Maintenance Manual For Loader, Scoop Type, Ded 4 X 4, Articulated Frame Steer, 4.5 To 5 Cu. Yd.

CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION
GENERAL INFORMATION
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRS)
Figure 3. Loader Serial Number Location on Rear Frame.
Figure 4. 817 Series C Diesel Engine.
EQUIPMENT DESCRIPTION AND DATA
EQUIPMENT DESCRIPTION
EQUIPMENT DATA
EQUIPMENT DATA - Continued
EQUIPMENT DATA - Continued
Figure 2. Dimension Diagram.
SYSTEM PRESSURES
THEORY OF OPERATION
ENGINE
Figure 1. Exploded View of Connecting Rod Assembly.
Figure 2. Exploded View of Piston Assembly.
Figure 3. Camshaft Components.
Figure 4. Gear Train.
ELECTRICAL SYSTEM
Figure 5. Typical Two-Unit Regulator.
Figure 6. Typical Wiring Diagram Showing Internal Circuits.
ELECTRICAL SYSTEM - Continued
Figure 7. Typical 6VDC Storage Battery.
ELECTRICAL SYSTEM - Continued
Figure 8. Diesel Engine Starter - Cross-Section.
Figure 9. Front of Transmission.
Figure 10. Rear of Transmission.
Figure 11. Propeller Shafts.
Figure 12. Transfer Drive.
Figure 13. Typical Solid Axle.
Figure 14. Brake System Schematic.
Figure 15. Brake System Schematic.
BRAKE SYSTEM
Figure 16. Air Control System.
Figure 17. Cutaway of Pressure Regulator.
Figure 18. Cutaway of Air Solenoid Valve (Closed).
Figure 19. Cutaway of Air Solenoid Valve (Opened).
Figure 20. Cutaway of Air Solenoid Valve (Closed).
Figure 21. Chassis Components.
Figure 22. Main Frame Assembly.
Figure 23. Sheet Cowling.
Figure 24. Operator's Compartment.
Figure 25. Boom and Bucket (4.5 cu. Yard Bucket Shown).
Figure 26. Boom Kick-Out Control System.
HYDRAULIC AND FLUID SYSTEMS
HYDRAULIC AND FLUID SYSTEMS - Continued
CHAPTER 2 OPERATOR INSTRUCTIONS
DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS
Figure 1. Controls.
OPERATOR CONTROLS
Figure 2. Controls.
OPERATOR CONTROLS - Continued
Figure 3. Controls.
Figure 4. Instrument Panel.
Figure 5. Instrument Panel.
OPERATOR CONTROLS - Continued
Figure 6. Air Cleaner Service Indicator.
Figure 7. Heater and Defroster Control.
Figure 8. Master Electrical Switch.
OPERATION UNDER USUAL CONDITIONS
Figure 1. Safety Bars and Pins in Stowed Position.
Figure 3. Safety Pin Installed in Full Turn Lock Position.
Figure 4. Starting The Engine.
STARTING THE ENGINE
Figure 5. Driving the Loader.
DRIVING THE LOADER
Figure 6. Boom Control Lever Positions.
Figure 7. Bucket Control Lever Positions.
Figure 8. Boom Stop Positioner.
Figure 9. Stopping the Loader.
STOPPING THE LOADER
Figure 10. Stopping the Engine.
OPERATING TECHNIQUES
Figure 11. Loading Sequence.
OPERATING TECHNIQUES - Continued
Figure 13. Loading Large Rock.
Figure 15. Transporting a Load.
Figure 17. V-Method of Loading.
Figure 20. Hopper Loading.
Figure 21. Dumping Into Truck Body.
'TM 255-14.book' by ndesantis - Page 104 of 1460
Figure 25. Avoid Overhangs.
Figure 27. Removing Small Trees.
Figure 28. Clearing Large Trees.
Figure 30. Access Panels.
Figure 31. Fan Guard.
OPERATION UNDER UNUSUAL CONDITIONS
SLAVE STARTING THE LOADER
OPERATION IN EXTREME COLD
OPERATION IN EXTREME COLD - Continued
OPERATION IN EXTREME HEAT
OPERATION IN EXTREME HEAT - Continued
OPERATION IN SANDY OR DUSTY CONDITIONS
OPERATION AT HIGH ALTITUDES
OPERATION IN SNOW AND ICE
STOWAGE AND DECAL, DATA PLATE, AND STENCIL GUIDE
Figure 3. Interior Decals.
Figure 4. Left Side Decals.
Figure 5. Right Side Decals.
Figure 6. Control Data Plates.
Figure 7. Left Side Data Plates.
Figure 8. Right Side Data Plates.
PREPARATION FOR STORAGE OR SHIPMENT
PREPARATION FOR STORAGE
PREPARATION FOR OPERATION
CHAPTER 3 OPERATOR TROUBLESHOOTING PROCEDURES
OPERATOR TROUBLESHOOTING INTRODUCTION
OPERATOR TROUBLESHOOTING SYMPTOM INDEX
BRAKE SYSTEM
OPERATOR TROUBLESHOOTING PROCEDURES
Table 1. Engine Troubleshooting Procedures for H100C Loader
Table 1. Engine Troubleshooting Procedures for H100C Loader - Continued
Table 2. Electrical Troubleshooting Procedures for H100C Loader.
Table 3. Transmission Troubleshooting Procedures for H100C Loader.
Table 4. Brake System Troubleshooting Procedures for H100C Loader.
Table 4. Brake System Troubleshooting Procedures for H100C Loader - Continued
Table 5. Steering Troubleshooting Procedures for H100C Loader.
Table 5. Steering Troubleshooting Procedures for H100C Loader - Continued
Table 6. Hydraulic System Troubleshooting Procedures for H100C Loader.
CHAPTER 4 OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL PMCS PROCEDURES
GENERAL PMCS PROCEDURES - Continued
OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C.
Figure 1. Air Tank Drain Valves.
Figure 2. Articulation Pivot Lubrication Points.
Figure 3. Checking Engine Oil Level.
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Figure 4. Air Filter.
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Figure 5. Air Cleaner Service Indicator.
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Figure 7. Transmission Oil.
Figure 8. Articulation Pivot Lubrication Points.
Figure 9. Coolant Level.
Figure 10. Hydraulic Reservoir.
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Figure 11. Bucket Link Lubrication Points.
Figure 12. Bucket Cylinder Front Lubrication Points.
Figure 14. Bucket Pivot.
Figure 15. Bellcrank Pivot Lubrication Points.
Figure 16. Boom Pivot Lubrication Points.
Figure 17. Boom Cylinder Bottom Lubrication Point.
Figure 18. Boom Cylinder Top Lubrication Point.
Figure 19. Steering Cylinder Front Lubrication Points.
Figure 20. Steering Cylinder Rear Lubrication Points.
Figure 21. Drag Link Front Lubrication Points.
Figure 23. Axle Cradle Lubrication Points.
Figure 24. Steering Cylinder Front Lubrication Points.
Figure 25. Steering Cylinder Rear Lubrication Points.
Figure 27. Drag Link Rear Lubrication Points.
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Figure 28. Bucket Link Lubrication Points.
Figure 29. Bucket Cylinder Front Lubrication Points.
Figure 31. Bucket Pivot Lubrication Points.
Figure 32. Bellcrank Pivot Lubrication Points.
Figure 33. Boom Pivot Lubrication Point.
Figure 34. Boom Cylinder Bottom Lubrication Points.
Figure 36. Cab Air Filter.
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Figure 37. Air Compressor Belt Tension Check Point.
Figure 38. Alternator Belt Tension Check Point.
Table 1. Preventive Maintenance Checks and Services (PMCS) for H100C - Continued
Figure 39. Intermediate Drive Block.
LUBRICATION INSTRUCTIONS
LUBRICATION INSTRUCTIONS - Continued
Table 2. Lubricants.
Figure 40. Lubrication Instructions - Checking OE/HDO and Antifreeze.
Table 3. Coolants.
Figure 41. Lubrication Instructions - GAA Applications.
