TABLE OF CONTENTSi UNIT MAINTENANCE MANUAL ...Technical Manual No. 5-2420-224-20-1 TM...

TM 5-2420-224-20-1Volume No. 1

TECHNICAL MANUAL

UNIT MAINTENANCE MANUALFOR

TRACTOR, WHEELED, 4 X 4 DEDSMALL EMPLACEMENT EXCAVATOR (SEE)

( N S N 2 4 2 0 - 0 1 - 1 6 0 - 2 7 5 4 ) ( E I C : E D L )

TRACTOR, WHEELED, 4 X 4 DED

TABLE OF CONTENTS i

HOW TO USE THISMANUAL

xii

PREVENTIVEMAINTENANCE 2-2CHECKS AND SERVICES

HIGH MOBILITY MATERIAL HANDLER (HMMH)(NSN 2420-01-205-8636)

INDEX Index-1

HEADQUARTERS, DEPARTMENT OF THE ARMY 28 JULY 1993This manual along with TM5-2420-224-20-2 and TM5-2420-224-34 supersedes

TM5–2420–224-24 dated December 1989Approved for public release; distribution is unlimited.

TM 5-2420-224-20-1

W A R N I N G

CARBON MONOXIDE POISONING CAN BE DEADLY

CARBON MONOXIDE IS A COLORLESS, ODORLESS, DEADLY POISONOUSGAS, WHICH, WHEN BREATHED, DEPRIVES THE BODY OF OXYGEN ANDCAUSES SUFFOCATION. EXPOSURE TO AIR CONTAMINATED WITH CARBONMONOXIDE PRODUCES SYMPTOMS OF HEADACHE, DIZZINESS, LOSS OFMUSCULAR CONTROL, APPARENT DROWSINESS, OR COMA. PERMANENTBRAIN DAMAGE OR DEATH CAN RESULT FROM SEVERE EXPOSURE.

CARBON MONOXIDE OCCURS IN THE EXHAUST FUMES OF FUEL-BURNINGH E A T E R S A N D I N T E R N A L - C O M B U S T I O N E N G I N E S A N D B E C O M E SD A N G E R O U S L Y C O N C E N T R A T E D U N D E R C O N D I T I O N S O F I N A D E Q U A T EVENTILATION. THE FOLLOWING PRECAUTIONS MUST BE OBSERVED TOE N S U R E T H E S A F E T Y O F P E R S O N N E L W H E N E V E R T H E P E R S O N N E LHEATER, MAIN, OR AUXILIARY ENGINE OF ANY VEHICLE IS OPERATED FORMAINTENANCE PURPOSES OR TACTICAL USE:

1.

2.

3.

4.

DO NOT operate engine of vehicle in an enclosed area unless it isADEQUATELY VENTILATED.

DO NOT idle engine for long periods without maintaining ADEQUATEVENTILATION in the personnel compartments.

DO NOT drive any vehicle with inspection plates, cover plates, or enginecompartment doors removed unless necessary for maintenance purposes.

BE ALERT. at all times during vehicle operation for exhaust odors andexposure symptoms. If either is present, IMMEDIATELY VENTILATEpersonnel compartments. If symptoms persist, remove affected personnelfrom vehicle and treat as follows: expose to fresh air; keep warm, DONOT PERMIT EXERCISE; if necessary, administer artificial respiration(see FM 21-11).

T H E B E S T D E F E N S E A G A I N S T C A R B O N M O N O X I D E P O I S O N I N G I SADEQUATE VENTILATION.

a

TM 5-2420-224-20-1

W A R N I N G

COMPRESSED AIR

To prevent injury, compressed air used for cleaning and drying purposes will notexceed 30 psi (207 kPa). Use only wi th ef fect ive chip guarding and personalprotective equipment (goggles/shield, gloves, etc.).

W A R N I N G

Drycleaning solvent P-D-680 is toxic and flammable. Wear protective goggles andgloves and use only in well-ventilated area. Avoid contact with skin, eyes, andclothes and do not breathe vapors. Do not use near open f lame or excessiveheat. Flash point is 100°-138° F (38°-50°C). I f you become dizzy whi le usingdrycleaning solvent, get fresh air immediately and get medical aid. If contact witheyes is made, wash your eyes with water and get medical aid immediately.

W A R N I N G

Remove r ings , b race le ts , wr i s twa tches , and neck cha ins be fo re work ing onvehicle. Jewelry can catch on equipment and cause injury, or may short acrossan electrical circuit and cause severe burns or electrical shock.

W A R N I N G

Diese l fue l i s f l ammab le . Do no t per fo rm th is p rocedure near f i re , f l ame, o rsparks. Injury or death to personnel could result.

W A R N I N G

Do not connect or d isconnect any electr ical connector unless vehic le MASTERdisconnect switch is OFF. To do so could result in injury to personnel.

W A R N I N G

Do not disconnect any air system lines or fitt ings unless vehicle engine is shuto f f and a i r sys tem pressure i s re l i eved . To do so cou ld resu l t i n i n ju ry topersonnel.

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TM 5-2420-224-20-1

W A R N I N G

All vehicle electrical switches must be OFF before disconnecting battery cables.Failure to do so could result in injury to personnel.

W A R N I N G

H i g h p r e s s u r e h y d r a u l i c s [ o i l u n d e r 2 4 5 0 p s i ( 1 6 , 8 9 3 k P a ) ] o p e r a t e t h i sequipment. Never disconnect any hydraul ic l ine or f i t t ing without f i rst droppingpressure to zero. A high pressure oil stream can pierce body and cause severeinjury to personnel.

If NBC exposure is suspected, all air filter media should be handled by personnelwearing protective equipment. Consult your unit NBC Officer or NBC NCO for

W A R N I N G

appropriate handling or disposal instructions.

W A R N I N G

Never use gasoline to clean parts. Gasoline is highly flammable. Serious personalinjury could - result if fuel ignites during cleaning.

W A R N I N G

Prior to initial use, new, extensively repaired, or altered forklift or crane must beload tested to prevent injury to personnel.

Steam cleaning creates hazardous noise levels and severe burn potential. Eye,skin, and ear protection are required.

W A R N I N G

W A R N I N G

Solvents used with spray gun must be used in spray booth with filter. Face shieldmust be used by personnel operating spray gun. Failure to do so could result inserious injury to personnel.

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TM 5-2420-224-20-1

W A R N I N G

Dri l l ing and gr inding operat ions are hazardous to the eyes. Eye protect ion isrequired.

Before starting engine, make sure all personnel are clear of engine. Failure to doso could result in injury to personnel.

W A R N I N G

On direct contact, uncured silicone sealant irritates eyes. In case of contact, flusheyes with water and seek medical attention. Avoid prolonged contact with skin.

