114272406-TM-10-3920-675-23-1-RTCH-RT-240.pdf

ARMY *TM 10-3930-675-23-1MARINE CORPS TM 11078A-OI/1

TECHNICAL MANUALFIELD MAINTENANCE MANUAL

FOR

ROUGH TERRAIN CONTAINER HANDLER (RTCH):RT 240; 53,000 LB CAPACITY; 4 X 4

NSN 3930-01-473-3998NSN 3930-01-522-7364

*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPSTM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes.

DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.

YMRA EHT FO TNEMTRAPED ,SRETRAUQDAEH SPROC ENIRAM .S.U ,SRETRAUQDAEH

01 OCTOBER 2012 PCN 184 110783 00

03/15/2011 Rel(1.8) root(frntcover) wpno(F00001)

VOLUME 1

WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understoodand applied during operation and maintenance of this equipment. Failure to observe these precautions could resultin serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons usedwithin the technical manual.

FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

EXPLANATION OF SAFETY WARNING ICONS

ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows thatshock hazard is present. May result in death or injury to personnel.

FLYING PARTICLES - Arrows bouncing off face with face shield shows that particles flying throughthe air will harm face. May result in death or injury to personnel.

HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life orlimb. May result in death or injury to personnel.

HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm. Mayresult in death or injury to personnel.

HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential fromimproper lifting technique. May result in death or injury to personnel.

HOT AREA - Hand over object radiating heat shows that part is hot and can burn. May result in deathor injury to personnel.

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WARNING SUMMARY - Continued

GENERAL SAFETY WARNING DESCRIPTIONS

WARNING

COMPRESSED AIR

Compressed air used for cleaning or drying purposes, or for cleaning restrictions, shouldnever exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injuryto personnel.

WARNING

ELECTRICAL SYSTEM MAINTENANCE

Remove all jewelry, watches, rings, etc. prior to disconnecting cables from batteries or otherelectrical source. Items can come in contact with battery or electrical source and causeelectrical shock. Failure to follow this warning may result in injury or death to personnel.

WARNING

HYDRAULIC SYSTEM

DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic systempressure has been relieved. Tighten all connections before applying pressure. Escapinghydraulic fluid under pressure can penetrate the skin, causing serious injury.Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.If an accident occurs, see a doctor immediately. Any fluid injected into the skin must besurgically removed within a few hours or gangrene may result.At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnectingany hydraulic lines. Failure to follow this warning may result in injury to personnel.Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warningmay result in injury to personnel.

WARNINGIR LIGHTS

DO NOT look directly at IR source without eye protection and maintain a minimum of12 inches from energized IR lights to prevent possible eye discomfort or damage.

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GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

LIFTING HEAVY COMPONENTS

Hydraulic jacks are intended only for lifting RTCH, not for supporting vehicle to performmaintenance. DO NOT get under vehicle after it is raised unless it is properly supported withblocks or other suitable cribbing. Failure to observe this warning may result in death or injuryto personnel. Use extreme caution when handling heavy parts. Provide adequate support and useassistance during procedure. Ensure that any lifting device used is in good condition and ofsuitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure tofollow this warning may result in death or injury to personnel.Improper use of lifting equipment and improper attachment of cables to vehicle can result inserious personnel injury and equipment damage. Observe all standard rules of safety.

WARNING

SLAVE STARTING

When slave starting RTCH, use NATO slave cable that DOES NOT have loose or missinginsulation. DO NOT proceed if suitable cable is not available. DO NOT use civilian-type jumper cables.

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EXPLANATION OF HAZARDOUS MATERIALS ICONS

BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses thatpresent a danger to life or health.

CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation tohuman skin or tissue.

EYE PROTECTION - Person with goggles shows that the material will injure the eyes.

FIRE - Flame shows that a material may ignite and cause burns.

HYDRAULIC FLUID PRESSURE - Hydraulic fluid spraying human figure shows that fluid escapingunder great pressure can cause injury or death.

RADIOACTIVE - Identifies a material that emits radioactive energy and can injure human tissue ororgans.

VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.

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HAZARDOUS MATERIALS DESCRIPTIONS

WARNING

BATTERY

Remove all jewelry, such as rings, I.D. tags, rings, bracelets, etc. If jewelry contactsa battery terminal, a direct short will result causing instant heating of jewelry. Failureto follow this warning may result in serious injury or death to personnel. Seek medicalattention in the event of an injury.

Battery acid (electrolyte) is extremely dangerous. Always wear eye protection andrubber gloves when performing battery checks or inspections. Serious injury topersonnel will result if battery acid contacts skin or eyes. Failure to follow this warningmay result in injury or death to personnel. Seek medical attention in the event of aninjury.

DO NOT perform battery system checks or inspections while smoking or near fire,flames, or sparks. Battery gases may explode. Failure to follow this warning maycause serious injury or death to personnel. Seek medical attention in the event of aninjury.