CHAPTER 5 FIELD TROUBLESHOOTING PROCEDURES
FIELD TROUBLESHOOTING INTRODUCTION
FIELD TROUBLESHOOTING SYMPTOM INDEX
FRONT AND REAR AXLES
HYDRAULIC
FIELD TROUBLESHOOTING PROCEDURES
Table 1. Engine Troubleshooting Procedures for the H100C Loader
Table 1. Engine Troubleshooting Procedures for the H100C Loader - Continued
Table 2. Electrical Troubleshooting Procedures for the H100C Loader.
Table 2. Electrical Troubleshooting Procedures for the H100C Loader - Continued
Table 3. Electrical System Instruments Troubleshooting Procedures for the H100C Loader.
Table 4. Transmission Troubleshooting Procedures for the H100C Loader.
Table 4. Transmission Troubleshooting Procedures for the H100C Loader - Continued
Table 5. Propeller Shafts Troubleshooting Procedures for the H100C Loader.
Table 6. Transfer Drive Troubleshooting Procedures for the H100C Loader.
Table 7. Front and Rear Axle Troubleshooting Procedures for the H100C Loader.
Table 8. Brake System Troubleshooting Procedures for the H100C Loader.
Table 8. Brake System Troubleshooting Procedures for the H100C Loader - Continued
Table 8. Brake System Troubleshooting Procedures for the H100C Loader - Continued
Table 8. Brake System Troubleshooting Procedures for the H100C Loader - Continued
Table 8. Brake System Troubleshooting Procedures for the H100C Loader - Continued
Table 10. Steering Gear Troubleshooting Procedures for the H100C Loader.
Table 12. Hydraulic Main Control Valve Troubleshooting Procedures for the H100C Loader.
Table 14. Hydraulic Steering Control Valve Troubleshooting Procedures for the H100C Loader.
CHAPTER 6 FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL LUBRICATION PROCEDURES
GENERAL PMCS PROCEDURES
FIELD PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INCLUDING LUBRICATION INSTRUCTIONS
Table 1. Field PMCS for the H100C Loader.
Figure 1. Axle Breather.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 2. Propeller Shaft Lubrication.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 3. Air Compressor Belt Adjustment.
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Figure 4. Axle Breather.
Figure 5. Fuel Tank Drain Plug.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 6. Priming and Venting the Fuel System.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 7. Crankcase Drain Plug.
Figure 8. Engine Lubricating Oil Filters.
Figure 9. Crankcase Oil Filler Cap and Level Gauge.
Figure 10. Transmission Sump Strainer and Drain Plug.
Figure 11. Sump Strainer Assembly.
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Figure 13. Transmission Oil Filter.
Figure 14. Air Filter.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 15. Alternator Belt Adjustment.
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Figure 16. Transmission Breather.
Figure 18. Sectional View of Valve Mechanism.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 19. Engine Cylinder Head Torquing Sequence.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 20. Intermediate Drive Block.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 21. Power Cluster.
Figure 22. Steering Gear.
Figure 23. Parking Brake Linkage.
Table 1. Field PMCS for the H100C Loader - Continued
Figure 24. Coolant Level.
Figure 25. Radiator Drain Valve Cover Plate.
Figure 26. Engine Oil Cooler Drain Valve.
Figure 27. Left Engine Crankcase Drain Valve.
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Figure 28. Exploded View of Hydraulic Reservoir.
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Table 1. Field PMCS for the H100C Loader - Continued
Figure 29. Axle Drain and Filler Plug.
gure 30. Planetary Drain Plug at 6 O'Clock Position.
Figure 31. Planetary Drain at 12 O'Clock Position.
LUBRICATION INSTRUCTIONS
LUBRICATION INSTRUCTIONS - Continued
Table 6. Lubricants.
Figure 32. Lubrication Instructions - Fluid and Filter Changes.
CHAPTER 7 FIELD MAINTENANCE
GENERAL MAINTENANCE INSTRUCTIONS
RELIEVING HYDRAULIC SYSTEM PRESSURE
CLEANING INSTRUCTIONS
CLEANING INSTRUCTIONS - Continued
INSPECTION INSTRUCTIONS
INSPECTION INSTRUCTIONS - Continued
REPAIR INSTRUCTIONS
STANDARD TOOL REQUIREMENTS
FLUID DISPOSAL
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS
Figure 1. Multiple-Pin Connector Identification.
Figure 2. Connector Repair.
Figure 4. Sealed Connector Repair.
Figure 5. Receptacle Connector Repair.
Figure 6. Waterproof Connector Repair.
Figure 7. Military Connector Repair.
Figure 8. Ring Terminal Repair.
ELECTRICAL GROUND POINTS
Figure 10. Multimeter Usage.
Figure 11. Testing Continuity.
Figure 12. Testing For Shorts.
Figure 13. Multimeter Usage.
Figure 1. Gauge Cluster.
Figure 2. Circuit Breaker.
Figure 3. Gauge Cluster.
ENGINE REPLACEMENT
Figure 1. Ether Supply Line.
Figure 2. Heater Hoses.
ENGINE REPLACEMENT - Continued
ENGINE REPLACEMENT - Continued
ENGINE REPLACEMENT - Continued
LUBRICATING OIL AND WATER PUMP REPLACEMENT
Figure 1. Radiator Hoses.
Figure 2. Hoses and Clamps.
Figure 3. Oil Pump Manifold.
Figure 4. Oil and Water Pump.
Figure 5. Oil and Water Pump.
Figure 6. Oil Pump Manifold.
Figure 7. Hoses and Clamps.
Figure 8. Radiator Hoses.
ENGINE OIL COOLER REPLACEMENT
Figure 1. Engine Oil Cooler.
ENGINE OIL COOLER REPLACEMENT - Continued
Figure 2. Cover Plates and Coupling Installed.
Figure 3. Engine Oil Cooler.
ENGINE BREATHER REPLACEMENT
Figure 2. Engine Breather.
Figure 3. Clamp.
INTAKE AND EXHAUST MANIFOLD REPLACEMENT
INTAKE AND EXHAUST MANIFOLD REPLACEMENT - Continued
Figure 1. Turbocharger Connections and Manifold.
Figure 2. Intake Manifold.
Figure 3. Intake Manifold.
Figure 4. Turbocharger Connections and Manifold.
Figure 1. Cylinder Head.
Figure 2. Fuel Lines.
Figure 3. Injector Nozzles.
Figure 4. Injector Nozzles.
Figure 5. Fuel Lines.
Figure 6. Cylinder Head.
FUEL INJECTION PUMP REPLACEMENT AND TIMING
Figure 1. Injection Pump Timing Port.
Figure 2. Exploded View of Injection Pump Adapter.
Figure 3. Fuel Injection Pump Cables.
Figure 4. Fuel Injection Lines and Pump.
Figure 5. Fuel Injection Lines and Pump
Figure 7. Injection Pump Adjustable Support with Bracket.
Figure 8. Fittings and Clamps.
Figure 9. Seal Wire Locations.
FUEL INJECTION PUMP REPLACEMENT AND TIMING - Continued
Figure 10. Seal Wire Locations.
FUEL INJECTION PUMP REPLACEMENT AND TIMING - Continued
Figure 11. Injection Pump Governor Control Lever and Shut-Off Lever Positions.
Figure 12. Injection Pump Timing Port in Crankcase Front Cover
AIR CLEANER ASSEMBLY REPLACEMENT
AIR CLEANER ASSEMBLY REPLACEMENT - Continued
Figure 1. Air Cleaner.
Figure 2. Air Cleaner Elements.
AIR CLEANER ASSEMBLY REPLACEMENT - Continued
Figure 3. Air Cleaner Elements.
Figure 4. Air Cleaner.
TURBOCHARGER REPLACEMENT
Figure 1. Turbocharger.
TURBOCHARGER REPLACEMENT - Continued
FUEL TANK REPLACEMENT
FUEL TANK REPLACEMENT - Continued
Figure 1. Fuel Tank and Related Parts.
FUEL TANK REPLACEMENT - Continued
Figure 2. Fuel Tank and Related Parts.