W A R N I N G

W A R N I N G

When replacing fuses, make sure only fuses of correct amperage are installed.Failure to do so could result in injury to personnel or damage to equipment.

d/(e Blank)

Technical ManualNo. 5-2420-224-20-1

TM 5-2420-224-20-1

HEADQUARTERSDEPARTMENT OF THE ARMY

Washington D. C., 28 July 1993

U N I T M A I N T E N A N C E M A N U A LFOR

T R A C T O R , W H E E L E D , 4 X 4 D E D

S M A L L E M P L A C E M E N T E X C A V A T O R ( S E E )(NSN 2420-01-160-2754) (EIC:EDL)

A N D

T R A C T O R , W H E E L E D , 4 X 4 D E DH I G H M O B I L I T Y M A T E R I A L H A N D L E R ( H M M H )

(NSN 2420-01-205-8636)

VOLUME 1 OF 2

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve the manual. If you find any mistakes or if you knowof a way to improve the procedures, please let us know. Mail your letter,DA Form 2028 (Recommended Changes to Publications and Blank Forms)or DA Form 2028-2 located in the back of this manual, direct to: Commander,U.S. Army Tank Automotive Command, Attn: AMSTA-MB, Warren, MI48397-5000. A reply will be furnished to you.

TABLE OF CONTENTS

VOLUME 1

Page

LIST OF TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. iii

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . .. xii

CHAPTER 1 INTRODUCTION

Section I General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section II Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . 1-3

Section Ill Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . ..1-8

CHAPTER 2 SERVICES AND SCHEDULED VEHICLE MAINTENANCE

Section I Repair Parts, Special Tools; Test, Measurement, and DiagnosticEquipment (TMDE); and Support Equipment . . . . . . . . . . . . . . . . 2-1

Section II Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Section Ill Preventive Maintenance Checks and Services . . . . . . . . . . . . . . . 2-2

This manual along with TM5-2420-224-20-2 and TM5-2420-224-34 supersedesTM5-2420-224-24 dated December 1989

Approved for public release; distribution unlimited i

TM 5-2420-224-20-1

TABLE OF CONTENTS (CONT)

Page

Section IV

Section V

Section VI

Section Vll

CHAPTER 3

Section I

Section II

Section III

Section IV

VOLUME 2

CHAPTER 4

Section I

Section II

Section Ill

Section IV

Section V

Section VI

Section Vll

Section Vlll

Section IX

Section X

Section XI

Section XII

Section XIII

Section XIV

Section XV

Section XVI

Section XVII

Section XVIII

Section XIX

APPENDIX A

APPENDIX B

APPENDIX C

APPENDIX D

APPENDIX E

Painting and Restenciling Markings . . . . . . . . . . . . . . . .

General Repair and Cleaning Methods . . . . . . . . . . . . .

General Hydraulic System Repair Methods . . . . . . . . . . . . . .

Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

2-14

2-15

2-32

2-36

Using Electrical Test Equipment . . . . . . . . . . . . . . . . . . . . . .

Wiring Harness and Wire Repair. . . . . . . . . . . . . . . . . . . . .

Using STE/lCE-R with the Tractor . . . . . . . . . . . . . . . . . . . .

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . .

Power Package Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System Maintenance . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . .

Front and Rear Axles Maintenance . . . . . . . . . . . . . . . . . . . . . .

Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frame and Towing Attachments Maintenance . . . . . . . . . . . . . . .

Springs and Shock Absorbers Maintenance . . . . . . . . . . . . .

Body, Cab, and Hood Maintenance . . . . . . . . . . . . . . . . . . . . .

Body and Chassis Accessory Items Maintenance . . . . . . . . . . . . .

Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . .

Gages (Non-Electrical) Maintenance . . . . . . . . . . . . . . . . . . . . . .

Machine Tools and Related Equipment Maintenance . . . . . . . . . . . .

Cranes, Shovels, and Earthmoving Equipment Components Maintenance

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . .

EXPENDABLE SUPPLIES AND MATERIALS LIST . . . . . . . . . . . .

ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . .

TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3-11

3-17

3-63

Index-1

4-1

4-2

4-12

4-24

4-79

4-86

4-109

4-240

4-245

4-249

4-335

4-338

4-362

4-367

4-384

4-474

4-499

4-727

4-736

4-751

A-1

B-1

C-1

D-1

E-1

Index-1

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TM 5-2420-224-20-1

L I S T O F T A S K S

VOLUME 2

A list of the maintenance procedures included in this manual is shown below, and on thefollowing pages. If more information IS needed, refer to the Table of Contents or the AlphabeticalIndex.

POWER PACKAGE MAINTENANCE (Section I)

Page

Valve Cover and Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-5Oil Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Engine Oil Filter Element and Bowl Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Engine Oil Hose and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Engine lnlet and Outlet Air Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

CLUTCH MAINTENANCE (Section II)

Clutch Pedal Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Clutch Hydraulic Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Clutch Hydraulic Reservoir Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . 4-17Clutch SIave Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Clutch Slave Cylinder Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21Clutch Master Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

FUEL SYSTEM MAINTENANCE (Section Ill)

Fuel Injector Lines Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25Fuel Primer Pump Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29Hand Primer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31Air Cleaner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32Air Cleaner Filter Elements Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35Air Cleaner Ducts Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38Vertical Air Intake Pipe Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39Fuel Tank Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40Fuel System Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41Fuel Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42Fuel Tank Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44Fuel Cap, Fittings, and Controls Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47Fuel Filter Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48Fuel Filter Assembly Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50Fuel Filter Pre-Sediment Bowl and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . 4-54Cold Start Aid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55Accelerator Pedal and Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 4-58Accelerator Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64Accelerator Linkage Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68Hand Throttle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70Air Cylinder Replacement (SEE).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72Air Cylinder Replacement (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74Air Cylinder Adjustment (SEE)... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76Air Cylinder Adjustment (HMMH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

i i i

TM 5-2420-224-20-1

Muffler Replacement . . . . . . . . . . . .Muffler Pipes and Clamps Replacement . . .

L I S T O F T A S K S ( C O N T )

EXHAUST SYSTEM MAINTENANCE (Section IV)

Page

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Manifold Screening Plate Replacement . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM MAINTENANCE (Section V)

Cooling System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coolant Expansion Tank Filler Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . .Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coolant Expansion Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coolant Expansion Tank Support Replacement . . . . . . . . . . . . . . . . . . . . . . . .Coolant Hoses and Clamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coolant Thermostat Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Coolant Water Outlet Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water Manifold and Gasket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan Impeller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM MAINTENANCE (Section Vl)

Alternator and Alternator Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polarity Breaker and Suppressor Filter Mounting Bracket Replacement . . . . . . . . . . . . .Polarity Breaker Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turn Signal Lever Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Press-to-Test Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .indicator (Gage) Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tachometer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ignition Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield Wiper/Washer Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hazard Warning Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ammeter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cold Start Switch Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Master Light Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instrument Cluster Panel Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield Heater Control Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . .Windshield Wiper/Washer Switch Relay Replacement . . . . . . . . . . . . . . . . . . . .Warning Delay Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Suspension Lockout Controls Replacement . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Light Control Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Oil Cooler Thermal Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bucket and Auxiliary Throttle Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . .Throttle Control Switch Replacement (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Throttle Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Throttle Control Switch Replacement (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . .

4-804-81 4-85

4-874-894-904-924-964-974-984-1004-1014-1024-1044-1054-1064-108

4-1124-1174-1194-1204-1214-1224-1234-1244-1284-1314-1324-1334-1344-1354-1364-1374-1384-1394-1404-1414-1424-1464-1474-150 4-1514-1544-1564-158

iv

TM 5-2420-224-20-1

LIST OF TASKS (CONT)

ELECTRICAL SYSTEM MAINTENANCE (Section VI)-CONT

Page

Tool and Work Light Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuse Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Light Diode Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Low Oil Pressure and High Water Temperature Alarm Replacement . . . . . . . . . . . .Main (Master) Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Slave Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Headlight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Headlight Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary Headlight Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Blackout Light Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Composite Light Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . .Work Light Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Mast Floodlight Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Composite Stoplight/Taillight Replacement and Repair . . . . . . . . . . . . . . . . . . .Dome Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turn Signal Flasher Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Start Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake Light Switch Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Lockout/Intermediate Speed Shift Sending Unit Replacement . . . . . . . . . . . . . .Oil Pressure Sender Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water Temperature Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Level Gage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Restrictor Indicator Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . .Power Take-Off Indicator Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Differential Lock Indicator Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Backup Alarm Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intermediate Speed Shift and Indicator Switch Replacement . . . . . . . . . . . . . . . . .Parking Brake Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STE/lCE-R Resistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STE/lCE-R Fuel Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .STE/lCE-R Shunt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horn, Low Beam/High Beam Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Box Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Trailer Connection Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Disc Brake Pad Indicator Wiring Harness Replacement . . . . . . . . . . . . . . . . .Suppressor Filters Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Temperature Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION MAINTENANCE (Section VII)

All Wheel Drive Selector Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .All Wheel Drive Pressure Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . .All Wheel Drive Control Cylinder Replacement And Adjustment . . . . . . . . . . . . . . . . .

4-1624-1664-1684-1694-1704-1714-1724-1734-1754-1794-1814-1834-1864-1884-1904-1954-1964-1994-2004-2014-2024-2034-2044-2054-2064-2074-2084-2094-2104-2114-2124-2134-2144-2154-2184-2194-2214-2264-2284-2304-2314-2354-238

4-2404-2424-243

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TM 5-2420-224-20-1


Page

FRONT AND REAR AXLES MAINTENANCE (Section Vlll)

Axle Vent Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Axle Final Drive Outer Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Axle Final Drive Outer Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake Controls Replacement

BRAKE MAINTENANCE (Section IX)

Parking Brake Adjustment . . . . . . .Brake Fluid Reservoir Replacement .Front Trailer Coupling Replacement .Protection/Relay Valve Replacement .Brake System Bleeding . . . . . . . .Brake Disc and Hub Replacement .Rear Disc Brake Pad Replacement .Front Disc Brake Pad Replacement .Brake Caliper Replacement . . . . . .Brake Master Cylinder Replacement .Rear Brake Calipers Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . .Brake Master Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . .Brake Pressure Regulator (ALB Valve) Lines and Fittings Replacement . . . . . . . . . . .Front Brake CaIipers Hydraulic Lines and Fittings Replacement . .Brake Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .Air Pressure Tanks Replacement . . . . . . . . . . . . . . . . . . . .Air Brake Booster Replacement.. . . . . . . . . . . . . . . . . . . .Antifreeze Reservoir Replacement . . . . . . . . . . . . . . . . . . .Antifreeze Device Replacement . . . . . . . . . . . . . . . . . . .Large Air Pressure Tank Overflow Valve and Fittings ReplacementSmall Air Pressure Tank Overflow Valve and Fittings ReplacementAccessory Air Supply Overflow Valve and Fittings ReplacementFluid Regulating Valve Replacement . . . . . . . . . . . . . .Trailer Service Air Supply Lines and Fittings Replacement . .Trailer Emergency Air Supply Lines and Fittings Replacement .Trailer Air Supply Valve Lines and Fittings Replacement . . .Air Pressure and Accessory Air Supply Lines and Fittings Replacement . . . . . . . . . . .Brake Booster and Air Pressure Lines and Fittings ReplacementProtection/Relay Valve Lines and Fittings Replacement . . . . .Tandem Valve Replacement . . . . . . . . . . . . . . . . . . . . . .Air System Supply Lines and Fittings Replacement . . . . . . . .Trailer Hand Brake Valve Replacement . . . . . . . . . . . . . . . .Trailer Air Supply Lines and Fittings Replacement . . . . . . .Trailer Hand Brake Valve Lines and Fittings Replacement . . . .Trailer Air Supply Valve Replacement . . . . . . . . . . . . . . . .Tractor Protection Valve Replacement . . . . . . . . . . . . . . . .Trailer Hand Brake Air Supply Lines and Fittings Replacement

WHEEL MAINTENANCE (Section

Wheel Assembly Replacement . . . . . . . . . . . . . . . . . . . . .Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-2454-2474-248

4-2514-2544-2574-2594-2614-2624-2654-2684-2714-2744-2764-2784-2804-2824-2844-2864-2874-2884-2954-2984-3004-3024-3034-3044-3064-3074-3104-3134-3154-3184-3204-3224-3244-3264-3274-3294-3314-3324-333

4-3354-337

VI

TM 5-2420-224-20-1


STEERING MAINTENANCE (Section Xl)

Tie Rod Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tie Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Wheel Bracket and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Drag Link Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering Upper Shaft Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Steering Gear Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Steering Pump Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . .Power Steering Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Power Steering Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Steering Tank (Reservoir) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRAME AND TOWING ATTACHMENTS MAINTENANCE (Section XII)

Backhoe Subframe Deck Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Decontamination Mounting Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . .Chassis Tool Box/Deck Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pintle Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPRINGS AND SHOCK ABSORBERS MAINTENANCE (Section XIII)

Front Rubber Bumpers Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Shock Absorbers Replacement (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Shock Absorbers Replacement (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Shock Absorbers Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Control Arm Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Control Arm Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Axle Torsion Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Axle Torsion Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BODY, CAB, AND HOOD MAINTENANCE (Section XIV)

Front Plate Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Canopy (FOPS) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outside Engine Hood Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Engine Hood Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare Tire and Mount Replacement (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spare Tire and Mount Replacement (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab Door and Window Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Control Tower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Fender and Splash Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Splash Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab Door Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab Drain Plug Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab Shock Absorbers and Mountings Replacement . . . . . . . . . . . . . . . . . . . . . . . .Cab Tilt and Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Floor PIatform Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator Seat and Framework Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operator Seat Framework Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

4-3384-3414-3434-3444-3464-3494-3514-3544-3564-3574-3594-360

4-3624-3634-3644-365

4-3674-3684-3694-3724-3744-3754-3764-378

4-3854-3874-3884-3894-3904-3914-3924-3934-4044-4094-4124-4134-4144-4154-4184-4334-4374-4424-444

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TM 5-2420-224-20-1

Backhoe Seat Repair . .


BODY, CAB, AND HOOD MAINTENANCE (Section XIV)-CONT

. . . . . . . . . . . . . . . . . . . . .Passenger Seat and Framework Replacement . . . . . . . . .Seat Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab Floor Linings Replacement.. . . . . . . . . . . . . . . . . . . . . .Sun Visor, Clothes Hook, and Grip Handles Replacement . . . . . . .Roof Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hose Reel Assembly Replacement and Repair . . . . . . . . . . . . . .Hose Reel Motor Spring Replacement . . . . . . . . . . . . . . . . . . .Hydraulic Accessory Box Replacement and Repair (SEE) . . . . . . . .Hydraulic Accessory Box Replacement and Repair (HMMH) . . . . . .Hydraulic Tool Hoses Replacement . . . . . . . . . . . . . . . . . .

