TM 5-3805-291-23-2

TM 5-3805-291-23-2 TECHNICAL MANUAL

MAINTENANCE MANUAL (Includes Unit and Direct Support Maintenance) FOR

LOADER, HEAVY, SCOOP: DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE 4.5 CUBIC YARD ROCK BUCKET NSN 3805-01-533-1857 AND

5.0 CUBIC YARD GENERAL PURPOSE BUCKET NSN 3805-01-533-1853 MODEL 966H

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

HEADQUARTERS, DEPARTMENT OF THE ARMY -$18$5<20

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TM 5-3805-291-23-2

WARNING SUMMARY This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

EAR PROTECTION - headphones over ears show that noise level will harm ears.

ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows that shock hazard is present.

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

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

FLYING PARTICLES - arrows bouncing off face with face shield shows that particles flying through the air will harm face.

HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.

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TM 5-3805-291-23-2

HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or limb.

HOT AREA - hand over object radiating heat shows that part is hot and can burn.

HYDRAULIC FLUID PRESSURE - hydraulic fluid spraying human hand shows that fluid escaping under great pressure can cause injury or death to personnel.

RADIOACTIVE - identifies a material that emits radioactive energy and can injure human tissue or organs.

SLICK FLOOR - wavy line on floor with legs prone shows that slick floor presents a danger from falling.

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

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TM 5-3805-291-23-2

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

WARNING CARBON MONOXIDE (EXHAUST GASES) CAN KILL! • Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can result from severe exposure. • Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine is operated. 1.

DO NOT operate engine in enclosed areas.

2.

DO NOT idle engine without adequate ventilation.

3.

DO NOT drive machine with inspection plates or cover plates removed.

4.

BE ALERT for exhaust poisoning symptoms. They are: • Headache • Dizziness • Sleepiness • Loss of muscular control

5.

If you see another person with exhaust poisoning symptoms: • Remove person from area. • Expose to fresh air. • Keep person warm. • Do not permit physical exercise. • Administer Cardiopulmonary Resuscitation (CPR), if necessary. • Notify a medic.

6.

BE AWARE. The field protective mask for Nuclear, Biological, and Chemical (NBC) protection will not protect you from carbon monoxide poisoning.

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation! c

TM 5-3805-291-23-2

WARNING BATTERIES • To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electric shock, damage to equipment, and injury to personnel. • Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in death or serious injury to personnel. a.

Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.

b.

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

c.

Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately.

d.

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

WARNING COMPRESSED AIR Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. Use a maximum of 30 psi (207 kPa) when cleaning components. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. Failure to follow this warning may result in injury to personnel.

WARNING ETHER COLD START SYSTEM Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes and avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation. Failure to follow this warning may cause injury or death to personnel. d

TM 5-3805-291-23-2

WARNING FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher inside an enclosed cab may result in temporary breathing difficulty during and immediately after the discharge event. Discharge fire extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry.

WARNING FUEL HANDLING • DO NOT smoke or permit any open flame in area of loader while you are servicing fuel system. Be sure hose nozzle is grounded against filler tube during refueling to prevent static electricity. Failure to follow this warning may result in injury to personnel or equipment damage. • DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment. • Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash exposed skin and change fuel-soaked clothing. Failure to follow this warning may result in injury to personnel.

WARNING HAZARDOUS WASTE DISPOSAL • When servicing this machine, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845. • Lubricating/hydraulic oils and engine coolant used in the performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

WARNING HEARING PROTECTION Your hearing can be PERMANENTLY DAMAGED if you are exposed to constant high noise levels of 85 dB or greater. Hearing protection is required when operating machine or when working on machine while it is operating. Failure to wear hearing protection may result in hearing loss.

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TM 5-3805-291-23-2

WARNING HYDRAULIC SYSTEM PRESSURE • DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury to personnel. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel.

WARNING HYDRAULIC SYSTEM PRESSURE The accumulator is filled with dry nitrogen. DO NOT loosen or remove the valve or cap from the top of the accumulator. Failure to follow this warning may result in injury to personnel.

WARNING MACHINE OPERATION • Use caution and maintain three-point contact at all times when mounting or dismounting machine. DO NOT use steering wheel as a handhold. Failure to follow this warning may result in injury or death to personnel. • BE ALERT for personnel in the area while operating machine. Always check to ensure area is clear of personnel and obstructions before moving. Failure to follow this warning may result in injury or death to personnel. • Use of seat belt while operating machine is mandatory. Fasten belt BEFORE operating machine. Trying to fasten belt during operation creates a hazardous condition. Failure to follow this warning may result in injury or death to personnel. • DO NOT allow riders on machine. Failure to follow this warning may result in injury or death to personnel. • NEVER leave operator compartment without applying parking brake. Failure to follow this warning may result in injury or death to personnel. • DO NOT use parking/emergency brake to stop a moving machine under usual conditions. Only if service brakes fail, apply parking/emergency brake. Failure to follow this warning may result in injury to personnel or damage to equipment. • NEVER use starting fluid or spray to aid in starting the engine, other than the on-board ether cold start system. Failure to follow this warning may cause injury or death to personnel or damage to equipment. • Always use a ground guide when driving machine up or down ramps in preparation for highway or marine transport. Failure to use a ground guide may cause injury or death to personnel or damage to equipment.

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TM 5-3805-291-23-2

WARNING NBC EXPOSURE • If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures. • Refer to FM 3-3, Chemical and Biological Contamination Avoidance, TM 3-4230-236-10, Decontamination System, Sorbent: MIC, and FM 3-3-1, Nuclear Contamination Avoidance. • NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. • Failure to follow these warnings may cause injury or death to personnel.

WARNING IF NBC EXPOSURE IS SUSPECTED ALL AIR FILTER MEDIA WILL BE HANDLED BY PERSONNEL WEARING FULL NBC PROTECTIVE EQUIPMENT. SEE OPERATOR/MAINTENANCE MANUAL. 7690-01-114-3702

To order this NBC decal use: National Stock Number (NSN) - 7690-01-114-3702 Part Number (PN) - 12296626 Commercial and Government Entity Code (CAGEC) - 19207

WARNING PRESSURIZED COOLING SYSTEM • DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant may result in serious burns. • DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may result in serious burns. • Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may result in injury to personnel.

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TM 5-3805-291-23-2

WARNING SOLVENT CLEANING COMPOUND Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel.

WARNING TIRES • Operating machine with an underinflated or defective tire may lead to tire failure and loss of traction or control. Failure to follow this warning may cause damage to equipment or injury to personnel. • If tire pressure is 0 psi (0 kPa) DO NOT inflate. Notify Unit Maintenance. Failure to follow this warning may cause injury or death to personnel. • Use a self-inflating chuck and stand at a distance behind tire when inflating tire. Failure to follow this warning may cause injury or death to personnel.

WARNING WORK SAFETY • Lifting cables, chains, hooks, and slings used for lifting machine must be in good condition and of suitable capacity. Failure to follow this warning may cause injury or death to personnel and damage to equipment. • Improper use of lifting equipment and improper attachment of cables to machine may cause injury to personnel and damage to equipment. Observe all standard rules of safety. • Hitch and steering movement can reduce clearances suddenly and cause injury. Always stop engine BEFORE working in area of hitch link. • Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may cause injury or death to personnel. • Wear suitable eye protection and keep face and eyes away from exhausting air tank drain valves. Failure to do so may cause injury to personnel. • Hot oil or metal parts can cause severe burns. Wear insulated gloves, long sleeves, and eye protection when working with heated parts. • Before operating machine, secure the steering frame lock in stowed position. DO NOT operate machine with steering frame lock connected. Failure to lock steering frame lock into stowed position can result in loss of steering and injury or death to personnel.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES Date of issue for original manual is: NOTE: Zero in the “Change No.” column indicates an original page or work package. Original . . . . . . . 1-DQXDU\ Total number of pages for front and rear matter is 54 and total number of work packages is 237 consisting of the following: Page/WP No.

Change No.

Front Cover (2 pgs) . . . . . . . . . . . . . . . . . . . . Warning Summary (8 pgs) . . . . . . . . . . . . . . i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 0050 00 (14 pgs.) . . . . . . . . . . . . . . . . . . WP 0051 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0052 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0053 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0054 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0055 00 (14 pgs.) . . . . . . . . . . . . . . . . . . WP 0056 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0057 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0058 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0059 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0060 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0061 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0062 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0063 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0064 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0065 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0066 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0067 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0068 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0069 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0070 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0071 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0072 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0073 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0074 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0075 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0076 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0077 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0078 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0079 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0080 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0081 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0082 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0083 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0084 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0085 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0086 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0087 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0088 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0089 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0090 00 (2 pgs.) . . . . . . . . . . . . . . . . . . .

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Page/WP No.

Change No.

WP 0091 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0092 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0093 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0094 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0095 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0096 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0097 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0098 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0099 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0100 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0101 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0102 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0103 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0104 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0105 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0106 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0107 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0108 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0109 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0110 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0111 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0112 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0113 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0114 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0115 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0116 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0117 00 (14 pgs.) . . . . . . . . . . . . . . . . . . WP 0118 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0119 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0120 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0121 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0122 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0123 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0124 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0125 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0126 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0127 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0128 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0129 00 (22 pgs.) . . . . . . . . . . . . . . . . . . WP 0130 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0131 00 (18 pgs.) . . . . . . . . . . . . . . . . . . WP 0132 00 (16 pgs.) . . . . . . . . . . . . . . . . . . WP 0133 00 (34 pgs.) . . . . . . . . . . . . . . . . . . WP 0134 00 (12 pgs.) . . . . . . . . . . . . . . . . . . A

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

TM 5-3805-291-23-2 Page/WP No.

Change No.

WP 0135 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0136 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0137 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0138 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0139 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0140 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0141 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0142 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0143 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0144 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0145 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0146 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0147 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0148 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0149 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0150 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0151 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0152 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0153 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0154 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0155 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0156 00 (26 pgs.) . . . . . . . . . . . . . . . . . . WP 0157 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0158 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0159 00 (16 pgs.) . . . . . . . . . . . . . . . . . . WP 0160 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0161 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0162 00 (26 pgs.) . . . . . . . . . . . . . . . . . . WP 0163 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0164 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0165 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0166 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0167 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0168 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0169 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0170 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . CHAPTER 4 title page . . . . . . . . . . . . . . . . . WP 0171 00 (38 pgs.) . . . . . . . . . . . . . . . . . . WP 0172 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0173 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0174 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0175 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0176 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0177 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0178 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0179 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0180 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0181 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0182 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0183 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0184 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0185 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0186 00 (4 pgs.) . . . . . . . . . . . . . . . . . . .

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Page/WP No.

Change No.

WP 0187 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0188 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0189 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0190 00 (14 pgs.) . . . . . . . . . . . . . . . . . . WP 0191 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0192 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0193 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0194 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0195 00 (24 pgs.) . . . . . . . . . . . . . . . . . . WP 0196 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0197 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0198 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0199 00 (32 pgs.) . . . . . . . . . . . . . . . . . . WP 0200 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0201 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0202 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0203 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0204 00 (20 pgs.) . . . . . . . . . . . . . . . . . . WP 0205 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0206 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0207 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0208 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0209 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0210 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0211 00 (18 pgs.) . . . . . . . . . . . . . . . . . . WP 0212 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0213 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0214 00 (28 pgs.) . . . . . . . . . . . . . . . . . . WP 0215 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0216 00 (12 pgs.) . . . . . . . . . . . . . . . . . . WP 0217 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0218 00 (14 pgs.) . . . . . . . . . . . . . . . . . . WP 0219 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0220 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0221 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0222 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0223 00 (16 pgs.) . . . . . . . . . . . . . . . . . . WP 0224 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0225 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0226 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0227 00 (10 pgs.) . . . . . . . . . . . . . . . . . . WP 0228 00 (16 pgs.) . . . . . . . . . . . . . . . . . . WP 0229 00 (16 pgs.) . . . . . . . . . . . . . . . . . . CHAPTER 5 title page . . . . . . . . . . . . . . . . . WP 0230 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . WP 0231 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . WP 0232 00 (22 pgs.) . . . . . . . . . . . . . . . . . . WP 0233 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0234 00 (22 pgs.) . . . . . . . . . . . . . . . . . . WP 0235 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . WP 0236 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . WP 0237 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . Index-1 to Index-16 . . . . . . . . . . . . . . . . . . . B

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

TM 5-3805-291-23-2 Page/WP No.

Change No.

Foldouts (52) . . . . . . . . . . . . . . . . . . . . . . . . . 0 Metric conversion chart. . . . . . . . . . . . . . . . . 0

Page/WP No.

Change No.

Back cover . . . . . . . . . . . . . . . . . . . . . . . . . . 0

C/D (Blank)

TM 5-3805-291-23-2

HEADQUARTERS DEPARTMENT OF THE ARMY Washington, D.C., 1-DQXDU\

TECHNICAL MANUAL FIELD MAINTENANCE MANUAL (Includes Unit and Direct Support Maintenance) FOR

LOADER, HEAVY, SCOOP: DIESEL ENGINE DRIVEN (DED), 4-WHEEL DRIVE 4.5 CUBIC YARD ROCK BUCKET NSN 3805-01-533-1857 AND

5.0 CUBIC YARD GENERAL PURPOSE BUCKET NSN 3805-01-533-1853 MODEL 966H REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, email, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP/TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The email address is [email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

i

TM 5-3805-291-23-2

Table of Contents Page Number Warning Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Electrical System WP 0050 00 WP 0051 00 WP 0052 00 WP 0053 00 WP 0054 00 WP 0055 00 WP 0056 00 WP 0057 00 WP 0058 00 WP 0059 00 WP 0060 00 WP 0061 00 WP 0062 00 WP 0063 00 WP 0064 00 WP 0065 00 WP 0066 00 WP 0067 00 WP 0068 00 WP 0069 00 WP 0070 00 WP 0071 00 WP 0072 00 WP 0073 00 WP 0074 00 WP 0075 00 WP 0076 00 WP 0077 00 WP 0078 00 WP 0079 00 WP 0080 00 WP 0081 00 WP 0082 00 WP 0083 00 WP 0084 00 WP 0085 00 WP 0086 00 WP 0087 00 WP 0088 00 WP 0089 00

Rearview Camera, Cable, and Display Replacement . . . . . . . . . . . . . . . . . . . . . 0050 00-1 Starter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1 HVAC Blend Door Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-1 Fuse, Relay, Circuit Breaker, and Arc Suppressor Replacement . . . . . . . . . . . . 0053 00-1 Instrument Cluster Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-1 Instrument Panels and Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1 Messenger ECM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1 Engine Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . 0057 00-1 Hood Tilt Actuator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1 Hood Tilt Switch and Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . 0059 00-1 Implement Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . 0060 00-1 Main Light Switch and Arctic Heater Switch Replacement . . . . . . . . . . . . . . . . 0061 00-1 Power Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1 Powertrain Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . 0063 00-1 Stoplight Limit Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1 Turnlamp Flasher Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1 Turnlamp Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1 Windshield Wiper Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00-1 Blackout Drive Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1 Dome Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1 Stoplight Assembly and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0070 00-1 Service Lights and Front Turnlamp Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0071 00-1 Worklights Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1 Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1 Boost Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1 Brake Pedal Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1 Camshaft Speed/Timing Sensor (Secondary) Replacement . . . . . . . . . . . . . . . . 0076 00-1 Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1 Crankshaft Speed/Timing Sensor (Primary) Replacement . . . . . . . . . . . . . . . . . 0078 00-1 Engine Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1 Fuel Level Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1 Front and Rear Axle Oil Temperature Sensors Replacement . . . . . . . . . . . . . . . 0081 00-1 Fuel Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1 Hydraulic Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1 Intake Manifold Air Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . 0084 00-1 Lift Kickout Position Sensor and Mounting Replacement . . . . . . . . . . . . . . . . . 0085 00-1 Parking Brake Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1 Service Brake Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1 Steering Oil Pressure Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1 Tilt Kickout Position Sensor and Mounting Replacement . . . . . . . . . . . . . . . . . 0089 00-1 ii

TM 5-3805-291-23-2

Table of Contents - Continued Page Number Electrical System-Continued WP 0090 00 Torque Converter Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . 0090 00-1 WP 0091 00 Torque Converter Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . 0091 00-1 Transmission System WP 0092 00 WP 0093 00 WP 0094 00 WP 0095 00 WP 0096 00 WP 0097 00 WP 0098 00 WP 0099 00 WP 0100 00 WP 0101 00 WP 0102 00 WP 0103 00 WP 0104 00 WP 0105 00 WP 0106 00

Transmission Oil Temperature Sensors Replacement. . . . . . . . . . . . . . . . . . . . . 0092 00-1 Transmission Output Speed Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1 Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1 Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1 Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1 Battery Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1 Battery Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1 NATO Slave Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00-1 Transmission Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00-1 Shift Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1 Transmission Oil Cooler Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1 Transmission Oil Filler Tube Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1 Transmission Oil Filter Base, Lines, and Bypass Switch Replacement . . . . . . . 0104 00-1 Transmission Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1 Transmission Test Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . 0106 00-1

Propeller and Propeller Shafts WP 0107 00 WP 0108 00 WP 0109 00 WP 0110 00 WP 0111 00

Center Drive Shaft (Slip Joint) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00-1 Front Drive Shaft Carrier Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0108 00-1 Front Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109 00-1 Rear Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1 Differential and Final Drive Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1

Brake System WP 0112 00 WP 0113 00 WP 0114 00 WP 0115 00 WP 0116 00 WP 0117 00 WP 0118 00

Parking Brake Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1 Parking Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1 Brake Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1 Parking Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1 Service Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1 Service Brake Lines and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1 Brake Pedals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0118 00-1

Wheel and Tire Maintenance WP 0119 00 Wheel and Tire Assembly (Front) Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1 WP 0120 00 Wheel and Tire Assembly (Rear) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1 Steering System WP 0121 00 WP 0122 00 WP 0123 00 WP 0124 00

Steering Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00-1 Steering Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122 00-1 Secondary Steering Pump and Electric Motor Maintenance. . . . . . . . . . . . . . . . 0123 00-1 Steering Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0124 00-1 iii

TM 5-3805-291-23-2

Table of Contents - Continued Page Number Steering System-Continued WP 0125 00 WP 0126 00 WP 0127 00 WP 0128 00

Steering Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00-1 Secondary Steering Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1 Steering Control Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1 Steering Metering Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1

Frame WP 0129 00 Remote Lubrication Lines, Hoses, and Fittings Replacement . . . . . . . . . . . . . . 0129 00-1 WP 0130 00 Counterweight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1 Body and Cab WP 0131 00 Cab Doors Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1 WP 0132 00 Cab Remove/Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1 WP 0133 00 Chassis Guard, Side Panels, Hydraulic Service Box, Circuit Breaker Box, and Battery Box Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1 WP 0134 00 Handrails, Ladders, and Steps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00-1 WP 0135 00 Side Covers and Hood Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00-1 WP 0136 00 Front Fenders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136 00-1 WP 0137 00 Rear Fenders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00-1 WP 0138 00 Cab Liners and Dome Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1 WP 0139 00 Cab Sun Visor and Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1 WP 0140 00 Seat Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00-1 WP 0141 00 Seat Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00-1 WP 0142 00 Rifle Rack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00-1 WP 0143 00 Toolbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00-1 Body, Chassis, Accessory Items WP 0144 00 WP 0145 00 WP 0146 00 WP 0147 00

Windshield Washer Bottle and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . 0144 00-1 Front Windshield Wipers and Motor Replacement. . . . . . . . . . . . . . . . . . . . . . . 0145 00-1 Rear Windshield Wiper and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1 Data Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147 00-1

Hydraulic System WP 0148 00 WP 0149 00 WP 0150 00 WP 0151 00 WP 0152 00 WP 0153 00 WP 0154 00

Hydraulic System Oil Change and Filter Replacement. . . . . . . . . . . . . . . . . . . . 0148 00-1 Quick Coupler Diverter Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1 Pilot Oil Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1 Ride Control Accumulator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1 Tilt Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1 Lift Cylinders Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1 Hydraulic System Oil Filter Bases and Cooler Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0154 00-1 WP 0155 00 Hydraulic System Oil Filter Bases Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1 WP 0156 00 Implement Hydraulic Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . 0156 00-1 WP 0157 00 Main Control Valve and Implement Pump Hydraulic Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1 iv

TM 5-3805-291-23-2

Table of Contents - Continued Page Number Hydraulic System-Continued WP 0158 00 Quick Coupler Cylinder Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1 WP 0159 00 Hydraulic Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1 WP 0160 00 Sight Gage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0160 00-1 Special Purpose Kits WP 0161 00 WP 0162 00 WP 0163 00 WP 0164 00 WP 0165 00 WP 0166 00 WP 0167 00

Arctic Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1 Arctic Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00-1 Bristles Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1 Broom Hose, Manifold, and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1 Broom Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1 Broom Shields and Springs Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-1 Pallet Forks Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1

Air Conditioning WP 0168 00 Air Conditioning/Heater Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . 0168 00-1 Earthmoving Equipment WP 0169 00 Quick Coupler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1 WP 0170 00 Bucket Tips and Cutting Edges Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1 CHAPTER 4. DIRECT SUPPORT MAINTENANCE INSTRUCTIONS Engine WP 0171 00 WP 0172 00 WP 0173 00 WP 0174 00 WP 0175 00 WP 0176 00 WP 0177 00 WP 0178 00 WP 0179 00 WP 0180 00 WP 0181 00 WP 0182 00 WP 0183 00 WP 0184 00 WP 0185 00 WP 0186 00

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1 Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1 Crankshaft Vibration Damper and Pulley Replacement . . . . . . . . . . . . . . . . . . . 0173 00-1 Front Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1 Rear Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1 Flywheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1 Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1 Intake/Exhaust Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1 Rocker Arms and Push Rods Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1 Engine Oil Pan Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1 Engine Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1 Piston Cooling Jets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00-1 Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1 Intake Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1 Idler Gears Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1

Fuel WP 0187 00 Fuel Injectors and Wiring Harness Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1 WP 0188 00 Fuel Transfer Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1 WP 0189 00 Aftercooler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1 v

TM 5-3805-291-23-2

Table of Contents - Continued Page Number Cooling System WP 0190 00 Cooling System Package (Radiator, Fan, Aftercooler, and Oil Cooler) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1 WP 0191 00 Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-1 WP 0192 00 Fan Hydraulic Motor and Fan Group Replacement . . . . . . . . . . . . . . . . . . . . . . 0192 00-1 WP 0193 00 Hydraulic Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1 Electrical System WP 0194 00 WP 0195 00 WP 0196 00 WP 0197 00 WP 0198 00 WP 0199 00 WP 0200 00

Accessory Support Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00-1 Cab Wiring Harness and Fuse/Relay Block Replacement . . . . . . . . . . . . . . . . . 0195 00-1 Engine Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1 Front Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197 00-1 Heater and Air Conditioning Wiring Harness Replacement . . . . . . . . . . . . . . . . 0198 00-1 Rear Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1 Secondary Steering Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1

Transmission WP 0201 00 WP 0202 00 WP 0203 00 WP 0204 00 WP 0205 00 WP 0206 00

Transmission Control Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . 0201 00-1 Transmission Hydraulic Control Relief Valve Replacement . . . . . . . . . . . . . . . 0202 00-1 Transmission Modulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1 Transmission and Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . 0204 00-1 Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1 Transmission Oil Pump (Gear Pump) Replacement . . . . . . . . . . . . . . . . . . . . . . 0206 00-1

Front Axle WP 0207 00 Front Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1 Rear Axle WP 0208 00 Rear Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-1 WP 0209 00 Rear Axle Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1 Steering System WP 0210 00 Steering Neutralizer Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210 00-1 Frame WP 0211 00 Separate Front Loader Frame and Rear Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00-1 Body and Cab WP 0212 00 Engine Compartment Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212 00-1 WP 0213 00 Windshield Front/Rear and Doors Glass Replacement . . . . . . . . . . . . . . . . . . . . 0213 00-1 Hydraulic System WP 0214 00 WP 0215 00 WP 0216 00 WP 0217 00 WP 0218 00

Seat Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00-1 Braking and Hydraulic Fan Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00-1 Piston Pumps (Steering and Implement/Pilot) Replacement. . . . . . . . . . . . . . . . 0216 00-1 Brake Charge and Hydraulic Fan Control Manifold Replacement . . . . . . . . . . . 0217 00-1 Main Hydraulic Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00-1 vi

TM 5-3805-291-23-2

Table of Contents - Continued Page Number Refrigeration and Air Conditioning WP 0219 00 WP 0220 00 WP 0221 00 WP 0222 00 WP 0223 00 WP 0224 00 WP 0225 00 WP 0226 00

Electrohydraulic Control (Joystick) Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0219 00-1 Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00-1 Air Conditioning System Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . 0221 00-1 Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-1 Refrigerant Hoses, Lines, Valves, Flanges, and Fittings Replacement. . . . . . . . 0223 00-1 Inline Refrigerant Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0224 00-1 Refrigerant Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00-1 Air Conditioning System Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . 0226 00-1

Earthmoving Equipment WP 0227 00 Evaporator Core Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0227 00-1 WP 0228 00 Bucket Tilt Lever and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00-1 WP 0229 00 Bucket Lift Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229 00-1 CHAPTER 5. SUPPORTING INFORMATION WP 0230 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0230 00-1 WP 0231 00 Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . 0231 00-1 WP 0232 00 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0232 00-1 WP 0233 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0233 00-1 WP 0234 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234 00-1 WP 0235 00 Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-1 WP 0236 00 Nomenclature Cross-Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0236 00-1 WP 0237 00 Schematics Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0237 00-1 Electrical Figure 1. Figure 1.