GOVERNOR REPLACEMENT AND ADJUSTMENT
Figure 1. Governor.
GOVERNOR REPLACEMENT AND ADJUSTMENT - Continued
ACCELERATOR LINKAGE REPLACEMENT
Figure 2. Foot Throttle (Pedal End).
Figure 3. Accelerator Pedal.
Figure 4. Hand Throttle.
ACCELERATOR LINKAGE REPLACEMENT - Continued
Figure 5. Accelerator Pedal.
Figure 6. Foot Throttle (Pedal End).
Figure 7. Foot Throttle (Engine End).
Figure 8. Accelerator Pedal.
Figure 9. Hand Throttle.
Figure 1. Emergency Shutdown Control Cable.
Figure 3. Emergency Shutdown Control Handle.
Figure 4. Emergency Shutdown Control Cable.
MUFFLER REPLACEMENT
MUFFLER REPLACEMENT - Continued
Figure 1. Muffler.
RADIATOR AND CONVERTER OIL COOLER REPLACEMENT
RADIATOR AND CONVERTER OIL COOLER REPLACEMENT - Continued
Figure 1. Radiator.
RADIATOR AND CONVERTER OIL COOLER REPLACEMENT - Continued
Figure 2. Radiator.
RADIATOR AND CONVERTER OIL COOLER REPLACEMENT - Continued
THERMOSTAT REPLACEMENT
Figure 1. Thermostat.
THERMOSTAT REPLACEMENT - Continued
FAN DRIVE ASSEMBLY REPLACEMENT
Figure 1. Fan Drive Assembly Removal.
Figure 2. Raised Boss on Fan Housing.
FAN DRIVE ASSEMBLY REPLACEMENT - Continued
Figure 3. Install Fan, Generator, Air Compressor, and Belts.
FAN DRIVE ASSEMBLY REPLACEMENT - Continued
Figure 4. Torque Adaptor and Mounting Assembly.
LUBRICATING OIL FILTER HOUSING AND VALVE REPLACEMENT
Figure 2. Pressure Regulating Valve.
Figure 3. Oil Filter Head.
Figure 4. Oil Filter Head.
Figure 5. Pressure Regulating Valve.
ALTERNATOR REPLACEMENT
Figure 1. Alternator Wiring.
Figure 2. Alternator Mounting.
Figure 3. Alternator Mounting.
Figure 4. Alternator Wiring.
STARTER REPLACEMENT
Figure 1. Starter Removal and Installation.
STARTER REPLACEMENT - Continued
SWITCH REPLACEMENT
Figure 2. ON/OFF Switch Wiring.
Figure 3. ON/OFF Switch.
Figure 4. Headlamp Switch Wiring.
Figure 5. Headlamp Switch.
Figure 6. Starter Button Switch Wiring.
Figure 7. Starter Button.
Figure 8. Headlamp Switch.
Figure 9. Headlamp Switch Wiring.
Figure 10. ON/OFF Switch.
Figure 12. Gauge Cluster.
ELECTRIC GAUGE REPLACEMENT
Figure 2. Gauge Removal.
Figure 3. Gauge Cluster
SENDING UNIT REPLACEMENT
SENDING UNIT REPLACEMENT - Continued
Figure 1. Fuel Tank and Related Parts.
Figure 2. Water Temperature Sending Unit.
Figure 3. Oil Pressure Sending Unit.
Figure 4. Oil Pressure Sending Unit.
Figure 5. Water Temperature Sending Unit.
SENDING UNIT REPLACEMENT - Continued
Figure 6. Fuel Tank and Related Parts.
SENDING UNIT REPLACEMENT - Continued
BATTERY SERVICE AND REPLACEMENT
BATTERY SERVICE AND REPLACEMENT - Continued
Figure 1. 12VDC Battery.
Figure 2. 6VDC Batteries.
BATTERY SERVICE AND REPLACEMENT - Continued
Figure 3. 12VDC Battery.
TRANSMISSION CONTROL LINKAGE REPLACEMENT
TRANSMISSION CONTROL LINKAGE REPLACEMENT - Continued
Figure 1. Transmission Control Linkage.
TRANSMISSION CONTROL LINKAGE REPLACEMENT - Continued
Figure 2. Transmission Control Linkage.
Figure 3. Transmission Control Linkage Adjustment.
TORQUE CONVERTER REPLACEMENT
Figure 1. Cooler Lines and Tube Removal.
Figure 2. Propshaft and Converter.
Figure 3. Propshaft and Converter.
Figure 4. Cooler Line Hoses and Tube.
TRANSMISSION REPLACEMENT
Figure 1. Rear Axle Propeller Shaft.
Figure 2. Demand Valve Hoses.
Figure 3. Hose Bracket and Demand Valve.
Figure 4. Transmission Mounts.
Figure 5. Transmission Mounts.
Figure 7. Demand Valve Hoses and Bracket.
Figure 8. Rear Axle Propeller Shaft.
PROPELLER SHAFT REPLACEMENT
Figure 1. Propeller Shaft Removal.
Figure 2. Propeller Shaft Disassembly.
Figure 4. Propeller Shaft Assembly.
Figure 5. Spider Installation.
Figure 7. Bearing Cap Wire Installation.
Figure 8. Propeller Shaft Installation.
TRANSFER DRIVE REPLACEMENT/REPAIR
Figure 1. Dipstick and Drain Plug Removal.
Figure 2. Transfer Drive Removal.
Figure 4. Transfer Drive Cover Removal.
Figure 6. Transfer Drive Shaft Removal.
Figure 8. Output Bearing and Seal Removal.
Figure 9. Bearing Cups Installation.
Figure 10. Bearing Installation.
Figure 12. Oil Seal Installation.
Figure 13. Cover Installation.
Figure 14. Yoke and Drum Installation.
Figure 15. Bearing Installation.
Figure 17. Drain Plug Installation.
Figure 18. Transfer Drive Installation.
FRONT AXLE ASSEMBLY REPLACEMENT
Figure 1. Front Axle.
FRONT AXLE ASSEMBLY REPLACEMENT - Continued
FRONT DIFFERENTIAL REPLACEMENT
Figure 1. Front Axle Differential.
FRONT DIFFERENTIAL REPLACEMENT - Continued
FRONT FINAL DRIVE/PLANETARY ASSEMBLY REPLACEMENT
Figure 3. Axle Removal.
Figure 5. Planetary Carrier Removal.
Figure 6. Planetary Fastener Installation.
Figure 8. Thrust Button Inspection.
Figure 9. Planetary Cover Installation.
REAR AXLE ASSEMBLY REPLACEMENT
Figure 1. Rear Axle.
REAR AXLE ASSEMBLY REPLACEMENT - Continued
REAR DIFFERENTIAL REPLACEMENT
Figure 1. Rear Differential Removal.
REAR DIFFERENTIAL REPLACEMENT - Continued
REAR FINAL DRIVE/PLANETARY ASSEMBLY REPLACEMENT
Figure 3. Axle Tool.
Figure 5. Planetary Fastener Removal.
Figure 6. Planetary Carrier Removal.
Figure 7. Planetary Fastener Installation.
Figure 9. Thrust Button Inspection.
Figure 11. Drain Plug Installation.
PARKING BRAKE LINKAGE REPLACEMENT
Figure 1. Parking Brake Linkage (Lower).
Figure 2. Parking Brake Linkage (Upper).
Figure 3. Parking Brake Linkage (Upper).
Figure 4. Parking Brake Linkage (Lower).
Figure 5. Parking Brake Linkage (Upper).
PARKING BRAKE ASSEMBLY REPLACEMENT
Figure 2. Yoke and Drum Separation.
Figure 3. Brake Shoe.
Figure 4. Cam Lever.
Figure 5. Backing Plate.
Figure 7. Cam Lever.
Figure 9. Drum Assembly.
Figure 10. Yoke and Drum Assembly.
Figure 11. Transmission to Transfer Drive.
SERVICE BRAKES REPLACEMENT/REPAIR
Figure 1. Spider Assembly.