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BODY AND CHASSIS ACCESSORY ITEMS MAINTENANCE (Section XV)

Interior Rear View Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exterior Rear View Mirror Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield Wiper/Washer Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield Wiper/Washer Motor Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . .Windshield Wiper Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield Washer Reservoir Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Windshield Washer Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defroster and Air Tubes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater Hoses and Clamps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Data Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM MAINTENANCE (Section XVI)

Front Hydraulic Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Hydraulic Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Hydraulic Pump Belt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . .Hydraulic Suspension Lockout Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Crane Hydraulic Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Suspension Lockout Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Suspension Lockout Accumulator Replacement . . . . . . . . . . . . . . . . . . . . .Backhoe Swing Control Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Swing Control Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Control Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Control Rod Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Loader/Forklift Control Valve Controls Replacement and Adjustment . . . . . . . . . . .Crane Controls and Linkages Replacement and Adjustment . . . . . . . . . . . . . . . . . . .ForkliftForkliftForkliftForkliftForkliftForkliftForkliftForklift

Crosshead Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rotator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Carriage Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mast Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forks Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Travel Lock Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Outrigger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Loader Hydraulic Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Left Loader Boom Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . .Right Loader Boom Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . .

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4-4754-4764-4774-4794-4824-4834-4844-4864-4884-4904-492

4-5024-5044-5064-5074-5094-5114-5164-5184-5224-5234-5314-5324-5384-5414-5464-5554-5594-5624-5634-5664-5674-5684-5694-572

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HYDRAULIC SYSTEM MAINTENANCE (Section XVI)-CONT

Page

Left Loader Bucket Rollback Cylinder Hydraulic Lines and Fittings Replacement . . . . . . .Right Loader Bucket Rollback Cylinder Hydraulic Lines and Fittings Replacement . . . . . .Front Loader Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . .Front Loader/Forklift Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . .Front Loader/Forklift Control Valve Hydraulic Lines and Fittings Replacement . . . . . . . . .Front Hydraulic Pump Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . .Hand Tool Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . .Front Hydraulic System Return Lines and Fittings Replacement . . . . . . . . . . . . . . . . .Rear Hydraulic Pump Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . .Rear Hydraulic System Return Lines and Fittings Replacement . . . . . . . . . . . . . . . .Backhoe/Crane Tilt Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . .Backhoe/Crane Latch Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . .Backhoe/Crane Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . .Right Backhoe Stabilizer Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . .Left Backhoe Stabilizer Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . .Backhoe Stabilizer Control Valve Hydraulic Lines and Fittings Replacement . . . . . . . . . .Backhoe Swing Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . .Backhoe Control Valve, Swing Section Hydraulic Lines and Fittings Replacement . . . . . .Backhoe Boom Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . .Backhoe Control Valve, Boom Section Hydraulic Lines and Fittings Replacement . . . . . .Backhoe Dipper Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . .Backhoe Bucket Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . .Backhoe Control Valve, Bucket Section Hydraulic Lines and Fittings Replacement . . . . . .Forklift Tilt Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . .Forklift Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Forklift Rotator Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . .Forklift Pulley Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . .Forklift Lift Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . .Forklift Lift Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane External End Extension Cylinder Hydraulic Lines and Fittings Replacement . . . . . .Crane Turntable Motor Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . .Crane Inner Boom Lift Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . .Crane Mast Locking Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . .Crane Supply Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Return Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . .Crane Outer Boom Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . .Crane Horizontal Outrigger Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . .Crane Vertical Outrigger Cylinder Hydraulic Lines and Fittings Replacement . . . . . . . . .Hydraulic Suspension Lockout Lines and Fittings Replacement . . . . . . . . . . . . . . . . . .Hydraulic Suspension Lockout Pump and Reservoir Lines and Fittings Replacement . . . . .Loader Boom Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Loader Bucket Rollback Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Boom Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Swing Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Bucket Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Dipper Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Stabilizer Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe/Crane Tilt Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe/Crane Latch Cylinder Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . .Backhoe Travel Lock Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Travel Lock Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe/Crane Latch Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5744-5764-5784-5804-5824-5844-5864-5884-5904-5924-5944-5964-5984-6004-6024-6044-6064-6084-6104-6124-6144-6164-6184-6204-6224-6244-6264-6284-6304-6324-6344-6364-6384-6404-6424-6444-6464-6484-6504-6524-6544-6564-6584-6604-6684-6704-6734-6754-6774-6784-6814-684

ix

TM 5-2420-224-20-1


HYDRAULIC SYSTEM MAINTENANCE (Section XVI)-CONT

Forklift Tilt Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forklift Rotator Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane External End Extension Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . .Crane inner Boom Lift Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Mast Locking Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Outer Boom Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Horizontal Outrigger Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Crane Vertical Outrigger Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Hydraulic Tank Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Hydraulic Tank Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Hydraulic Tank Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Tank Sight Indicator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear Hydraulic Tank Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Oil Cooler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GAGES (NON-ELECTRICAL) MAINTENANCE (Section XVII)

Speedometer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Speedometer Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inclinometer Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Counter Engine Revolution (Hourmeter) Replacement . . . . . . . . . . . . . . . . . . . . . . .STE/lCE-R Tachometer Drive and Cable Replacement . . . . . . . . . . . . . . . . . . . . . . .

MACHINE TOOLS AND RELATED EQUIPMENT MAINTENANCE (Section XVIII)

Hammer Drill Hoses Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Impact Wrench Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pavement Breaker Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain Saw Hoses Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain Saw Chain and Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chain Saw Trigger, Guard, and Handle Bar Replacement . . . . . . . . . . . . . . . . . . . .

CRANES, SHOVELS, AND EARTHMOVING EQUIPMENT COMPONENTS MAINTENANCE(Section XIX)

Backhoe Boom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Assembly Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Dipper Replacement and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Bucket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Bucket (Ripper) Bearings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Bucket Links Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Bucket/Ripper Tooth Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Boom Latch Release Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Boom Latch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Swing Tower Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Stabilizer Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Hook Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Rear Outrigger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crane Travel Lock Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . - -Crane Rotation Lock Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .Front Loader Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

4-6864-6884-6904-6924-6944-6964-6984-7004-7024-7094-7124-7194-7204-722

4-7274-7304-7314-7334-734

4-736 4-7384-7404-7424-7444-746

4-7524-7544-7604-7624-7634-7644-7664-7684-7704-7724-7744-7764-7834-7844-7864-7904-794

x

TM 5-2420-224-20-1


CRANES, SHOVELS, AND EARTHMOVING EQUIPMENT COMPONENTS MAINTENANCE(Section XIX)-CONT

Page

Front Loader Main Frame Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-800Front Loader Bucket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-802Front Loader Bucket Tooth Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-804Front Loader Lift Arm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-805

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TM 5-2420-224-20-1

H O W T O U S E T H I S M A N U A L

This manual has an edge index that will help you find specific information in a hurry. Simply spread the pages in the right edge of the manual until the printed blocks can be seen. Open themanual where the block on the edge of the page lines up with your selected topic printed in thefront cover block.

This manual is organized by chapters, sections, and appendices. A summary of the organizationof this manual, by major divisions, follows:

Front cover index gives you a quick reference to chapters, sections, and appendices that youwill use often.