Electrical Schematics - Key to Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1/(FP-2 Blank) Electrical Schematics - Key to Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-3/(FP-4 Blank)

Figure 1.

Electrical Schematics - Lighting Circuit (Sheet 1 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-5/(FP-6 Blank)

Figure 1.


Figure 1.

Electrical Schematics - Accessories Circuit (Sheet 3 of 21) . . . . . . . . . . . . . . . . . . . . . . . FP-9/(FP-10 Blank)

Figure 1.

Electrical Schematics - Accessories Circuit (Sheet 4 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-11/(FP-12 Blank)

Figure 1.


Figure 1.


Figure 1.

Electrical Schematics - Implement Circuit (Sheet 7 of 21) . . . . . . . . . . . . . . . . . . . . . . . FP-17/(FP-18 Blank)

Figure 1.


Figure 1.


Figure 1.

Electrical Schematics - Implement Circuit (Sheet 10 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-23/(FP-24 Blank)

Figure 1.


Figure 1.

Electrical Schematics - Engine Circuit (Sheet 12 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . FP-27/(FP-28 Blank)

Figure 1.

Electrical Schematics - Engine Circuit (Sheet 13 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . FP-29/(FP-30 Blank) vii

TM 5-3805-291-23-2

Table of Contents - Continued Page Number Electrical - Continued Figure 1.

Electrical Schematics - Transmission Circuit (Sheet 14 of 21) . . . . . . . . . . . . . . . . . . . . FP-31/(FP-32 Blank)

Figure 1.


Figure 1.


Figure 1.

Electrical Schematics - Starting Circuit (Sheet 17 of 21). . . . . . . . . . . . . . . . . . . . . . . . . FP-37/(FP-38 Blank)

Figure 1.


Figure 1.

Electrical Schematics - Power Distribution Circuit (Sheet 19 of 21). . . . . . . . . . . . . . . . FP-41/(FP-42 Blank)

Figure 1.

Electrical Schematics - Messenger Circuit (Sheet 20 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-43/(FP-44 Blank)

Figure 1.

Electrical Schematics - Legend (Sheet 21 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-45/(FP-46 Blank)

Hydraulic Figure 2.

Hydraulic Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-47/(FP-48 Blank)

Figure 2.

Hydraulic Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-49/(FP-50 Blank)

Figure 2.

Hydraulic Schematic Legend (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-51/(FP-52 Blank)

viii

TM 5-3805-291-23-2

HOW TO USE THIS MANUAL NOTE If at any time you are unsure how to use this manual or you cannot locate the information you need, notify your supervisor. INTRODUCTION 1.

This manual is designed to help you operate the 966H Loader and to perform troubleshooting and maintenance on the equipment.

2.

This manual is written in work package format: a.

Chapters divide the manual into major categories of information (e.g., Introductory Information, Equipment Description and Data, and Theory of Operation; Troubleshooting Procedures; Unit Maintenance Instructions; Direct Support and Maintenance Instructions; and Supporting Information).

b.

Each Chapter is divided into work packages, which are identified by a 6-digit number (e.g., 0001 00, 0002 00) located on the upper right-hand corner of each page. The work package page number (e.g., 0001 00-1, 0001 00-2) is located centered at the bottom of each page.

c.

If a Change Package is issued to this manual, added work packages use the 5th and 6th digits of their number to indicate new material. For instance, work packages inserted between WP 0001 00 and WP 0002 00 are numbered WP 0001 01, WP 0001 02, etc.

3.

Read through this manual to become familiar with its organization and contents before attempting to operate or maintain the equipment.

4.

This manual is published in two volumes: Volume I covers Chapters 1 and 2. Both volumes contain Chapter 5, Supporting Information.

5.

The second volume (TM 5-3805-291-23-2) contains Chapters 3 and 4.

CONTENTS OF THIS MANUAL 1.

A Warning Summary is located at the beginning of each volume of the manual. Become familiar with these warnings before operating or performing operator troubleshooting or maintenance on the machine.

2.

A Table of Contents in Volume I lists the contents of Volumes I and II. The Table of Contents in Volume II lists the contents of Volume II only. a.

The Table of Contents also provides Reporting Errors and Recommending Improvements information and DA Form 2028 addresses, for the submittal of corrections to this manual.

b.

If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual. The alphabetical Index for each volume lists only those work packages found in that volume.

3.

Chapter 1, Introductory Information, Equipment Description and Data, and Theory of Operation, provides general information on the manual and the equipment.

4.

Chapter 2, covers all Troubleshooting Procedures. WP 0007 00 contains a Troubleshooting Symptom Index. If the machine malfunctions, this index should always be consulted to locate the appropriate troubleshooting procedure.

5.

Chapter 3, describes Unit Maintenance Instructions. Major areas covered are Preventive Maintenance Checks and Services (PMCS) and unit level maintenance tasks.

6.

Chapter 4, covers Direct Support Maintenance Instructions.

7.

Chapter 5, includes Supporting Information: References, Maintenance Allocation Chart (MAC) Introduction, Maintenance Allocation Chart (MAC), Expendable and Durable Items List, Torque Limits, Preparation for Storage or Shipment, Nomenclature Cross-Reference List, and Schematics. ix

TM 5-3805-291-23-2 FEATURES OF THIS MANUAL 1.

WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid.

WARNING A WARNING indicates a hazard which may result in injury or death to personnel.

CAUTION A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment.

NOTE A NOTE is a statement containing information that will make the procedures easier to perform. 2.

Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.

3.

Within a procedural step, reference may be made to another work package in this manual or to another manual. These references indicate where you should look for more complete information. a.

If you are told: “Start engine (TM 5-3805-291-10),” go to TM 5-3805-291-10 for instructions on engine starting.

b.

If you are told: “For complete information on servicing batteries, refer to TM 9-6140-200-14,” go to the References work package (WP 0230 00) for complete information.

4.

Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art are text or numbers.

5.

Numbers located at lower right corner of art (e.g., 427-C001; 427-C002) are art control numbers and are used for tracking purposes only.

6.

Dashed leader lines used in the Lubrication Chart and in the PMCS Table indicate that called out lubrication points are located on both sides of the machine.

7.

Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is located on the inside back cover of the manual.

x

14 TM 5-3805-291-23-2

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT

0050 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation

INITIAL SETUP Equipment Conditions

Maintenance Level Unit

Machine parked on level ground (TM 5-3805-29110)

Tools and Special Tools

Work tool lowered to ground (TM 5-3805-291-10)

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00)

Parking brake engaged (TM 5-3805-291-10)

Materials/Parts

Wheels chocked

Cleaning compound, solvent, type III (Item 7, WP 0233 00)

Battery disconnect switch in OFF position (TM 53805-291-10)

Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00)

Drawings Required TM 5-3805-291-23P, Figure 54

Locknuts (4)

Estimated Time to Complete Task

Personnel Required MOS 62B, Construction Equipment Repairer

6.0 hr

WARNING Ensure battery disconnect switch is in OFF position before performing this task. Failure to follow this warning may result in injury to personnel or damage to equipment.

NOTE If only display requires replacement, proceed to Steps 24 through 26 and 28 through 30.

0050 00-1

TM 5-3805-291-23-2

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED REMOVAL 1.

Open rear door on hood (TM 5-3805-291-10).

2.

Disconnect camera connector (1) from rear camera cable (7).

3.

Remove four locknuts (2) and washers (4) from bracket (3). Discard locknuts.

4.

Push grommet (5) through hood (6).

5.

Remove bracket (3) from hood (6).

6.

Remove two nuts (9), washers (10), camera (14) and gasket (15) from bracket (3).

7.

Remove two bolts (13), nuts (12), camera bracket (11) from camera (14).

8.

Remove two bolts (8) from bracket (11).

0050 00-2

0050 00

TM 5-3805-291-23-2

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED REMOVAL - CONTINUED 9.

Remove seven bolts (16), washers (18), and clamps (17) from hood (6) and rear camera cable (7).

10.

Close rear door on hood and open hood (TM 5-3805-291-10).

11.

Remove four bolts (19) and washers (20) from rear plate (22) and position rear panel aside.

12.

Remove and discard tiedown straps (21) from rear camera cable (7) toward rear of cab.

0050 00-3

0050 00

TM 5-3805-291-23-2

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED

0050 00

REMOVAL - CONTINUED 13.

Disconnect rear camera cable (7) from rear connector (24).

14.

Remove rear camera cable (7) from machine.

15.

Remove nut (23) from rear connector (24).

16.

Remove three bolts (25) and washers (26), two bolts (28) and plastic washers (25), and rear panel (27) from cab.

0050 00-4

TM 5-3805-291-23-2


Disconnect cab camera cable (30) from rear connector (24).

18.

Disconnect cab camera cable (30) from upper connector (32) and remove cable from machine.

19.

Disconnect camera display cable (31) from upper connector (32).

20.

Remove nut (33) and upper connector (32) from panel (34).

0050 00-5

0050 00

TM 5-3805-291-23-2


Remove four bolts (39) from trim panel (38) and pull trim panel aside.

22.

Remove four bolts (36) from rear console (37).

23.

Remove two bolts (41) and two bolts (40) from front console (35).

0050 00-6

0050 00

TM 5-3805-291-23-2


0050 00


Pull down display cable (31) and cab harness (50) from headliner (42) and disconnect from camera display harness (49).

25.

Remove four bolts (45), washers (44), and display (48) with mount (46) from mount bracket (43).

26.

Remove two bolts (52) and mount bracket (43) from support bracket (51).

27.

Remove and discard tiedown straps (47) from camera display cable (31) and remove camera display cable from machine.

28.

Remove four bolts (53), washers (54) and mount (46) from camera display (48).

29.

Remove two screws (55) and cover (56) from camera display (48).

30.

Disconnect camera display harness (49) from camera display (48).

0050 00-7

TM 5-3805-291-23-2


0050 00

CLEANING AND INSPECTION

WARNING •

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel.

•

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield. Failure to follow this warning may result in injury to personnel.

1.

Clean all metal parts and surfaces with solvent cleaning compound.

2.

Dry parts with compressed air.

3.

Inspect all parts for damage, wear, pitting, cracks, or corrosion and replace if necessary.

4.

Clean upholstery with detergent.

INSTALLATION 1.

Connect camera display harness (49) to camera display (48).

2.

Install cover (56) on camera display (48) with two screws (55).

3.

Install mount (46) on camera display (48) with four bolts (53) and washers (54.)

NOTE If only display requires replacement, proceed to Steps 5 through 7.

0050 00-8

TM 5-3805-291-23-2


0050 00

INSTALLATION - CONTINUED 4.

Position camera display cable (31) in machine and secure with tiedown straps (47).

5.

Install mount bracket (43) on support bracket (51) with two bolts (52).

6.

Install display (48) with mount (46) on mount bracket (43) with four washers (44) and bolts (45).

7.

Connect camera display harness (49) to cab harness (50) and camera display cable (31). Position cab harness and camera display cable behind headliner (42).

0050 00-9

TM 5-3805-291-23-2

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 8.

Secure front console (35) in cab with two bolts (41) and two bolts (40).

9.

Secure rear console (37) in cab with four bolts (36).

10.

Position trim panel (38) in cab and secure with four bolts (39).

0050 00-10

0050 00

TM 5-3805-291-23-2


Install upper connector (32) in panel (34) with nut (33).

12.

Connect camera display cable (31) to upper connector (32).

13.

Connect cab camera cable (30) to upper connector (32).

14.

Connect cab camera cable (30) to rear connector (24).

0050 00-11

0050 00

TM 5-3805-291-23-2


0050 00


Install rear panel (27) in cab with two plastic washers (29) and bolts (28) and three washers (26) and bolts (25).

16.

Install nut (23) on rear connector (24).

17.

Position rear camera cable (7) in machine and connect to rear connector (24).

0050 00-12

TM 5-3805-291-23-2


Install new tiedown straps (21) on rear camera cable (7).

19.

Secure rear plate (22) on machine with four washers (20) and volts (19).

20.

Close hood and open rear door on hood (TM 5-3805291-10).

21.

Install seven clamps (17) on rear camera cable (7) and hood (6) with washers (18) and bolts (16).

0050 00-13

0050 00

TM 5-3805-291-23-2


Install two bolts (8) on bracket (11).

23.

Install camera bracket (11) on camera (14) with two bolts (13) and nuts (12).

24.

Install camera (14) and gasket (15) on bracket (3) with two nuts (9), and washers (10).

25.

Position bracket (3) on hood (6).

483-1040

26.

Push grommet (5) through hood (6).

27.

Install four washers (4) and new locknuts (2) on bracket (3).

28.

Connect camera connector (1) to rear camera cable (7).

29.

Close rear door on hood (TM 5-3805-291-10).

30.

Switch on machine (TM 5-3805-291-10).

31.

Check for correct operation of rearview camera (TM 5-3805-291-10).

32.

Switch off machine (TM 5-3805-291-10).

33.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE 0050 00-14

0050 00

10 TM 5-3805-291-23-2

STARTER REPLACEMENT

0051 00

THIS WORK PACKAGE COVERS Removal, Installation, Pinion Clearance Adjustment INITIAL SETUP Personnel Required

Maintenance Level

MOS 62B, Construction Equipment Repairer (2)

Unit

References

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00)

WP 0013 00

Equipment Conditions Hood opened (TM 5-3805-291-10)

Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00)

Battery cables disconnected from batteries (WP 0096 00) Drawings Required

Lifting equipment, 90-lb capacity Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)

TM 5-3805-291-23P, Figure 48 Estimated Time to Complete Task 2.0 hr

Materials/Parts Rag, wiping (Item 35, WP 0233 00) Tag, marker (Item 43, WP 0233 00) Locknut Lockwasher

WARNING Ensure battery cables are disconnected before performing this task. Failure to follow this warning may result in injury to personnel or damage to equipment.

CAUTION Always test starter before replacing it. Refer to Starting Motor Test (WP 0013 00). Failure to do so may result in unnecessary replacement of starter.

NOTE •

Tag wires prior to removal to ensure correct installation.

•

Wipe area clean around component before removal.

0051 00-1

TM 5-3805-291-23-2

STARTER REPLACEMENT - CONTINUED

0051 00

REMOVAL 1.

Remove starter cable nut (1) from starter solenoid (2).

2.

Disconnect starter cable (3) from starter solenoid (2).

3.

Remove starter solenoid cover nut (4) and lockwasher (5) from starter solenoid (2). Discard lockwasher.

4.

Remove starter solenoid cover (6) from starter solenoid (2).

427-C0069

5.

Remove two nuts (7) and washers (8) and disconnect ground cables (9) from starter (10).

427-C0070

0051 00-2

TM 5-3805-291-23-2


0051 00


Remove nut (11), cover (12), and locknut (13) and disconnect chassis wiring harness (14). Discard locknut.

427-C0071

7.

Remove three bolts (15) and washers (16) from starter (10).

427-C0072

0051 00-3

TM 5-3805-291-23-2


0051 00

REMOVAL - CONTINUED

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE The starter weighs approximately 60 lb (27 kg). 8.

Remove bolt (17), washer (18), and clip (19) from frame (20).

9.

Loosen bolt (21) and slide starter (10) toward rear.

10.

Attach lifting equipment to starter (10).

11.

Remove bolt (21) and washer (22) from starter (10).

12.

With assistance, use lifting equipment to remove starter (10) from machine.

427-C0073

0051 00-4

TM 5-3805-291-23-2


0051 00

INSTALLATION

WARNING


NOTE The starter weighs approximately 60 lb (27 kg).

1.

With assistance, use lifting equipment to position starter (10) on machine.

2.

Install washer (22) and bolt (21) on starter (10).

3.

Install clip (19), washer (18), and bolt (17) on frame (20).

4.

Install three washers (16) and bolts (15) on starter (10).

427-C0072

0051 00-5

TM 5-3805-291-23-2


0051 00


Connect chassis wiring harness (14) and install new locknut (13), cover (12), and nut (11).

427-C0071

6.

Position two ground cables (9) on starter (10) and install two washers (8) and nuts (7). Tighten nuts to 22 ± 3 lb-ft (30.5 ± 3.5 Nm).

427-C0070

0051 00-6

TM 5-3805-291-23-2


0051 00


Position starter solenoid cover (6) on starter solenoid (2) and install starter solenoid cover nut (4) and new lockwasher (5).

8.

Position starter cable (3) on starter solenoid (2) and install starter cable nut (1). Tighten starter cable nut to 22 ± 3 lb-ft (30.5 ± 3.5 Nm).

427-C0069

9.

Connect battery cables to batteries (WP 0096 00).

10.

Close hood (TM 5-3805-291-10).

0051 00-7

TM 5-3805-291-23-2


0051 00

PINION CLEARANCE ADJUSTMENT

NOTE When the solenoid is installed, make an adjustment of the pinion clearance. The adjustment should be made with the starting motor removed.

1.

Disconnect starting motor negative wire from “G” ground terminal of solenoid.

427-C1979

2.

Connect batteries directly to solenoid as shown below. Connect positive side of battery cable to “S” terminal of starting motor solenoid. Connect negative side of battery to “G” terminal of starting motor.

3.

Temporarily, touch a wire from “G” terminal to “Mtr” terminal. Pinion will shift to crank position and stay there until battery is disconnected.

4.

Remove plug from starter.

5.

Push pinion toward commutator in order to remove free movement.

6.

Measure clearance (X) from pinion to pinion drive housing. Pinion clearance (X) must be 0.36 ± 0.03 in. (9.10 ± 0.8 mm).

427-C1980

0051 00-8

TM 5-3805-291-23-2


0051 00

PINION CLEARANCE ADJUSTMENT - CONTINUED 7.

If clearance is not correct, remove plug on pinion drive housing. Turn adjustment nut until clearance is correct. Turning nut clockwise will decrease clearance (X).

NOTE The plunger may turn when the adjustment nut is being turned. If the plunger turns, disconnect the battery from the solenoid. Remove the solenoid from the starting motor. Hold the plunger from the turning and adjust the nut. This procedure may need to be performed several times until the correct clearance is obtained.

8.

Disconnect the batteries from solenoid and install plug in shift lever housing.

END OF WORK PACKAGE

0051 00-9/(0051 00-10 Blank)

10 TM 5-3805-291-23-2

HVAC BLEND DOOR ACTUATOR REPLACEMENT

0052 00


INITIAL SETUP Maintenance Level

References TM 5-3805-291-10

Unit

Equipment Conditions





Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Primer coating (Item 34, WP 0233 00)

Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figure 172

Personnel Required

Estimated Time to Complete Task 1.5 hr

MOS 62B, Construction Equipment Repairer

0052 00-1

TM 5-3805-291-23-2

HVAC BLEND DOOR ACTUATOR REPLACEMENT - CONTINUED REMOVAL 1.

Remove three screws (1) from tray (2).

2.

Remove screw (3) and tray (2) from machine.

0052 00-2

0052 00

TM 5-3805-291-23-2

HVAC BLEND DOOR ACTUATOR REPLACEMENT - CONTINUED REMOVAL - CONTINUED 3.

Remove three screws (4) from cover assembly (5).

4.

Remove three screws (6) and washers (7) from cover assembly (5).

0052 00-3

0052 00

TM 5-3805-291-23-2


Loosen two thumbwheel screws (8) on air filter cover (9) and remove from cover assembly (5).

6.

Remove filter (10) from cover assembly (5).

0052 00-4

0052 00

TM 5-3805-291-23-2


Remove screw (11) from cover assembly (5).

8.

Remove cover assembly (5) from machine.

9.

Disconnect harness (13) from actuator (15).

10.

Remove three bolts (14) and actuator (15) from housing (12).

0052 00-5

0052 00

TM 5-3805-291-23-2

HVAC BLEND DOOR ACTUATOR REPLACEMENT - CONTINUED

0052 00


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Install actuator (15) and three bolts (14) on housing (12).