Figure 3. Wedge and Roller Removal.
Figure 4. Wedge and Roller Disassembly.
Figure 5. Brake Shoe Disassembly.
Figure 6. Plunger Disassembly.
Figure 7. Brake Relining.
Figure 9. Brake Line at Wheel Cylinder.
Figure 10. Brake Line at Power Cluster.
Figure 11. Brake Line at Wheel Cylinder.
Figure 12. Brake Line at T-Fitting.
Figure 14. Brake Line at Wheel Cylinder.
Figure 15. Brake Line at T-Fitting.
Figure 16. Plunger Assembly.
Figure 17. Brake Shoe Assembly.
Figure 19. Wedge and Roller Installation.
Figure 20. Wheel Cylinder Assembly.
SERVICE BRAKES REPLACEMENT/REPAIR - Continued
Figure 21. Spider Assembly.
SERVICE BRAKES REPLACEMENT/REPAIR - Continued
POWER CLUSTER ASSEMBLIES REPLACEMENT/REPAIR
Figure 1. Power Cluster Lines.
Figure 2. Power Cluster.
Figure 4. Bracket.
Figure 6. Air Cylinder.
Figure 8. Rod Boot.
Figure 9. Hydraulic Cylinder Disassembly.
Figure 11. Check Valve.
Figure 13. Hydraulic Cylinder Assembly.
Figure 15. Piston Cup.
Figure 17. Return Spring.
Figure 19. Hydraulic Cylinder.
Figure 21. Power Cluster Lines.
TREADLE VALVES REPAIR
Figure 1. Treadle.
Figure 2. Roller.
Figure 3. Left Treadle Valve.
Figure 4. Right Treadle Valve.
Figure 5. Plunger.
Figure 7. Piston Spring.
Figure 9. Valves.
Figure 10. Cover.
Figure 11. Packing.
Figure 12. Cover.
Figure 14. Push Rod.
Figure 15. Piston Spring.
Figure 17. Right Treadle Valve.
Figure 18. Plunger.
Figure 19. Left Treadle Valve.
Figure 21. Treadle.
TREADLE VALVES REPAIR - Continued
AIR RESERVOIR REPLACEMENT
Figure 1. Reservoir (Left Side).
Figure 2. Reservoir (Right Side).
Figure 3. Reservoir (Right Side).
Figure 4. Reservoir (Left Side).
SAFETY VALVE AND CHECK VALVE REPLACEMENT
Figure 1. Safety Valve.
SAFETY VALVE AND CHECK VALVE REPLACEMENT - Continued
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 500)
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 500) - Continued
Figure 1. Air Compressor Mounting.
Figure 2. Air Compressor Cylinder Head.
Figure 3. Air Discharge.
Figure 4. Base Plate.
Figure 5. Cylinder Block.
Figure 6. Piston.
Figure 7. Crankshaft.
Figure 8. Seating Discharge Valve with Dowel.
Figure 9. Checking Piston and Cylinder Bore Clearance.
Figure 11. Checking Piston Ring Gap.
Figure 12. Position and Clearance of Piston Rings.
Figure 13. Crankshaft.
Figure 14. Piston.
Figure 15. Method of Installing Wrist Pin Lockwire.
Figure 16. Piston.
Figure 17. Cylinder Block.
Figure 18. Base Plate.
Figure 19. Air Discharge.
Figure 20. Air Compressor.
Figure 21. Air Compressor Mounting.
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 500) - Continued
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 501)
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 501) - Continued
Figure 1. Air Compressor Mounting.
Figure 2. Air Compressor Cylinder Head.
Figure 3. Base Plate.
Figure 4. Piston.
Figure 5. Crankshaft.
Figure 6. Correct Piston Ring Groove Clearance.
Figure 7. Crankshaft.
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 501) - Continued
Figure 8. Piston.
AIR COMPRESSOR REPLACEMENT AND REPAIR (MODEL 501) - Continued
Figure 9. Air Compressor Cylinder Head.
Figure 10. Air Compressor Mounting.
Figure 11. Air Compressor Mounting.
WHEEL REPLACEMENT
Figure 2. Wheel Assembly.
STEERING WHEEL AND COLUMN REPLACEMENT
Figure 1. Steering Wheel Replacement.
Figure 2. Steering Column Removal.
Figure 3. Steering Column Disassembly.
Figure 5. Seal and Bushing Removal.
Figure 6. Seal and Bushing Installation.
Figure 8. Steering Column Disassembly.
STEERING WHEEL AND COLUMN REPLACEMENT - Continued
Figure 9. Steering Column Installation.
Figure 10. Steering Wheel Replacement.
STEERING GEAR REPLACEMENT/ADJUSTMENT
Figure 3. Steering Gear Installation.
Figure 4. Adjustment.
Figure 5. Gear Lash Final Adjustment.
STEERING LINKAGE REPLACEMENT
STEERING LINKAGE REPLACEMENT - Continued
Figure 1. Steering Linkage.
Figure 2. Pitman Arm.
Figure 3. Tie-Rod End.
Figure 4. Tie-Rod End.
Figure 5. Pitman Arm.
STEERING LINKAGE REPLACEMENT - Continued
Figure 6. Steering Linkage.
Figure 7. Steering Gear Lock Stop Bolt.
STEERING PUMP ASSEMBLY REPLACEMENT
Figure 1. Steering Pump.
STEERING PUMP ASSEMBLY REPLACEMENT - Continued
STEERING CYLINDER REPLACEMENT
Figure 1. Steering Cylinder (Front).
Figure 2. Steering Cylinder (Rear).
Figure 3. Steering Cylinder (Rear).
Figure 4. Steering Cylinder (Front).
STEERING CONTROL VALVE REPLACEMENT
Figure 1. Steering Control Valve, Left Side.
Figure 2. Steering Control Valve, Right Side.
Figure 3. Steering Control Valve, Right Side.
Figure 4. Steering Control Valve, Left Side.
Figure 5. Steering Control Valve Adjustment.
DEMAND VALVE REPLACEMENT AND REPAIR
Figure 1. Demand Valve, Passenger Side.
Figure 2. Demand Valve, Driver Side.
DEMAND VALVE REPLACEMENT AND REPAIR - Continued
Figure 3. Demand Valve.
DEMAND VALVE REPLACEMENT AND REPAIR - Continued
Figure 4. Demand Valve.
Figure 5. Demand Valve, Driver Side.
Figure 6. Demand Valve, Passenger Side.
CENTER HINGE ADJUSTMENT
CENTER HINGE ADJUSTMENT - Continued
Figure 3. Center Hinge Bushing.
Figure 5. Lower Hinge Detail.
CAB REPLACEMENT
Figure 2. Heater Hoses.
Figure 3. Wiper Control Valve.
Figure 4. Wiper Motor and Arms.
Figure 5. Control Rod.
Figure 7. Seat Assembly.
Figure 8. Floor Wiring.
Figure 9. Control Box and Cover.
Figure 10. Ladder and Handrail.
Figure 12. Cab Bottom Fasteners.
Figure 13. Cab Side Fasteners.
Figure 14. Bracket.
Figure 15. Upper Floor Plates.
Figure 16. Lower Floor Plates.
Figure 17. Brackets.
Figure 18. Lower Floor Plates.
Figure 19. Upper Floor Plate.
Figure 20. Cab.
Figure 21. Bracket.
Figure 22. Cab Side Fasteners.
Figure 23. Cab Bottom Fasteners.
Figure 24. Ladder and Handrail.
Figure 25. Control Box and Cover.
Figure 27. Seat Assembly.
Figure 28. Boom Stop Positioner Control.
Figure 30. Wiper Motor and Arms.
Figure 31. Wiper Control Valve.
Figure 32. Heater Hoses.
Figure 33. Power Wire.
WINDSHIELD WIPER MOTOR REPLACEMENT
Figure 2. Front Windshield Wiper Motor.
Figure 4. Rear Windshield Wiper Motor.
Figure 5. Rear Wiper Motor Bracket.
Figure 6. Rear Wiper Motor Bracket.