Sulfuric acid contained in batteries can cause serious burns. If battery corrosion orelectrolyte makes contact with skin, eyes, or clothing, take immediate action to stopthe corrosive burning effects. Failure to follow this warning may cause injury topersonnel. Seek medical attention in the event of an injury.

a. Eyes. Flush with cold water for no less than 15 minutes and immediatelyseek medical attention.

b. Skin. Flush with large amounts of cold water until all acid is removed. Seekmedical attention as required.

c. Internal. If corrosion or electrolyte is ingested, drink large amounts of wateror milk. Follow with milk of magnesia, beaten egg, or vegetable oil.Immediately seek medical attention.

d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralizeacid with baking soda or household ammonia.

California Proposition 65 Warning. Battery posts, terminals, and related accessoriescontain lead and lead components. These chemicals are known to the State ofCalifornia to cause cancer and reproductive harm. Wash hands after handling.Failure to follow this warning may result in injury or death to personnel. Seek medicalattention in the event of an injury.

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HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

Carbon monoxide is a colorless, odorless, deadly poisonous gas which, when breathed,deprives the body of oxygen and causes suffocation. Exposure to air containing carbonmonoxide produces symptoms of headache, dizziness, loss of muscular control, apparentdrowsiness, and coma. Permanent brain damage or death may result from severe exposure.Seek medical attention in the event of an injury.Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxidecan become dangerously concentrated under conditions of inadequate ventilation. Thefollowing precautions must be observed to ensure safety of personnel when engine of RTCHis operated for any purpose.

1. DO NOT operate RTCH engine in enclosed areas. Good ventilation is essential.2. BE ALERT at all times for exhaust odors.3. BE ALERT for exhaust poisoning symptoms. They are:

Headache Dizziness Drowsiness Loss of muscular control

4. If you see another person with exhaust poisoning symptoms: Remove person from area. Expose person to fresh air. Keep person warm. DO NOT permit physical exercise. Administer cardiovascular pulmonary resuscitation (CPR), if necessary. Notify a medic.

5. BE AWARE: The field protective mask for chemical-biological-radiological-nuclear(CBRN) protection will not protect you from carbon monoxide poisoning.

6. The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation.7. Failure to follow this warning may result in injury or death to personnel.8. Seek medical attention in the event of an injury.

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WARNING

CBRN EXPOSURE

If CBRN exposure is suspected, personnel wearing protective equipment must handle all aircleaner media. Contaminated filters must be handled using adequate precautions and mustbe disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO forappropriate handling or disposal procedures. Failure to follow this warning may cause injuryor death to personnel. Seek medical attention in the event of an injury.

To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083

WARNING

CLEANING AGENTS

Improper cleaning methods and use of unauthorized cleaning agents can injure personneland damage equipment. To prevent this, refer to TM 9-247 for further instructions.

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WARNING

DIESEL FUEL HANDLING

DO NOT perform fuel system checks, inspections, or maintenance while smoking ornear fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injuryor death to personnel.

Wear fuel-resistant gloves when handling fuels and promptly wash exposed skin andchange fuel-soaked clothing.

WARNING

CLEANING COMPOUND, SOLVENT

Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protectivegoggles and gloves and use only in a well-ventilated area. Avoid contact with skin,eyes, and clothes and do not breathe vapors. DO NOT use near open flames orexcessive heat. The solvent's flash point is 200F (94C). If you become dizzy whileusing cleaning compound, solvent, get fresh air immediately and get medical aid. Ifsolvent contacts eyes, wash your eyes and get medical aid immediately.

WARNING

ETHER COLD START

Ether is extremely flammable and explosive. DO NOT perform ether cold start systemchecks, inspections or maintenance while smoking or near fire, flames or sparks.Failure to follow this warning may cause a fire and explosion, causing serious injuryor death to personnel.

Avoid breathing cold start system fluid vapors. Wear goggles and fuel-resistantgloves when handling fluid. Failure to follow this warning may result in serious injuryor death to personnel.

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WARNING

FIRE EXTINGUISHER

Discharging large quantities of dry chemical fire extinguisher in cab may result in temporarybreathing difficulty during and immediately after the discharge event. If at all possible,discharge fire extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry.

WARNING

HAZARDOUS WASTE DISPOSAL

When servicing this vehicle, performing maintenance, or disposing of materials such asengine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consultyour unit/local hazardous waste disposal center or safety office for local regulatory guidance.If further information is needed, please contact The Army Environmental Hotline at1-800-327-3845. Failure to follow this warning may result in death or injury to personnel.

WARNING

PRESSURIZED COOLING SYSTEM

DO NOT service cooling system unless engine has been allowed to cool down. Thisis a pressurized cooling system and escaping steam or hot coolant will cause seriousburns.