2.

Connect harness (13) on actuator (15).

0052 00-6

TM 5-3805-291-23-2

HVAC BLEND DOOR ACTUATOR REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 3.

Position cover assembly (5) on machine.

4.

Install screw (11) on cover assembly (5).

0052 00-7

0052 00

TM 5-3805-291-23-2


Install filter (10) on cover assembly (5).

6.

Position air filter cover (9) on cover assembly (5).

7.

Tighten two thumbwheel screws (8) on air filter cover (9).

0052 00-8

0052 00

TM 5-3805-291-23-2


Install three washers (7) and screws (6) on cover assembly (5).

9.

Install three screws (4) on cover assembly (5).

0052 00-9

0052 00

TM 5-3805-291-23-2


Position tray (2) on machine.

11.

Install screw (3) on tray (2).

12.

Install three screws (1) on tray (2).

13.

Verify correct operation of machine (TM 5-3805-291-10).

END OF WORK PACKAGE

0052 00-10

0052 00

10 TM 5-3805-291-23-2

FUSE, RELAY, CIRCUIT BREAKER, AND ARC SUPPRESSOR REPLACEMENT

0053 00

THIS WORK PACKAGE COVERS Fuse: Removal, Installation Hood Tilt Relay: Removal, Installation Cab Circuit Breaker: Removal, Installation Panel Box Circuit Breaker: Removal, Installation Arc Suppressor: Removal, Installation

INITIAL SETUP References


TM 5-3805-291-10


Equipment Conditions Right rear interior cover removed (interior wiring) (WP 0138 00)

Materials/Parts Rag, wiping (Item 35, WP 0233 00)

Drawings Required

Tag, marker (Item 43, WP 0233 00)

TM 5-3805-291-23P, Figures 51 and 56

Tiestraps



0.3 hr

FUSE REMOVAL

0053 00


CAUTION Replace fuses with same type and size only. Otherwise, electrical damage can result.

NOTE •

These procedures show one fuse, relay, or circuit replacement. Replacement is the same for each fuse, relay, or circuit.

•

Refer to inside cover of fuse box for fuse locations.

•

Tag wiring harnesses prior to disconnection to ensure correct installation.

0053 00-1

TM 5-3805-291-23-2

FUSE, RELAY, CIRCUIT BREAKER, AND ARC SUPPRESSOR REPLACEMENT - CONTINUED FUSE REMOVAL - CONTINUED

0053 00-2

0053 00

TM 5-3805-291-23-2

FUSE, RELAY, CIRCUIT BREAKER, AND ARC SUPPRESSOR REPLACEMENT - CONTINUED

0053 00

FUSE REMOVAL - CONTINUED 1.

Open access door (1).

427-C1071-1

2.

Remove fuse box cover (2) from fuse box (3).

0053 00-3

TM 5-3805-291-23-2


0053 00

FUSE REMOVAL - CONTINUED 3.

Remove fuse (4) from fuse box (3).

427-C1337

FUSE INSTALLATION 1.

Install fuse (4) in fuse box (3).

2.

Install fuse box cover (2) on fuse box (3).

483-1527

0053 00-4

TM 5-3805-291-23-2


0053 00

FUSE INSTALLATION - CONTINUED 3.

Close access door (1).

427-C1071-1

HOOD TILT RELAY REMOVAL 1.

0053 00

Remove three bolts (5), washers (6), and panel (7) from machine.

0053 00-5

TM 5-3805-291-23-2

FUSE, RELAY, CIRCUIT BREAKER, AND ARC SUPPRESSOR REPLACEMENT - CONTINUED HOOD TILT RELAY REMOVAL - CONTINUED 2.

Disconnect wiring harness (8) from wiring harness (9).

3.

Remove four bolts (10) and washers (11) from relay (12).

4.

Remove relay (12) from panel.

HOOD TILT RELAY INSTALLATION 1.

Position relay (12) on panel.

2.

Install four washers (11) and bolts (10) on relay (12).

3.

Connect wiring harness (9) to wiring harness (8)

4.

Install panel (7), three washers (6), and bolts (5) on machine.

0053 00-6

0053 00

TM 5-3805-291-23-2


0053 00

CAB CIRCUIT BREAKER REMOVAL

0053 00

1.

Remove two nuts (13) and bolts (14) from circuit breaker (15).

2.

Remove circuit breaker (15) from bracket (16).

3.

Remove two screws (17) and disconnect two wiring harnesses (18) from circuit breaker (15).

427-C1334

CAB CIRCUIT BREAKER INSTALLATION 1.

Connect two wiring harnesses (18) and install two screws (17) on circuit breaker (15).

2.

Position circuit breaker (15) on bracket (16).

3.

Install two bolts (14) and nuts (13) on circuit breaker (15).

PANEL BOX CIRCUIT BREAKER REMOVAL

0053 00

NOTE This procedure shows one circuit replacement in the panel box. Replacement is the same for each circuit in the panel box.

1.

Remove nut (19) from circuit breaker (20).

2.

Loosen nut (21) and remove one end of buss bar (22) from circuit breaker (20).

3.

Remove nut (23), washer (24), and wiring harness (25) from circuit breaker (20).

4.

Remove two screws (26) from circuit breaker (20).

5.

Remove circuit breaker (20) from machine.

427-C1332

0053 00-7

TM 5-3805-291-23-2


0053 00

PANEL BOX CIRCUIT BREAKER INSTALLATION 1.

Position circuit breaker (20) on machine.

2.

Install four nuts (26) on circuit breaker (20).

3.

Install wiring harness (25), washer (24), and nut (23) on circuit breaker (20).

4.

Install one end of buss bar (22) and tighten nut (21) on circuit breaker (20).

5.

Install nut (19) on circuit breaker (20).

427-C1332

6.

Install right rear interior cover (WP 0138 00).

7.

Verify correct operation of electrical accessories and components (TM 5-3805-291-10).

0053 00-8

TM 5-3805-291-23-2

FUSE, RELAY, CIRCUIT BREAKER, AND ARC SUPPRESSOR REPLACEMENT - CONTINUED ARC SUPPRESSOR

NOTE All arc suppressors are replaced in the same manner.

Removal 1.

Cut tie strap (27) and discard.

2.

Remove arc suppressor (28) from wiring harness (29).

Installation 1.

Install arc suppressor (28) on wiring harness (29).

2.

Install new tie strap (27).

483-1037

END OF WORK PACKAGE 0053 00-9/(0053 00-10 Blank)

0053 00

2 TM 5-3805-291-23-2

INSTRUMENT CLUSTER REPLACEMENT

0054 00

THIS WORK PACKAGE COVERS Removal, Installation INITIAL SETUP Equipment Conditions






Wheels chocked

Materials/Parts

Parking brake engaged (TM 5-3805-291-10) Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required

Rag, wiping (Item 35, WP 0233 00)

TM 5-3805-291-23P, Figure 50




0.2 hr


0054 00-1

TM 5-3805-291-23-2

INSTRUMENT CLUSTER REPLACEMENT - CONTINUED

0054 00

REMOVAL

NOTE Tag wiring harness prior to removal to ensure correct installation. 1.

Remove 12 screws (1) from instrument cluster (2).

2.

Pull out instrument cluster (2) from duct assembly (3).

3.

Disconnect upper cab wiring harness (4) from instrument cluster (2).

4.

Remove instrument cluster (2) from duct assembly (3).

427-C1523

INSTALLATION 1.

Connect upper cab wiring harness (4) to instrument cluster (2).

2.

Install instrument cluster (2) on duct assembly (3).

3.

Install 12 screws (1) on instrument cluster (2).

4.

Verify correct operation of instrument cluster (TM 5-3805-291-10).


14 TM 5-3805-291-23-2

INSTRUMENT PANELS AND SWITCHES REPLACEMENT

0055 00

THIS WORK PACKAGE COVERS Cover: Removal, Installation Instrument Panel: Removal, Installation Switch: Removal, Installation 12 Volt Socket: Removal, Installation


Equipment Conditions Machine parked on level ground (TM 5-3805-29110)

Unit Tools and Special Tools



Parking brake engaged (TM 5-3805-291-10) Wheels chocked

Materials/Parts


Rag, wiping (Item 35, WP 0233 00) Tag, marker (Item 43, WP 0233 00)

Drawings Required

Lockwasher

TM 5-3805-291-23P, Figures 49 and 50

Personnel Required



COVER REMOVAL


0055 00-1

TM 5-3805-291-23-2

INSTRUMENT PANELS AND SWITCHES REPLACEMENT - CONTINUED

0055 00

COVER REMOVAL - CONTINUED

CAUTION Tag wiring harnesses prior to removal to ensure correct installation.

1.

Remove four screws (1) from cover (2).

427-C0074

2.

Disconnect all wiring harnesses (3) from rocker switches (4).

3.

Remove cover (2) from machine.

427-C0075

0055 00-2

TM 5-3805-291-23-2


0055 00

COVER REMOVAL - CONTINUED


4.

Remove three screws (5) from center switch panel (6).

427-C0077

5.


427-C0078

0055 00-3

TM 5-3805-291-23-2


0055 00

COVER REMOVAL - CONTINUED 6.

Disconnect three wiring harnesses (9) from panel (6).

7.

Remove panel (6) from machine.

427-C0079

8.

Remove two screws (10) from cover (11).

427-C0081

0055 00-4

TM 5-3805-291-23-2


0055 00

COVER REMOVAL - CONTINUED 9.

Remove two screws (12) from cover (11).

10.

Disconnect four wiring harnesses (13) from rocker switches (14) and messenger (15).

11.


427-C0083

0055 00-5

TM 5-3805-291-23-2


0055 00

COVER INSTALLATION 1.

Position cover (11) on machine.

2.

Connect four wiring harnesses (13) to messenger (15) and rocker switches (14).

427-C0083

3.

Install two screws (12) on cover (11).

4.

Install two screws (10) on cover (11).

427-C0081

0055 00-6

TM 5-3805-291-23-2


0055 00

COVER INSTALLATION - CONTINUED 5.

Position panel (6) on machine.

6.

Connect three wiring harnesses (9) to panel (6).

427-C0079

7.

Connect wiring harness (7) to wiring harness (8).

427-C0078

8.

Install three screws (5) on panel (6).

427-C0077

0055 00-7

TM 5-3805-291-23-2


0055 00

COVER INSTALLATION - CONTINUED 9.

Position cover (2) on machine.

10.

Connect all wiring harnesses (3) to rocker switches (4).

427-C0075

11.

Install four screws (1) on cover (2).

427-C0074

0055 00-8

TM 5-3805-291-23-2


0055 00

INSTRUMENT PANEL REMOVAL

CAUTION Tag wiring harnesses prior to removal to ensure correct installation.

1.

Remove 12 screws (16) from instrument panel (17).

2.

Remove instrument panel (17) from duct (18).

3.

Disconnect 10 wiring harnesses (19) from instrument panel (17).

4.

Remove instrument panel (17) from machine.

427-C0080

0055 00-9

TM 5-3805-291-23-2


0055 00

INSTRUMENT PANEL INSTALLATION 1.

Position instrument panel (17) on machine.

2.

Connect 10 wiring harnesses (19) to instrument panel (17).

3.

Install instrument panel (17) on duct (18).

4.

Install 12 screws (16) on instrument panel (17).

427-C0080

0055 00-10

TM 5-3805-291-23-2


0055 00

SWITCH REMOVAL AND INSTALLATION

NOTE The number of switches can vary depending on the machine configuration. Use the following procedures for all switches.

Rotary Switch Removal

0055 00

1.

Remove applicable panel to access switches.

2.

Loosen setscrew (19) and remove switch knob (20) from rotary switch (21).

3.

Remove nut (22) and washer (23) from rotary switch (21).

4.

Remove rotary switch (21) from panel.

Rotary Switch Installation

0055 00

1.

Position rotary switch (21) on panel.

2.

Install nut (22) and washer (23) on rotary switch (21).

3.

Install switch knob (20) on rotary switch (21) and tighten setscrew (19).

4.

Install applicable panel.

Rocker Switch Removal

427-C1519

0055 00

1.

Remove applicable panel to access switches.

2.

Depress switch sides (24) and remove switch from panel.

427-C1320

0055 00-11

TM 5-3805-291-23-2


0055 00

SWITCH REMOVAL AND INSTALLATION - CONTINUED Rocker Switch Installation 1.

Insert switch (24) in panel.

2.

Install applicable panel.

0055 00

427-C1320

12V SOCKET REMOVAL AND INSTALLATION 12V Socket Removal

0055 00

1.

Remove instrument panel (17) to access 12V socket (25).

2.

Remove nut (26) from 12V socket (25).

3.

Remove 12V socket (25) from instrument panel (17).

12V Socket Installation

0055 00

1.

Position 12V socket (25) on instrument panel (17).

2.

Install nut (26) on 12V socket (25).

3.

Install instrument panel (17).

427-C1520

0055 00-12

TM 5-3805-291-23-2


0055 00

SWITCH REMOVAL AND INSTALLATION - CONTINUED Engine Start Switch Removal

0055 00

1.

Remove instrument panel (17) to access engine start switch (27).

2.

Remove screw (28), lockwasher (29), and knob (30) from engine start switch (27). Discard lockwasher.

3.

Remove nut (31) from engine start switch (27).

4.

Remove engine start switch (27) from instrument panel (17).

Engine Start Switch Installation 1.

Position engine start switch (27) on instrument panel (17).

2.

Install nut (31) on engine start switch (27).

3.

Install knob (30), new lockwasher (29), and screw (28) on engine start switch (27).

4.

Install instrument panel (17).

5.

Verify correct operation of all switches (TM 5-3805291-10).

0055 00-13

TM 5-3805-291-23-2


0055 00

QUICK COUPLER ALARM REMOVAL AND INSTALLATION Removal

0055 00

1.

Remove cover. Refer to cover removal in this work package.

2.

Cut tie straps (32) and discard.

3.

Disconnect quick coupler alarm (33) from upper cab wiring harness (34).

Installation

0055 00

1.

Connect quick coupler alarm (33) to upper cab wiring harness (34).

2.

Install new tie straps (32).

END OF WORK PACKAGE

0055 00-14

6 TM 5-3805-291-23-2

MESSENGER ECM REPLACEMENT

0056 00

THIS WORK PACKAGE COVERS System Configuration Parameters, Copy Configuration from ECM, Remove Messenger, Install Messenger, Flash Programming, Copy Configuration (Program ECM)


References WP 0005 00

Unit

WP 0006 00



Adapter, test (Item 3, WP 0232 00)


Software kit (Item 75, WP 0232 00)


Test set, electronic systems (MSD) (Item 86, WP 0232 00)

Wheels chocked

Materials/Parts

Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required


TM 5-3805-291-23P, Figure 49

Personnel Required



CAUTION •

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

•

The replacement ECM must have the same serial number suffix or damage to the engine may result.

NOTE If mission dictates, you may need to remove an ECM from a machine not in service. Refer to the following steps to ensure that the configuration parameters match those in the faulty ECM. Be sure to clear any logged codes if you use a substitute ECM.

0056 00-1

TM 5-3805-291-23-2

MESSENGER ECM REPLACEMENT - CONTINUED

0056 00

SYSTEM CONFIGURATION PARAMETERS

0056 00

System configuration parameters are parameters that affect emissions, engine power, and machine applications. Default values for the parameters are programmed at the factory. Some parameters (such as Service Mode Enable Code or Information Units Status) may be changed to suit the needs of the specific application. View and/or change parameters using the Configuration Tool on the toolbar, or by selecting “Configuration” from the “Service” menu in ET. The Configuration display area in ET has four columns: Description, Value, Unit, and TT. The Description column gives the name of the parameter. The Unit column displays the configuration parameter units. The TT column displays the list of the total tattletales, which represent the number of times the configuration parameter value has changed. The push-buttons in the Configuration screen are “Change” or “Print”. The “Change” push-buttons allow you to change the configuration values. This is only enabled if the parameter’s configuration can be changed. Parameters that cannot be changed have a yellow key symbol on the left. The ECM Replacement function in ET copies the relevant configuration parameters from one ECM to the other. The table below lists the system configuration parameters, definition location, data range, default value and unit for the 966H loader.

PARAMETER DESCRIPTION

DEFINITION/ LOCATION

RANGE OF VALUES

DEFAULT VALUE

INPUT

Product ID

Registration #

8 characters

Blank

Customer defined

Equipment ID

Serial #

9 characters

Blank

Customer defined

ECM part number

ECM

9 characters

From factory

ECM serial number

ECM

10 characters

From factory

ECM software group part number

9 characters

FLASH

ECM software release date

5 characters MONTH YR (NOV99)

ECM software group description

7 characters

APR07

FLASH

FLASH

To replace the ECM, perform the following steps, which are explained in more detail in the sections identified below. a.

Record all diagnostic codes before replacing messenger (WP 0006 00).

b.

Copy configuration of the existing ECM to the MSD. Refer to Copy Configuration from ECM in this work package.

c.

Remove the ECM. Refer to Remove Messenger in this work package.

d.

Install the new ECM. Refer to Install Messenger in this work package.

e.

Flash program ECM. Refer to Flash Programming in this work package.

f.

Copy the configuration of the old ECM to the new ECM. Refer to Copy Configuration (Program ECM) in this work package. 0056 00-2

TM 5-3805-291-23-2


0056 00

COPY CONFIGURATION FROM ECM

0056 00

CAUTION You must copy the configuration of the existing ECM prior to replacing it with a substitute ECM or new ECM to avoid damage to the engine.

1.

Connect ET to MSD and start ET (WP 0005 00).

NOTE ET lists “Messenger” as “Monitor-966”.

2.

After ET establishes a connection with the ECMs, highlight the ECM and click “OK”.

3.

Ensure the correct ECM is highlighted. Select “Copy Configuration” from the “Service” menu, then select “ECM Replacement” from the sub-menu.

4.

The screen will display any previously saved configuration files. Close the dialogue box to load the current configuration.

5.

The “No data is available” dialogue box is displayed. Press “Yes” to load the data from the messenger.

6.

Highlight the ECM that is being replaced and click “OK”.

NOTE As the data is loading from the ECM, the “Please wait...” message displays, then the “Loading data from the ECM...” progress bar is displayed. You may cancel the process at any time by pressing the “Cancel” push-button. The “Are you sure...” dialogue box is displayed. Press “Yes” to cancel loading the data or “No” not to cancel.

7.

“The current ECM Replacement data...Load from...” message appears. Click “OK” button.

NOTE The display area lists the configuration parameters that were loaded from the ECM.

8.

Save all parameters on the “Configuration” screen by selecting “Save To File” from the bottom toolbar, then click “OK”. Note the file name, then click “Save”.

9.

Wait for the message “ECM replacement data saved successfully,” then click OK.

10.

Select “Disconnect” from the “File” menu or click the “Disconnect Tool” on the toolbar.

11.

Proceed to Remove Messenger in this work package.

0056 00-3

TM 5-3805-291-23-2


0056 00

REMOVE MESSENGER

0056 00


NOTE •

Follow troubleshooting procedures in this manual to ensure that replacing the ECM will correct the problem.

1.

• Ensure that all diagnostic codes are noted before removing ECM. Carefully pry messenger (1) from console (2).

2.

Disconnect messenger (1) from wiring harness (3).

0056 00-4

TM 5-3805-291-23-2


0056 00

INSTALL MESSENGER 1.

Connect wiring harness (3) to messenger (1).

2.

Install messenger (1) in console (2).

483-1529

3.

Proceed to Flash Programming in this work package.

FLASH PROGRAMMING

0056 00

1.

Turn Battery Disconnect Switch to ON position (TM 5-3805-291-10).

2.

Connect MSD to machine and start ET (WP 0005 00).

NOTE ET lists “Messenger” as “Monitor-966”.

3.

Highlight the ECM and click “OK”.

4.

Insert flash file CD and read the “read me” file to determine the correct ECM flash file name.

NOTE ET lists “Messenger” as “Graphical Display Module”.

5.

Select “WinFlash” from the “Utilities” menu in ET. “WinFlash” will attempt to detect an ECM. Read and close the WinFlash Quick Help Guide.

6.

Highlight the ECM.

7.

Browse to “My Computer” and select “ET Flash Files”.

8.

Open the “Flash Files” folder and select the system folder.

9.

Select the correct flash file noted in step 4.

10.

Click the “Begin flash” button located in the bottom right corner of the display screen to start flashing the ECM. From this point, the flash process will proceed automatically.

NOTE If any error messages are received during the flash programming, click “Cancel” to stop the process, then verify the file and engine being flashed match. Repeat steps 3 through 10 until the flash programming is completed and you see “Flash Completed Successfully.”

11.

Select ET from the button options. 0056 00-5

TM 5-3805-291-23-2


0056 00

FLASH PROGRAMMING - CONTINUED

NOTE If flash programming the ECM as directed by troubleshooting, proceed to step 12. If replacing an ECM, proceed to Copy Configuration (Program ECM) in this work package.

12.

Start engine. Run until operating temperature is reached and verify proper operation of all components (TM 5-3805291-10). Check for active diagnostic codes (WP 0006 00).

COPY CONFIGURATION (PROGRAM ECM)

0056 00

1.

Highlight the ECM, then click “OK”.

2.

Ensure the correct ECM is highlighted. Select “Copy Configuration” from the “Service” menu, then select “ECM replacement” from the sub-menu.

3.

Highlight configuration file that was saved earlier and double click to open. “The current ECM Replacement data came from...” dialogue box opens. Select “OK”.

4.

Select “Program ECM” push-button, then highlight the ECM to be programmed and click “OK”.

5.

Read the “Warning! This configuration is for the control...” message and verify that the Equipment ID appears, then select “Yes” to “Program the ECM”.

6.

If the “Programming parameter cannot be programmed...” message appears, select “OK”.

7.

Close the “Programming complete...” dialogue box by selecting “OK”.

8.

The “Programming parameter cannot be programmed...” message will reappear. Then select “OK”.

9.

Start engine. Run until operating temperature is reached and verify proper operation of all components (TM 5-3805291-10). Check for active diagnostic codes by selecting “Active Diagnostic Codes” from the “Diagnostics” menu (WP 0006 00).

10.

Disconnect ET (WP 0005 00).