Figure 7. Rear Windshield Wiper Motor.
Figure 8. Rear Wiper Arm.
Figure 9. Front Windshield Wiper Motor.
Figure 10. Front Windshield Wiper Arms.
MAIN HYDRAULIC PUMP REPLACEMENT
Figure 1. Main Hydraulic Pump.
MAIN HYDRAULIC PUMP REPLACEMENT - Continued
MAIN CONTROL VALVE REPLACEMENT
Figure 2. Front Hydraulic Line.
Figure 3. Side Hydraulic Line.
Figure 4. Main Control Valve.
Figure 5. Side Hydraulic Lines.
Figure 6. Side Hydraulic Lines.
MAIN CONTROL VALVE REPLACEMENT - Continued
MAIN CONTROL VALVE REPLACEMENT - Continued
Figure 8. Main Control Valve Relief Valve.
MAIN CONTROL VALVE REPLACEMENT - Continued
Figure 9. Bucket Circuit Relief Valve.
MAIN CONTROL VALVE REPLACEMENT - Continued
RESERVOIR RELIEF VALVE REPLACEMENT
Figure 1. Reservoir Relief Valve.
HYDRAULIC CONTROL LINKAGE REPLACEMENT
Figure 1. Hydraulic Control Linkage at Bellcrank.
Figure 2. Control Rods to Control Levers.
Figure 3. Bellcrank Assembly.
Figure 4. Control Levers.
HYDRAULIC CONTROL LINKAGE REPLACEMENT - Continued
Figure 5. Control Levers.
Figure 6. Bellcrank Assembly.
Figure 7. Control Rods.
Figure 8. Hydraulic Control Linkage at Bellcrank.
Figure 9. Hydraulic Control Linkage Adjustment.
BUCKET CYLINDER REPLACEMENT
Figure 1. Air Lines.
Figure 2. Hydraulic Lines.
Figure 3. Bucket Cylinder.
Figure 4. Hydraulic Lines.
Figure 5. Air Lines.
BOOM CYLINDER REPLACEMENT
Figure 1. Weatherseal Clamps.
Figure 2. Hydraulic Lines.
Figure 3. Boom Cylinder.
BOOM CYLINDER REPLACEMENT - Continued
Figure 4. Hydraulic Lines.
Figure 5. Weatherseal Clamps.
HYDRAULIC TANK/RESERVOIR REPLACEMENT
Figure 1. Air Filter Indicator.
Figure 2. Hydraulic Reservoir/Tank.
Figure 3. Hydraulic Reservoir/Tank.
Figure 4. Air Filter Indicator.
PRESSURE GAUGE REPLACEMENT
Figure 2. Gauge.
Figure 3. Gauge Cluster.
BUCKET TIPS REPLACEMENT
Figure 1. Cutting Edge Replacement.
Figure 3. Weld Removal.
Figure 4. Backing Plate Preparation.
Figure 6. Cutting Edge Tip Attachment.
BUCKET TIPS REPLACEMENT - Continued
Figure 8. Bucket Teeth.
Figure 9. Type 2 Bucket Teeth.
Figure 10. Type 1 Bucket Teeth Assembly.
Figure 11. Type 2 Bucket Teeth Assembly.
BUCKET REPLACEMENT
Figure 2. Typical Bucket Removal.
Figure 3. Bucket Links Wired Up.
Figure 4. Bucket Placement.
Figure 6. Boom Kick-Out Control System.
CHAPTER 8 SUSTAINMENT MAINTENANCE INSTRUCTIONS
CYLINDER SLEEVES REPLACEMENT
Figure 1. Cylinder Sleeve.
Figure 2. Removing Cylinder Sleeve.
Figure 3. Cylinder Sleeve with Packing Rings and Shims.
Figure 4. Checking Crankcase Counterbore Depth.
Figure 5. Rework for Crankcase Lower Sleeve Insert.
Figure 6. Modification of Crankcase.
Figure 7. Cylinder Sleeve Holding Adapter.
Figure 8. Cylinder Sleeve Clamping.
Figure 9. Cross-Section of Engine Crankcase.
Figure 10. Checking Crankcase Counterbore Depth.
CYLINDER SLEEVES REPLACEMENT - Continued
FRONT AND REAR MAIN OIL SEALS REPLACEMENT
FRONT AND REAR MAIN OIL SEALS REPLACEMENT - Continued
Figure 1. Assembling Seal to Sleeve.
FRONT AND REAR MAIN OIL SEALS REPLACEMENT - Continued
Figure 2. Oil Seal and Wear Sleeve Installation Program.
FRONT AND REAR MAIN OIL SEALS REPLACEMENT - Continued
Figure 3. Vibration Damper Hub with a Wear Sleeve and Driver.
Figure 4. Installing Crankshaft Gear.
FRONT AND REAR MAIN OIL SEALS REPLACEMENT - Continued
FRONT AND REAR MAIN OIL SEALS REPLACEMENT - Continued
CYLINDER HEAD REPLACEMENT
Figure 1. Water Transfer Tube.
Figure 2. Final Fuel Filter and Connections.
Figure 3. Injection Pump Fuel Lines.
Figure 4. Coolant Manifolds.
Figure 5. Fuel Return Lines.
Figure 6. Valve Housing Cover and Gasket.
Figure 7. Valve Lever Assembly.
Figure 8. Cylinder Head and Gasket.
Figure 9. Valve Lever Assembly.
Figure 10. Removing Valves and Hardware.
Figure 11. Valve Protrusion from Cylinder Head.
Figure 12. Cylinder Head Stud Height.
Figure 13. Cylinder Head Pressure Check.
Figure 14. Cylinder Head Pressure Plate.
Figure 16. Side Plate with Drain Plug.
Figure 17. Removing Injector Sleeve.
Figure 18. Injector Nozzle Sleeve Bottoming Tool.
Figure 19. Sealing Injector Sleeve with Rolling Tool.
Figure 20. Injector Sleeve Bottoming Tool.
Figure 21. Checking Valve Lever Bushing and Shaft for Wear.
Figure 22. Cylinder Head Valves.
Figure 23. Valve Lever Assembly.
Figure 24. Cylinder Head and Gasket.
Figure 25. Torquing Injector Nozzle Crab Bolt.
Figure 26. Valve Lever Assembly.
Figure 27. Water Transfer Tube.
Figure 28. Sequence for Tightening Cylinder Head Nut.
Figure 29. Valve Housing Cover.
Figure 30. Fuel Lines.
Figure 31. Coolant Manifolds.
Figure 32. Final Fuel Filter and Connections.
Figure 33. Timing Mark.
Figure 34. Valve Arrangement.
Figure 35. Valve Lash Adjustment.
CRANKSHAFT AND MAIN BEARINGS REPLACEMENT
Figure 1. Removing Gear Oil Jet Tube.
Figure 2. Removing Lower Bearings.
Figure 3. Removing Upper Half of Crankshaft Bearing.
Figure 4. Removing Crankshaft.
Figure 5. Removing Upper Main Bearing Halves.
CRANKSHAFT AND MAIN BEARINGS REPLACEMENT - Continued
Figure 6. Measuring Crankshaft Journal.
Figure 7. Cleaning Crankshaft Oil Passages.
Figure 8. Dimensions to Which Crankshaft May be Ground.
Figure 9. Installing Upper Halves of Main Bearings.
Figure 10. Main Bearing and Connecting Rod Cap Installation.
Figure 11. Checking Main Bearing Running Clearance.
Figure 12. Checking Crankshaft End Clearance.
Figure 13. Assembling Seal to Sleeve.
Figure 14. Oil Seal and Wear Sleeve Installation Diagram.
CRANKSHAFT AND MAIN BEARINGS REPLACEMENT - Continued
FLYWHEEL REPLACEMENT/REPAIR
Figure 1. Flywheel Removal.
Figure 2. Checking Run-Out of Flywheel Housing Face.
Figure 3. Checking Eccentricity of Flywheel Housing Bore.
Figure 4. Flywheel Installation.