WARNINGS—AII warnings you should observe while working on or around the SEE/HMMH areshown in this part of the manual. These are repeated in the parts of the manual where they apply.

Table of Contents—The contents of the chapters and appendices are listed here.

Chapter 1—This chapter contains general information about the SEE/HMMH. It also shows anddescribes major components and lists specific data that you will find helpful while performingmaintenance tasks.

Chapter 2—This chapter describes services and inspections that must be performed at the unitlevel, such as services you must perform upon receipt of the vehicle, and preventive maintenancechecks and services. Other sections contain painting and restenciling of markings and generalrepair and cleaning methods.

Chapter 3—This chapter outlines troubleshooting of the SEE/HMMH and their systems. Itincludes a troubleshooting index, by symptom and system, and procedures on how to use theSTE/lCE-R components while troubleshooting.

Chapter 4—This chapter contains step-by-step instructions for doing the maintenance tasks.Each system of the SEE/HMMH has its own section within the chapter, and any special tools,equipment, or supplies you may need for a task are listed.

Appendix A—This appendix lists the technical manuals and other publications you may have torefer to while working on the SEE/HMMH.

Appendix B—This appendix contains the Maintenance Allocation Chart (MAC) for the SEE/HMMH.

Appendix C—This appendix lists the expendable supplies and materials you will need whileperforming maintenance on the SEE/HMMH.

Appendix D—This appendix lists and describes any manufactured items you will need forperforming maintenance on the SEE/HMMH.

Appendix E—This appendix describes the proper method of tightening fasteners.

Index—The index is an alphabetical listing of the contents of this manual.

Back Cover—The inside back cover contains a metric conversion table.

xii

TM 5-2420-224-20-1

USING THE MANUAL ON THE JOB

Find the task or component that needs repair by using the LIST OF TASKS (page iii) or theIndex (page Index-1), then turn to the page listed for that task or component.

Read the INITIAL SETUP procedures, and gather the necessary items and personnel. Payattention to the warnings. The INITIAL SETUP sheet is described on page xiv.

Although tasks are complete in detail, complete only the part of the task required. For example,if your task is to replace both air cleaner elements, you need not perform the remainder of thetask to remove and replace the air cleaner canister.

xiii

TM 5-2420-224-20-1

TM 5-2420-224-20-2

FORKLIFT REPLACEMENTThis task covers: a. Removal b. Installation

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

TITLE—This is the name of the task.

WARNING HMMH should not be

operated with forkliftremoved, except in amaintenance facility. Whenmaintenance is required andforklift is removed, neveroperate HMMH at speedsgreater than 5 mph. Tractorstability and handlingcharacteristics are greatlyaffected with forklift removed.This could cause loss ofcontrol and injury topersonnel or damage tovehicle.

High pressure hydraulics [oilunder 2450 psi (26,893 kPa)]operate this equipment.Never disconnect anyhydraulic fine or fittingwithout first dropping

TASK COVERS-This lists all the tasks included in the module.

APPLICABLE CONFIGURATION—lf the task is applicable to only one of the vehicles. SEE orHMMH (as appropriate) will be listed here.

TOOLS AND SPECIAL EQUIPMENT—These are the tools and equipment you will need to dothe task.

MATERIALS/PARTS—These are the supplies you will need to do the task. If parts or materialsare required, they are listed here or referenced to Appendix C.

PERSONNEL REQUIRED-Personnel required to perform a task will be identified if the taskrequires more than one.

REFERENCES-These are the other technical publications you will need to do the task.

EQUIPMENT CONDITION—This is the condition(s) the vehicle must be in before you start thetask. Other tasks that must be done first are listed by page number or by technical manualnumber if another manual is required.

GENERAL SAFETY lNSTRUCTIONS—These are the safety precautions that must be observedwhile you are doing the task.

FOLLOW-ON MAINTENANCE—These are the tasks listed at the end of the procedure thatmust be completed to return the vehicle to an operational condition.

xiv

TM 5-2420-224-20-1

Small Emplacement Excavator (SEE)

xv

TM 5-2420-224-20-1

High Mobility Material Handler (HMMH)

xvi

TM 5-2420-224-20-1

C H A P T E R 1I N T R O D U C T I O N

Section I.

A list of sections contained in this chapter is shown below.

General Information . . . . . . . . . .

Section II. Equipment Description and Data . . . .

Section III. Principles of Operation . . . . . . . . . .

S e c t i o n I . G E N E R A L I N F O R M A T I O N

Page

. . . . . . . . . . . . . . . . . . . . 1-1

. . . . . . . . . . . . . . . . . . . . 1-3

. . . . . . . . . . . . . . . . . . . . 1-8

Type of Manual: Unit Maintenance.

Model Number and Equipment Name:

Model No. FLU10144 Tractor, Wheeled, 4X4 DED Small Emplacement Excavator (SEE)with Attachments, NSN 2420-01-160-2754 (EIC:EDL).

Model No. FLU10344 Tractor, Wheeled, 4X4 DED High Mobility Material Handler (HMMH)with Attachments, NSN 2420-01-205-8636.

Purpose of Equipment:

The SEE is used for excavation, loading, lifting, and grading on various types of terrain.The vehicle is equipped with a front loader, backhoe, chain saw, pavement breaker, andhammer drill and is capable of rapid deployment for constructing protective positions.

The HMMH is used for material handling with forklift and crane attachments. The vehicleis equipped with an impact wrench to assist in maintenance of other equipment and iscapable of rapid deployment.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be thoseprescribed by DA Pam 738-750, The Army Maintenance Management System (TAMMS).

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

When the tactical situation requires that Army materiel be abandoned, refer to TM 750-244-6,Procedures for Destruction of Tank-Automotive Equipment to Prevent Enemy Use, for procedureson destruction of the vehicle(s).

1-1

TM 5-2420-224-20-1

P R E P A R A T I O N F O R S T O R A G E O R S H I P M E N T

Instructions for storage and shipment, including administrative storage, are found inTM 740-90-1, MIL-V-62038D, and Chapter 2, Section VIl.

REPORTING EQUIPMENT lMPROVEMENT RECOMMENDATIONS (EIRs)

If your vehicle needs improvement, let us know. Send us a Quality Deficiency Report. You, theuser, are the only one who can tell us what you don’t like about your equipment. Let us knowwhy you don’t like the design or performance. Put it on an SF Form 368 (QDR) and mail it to:

CommanderU.S. Army Tank-Automotive CommandAttn: AMSTA-QRTWarren, Ml 48397-5000

WARRANTY INFORMATION

The vehicles are warranted by Freightliner Corporation in accordance with TB 5-2420-224-15.Warranty starts on the date found in block 23, DA Form 2408-9 in the logbook. Report all defectsin material or workmanship to your supervisor, who will take appropriate action through your unitmaintenance shop.

METRIC SYSTEM

The equipment described herein contains metric components and requires metric common andspecial tools; therefore, metric units in addition to English units will be used throughout the manual.An English-to-metric conversion table is included as the last page of this manual inside the backcover.

