transport position. Posi- Limit swiTcH LOCKNUT 2 — Sp. FLAT WASHER (2) Figure 3-34. Azimuth and Roll Limit Switch Replacementtion MASTER SWITCH to OFF position. (b) Remove battery cover and disconnect battery negative ground cable at battery. (c) Remove two screws, washers, nuts, and bracket which secure 1 t switch to trans- fer arm. Remove two screws and lockwashers which secure cover to housing; remove cover and gasket. (4) Disconnect brown lead from NO terminal and red lead from COM terminal of the switch. (e) Back off nut which retains cable to switch housing and pull cable leads free. (2) Installation, Install the limit switch by reversing the sequence of the removal pro- cedure. (3) Adjustment. (a) Remove nut which secures roller arm to limit switch. (b) Adjust switch to lock out azimuth control when bottom of missiles are a minimum of 2 inches away from rear missile supports when re- tracting the superstructure. Azimuth control should cut in again when bottom of m: siles are raised a maximum of 10 inches above rear m sile supports (c) Install nut and secure rol- ler arm to switch. Transfer Arm Limit Switch. (1) Removal (fig. 3-35). (a) Retract superstructure (b) Reuove battery cover and disconnect battery negative ground cable at battery. (e) Remove two capscrews and lock- washers which secure striker plate to link assembly Loosen switch locknuts and remove striker plate from switch. (4) Disconnect brown electrical @ @ ¢. Index Bo 10A3S14) - aw (a) (b) (ce) (a) (e) lead from NC terminal and red electrical lead from COM terminal of the switch. Remove switch. Installation. Install the limit switch to link assembly by reversing the sequence of the removal procedure Adjustment. Adjust switch 80 that plunger protrudes 0.070 40.010 inch from outside face of striker plate. it S I Removal (fig. 3-36). Make sure that MASTER SWITCH is in OFF position. Remove three screws, flat washers, and nuts which secure switch to mounting bracket. Remove two screws and lock- washers which retain ewitch cover to switch housing. Remove cover and gasket. Disconnect brown lead from NC terminal and red lead from COM terminal of the awitch. Back off the nut which re~ tains cable to switch housing and pull cable leads free. Change 1 3-59‘TM 9-1450-600-20 STRIKER PLATE ~~ ~ ~ LOCKWASHER CAPSCREW (2) TA09s836 Pigure 3-35. Transfer Arm/Link Assembly Limit Switch Replacement (2) Installation. (a) Install cable leads through switch housing and secure both leads. NOTE Verify that microswitch plunger engages the ing mechanism in the switch housing before installing switch assembly on link arm. (b) Tighten cable retaining nut. (ce) Replace gasket and cover and position switch assembly on mounting bracket. Secure with three screws, flat wash- ere and nuts ‘Change 1 (4) Install two screw: washers into remaining cover holes. (3) Adjustment. With superstruc- ture fully retracted (transport position), back out switch adjusting screw until it just contacts boom surface. Fully extend superstructure and turn itch adjusting screw an addi- tional 0.250 +0.032 inches. Tighten adjusting screw lock- nut. Retract superstructure. Index Boom Limit Switch (Part Number 11675108). (1) Removal (fig. 3.36.1). (a) Make sure that MASTER SWITCH is in OFF position.(b) Remove two screws and lock- washers which secures switch to adapter plate. Remove two screws which secures access plate to switch housing. Remove gasket and access plate. © Disconnect brown lead from NC terminal and red lead from COM terminal of switch. (a) (e) Back off the nut which retains cable to coupling. Pull cable leads free from switch housing. (f) (2) Installation. NOTE Do step (a) if switch Part Number 11675108 is being installed on your Guided Missile Loader-Transporter for the first time. (3) Adjustment. ‘TM 9-1450-600-20 (e) Position switch on adapter plate with threaded stud down and over the fork of the index boom. Secure with two screws and lockwashers. (£) Remove two screws which secure the access plate to switch housing. Remove access plate and gasket. (g) Install cable leads through coupling. (h) Connect brown lead to NC ter- minal and red lead to COM ter- minal of the switch. (4) Tighten cable retaining nut to coupling. (Q) Position gasket and access plate on switch housing. Secure with two screws. With superstructure fully retracted (transport position), back out cap until it just contacts boom surface: (a) Position adapter plate on mounting Fully extend super- bracket. Secure with three screws, | Structure and turn cap out and ad— flat washers and nuts. ditional 0.200 + .015 inch. Tighten locknut against cap. Retract super- (b) Place gasket on coupling. structure. 3-49, Battories (c) Install coupling with gasket on switch housing. a. Removal (fig. 3-37). (4) Install locknut and cap on threaded (1) Remove battery cover and dis stud of switch. Do not adjust at this time. connect battery negative ground Change 1 360.1TM 9-1450-500-20 ATTACHING SCREW MOUNTING BRACKET MOUNTING BRACKET ATTACHING , SCREW, WASHER AND NUT ADAPTER PLATE CABLE RETAINING (11675108) a conwecron rneaDep roxsaiare ‘THREADED cap INDEX BOOM, FORK ATTACHING, SCREW AND LOCKWASHER GASKET CURLING LINK ASSEMBLY ‘AND INDEX BOOM LIMIT SWITCH + wai Figure 3-36.1. Link Assembly and Index Boom Limit Switch Replacement 3-60.2 Change 1 Gooal(a (3) CONNECTOR YoAsalzr2 LUNK ASSEMBLY. ‘AND INDEX BOOM UUMIT SWITCH Pigure 3-36. Link Assembly and Index Boom Limit Switch Replacement cable at the battery (rear battery) then disconnect bat- tery positive cable and jumper cable. Remove two self-locking nuts on both T-bolts. Lift out retainer frame. Lift batteries straight up from support bracket. WARNING Avoid spilling electrolyte on skin or clothing. Wash affect- ed areas immediately if spill- age should occur. Installation. (1) Position batteries on support bracket. 