PISTONS INSPECTION/REPLACEMENT
Figure 1. Cleaning Piston Ring Grooves.
Figure 2. Checking Sleeve ID.
PISTONS INSPECTION/REPLACEMENT - Continued
Figure 4. Checking Piston Ring Gap.
Figure 5. Checking Oil Control Ring Side Clearance.
Figure 6. Checking Piston Compression Ring Grooves.
Figure 7. Checking Piston Ring Drop.
Figure 8. Checking Piston Pin End Clearance.
Figure 9. Piston Rings Correctly Installed on Piston.
Figure 10. Installing Connecting Rod and Piston.
PISTONS INSPECTION/REPLACEMENT - Continued
CONNECTING ROD REPLACEMENT
Figure 1. Removing Piston Cooling Jet.
Figure 2. Correct Position for Removing Cooling Jet.
Figure 3. Connecting Rod Cap Removal.
Figure 4. Removing Piston and Connecting Rod.
Figure 5. Piston Disassembly.
Figure 6. Connecting Rod Bushing Removal and Installation Tools.
Figure 7. Removing Bushing (First Step).
Figure 8. Removing Bushing (Second Step).
Figure 9. Connecting Rod Bushing Installation.
Figure 10. Piston Installation.
Figure 11. Piston Installation.
Figure 12. Connecting Rod Cap Installation.
Figure 13. Correct Position for Installing Cooling Jet.
Figure 15. Oil Pickup Tube Installation.
CONNECTING ROD BEARING REPLACEMENT
Figure 1. Illustrating Bearing Crush.
Figure 2. Illustrating Bearing Spread.
Figure 4. Checking Connecting Rod End Clearance.
VALVES REPLACEMENT
Figure 1. Removing, Valves, Springs, Rotators, Seats, and Keepers.
Figure 2. Cleaning Carbon from Valve.
Figure 5. Scuffed Valve Stem.
Figure 7. Checking Valve Stem Straightness and Face Runout.
Figure 8. Locating Valve and Grinding Stone to Specified Angle.
Figure 9. Maintaining Proper Margin.
Figure 10. Refacing Valve Stem End.
Figure 11. Checking Guide ID.
Figure 12. Measuring Position of Valve Guides.
Figure 13. Removing Valve Bridge Guides.
Figure 14. Checking Valve Bridge for Wear.
VALVES REPLACEMENT - Continued
Figure 15. Removing Exhaust Valve Seat Insert.
Figure 16. Insert Ring Properly Installed.
Figure 17. Installing Insert.
Figure 18. Grinding Valve Seat.
Figure 19. Valve Seat Width Must Conform to Specifications and Center of Valve Face.
Figure 20. Narrowing Valve Seat Width.
Figure 22. Checking Valve Spring Squareness.
Figure 23. Testing Valve Rotator.
Figure 24. Valve Specifications.
VALVES REPLACEMENT - Continued
Figure 25. Valve Assembly Installation.
CAMSHAFT REPLACEMENT
Figure 2. Removing Front Cover.
Figure 3. Measuring Camshaft End-Play.
Figure 4. Timing Marks Alignment.
Figure 5. Camshaft Thrust Bearing Hub Removal.
Figure 6. Camshaft Removal.
CAMSHAFT REPLACEMENT - Continued
Figure 7. Points of Measurement to Determine Camshaft Lobe Wear.
Figure 8. Camshaft Thrust Hub and Face Inspection.
Figure 10. Camshaft Thrust Hub and Face Inspection.
Figure 11. Camshaft Drive Gear Installation.
Figure 12. Camshaft Gear Backlash Measurement.
Figure 14. Crank Gear Nut Installation.
TIMING GEARS REPLACEMENT
Figure 1. Removing Vibration Damper.
Figure 2. Front Cover Removal.
Figure 3. Measuring Gear Train Backlash.
Figure 4. Removing Camshaft Gear.
Figure 5. Removing Hydraulic Pump Idler Gear.
Figure 6. Removing Fan Drive Idler Gear Shaft.
Figure 8. Removing Crankcase Front Plate.
Figure 9. Bearing Cup Retaining Snap Ring.
Figure 10. Adjustment of Tapered Roller Bearings.
Figure 11. Vibration Damper Hub with Wear Sleeve and Driver.
Figure 12. Installing Crankshaft Gear.
Figure 13. Fan Idler Gear Shaft in Correct Position.
Figure 14. Hydraulic Pump Idler Gear Installation.
Figure 15. Camshaft Gear Installation.
Figure 17. Gear Train Lubricating Oil Spray Jets.
Figure 18. Gear Train Front Cover Installation.
Figure 19. Lube Oil Suction Pipe Installation.
LUBRICATING OIL AND WATER PUMP REPAIR
Figure 1. Checking Drive Shaft End-Play.
Figure 2. Oil and Water Pump Disassembly.
Figure 3. Removing Water Pump Impeller.
Figure 4. Removing Water Pump Housing.
Figure 6. Measuring Gear Backlash.
Figure 7. Measuring Radial Clearance.
Figure 8. Oil Pump Gear Removal.
Figure 9. Scavenging Oil Pump Body Removal.
Figure 10. Removing Drive Gear Nut.
Figure 11. Pushing Drive Shaft Out of Drive Gear.
Figure 12. Removing Idler Shaft.
Figure 13. Cleaning and Inspection.
Figure 14. Measuring Gear Width.
Figure 17. Idler Shaft and Drive Shaft Measurement.
Figure 19. Scavenge Oil Pump Manifold and O-Rings.
Figure 21. Oil Pump Assembly.
Figure 22. Scavenging Oil Pump Housing Installation.
Figure 24. Garter Oil Seal Installation.
Figure 25. Water Pump Housing Installation.
Figure 26. Water Pump Impeller-to-Housing Clearance.
FUEL INJECTOR TESTING AND REPAIR
FUEL INJECTOR TESTING AND REPAIR - Continued
FUEL INJECTION PUMP ADAPTER HOUSING REPLACEMENT/REPAIR
Figure 1. Injection Pump Adapter Disconnect Points.
Figure 3. Pinion Shaft Nut Removal.
Figure 4. Hub Removal.
Figure 5. Pinion Shaft and Bearing Removal.
Figure 7. Component Inspection.
Figure 8. Tapered Roller Bearing Measurement.
Figure 10. Injection Pump Adapter Assembly.
Figure 11. Torquing Pinion Shaft Nut.
Figure 13. Drive Gear Phasing.
Figure 15. Injection Pump Adjustable Support with Bracket.
Figure 16. Injection Pump Timing Port.
FUEL INJECTION PUMP ADAPTER HOUSING REPLACEMENT/REPAIR - Continued
FAN DRIVE ASSEMBLY REPAIR
Figure 1. Fan Mounting Assembly Disassembly.
Figure 2. Checking Clutch Slip Torque.
Figure 3. Snap Ring Removal.
Figure 4. Exploded View of Fan Mounting Assembly.
FAN DRIVE ASSEMBLY REPAIR - Continued
Figure 5. Friction Disc and Friction Bearing Assembly.
FAN DRIVE ASSEMBLY REPAIR - Continued
Figure 6. Fan Mounting Assembly.
Figure 8. Snap Ring Installation.
Figure 9. Removing Jam Nut.
FAN DRIVE ASSEMBLY REPAIR - Continued
Figure 11. Dimensional Drawing of Fan Housing.
Figure 12. Pressing Bearings and Spacer to Shaft.
Figure 13. Pressing Shaft and Bearing in Housing.
Figure 14. Pressing Gear on Shaft.
Figure 15. Installing Jam Nut.
Figure 16. Bolts Installed in Housing.
Figure 17. Pressing on Fan Mounting Assembly.
Figure 18. Fan Hub Retaining Nut.
TORQUE CONVERTER REPAIR
Figure 1. Torque Converter Positioning.
Figure 2. Seal Ring Removal.
Figure 4. Hub and Shims Removal.
Figure 7. Converter Positioning.
Figure 9. Turbine Removal.
Figure 11. Stator Removal
Figure 12. Accessory Drive Gear Removal.