DO NOT remove cooling system radiator cap when engine is hot. Allow engine tocool down. Failure to follow this warning may cause serious burns.

Wear effective eye, glove, and skin protection when handling coolants. Failure tofollow this warning may result in injury.

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WARNING

R-134A REFRIGERANT

Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eyetissue. Take care to prevent refrigerant from touching your skin or eyes. Serious injuryor blindness may result if you come in contact with liquid refrigerant.

Refrigerant R-134a air conditioning systems should not be pressure tested or leaktested with compressed air. Combustible mixtures of air and R-134a may form,resulting in a fire or explosion, which could cause personnel injury.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES

NOTE: This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPSTM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. Zero in the "Change No." column indicates an original page or work package. This manual has two volumes.

Date of issue for the original manual is:

Original 01 OCTOBER 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 112 AND TOTAL NUMBER OFWORK PACKAGES IS 134 CONSISTING OF THE FOLLOWING:

Page/WP No. Change No.

VOLUME 1Front Cover 0Promulgation Letter (2 pages) 0Warning Summary (10 pages) 0Title Block Page (2 pages) 0Table Of Contents (66 pages) 0How to Use This Manual (4 pages) 0Chapter 1 Title Page 0WP 0001 (4 pages) 0WP 0002 (8 pages) 0WP 0003 (4 pages) 0Chapter 2 Title Page 0WP 0004 (44 pages) 0WP 0005 (18 pages) 0WP 0006 (100 pages) 0WP 0007 (56 pages) 0WP 0008 (18 pages) 0WP 0009 (6 pages) 0WP 0010 (14 pages) 0WP 0011 (4 pages) 0WP 0012 (10 pages) 0WP 0013 (12 pages) 0WP 0014 (8 pages) 0WP 0015 (8 pages) 0WP 0016 (22 pages) 0WP 0017 (16 pages) 0WP 0018 (8 pages) 0WP 0019 (14 pages) 0WP 0020 (26 pages) 0WP 0021 (12 pages) 0WP 0022 (14 pages) 0WP 0023 (14 pages) 0WP 0024 (8 pages) 0WP 0025 (6 pages) 0WP 0026 (10 pages) 0WP 0027 (16 pages) 0WP 0028 (10 pages) 0WP 0029 (6 pages) 0WP 0030 (6 pages) 0


WP 0031 (6 pages) 0WP 0032 (16 pages) 0WP 0033 (6 pages) 0WP 0034 (16 pages) 0WP 0035 (2 pages) 0WP 0036 (4 pages) 0WP 0037 (4 pages) 0WP 0038 (10 pages) 0WP 0039 (10 pages) 0WP 0040 (10 pages) 0WP 0041 (8 pages) 0WP 0042 (10 pages) 0WP 0043 (10 pages) 0WP 0044 (6 pages) 0WP 0045 (8 pages) 0WP 0046 (10 pages) 0Chapter 3 Title Page 0WP 0047 (2 pages) 0WP 0048 (8 pages) 0Chapter 4 Title Page 0WP 0049 (2 pages) 0WP 0050 (20 pages) 0WP 0051 (8 pages) 0WP 0052 (18 pages) 0WP 0053 (6 pages) 0WP 0054 (10 pages) 0WP 0055 (10 pages) 0WP 0056 (24 pages) 0WP 0057 (4 pages) 0WP 0058 (4 pages) 0WP 0059 (4 pages) 0WP 0060 (14 pages) 0WP 0061 (6 pages) 0WP 0062 (6 pages) 0WP 0063 (6 pages) 0WP 0064 (4 pages) 0WP 0065 (8 pages) 0WP 0066 (8 pages) 0WP 0067 (6 pages) 0

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LIST OF EFFECTIVE PAGES/WORK PACKAGES - Continued


WP 0068 (4 pages) 0WP 0069 (6 pages) 0WP 0070 (4 pages) 0WP 0071 (6 pages) 0WP 0072 (8 pages) 0WP 0073 (8 pages) 0WP 0074 (4 pages) 0WP 0075 (4 pages) 0WP 0076 (4 pages) 0WP 0077 (10 pages) 0WP 0078 (10 pages) 0WP 0079 (6 pages) 0WP 0080 (4 pages) 0WP 0081 (8 pages) 0WP 0082 (8 pages) 0WP 0083 (12 pages) 0WP 0084 (2 pages) 0WP 0085 (2 pages) 0WP 0086 (2 pages) 0WP 0087 (4 pages) 0WP 0088 (6 pages) 0WP 0089 (6 pages) 0WP 0090 (8 pages) 0WP 0091 (4 pages) 0WP 0092 (4 pages) 0WP 0093 (6 pages) 0WP 0094 (14 pages) 0WP 0095 (8 pages) 0WP 0096 (4 pages) 0WP 0097 (14 pages) 0WP 0098 (4 pages) 0WP 0099 (4 pages) 0WP 0100 (8 pages) 0WP 0101 (2 pages) 0WP 0102 (10 pages) 0WP 0103 (16 pages) 0WP 0104 (16 pages) 0WP 0105 (8 pages) 0WP 0106 (4 pages) 0WP 0107 (4 pages) 0WP 0108 (24 pages) 0WP 0109 (6 pages) 0WP 0110 (6 pages) 0WP 0111 (6 pages) 0WP 0112 (8 pages) 0WP 0113 (8 pages) 0WP 0114 (4 pages) 0WP 0115 (4 pages) 0WP 0116 (2 pages) 0WP 0117 (2 pages) 0WP 0118 (12 pages) 0