END OF WORK PACKAGE

0056 00-6

8 TM 5-3805-291-23-2

ENGINE ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT

0057 00

THIS WORK PACKAGE COVERS System Configuration Parameters, Copy Configuration from ECM, Remove ECM, Install ECM, Flash Programming, Copy Configuration (Program ECM)

INITIAL SETUP References


WP 0005 00 WP 0006 00


WP 0096 00



Adapter, test (Item 3, WP 0232 00) Software kit (Item 75, WP 0232 00)



Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10)

Wrench, torque, dial, 3/8” drive, 300 lb-in. (Item 97, WP 0232 00)

Wheels chocked

Materials/Parts

Hood opened (TM 5-3805-291-10)


Drawings Required

Strap, tiedown, electrical components (Item 42, WP 0233 00)

TM 5-3805-291-23P, Figure 52 Estimated Time to Complete Task


2.0 hr

CAUTION •


•


NOTE If mission dictates, you may need to remove an ECM from an engine that is not in service. Refer to the following procedures to ensure that the configuration parameters match those in the faulty ECM. Be sure to clear any logged codes if you use a substitute ECM.

0057 00-1

TM 5-3805-291-23-2

ENGINE ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED

0057 00

SYSTEM CONFIGURATION PARAMETERS 00057 00 System configuration parameters are parameters that affect emissions, engine power, and machine applications. Default values for the parameters are programmed at the factory. Some parameters (such as Engine Fan Control or Ether Solenoid Configuration) may be changed to suit the needs of the specific application. Other parameters, such as Full Load Setting (FLS) or Full Torque Setting (FTS), should not be changed unless the engine is rerated or a new ECM is installed. FLS and FTS are stamped on the engine information ratings plate located on the engine (TM 5-3805-291-10). These parameters are protected from unauthorized change by passwords. View and/or change parameters using the Configuration Tool on the toolbar or by selecting “Configuration” from the “Service” menu in ET. The Configuration display area in ET has four columns: Description, Value, Unit, and TT. The Description column gives the name of the parameter. The Unit column displays the configuration parameter units. The TT column displays the list of the total tattletales, which represent the number of times the configuration parameter value has changed. The push-buttons in the Configuration screen are “Change” or “Print”. The “Change” push-buttons allow you to change the configuration values. This is only enabled if the parameter’s configuration can be changed. Parameters that cannot be changed have a yellow key symbol on the left. The ECM Replacement function in ET copies the relevant configuration parameters from one ECM to the other. Table 1 lists the system configuration parameters, data range, default value, and unit for the 966H Wheel Loader. Table 1. Configuration Parameters. PARAMETER DESCRIPTION


RANGE OF VALUES

DEFAULT VALUE

INPUT

Product ID

Registration Number 8 characters

Blank

Customer Defined

Equipment ID

Serial Number/VIN

4 characters

Blank

Customer Defined

Engine Serial Number

Engine Data Plate

8 characters

Blank

Customer Defined

ECM Part Number

ECM

9 characters

From Factory

ECM Serial Number

ECM

10 characters

From Factory

ECM Software Group Part Number

9 characters

FLASH

ECM Software Release Date


ECM Software Group Description

7 characters

FLASH

APR07

FLASH

Full Load Setting

Engine Data Plate

2 characters

COPY CONFIG

Full Torque Setting

Engine Data Plate

2 characters

COPY CONFIG


Record all diagnostic codes before replacing ECM (WP 0006 00).

b.


c.

Remove the ECM. Refer to Remove ECM in this work package.

d.

Install the new ECM. Refer to Install ECM in this work package.

e.


f.


TM 5-3805-291-23-2

ENGINE ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED COPY CONFIGURATION FROM ECM

0057 00 00057 00


1.


NOTE ET lists Engine ECM as “C11-966H”.

2.


3.


4.


5.

The “No data is available” dialogue box is displayed. Press “Yes” to “Load the data from the ECM”.

6.


NOTE As the data is loading from the ECM, the “Please wait...” message displays, Then the “Loading data from the ECM...” progress bar is displayed. You may cancel the process at any time by pressing the “Cancel” push-button. The “Are you sure...” dialogue box is displayed. Press “Yes” to cancel loading the data or “No” not to cancel.

7.

“The current ECM Replacement data...Load from...” message appears. Click the “OK” button.


8.


9.

Wait for the message “ECM Replacement data saved successfully”, then click “OK”.

10.

Select “Disconnect” from the “File” menu or click the “Disconnect Tool” button on the toolbar.

11.

Proceed to Remove ECM in this work package.

0057 00-3

TM 5-3805-291-23-2

ENGINE ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED REMOVE ECM

0057 00 00057 00


NOTE •

Follow troubleshooting procedures in this manual to ensure replacing the ECM will correct the problem.

•

Ensure all diagnostic codes are noted before removing ECM.

1.

Disconnect battery cables from batteries (WP 0096 00).

2.

Remove bolt (1), nut (2), two washers (3), and clamps (4 and 5) from hydraulic hoses (6 and 7).

427-C2022

0057 00-4

TM 5-3805-291-23-2


0057 00

REMOVE ECM - CONTINUED 3.

Cut and discard three tiedown straps (8) from wiring harness (9).

4.

Loosen two bolts (10) on wiring harness (9).

5.

Disconnect wiring harness (9) from ECM (11).

6.

Remove two bolts (12) and washers (13) from brackets (14).

7.

Remove two brackets (14) from ECM (11).

8.

Remove screw (15) and two ground wires (16).

9.

Remove two nuts (17), brackets (18), four washers (19), mounts (20), and two spacers (21) from ECM (11).

10.

Remove two bolts (22), washers (23), four mounts (24), and two spacers (25) from ECM (11).

11.

Remove ECM (11) from machine.

INSTALL ECM

00057 00

1.

Position ECM (11) on machine.

2.

Install two spacers (25), four mounts (24), two washers (23), and bolts (22) on ECM (11).

3.

Install two spacers (21), four mounts (20), washers (19), two brackets (18), and nuts (17) on ECM (11).

4.

Connect two ground wires (16) and install screw (15).

5.

Position two brackets (14) on ECM (11).

6.

Install two washers (13) and bolts (12) on brackets (14).

7.

Connect wiring harness (9) to ECM (11).

8.

Tighten two bolts (10) on wiring harness (9) to 53 ± 9 lb-in. (6 ± 1 Nm).

9.

Install three new tiedown straps (8) on wiring harness (9).

10.

Install clamps (5 and 4) on hydraulic hoses (7 and 6) with two washers (3), nut (2), and bolt (1).

11.


12.

Proceed to Flash Programming in this work package. 0057 00-5

TM 5-3805-291-23-2


0057 00

FLASH PROGRAMMING 1.

Turn battery disconnect switch to ON position (TM 5-3805-291-10).

2.


NOTE ET lists Engine ECM as “C11-966H”.

3.


4.

Insert flash file CD and read the “read me” file. Note the correct ECM flash file and folder name.

5.


6.

Highlight the ECM.

7.


8.


9.


10.


NOTE If any error messages are received during the flash programming, click “Cancel” to stop the process, then verify the file and engine being flashed match. Repeat steps 3 thru 10 until the flash programming is completed and you see “Flash Completed Successfully”.

11.

Select ET from the button options.


12.


COPY CONFIGURATION (PROGRAM ECM) 1.


2.


3.


4.


5.

“Programming Conflict Warning” will appear. Click “OK.” 0057 00-6

TM 5-3805-291-23-2


0057 00

COPY CONFIGURATION (PROGRAM ECM) - CONTINUED

NOTE As the data is loading to the ECM, the “Testing ECM...” message displays. You may cancel the process at any time by pressing the “Cancel” push-button. The “Are you sure...” dialogue box is displayed. Press “Yes” to cancel loading the data or “No” not to cancel.

6.

If the “The following parameters cannot be programmed...” message appears, select “OK”.

7.

Close the “The Programming complete...” dialogue box by selecting “OK”.

8.

The “The following parameters cannot be programmed...” message will reappear. Then select “OK”.

9.


10.

Disconnect ET (WP 0005 00). Table 2. Engine ECM Replacement. PARAMETER Engine Fan Control

VALUE ON

Low System Battery Voltage Elevated

Enabled

Ether Solenoid Configuration

Continuous Flow Solenoid

Engine Fan Reversing Feature

Disabled

Engine Warm-Up Elevated Idle Feature Enable Status

Enabled

Machine Working Engine Low Idle Speed Configuration Machine Hibernating Engine Low Idle Speed Configuration END OF WORK PACKAGE

0057 00-7/(0057 00-8 Blank)

950.0 rpm 6,000.0 rpm

6 TM 5-3805-291-23-2

HOOD TILT ACTUATOR REPLACEMENT

0058 00

THIS WORK PACKAGE COVERS Removal, Installation INITIAL SETUP Maintenance Level








Wheels chocked

Bracket, link (Item 17, WP 0232 00)

Steering frame lock connected (TM 5-3805-29110)

Lifting equipment, 600-lb capacity


Materials/Parts

Drawings Required


TM 5-3805-291-23P, Figure 57

Personnel Required



1.0 hr


0058 00-1

TM 5-3805-291-23-2

HOOD TILT ACTUATOR REPLACEMENT - CONTINUED

0058 00

REMOVAL 1.

Remove plug (1) from hood (2).

427-C0277

WARNING


NOTE The hood weighs 400 lb (181 kg). 2.

Install link bracket on hood (2) in hole from which plug (1) was removed.

3.

Attach lifting equipment to link bracket and hood (2).

427-C0278

0058 00-2

TM 5-3805-291-23-2


0058 00


Remove four bolts (3) and washers (4) from backup alarm (5). Position backup alarm aside.

5.

Remove four bolts (6), washers (7), and cover (8) from machine.

427-C0279

6.

Remove pin (9) and pin (10) from hood tilt actuator (11).

427-C0280

0058 00-3

TM 5-3805-291-23-2


0058 00


Disconnect connector (12) from chassis wiring harness (13).

8.

Remove pin (14) and pin (15) from tilt actuator (11).

9.

Remove tilt actuator (11) from machine.

427-C0281

INSTALLATION 1.

Place tilt actuator (11) in position and install pin (15) and pin (14) in tilt actuator.

2.

Connect connector (12) to chassis wiring harness (13).

3.

Install pin (10) and pin (9) in hood tilt actuator (11).

427-C0280

0058 00-4

TM 5-3805-291-23-2


0058 00


Place cover (8) in position and install four washers (7) and bolts (6) on cover.

5.

Place backup alarm (5) in position and install four washers (4) and bolts (3) on backup alarm.

427-C0279

WARNING


NOTE The hood weighs 400 lb (181 kg).

6.

Remove lifting equipment from link bracket and hood (2).

7.

Remove link bracket from hood (2).

427-C0278

0058 00-5

TM 5-3805-291-23-2


0058 00


Install plug (1) on hood (2).

9.

Close hood (TM 5-3805-291-10).

10.

Verify correct operation of hood (TM 5-3805-291-10).

427-C0277

WARNING Before operating the machine, secure the steering frame lock in the stowed position. DO NOT operate machine with steering frame lock connected. Failure to lock steering frame lock into the stowed position before operating can result in loss of steering and injury or death to personnel.

11.

Secure steering frame lock in stowed position (TM 5-3805-291-10).

END OF WORK PACKAGE

0058 00-6

2 TM 5-3805-291-23-2

HOOD TILT SWITCH AND WIRING HARNESS REPLACEMENT

0059 00

THIS WORK PACKAGE COVERS Removal, Installation



Unit

References


TM 5-3805-291-10


Equipment Conditions Control box cover removed (Hood Tilt Relay Removal in WP 0053 00)

Materials/Parts

Drawings Required


TM 5-3805-291-23P, Figures 56 and 72 Estimated Time to Complete Task 0.5 hr

Lockwasher


0059 00-1

TM 5-3805-291-23-2

HOOD TILT SWITCH AND WIRING HARNESS REPLACEMENT - CONTINUED

0059 00

REMOVAL 1.

Remove nut (4), lockwasher (5), switch cover (1), and toggle switch (3) from control box (2). Discard lockwasher.

483-1530

2.

Cut and remove tiedown strap (6) from wiring harnesses (7 and 8). Discard tiedown strap.

3.

Disconnect chassis wiring harness (7) from tilt switch wiring harness (8).

4.

Remove chassis wiring harness (7) from control box (2).

483-1531

INSTALLATION 1.

Position chassis wiring harness (7) in control box (2).

2.

Connect chassis wiring harness (7) to tilt switch wiring harness (8).

3.

Install new tiedown strap (6) on wiring harnesses (7 and 8).

4.

Install toggle switch (3), switch cover (1), new lockwasher (5), and nut (4) on control box (2).

5.

Install control box (Hood Tilt Relay Installation in WP 0053 00).

6.

Verify system operation (TM 5-3805-291-10).


6 TM 5-3805-291-23-2

IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT

0060 00

THIS WORK PACKAGE COVERS System Configuration Parameters, Copy Configuration from ECM, Remove ECM, Install ECM, Flash Programming, Copy Configuration (Program ECM)



Unit

WP 0006 00


WP 0096 00 Equipment Conditions






Parking brake engaged (TM 5-3805-291-10) Lockout switch set (TM 5-3805-291-10)

Wrench, torque, dial, 3/8” drive, 300 lb-in. (Item 97, WP 0232 00) Materials/Parts

Wheels chocked Drawings Required


TM 5-3805-291-23P, Figure 53

Personnel Required



2.0 hr

CAUTION •


•


NOTE If mission dictates, you may need to remove an ECM from an engine that is not in service. Refer to the following procedure to ensure the configuration parameters match those in the faulty ECM. Be sure to clear any logged codes if you use a substitute ECM.

0060 00-1

TM 5-3805-291-23-2

IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED SYSTEM CONFIGURATION PARAMETERS

0060 00 00060 00

System configuration parameters are parameters that affect emissions, engine power, and machine applications. Default values for the parameters are programmed at the factory. Some parameters (such as Joystick Installation Status or Dump Kickout Enable Status) may be changed to suit the needs of the specific application. Other parameters (such as Autodig Installation Status or Security System immobilizer Installation Status) are protected from unauthorized change by passwords. View and/or change parameters using the Configuration Tool on the toolbar or by selecting “Configuration” from the “Service” menu in ET. The Configuration display area in ET has four columns: Description, Value, Unit, and TT. The Description column gives the name of the parameter. The Unit column displays the configuration parameter units. The TT column displays the list of the total tattletales, which represent the number of times the configuration parameter value has changed. The push-buttons in the Configuration screen are “Change” or “Print”. The Change push-buttons allow you to change the configuration values. This is only enabled if the parameter’s configuration can be changed. Parameters that cannot be changed have a yellow key symbol on the left. The ECM Replacement function in ET copies the relevant configuration parameters from one ECM to the other. Table 1 lists the system configuration parameters, data range, default value, and unit for the 966H Wheel Loader. Table 1. Configuration Parameters. Parameter Description

Definition/ location

Product ID


Blank

Customer Defined

Equipment ID

Serial Number

9 characters

Blank

Customer Defined

ECM Part Number

ECM

9 characters

From Factory

ECM Serial Number

ECM

10 characters

From Factory


9 characters

FLASH




13 characters

Range of Values

Default Value Input

APR07

FLASH

FLASH



b.


c.


d.


e.


f.


TM 5-3805-291-23-2

IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED COPY CONFIGURATION FROM ECM

0060 00 00060 00


1.


2.


3.


4.


5.


6.


NOTE As the data is loading from the ECM, the “Loading data from the ECM...” progress bar is displayed. You may cancel the process at any time by pressing the “Cancel” push-button. The “Are you sure...” dialogue box is displayed. Press “Yes” to cancel loading the data or “No” not to cancel.

7.



8.


9.


10.


11.


0060 00-3

TM 5-3805-291-23-2

IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED REMOVE ECM

0060 00 00060 00


NOTE •


1.

• Ensure that all diagnostic codes are noted before removing ECM. Disconnect battery cables from batteries (WP 0096 00).

2.

Remove three screws (1) and two screws (2) from interior panel (3).

3.

Remove interior panel (3) from machine.

0060 00-4

TM 5-3805-291-23-2

IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED

0060 00


Disconnect upper cab wiring harness (4) from lower cab wiring harness (5).

5.


6.

Remove four bolts (8), washers (9), spacers (10), rear washers (11), and ground strap (12) from ECM (7).

7.


8.

Remove eight mounts (13) from ECM (7).

INSTALL ECM 1.

Install eight mounts (13) on ECM (7).

2.


3.

Install ground strap (12), four rear washers (11), spacers (10), washers (9), and bolts (8) on ECM (7).

4.


5.

Tighten socket-head screw for connectors to 53 lb-in. (6 Nm).

6.

Connect upper cab wiring harness (4) to lower cab wiring harness (5).

7.

Install interior panel (3), two screws (2), and three screws (1) on machine.

8.


9.


FLASH PROGRAMMING 1. Turn battery disconnect switch to ON position (TM 5-3805-291-10). 2. Connect ET to MSD and start ET (WP 0005 00). 3. Highlight the ECM and click “OK”.

00060 00

4.


5.

Select “WinFlash” from the “Utilities” menu in ET. “WinFlash” will attempt to detect an ECM. Read and close the WinFlash Quick Help Guide. 0060 00-5

TM 5-3805-291-23-2

IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED FLASH PROGRAMMING - CONTINUED

0060 00 00060 00

6.

Highlight the ECM.

7.


8.


9.


10.



11.

Select ET from the button options.

NOTE If flash programming the ECM as directed by troubleshooting, proceed to step 12. If replacing an ECM, proceed to the Copy Configuration (Program ECM) in this work package.

12.




2.


3.


4.


5.

If the “Programming parameter cannot be programmed...” message appears, select “OK”.

6.


7.

Start engine. Turn lockout switch off (TM 5-3805-291-10). Run until operating temperature is reached and verify proper operation of all components (TM 5-3805-291-10). Check for active diagnostic codes by selecting “Active Diagnostic Codes” from the “Diagnostics” menu (WP 0006 00).

8.



4 TM 5-3805-291-23-2

MAIN LIGHT SWITCH AND ARCTIC HEATER SWITCH REPLACEMENT

0061 00

THIS WORK PACKAGE COVERS Main Light Switch: Removal, Installation Arctic Heater Switch: Removal, Installation INITIAL SETUP Equipment Conditions

Maintenance Level





Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10)


Drawings Required


TM 5-3805-291-23P, Figure 56

Personnel Required




0061 00-1

TM 5-3805-291-23-2

MAIN LIGHT SWITCH AND ARCTIC HEATER SWITCH REPLACEMENT - CONTINUED

0061 00

MAIN LIGHT SWITCH REMOVAL

0061 00

NOTE Tag wiring harness prior to removal to ensure correct installation. 1.

Remove four screws (1) and cover (2) from control box (3).

2.

Remove four screws (4), washers (6), and main light switch (5) from control box (3).

3.

Remove nut (7) and disconnect wiring harness (8) from main light switch (5).

MAIN LIGHT SWITCH INSTALLATION

0061 00

1.

Connect wiring harness (8) and install nut (7) on main light switch (5).

2.

Install main light switch (5), four washers (6), and screws (4) on control box (3).

3.

Verify correct operation of switch (TM 5-3805-29110).

4.

Install cover (2) and four screws (1) on control box (3). 0061 00-2

TM 5-3805-291-23-2

MAIN LIGHT SWITCH AND ARCTIC HEATER SWITCH REPLACEMENT - CONTINUED

0061 00

ARCTIC HEATER SWITCH REMOVAL

0061 00

1.

Remove four screws (9) and cover (2) from control box (3).

483-1533

NOTE Tag leads prior to removal to ensure correct installation. 2.

Disconnect arctic heater switch (10) from wiring harness (8).

3.

Remove nut (11) and arctic heater switch (10) from control box (3).

ARCTIC HEATER SWITCH INSTALLATION 0061 00 1.

Install arctic heater switch (10) and nut (11) on control box (3).

2.

Connect arctic heater switch (10) to wiring harness (8).

3.

Verify correct operation of switch (TM 5-3805-29110).

4.

Install cover (2) on control box (3) with four screws (9).

END OF WORK PACKAGE

0061 00-3/(0061 00-4 Blank)

4 TM 5-3805-291-23-2

POWER CONVERTER REPLACEMENT

0062 00








Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00)



TM 5-3805-291-23P, Figure 54

Personnel Required




0062 00-1

TM 5-3805-291-23-2

POWER CONVERTER REPLACEMENT - CONTINUED REMOVAL 1.

Remove three bolts (1), washer (2), and strap (3) from rear panel (4).

2.

Remove two bolts (6), plastic washers (5), and rear panel (4) from cab.

3.

Disconnect cab harness (8) from power converter (7).

4.

Remove three bolts (9) and power converter (7) from cab.

0062 00-2

0062 00

TM 5-3805-291-23-2

POWER CONVERTER REPLACEMENT - CONTINUED

0062 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION 1.

Install power converter (7) in cab with three bolts (9).

2.

Connect cab harness (8) to power converter (7).

0062 00-3

TM 5-3805-291-23-2

POWER CONVERTER REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 3.

Install rear panel (4) in cab with two plastic washers (5) and bolts (6).

4.

Install three bolts (1), washer (2), and strap (3) on rear panel (4).

5.

Switch on machine (TM 5-3805-291-10).

6.

Check for correct operation of rearview camera (TM 5-3805-291-10).

7.

Switch off machine (TM 5-3805-291-10).

8.

Close hood (TM 5-3805-291-10)

END OF WORK PACKAGE.

0062 00-4

0062 00

12 TM 5-3805-291-23-2

POWERTRAIN ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT

0063 00

THIS WORK PACKAGE COVERS System Configuration Parameters, Copy Configuration from ECM (Load from ECM), Remove ECM, Install ECM, Flash Programming, Copy Configuration (Program ECM)


References

Unit

WP 0005 00 WP 0006 00



Adapter, test (Item 3, WP 0232 00) Software kit (Item 75, WP 0232 00)




Materials/Parts

Wheels chocked


Drawings Required TM 5-3805-291-23P, Figure 53 Estimated Time to Complete Task


2.0 hr

CAUTION •


•


NOTE If mission dictates, you may need to remove an ECM from an engine that is not in service. Refer to the following procedure to ensure the configuration parameters match those in the faulty ECM. Be sure to clear any logged codes if you use a substitute ECM.