361TM 9-1460-600-20 |SCREWLOCK FASTENER co) (REF) Figure 3-37. Batteries, Cables, and Mounting Hardware Replacement (2) Replace battery retainer and install self-locking nuts on T-bol | (3) Install battery positive cable (circuit 6 to positive (+) terminal). Install jumper cable. Install negative ground (circuit 7 to negative 362 Change 2 (-) terminal) last. Tighten all connections securely. NOTE Make new battery leads from parts Listed in TM 9-1450-500-24P using standard repair practices. Pre- cise lengths of cables are pro— vided in that manual.3-650. NOTE Batteries operating in torrid climates should have weaker electrolyte. Instead of 1.280 specific gravity, the electro- lyte should be diluted to 1.200 to 1.240 specific gravity. Batteries should be re- charged at about 1.160 speci- fic gravity. Wiring Harnesses (fig. 3-20 and 3-21): Description. Groups of cables Teading from one part of the vehi- cle to another are bundled to- gether into a harness formed of waterproof electrical tape. Har- ness ends usually terminate at multiple-plug and receptacle-type connectors. One or more cables may branch from a harness and enter separate connectors at var- ious points on the harness. All splices are soldered together and covered with molded insula- tion. Removal of Branched Wiring Harness. (1) Turn MASTER SWITCH to OFF position. (2) Remove universal joint front cover, propeller shaft front and rear covers, right and left drive shaft covers, and ission and engine access Refer to figures 3-54 (3) Remove hood and hood cover (fig. 3-54). (4) Open hydraulic control console. (5) (6) q@) (8) q9) (io) ql) a2) (13) (4) TM 9-1450-500-20 Tag wires for identification and disconnect wiring at left headlight, marker backout lamp and blackout drive light. Repeat step (5) for the right headlight and blackout drive light. Remove two each screw, clamp, and nut which secure harnes: to top forward surface of left fender. Repeat step (7) for right fender. Remove two each screw and clamp from the welded bosses on the right and left forward miss: support brackets Disconnect wiring at dimmer switch connector. Remove screw from clamps which secure harness and tachometer drive housing to chassis stand- off. Remove protective plate over harness just forward of shift lever. Remove screw from clamps which secure harness and tachometer drive housing to chassis stand- off under front universal joint. Tag wires for identification and disconnect hydraulic sole- noid wiring and starter switch wiring at the quick-disconnects adjacent to the transmission rear mount.TM 9-1450-600-20 NOTE To remove hydraulic console wiring harness, tag single wires and connectors for iden- tification and disconnect wires and and qs) (6) a7) (8) ay) (20) (21) (22) connectors from terminals solenoids Tag wiring for identification and disconnect wires at quick- disconnects at the right and left taillights, differential sensing switch, fuel pump and sending unit, and engine com- partment components. Disconnect wiring from master switch. Remove clamp and screw which hold harness to right and left rear fender support brackets. Pull wiring through grommets into drive shaft compartment Remove clamps and screws which secure harness in right and left drive shaft compartment Remove clamps which secure harness to chassis structural member under differential. Working from the underside of the vehicle, if necessary, remove clamps which secure harness to chassis supports under the transmission and engine. Disconnect harness connectors from distribution box. Remove wiring harness, being carefut during the removal Process not to damage wiring components. If wiring is dif- ficult to remove, check care- fully throughout routing to be sure all clamps were removed . Repair. Repair of harnesses is Limited to replacement of connec- tors and terminals on harness or cable ends. Refer to TM 9- 1450-500-24P for repair parts authorized for maintenance at the organizational level of maintenance. Installation. Install the wiring harness by reversing the sequence of the removal procedure. 