WP 0119 (4 pages) 0WP 0120 (6 pages) 0WP 0121 (6 pages) 0WP 0122 (4 pages) 0WP 0123 (10 pages) 0WP 0124 (4 pages) 0WP 0125 (8 pages) 0WP 0126 (4 pages) 0WP 0127 (4 pages) 0WP 0128 (4 pages) 0WP 0129 (6 pages) 0WP 0130 (4 pages) 0WP 0131 (4 pages) 0WP 0132 (4 pages) 0WP 0133 (2 pages) 0WP 0134 (6 pages) 0Index (4 pages) 0Back Cover 0VOLUME 2 0WP Front Cover (6 pages) 0Warning Summary (10 pages) 0Title Block Page (2 pages) 0Table Of Contents (4 pages) 0How To Use This Manual (4 pages) 0Chapter 5 Title Page 0WP 0135 (20 pages) 0WP 0136 (6 pages) 0WP 0137 (4 pages) 0WP 0138 (4 pages) 0WP 0139 (4 pages) 0WP 0140 (10 pages) 0WP 0141 (8 pages) 0WP 0142 (6 pages) 0WP 0143 (8 pages) 0WP 0144 (4 pages) 0WP 0145 (8 pages) 0WP 0146 (8 pages) 0WP 0147 (6 pages) 0WP 0148 (4 pages) 0WP 0149 (10 pages) 0WP 0150 (4 pages) 0WP 0151 (4 pages) 0WP 0152 (2 pages) 0WP 0153 (4 pages) 0WP 0154 (4 pages) 0WP 0155 (16 pages) 0WP 0156 (4 pages) 0WP 0157 (4 pages) 0WP 0158 (6 pages) 0WP 0159 (4 pages) 0WP 0160 (8 pages) 0

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WP 0263 (20 pages) 0WP 0264 (8 pages) 0WP 0265 (2 pages) 0WP 0266 (4 pages) 0WP 0267 (20 pages) 0WP 0268 (10 pages) 0WP 0269 (2 pages) 0WP 0270 (4 pages) 0WP 0271 (6 pages) 0WP 0272 (62 pages) 0


Chapter 6 Title Page 0WP 0273 (2 pages) 0WP 0274 (4 pages) 0WP 0275 (28 pages) 0WP 0276 (6 pages) 0WP 0277 (8 pages) 0WP 0278 (10 pages) 0Index (8 pages) 0Back Cover 0

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ARMY *TM 10-3930-675-23-1MARINE CORPS TM 11078A-OI/1

HEADQUARTERS, DEPARTMENT OF THE ARMYHEADQUARTERS, U.S. MARINE CORPSWASHINGTON, D.C., 01 OCTOBER 2012

TECHNICAL MANUAL

FIELD MAINTENANCE MANUALFOR

ROUGH TERRAIN CONTAINER HANDLER (RTCH):RT 240; 53,000 LB CAPACITY; 4 X 4

NSN 3930-01-473-3998NSN 3930-01-522-7364

*TM 10-3930-675-23-1

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REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve theprocedures, please let us know. Reports, as applicable by the requiring service, should be submittedas follows:(a) Army (A) - The preferred method is to submit your DA Form 2028 (Recommended Changes toPublications and Blank Forms) through the Internet on the TACOM Unique Logistics SupportApplications (TULSA) website. The Internet address is https://tulsa.tacom.army.mil.The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill outthe form and click on SUBMIT. Using this form on the TULSA website will enable us to respond morequickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail,or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle ManagementCommand. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN:AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail addressis [email protected]. The fax number is DSN 786-1856 orCommercial (586) 282-1856.(b) Marine Corps (MC) - Submit notice of discrepancies or suggested changes on a NAVMC 10772.The NAVMC may be submitted using either of the following:a. The preferred method of submittal is using https://portal.logcom.usmc.mil/sites/pubs/ URL which will allow direct connection to the LOGCOM SharePoint Pubs site (LOGCOM SharePoint access and CAC required) where the form can be filled out and be submitted to the NAVMC SharePoint database. Problems or questions regarding the NAVMC 10772 program should be reported by calling DSN 567-7628 or DSN 567-5017 (Commercial number is (229) 639-7628 or (229) 639-5017).b. The alternate method of submittal does not require a Common Access Card (CAC) to access the form. Click on http://navalforms.daps.dla.mil/web/public/forms, select the "Keyword Search" button, enter "10772" in the Search Criteria Box. Under "type" click on download page button. Click on PDF icon. Enter user data in the appropriate fields. Must have users contact information block filled with Unit address and telephone number. Click on the 'Envelope' icon in the tool bar. Select "Send Copy click on "OK". When the PDF document is created, an Outlook Email screen will open with the.PDF as an attachment. On the TO: line type [email protected]. In the body of the email, type any additional information you wish to provide. Click SEND.c. A reply will be furnished to you.