0063 00-1

TM 5-3805-291-23-2

POWERTRAIN ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED

0063 00

SYSTEM CONFIGURATION PARAMETERS

00063 00

System configuration parameters are parameters that affect emissions, engine power, and machine applications. Default values for the parameters are programmed at the factory. Some parameters (such as Transmission Maximum Forward Gear and Transmission Maximum Reverse Gear) may be changed to suit the needs of the specific application. Other parameters, such as Ground Speed Limiter Installation Status and Automatic Differential Lock Feature Status, are protected from unauthorized change by passwords. View and/or change parameters using the Configuration Tool on the toolbar or by selecting “Configuration” from the “Service” menu in ET. The Configuration display area in ET has four columns: Description, Value, Unit, and TT. The Description column gives the name of the parameter. The Unit column displays the configuration parameter units. The TT column displays the list of the total tattletales, which represent the number of times the configuration parameter value has changed. The push-buttons in the Configuration screen are “Change” or “Print”. The “Change” push-buttons allow you to change the configuration values. This is only enabled if the parameter’s configuration can be changed. Parameters that cannot be changed have a yellow key symbol on the left. The ECM Replacement function in ET copies the relevant configuration parameters from one ECM to the other. Table 1 below lists the system configuration parameters, data range, default value, and unit for the 966H Wheel Loader. Table 1. Configuration Parameters. PARAMETER DESCRIPTION


RANGE OF VALUES

DEFAULT VALUE

INPUT

Product ID


Blank

Customer Defined

Equipment ID

Serial Number

9 characters

Blank

Customer Defined

Transmission Serial Number

Transmission Data Plate

8 characters

Blank

Customer Defined

ECM Part Number

ECM

9 characters

From Factory

ECM Serial Number

ECM

10 characters

From Factory


9 characters

FLASH




6 characters

APR07

FLASH

FLASH



b.


c.


d.


e.


f.


TM 5-3805-291-23-2


0063 00

COPY CONFIGURATION FROM ECM


NOTE ET lists Powertrain ECM as “Transmission ECM”.

1.


2.


3.


4.


5.


6.


NOTE As the data is loading from the ECM, the “Please wait...” message displays, Then the “Loading data from the ECM...” progress bar is displayed. You may cancel the process at any time by pressing the “Cancel” push-button. The “Are you sure...” dialogue box is displayed. Press “Yes” to cancel loading the data or “No” not to cancel.

7.



8.


9.


10.


11.


0063 00-3

TM 5-3805-291-23-2

POWERTRAIN ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED REMOVE ECM

0063 00 00063 00


NOTE •


•

Ensure that all diagnostic codes are noted before removing ECM.

1.

Disconnect battery cables from batteries (WP 0096 00).

2.


427-C0135

3.


427-C0136

0063 00-4

TM 5-3805-291-23-2


0063 00



427-C0137

5.


427-C0138

0063 00-5

TM 5-3805-291-23-2


0063 00



427-C0139

7.


427-C0140

8.


9.


427-C0141

0063 00-6

TM 5-3805-291-23-2


0063 00


Remove and discard tiedown strap (12) from wiring harness (13).

11.


12.

Remove four bolts (15), washers (16), spacers (17), rear washers (18), and ground strap (19) from ECM (14).

13.


14.

Remove eight mounts (20) from ECM (14).

427-C0337

INSTALL ECM 1.

Install eight mounts (20) on ECM (14).

2.


3.

Install ground strap (19), four rear washers (18), ECM (14), spacers (17), washers (16), and bolts (15) on machine.

4.


5.


6.


7.

Attach new tiedown strap (12) to wiring harness (13).

8.


9.


10.


0063 00-7

TM 5-3805-291-23-2


0063 00

INSTALL ECM - CONTINUED 11.


427-C0138

12.


427-C0137

13.


14.


427-C0136

0063 00-8

TM 5-3805-291-23-2


0063 00

INSTALL ECM - CONTINUED 15.

Install tray (2) and three screws (1).

427-C0135

16.


17.


FLASH PROGRAMMING

00063 00

1.


2.


NOTE ET lists Powertrain ECM as “Transmission ECM”.

3.


4.


5.


6.

Highlight the ECM.

7.


8.


9.


10.



11.

Select ET from the button options. 0063 00-9

TM 5-3805-291-23-2

POWERTRAIN ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED FLASH PROGRAMMING - CONTINUED

0063 00 00063 00


12.




2.

Ensure the correct ECM is highlighted, Select “Copy Configuration” from the “Service menu”, then select “ECM Replacement” from the sub-menu.

3.


4.


5.


6.


7.


0063 00-10

TM 5-3805-291-23-2

POWERTRAIN ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT - CONTINUED COPY CONFIGURATION (PROGRAM ECM) - CONTINUED

00063 00

Table 2. Powertrain ECM Replacement. PARAMETER

VALUE

Transmission Maximum Forward Gear

4

Transmission Maximum Reverse Gear

4

Ground Speed Limiter Installation Status

Not Installed

Forward to Reverse Desired Gear

2

Reverse to Forward Desired Gear

2

CTS Enabled

Enabled

Ride Control Configuration

Improved (2-valve)

Ride Control Forward Activation Speed

6.0 mph

Ride Control Reverse Activation Speed

6.0 mph

Ride Control Pressure Equalization Time Secondary Steering

3 Seconds Installed

Command Control Steering Installation Configuration Integrated Braking System Manual Mode Enabled Status

Not Installed Enabled

Differential Lock Installation Configuration

Not Installed

Advanced Machine Security System Installation Status

Not Installed

Sunday Security System Bypass Start Time

Disabled or Not Installed

Sunday Security System Bypass Stop Time


Monday Security System Bypass Start Time


Monday Security System Bypass Stop Time


Tuesday Security System Bypass Start Time


Tuesday Security System Bypass Stop Time


Wednesday Security System Bypass Start Time


Wednesday Security System Bypass Stop Time


Thursday Security System Bypass Start Time


Thursday Security System Bypass Stop Time


Friday Security System Bypass Start Time


Friday Security System Bypass Stop Time


Saturday Security System Bypass Start Time


Saturday Security System Bypass Stop Time



0063 00

4 TM 5-3805-291-23-2

STOPLIGHT LIMIT SWITCH MAINTENANCE

0064 00

THIS WORK PACKAGE COVERS Removal, Installation, Adjustment


Maintenance Level








Materials/Parts

TM 5-3805-291-23P, Figure 56



Personnel Required

0.5 hr



0064 00-1

TM 5-3805-291-23-2

STOPLIGHT LIMIT SWITCH MAINTENANCE - CONTINUED

0064 00

REMOVAL 1.

Remove six bolts (1) from LH brake pedal assembly (2). Remove brake cover (3) from brake pedal assembly.

2.

Remove two screws (4) from stoplight limit switch (5).

3.

Disconnect connectors (6 and 7) from stoplight limit switch (5).

4.

Remove stoplight limit switch (5) from brake pedal assembly (2).

427-C0096

427-C0098

INSTALLATION 1.

Position stoplight limit switch (5) in brake pedal assembly (2).

2.

Connect connectors (6 and 7) to stoplight limit switch (5).

3.

Install two screws (4) on stoplight limit switch (5).

4.

Install brake cover (3) on brake pedal assembly (2). Install six bolts (1) on brake pedal assembly.

0064 00-2

TM 5-3805-291-23-2

STOPLIGHT LIMIT SWITCH MAINTENANCE - CONTINUED

0064 00

ADJUSTMENT 1.

Remove plug (8) from brake pedal assembly (2).

2.

Ensure brake pedal is in RELEASED position, then turn adjustment screw (9) clockwise until stoplights turn OFF.

427-C0099

NOTE Stoplights should turn ON after approximately 7 degrees of pedal travel.

3.

Operate brake pedal several times while checking stoplight limit switch and stoplight operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0064 00-3/(0064 00-4 Blank)

2 TM 5-3805-291-23-2

TURNLAMP FLASHER REPLACEMENT

0065 00

THIS WORK PACKAGE COVERS Removal, Installation INITIAL SETUP Personnel Required



Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00)

Equipment Conditions Right rear interior panel removed (WP 0138 00) Drawings Required TM 5-3805-291-23P, Figure 55

Materials/Parts Estimated Time to Complete Task


0.5 hr



0065 00-1

TM 5-3805-291-23-2

TURNLAMP FLASHER REPLACEMENT - CONTINUED

0065 00

REMOVAL 1.

Disconnect wiring harness (1) from turnlamp flasher (2).

2.

Remove bolt (3), washer (4), and turnlamp flasher (2) from machine.

427-C1335

INSTALLATION 1.

Install turnlamp flasher (2), washer (4), and bolt (3) on machine.

2.

Connect wiring harness (1) to turnlamp flasher (2).

3.

Install right rear interior panel (WP 0138 00).

4.

Verify correct turnlamp operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0065 00-2

4 TM 5-3805-291-23-2

TURNLAMP SWITCH REPLACEMENT

0066 00







Wheels chocked

Materials/Parts

Parking brake engaged (TM 5-3805-291-10) Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required


TM 5-3805-291-23P, Figure 55




0.5 hr

REMOVAL


0066 00-1

TM 5-3805-291-23-2

TURNLAMP SWITCH REPLACEMENT - CONTINUED

0066 00


Remove plate (1) from lever (2).

2.

Remove screw (3) and washer (4) from turnlamp lever (2).

3.

Remove lever (2) from turnlamp switch (5).

4.

Remove four screws (6), washers (7), and cover (8) from turnlamp switch (5).

427-C1314

0066 00-2

TM 5-3805-291-23-2

TURNLAMP SWITCH REPLACEMENT - CONTINUED

0066 00


Remove three screws (9) from turnlamp switch (5).

427-C1315

NOTE Tag wires prior to removal to ensure correct installation.

6.

Disconnect six wires (10) from turnlamp switch (5).

7.

Remove turnlamp switch (5) from bracket (11).

INSTALLATION 1.

Position turnlamp switch (5) on bracket (11).

2.

Connect six wires (10) to turnlamp switch (5).

3.

Install three screws (9) on turnlamp switch (5).

4.

Install cover (8), four screws (6), and washers (7) on turnlamp switch (5).

427-C1316

5.

Install lever (2) on turnlamp switch (5).

6.

Install washer (4) and screw (3) on lever (2).

7.

Install plate (1) on lever (2).

8.

Verify correct turnlamp operation (TM 5-3805-291-10).


2 TM 5-3805-291-23-2

WINDSHIELD WIPER SWITCHES REPLACEMENT

0067 00







Materials/Parts


Rag, wiping (Item 35, WP 0233 00) Personnel Required

Drawings Required


TM 5-3805-291-23P, Figure 49

References


WP 0055 00


0067 00-1

TM 5-3805-291-23-2

WINDSHIELD WIPER SWITCHES REPLACEMENT - CONTINUED

0067 00

REMOVAL 1.

Loosen two setscrews (1) on two knobs (2) and remove knobs from panel (3).

427-C0468-1

2.

Remove panel (3) from machine (WP 0055 00).

3.

Remove two nuts (4) and washers (5) from switches (6).

4.

Remove switches (6) from panel (3).

427-C0295

INSTALLATION 1.

Install switches (6) in panel (3).

2.

Install two washers (5) and nuts (4) on switches (6).

3.

Install panel (3) in machine (WP 0055 00).

4.

Install two knobs (2) and tighten two setscrews (1) on knobs.

5.

Verify windshield wiper switch operation (TM 5-3805-291-10).


2 TM 5-3805-291-23-2

BLACKOUT DRIVE LIGHT REPLACEMENT

0068 00


Maintenance Level







Drawings Required

Lockwasher

TM 5-3805-291-23P, Figure 58

Personnel Required




0068 00-1

TM 5-3805-291-23-2

BLACKOUT DRIVE LIGHT REPLACEMENT - CONTINUED REMOVAL 1.

Remove four bolts (7), washers (8), and plate (6) from headlamp housing (9).

2.

Disconnect blackout drive light (1) from wiring harness (5).

3.

Remove bolt (3), two washers (4), nut (10), and ground lead (2) from blackout drive light (1).

4.

Remove blackout drive light (1) from headlamp housing (9).

INSTALLATION 1.

Position blackout drive light (1) on headlamp housing (9).

2.

Install ground lead (2), nut (10), two washers (4), and bolt (3) on blackout drive light (1).

3.

Connect blackout drive light (1) to wiring harness (5).

4.

Install plate (6) on headlamp housing (9) with four washers (8) and bolts (7).

5.

Verify correct operation of blackout drive light (TM 5-3805-291-10).

END OF WORK PACKAGE

0068 00-2

0068 00

6 TM 5-3805-291-23-2

DOME LAMP REPLACEMENT

0069 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation INITIAL SETUP References

Maintenance Level

TM 5-3805-291-10

Unit



Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10)





Personnel Required

Wheels chocked

Drawings Required


0069 00-1

TM 5-3805-291-23-2

DOME LAMP REPLACEMENT - CONTINUED

0069 00

REMOVAL 1.

Remove light lens (1) from dome lamp (3).

2.

Remove switch cover (2) from dome lamp (3).

3.

Remove incandescent lamp (4) from dome lamp (3).

4.

Remove three screws (5) from dome lamp (3).

0069 00-2

TM 5-3805-291-23-2


0069 00


Disconnect electrical connector (6) and remove dome lamp (3) from cab.


WARNING •


•


1.

Clean mating surfaces with solvent cleaning compound.

2.


3.

Inspect parts for wear, pitting, cracks, or corrosion and replace if necessary.

0069 00-3

TM 5-3805-291-23-2


0069 00

INSTALLATION 4.

Position dome lamp (3) in cab and connect electrical connector (6).

5.

Install three screws (5) on dome lamp (3).

0069 00-4

TM 5-3805-291-23-2

DOME LAMP REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 6.

Install incandescent lamp (4) on dome lamp (3).

7.

Install switch cover (2) on dome lamp (3).

8.

Install light lens (1) on dome lamp (3).

END OF WORK PACKAGE

0069 00-5/(0069 00-6 Blank)

0069 00

6 TM 5-3805-291-23-2

STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT

0070 00


Maintenance Level







Drawings Required


TM 5-3805-291-23P, Figure 58

Personnel Required




0070 00-1

TM 5-3805-291-23-2

STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT - CONTINUED

NOTE •


•

Procedure describes removal of one rear lamp housing. Repeat procedure to remove other housings.

REMOVAL 1.

Remove bolt (1) and washer (2) from clamp (3).

2.

Remove clamp (3) from taillamp wiring (4).

0070 00-2

0070 00

TM 5-3805-291-23-2

STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT - CONTINUED REMOVAL - CONTINUED 3.

Disconnect wiring harness (6) from five connectors (5).

4.

Remove six screws (8) and stoplight (7) from bracket (9).

0070 00-3

0070 00

TM 5-3805-291-23-2

STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT - CONTINUED REMOVAL - CONTINUED 5.

Remove two bolts (10) and washers (11) from bracket (9).

6.

Remove bracket (9) from machine.

0070 00-4

0070 00

TM 5-3805-291-23-2

STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT - CONTINUED

0070 00

INSTALLATION 1.

Install bracket (9) on machine.

2.

Install two washers (11) and bolts (10) on bracket (9).

3.

Install stoplight (7) on bracket (9) with six screws (8).

483-1538

0070 00-5

TM 5-3805-291-23-2

STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT - CONTINUED INSTALLATION – CONTINUED 4.

Connect wiring harness (6) to five connectors (5).

5.

Install clamp (3) on taillamp wiring (4).

6.

Install washer (2) and bolt (1) on clamp (3).

7.

Verify correct operation of all rear lights (TM 5-3805291-10).


0070 00

12 TM 5-3805-291-23-2

SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT

0071 00

THIS WORK PACKAGE COVERS Service Light: Removal, Installation Turnlamp: Removal, Installation Service Light, Housing Assembly, and Wiring Harness: Removal, Installation



Unit





Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked

Materials/Parts

Battery disconnect switch in OFF position (TM 5-3805-291-10)

Rag, wiping (Item 35, WP 0233 00) Bulbs

Drawings Required

Locknut (2)

TM 5-3805-291-23P, Figure 58

Personnel Required




0071 00-1

TM 5-3805-291-23-2

SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT - CONTINUED SERVICE LIGHT REMOVAL

0071 00

0071 00

NOTE Procedure describes removal of one service light. Repeat procedure to remove other service lights. 1.

Remove four bolts (1) and washers (2) from rear cover (3).

2.

Remove rear cover (3) from housing (4).

427-C0430

3.

Disconnect wiring harness (5) from service light (6).

427-C0431

4.

Remove locknut (7) and washer (8) from bolt (9). Discard locknut.

5.

Remove service light (6) from housing (4).

427-C0432

0071 00-2

TM 5-3805-291-23-2

SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT - CONTINUED

0071 00

SERVICE LIGHT REMOVAL - CONTINUED 6.

Remove locknut (10), bolt (11), and washer (12) from bracket (13). Discard locknut.

7.

Remove bracket (13) from service light (6).

427-C0433

8.

Remove three brackets (14) from service light (6).

427-C1257

9.

Remove two washers (15), rubber washers (16), and bolt (9) from bracket (13).

427-C1258

0071 00-3

TM 5-3805-291-23-2

SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT - CONTINUED SERVICE LIGHT REMOVAL - CONTINUED 10.

Remove two screws (18), retainer (17), and light housing (19) from service light (6).

11.

Disconnect bulb (20) from lamp connector (22).

12.

Release clip (21) and remove bulb (20) from light housing (19).

0071 00-4

0071 00

TM 5-3805-291-23-2


0071 00

SERVICE LIGHT INSTALLATION

CAUTION Do not touch bulb with bare hands. 1.

Secure bulb (20) in lamp housing (19) with a clip (21).

2.

Connect bulb (20) to lamp connector (22).

3.

Install light housing (19) and retainer (17) in service light (6) with two screws (18).

427-C1258

0071 00-5

TM 5-3805-291-23-2


0071 00

SERVICE LIGHT INSTALLATION – CONTINUED 4.

Install bolt (9), two rubber washers (16), and washers (15) on bracket (13).

427-C1258

5.

Install three brackets (14) on service light (6).

427-C1257

0071 00-6

TM 5-3805-291-23-2


0071 00

SERVICE LIGHT INSTALLATION - CONTINUED 6.

Place bracket (13) on service light (6) and install washer (12), bolt (11), and new locknut (10) on bracket (13).

427-C0433

7.

Place service light (6) in housing (4) and install washer (8) and new locknut (7) on bolt (9).

427-C0432

0071 00-7

TM 5-3805-291-23-2


0071 00

SERVICE LIGHT INSTALLATION - CONTINUED 8.

Connect wiring harness (5) to service light (6).

427-C0431

9.

Place rear cover (3) on housing (4).

10.

Install four washers (2) and bolts (1) on rear cover (3).

11.

Verify correct operation of service light (TM 5-3805-291-10).

427-C0430

0071 00-8

TM 5-3805-291-23-2


0071 00

TURNLAMP REMOVAL

0071 00

1.

Remove service light (6) from housing (29). Refer to Service Light Removal in this work package.

2.

Disconnect turnlamp wiring harness (23) from connector (24).

3.

Remove bolt (26), washer (25), and connector (24) from housing (29).

4.

Remove three bolts (28), washers (30), and bracket (27) with turnlamp (33) from housing (29).

5.

Remove three nuts (31) and washers (32) from turnlamp (33).

6.

Remove turnlamp (33) from bracket (27).

0071 00-9

TM 5-3805-291-23-2

SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT - CONTINUED TURNLAMP REMOVAL – CONTINUED 7.

Remove two screws (34) and lens (33) from turnlamp (27).

8.

Remove bulb (35) from turnlamp (27).

TURNLAMP INSTALLATION 1.

Install bulb (35) in turnlamp (27).

2.

Install lens (33) on turnlamp (27) with two screws (34).

0071 00-10

0071 00

TM 5-3805-291-23-2

SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT - CONTINUED TURNLAMP INSTALLATION –CONTINUED 3.

Place turnlamp (33) on bracket (27).

4.

Install three washers (32) and nuts (31) on turnlamp (33).

5.

Install bracket (27) with turnlamp (33) in housing (29) with three bolts (28) and washers (30).

6.

Install connector (24) on housing (29) with washer (25) and bolt (26).

7.

Connect turnlamp wiring harness (23) to connector (24).

8.

Install service light (6) in housing (29). Refer to Service Light Installation in this work package.

9.

Verify correct operation of turnlamp (TM 5-3805-291-10).

0071 00-11

0071 00

TM 5-3805-291-23-2


0071 00

SERVICE LIGHT, HOUSING ASSEMBLY, AND WIRING HARNESS REMOVAL 1.

Remove service light from housing. Refer to Service Light Removal in this work package.

2.

Remove turnlamp from housing. Refer to Turnlamp Removal in this work package.

3.

Remove blackout drive light (WP 0068 00).

4.

Disconnect wiring harness (26) from connector (27).

5.

Remove four bolts (28) and washers (29) from housing (4).

6.

Remove housing (4) from machine.

7.

Remove wiring harness (26) from housing (4).

427-C1260

SERVICE LIGHT, HOUSING ASSEMBLY, AND WIRING HARNESS INSTALLATION 1.

Install wiring harness (26) in housing (4).

2.

Install housing (4) on machine.

3.

Install four bolts (28) and washers (29) on housing (4).

4.

Connect wiring harness (26) to connector (27).

5.

Install blackout drive light (WP 0068 00).

6.

Install turnlamp. Refer to Turnlamp Installation in this work package.

7.

Install service light in housing. Refer to Service Light Removal in this work package.

8.

Verify correct operation of service light (TM 5-3805-291-10).

END OF WORK PACKAGE

0071 00-12

4 TM 5-3805-291-23-2

WORKLIGHTS MAINTENANCE

0072 00

THIS WORK PACKAGE COVERS Bulb: Removal, Installation Lamp Housing: Removal, Installation INITIAL SETUP Equipment Conditions

Maintenance Level







Drawings Required


TM 5-3805-291-23P, Figure 59

Personnel Required




NOTE Procedure describes removal of one bulb. Repeat procedure to remove other bulbs.

0072 00-1

TM 5-3805-291-23-2

WORKLIGHTS MAINTENANCE - CONTINUED

0072 00

BULB REMOVAL

0072 00

1.

Remove two screws (1) from grill (2).

2.

Remove grill (2) and lamp cover (3) from lamp housing (4).

427-C0421

3.

Pull lamp (5) away from lamp housing (4).

NOTE Tag wires prior to removal to ensure correct installation. 4.

Disconnect wiring harness (6) and ground lead (7) from lamp (5).

5.

Remove lamp (5) from lamp housing (4).

427-C0422

0072 00-2

TM 5-3805-291-23-2


0072 00

BULB REMOVAL - CONTINUED

0072 00

6.

Pinch retaining clip (8) to release bulb (9) from locked position.

427-C0423

7.

Remove bulb (9) from lamp (5).

427-C0424

BULB INSTALLATION 1.

Install bulb (9) in lamp (5).

2.