3-61. Transfer Arm Cable Assembly (1) Detach azimuth and roll control Limit switch (para 3-48a). (2) Detach cable connector from top of transfer arm. Raise connector to make cable access- ible. Securely tape one end of a 10-foot length of lockwire to cable 2 inches below con- nector. (3) Push back or remove insulation sleeving and unsolder the cable leads from connector; remove connector and gasket and secure free end of lockwire near top of transfer arm. (4) Detach cable connector from bottom of transfer arm. Pull cable out of transfer arm through bottom aperture. De- tach lockwire from cable and remove cable and gasket. Leave lockwire laced through transfer arn. Installation. (1) Install gasket on cable and securely tapé lower end of lockwire to cable leads. When cable is installed on a new transfer arm, the lockwire has to be laced through the arm first.TM 9-1450-600-20 Figure 3-38. Transfer Arm Cable Assembly (Sheet 1 of 2) - 366 Google c aTM 9-1450-500-20 ‘GREEN ( SPARE ) ‘YELLOW ( SPARE ) YELLOW & WHITE UNWIRED BLUE RED & WHITE ORANGE & WHITE UNWIRED VIEW LOOKING INTO REAR OF SOCKET INSERT CONNECTOR WIRE COLOR H wenvonnnnwnnmnnnnnnnnnnmmne ORANGE & WHITE J orrrrrrononnonn orn YELLOW 8 WHITE k weceenennnnnsonso== SLATE L wecnennnennnnnnnnnnnnnnnnn= UNWIRED ™ weanannnenaan-o= YELLOW ( SPARE ) N= wonenonnncnancnnn= GREEN ( SPARE) BP mecannnnnnnnnnnennnnnnnnnne RED R wnwnnnnnnnnnnnnannnnnnnamnn= UNWIRED $ woececenenwnnnnnnnnnnnanene= BLUE VIOLET Taosse40 J mecennennennenennmnne Figure 3-38. Transfer Arm Cable Assembly (Sheet 2 of 2)(2) Pull cable through the trans- fer arm and secure connector and gasket on bottom of trans- fer arm. (3) Install azimuth and roll con- trol limit switch (para 3-48a). (4) Remove lockwjre, install gas- ket over cable and install 1 inch of insulation sleeving on each cable lead. (5) Solder cable leads to connector beginning with center connec- tion and work outwards. See fig. 3-38 (sheet 2) for color code and wiring diagram. When TM 9-1450-600-20 cable colors are not clear, use multimeter to trace cir- cuits (6) Slide insulation sleeving over exposed leads and apply 250 to 275°F heat to shrink sleev- ing. (7) Secure connector and gasket at top of transfer arm. NOTE Verify continuity by using electrical schematic, FO-2, from 10A3A15J1 to 10A3A15J2. Section V. MAINTENANCE OF POWER TRAIN 3-52, General This section provides removal and installation procedures for the power train components (fig. 3-39). The power train repair items are the differential, final drives, propeller shaft, universal joints, yokes, and left and right drive shafts. 3-53. Propeller Shaft a. Removal (fig. 3-40). (1) Remove forward and rear access covers of propeller shaft (fig. 3-55). (2) Remove both universal joint access covers (fig. 3-55). (3) Remove grille, engine hooa cover, and engine hood bly (fig. 3-54). (4) Remove cover support(tig. 3-54) by removing ‘two screws, nuts, and washers which attach cover support to engine sup- port frame assembly and one nut washer which secure cover’ support leg to. chassis. (5) Remove fuel pump, fuel filter, and bracket (para 3-17 and 3-18). Lay the removed items across the fuel tank out of the way. (6) Remove four screws and two locking plates which couple the propeller shaft to differ- ential input yoke. (7) Loosen knurled coupling nut on propeller shaft forward yoke assembly. Slide propel- ler shaft out of yoke and re- move propeller shaft toward rear of vehicle. b. Installat: (1) Slide propeller shaft into place and aline axis cf spiders on each end of propeller shaft within one tooth. (2) Complete the installation by reversing the sequence of the removal procedure.TM 9-1450-500-20 UNIVERSAL, Figure 3-39. 54. Drive Shafts a. Removal (fig. 3-40). NOTE The procedure for removing either left or right drive shaft is the same. qa) (2) (3) (4) (5) Remove engine hood cover, en- gine hood assembly, and grille (fig. 3-54). Remove applicable drive shaft cover access cover (fig. 3-55). Remove bolts which secure drive shaft yoke to final drive spider. Remove bolts which secure drive aft yoke to differential spider. Remove drive shaft. b. Installation. a) Place the shaft in position and aline the axis of spiders on each end of shaft within one tooth. (2) FINAL DRIVE (2) ‘TADRSE41 Power Train Components Complete the installation by reversing the sequence of the removal procedure. 3-55. Universal Joint (2) (1) Remove applicable drive shaft access covers, engine hood cover, engine hood, and grille GE necessary). Remove eight screws and four locking plates which secure universal joint to yokes Remove universal joint. Cleaning and Inspection. Clean ‘and inspect the yokes for cracks, wear, or deformation. Remove slight nicks or burrs with a fine stone. When necessary, soak the parte in solvent, item 19, App. D, and brush with a stiff brush to remove caked grease. Dry the parts thoroughly with compressed air.RIGHT DRIVE | SHAFT| UNIVERSAL JOINT PROPELLER SHAFT TRANSFER TRANSMISSION ‘TO DIFFERENTIAL ‘UNIVERSAL JOINT Figure 3-40. ¢. Installation. Install the univer- a joint by reversing the se- quence of the removal procedure. 3-56. Differential a a. Removal (fig. 3-41). The follow- ing special tools are required to perform the removal procedure: Part (3) Special tool NSN number Driver, oil, 5120-00-473-7025 7079403 and water line fer- (4) rule Remover and 5120-00-991-3150 10892939 replacer TM 9-1450-600-20 DIFFERENTIAL ‘SPIDER (2) YOKE LEFT FINAL DRIVE ‘Tamp5842 Propeller and Drive Shafts Replacement Remove left and right drive shaft access covers (fig. 3-55). Remove engine hood cover, hood and grille, propeller shaft rear access cover, and support assembly (fig. 3-54). Remove differential rear mount- ing access cover. Disconnect lead from high temperature sending unit. Remove two cotter pins, wash- ers, and pins which secure control levers to differential arms. 3468‘TM 9-1450-600-20 HE COTTER PIN (2) Figure 3-41. Differential Replacement 370 Google(5) Disconnect propeller shaft and drive shafts from differen- tial (para 3-54 and 3-55). CAUTION Support differential suffi- ciently to prevent dropping when removing pins and