1-2

TM 5-2420-224-20-1

Section I I . EQUIPMENT DESCRIPTION AND DATA

This section contains information useful when performing unit level maintenance tasks on theSEE/HMMH. Refer to TM 5-2420-224-10 for additional equipment description and data.

EQUIPMENT CHARACTERISTICS, CAPABILIT IES, AND FEATURES

Characteristics

Low center of gravity for stability

Convoy speed

Small turning radius

17-in. (43.2-cm) ground clearance under axles and frame

Rapid deployment

Multiple attachment versatility

Capabilities and Features

Broad range of angles of approach and departure

Four-wheel drive and differential locks on both axles can be engaged and disengagedwhile moving

High-mounted air intake and vertical exhaust

Traverse up and down 60% slopes and 30% side slopes

30-in. (76.2-cm) fording depth

Power assisted disc brakes on all four wheels

Power steering

All steel cab

Roll-Over Protective Structure (ROPS)

Falling Objects Protective Structure (FOPS)

Utility mounting platforms

Trailer towing equipment

Front loader/forklift or backhoe/crane and machine (hydraulic) tools can be operatedsimultaneously

1-3

TM 5-2420-224-20-1

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

ROLL-OVER PROTECTIVE STRUCTURE (ROPS) (1). Protects cab if vehicle roll-over occurs.

STOWAGE (2). Hydraulic tools and equipment.

HYDRAULIC SYSTEM (3). Belt driven front system and Power Take-Off (PTO) driven rear system,rated to power front loader/forklift, backhoe/crane, and machine tools.

UTILITY PLATFORM (4). Solid base, access backhoe operations.

BASIC ISSUE ITEMS (Bll) TOOLS (5). Stored behind cab in hydraulic accessory box.

VERTICAL EXHAUST (6). Mounted behind cab.

TRAILER TOWING EQUIPMENT (7). Tow pintle with air brake and electrical connections.

FOUR-WHEEL DRIVE (8). Four-wheel drive with differential lock, front and rear axles.

CHASSIS FRAME (9). Flexible, ladder-type, high-strength steel.

FRONT LOADER (SEE) (10). Used for excavating and filling excavations.

BACKHOE (SEE) (11). Digs excavations and trenches.

1-4

TM 5-2420-224-20-1

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (CONT)

MULTIPLE PURPOSE TIRES (MPT) (12). Low-pressure high-traction radial ply with mounted spare.

SUSPENSION (13). Coil springs, shock absorbers, and front suspension lockout cylinders on theHMMH.

POWER TAKE-OFF (PTO) (14). Supplies power to the rear hydraulic pump.

ENGINE (15). Four-stroke, six-cylinder diesel.

TRANSMISSION (16). Fully synchronized 16 forward, 8 reverse, and pneumatic preselect shiftmechanism.

CAB (17). Two-person, all steel construction.

HIGH MOUNTED AIR INTAKE (18). Mounted on left front corner of cab.

FALLING OBJECTS PROTECTIVE STRUCTURE (FOPS) (19). Protects cab from falling objects.

HYDRAULIC TOOL COUPLINGS (20). Quick-disconnect type.

FRONT LOADER/FORKLIFT and BACKHOE/CRANE ATTACHMENT POINTS (21). One-personoperation, easy installation and removal of front loader/forklift and backhoe/crane.

FORKLIFT (HMMH) (22). Loads and unloads palletized material.

CRANE (HMMH) (23). Lifts material for maintenance and supply operations.

FIRE EXTINGUISHER (24). Mounted between seats.

1-5

TM 5-2420-224-20-1

E Q U I P M E N T D I F F E R E N C E S

SEE TractorFront LoaderBackhoeChain sawPavement breakerHammer drill

HMMH TractorSuspension lockout systemForkliftCraneImpact wrench

EQUIPMENT DATA

EngineManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daimler-BenzModel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353.999Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-stroke diesel, 6 cylinderHorsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110(81kW

ClutchType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single dry plate

Engine Air CleanerManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. DonaldsonModel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FSGO9-0160Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry

Fuel SystemFuel Pump

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BoschTiming @ 700 rpm +50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Low idleInjection Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5-3-6-2-4

Fuel TankCapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 gallons(114 I)

Cooling SystemCapacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 gallons (23 I)

Electrical SystemBatteries

Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Lead-acidVoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12vdcConnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SeriesOutput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 vdcPost to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative

AlternatorManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BoschRating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..55 ampsDrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt, by engine

StarterManufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bosch

TransmissionType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully synchronizedSpeeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 forward, 8 reversePower Take-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven

1-6

TM 5-2420-224-20-1

EQUIPMENT DATA (CONT)

AxlesType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Portal with reduction thrust tubesDrive. . . . . . . . . . . . . . . . . . . . . . . . . .

SuspensionSprings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BrakesService

. . . . . . . . . . . . . . . . . . . 4-wheel

. . . . . . . . . . . . . . . . . . Coil

Hydraulic actuated (HMMH)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-wheel, dual-circuit disc/caliperPower Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Hydraulic, air assistWarning System . . . . . . . . . . . . . . . . . . . . . . . . . Low-air pressure (audible and visual)

ParkingType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caliper, mechanical cable, rear wheels

Air CompressorType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Engine drivenCylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.03 inches (77 mm)Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18 inches (30 mm)Capacity @ 2600 rpm . . . . . . . . . . . . . . . . . . . 4.77 cfm (135 Ipm) @ 105 psi (724 kPa)

WheelsType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interchangeable rim and wheelTires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 multipurpose

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5 R20 12 PR radialPressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Track Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SteeringType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. RecirculatingPower Steering Pump.... . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic SystemFront (SEE)

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Capacity . . . . . . . . . . . . . 8 gpm @ 2450 psi (30 lpm @ 167Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front

Rear (SEE)Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Capacity . . . . . . . . . . . . . . . 26 gpm @ 2450 psi (98 Ipm @ 167Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front (HMMH)Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Capacity . . . . . . . . . . . . . . . 8 gpm @ 2450 psi (30 Ipm @ 167

. .

. .

Low. . .64 inches (163 cm)

ball with power assist. . . Belt, by engine

. . . . . . . . . Enginebar) @ 2000 engine rpmloader and machine tools

. . . . . . . . . . . . . . .PTObar) @ 2000 engine rpm. . . . . . . . . . Backhoe

. . . . . . . . . . . . . .Enginebar) @ 2000 engine rpm

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forklift and impact wrenchRear (HMMH)

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTOCapacity . . . . . . . . . . . . . . . 14 gpm @ 2450 psi (54 Ipm at 167 bar) @ 1100 engine rpmUse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crane

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TM 5-2420-224-20-1

S A F E T Y , C A R E , A N D H A N D L I N G

Warnings and cautions are listed in the front of the manual, at the beginning of each task, and at points where they apply in the maintenance procedures. In addition to these warnings, alwayskeep in mind the following when working on the SEE/HMMH:

The hydraulic system operates at pressures up to 2450 psi (167 bar).

Be aware of where personnel are at all times when operating front Ioader/forklift andbackhoe/crane.

Do not allow personnel to walk under a raised front loader/forklift or backhoe/crane eitherduring operation or maintenance.

Always remove all jewelry and wristwatch, and make sure the vehicle MASTER disconnectswitch is OFF before working on the electrical system.