*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PCN 184 110783 00

TABLE OF CONTENTS

Page No.WP Sequence No.

Volume 1

HOW TO USE THIS MANUAL .......................................................................................................................... lxix

Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OFOPERATION

GENERAL INFORMATION.......................................................................................................................... WP 0001

Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-2

EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002

Figure 1. Major Components............................................................................................................... 0002-2Table 1. Description of Major Components........................................................................................ 0002-2Figure 2. Major Components............................................................................................................... 0002-3Table 2. Description of Major Components........................................................................................ 0002-3Figure 3. Major Components............................................................................................................... 0002-4Table 3. Description of Major Components........................................................................................ 0002-4

THEORY OF OPERATION.......................................................................................................................... WP 0003

Chapter 2 - TROUBLESHOOTING PROCEDURES

ERROR CODE REFERENCES................................................................................................................... WP 0004

Table 1. Driver Action Icons............................................................................................................... 0004-1

Table 2. Type of Fault Icons............................................................................................................... 0004-1

Table 3. Function Icons...................................................................................................................... 0004-2

Table 4. Error Code Reference Index................................................................................................ 0004-4

TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0005

TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)................................................................. WP 0006Figure 1. Starter Motor........................................................................................................................ 0006-3

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING................................................................... WP 0007

Figure 1. Actuator Harness Test.......................................................................................................... 0007-3



Figure 4. Actuator Harness Test........................................................................................................ 0007-11

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TABLE OF CONTENTS - Continued







Figure 10. 15-Pin Connector Test....................................................................................................... 0007-21

Figure 11. 15-Pin Connector Test....................................................................................................... 0007-22

Figure 12. Solenoid Connector Test.................................................................................................... 0007-23


Figure 14. Actuator Harness Connector Test...................................................................................... 0007-25

Figure 15. Actuator Harness Connector Test...................................................................................... 0007-26

Figure 16. Injector Wiring Test............................................................................................................ 0007-27Figure 17. Actuator Harness Test........................................................................................................ 0007-28

Figure 18. Solenoid Connector Test.................................................................................................... 0007-29




Figure 22. Injector Wiring Test............................................................................................................ 0007-33Figure 23. Injector Wiring Test............................................................................................................ 0007-34Figure 24. Injector Wiring Test............................................................................................................ 0007-35Figure 25. Actuator Harness Test........................................................................................................ 0007-36



Figure 28. Injector Wiring Test............................................................................................................ 0007-39Figure 29. Actuator Harness Test........................................................................................................ 0007-40



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Figure 43. Cylinder #1 Supply and Return.......................................................................................... 0007-54






ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING............................................................ WP 0008

Figure 1. Accelerator Pedal Wiring Test.............................................................................................. 0008-3


Figure 3. OEM Harness Connector Test............................................................................................. 0008-5





Figure 8. OEM Wiring Harness Test.................................................................................................. 0008-10

Figure 9. OEM Wiring Harness Test.................................................................................................. 0008-10

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Figure 10. Accelerator Pedal Calibration............................................................................................. 0008-11

Figure 11. Accelerator Pedal Test....................................................................................................... 0008-12

Figure 12. Accelerator Pedal Resistance Test.................................................................................... 0008-13

Figure 13. Idle Validation Circuit Voltage Test.................................................................................... 0008-13

Figure 14. Idle Validation Circuit Voltage Test.................................................................................... 0008-14

Figure 15. TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-16

Figure 16. TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-17

COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING............................................. WP 0009

Figure 1. Cooling Fan Diagnostics...................................................................................................... 0009-5

OVERLOAD PROTECTION TROUBLESHOOTING................................................................................... WP 0010

Figure 1. Overload Protection Diagnostics........................................................................................ 0010-12

Figure 2. Overload Protection Diagnostics........................................................................................ 0010-13

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING............................... WP 0011Figure 1. Tophandler ECU Diagnostics............................................................................................... 0011-3

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING.................................... WP 0012Figure 1. ECU Input Diagnostics......................................................................................................... 0012-8

Figure 2. ECU Input Diagnostics......................................................................................................... 0012-9

Figure 3. ECU Input Diagnostics....................................................................................................... 0012-10

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING....................................................................... WP 0013

STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794)TROUBLESHOOTING................................................................................................................................. WP 0014

Figure 1. Use Test Lead Kit................................................................................................................. 0014-4

Figure 2. Engine ECU Circuit Test...................................................................................................... 0014-5



Figure 5. Engine ECU Test.................................................................................................................. 0014-8

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING................................ WP 0015INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING.............................. WP 0016

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ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING......................................... WP 0017Figure 1. Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-2

Figure 2. Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-3



Figure 5. Sensor Voltage Supply Test................................................................................................. 0017-6






Figure 11. Sensor Voltage Supply Test............................................................................................... 0017-10




Figure 15. OEM Harness Connector Circuit Check............................................................................. 0017-15

Figure 16. Oil Pressure/Temperature Sensor Circuits......................................................................... 0017-15

ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING.............................................................. WP 0018

Figure 1. Engine Harness Circuit Resistance Check........................................................................... 0018-3




Figure 5. Engine Position Sensor Circuits........................................................................................... 0018-8

ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING...................................................................... WP 0019

Figure 1. Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-2



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Figure 4. Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-4


Figure 6. Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-6

Figure 7. Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-7

Figure 8. Oil Pressure Sensor Test..................................................................................................... 0019-7



Figure 11. Oil Pressure Sensor Circuit Resistance Test..................................................................... 0019-10

Figure 12. Oil Pressure Sensor Circuit Failure Test............................................................................ 0019-11

Figure 13. Oil Pressure Sensor Circuit Identification........................................................................... 0019-13

ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING......................................... WP 0020

Figure 1. Coolant Temperature Sensor Test....................................................................................... 0020-3

Figure 2. Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-4


Figure 4. Coolant Temperature Sensor Resistance Test.................................................................... 0020-6

Figure 5. Coolant Temperature Sensor Resistance Test.................................................................... 0020-7



Figure 8. Intake Air Temperature Sensor Resistance Test............................................................... 0020-10

Figure 9. Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-11






Figure 15. Oil Temperature Sensor Resistance Test.......................................................................... 0020-17

Figure 16. Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-18

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Figure 22. Engine Sensors Replacement............................................................................................ 0020-24

Figure 23. Intake Manifold Temperature Sensor Circuit Information................................................... 0020-25

ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING.......................... WP 0021

Figure 1. Ambient Air Temperature Sensor Voltage Test.................................................................... 0021-3

Figure 2. Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-3

Table 1. Altitude (Ft.) vs. Voltage....................................................................................................... 0021-4Figure 3. Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-4

Figure 4. Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5

Figure 5. Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5



Table 2. Altitude (Ft.) vs. Voltage....................................................................................................... 0021-8Figure 8. Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-8



Figure 11. Ambient Air Temperature Sensor Circuit Resistance Test................................................. 0021-10

Figure 12. Ambient Air Temperature Sensor Circuit Test.................................................................... 0021-11

ENGINE PRESSURE SENSOR TROUBLESHOOTING............................................................................. WP 0022

Figure 1. Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-3




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Figure 5. Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-5






Figure 11. Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-10



Figure 14. Intake Manifold Pressure Sensor Circuit Test.................................................................... 0022-11




Figure 18. Intake Manifold Pressure Sensor Circuit Information......................................................... 0022-14

ENGINE FUEL PRESSURE SENSORS AND CIRCUITS TROUBLESHOOTING...................................... WP 0023

Figure 1. Fuel Shutoff Solenoid Post Inspection................................................................................. 0023-2

Figure 2. Fuel Shutoff Solenoid Voltage Test...................................................................................... 0023-2

Figure 3. Fuel Shutoff Valve Actuator Wire......................................................................................... 0023-3

Figure 4. Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-4

Figure 5. Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-5


Figure 7. Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-6


Figure 9. Fuel Inlet Restriction Sensor Circuit Resistance Test.......................................................... 0023-8

Figure 10. Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9

Figure 11. Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9

Figure 12. Fuel Inlet Restriction Sensor Circuit Voltage Test.............................................................. 0023-10

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Figure 13. Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-11



ENGINE BATTERY VOLTAGE CIRCUITS TROUBLESHOOTING............................................................ WP 0024

Figure 1. OEM Harness Circuit Resistance Test................................................................................. 0024-3

Figure 2. Starter Solenoid Lockout Relay Circuit Resistance Test...................................................... 0024-6

Figure 3. Starter Solenoid Lockout Relay Circuit Continuity Test........................................................ 0024-7

Figure 4. Battery Cranking Voltage Test............................................................................................. 0024-8

Figure 5. Alternator Charging Amperage Test..................................................................................... 0024-8

TRANSMISSION TEMPERATURE TROUBLESHOOTING........................................................................ WP 0025

Figure 1. Component Locations.......................................................................................................... 0025-6

TRANSMISSION SPEED SENSORS TROUBLESHOOTING..................................................................... WP 0026

Figure 1. Component Locations........................................................................................................ 0026-10

TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING..................................................................... WP 0027

MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING..................................................... WP 0028

INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING............................... WP 0029

BRAKE SYSTEM TROUBLESHOOTING.................................................................................................... WP 0030


AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING........................................................................ WP 0031

STEERING VALVE CIRCUIT TROUBLESHOOTING................................................................................. WP 0032

Figure 1. Connector 770 Numbering................................................................................................. 0032-14

MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING........................................ WP 0033

STEERING SENSOR TROUBLESHOOTING............................................................................................. WP 0034

HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790)TROUBLESHOOTING................................................................................................................................. WP 0035


AUXILIARY PUMP TROUBLESHOOTING.................................................................................................. WP 0036

HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING................................................................ WP 0037

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HYDRAULIC FILTER INDICATORS TROUBLESHOOTING...................................................................... WP 0038



BOOM LIFTING/LOWERING TROUBLESHOOTING................................................................................. WP 0039



BOOM IN/OUT TROUBLESHOOTING........................................................................................................ WP 0040



TOPHANDLER SLEWING TROUBLESHOOTING...................................................................................... WP 0041



TOPHANDLER TILT TROUBLESHOOTING............................................................................................... WP 0042



TOPHANDLER LEVELING TROUBLESHOOTING..................................................................................... WP 0043

Figure 1. Component Locations. ........................................................................................................ 0043-8

Figure 2. Component Locations. ........................................................................................................ 0043-9

TOPHANDLER SIDESHIFT TROUBLESHOOTING................................................................................... WP 0044


TOPHANDLER SPREADER TROUBLESHOOTING.................................................................................. WP 0045


TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING.................................... WP 0046

Figure 1. Tophandler Twistlocks Indication Failure............................................................................. 0046-3



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Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Introduction...................................... WP 0047

Table 1. Leakage Definitions for PMCS............................................................................................. 0047-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0048Table 1. Preventive Maintenance Checks and Services (PMCS) for the RTCH................................ 0048-1Table 2. PMCS Mandatory Replacement Parts List........................................................................... 0048-8

Chapter 4 - MAINTENANCE INSTRUCTIONS

SERVICE UPON RECEIPT......................................................................................................................... WP 0049

ENGINE ASSEMBLY REPLACEMENT....................................................................................................... WP 0050

Figure 1. Engine Removal................................................................................................................... 0050-3









Figure 10. Engine Removal................................................................................................................. 0050-10

Figure 11. Engine Installation.............................................................................................................. 0050-12








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ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT............................................................... WP 0051

Figure 1. Lifting Brackets Removal...................................................................................................... 0051-2

Figure 2. Lifting Brackets Installation................................................................................................... 0051-3

Figure 3. Front Engine Mount Installation............................................................................................ 0051-5

Figure 4. Rear Engine Mount Removal............................................................................................... 0051-7

CYLINDER HEAD REPLACEMENT............................................................................................................ WP 0052

Figure 1. Cylinder Head Removal....................................................................................................... 0052-1










Figure 11. Cylinder Head Inspection..................................................................................................... 0052-8

Figure 12. Cylinder Head Inspection..................................................................................................... 0052-9

Figure 13. Cylinder Head Inspection................................................................................................... 0052-10

Table 1. Cylinder Head Flatness Measurements............................................................................. 0052-10



Figure 16. Cylinder Head Installation.................................................................................................. 0052-12



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Figure 23. Cylinder Head Removal..................................................................................................... 0052-16


VIBRATION DAMPER REPLACEMENT..................................................................................................... WP 0053

Figure 1. Vibration Damper Removal.................................................................................................. 0053-2

Figure 2. Thickness Measure.............................................................................................................. 0053-3

Figure 3. Eccentricity Check................................................................................................................ 0053-3

Figure 4. Wobble Check...................................................................................................................... 0053-4

Figure 5. Vibration Damper Installation............................................................................................... 0053-5

FLYWHEEL ASSEMBLY REPLACEMENT................................................................................................. WP 0054

Figure 1. Flywheel Assembly Removal............................................................................................... 0054-2



Figure 4. Flywheel Assembly Inspection............................................................................................. 0054-5

Figure 5. Flywheel Assembly Inspection............................................................................................. 0054-6

Table 1. Flywheel Face Runout.......................................................................................................... 0054-7

Figure 6. Flywheel Assembly Installation............................................................................................ 0054-8

Figure 7. Flywheel Assembly Installation............................................................................................ 0054-9

REAR MAIN OIL SEAL REPLACEMENT.................................................................................................... WP 0055

Figure 1. Rear Main Oil Seal Removal................................................................................................ 0055-2

Figure 2. Wear Sleeve Removal.......................................................................................................... 0055-3




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Figure 6. Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-5







ROCKER ARM ASSEMBLY MAINTENANCE............................................................................................. WP 0056