screws. Be careful not to damage the sending unit. (6) Remove front mounting screw, two bushings, and nut. Use driver, special tool (2, fig- ure 1-4) for bushing. (7) Remove four cotter pins, two pins, and four washers from differential rear mounts. Remove differential. b. Refer to figure 3-42 for disassem- bly and reassembly. Use remover and replacer, special tool (4, fig. 1-4) to remove or install resilient mounts. c. Installation. Install the differ- ential by reversing the sequence of the removal procedure. Refer to LO 9-1450-500-12 for lubrica~ tion instructions. ‘3-57. Final Drive Removal (fig. 3-43). The follow- ing special tool is required t perform the removal procedures Part Special tool NSN number Clamp assembly: 4910-00-799-0018 1094365 tracking mounting (1) Remove access covers which cover left and right drive shafts (fig. 3-55). (2) Disconnect drive shaft at final drive yoke and remove universal joint and yoke. ‘TM 8-1450-600-20 ‘Of LeveL INDICATOR A DIFFERENTIAL CASE Gascet “@— DRAIN PLUG raopanas Figure 3-42, Differential Component Replacement Figure 3-43. Pinal Drive Replacement 371‘TM 9-1450-600-20 b. (3) Relieve track tension by loos- ening six screws through final drive plate and the track ad- justing screw. NOTE Loosen just enough to release clamping pressure on chai (4) (5) (6) Using a track mounting clamp, special tool’ (6, fig. 1-4), (fig. 3-44), separate track and move loose ends out of the way (para 3-60). Remove six nuts which secure drive sprocket to final drive and remove drive sprocket. Remove track adjusting nut and lockwasher from screw. Remove screw, washer, and ser- rated washer. Remove and care- fully preserve adjusting shim pack located between final drive and chassis. Keep shims together. (7) Remove six screws which secure final drive to clamping flange. Remove final drive. (8) Remove jack screw and clip, Installation. CAUTION (2) Measure gap between final drive at. adjustment point ured gap within 0.017 inch. (3) Assemble flat washer and ser- sert screw through chassis adjustment slot and final drive, with selected shim pack Install final drive housing. washer and nut. CAUTION The shim pack provides for the amount of draw on the lug of the final drive casting. The final drive casting may become cracked if the draw at the screw is too tight. (4) Be sure serrations of serrated plate engage serrations of chassis, then tighten screw sufficiently to hold parts in place. Install jack screv and clip in forward end of final drive and tighten jack screw to 1-2 £t-1b torque. Loosen six attaching screws and adjusting screw. (5) Install drive sprocket on final drive and tighten six attaching nuts to 75-80 ft-1b torque. (6) Install track (para 3-60). This is a critical installe- tion. All torque values and measurements must be maintained. (7) Install universal joint and connect drive shafts to final (1) Position final drive assembly cearee on chassis. Install clamping flange over final drive and (8) Adjust track tension (para install six screws. Tighten 3-61). six screws to 25-30 £t-1b torque. (9) Install acce: covers. 372‘TM 9-1450-500-20 Section VI. MAINTENANCE OF TRACKS AND SUSPENSION 368. General This section describes and illustrates the removal and installation procedures for the tracks and suspension system. The loader is equipped with center guide, double pin, rubberized chevron type tracks and a trailing arm torsion bar suspension system. The suspension system includes torsion bars, shock ab- sorbers, hub and arm assemblies, road wheels, drive sprockets, and associated items. Together, the track and suspen- sion system provide support and traction over all types of terrain. A suspension lockout system locks out the front and center road wheel arms to stabilize the loader when used as a crane, when rigged with a hoist adapter, or for transporting pallets. 3-69. Driye Sprocket a The following special e required to perform the removal procedures: Part Special tool NSN number Clamp assem- 4910-00-799-0018 10943651 bly: track mounting Gage 5220-00-443-0529 11626018 (1) Relieve track tension by loos- ening six screws through final drive plate and loosening track adjusting screw. (2) Using a track mounting clamp, special tool (6, figure 1-4), separate track and move loose ends back out of the way. (3) Remove complete drive sprocket assembly (including inner and outer drive sprocket rings and hub) by removing six screws which secure drive sprocket to final drive. (4) Remove 10 screws and tab lock yi washers to remove inner drive sprocket ring. (5) Repeat step (4) to remove outer drive sprocket ring. b. Inspection. (1) Inspect sprocket teeth for evi- dence of cracks and deforma- tion. If cracks are detected, or deformation of sprocket teeth is evident, the sprocket ring must be replaced. NOTE The sprocket rings (inner and outer) are heat treated. No welding repairs are authorized. (2) Inspect wheel hub for evidence of cracks; if cracks are de- tected, hub must be replaced. (3) Using gage, special tool (3, figure 1-4), check drive sprockets for wear. NOTE When checking drive sprockets for wear, do not force gage between drive sprockets. If gage cannot be fitted between drive sprockets, replacement is not required. (4) Attempt to fit (do not force) gage between two drive sprock- ets. If gage can be fitted between two drive sprockets, it is an indication that the drive sprockets are worn be- yond their wear limit and must be replaced. c. Installation. (1) Position inner and outer drive sprocket rings on hub and 3-73‘TM 9-1450-500-20 secure each in place with 10 each screws and tab lock- washers. (2) Install drive sprocket assen- bly on final drive and tighten six attaching nuts to 75-80 ft-lb torque. (3) Connect track (para 2-60) and adjust track tension (para 3-61). 