S e c t i o n I l l . P R I N C I P L E S O F O P E R A T I O N

O V E R V I E W

This section contains information on the principles of operation of the SEE/HMMH. The generalfunctional description of the vehicle’s separate systems is contained in this section. Unit maintenancepersonnel should be familiar with the principles of operation of these systems before working on ortroubleshooting these systems. A more thorough understanding of the electrical system can beobtained by referring to the electrical system schematic diagrams In the troubleshooting section InChapter 3. The systems and components are:

Power TrainEngine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Shafts . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical System

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..StarterMotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switches and Gages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sending Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake SystemService Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SteeringSystem . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Earthmoving, Material Handling Components and Controls

Front Loader (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Loader Controls (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forklift (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forklift Controls (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backhoe (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Backhoe Controls (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

1-91-91-91-101-101-101-101-11

1-111-111-111-121-12

1-121-121-131-13

1-141-141-141-141-151-15

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TM 5-2420-224-20-1

OVERVIEW (CONT)

Page

Crane (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15Crane Controls (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Hydraulic SystemFront System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16Rear System . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16Machine (Hydraulic) Tools

Chain Saw (SEE) . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17Pavement Breaker (SEE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-17Hammer Drill (SEE) 1-17Impact Wrench (HMMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Engine. The engine is an in-line six cylinder, four stroke-cycle direct injection starting,valve-in-head type diesel that develops 110 horsepower (81 kW). An ether injection system isconnected to the air intake manifold to aid in cold weather starting. The engine is water-jacketcooled. An engine oil sampling valve is supplied to easily obtain a sample of the engine oil.(Refer to LO 5-2420-224-12 for oil sampling procedures.)

Transmission. The transmission is manually operated with a single dry plate clutch. The mainlever shifts all speeds no matter what gear range or intermediate speeds are preselected.Intermediate speed controls are main transmission reduction speeds and can be engaged anddisengaged while driving in either forward or reverse. The group shift selector has three shiftingfunctions: Range I, Range II, and Reverse. The Power Take-Off (PTO) lever engages anddisengages the PTO when the clutch is fully depressed.

Drive Shafts. The purpose of the drive shafts is to transmit power to the axles from thetransmission. The rear axle drive, four-wheel drive, and differential locks located on both axles canbe engaged pneumatically while driving without interrupting the power flow.

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TM 5-2420-224-20-1

POWER TRAIN (CONT)

Axles. There are two portal axles with hub reduction thrust tube mounted.

Wheels and Tires. Multipurpose tires are mounted on solid disc type wheels with the front andrear tires being equal in size. The rim size is 11.00-20, tire size is 12.5 R20 12 PR radial, andthe track width is 64 in. (163 cm).

F U E L S Y S T E M

The fuel to power the engine is pumped out of the fuel tank by the fuel primer pump mountedon the fuel injection pump. The fuel pump is gear-driven directly from the engine camshaft. Thefuel is filtered through a pre-sediment bowl and a primary and secondary fuel filter before itreaches the fuel injection pump, where it will be delivered to the fuel injectors. Fuel may be shutoff near the tank with the shutoff valve.

E X H A U S T S Y S T E M

The exhaust system consists of an exhaust pipe from the manifold, a muffler, a verticalexhaust pipe, and a spark arrester.

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TM 5-2420-224-20-1

C O O L I N G S Y S T E M

The coolant heated in the engine is circulated through the cooling system by an engine-drivencoolant pump. The coolant is cooled in the coils of the radiator and any overflow is received inthe expansion tank. The crankshaft-driven fan blows air through the radiator coils to aid cooling.The thermostat automatically regulates engine temperature by regulating the flow of heated coolantto the radiator.

E L E C T R I C A L S Y S T E M

Alternator. The alternator is belt-driven at a speed sufficient to provide the electrical energy forthe normal demands of the electrical system. Some of this energy is used to keep the batteriescharged.

Starter Motor. The starter motor is located on the left rear side of the engine. It is activatedby the start switch when the MASTER disconnect switch and power switch are on and the clutchis fully depressed.

Batteries. The two lead-acid batteries are mounted in a battery box located on the left sidebeneath the rear of the cab near the air reservoir tanks. The batteries provide electrical power tostart the engine and supply power to the auxiliary circuit when the engine is stopped. ANATO-type slave receptacle is located next to the battery box to provide capability for a jump startfrom an auxiliary source if the batteries are too low to start the engine.

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TM 5-2420-224-20-1

ELECTRICAL SYSTEM (CONT)

Switches and Gages. Refer to TM 5-2420-224-10 for the locations and detailed descriptions of the switches and gages.

Sending Units. The intermediate speed indicator is located on the right side of thetransmission; the parking brake indicator is located on the cable lever at the center of the rearaxle; the low air warning indicator is located on the air line to the trailer air brake valve; thePower Take-Off (PTO) indicator is located on the left side of the transmission housing at the PTOhousing; the fuel level sending indicator is located on the right side top of the fuel tank; theneutral start switch indicator is located under the clutch pedal on the left side of the cab.

The vehicle is equipped with air-assisted hydraulic brakes. The dual circuit brake system utilizesfour-wheel disc brakes with two calipers on each front wheel, one on each rear wheel, and acable-operated parking brake at the rear.

Service Brakes. The service brakes consist of the brake booster, master cylinder, brake pedal,brake pads and discs, service brake warning light, and air pressure warning alarm.

Parking Brake. A cable-actuated cam acts on the caliper brake on the rear wheel when thelever is pulled. There is also a parking brake warning light.

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TM 5-2420-224-20-1

Steering is hydraulically powered and consists of a V-belt driven power steering pump, tie rods,drag link, pitman arm, and hydraulic reservoir and filter.

The suspension is mechanical and consists of coil springs, telescopic shock absorbers, andstabilizers. The HMMH uses a front suspension lockout system for use with forklift and craneoperations.

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TM 5-2420-224-20-1

EARTHMOVING, MATERIAL HANDLING COMPONENTS AND CONTROLS

Front Loader (SEE). The front loader is used to scoop earth to construct fighting positions andartillery and missile emplacements, to grade surfaces, and to backfill excavations made with thebackhoe.

Front Loader Controls (SEE). The front loader is equipped with two control levers locatedbetween the seats in the cab. Pull up on the left lever to raise the loader bucket, push down onthe lever to lower the bucket, and push down past detent to activate the float feature. Pull up onthe right lever to curl the loader bucket back, push down on the lever to curl the bucket down.

Forklift (HMMH). The forklift loads and unloads palletized cargo with the aid of the frontsuspension lockout system.

Forklift Controls (HMMH). The forklift is equipped with two control levers located between theseats in the cab. Pull up on the left lever to raise the mast, push down on the lever to lower themast. Pull up on the right lever to tilt the mast back, push down on the lever to tilt the mastforward. Press the button on the right lever and pull up to rotate the carriage clockwise, press thebutton and push down to rotate the carriage counterclockwise.

1-14

TM 5-2420-224-20-1

EARTHMOVING, MATERIAL HANDLING COMPONENTS AND CONTROLS (CONT)

Backhoe (SEE). The backhoe is used to excavate trenches for fighting positions,communications, explosives, and power lines.