Pinch retaining clip (8) and latch bulb (9) in place.

3.

Position lamp (5) near lamp housing (4).

4.

Connect wiring harness (6) and ground lead (7) to lamp (5).

5.

Install lamp (5) on lamp housing (4).

6.

Install cover (3) and grill (2) on lamp housing (4).

7.

Install two screws (1) on grill (2). 0072 00-3

TM 5-3805-291-23-2


0072 00

LAMP HOUSING REMOVAL

0072 00

1.

Disconnect wiring harness (10) from lamp housing (4).

427-C0425

2.


3.

Remove lamp housing (4) from bracket (13).

427-C0426

LAMP HOUSING INSTALLATION 1.

Install lamp housing (4) on bracket (13).

2.


3.

Connect wiring harness (10) to lamp housing (4).

4.


5.

Verify correct light operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0072 00-4

2 TM 5-3805-291-23-2

ATMOSPHERIC PRESSURE SENSOR REPLACEMENT

0073 00








Materials/Parts Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00)


Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)

Hood opened (TM 5-3805-291-10) Drawings Required


TM 5-3805-291-23P, Figure 61

O-ring



0.5 hr


0073 00-1

TM 5-3805-291-23-2

ATMOSPHERIC PRESSURE SENSOR REPLACEMENT - CONTINUED

0073 00

REMOVAL 1.

Disconnect atmospheric pressure sensor wiring harness connector (1) from wiring harness (2).

2.

Remove atmospheric pressure sensor (3) and O-ring (4) from turbo charger air inlet (5). Discard O-ring.

483-1409

INSTALLATION 1.

Lubricate new O-ring (4) with a thin coat of clean oil. Install O-ring and atmospheric pressure sensor (3) on turbocharger air inlet (5).

2.

Connect atmospheric pressure sensor wiring harness connector (1) to wiring harness (2).

3.

Run engine and check for correct engine operation (TM 5-3805-291-10).

4.

Shut down engine (TM 5-3805-291-10).

5.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0073 00-2

2 TM 5-3805-291-23-2

BOOST PRESSURE SENSOR REPLACEMENT

0074 00


INITIAL SETUP Personnel Required

Maintenance Level


Unit










Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)



Wheels chocked

Drawings Required TM 5-3805-291-23P, Figure 61 Estimated Time to Complete Task 0.5 hr

O-ring


0074 00-1

TM 5-3805-291-23-2

BOOST PRESSURE SENSOR REPLACEMENT - CONTINUED

0074 00

REMOVAL 1.

Remove and discard five tiedown straps (1) from wiring harness (2).

2.

Disconnect sensor lead (2) from wiring harness (3).

3.

Remove boost pressure sensor (4) from machine.

4.

Remove O-ring (5) from boost pressure sensor (4). Discard O-ring.

427-C0094

INSTALLATION 1.

Lubricate new O-ring (5) with a thin coat of clean oil. Install new O-ring on boost pressure sensor (4).

2.

Install boost pressure sensor (4) on machine.

3.

Connect wiring harness (3) to sensor lead (2).

4.

Install five new tiedown straps (1) on wiring harness (3).

5.


6.


7.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0074 00-2

4 TM 5-3805-291-23-2

BRAKE PEDAL POSITION SENSOR REPLACEMENT

0075 00



Maintenance Level


Unit






Materials/Parts

Drawings Required


TM 5-3805-291-23P, Figure 65 Personnel Required




0075 00-1

TM 5-3805-291-23-2

BRAKE PEDAL POSITION SENSOR REPLACEMENT - CONTINUED

0075 00

REMOVAL 1.

Remove six bolts (1) from brake pedal assembly (2). Remove brake cover (3) from brake pedal assembly.

427-C0096

2.

Remove two screws (4) from brake pedal position sensor (5).

3.

Remove brake pedal position sensor (5) from brake pedal assembly (2).

427-C0095

0075 00-2

TM 5-3805-291-23-2

BRAKE PEDAL POSITION SENSOR REPLACEMENT - CONTINUED INSTALLATION 1.

Place brake pedal position sensor (5) on brake pedal assembly (2).

2.

Install two screws (4) on brake pedal position sensor (5).

3.

Place brake cover (3) on brake pedal assembly (2). Install six bolts (1) on brake pedal assembly.

4.

Operate brake pedal assembly (2) several times to verify brake operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0075 00-3/(0075 00-4 Blank)

0075 00

4 TM 5-3805-291-23-2

CAMSHAFT SPEED/TIMING SENSOR (SECONDARY) REPLACEMENT

0076 00









Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)








Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) (3)


O-ring

0.5 hr


0076 00-1

TM 5-3805-291-23-2

CAMSHAFT SPEED/TIMING SENSOR (SECONDARY) REPLACEMENT - CONTINUED REMOVAL 1.

Remove and discard three tiedown straps (1) from wiring harness (2).

2.

Disconnect wiring harness (2) from camshaft speed/timing sensor connector (3).

3.

Remove bolt (4) and washer (5) from camshaft speed/timing sensor (6).

4.

Remove camshaft speed/timing sensor (6) and O-ring (7). Discard O-ring.

427-C0271

0076 00-2

0076 00

TM 5-3805-291-23-2

CAMSHAFT SPEED/TIMING SENSOR (SECONDARY) REPLACEMENT - CONTINUED

0076 00

INSTALLATION 1.

Lubricate new O-ring (7) with a thin coat of clean oil. Install new O-ring on camshaft speed/timing sensor (6) then place in position.

2.

Install washer (5) and bolt (4) in camshaft speed/timing sensor (6). Tighten bolt to 21 ± 5 lb-ft (28 ± 7 Nm).

3.

Connect wiring harness (2) to camshaft speed/timing sensor connector (3).

4.

Install three new tiedown straps (1) around wiring harness (2).

5.

Run engine until normal operating temperature is reached (TM 5-3805-291-10).

6.


7.

Check for oil leaks.

8.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0076 00-3/(0076 00-4 Blank)

2 TM 5-3805-291-23-2

COOLANT TEMPERATURE SENSOR REPLACEMENT

0077 00




Unit




Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts

Coolant drained below level of sensor (WP 0041 00) Drawings Required

Antifreeze (Item 1, WP 0233 00)

TM 5-3805-291-23P, Figure 61



O-ring

•

WARNING •

DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant may result in serious burns.

•

DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may result in serious burns to personnel.

•

Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may result in injury to personnel.

•

When servicing this machine, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845.

•

Ensure battery disconnect switch is in OFF position before performing this task. Failure to follow this warning may result in injury to personnel or damage to equipment.

•

0077 00-1

TM 5-3805-291-23-2

COOLANT TEMPERATURE SENSOR REPLACEMENT - CONTINUED

0077 00

REMOVAL 1.

Disconnect coolant temperature sensor wiring harness connector (1) from coolant temperature sensor (2).

2.

Remove coolant temperature sensor (2) and O-ring (3) from engine. Discard O-ring.

427-C0253

INSTALLATION 1.

Lubricate new O-ring (3) with coolant and install Oring and coolant temperature sensor (2) on engine.

2.

Connect coolant temperature sensor wiring harness connector (1) to coolant temperature sensor (2).

3.


4.


5.

Fill cooling system (WP 0041 00).

6.

Check for cooling system leaks.

7.

Close hood (TM 5-3805-291-10).

427-C0254

END OF WORK PACKAGE

0077 00-2

2 TM 5-3805-291-23-2

CRANKSHAFT SPEED/TIMING SENSOR (PRIMARY) REPLACEMENT

0078 00




Unit






Materials/Parts




Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)


O-ring


0078 00-1

TM 5-3805-291-23-2

CRANKSHAFT SPEED/TIMING SENSOR (PRIMARY) REPLACEMENT - CONTINUED

0078 00

REMOVAL 1.

Remove nut (1) and washer (2) from oil pan stud (3).

2.

Remove connector (4) from clamp (5).

3.

Disconnect connector (4) from engine wiring harness (6).

4.

Remove bolt (7) and washer (8) from crankshaft speed/timing sensor (9).

5.

Remove crankshaft speed/timing sensor (9), wiring harness (10), and O-ring (11). Discard O-ring.

427-C0272

INSTALLATION 1.

Lubricate new O-ring (11) with a thin coat of clean oil. Install new O-ring in wiring harness (10) and then place crankshaft speed/timing sensor (9) in position.

2.

Install washer (8) and bolt (7) in crankshaft speed/timing sensor (9).

3.

Connect connector (4) to engine wiring harness (6).

4.

Install connector (4) on clamp (5).

5.

Install washer (2) and nut (1) on oil pan stud (3).

6.


7.


8.



2 TM 5-3805-291-23-2

ENGINE OIL PRESSURE SENSOR REPLACEMENT

0079 00



Maintenance Level


Unit













Wheels chocked


O-ring


0079 00-1

TM 5-3805-291-23-2

ENGINE OIL PRESSURE SENSOR REPLACEMENT - CONTINUED

0079 00

REMOVAL 1.

Remove and discard tiedown strap (1) from clamp (2).

2.

Remove wiring harness clamp (3) from wiring harness (4).

3.

Disconnect oil pressure sensor wiring harness connector (5) from oil pressure sensor wiring harness (6).

4.

Remove engine oil pressure switch (7) and O-ring (8) from engine. Discard O-ring.

INSTALLATION 1.

Lubricate new O-ring (8) with a thin coat of clean oil. Install O-ring and engine oil pressure switch (7) on engine.

2.

Connect oil pressure sensor wiring harness connector (5) to oil pressure sensor wiring harness (6).

3.

Install wiring harness clamp (3) on wiring harness (4).

4.

Install new tiedown strap (1) on clamp (2).

5.

Check oil level (TM 5-3805-291-10).

6.


7.


8.


9.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0079 00-2

4 TM 5-3805-291-23-2

FUEL LEVEL SENDING UNIT REPLACEMENT

0080 00










Materials/Parts


Rag, wiping (Item 35, WP 0233 00) Gasket cement (Item 14, WP 0233 00)

Drawings Required



Personnel Required

1.0 hr



0080 00-1

TM 5-3805-291-23-2

FUEL LEVEL SENDING UNIT REPLACEMENT - CONTINUED

0080 00

REMOVAL

WARNING DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

1.

Remove and discard tiedown strap (6) from sending unit wire (3).

2.

Remove nut (4), washer (5), and sending unit connector (2) from machine.

3.

Disconnect sending unit connector (2) from wiring harness (1).

4.

Remove five bolts (7) and washers (8) from fuel level sending unit (9).

5.

Remove fuel level sending unit (9) from fuel tank (10).

0080 00-2

TM 5-3805-291-23-2

FUEL LEVEL SENDING UNIT REPLACEMENT - CONTINUED

0080 00

INSTALLATION

WARNING DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

NOTE Apply thin coat of gasket cement to fuel sending unit prior to installation.

1.

Install fuel level sending unit (9) on fuel tank (10).

2.

Install five washers (8) and bolts (7) on fuel level sending unit (9).

3.

Connect sending unit connector (2) to wiring harness (1).

4.

Install nut (4), washer (5), and sending unit connector (2) on machine.

5.

Install new tiedown strap (6) on sending unit wire (3).

6.

Set battery disconnect switch to ON position (TM 5-3805-291-10).

7.

Set engine start switch to ON position (TM 5-3805-291-10).

8.

Check fuel level gage for correct fuel level sending unit operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0080 00-3/(0080 00-4 Blank)

2 TM 5-3805-291-23-2

FRONT AND REAR AXLE OIL TEMPERATURE SENSORS REPLACEMENT

0081 00








Materials/Parts

Wheels chocked

Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Oil, lubricating, TO-4 (Item 31, WP 0233 00)



TM 5-3805-291-23P, Figure 65

O-ring (2)


Personnel Required

0.5 hr



0081 00-1

TM 5-3805-291-23-2

FRONT AND REAR AXLE OIL TEMPERATURE SENSORS REPLACEMENT - CONTINUED

NOTE The procedure for replacing the rear axle oil temperature is the same as for the front.

REMOVAL 1.

Remove two bolts (1) and shield (2).

2.

Disconnect wiring harness connector (3) from temperature sensor (4).

3.

Remove temperature sensor (4) and O-ring (5) from machine. Discard O-ring.

427-C0275

INSTALLATION 1.

Lubricate new O-ring (5) with a thin coat of clean oil. Install new O-ring and temperature sensor (4) on machine.

2.

Connect wiring harness connector (3) to temperature sensor (4).

3.

Install shield (2) and two bolts (1).

4.


5.


6.

Check for leaks.

END OF WORK PACKAGE

0081 00-2

0081 00

4 TM 5-3805-291-23-2

FUEL TEMPERATURE SENSOR REPLACEMENT

0082 00









Materials/Parts


Diesel fuel, DF-1 (Item 10, WP 0233 00) Fuel oil, diesel, DF-2 (Item 11, WP 0233 00)


Fuel, turbine, aviation (Item 12, WP 0233 00)

Drawings Required


TM 5-3805-291-23P, Figure 61

O-ring



0.5 hr

WARNING •

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

•


•


0082 00-1

TM 5-3805-291-23-2

FUEL TEMPERATURE SENSOR REPLACEMENT - CONTINUED

0082 00

REMOVAL

NOTE Connector has a lock tab that has to be released in order to disconnect. 1.

Disconnect fuel temperature sensor connector (1) from fuel temperature sensor (2).

2.

Remove fuel temperature sensor (2) and O-ring (3) from engine. Discard O-ring.

427-C0254

0082 00-2

TM 5-3805-291-23-2

FUEL TEMPERATURE SENSOR REPLACEMENT - CONTINUED INSTALLATION 1.

Lubricate new O-ring (3) with clean fuel. Install fuel temperature sensor (2) with new O-ring on engine.

2.

Connect fuel temperature sensor connector (1) to fuel temperature sensor (2).

3.


4.


5.

Check for fuel system leaks.

6.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0082 00-3/(0082 00-4 Blank)

0082 00

4 TM 5-3805-291-23-2

HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT

0083 00






References


TM 5-3805-291-10 Equipment Conditions

Materials/Parts

Air cleaner removed (WP 0030 00)

Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)

Hydraulic tank drained (WP 0148 00) Drawings Required




3.5 hr

O-ring


0083 00-1

TM 5-3805-291-23-2

HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT - CONTINUED

0083 00

REMOVAL 1.

Remove two bolts (1) and washers (2) from clamps (3) and remove clamps from machine.

2.

Position refrigerant dryer (4) and accumulator (8) aside.

3.

Remove three bolts (5) and washers (6) from sound suppression panel (7) and remove sound suppression panel from machine.

0083 00-2

TM 5-3805-291-23-2

HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT - CONTINUED

0083 00


At bottom of hydraulic tank (9), disconnect chassis wiring harness (10) from hydraulic oil temperature sensor (11).

5.

Remove hydraulic oil temperature sensor (11) and O-ring (12) from hydraulic tank (9). Discard O-ring.

INSTALLATION 1.

Apply a thin coat of clean oil to new O-ring (12). Install new O-ring on hydraulic oil temperature sensor (11).

2.

Install hydraulic oil temperature sensor (11) on hydraulic tank (9).

3.

Connect chassis wiring harness (10) to hydraulic oil temperature sensor (11).

4.

Position sound suppression panel (7) on machine and install three washers (6) and bolts (5) on sound suppression panel.

5.

Position accumulator (8) refrigerant dryer (4) and two clamps (3) on machine and install two washers (2) and bolts (1) on clamps.

6.

Install air cleaner (WP 0030 00).

7.

Fill hydraulic oil tank (WP 0148 00).

8.

Operate machine and verify correct operation of AC and hydraulic system (TM 5-3805-291-10).

9.


10.

Check for leaks.


2 TM 5-3805-291-23-2

INTAKE MANIFOLD AIR TEMPERATURE SENSOR REPLACEMENT

0084 00











Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Materials/Parts

Hood opened (TM 5-3805-291-10) Drawings Required


TM 5-3805-291-23P, Figure 61

O-ring


Personnel Required

0.5 hr



0084 00-1

TM 5-3805-291-23-2

INTAKE MANIFOLD AIR TEMPERATURE SENSOR REPLACEMENT - CONTINUED

0084 00

REMOVAL 1.

Disconnect connector (1) from intake manifold air temperature sensor (2).

2.

Remove intake manifold air temperature sensor (2) and O-ring (3) from manifold (4). Discard O-ring.

427-C0259

INSTALLATION 1.

Install new O-ring (3) and intake manifold air temperature sensor (2) in manifold (4). Tighten intake manifold air temperature sensor to 15 ± 4 lb-ft (20 ± 5 Nm).

2.

Connect connector (1) to intake manifold air temperature sensor (2).

3.


4.


5.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0084 00-2

6 TM 5-3805-291-23-2

LIFT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT

0085 00


Maintenance Level


Unit






Materials/Parts

Drawings Required


TM 5-3805-291-23P, Figure 64 Personnel Required




0085 00-1

TM 5-3805-291-23-2

LIFT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT - CONTINUED

0085 00

REMOVAL 1.

Remove nut (1) from arm (2).

2.

Remove rod end (3) from arm (2).

3.

Remove two bolts (4) and washers (5) from arm (2).

4.

Remove arm (2) from machine.

427-C0283

5.

Remove nut (6) from bracket (7).

6.

Disconnect connector (8) from lift position sensor (9).

427-C0284

7.

Remove two nuts (10) and washers (11) from bracket (7).

427-C0285

0085 00-2

TM 5-3805-291-23-2


0085 00


Remove wiring harness (12) from clip (13).

9.

Remove two bolts (14), washers (15), and plate (16) from rod end (17).

10.

Remove five bolts (18), washers (19 and 20), and nuts (21) from bracket (7).

11.

Remove tilt position sensor (22) from bracket (7).

427-C0286

0085 00-3

TM 5-3805-291-23-2


0085 00

INSTALLATION 1.

Place tilt position sensor (22) on bracket (7).

2.

Install five nuts (21), washers (20 and 19), and bolts (18) on bracket (7).

3.

Install plate (16), two washers (15), and bolts (14) on rod end (17).

4.

Install wiring harness (12) on clip (13).

427-C0286

5.

0085 00-4

TM 5-3805-291-23-2


0085 00


Install two washers (11) and nuts (10) on bracket (7).

427-C0285

6.

Connect connector (8) to lift position sensor (9).

7.

Install nut (6) on bracket (7).

427-C0284

0085 00-5

TM 5-3805-291-23-2


0085 00


Position arm (2) on machine.

9.

Install two washers (5) and bolts (4) on arm (2).

10.

Install rod end (3) on arm (2).

11.

Install nut (1) on arm (2).

427-C0283

12.

Verify correct lift kickout operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0085 00-6

4 TM 5-3805-291-23-2

PARKING BRAKE OIL PRESSURE SWITCH REPLACEMENT

0086 00

THIS WORK PACKAGE COVERS Removal, Installation INITIAL SETUP Materials/Parts - Continued

Maintenance Level



O-ring


Personnel Required







Materials/Parts

Wheels chocked

Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figure 65 Estimated Time to Complete Task 0.5 hr



0086 00-1

TM 5-3805-291-23-2

PARKING BRAKE OIL PRESSURE SWITCH REPLACEMENT - CONTINUED REMOVAL 1.

Remove and discard tiedown strap (1) from parking brake oil pressure switch (2).

2.

Disconnect wiring harness (3) from parking brake oil pressure switch (2).

3.

Remove parking brake oil pressure switch (2) and O-ring (4) from machine. Discard O-ring.

0086 00-2

0086 00

TM 5-3805-291-23-2

PARKING BRAKE OIL PRESSURE SWITCH REPLACEMENT - CONTINUED

0086 00

INSTALLATION 1.

Lubricate new O-ring (4) with a thin coat of clean oil. Install new O-ring and parking brake oil pressure switch (2) on machine. Tighten parking brake oil pressure switch to 35 ± 4 lb-ft (48 ± 5 Nm).

2.

Connect wiring harness (3) to parking brake oil pressure switch (2).

3.

Install new tiedown strap (1) on parking brake oil pressure switch (2).

4.

Check brake fluid level (TM 5-3805-291-10).

5.


6.


7.

Check for leaks.

8.

Operate parking brake several times to verify correct parking brake pedal operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0086 00-3/(0086 00-4 Blank)

2 TM 5-3805-291-23-2

SERVICE BRAKE OIL PRESSURE SWITCH REPLACEMENT

0087 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)

O-ring Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions Right side cover removed (WP 0135 00)

Materials/Parts Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)



0087 00-1

TM 5-3805-291-23-2

SERVICE BRAKE OIL PRESSURE SWITCH REPLACEMENT - CONTINUED

0087 00

REMOVAL 1.


2.

Remove clamp (3) from wiring harness (4).

427-C1555

3.

Disconnect wiring harness (5) from engine wiring harness (4).

4.

Remove service brake oil pressure switch (6) from T (7). Remove and discard O-ring (8).

427-C1556

INSTALLATION 1.

Lubricate new O-ring (8) with clean oil. Install new O-ring in service brake oil pressure switch (6).

2.

Install service brake oil pressure switch (6) on T (7). Tighten switch to 35 ± 4 lb-ft (48 ± 5 Nm).

3.

Connect wiring harness (5) to engine wiring harness (4).

4.

Install clamp (3) on wiring harness (4).

5.


6.

Install right side cover (WP 0135 00).

7.


8.


9.


10.



2 TM 5-3805-291-23-2

STEERING OIL PRESSURE SWITCHES REPLACEMENT

0088 00


INITIAL SETUP Materials/Parts - Continued

Maintenance Level



O-ring (2)


Personnel Required







Materials/Parts

Wheels chocked


Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figure 65 Estimated Time to Complete Task 0.5 hr



0088 00-1

TM 5-3805-291-23-2

STEERING OIL PRESSURE SWITCHES REPLACEMENT - CONTINUED

0088 00

REMOVAL 1.

Remove and discard tiedown strap (1) from connector (2).

2.

Disconnect connectors (2 and 3) from wiring harness (4).

3.

Remove two steering oil pressure switches (5) and Orings (6) from machine. Discard O-rings.

INSTALLATION 1.

Lubricate two new O-rings (6) with a thin coat of clean oil, then install O-rings and steering oil pressure switches (5) on machine. Tighten steering oil pressure switches to 55 ± 5 lb-ft (75 ± 7 Nm).

2.

Connect connectors (2 and 3) to wiring harness (4).

3.

Install new tiedown strap (1) on connector (2).

4.

Check steering fluid level (TM 5-3805-291-10).

5.


6.


7.

Check for steering fluid leaks.