3-60. Tracks a, Removal (fig. 3-44). The follow ing special tool is required ti perform the removal procedures Part Special tool NSN number Clamp assem- 4910-00-799-0018 10943651 bly: track mount ing q) (2) Qa) (4) (5) (6) q@ Position the desired point of separation above and between center and rear roadvheels. Remove applicable drive shaft cover (fig. 3-55). { Relieve track tension (para 3-61). Remove two bolts and two wedge nuts from track on opposite sides of track. Install track mounting clamp, special tool (6, fig. 1-4), (fig. 3-44) and tighten until links are loose on track pins. Remove two links, release track mounting clamp, and separate track. Repeat steps (4), (5), and (6) if track shoe section is to be replaced. If entire track Figure 3-44. 374 Track Replacement361. is to be replaced, lay old track forward on ground and connect new track to this end. Drive loader forward until end of new track is positioned be- tween center and rear road wheels. Disconnect and remove old track. Inspection. Inspect the connect- ing links and track shoe pins for wear and general condition. Re- place broken links. Replace track shoes if guides are broken or missing. Replace tracks, sec- tions, or shoes when effective traction cannot be obtained on the local terrain. Replace track (by sections) when proper tension cannot be achieved due to accumu~ lated wear of connecting links and track shoe pins. Installation. (1) Place new link(s) in position. If entire track is being re- placed, position new track and install track mounting clamp. Tighten clamp and install links, wedge nuts and bolts. Remove track mounting clamp. (2) Adjust track tension (para 3-61). (3) Tighten wedge nut bolts to 25- 30 ft-1b torque. (4) Install applicable drive shaft cover (fig. 3-55). ‘Track and Track Tension Adjustment Make track adjustments with loader placed flat level surface with missiles removed. Set brakes on loader and place shift lever in N (neutral). In- stall blocks on lower track as shown in figure 3-45. TM 9-1450-500-20 c. Remove right and left drive shaft covers from loader. Loosen jack screw in forward flange of final drive assembly to 1 ft-1b torque. Then loosen final drive adjusting bolt lock- nut to free locking plate from serrations in chassis. e. Loosen the six screws which se~ f. cure the final drive to the shaft. CAUTION Screws should be loosened only enough to release clamping of flange. The placement of shims and washers between the final drive rear flange and chassis provides a critical alinement which may cause damage to the final drive casting if altered. Do not remove the track adjust- ing bolt, locking plate, wash- ers, shims, or nut. To increase track tension, place shift lever in R (reverse) and carefully release brakes. This will cause the drive sprocket to move upward. CAUTION Do not attempt to rotate the final drive by any other method as damage to aluminum housing may result. NOTE Moving the vehicle in forward gear will cause the sprocket to move downward, which de~ creases the track tension. Adjust track tension so that clearance between upper track and top of center road wheel is 1 inch without antiskid cleats installed on track or 3/4 inch with anti- skid cleats installed (para 3-65). 376Pigure 3-45. Track AdjustmentNOTE If this clearance cannot be obtained, remove one track shoe from each track (para 3-60), reconnect tracks, and repeat the adjustment procedure. Apply brakes on vehicle and tighten the six screws (loosened in step (4)) to secure the final drive to the chassis. Engage serrations of track adjust- ing washer with serrations of the chassis and tighten adjustment screw to 175-200 £t-1b torque. Tighten the jack screw in the forward flange of the final drive to 1-2 £t-1b torque and bend clip over screw head. Remove blocks from lower track. Drive vehicle approximately 15 feet and coast to a stop with shift lever in N (neutral). Do not apply brakes. Measure the upper track clearance as specified in step (6). Read- just track if necessary to obtain proper clearance. NOTE The proper clearance should be 1/2 to 3/4 inch without anti- skid cleats installed on track, or 1/4 to 1/2 inch with anti- skid cleats installed. If this clearance cannot be obtained, remove one track shoe from each track (para 3-60), reconnect tracks, and repeat the adjustment procedure. Check to make sure the six final drive attaching screws are tight- ened to 25-30 ft-lb torque. In- stall right and left drive shaft covers. TM 9-1460-500-20 3-62. Antiskid Cleats Antiskid cleats (fig. 3-46) are in- stalled on the track when the vehicle is operated in mud, ice, or snow. For track tension adjustment with antiskid cleats installed on track, see para~ graph 3-61. Pigure 3-46. Antiskid Cleat Replacement a. Removal. (1) Inspect the cleat to determine if replacement is required. If the waffle tread is worn down to the screw heads, the cleat must be replaced. NOTE Tracks do not have to be re- moved from vehicle to replace cleat (2) Remove two nuts, four washers, and two screws which secure cleat to track section. Re- move cleat. 