Figure 1. Push Rods and Push Tubes Removal................................................................................. 0056-2

Figure 2. Key Stock Installation........................................................................................................... 0056-2

Figure 3. Front Rocker Arm Assembly Removal................................................................................. 0056-3

Figure 4. Rocker Levers Removal....................................................................................................... 0056-4

Figure 5. Rocker Lever Disassembly................................................................................................... 0056-4

Figure 6. Rocker Lever Bushing Measurement................................................................................... 0056-5

Figure 7. Rocker Lever Shaft Measurement........................................................................................ 0056-5

Figure 8. Rocker Arm Shaft Assembly................................................................................................ 0056-6




Figure 12. Rocker Arm Shaft Installation............................................................................................... 0056-8



Figure 15. Rocker Arm Shaft Installation............................................................................................. 0056-10


Figure 17. Rocker Arm Shaft Installation. ........................................................................................... 0056-11



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Figure 22. Valve Lash Check.............................................................................................................. 0056-14

Table 1. Injector and Valve Measurement Sequence...................................................................... 0056-15Figure 23. Valve Lash Check.............................................................................................................. 0056-15

Figure 24. Valve Lash Check.............................................................................................................. 0056-16

Table 2. M Series Valve Lash Recheck Limits................................................................................. 0056-16

Figure 25. Injector Lash Check............................................................................................................ 0056-17Figure 26. Injector Lash Check............................................................................................................ 0056-18Table 3. M Series Injector Lash Recheck Limits.............................................................................. 0056-18Figure 27. Injector Adjustment............................................................................................................. 0056-19Figure 28. Injector Adjustment............................................................................................................. 0056-19Figure 29. Valve Adjustment............................................................................................................... 0056-20Figure 30. Valve Adjustment............................................................................................................... 0056-21Figure 31. Valve Adjustment............................................................................................................... 0056-21Figure 32. Valve Adjustment............................................................................................................... 0056-22Figure 33. Valve Adjustment............................................................................................................... 0056-22Figure 34. Valve Adjustment............................................................................................................... 0056-23

ROCKER ARM COVER AND GASKET REPLACEMENT........................................................................... WP 0057

Figure 1. Rocker Arm Cover and Gasket Replacement...................................................................... 0057-2

Figure 2. Rocker Arm Cover Tightening Sequence............................................................................. 0057-3

OIL PAN REPLACEMENT........................................................................................................................... WP 0058

Figure 1. Oil Pan Removal.................................................................................................................. 0058-2

Figure 2. Oil Pan Installation............................................................................................................... 0058-3

Figure 3. Oil Pan Installation............................................................................................................... 0058-3

ENGINE OIL AND OIL FILTER REPLACEMENT........................................................................................ WP 0059

Figure 1. Drain Engine Oil................................................................................................................... 0059-2

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Figure 2. Oil Filter and Gasket............................................................................................................. 0059-3

OIL FILTER HEAD AND OIL COOLER MAINTENANCE............................................................................ WP 0060

Figure 1. Oil Filter Head and Oil Cooler Removal............................................................................... 0060-2



Figure 4. Oil Filter Head and Oil Cooler Disassembly......................................................................... 0060-5

Figure 5. Oil Cooler Testing................................................................................................................. 0060-7

Figure 6. Oil Cooler Cleaning.............................................................................................................. 0060-8

Figure 7. Oil Cooler Pressure Test...................................................................................................... 0060-9

Figure 8. Oil Filter Head Assembly...................................................................................................... 0060-9

Figure 9. Oil Filter Head Assembly.................................................................................................... 0060-10

Figure 10. Oil Filter Head Installation.................................................................................................. 0060-10

Figure 11. Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-11



ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT..................................................... WP 0061

Figure 1. Engine Oil Dipstick Replacement and Fill Hose Removal.................................................... 0061-3

Figure 2. Oil Dipstick Cover and Cylinder Block Cleaning................................................................... 0061-4

Figure 3. Engine Oil Dipstick and Fill Hoses Installation..................................................................... 0061-5

OIL SAMPLING VALVES AND HOSES REPLACEMENT.......................................................................... WP 0062

Figure 1. Oil Sampling Valve............................................................................................................... 0062-2

Figure 2. Engine Oil Sampling Valve Hose......................................................................................... 0062-3

Figure 3. Transmission Oil Sampling Valve Hose............................................................................... 0062-4

Figure 4. Hydraulic System Oil Sampling Valve Hose......................................................................... 0062-5

EXHAUST MANIFOLD REPLACEMENT.................................................................................................... WP 0063

Figure 1. Exhaust Manifold Removal................................................................................................... 0063-1

Figure 2. Exhaust Manifold Removal................................................................................................... 0063-2

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Figure 3. Exhaust Manifold Installation................................................................................................ 0063-3



INTAKE MANIFOLD REPLACEMENT................................................................

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