Backhoe Controls (SEE). The backhoe controls are located on the backhoe and operate thecontrol cylinders. The backhoe controls consist of the stabilizer control levers, bucket control lever,dipper control lever, boom control lever, transport lock latch, and swing control pedals.

Crane (HMMH). The crane loads and unloads cargo and provides maintenance support inforward combat areas with the aid of the front suspension lockout system.

Crane Controls (HMMH). The crane controls are located on both sides of the vehicle when thecrane is deployed. The crane controls consist of the mast folding lever, left outrigger vertical lever,right outrigger vertical lever, outrigger horizontal lever, boom extension lever, outer boom lever,inner boom lever, boom rotation lever, and latch levers.

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TM 5-2420-224-20-1

HYDRAULIC SYSTEM

Front System. The front hydraulic system pump is belt-driven and supplies hydraulic fluid tothe front loader/forklift and machine tools through an 11-gal (41.6-l) hydraulic tank located to theleft rear of the cab.

Rear System. The rear hydraulic system pump is PTO-driven and supplies hydraulic fluid tothe backhoe/crane through a 21-gal (79.4-l) hydraulic tank located to the right rear of the cab.

AIR SYSTEM

The air system consists of an air compressor, two air tanks, air pressure gage, low pressureindicator, low pressure buzzer, air pressure regulator, and compressed air anitfreeze unit.

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TM 5-2420-224-20-1

M A C H I N E ( H Y D R A U L I C ) T O O L S

Chain Saw (SEE). The chain saw is used for debranching, pruning, and removal of trees andwood products. The 15-in. bar allows cutting of wood up to 30 in. in diameter. Squeezing thetrigger controls the speed of the chain saw.

Pavement Breaker (SEE). The pavement breaker is used for breaking and chipping concrete,rock, pavement, and hard ground. The pavement breaker uses moil points, spade, and chiselattachments for breaking and chipping. Squeezing the trigger activates the pavement breaker.

Hammer Drill (SEE). The hammer drill is used for drilling holes in rock, concrete, or asphalt3/4, 1, or 2 in. (12.7, 25.4, or 50.8 mm) in diameter. A switch controls the direction the tooloperates. Squeezing the trigger activates and controls the speed of the hammer drill.

Impact Wrench (HMMH). The impact wrench is used for removing and installing hardware fromcontainers and other equipment. A lever controls the direction and the trigger controls the speed ofthe impact wrench.

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TM 5-2420-224-20-1

C H A P T E R 2SERVICES AND SCHEDULED VEHICLE MAINTENANCE

This chapter contains information you wiII need to prepare the SEE/HMMH for daily use and toperform preventive and scheduled maintenance. The following sections are included in this chapter.

Section I

Section Il.

Section Ill.

Section IV.

Section V.

Section VI.

Section VIl.

This section includes information on tools and equipment you need to support the SEE and HMMHtractors.

Repair Parts, Special Tools; Test, Measurement, and . . . . . . . . .Diagnostic Equipment (TMDE); and Support Equipment

Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preventive Maintenance Checks and Services . . . . . . . . . . . . . . .

Painting and Restenciling Markings . . . . . . . . . . . . . . . . . . .

General Repair and Cleaning Methods . . . . . . . . . . . . . . . .

General Hydraulic System Repair Methods . . . . . . . . . . . . . .

Preparation for Storage or Shipment . . . . . . . . . . . . . .

Section I . REPAIR PARTS, SPECIAL TOOLS;

Page

2-1

2-2

2-2

2-14

2-15

2-32

2-36

TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);AND SUPPORT EQUIPMENT

C O M M O N T O O L S AND E Q U I P M E N T

For authorized common tools and equipment, refer to the Modified Table of Organization andEquipment (MTOE) applicable to your unit. Tool kits required for each task in this manual are listed inthe Maintenance Allocation Chart (MAC) in Appendix B and on the INITIAL SETUP page of each task.

SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

Special tools and support equipment required to maintain the SEE/HMMH are listed in theMaintenance Allocation Chart (MAC) Appendix B and on the INITIAL SETUP page of each task.Special tools are also listed in the Repair Parts and Special Tools List (TM5-2420-224-24P). Toolsthat are to be fabricated are described and listed in Appendix D of this manual.

Repair parts are listed and illustrated in the Repair Parts and Special TO OIS List(TM5-2420-224-24P) covering the unit maintenance of this equipment.

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TM 5-2420-224-20-1

S e c t i o n I l . S E R V I C E U P O N R E C E I P T

This section contains information on what to do when the vehicle is received.

C H E C K I N G E Q U I P M E N T

1. Inspect the equipment for damage incurred during shipment. If the equipment has beendamaged, report the damage on DD Form 6, Packaging Improvement Report.

2. Check the equipment against the packing slip to see if the shipment is complete. Report alldiscrepancies with the instructions of DA PAM 738-750, The Army Maintenance ManagementSystem (TAMMS).

3. Check to see whether the equipment has been modified.

INITIAL SERVICES

1.

2.

3.

4.

5.

6.

Follow all precautions and instructions on tag DA Form 1397, Processing Record for Shipment,Storage, and Issue of Vehicle and Spare Engines.

Remove all packing and shipping materials, such as tape, tiedowns, protective covers, andshipping seals.

Remove all BII and COEI equipment and store in accordance with TM 5-2420-224-10.

If batteries have not been serviced, refer to TM 9-6140-200-14.

Service the vehicle in accordance with TM 5-2420-224-10 and LO 5-2420-224-12.

Refer to TM 5-2420-224-10 and perform functional checks of all major vehicle systems.

Section I l l . PREVENTIVE MAINTENANCE CHECKS AND SERVICES

This section details the Preventive Maintenance Checks and Services (PMCS) required for theSEE/HMMH. PMCS is a scheduled, step-by-step inspection and service of the vehicle and vehiclecomponents. Its purpose is to keep the vehicle in good condition and to identify and correctproblems before costly and time-consuming repairs are needed.

MAINTENANCE FORMS AND RECORDS

Use DA Form 2404, Equipment Inspection and Maintenance Worksheet, to record periodicmaintenance services performed and faults corrected. The item number on the DA Form 2404 mustbe the same as the item number of the PMCS. For information on maintenance forms and records,see DA Pam 738-750.

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TM 5-2420-224-20-1

OPERATOR PARTICIPATION

The operator will perform the operator PMCS (TM 5-2420-224-10) and will also help unitmaintenance do the unit PMCS, and perform lubrication in accordance with LO 5-2420-224-12.

Unit PMCS should be performed at the intervals shown below:

Do your (Q) PMCS quarterly (every 3 months).

Do your (S) PMCS semiannually (every 6 months).

Do your (A) PMCS annually (once every year).

Refer to the following illustrations and descriptions for information on how to inspect commonitems on the vehicle.

NUTS, BOLTS, AND SCREWS: Check for looseparts by looking for cracked or chipped paintaround screw and bolt heads. Check for missingor broken cotter pins or

TABLE OF CONTENTSi UNIT MAINTENANCE MANUAL ...Technical Manual No. 5-2420-224-20-1 TM...

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