377‘TM 9-1450-500-20 b. 3-63. Inst. tion. (1) Position new cleat on track section and install two screws, four washers, and two nuts. NOTE Place one washer under the screw head and the other under the nut for each screw. (2) Tighten nuts to 100-115 in-1b torque. (3) Drive loader forward and re- peat removal procedure and steps (1) and (2) of install, tion to replace all worn cleats. Road Wheels Removal (fig. 3-47). (1) Remove track, if necessary (para 3-60). (2) Place jack in a suitable safe position to relieve loader weight from road wheel to be removed. (3) Remove six nuts which secure road wheel to hub. Remove road wheel halves as a unit. Installation. Install the road wheel on the hub by reversing the Sequence of the removal procedure. Tighten the wheel nuts to 75-80 ft-lb torque. Check track ten- sion and adjust (para 3-61), if 3-64. Torsion Bars 378 (Removal (fig. 3-47). The follow- ing special tools are required to perform the removal procedures: Part Special tool NSN number Adapter, 5120-00-708-3254 7083254 mechanical puller CAUTION Extreme care must be exercised when handling and withdrawing the torsion bar from the tor- sion bar anchors and wheel supports. Scoring or marring of the torsion bar surface may upset the preset torque and fracture the torsion bar or cause premature failure of the torsion ba: a) (2) (3) (4) «s) (6) Separate track over wheel to be removed (para 3-60). Remove road wheel (para 3-63). Disconnect shock absorber (if applicable). Remove torsion bar screw and ‘Attach mechanical puller adapt- er, special tool (1, fig. 1-4), to torsion bar, and using standard puller, exert only enough force on adapter to re- lease torsion bar. Remove puller and adapter from torsion bar and remove torsion bar. NOTE I£ torsion bar is broken, it will be neces: axle and hub ry to remove embly to re~ move the broken portion inside cross member. Refer raph 3-67 for axle andTM 9-1450-500-20 HEX-HEAD PRESSURE RELIEF FITTING. feo MMICATION FITING ‘PRESSURE RELIEF ‘ming -p—_} Figure 3-47. Suspension Component Replacement TASB 379TM 9-1450-600-20 b. 3-66. Installation. CAUTION Use extreme care when install- ing torsion bars to prevent scoring or marring of polished surfaces. (1) Insert torsion bar through hole in axle and hub assembly with preset arrow marking (fig. 3-50) pointing counter- clockwise on left side of vehi- cle, or clockwise on right side. Slide torsion bar into chassis cross member until it seats in torsion bar anchor. Rotate torsion bar as required to seal bar in keyway of anchor. NOTE Remove torsion bar anchor cover plate (para 3-65) if necessary, to aline anchor with torsion bar. (2) Install torsion bar plug and screw in axle and hub assem- bly. Tighten screw to 25-30 ft-1b torque. (3) Connect shock absorber (para 3-66). (4) Install road wheel (para 3-63). (5) Connect track assembly (para 3-60). (6) Adjust track tension (para 3-61). Torsion Bar Anchor Removal (fig. 3-47). (1) Remove track and applicable road wheel (para 3-60 and 3-63). (2) Remove left rear torsion bar anchor as follows: { (a) Remove fuel tank (para 3-19). (b) Remove four screws, four washers, gasket, and plate. (c) Remove torsion bar (para 3-64). (4) Remove torsion bar anchor. (3) Remove right front torsion bar anchor as follows: (a) Remove quick release pin fro zimuth cylinder rod end and swivel cylinder forward. (b) Repeat steps (2)(b), (c), and (d). (4) Remove right center torsion bar anchor as follows: (a) Raise the hydraulic control console cover. (b) Repeat steps (2)(b), (c), and (4). (5) Remove right rear torsion bar anchor as follow (a) Remove muffler, hood, hood cover, battery support frame, and engine side panel (fig. 3-54 and 3-55). (b) Repeat steps (2)(b), (ec), and (4). b. Installation. Install the torsion bar anchor by reversing the se- quence of the removal procedure. CAUTION Use extreme care when replac— ing and handling torsion bars to prevent marring and damage to surface and spline:3-66. Shock Absorber a. b. 3-67. Removal (fig. 3-47). (1) Disconnect track (para 3-60) and remove applicable road wheel (para 3-63). (2) Install a C-clamp (8 inches minimum) between road wheel arm bumper bracket on chassis and road wheel arm. Tighten clamp sufficiently to remove pressure exerted on shock absorber. WARNING Using a jack in lieu of a clamp to raise road wheel arm may result in injury to personnel or damage to equipment. (3) Remove two each cotter pins, slotted hex nuts, and washers from shock absorber mounting studs. If necessary, remove the outer rubber bushing from each end of shock absorber to obtain additional play between mounting stud and shock ab- sorber. Work shock absorber off mounting studs and remove shock absorber. (4) Remove and discard rubber bushings. Installation. Install the shock ‘absorber by reversing the se- quence of the removal procedure. NOTE Install new rubber bushings. ‘Axle and Hub Assembly Removal (fig. 3-47). (1) Separate track over wheel of axle and hub assembly to be removed (para 3-60). (2) Remove road wheel (para 3-63). ‘TM 9-1450-600-20 NOTE Plug and access plate cover should be examined for damaged threads and replaced re- quired. When damaged threads are not evident, use