Figure 14. Bearing Retainer Removal.
Figure 15. Output Shaft and Bearing Removal.
Figure 18. Charging Pump Drive Gear Removal.
Figure 19. Charging Pump Retainer Removal.
Figure 21. Pump Plates Removal.
Figure 23. Ground Sleeve Hub Removal.
Figure 24. Ground Sleeve Hub Installation.
Figure 25. Seal Ring and Inner Bearings Installation.
Figure 27. Drive Gears Installation.
Figure 28. Pump and O-Rings Installation.
Figure 29. Pump Drive Gear Installation.
Figure 31. Output Shaft Installation Preparation.
Figure 33. Output Shaft Seal Installation.
Figure 34. Shim Pack Thickness Determination.
Figure 36. Shim Pack and Bearing Retainer Installation.
Figure 39. Output Shaft Snap Ring Installation.
Figure 41. Impeller Installation.
Figure 42. Turbine Hub Bearing Installation.
Figure 44. Clearance Measurement.
Figure 46. Pin Alignment.
Figure 48. Stator and Spacer Installation.
Figure 50. Converter Assembly Installation.
Figure 51. Shim Pack Installation.
Figure 53. Clearance Determination.
Figure 55. Drive Housing Shim Pack Installation.
Figure 58. O-Ring Installation.
TRANSMISSION REPAIR
Figure 1. Main Regulator Valve Removal.
Figure 2. Input Yoke Removal.
Figure 5. Oil Supply Covers Removal.
Figure 6. Bearing Covers Removal.
Figure 9. Range Selector Valve Removal.
Figure 10. Rear Cover Removal.
Figure 11. Oil Transfer Tubes Removal
Figure 13. Gather Shaft Assembly Removal.
Figure 15. 1st and 3rd Clutch Pack Removal.
Figure 17. Oil Baffle Removal.
Figure 19. Bearing Retainer and Output Shaft Removal.
Figure 21. Front Cover Removal.
Figure 22. Front Cover Bearings Removal.
Figure 23. Reverse Idler Shaft Disassembly.
Figure 26. Output Shaft Bearing Removal.
Figure 27. Oil Supply Cover Removal.
Figure 29. O-Ring Removal.
Figure 30. Rear Cover Bearings Removal.
Figure 31. Filter Housing Removal.
Figure 33. Output Shaft Rear Seal.
Figure 35. Output Shaft Rear Seal Installation.
Figure 36. Filter Assembly.
Figure 37. Rear Cover Bearings Installation.
Figure 38. O-Rings Installation.
Figure 39. Seal Rings Installation.
Figure 40. Oil Supply Cover Installation.
Figure 43. Gather Shaft Assembly.
Figure 44. Reverse Idler Shaft Assembly.
Figure 45. Cover Bearings and Spacers Installation.
Figure 48. Output Shaft Retainer Installation.
Figure 49. Output Shaft Installation.
Figure 51. 1st and 3rd Clutch Pack Installation.
Figure 53. Gather Shaft Assembly Installation.
Figure 55. Oil Transfer Tubes Installation.
TRANSMISSION REPAIR - Continued
Figure 56. Rear Cover Installation.
Figure 57. Range Selector Valve Installation.
Figure 60. Shaft Covers Installation.
Figure 62. Output Shaft Front Retainer Installation.
Figure 63. Output Shaft Bearing Seat Procedure.
Figure 64. Clearance Measurement.
Figure 67. Front Output Yoke Installation.
Figure 68. Input Yoke Installation.
Figure 69. Main Regulator Valve Installation.
CLUTCH PACK ASSEMBLY REPAIR
Figure 2. Range Clutch Bearing Race Removal.
Figure 4. Gear and Bearing Removal.
Figure 6. Clutch Hub and Plate Removal.
Figure 8. Hub and Plate Snap Ring Removal.
Figure 9. Backing Plate and Dowel Pin Removal.
Figure 11. Snap Ring Removal.
Figure 13. Piston Removal.
Figure 15. Seal Ring Removal.
Figure 17. Clutch Shaft Disassembly.
Figure 19. Clutch Shaft Assembly.
Figure 21. Accelerating Pistons Installation.
Figure 23. Shaft Seal Ring Installation.
Figure 25. Seal Lubrication.
Figure 27. Snap Ring Installation.
Figure 29. Hub and Hub Retainer Installation.
Figure 31. Clutch Plates Installation.
Figure 33. Retaining Ring Installation.
Figure 35. Bearing Race Installation.
Figure 36. Directional Clutch Shaft Assembly.
Figure 37. Roller Bearings Installation.
Figure 39. Roller Bearing Installation.
Figure 41. Snap Ring Installation.
TRANSMISSION FORWARD AND REVERSE VALVE REPAIR/OVERHAUL
Figure 1. Forward and Reverse Valve.
TRANSMISSION FORWARD AND REVERSE VALVE REPAIR/OVERHAUL - Continued
TRANSMISSION CHARGING PUMP REPAIR
Figure 1. Transmission Charging Pump.
Figure 2. Transmission Oil Pump (Late Type).
TRANSMISSION MAIN REGULATOR VALVE REPAIR
Figure 1. Main Regulator Control Valve.
TRANSMISSION MAIN REGULATOR VALVE REPAIR - Continued
TRANSMISSION NEUTRAL KNOCKDOWN VALVE REPAIR
Figure 2. Transmission Neutral Knockdown Valve Assembly.
TRANSMISSION RANGE SELECTOR VALVE REPAIR
Figure 1. Range Control Valve.
TRANSMISSION RANGE SELECTOR VALVE REPAIR - Continued
FRONT AXLE ASSEMBLY REPAIR/OVERHAUL
Figure 1. Shim Pack Removal.
Figure 2. Ring Gear and Hub Removal
Figure 3. Hub and Drum Removal.
Figure 4. Seal and Retainer Removal.
TRANSMISSION RANGE SELECTOR VALVE REPAIR - Continued
Figure 6. Differential Installation.
Figure 8. Oil Seals Installation.
Figure 9. Hub and Drum Positioning.
Figure 12. Shim Pack Determination.
Figure 13. Final Retainer Installation.
Figure 14. Lubricant Installation and Check.
Figure 15. Drain Plug Installation.
FRONT DIFFERENTIAL REPAIR/OVERHAUL
Figure 1. Front Differential Disassembly.
Figure 2. Marking Bearing Caps.
Figure 3. Bearing Cap Removal.
Figure 5. Differential Removal.
Figure 6. Thrust Block Removal.
Figure 8. Spider Assembly Removal.
Figure 10. Differential Bearings Removal.
Figure 12. Pinion Removal.
Figure 14. Pinion Bearing Cage Disassembly.
Figure 16. Washer and Bearing Removal.
FRONT DIFFERENTIAL REPAIR/OVERHAUL - Continued
Figure 17. Bearing Cup Installation.
Figure 19. Pilot Bearing Installation.
Figure 20. Pinion Assembly.
Figure 21. Rotating Torque Measurement.
Figure 22. Companion Flange Installation.
Figure 23. Pinion Assembly Installation.
Figure 24. Adjusting Screw Installation.
Figure 26. Side Gear Installation.
Figure 27. Spider Installation.
Figure 29. Differential Installation.
igure 30. Bearing Cap Installation.
Figure 31. Backlash Adjustment.
Figure 32. Prussian Blue Compound Application.
Figure 34. High Contact Pattern.
Figure 35. Low Contact Pattern.
Figure 37. Thrust Block Clearance Adjustment.
Figure 38. Oil Distributor Installation.
FRONT PLANETARY ASSEMBLY REPAIR
FRONT PLANETARY ASSEMBLY REPAIR - Continued
Figure 1. Planetary.
FRONT PLANETARY ASSEMBLY REPAIR - Continued
Figure 2. Planetary.
REAR AXLE ASSEMBLY REPAIR/OVERHAUL
Figure 1. Shim Pack Removal.
Figure 2. Ring Gear and Hub Removal.
Figure 3. Hub and Drum Removal.
Figure 4. Seal and Retainer Removal.