6 TM 5-3805-291-23-2

TILT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT

0089 00






Parking brake engaged (TM 5-3805-291-10) Wheel chocked

Materials/Parts


Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Personnel Required




0089 00-1

TM 5-3805-291-23-2

TILT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT - CONTINUED REMOVAL 1.

Remove four bolts (2), washers (3), and cover (1) from machine.

0089 00-2

0089 00

TM 5-3805-291-23-2

TILT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT - CONTINUED REMOVAL - CONTINUED 2.

Disconnect wiring harness (4) from tilt kickout position sensor (6).

3.

Remove bolt (23), washer (5), clip (24), and spacer (12) from bracket (13).

4.

Remove two bolts (15), washers (16), and tilt arm (17) from machine.

5.

Remove bolt (21) and sleeve (20) from tilt arm (17).

6.

Remove two bolts (18), washers (19), and plate assembly (22) from tilt kickout position sensor (6).

7.

Remove five bolts (8), washers (9), clip (14), and tilt kickout position sensor (6) from bracket (13).

8.

Remove and discard tiedown strap (7) from tilt kickout position sensor (6).

9.

Remove two bolts (10), washers (11), spacers (12), and bracket (13) from machine.

483-1542

0089 00-3

0089 00

TM 5-3805-291-23-2

TILT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT - CONTINUED INSTALLATION 1.

Position bracket (13) on machine.

2.

Install two spacers (12), washers (11), and bolts (12) on bracket (13).

3.

Install new tiedown strap (7) on tilt kickout position sensor (6).

4.

Position tilt kickout position sensor (6) on bracket (13).

5.

Install five bolts (8), washers (9), and clip (14) on tilt kickout position sensor (6).

6.

Install two washers (19), bolts (18), and plate assembly (22) on tilt kickout position sensor (6).

7.

Install sleeve (20) and bolt (21) on tilt arm (17).

8.

Install two washers (16), bolts (15), and tilt arm (17) on machine.

9.

Install spacer (12), clip (24), washer (5), and bolt (23) on bracket (13).

10.

Connect wiring harness (4) to tilt kickout position sensor (6).

0089 00-4

0089 00

TM 5-3805-291-23-2

TILT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT - CONTINUED INSTALLATION - CONTINUED

NOTE Maintain a 0.1 to 0.2 in. gap between cover and tilt kickout position sensor. 11.

Position cover (1) on machine and install four washers (3) and bolts (2) on cover.

12.

Adjust tilt kickout position (TM 5-3805-291-10).

13.

Verify correct tilt kickout position sensor operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0089 00-5/(0089 00-6 Blank)

0089 00

2 TM 5-3805-291-23-2

TORQUE CONVERTER OIL TEMPERATURE SENSOR REPLACEMENT

0090 00





Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts

References TM 5-3805-291-10 Equipment Conditions

Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

Transmission oil drained (WP 0100 00) Drawings Required TM 5-3805-291-23P, Figure 62

Oil, lubricating, TO-4 (Item 31, WP 0233 00)


Rag, wiping (Item 35, WP 0233 00) O-ring

0.5 hr


0090 00-1

TM 5-3805-291-23-2

TORQUE CONVERTER OIL TEMPERATURE SENSOR REPLACEMENT - CONTINUED REMOVAL 1.

At right side of machine, disconnect engine wiring harness (1) from sensor (2).

2.

Remove oil temperature sensor (3) and O-ring (4) from cooler tube (5). Discard O-ring.

INSTALLATION 1.

Apply a thin coat of clean oil to new O-ring (4). Install new O-ring on temperature sensor (3).

2.

Install oil temperature sensor (3) on cooler tube (5).

3.

Connect engine wiring harness (1) to sensor (2).

4.

Fill transmission with oil (WP 0100 00).

5.


6.


7.

Check for leaks.


0090 00

4 TM 5-3805-291-23-2

TORQUE CONVERTER OUTPUT SPEED SENSOR REPLACEMENT

0091 00






References TM 5-3805-291-10 Equipment Conditions Left side cover removed (WP 0135 00) Drawings Required

Materials/Parts Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00)



1.0 hr

Seal


0091 00-1

TM 5-3805-291-23-2

TORQUE CONVERTER OUTPUT SPEED SENSOR REPLACEMENT - CONTINUED

0091 00

REMOVAL 1.

At top right of transmission, remove bolt (1), washer (2), and clip (3) from transmission flange (4).

2.

Remove bolt (5), washer (6), and clip (7) from transmission housing (8).

3.

Disconnect wiring harness (9) from torque converter output speed sensor (10).

4.

Remove torque converter output speed sensor (10) and seal (11) from transmission flange (4). Discard seal.

INSTALLATION 1.

Lubricate new seal (11) with a thin coat of clean oil. Install new seal on torque converter output speed sensor (10).

2.

Place torque converter output speed sensor (10) in transmission flange (4).

3.

Connect wiring harness (9) to torque converter output speed sensor (10).

4.

Install clip (7), washer (6), and bolt (5) on transmission housing (8).

5.

At top right of transmission, install clip (3), washer (2), and bolt (1) on transmission flange (4). 0091 00-2

TM 5-3805-291-23-2

TORQUE CONVERTER OUTPUT SPEED SENSOR REPLACEMENT - CONTINUED

0091 00

ADJUSTMENT 1.

Loosen nut (12) and remove torque converter output speed sensor (10) from transmission flange (4).

2.

Align gear tooth (13) directly in center of threaded sensor opening (14).

3.

Screw torque converter output speed sensor (10) into hole until end of sensor contacts gear tooth (13).

4.

Turn torque converter output speed sensor (10) counterclockwise 1/2 turn. This will set air gap (A) to 0.028 in. (0.71 mm).

5.

Tighten nut (12).

6.

Install left side cover (WP 0135 00).

A

427-C0413

7.

Close hood (TM 5-3805-291-10).

8.

Drive machine to verify correct operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0091 00-3/(0091 00-4 Blank)

4 TM 5-3805-291-23-2

TRANSMISSION OIL TEMPERATURE SENSORS REPLACEMENT

0092 00



Materials/Parts - Continued Strap, tiedown, electrical components (Item 42, WP 0233 00)

Unit

O-ring (2)


Personnel Required MOS 62B, Construction Equipment Repairer References

Materials/Parts

TM 5-3805-291-10

Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00)



Drawings Required


Transmission oil drained (WP 0100 00)




0092 00-1

TM 5-3805-291-23-2

TRANSMISSION OIL TEMPERATURE SENSORS REPLACEMENT - CONTINUED REMOVAL 1.

At right side of transmission, slide connector (1) off clip (2) on transmission housing (3).

2.

Disconnect oil temperature sensor connector (4) from wiring harness (5).

3.

Remove tiedown strap (6) from oil temperature sensor wiring (7). Discard tiedown strap.

4.

Remove oil temperature sensor (8) and O-ring (9) from adapter (10). Discard O-ring.

5.

Remove adapter (10) and O-ring (11) from transmission housing (3). Discard O-ring.

0092 00-2

0092 00

TM 5-3805-291-23-2

TRANSMISSION OIL TEMPERATURE SENSORS REPLACEMENT - CONTINUED INSTALLATION

NOTE Apply a thin coat of clean oil to all O-rings before installation.

1.

Install new O-ring (11) on adapter (10).

2.

Install adapter (10) on transmission housing (3).

3.

Install new O-ring (9) on oil temperature sensor (8).

4.

Install oil temperature sensor (8) in adapter (10).

5.

Secure oil temperature sensor wiring (7) to clip (2) with new tiedown strap (6).

6.

Connect wiring harness (5) to oil temperature sensor connector (4).

7.

Slide connector (1) onto clip (2) on transmission housing (3).

8.


9.


10.


11.

Check for leaks.

END OF WORK PACKAGE

0092 00-3/(0092 00-4 Blank)

0092 00

4 TM 5-3805-291-23-2

TRANSMISSION OUTPUT SPEED SENSOR REPLACEMENT

0093 00











Materials/Parts Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Hood opened (TM 5-3805-291-10) Drawings Required TM 5-3805-291-23P, Figure 62

Seal (2)


Personnel Required

1.0 hr



0093 00-1

TM 5-3805-291-23-2

TRANSMISSION OUTPUT SPEED SENSOR REPLACEMENT - CONTINUED REMOVAL

NOTE Perform steps 1 thru 4 to remove each of two transmission output speed sensors from transmission.

1.

At top front of transmission, remove bolt (1), washer (2), and clip (3) from transmission housing (4).

2.

Remove output speed sensor connector (5) from clip (3).

3.

Disconnect output speed sensor connector (5) from wiring harness (6).

4.

Remove transmission output speed sensor (7) and seal (8) from transmission housing (4). Discard seal.

INSTALLATION

NOTE Perform steps 1 thru 4 to install each of two transmission output speed sensors in transmission.

1.

Lubricate new seal (8) with a thin coat of clean oil. Install new seal on transmission output speed sensor (7).

2.

Install transmission output speed sensor (7) in transmission housing (4).

3.

Connect wiring harness (6) to output speed sensor connector (5).

4.

Install output speed sensor connector (5) in clip (3).

5.

Install clip (3), washer (2), and bolt (1) on transmission housing (4).

0093 00-2

0093 00

TM 5-3805-291-23-2

TRANSMISSION OUTPUT SPEED SENSOR REPLACEMENT - CONTINUED

0093 00

ADJUSTMENT 1.

Loosen nut (9) and remove transmission output speed sensor (7) from transmission housing (4).

2.

Align gear tooth (10) directly in center of threaded sensor opening (11).

3.

Screw transmission output speed sensor (7) into hole until end of sensor contacts gear tooth (10).

4.

Turn transmission output speed sensor (7) counterclockwise 1/2 turn. This will set air gap (A) to 0.028 in. (0.71 mm).

5.

Tighten nut (9).

427-C0503

6.

Close hood (TM 5-3805-291-10).

7.

Drive machine to verify correct operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0093 00-3/(0093 00-4 Blank)

2 TM 5-3805-291-23-2

BACKUP ALARM REPLACEMENT

0094 00

THIS WORK PACKAGE COVERS Removal, Installation INITIAL SETUP Equipment Conditions - Continued






Wheel chocked Battery disconnect switch in OFF position (TM 53805-291-10)



Personnel Required

Drawings Required


TM 5-3805-291-23P, Figure 67




0094 00-1

TM 5-3805-291-23-2

BACKUP ALARM REPLACEMENT - CONTINUED

0094 00

REMOVAL 1.

Remove nut (1), bracket (2), and ground wire (3).

2.

Disconnect chassis wiring harness (4) from connector (5).

3.

Remove four bolts (6) and washers (7) from backup alarm (8).

4.

Remove backup alarm (8) from machine.

INSTALLATION 1.

Position backup alarm (8) on machine.

2.

Install four washers (7) and bolts (6) on backup alarm (8).

3.

Connect chassis wiring harness (4) to connector (5).

4.

Install ground wire (3), bracket (2), and nut (1).

5.

Verify correct operation of backup alarm (TM 5-3805-291-10).

END OF WORK PACKAGE

0094 00-2

2 TM 5-3805-291-23-2

HORN REPLACEMENT

0095 00









Drawings Required


TM 5-3805-291-23P, Figure 66




0095 00-1

TM 5-3805-291-23-2

HORN REPLACEMENT - CONTINUED

0095 00

REMOVAL 1.

Disconnect two wiring harness connectors (1) from horns (2).

2.

Remove two bolts (3) and washers (4) from horns (2).

3.

Remove two horns (2) from machine.

INSTALLATION 1.

Position two horns (2) on machine.

2.

Install two washers (4) and bolts (3) on horns (2).

3.

Connect two wiring harness connectors (1) to horns (2).

4.

Set battery disconnect switch to ON position (TM 5-3805-291-10).

5.

Verify correct horn operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0095 00-2

6 TM 5-3805-291-23-2

BATTERIES REPLACEMENT

0096 00



Battery compartment door opened (TM 5-3805291-10)

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Lifting equipment, 150-lb capacity

Ladder removed (WP 0134 00) Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figure 68

Rag, wiping (Item 35, WP 0233 00) Estimated Time to Complete Task

Personnel Required MOS 62B, Construction Equipment Repairer (2)

1.2 hr

WARNING •

To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. Do not smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will cause instant heating, damage to equipment, and injury to personnel.

•


•

Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in injury or death to personnel. a. b. c. d.

•

Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may result in injury or death to personnel.

0096 00-1

TM 5-3805-291-23-2

BATTERIES REPLACEMENT - CONTINUED

0096 00

REMOVAL

WARNING Be careful not to touch tool used to disconnect cable clamp to any part of machine. Sparks may occur resulting in injury to personnel or damage to equipment.

NOTE •

Steps 1 thru 10 remove two batteries from upper battery compartment. Steps 11 thru 19 remove two batteries from lower battery compartment for machines equipped with arctic heater.

•

Disconnect negative (black) cable first.

1.

Pull back cover (1) on cable clamp (19).

2.

Loosen nut (18) and disconnect cable clamp (19) on cable (2) from battery (17).

3.

Pull back two covers (3 and 9) from cable clamps (16).

4.

Loosen two nuts (15) and disconnect two cable clamps (16) from batteries (14 and 17).

5.

Remove battery cable (7) from machine.

6.


7.


0096 00-2

TM 5-3805-291-23-2


0096 00


Remove two nuts (5) and washers (6) from rod (4) battery hold down (8).

9.

Remove battery hold down (8) from batteries (14 and 17).

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may cause injury or death to personnel.

NOTE •

Standard battery weighs 119 lb (54 kg).

•

Arctic battery weighs 60 lb (27 kg).

10.

With assistance, remove two batteries (14 and 17) from upper battery compartment (20).

11.


12.


13.


14.


15.

Remove nut (26) and washer (27) from battery hold down (28).

16.

Remove battery hold down (28) from batteries (33 and 34).

17.

With assistance, remove batteries (33 and 34) from lower battery compartment (20).

18.

Pull back two covers (22) on cable clamps (24).

19.

Loosen two nuts (23) and disconnect cable clamps (24) on cable (25) from batteries (33 and 34).

0096 00-3

TM 5-3805-291-23-2


0096 00

INSTALLATION 1.

Install battery cable (25) on batteries (33 and 34).

2.

Tighten two nuts (23) on cable clamps (24) and install two covers (22) on cable clamps.


NOTE •

Standard battery weighs 119 lb (54 kg).

•

Arctic battery weighs 60 lb (27 kg).

3.

With assistance, position batteries (33 and 34) in lower battery compartment (20).

4.

Install battery hold down (28) on batteries (33 and 34).

5.

Install washer (27) and nut (26) on battery hold down (28).

6.

Connect cable clamp (32) on cable (29) to battery (33) and tighten nut (31).

7.

Install cover (30) on cable clamp (32).

8.


9.


10.

With assistance, position batteries (14 and 17) in upper battery compartment (20).

11.

Install battery hold down (8) on batteries (14 and 17).

12.

Install two washers (6) and nuts (5) on battery hold down (8) and rod (4).

0096 00-4

TM 5-3805-291-23-2

BATTERIES REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 13.


14.

Install cover (11) over cable clamp (13).

15.

Position cable (7) on machine.

16.

Connect two cable clamps (16) to batteries (14 and 17) and tighten nuts (12).

17.

Install covers (3 and 9) on cable clamps (16).

18.

Install ladder (WP 0134 00).

19.


20.


21.

Close battery compartment door (TM 5-3805-291-10).

22.

Start engine to verify correct operation of electrical system (TM 5-3805-291-10).

23.



0096 00

12 TM 5-3805-291-23-2

BATTERY CABLES REPLACEMENT

0097 00


Maintenance Level

Left rear fender removed (WP 0137 00)

Unit Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts

Left upper chassis guard panel removed (WP 0133 00) Battery cables disconnected from battery disconnect switch (WP 0098 00) Battery cables disconnected from batteries (WP 0096 00)


Drawings Required

Personnel Required

TM 5-3805-291-23P, Figures 70 and 167



References

2.0 hr

TM 5-3805-291-10

0097 00-1

TM 5-3805-291-23-2

BATTERY CABLES REPLACEMENT - CONTINUED REMOVAL 1.

Remove two bolts (2), small washers (3), large washers (1), spacers (5), and clamps (4) from battery box (6).

2.

Remove two bolts (7), washers (8), and four clips (9) from cable (10).

3.

Pull back protective cover (11) on terminal (12).

4.

Loosen nut (13) and remove cable (10) from junction (14).

5.

Remove cable (10) from machine.

0097 00-2

0097 00

TM 5-3805-291-23-2

BATTERY CABLES REPLACEMENT - CONTINUED REMOVAL - CONTINUED

0097 00-3

0097 00

TM 5-3805-291-23-2

BATTERY CABLES REPLACEMENT - CONTINUED

0097 00


Remove four nuts (15), washers (16), and clips (17) from cable (18).

7.

Remove nine bolts (19), washers (20), and clips (17) from cable (18).

8.

Pull back protective cover (21) from starter terminal (22).

9.

Remove nut (23), washer (24), and cable (18) from starter terminal (22).

10.


483-1343

0097 00-4

TM 5-3805-291-23-2


0097 00


Pull back protective cover (25) on cable terminal (26).

12.

Remove nut (27), washer (28), and cable (29) from junction block (30).

13.

Remove three clips (17) from cable (29).

14.

Remove two bolts (31), washers (32), and clips (17) from cable (29).

15.

Pull back protective cover (33) on cable terminal (34).

16.

Remove nut (35), washer (36), and cable (29) from alternator terminal (37).

17.


483-1546

0097 00-5

TM 5-3805-291-23-2


0097 00


Remove two nuts (38), washers (39), and disconnect positive cables (40) from junction block (30).

19.

Remove two bolts (41) and washers (42) from NATO slave receptacle (43).

20.

Remove three bolts (44), washers (45), five clamps (46), two positive cables (40), and cable (47) from machine.

0097 00-6

TM 5-3805-291-23-2

BATTERY CABLES REPLACEMENT - CONTINUED INSTALLATION 1.


2.

Install cable (10) and tighten nut (13) on junction (14).

3.

Install protective cover (11) on terminal (12).

4.

Install four clips (9), two washers (8), and bolts (7) on cable (10).

0097 00-7

0097 00

TM 5-3805-291-23-2

BATTERY CABLES REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 5.


6.

Install cable (18), washer (24), and nut (23) on starter terminal (22).

7.

Install protective cover (21) on starter terminal (22).

8.

Install nine clips (17), washers (20), and bolts (19) on cable (18).

9.

Install four clips (17), washers (16), and nuts (15) on cable (18).

0097 00-8

0097 00

TM 5-3805-291-23-2


Install cable (47), two positive cables (40), five clamps (46), three washers (43), and bolts (44).

11.

Install two washers (42) and bolts (41) on NATO slave receptacle (43).

12.

Install two positive cables (40), washers (39), and nuts (38) on junction block (30).

0097 00-9

0097 00

TM 5-3805-291-23-2



14.

Install cable (29), washer (36), and nut (35) on alternator terminal (37).

15.

Install protective cover (33) on cable terminal (34).

16.

Install two clips (17), washers (32), and bolts (31) on cable (29).

17.

Install three clips (17) on cable (29).

18.

Install cable (29), washer (28), and nut (27) on junction (30).

19.

Install protective cover (25) on cable terminal (26).

0097 00-10

0097 00

TM 5-3805-291-23-2


Install two clamps (4), spacers (5), large washers (1), small washers (3), and bolts (2) on battery box (6).

21.


22.

Connect battery cables to battery disconnect switch (WP 0098 00).

23.

Install upper chassis guard panel (WP 0133 00).

24.

Install rear fender (WP 0137 00).

25.

Start engine to verify correct operation of electrical system (TM 5-3805-291-10).

26.


END OF WORK PACKAGE

0097 00-11/(0097 00-12 Blank)

0097 00

4 TM 5-3805-291-23-2

BATTERY DISCONNECT SWITCH REPLACEMENT

0098 00

THIS WORK PACKAGE COVERS Removal, Installation INITIAL SETUP References


TM 5-3805-291-10




Battery cables disconnected from batteries (WP 0096 00) Drawings Required


TM 5-3805-291-23P, Figure 70

Lockwasher (4)


Personnel Required

0.5 hr



REMOVAL 1.

Remove three bolts (1), washers (2), and panel (3) from machine.

0098 00-1

TM 5-3805-291-23-2

BATTERY DISCONNECT SWITCH REPLACEMENT - CONTINUED REMOVAL - CONTINUED 2.

Pull back boots (4) and remove two nuts (7) and lockwashers (8) from battery disconnect switch (6). Discard lockwashers.

3.

Remove two cables (5) from battery disconnect switch (6).

0098 00-2

0098 00

TM 5-3805-291-23-2

BATTERY DISCONNECT SWITCH REPLACEMENT - CONTINUED REMOVAL - CONTINUED 4.

Remove key (9) from battery disconnect switch (6).

5.

Remove nut (10) and lockwasher (11) from battery disconnect switch (6). Discard lockwasher.

6.

Remove battery disconnect switch (6), lockwasher (11), and plate (12) from machine. Discard lockwasher.

0098 00-3

0098 00

TM 5-3805-291-23-2

BATTERY DISCONNECT SWITCH REPLACEMENT - CONTINUED INSTALLATION 1.

Position battery disconnect switch (6), new lockwasher (11), and plate (12) on machine.

2.

Install new lockwasher (11) and nut (10) on battery disconnect switch (6).

3.

Install key (9) in battery disconnect switch (6).

4.

Connect two cables (5) to battery disconnect switch (6).

5.

Install two new lockwashers (8) and nuts (7) on battery disconnect switch (6).

6.

Install panel (3), three washers (2), and bolts (1) on machine.

7.


8.

Verify correct battery disconnect switch operation (TM 5-3805-291-10).

9.


END OF WORK PACKAGE

0098 00-4

0098 00

2 TM 5-3805-291-23-2

NATO SLAVE RECEPTACLE REPLACEMENT

0099 00



TM 5-3805-291-10




Battery cables disconnected from batteries and NATO slave receptacle (WP 0097 00) Drawings Required


TM 5-3805-291-23P, Figure 70



Personnel Required

0.5 hr



0099 00-1

TM 5-3805-291-23-2

NATO SLAVE RECEPTACLE REPLACEMENT - CONTINUED REMOVAL 1.

Remove four bolts (1), eight washers (2), four nuts (3), cover (4), and tether (5) from slave receptacle (6).

2.

Remove slave receptacle (6) and plate (7) from battery box (8).

INSTALLATION 1.

Install plate (7) and slave receptacle (6) in battery box (8).

2.