gasket forming compound, item 10 or 11, App D, to stop oil seep- age. An open end wrench (9/16") should be used to remove and install plug to prevent plug head damage. (3) Remove caulking and drain plug to drain oil from hub-assembly. (4) Remove cotter pin, slotted hex nut, and washer from shock absorber mounting stud on axle and hub assembly. (5) Remove torsion bar (para 3-64). (6) Remove four mounting screws securing axle and hub assembly to chassis. (7) Remove axle and hub assembly leaving shock absorber attached to chassis upper mounting stud. b. Installation. Install the axle and hub assembly by reversing the Sequence of the removal proce- dure. After installation is com plete, adjust track tension (para 3-61). Fill hub assembly with oil as specified in LO 9-1450-500-12. Apply caulking compound per MIL-C- 18255 (Appx. D) on mounting plate and chassis interface surfaces. 3-68, Suspension Lockout Assembly a. Removal (fig. 3-48). (1) Place suspension control lever in unlocked position by pull- ing handle outboard. (2) Remove one cotter pin and headed pin which retain rear stop lever hook assembly to rear mounting bracket. Change 2 381SUSPENSION ARH G3) b. Installation. NOTE 1. HEAYY UNE INDICATES toex rosmon. 2. BROKEN SHADED UNE INDICATES UNLOCKED rosnon Figure 3-48. Remove bolts from forward stop lever and rear pawl lever lock. Pull suspension control lever out from loader to release rear pawl lever lock and forward stop lever. Install the suspen- sion lockout assembly by revers- ing the sequence of the removal procedure. c. Adjustment. Make adjustments to euepension lockout assembly with loader on a flat surface. a) (2) Place suspension control lever (view A) and forward stop lever (view B) to the positions shown in figure 3-49. Tighten screw (view B) to 30- 35 ft-1b torque. Qa) (@) (5s) (6) Suspension Lockout System Place track lockup hook and actuator lever to the positios shown in view C. Adjust track lockup hook until it engages track arm. Then tighten hex nut (view C) against the track lockup hook. actuator hanger with shit til actuator lever is fully locked on the suspension loct- out hook (view C). * Tighten the screw on the sus- pension actuator hanger to 30° 35 ft-lb. torque. Then back off hex nut which secures tratt lockup hook. This allows the track lockup hook to be backedTM 8-1450-600-20 TAMRS51 Suspension Lockout System Adjustment Pigure 3-49.‘TM 9-1450-600-20 off one or two turns until hook swings back to its original position without interference. (7) Tighten hex nut against the track lockup hook to secure it. ‘Section VII, MAINTENANCE OF CONTROLS AND LINKAGE 3-69, General This section describes and illustrat the removal and installation procedures for the steering and braking controls and associated linkage, brake control lever assembly, throttle and choke con- trols, and foot accelerator and trans- mission controls and linkage. 3-70. Steering-Braking Control Assembly a. Removal (fig. 3-50). (1) Remove hood cover, hood and grille, propeller shaft rear cover, and battery cover (fig. 3-54 and 3-55). (2) Remove batteries and battery support (para 3-49), (3) Release brake tension. (4) Remove cotter pins, flat wash- ers, and clevis pins securing brake lever rod assembly to brake control lever assembly. (5) Remove four locknuts and flat washers which secure brake control lever assembly to Remove control (6) Remove cotter pins, flat wash- ers, and clevis pins which secure brake lever rods to brake control shaft levers. (7) Remove clevis fittings from end of rods. (8) Remove two pipe plugs in rear of chassis and remove control rods from vehicle through the holes. (9) Remove cotter pins, washers, and clevis pine from both ends of differential linkage rods and remove rods. (10) Remove eight bolte and flat washers which secure brake con- trol shaft brackets to chassis. (11) Remove brake control shaft and c. (2) With brake control leve: bracket: Installation. Install the steer- ing: ing control assembly by reversing the sequence of the re- moval procedure. The following adjustment procedure must be ac- complished prior to installing access covers. Adjustment. (1) With brake control levers re- leased (full forward), adjust brake rods so that the end of the rear clevis is 3/4 inch from chi jis crossmember. Tighten clevis locknuts and secure clevis pins with cotter pins. re- leased, adjust differential linkage rods so that differen- tial control levers contact stop plate. Tighten clevis locknuts and secure clevis pins with cotter pins (3) Pull both brake control levers back (toward operator). Brakes should be tight when levers are back to the fourth notch of the ratchet quadrant. If thie condition does not ex ist, release brake control levers and adjust brake bands‘TM 9-1450500-20 BRAKE ROD, corres ev ct) Figure 3-50. Steering-Braking Control Assembly Replacement‘TM 9-1450-600-20 as specified on plate on front (3) Compress collar and spring. of differential. Remove pin which retains but- ton to rod. Remove button, (4) The minimum turning circle of collar spring, and bushing the loader shall be measured. from rod. The loader shall remain within a 40-foot diameter circle when (4) Back out setscrew on outside turning to the right or left. of handle, adjacent to pawl. 3-71. Brake Control Lever (5) Remove pawl and rod assembly. Loosen locknut and unscrew a. Removal (fig. 3-51). pawl from the rod. (1) Remove locknut, flat washer, c. Assembly. Assemble the brake and bolt from arm on inboard control lever by reversing the end of lever shaft. sequence of the disassembly procedure. (2) Remove arm. NOTE NOTE , Tighten setscrews in sides of Disconnect brake lever linkage levers sufficiently to remove at arm, if necessary. excessive play without binding. (3) Remove locknut, flat washer, 4. Installation. Install the brake and bolt from right hand lever. control lever by reversing the sequence of the removal procedure. (4) Remove lubrication fitting from outboard end of lever shaft 3-72. Throttle Control (Side-mounted) and tap shaft out from levers u and mounting bracket. a. Removal (fig. 3-52). (5) Remove left and right lever (1) Remove engine hood, grille, handles and two woodruff keys. and hood cover (fig. 3-54). (6) Remove two locknuts, bolts, (2) Remove loop clamp which se- and spacers which secure quad- cures throttle cable housing rants to mounting bracket. to chassis. b. Disassembly (fig. 3-51). (3) Straighten throttle wire and remove stop clamp. NOTE (4) Loosen locknut which secures Steps (1) through (5) follow- throttle control handle. ing are the same for right and : left levers. (5) Slide locknut and washer off throttle control and remove (1) Unscrew guide from lever throttle control. handle. b. Ins ion. Install the throt- (2) Knock out pin which retains tle control by reversing the se- collar to rod. quence of the removal procedure. 3-96 change 2TM 9-1450-600-20 Figure 3-51. Steering-Braking Levers and Component Replacement‘TM 9-1450-500-20 ¥ if 8 oh = tac Figure 3-52. Choke and Throttle Controls and Linkage3.72.1. THROTTLE CONTROL (console mounted) a. Removal (fig. 3-52.1) (1) Loosen setscrew (1) that holds cable end in collar (2) behind gearshift. (2) Remove clamp (3) from side by removing nut (4), washer (5), and screw (6). (3) Remove clamp (7) from vehicle frame by removing screw (8) and washer (9). (4) Remove clamp (10) from vehicle lower frame by removing screw (11) (5) Loosen locknut (12) to release throttle control assembly (13) from console bracket. (6) Pull throttle control assembly cable through clamps and remove. b. Installation (1) Replace clamps (3), (7), and (10), using mounting hardware above. (2) Replace throttle control assembly (13) in console bracket and tighten Jocknut (12). (3) Thread throttle assembly cable through clamps (10), (7), and (3) and insert end in collar (2) behind gearshift. (4) Tighten setscrew (1) to hold cable in collar (2). CHANGE 2 ‘TM 9-1450-500-203-73. Choke Control a. Removal (fig. 3-52). qa) (2) Qa) (4) qs) Remove engine hood, grille, and hood cover (fig. 3-54). Loosen clamp which secures choke assembly to carburetor choke shaft lever. Loosen screw shich secures choke wire to lever. clamp which esembly to Remove loop secures choke valve cover. Back off locknut which holds choke assembly to engine hood support frame. Slide locknut and washer off choke cable and remove choke assembly. b. Installation. qa) (2) @) () qs) (6) Insert choke cable through mounting hole in engine hood support frame. Install lock- nut on rear of frame. Insert choke housing through cable retaining clamp and choke wire through butterfly swivel clamp. Tighten cable housing retaining clamp. Verify choke control knob is fully in and tighten swivel clamp while holding butterfly in full open position. Install loop clamp (loop down) to secure choke cable housing to valve cover. Operate choke control to make sure proper carburetor action is obtained. Install remove covers. 3-74. b. (2) q@) ‘TM 9-1450-600-20 Accelerator Controls and Linkage Pedal Assembly. (1) Removal (fig. 3-53). (a) Remove universal _ joint access cover (fig. 3-55). (b) Remove locknut which secures ball joint end of accelera- tor rod to pedal shaft lever. Pull ball-joint end of rod away from pedal lever. (c) Pull pedal back to remove bolts and locknuts which secure pedal assembly to pedal shaft. (d) Remove locknut, pedal shaft lever, and two plain nuts from shaft lever. Remove pedal shaft from pedal mounting bracket. Remove accelerator pedal sembly from mounting bracket. Installation. Install the pedal assembly by reversing the sequence of the removal procedure. Accelerator Linkage. Removal (fig. 3-53). (a) Remove cotter pin and flat head pin which secures ac- celerator rod clevis to in- board accelerator control shaft lever. Remove locknut which secures ball-joint end of accelerator rod to accelerator pedal shaft lever. Remove rod assembly. (b) Remove throttle control rod assembly and transmission- to-engine throttle link rod by removing locknuts whichTM 9-1450-600-20 CARBURETOR BELLCRANK CARBURETOR BELLCRANK ROD ASSEMBLY CONNECTING LEVER ‘TRANSMISSION ‘THROTTLE VALVE Lever LEVER ARM DASHEGT DOWNSHIFT ADJUSTING SCREW THROTTLE CONTROL, ROD ASSEMBLY DOWNSHIFT LINKAGE DOWNSHIFT LEVER TRANSMISSION | CONTROL ROD ASSEMBLY | Z - fo <5 CONTROL SHIFT Te GROMMET sececton f Se acceltnnron SASS CONTROL Levert PK OUTBOARD: TRANSMISSION CONTROL ASSEMBLY PEDAL - ASSEMBLY a . ACCELERATOR CONTROL LEVER TRANSMISSION contro sHarT Leven ¥ . SWITCH ~ SPRING BEARING: ‘ e* ASSEMBLY, COTTER PIN RETAINER ; accetenaror “ ro CONTROL SHAFT Far HEX pin ‘KeceLERATOR| vs» ROD ASSEMBLY’ PEDAL SHAFT) © TRANSMISSION x

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