REAR AXLE ASSEMBLY REPAIR/OVERHAUL - Continued
Figure 6. Differential Installation.
Figure 7. Oil Seal Installation.
Figure 9. Hub and Drum Positioning.
Figure 12. Shim Pack Determination.
Figure 13. Final Retainer Installation.
Figure 14. Lubricant Installation and Check.
Figure 15. Drain Plug Installation.
REAR DIFFERENTIAL REPAIR/OVERHAUL
Figure 1. Rear Differential Disassembly.
Figure 2. Marking Bearing Caps.
Figure 3. Bearing Cap Removal.
Figure 5. Differential Removal.
Figure 6. Thrust Block Removal.
Figure 8. Spider Assembly Removal.
Figure 10. Differential Bearings Removal.
Figure 12. Pinion Removal.
Figure 15. Felt and Oil Seals Removal.
Figure 16. Washer and Bearing Removal.
REAR DIFFERENTIAL REPAIR/OVERHAUL - Continued
Figure 17. Bearing Cup Installation.
Figure 19. Pilot Bearing Installation.
Figure 20. Pinion Assembly.
Figure 21. Rotating Torque Measurement.
Figure 22. Companion Flange Installation.
Figure 23. Pinion Assembly Installation.
Figure 24. Adjusting Screw Installation.
Figure 26. Side Gear Installation.
Figure 27. Spider Installation.
Figure 29. Differential Installation.
Figure 30. Bearing Cap Installation.
Figure 31. Backlash Adjustment.
Figure 32. Prussian Blue Compound Application.
Figure 34. High Contact Pattern.
Figure 35. Low Contact Pattern.
Figure 37. Thrust Block Clearance Adjustment.
Figure 38. Oil Distributor Installation.
REAR PLANETARY ASSEMBLY REPAIR
REAR PLANETARY ASSEMBLY REPAIR - Continued
Figure 1. Planetary.
REAR PLANETARY ASSEMBLY REPAIR - Continued
Figure 2. Planetary.
STEERING GEAR REPAIR
Figure 1. Steering Gear.
Figure 2. Cover Plate Removal.
Figure 3. Gear Housing Disassembly.
Figure 4. Steering Gear Inspection.
Figure 5. Housing Bushing and Seal Replacement.
Figure 7. Worm and Ball Nut Assembly.
Figure 8. Ball and Guide Assembly.
Figure 10. Ball Guide Fastener Installation.
Figure 12. Pitman Arm Shaft Installation.
Figure 14. Pitman Shaft Installation.
Figure 16. Steering Gear Assembly.
Figure 17. Bearing Installation.
STEERING PUMP ASSEMBLY REPAIR
Figure 1. Steering Pump Assembly.
STEERING PUMP ASSEMBLY REPAIR - Continued
HYDRAULIC STEERING CYLINDERS REPAIR
HYDRAULIC STEERING CYLINDERS REPAIR - Continued
Figure 1. Steering Cylinder Assembly.
HYDRAULIC STEERING CYLINDERS REPAIR - Continued
Figure 2. Steering Cylinder Assembly.
STEERING CONTROL VALVE REPAIR
Figure 2. Plunger Seal Plate Removal.
Figure 5. Lock Plunger Removal.
Figure 6. Lock Plunger Disassembly.
Figure 8. Adjusting Screw Assembly Removal.
Figure 9. Poppet Removal.
Figure 11. Check Valve Removal.
Figure 12. Check Valve Installation.
Figure 14. Adjusting Screw Installation.
Figure 16. Plunger Assembly.
Figure 18. Control Plunger Assembly.
Figure 20. Plunger Fastener Installation.
Figure 21. Seal Plate Installation.
MAIN HYDRAULIC PUMP REPAIR
MAIN HYDRAULIC PUMP REPAIR - Continued
Figure 1. Main Hydraulic Pump.
MAIN HYDRAULIC PUMP REPAIR - Continued
Figure 2. Main Hydraulic Pump.
MAIN CONTROL VALVE OVERHAUL
Figure 1. Main Control Valve (Spool End).
Figure 3. Poppet Removal.
Figure 4. Pistons Removal.
Figure 6. Plunger Cap Removal.
Figure 8. Boom Plunger Assembly Removal.
Figure 10. Spring, Cam and Detent Balls Removal.
Figure 12. Plunger Disassembly.
Figure 13. Main Relief Valve Disassembly.
MAIN CONTROL VALVE OVERHAUL - Continued
Figure 14. Main Control Valve - Relief Valve.
Figure 15. Check Valves Removal.
MAIN CONTROL VALVE OVERHAUL - Continued
MAIN CONTROL VALVE OVERHAUL - Continued
Figure 17. Main Relief Valve Assembly.
MAIN CONTROL VALVE OVERHAUL - Continued
Figure 18. Relief Valve.
MAIN CONTROL VALVE OVERHAUL - Continued
Figure 19. Main Control Valve (Spool End).
Figure 20. Main Control Valve (Plunger Cap End).
Figure 21. Plunger Bolt and Nut Installation.
Figure 22. O-Ring and Backup Ring Installation.
Figure 23. Plunger Assembly.
Figure 25. Plunger Cap Installation.
Figure 27. Detent Sleeves Assembly.
Figure 29. O-Ring and Spacer Ring Installation.
BUCKET CYLINDER OVERHAUL
BUCKET CYLINDER OVERHAUL - Continued
Figure 1. Bucket Cylinder.
BUCKET CYLINDER OVERHAUL - Continued
Figure 2. Bucket Cylinder.
BOOM CYLINDER OVERHAUL
BOOM CYLINDER OVERHAUL - Continued
Figure 1. Boom Cylinder.
BOOM CYLINDER OVERHAUL - Continued
Figure 2. Boom Cylinder.
HYDRAULIC TANK/RESERVOIR REPAIR
Figure 1. Hydraulic Reservoir/Tank Assembly.
Figure 2. Hydraulic Reservoir/Tank Assembly.
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Table 1. Fabricated Tools for H100C Loader.
Item 2. Transmission Clutch Lifting Tool.
Item 4. Axle Removal and Installation Tool.
Item 5. Assembled Differential Holding Fixture.
Item 5a. Swivel Weldment (Two Required).
Item 5b. Stand Weldment Assembly - Left Hand (One Required).
Item 5d. Clamp Assembly - Right Hand (Two Required).
Item 5g. Slide - Stand Weldment (Right Hand).
Item 5h. Slide - Stand Weldment (Left Hand).
Item 6. Wheel Hub - Brake Drum Lifting Tool.
Item 9. Fan Drive Housing Belleville Spring Compressing Tool.
Item 10. Fan Drive Housing Snap Ring Installation Tool.
Item 11. Cover Plate and Coupling for Testing Oil Cooler.
Item 11a. Cover Plate and Coupling for Testing Oil Cooler - Installed.
Item 12. Fan Pulley Torque Fixture.
Item 13. Fan Pulley Holding Fixture.
CHAPTER 9 SUPPORTING INFORMATION
REFERENCES
MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION
MAINTENANCE FUNCTIONS
EXPLANATION OF COLUMNS IN THE MAC
EXPLANATION OF COLUMNS IN THE MAC
MAINTENANCE ALLOCATION CHART (MAC)
Table 1. Maintenance Allocation Chart for the H100C.
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 1. Maintenance Allocation Chart for the H100C. - Continued
Table 2. Tool and Test Equipment Requirements.
Table 2. Tool and Test Equipment Requirements. - Continued
BASIC ISSUE ITEMS (BII) LIST
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List for H100C Loader.
Table 1. Expendable and Durable Items List for H100C Loader - Continued
Table 1. Expendable and Durable Items List for H100C Loader - Continued
Table 1. Expendable and Durable Items List for H100C Loader - Continued
TORQUE LIMITS
Table 1. Torque Limits - SAE Standard Fasteners.
Table 2. Torque Limits - Metric Fasteners.
TORQUE VALUES FOR STANDARD FASTENERS
TORQUE VALUES FOR HOSE CLAMPS

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