Install eight washers (2), four bolts (1), nuts (3), cover (4), and tether (5) on slave receptacle (6).

3.

Connect battery cables to NATO slave receptacle and batteries (WP 0097 00).

4.

Start engine and verify correct starting system operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0099 00-2

0099 00

6 TM 5-3805-291-23-2

TRANSMISSION SERVICE

0100 00

THIS WORK PACKAGE COVERS Draining, Filling




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Nipple, pipe (Item 41, WP 0232 00)

References WP 0105 00 Equipment Conditions Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10)




Wheels chocked



Oil, lubricating, TO-4 (Item 31, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

TM 5-3805-291-23P, Figures 87 and 93

Spill containment unit, hazardous material (Item 41, WP 0233 00) O-ring (2)


0100 00-1

TM 5-3805-291-23-2

TRANSMISSION SERVICE - CONTINUED

0100 00

DRAINING

NOTE Use a container to catch any fluid that may drain from system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up.

1.


2.


3.

Remove transmission oil drain plug (1) from bottom of transfer case (2).

4.

Remove and discard O-ring from transmission oil drain plug (1).

5.

Install pipe nipple.

6.

Drain transmission fluid. Remove pipe nipple.

7.

Replace transmission oil filter (WP 0105 00).

427-C0129

0100 00-2

TM 5-3805-291-23-2


0100 00

NOTE Magnetic strainer is located on right side of transfer case. 8.

Remove four bolts (3) and washers (4) from magnetic strainer cover (5).

9.

Remove magnetic strainer cover (5) and O-ring (6) from transfer case housing (7). Discard O-ring.

WARNING Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel.

NOTE Check bottom of strainer to ensure correct orientation during installation. 10.

Remove and clean screen (8) and magnet assembly (9) with solvent.

427-C0130

0100 00-3

TM 5-3805-291-23-2


0100 00

FILLING 1.

Install magnet assembly (9) and screen (8) in transfer case housing (7).

2.

Apply a thin coat of clean lubricating oil to new O-ring (6) and install O-ring and strainer cover (5) on transfer case housing (7).

3.

Install four washers (4) and bolts (3) in strainer cover (5).

4.

Install new O-ring on drain plug (1).

5.

Install transmission oil drain plug (1) in bottom of transfer case (2).

NOTE •

Transmission oil filler cap and tube are located on left-side of machine.

•

Transmission capacity is 13.2 gal. (50 L).

6.

Remove transmission oil filler cap (10) from fill tube (11).

7.

Fill transmission with oil.


8.

Use solvent cleaning compound to clean and inspect transfer case breather (12) located on top of transfer case (2).

427-C0132

0100 00-4

TM 5-3805-291-23-2

TRANSMISSION SERVICE - CONTINUED FILLING - CONTINUED 9.


10.

Slowly operate transmission controls (TM 5-3805-291-10).

11.

Check transmission for leaks.

12.


13.

Check transmission fluid level (TM 5-3805-291-10).

END OF WORK PACKAGE

0100 00-5/(0100 00-6 Blank)

0100 00

4 TM 5-3805-291-23-2

SHIFT LEVER REPLACEMENT

0101 00


References

Unit

TM 5-3805-291-10


Equipment Conditions Steering wheel removed (WP 0122 00) Steering column cover removed (WP 0121 00)


Drawings Required




2.8 hr

REMOVAL 1.

Remove two bolts (1), four washers (2), and bracket (3) from steering column (4).

427-C1928-1

0101 00-1

TM 5-3805-291-23-2

SHIFT LEVER REPLACEMENT - CONTINUED

0101 00


Remove and discard two tiedown straps (5) from shift lever (6).

3.

Disconnect shift lever (6) from wiring harness (7).

4.

Remove four bolts (8) from shift lever (6).

5.

Remove shift lever (6) from machine.

427-C0349

0101 00-2

TM 5-3805-291-23-2

SHIFT LEVER REPLACEMENT - CONTINUED

0101 00

INSTALLATION 1.

Position shift lever (6) on machine.

2.

Install four bolts (8) on shift lever (6).

3.

Connect shift lever (6) to wiring harness (7).

4.

Install two new tiedown straps (5) on shift lever (6).

5.

Install bracket (3), four washers (2), and two bolts (1) on steering column (4).

6.

Install steering column cover (WP 0121 00).

7.

Install steering wheel (WP 0122 00).

8.

Start machine (TM 5-3805-291-10).

9.

Run engine until operating temperature is reached and verify correct operation of machine (TM 5-3805-29110).

10.


427-C1928-1

END OF WORK PACKAGE

0101 00-3/(0101 00-4 Blank)

6 TM 5-3805-291-23-2

TRANSMISSION OIL COOLER LINES REPLACEMENT

0102 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation INITIAL SETUP Maintenance Level

Materials/Parts - Continued Spill containment unit, hazardous material (Item 41, WP 0233 00)



Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00)

O-ring (4) Seal Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions

Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00)

Steering frame lock connected (TM 5-3805-29110) Side covers removed from machine (WP 0135 00) Oil cooler lines removed from oil cooler (WP 0205 00)


Drawings Required



TM 5-3805-291-23P, Figure 91

1.5 hr


0102 00-1

TM 5-3805-291-23-2

TRANSMISSION OIL COOLER LINES REPLACEMENT - CONTINUED

0102 00

REMOVAL

CAUTION Wipe area clean around all connections to be opened during removal. Cap lines and hoses and plug openings after removing lines. Contamination of system could result in premature failure.

NOTE •

Tag hoses prior to removal to ensure correct installation.

•

Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up.

1.

Remove bolt (1), washer (2), and nut (3) from clamps (4 and 5).

2.

Remove clamps (4 and 5) from tubes (6 and 7).

3.


4.

Remove clamp (10) from tube (6).

5.


6.

Remove clamp (13) from tube (7).

7.

Remove four bolts (14), washers (15), flange (16), two O-rings (17), seal (18), and tube (6) from flange (19). Discard Orings and seal.

8.

Disconnect test probe (20) from tube (7).

427-C0338

0102 00-2

TM 5-3805-291-23-2


0102 00


Remove bolt (21), washer (22), and two clamps (23) from machine and position hose (24) and battery cable (25) aside.

10.

Remove bolt (26), washer (27), and two clamps (28) from machine and position hydraulic lines (29) aside.

427-C1940

11.

Remove tube (6) from machine.

12.

Remove four bolts (30), washers (31), flange (32), two O-rings (33), and tube (7) from elbow (34). Discard O-rings.

13.

Remove tube (7) from machine.


WARNING •


•


1.

Clean all parts and surfaces with solvent cleaning compound.

2.


3.

Inspect all parts for damage, wear, pitting, cracks, or corrosion and replace if necessary. 0102 00-3

TM 5-3805-291-23-2


0102 00

INSTALLATION


1.

Position tube (7) on machine.

2.

Install two new O-rings (33), tube (7), flange (32), four washers (31), and bolts (30) on elbow (34).

3.

Position tube (6) on machine.

427-C0338

0102 00-4

TM 5-3805-291-23-2


0102 00


Position hydraulic lines (29) and install two clamps (28), washer (27), and bolt (26) on machine.

5.

Position battery cable (25) and hose (24) and install two clamps (23), washer (22), and bolt (21) on machine.

427-C1940

6.

Connect test probe (20) to tube (7).

7.

Install new seal (18), two new O-rings (17), tube (6), flange (16), four washers (15), and bolts (14) on flange (19).

8.

Install clamp (13) on tube (7).

9.


10.

Instal clamp (10) on tube (6).

11.


12.

Install clamps (5 and 4) on tubes (7 and 6).

13.

Install washer (2), bolt (1), and nut (3) on clamps (5 and 4).

14.

Install oil cooler lines on oil cooler (WP 0205 00).

15.

Install side covers (WP 0135 00).


16.


17.


18.

Run engine until operating temperature is reached and verify correct operation of machine (TM 5-3805-291-10).

19.


20.

Check for leaks.


4 TM 5-3805-291-23-2

TRANSMISSION OIL FILLER TUBE REPLACEMENT

0103 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation INITIAL SETUP Materials/Parts - Continued

Maintenance Level


Unit

Spill containment unit, hazardous material (Item 41, WP 0233 00)


Gasket (2) Personnel Required MOS 62B, Construction Equipment Repairer

Materials/Parts

References

Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

TM 5-3805-291-10 Equipment Conditions Transmission oil drained (WP 0100 00) Drawings Required TM 5-3805-291-23P, Figure 88 Estimated Time to Complete Task 0.5 hr


NOTE Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up.

0103 00-1

TM 5-3805-291-23-2

TRANSMISSION OIL FILLER TUBE REPLACEMENT - CONTINUED

0103 00

REMOVAL

CAUTION Keep all parts free of dirt, debris, and any contamination. Dirt, debris, or contamination entering transmission will cause rapid wear and shortened transmission life.

1.

Loosen two clamps (11) on hose (12)

2.

Remove two bolts (13), washers (14), and clamps (5) from upper filler tube (6) and battery box (15).

3.

Remove upper tube (6) from hose (12).

4.

Remove hose (12) from lower filler tube (10).

5.

Remove four bolts (7), washers (8), lower filler tube (10), and gasket (9) from machine. Discard gasket.

6.

Remove cap (1), ball (2), plate (3), and gasket (4) from upper filler tube (6). Discard gasket.

0103 00-2

TM 5-3805-291-23-2

TRANSMISSION OIL FILLER TUBE REPLACEMENT - CONTINUED

0103 00


WARNING •


•


1.

Clean all parts and mating surfaces with solvent cleaning compound.

2.


3.

Inspect all parts for wear, pitting, cracks, or corrosion and replace if necessary.

4.

Inspect oil passages to ensure they are clean and unobstructed.

INSTALLATION 1.

Install new gasket (4), plate (3), ball (2), and cap (1) on upper filler tube (6).

2.

Install new gasket (9), lower filler tube (10), four washers (8), and bolts (7) on machine.

3.

Install hose (12) on lower filler tube (10).

4.

Install upper tube (6) in hose (12)

5.

Install two clamps (5), washers (14), and bolts (13) on upper filler tube (6) and battery box (15).

6.

Tighten two clamps (11) on hose (12).

7.


8.

Start engine (TM 5-3805-291-10).

9.

Shut off engine and check for leaks.

END OF WORK PACKAGE

0103 00-3/(0103 00-4 Blank)

8 TM 5-3805-291-23-2

TRANSMISSION OIL FILTER BASE, LINES, AND BYPASS SWITCH REPLACEMENT

0104 00




Unit



O-ring (12) Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions Machine parked on level ground (TM 5-3805-29110)



Materials/Parts

Wheels chocked



Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Oil, lubricating, TO-4 (Item 31, WP 0233 00)

Steering frame lock connected (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figures 65 and 92 Estimated Time to Complete Task


2.5 hr


NOTE •


•


0104 00-1

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER BASE, LINES, AND BYPASS SWITCH REPLACEMENT - CONTINUED 0104 00 REMOVAL 1.

Remove four bolts (1), washers (2), flanges (3 and 4), O-ring (5), and hose (6) from filter base assembly (7). Discard O-ring.

2.

Remove four bolts (8), washers (9), flanges (10 and 11), O-ring (12), and hose (13) from filter base assembly (7). Discard O-ring.

3.

Disconnect bypass switch (14) from chassis wiring harness (15).

4.

Remove three bolts (16) and washers (17) from filter base assembly (7).

5.

Remove filter base assembly (7) from machine.

427-C0346

0104 00-2

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER BASE, LINES, AND BYPASS SWITCH REPLACEMENT - CONTINUED 0104 00 REMOVAL - CONTINUED 6.

Remove transmission oil sampling valve (18) and O-ring (19) from filter base assembly (7). Discard O-ring.

7.

Remove oil filter bypass switch (14) and O-ring (20) from filter base assembly (7). Discard O-ring.

8.

Remove adapter (21), O-ring (22), bypass spool (23), and springs (24 and 25) from filter assembly (7). Discard O-ring.

9.

Remove plug (26) and O-ring (27) from filter assembly (7). Discard O-ring.

427-C0347

0104 00-3

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER BASE, LINES, AND BYPASS SWITCH REPLACEMENT - CONTINUED 0104 00 REMOVAL - CONTINUED 10.

Remove bolt (28), washer (29), and two clamps (30) from hoses (6 and 13).

11.

Disconnect hose (6) and remove O-ring (31) from elbow (32). Discard O-ring.

12.


13.

Remove bolt (35), washer (36), and two clamps (37) from lines (38 and 39).

14.

Disconnect line (38) and remove O-ring (40) from elbow (32). Discard O-ring.

15.

Disconnect line (39) and remove O-ring (41) from elbow (34). Discard O-ring.

16.

Remove nut (42) from elbow (32).

17.

Remove elbow (32) from bracket (43).

18.

Remove nut (44) from elbow (34).

19.

Remove elbow (34) from bracket (43).

20.

Remove four bolts (45), washers (46), two flanges (47), O-ring (48), and line (38) from transmission (49). Discard O-ring.

21.

Remove four bolts (50), washers (51), two flanges (52), O-ring (53), and line (39) from transmission (49). Discard O-ring.

427-C0348

0104 00-4

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER BASE, LINES, AND BYPASS SWITCH REPLACEMENT - CONTINUED 0104 00 CLEANING AND INSPECTION

WARNING •


•


1.


2.


3.


INSTALLATION


1.

Install new O-ring (53), line (39), two flanges (52), four washers (51), and bolts (50) on transmission (49).

2.

Install new O-ring (48), line (38), two flanges (47), four washers (46), and bolts (45) on transmission (49).

3.

Position elbow (34) on bracket (43).

4.

Install nut (44) on elbow (34).

5.

Position elbow (32) on bracket (43).

6.

Install nut (42) on elbow (32).

7.

Install new O-ring (41) and line (39) on elbow (34).

8.

Install new O-ring (40) and line (38) on elbow (32).

9.

Install two clamps (37), washer (36), and bolt (35) on lines (39 and 38).

10.

Install new O-ring (33) and hose (13) on elbow (34).

11.

Install new O-ring (31) and hose (6) on elbow (32).

12.

Install two clamps (30), washer (29), and bolt (28) on hoses (13 and 6). 0104 00-5

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER BASE, LINES, AND BYPASS SWITCH REPLACEMENT - CONTINUED 0104 00 INSTALLATION - CONTINUED 13.

Install new O-ring (27) and plug (26) on filter assembly (7).

14.

Install new O-ring (22), springs (25 and 24), bypass spool (23), and adapter (21) on filter assembly (7).

15.

Install new O-ring (20) and oil filter bypass switch (14) on filter base assembly (7). Tighten switch to 60 ± 7 lb-ft (80 ± 10 Nm).

16.

Install new O-ring (19) and transmission oil sampling valve (18) on filter base assembly (7).

427-C0347

0104 00-6

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER BASE, LINES, AND BYPASS SWITCH REPLACEMENT - CONTINUED 0104 00 INSTALLATION - CONTINUED 17.

Position filter base assembly (7) on machine.

18.

Install three washers (17) and bolts (16) on filter base assembly (7).

19.

Connect bypass switch (14) to chassis wiring harness (15).

20.

Install new O-ring (12), hose (13), flanges (11 and 10), four washers (9), and bolts (8) on filter base assembly (7).

21.

Install new O-ring (5), hose (6), flanges (4 and 3), four washers (2), and bolts (1) on filter base assembly (7).

427-C0346


22.


23.


24.


25.


26.

Check for leaks.

END OF WORK PACKAGE

0104 00-7/(0104 00-8 Blank)

4 TM 5-3805-291-23-2

TRANSMISSION OIL FILTER ELEMENT REPLACEMENT

0105 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation INITIAL SETUP Personnel Required



Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Oil, lubricating, TO-4 (Item 31, WP 0233 00)

Equipment Conditions Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required

Rag, wiping (Item 35, WP 0233 00) Spill containment unit, hazardous material (Item 41, WP 0233 00)


Filter element O-ring (2)

0.2 hr

0105 00-1

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER ELEMENT REPLACEMENT - CONTINUED

0105 00

REMOVAL


NOTE • Use a container to catch any fluid that may drain from system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Transmission oil filter is located on right side of machine under platform. 1.


2.


3.

Open access panel (TM 5-3805-291-10).

4.

Remove filter housing drain plug (1) and allow oil in filter to drain.

5.

Remove and discard O-ring (2) from filter housing drain plug (1).

6.

Remove filter housing (3) and O-ring (4) from machine. Discard O-ring.

427-C0128

7.

Remove used filter element (5) from filter housing (3). Discard filter element.

0105 00-2

TM 5-3805-291-23-2

TRANSMISSION OIL FILTER ELEMENT REPLACEMENT - CONTINUED

0105 00


WARNING •


•


1.


2.


3.


INSTALLATION


1.

Install new filter element (5) in filter housing (3).

2.

Install new O-ring (4) and filter housing (3) on machine.

3.

Install new O-ring (2) on filter housing drain plug (1).

4.

Install filter housing drain plug (1) on filter housing (3).

5.


6.


7.

Check for leaks.

8.

Check transmission fluid level (TM 5-3805-291-10).

END OF WORK PACKAGE

0105 00-3/(0105 00-4 Blank)

4 TM 5-3805-291-23-2

TRANSMISSION TEST LINES AND FITTINGS REPLACEMENT

0106 00




Unit



Tag, marker (Item 43, WP 0233 00) O-ring (36) Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions

Materials/Parts

Hydraulic filter access door opened (TM 5-3805291-10)

Cap set, protective (Item 6, WP 0233 00)

Hydraulic system pressure relieved (TM 5-3805291-10)


Hydraulic tank drained (WP 0148 00)


Drawings Required



TM 5-3805-291-23P, Figure 92


3.0 hr

WARNING •

DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury to personnel.

•

At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel.

•

Hydraulic oil used in the performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

0106 00-1

TM 5-3805-291-23-2

TRANSMISSION TEST LINES AND FITTINGS REPLACEMENT - CONTINUED

0106 00


NOTE •


•


REMOVAL 1.

Disconnect six lines (1) from elbows (2). Remove and discard six O-rings (3).

2.

Remove six elbows (2) from fittings (4). Remove and discard six O-rings (5).

3.

Remove six fittings (4) from machine. Remove and discard six O-rings (6).

4.

Remove all associated tie straps (7) and clips (8). Discard tiedown straps.

427-C1359

0106 00-2

TM 5-3805-291-23-2

TRANSMISSION TEST LINES AND FITTINGS REPLACEMENT - CONTINUED REMOVAL - CONTINUED 5.

Disconnect six lines (1) from elbows (9). Remove and discard six O-rings (10).

6.

Remove six elbows (9) from fittings (11). Remove and discard six O-rings (12).

7.

Remove six fittings (11) from machine. Remove and discard six O-rings (13).

INSTALLATION

NOTE Apply a thin coat of clean oil to all O-rings prior to installation.

1.

Install six new O-rings (13) and fittings (11) on machine.

2.

Install six new O-rings (12) and elbows (9) on fittings (11).

3.

Install six new O-rings (10) and connect lines (1) to elbows (9).

4.

Install all associated clips (8) and new tiedown straps (7).

5.

Install six new O-rings (6) and fittings (4) on machine.

6.

Install six new O-rings (5) and elbows (2) on fittings (4).

7.

Install six new O-rings (3) and connect lines (1) to elbows (2).

8.

Fill hydraulic tank (WP 0148 00).

9.

Operate machine and verify correct operation (TM 5-3805-291-10).

10.


11.

Check for leaks.

12.

Close access door (TM 5-3802-291-10).


0106 00

4 TM 5-3805-291-23-2

CENTER DRIVE SHAFT (SLIP JOINT) REPLACEMENT

0107 00



Grease, multipurpose (Item 18, WP 0233 00)



Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00) Lifting equipment, 90-lb capacity

Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions Steering frame lock connected (TM 5-3805-29110) Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figure 94



Grease, molybdenum (Item 17, WP 0233 00)

0107 00-1

TM 5-3805-291-23-2

CENTER DRIVE SHAFT (SLIP JOINT) REPLACEMENT - CONTINUED

0107 00

REMOVAL

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE •

Center drive shaft weighs 60 lb (27 kg).

•

Index mark drive shaft to U-joint.

1.

Use lifting equipment to support center driveshaft.

2.

Remove four bolts (1) and two straps (2) from both ends of center drive shaft (3).

3.

With assistance, remove center drive shaft (3).

427-C0452


WARNING •


•


1.

Clean U-joints and mating surfaces with solvent cleaning compound.

2.


3.

Inspect U-joints for wear, pitting, cracks, or corrosion and replace if necessary. 0107 00-2

TM 5-3805-291-23-2

CENTER DRIVE SHAFT (SLIP JOINT) REPLACEMENT - CONTINUED

0107 00

INSTALLATION

WARNING


NOTE •

Center drive shaft weighs 60 lb (27 kg).

•

Align index marks on drive shaft and U-joint.

1.

Use lifting equipment to support center driveshaft.

2.

With assistance, position center drive shaft (3) on machine and install two straps (2) and four bolts (1) to both ends of center drive shaft. Tighten bolts to 111 ± 11 lb-ft (150 ± 15 Nm).

WARNING Before operating the machine, secure the steering frame lock in the stowed position. DO NOT operate machine with steering frame lock connected. Failure to lock steering frame lock into the stowed position before operating can result in loss of steering and injury or death to personnel. 3.


NOTE •

Lubricate all grease fittings with multipurpose grease.

•

Lubricate splines with molybdenum or multipurpose grease.

4.

Lubricate center drive shaft (3).

5.

Drive machine and verify correct operation of center drive shaft (TM 5-3805-291-10).

END OF WORK PACKAGE

0107 00-3/(0107 00-4 Blank)

4 TM 5-3805-291-23-2

FRONT DRIVE SHAFT CARRIER BEARING REPLACEMENT

0108 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Lifting equipment, 60-lb capacity

Equipment Conditions Steering frame lock connected (TM 5-3805-29110) Parking brake removed (WP 0113 00) Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figure 94

Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)


0108 00-1

TM 5-3805-291-23-2

FRONT DRIVE SHAFT CARRIER BEARING REPLACEMENT - CONTINUED

0108 00

REMOVAL

WARNING

Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may result in injury to personnel.

NOTE Front drive shaft weighs 40 lb (18 kg). 1.

Use lifting equipment to support front drive shaft (1).

2.

Remove lock ring (2) and setscrew (3) from front drive shaft (1).

3.

Remove bolts (4) and spacers (5) from machine.

427-C0450

4.

Remove carrier bearing (6) from machine.

427-C0451

0108 00-2

TM 5-3805-291-23-2

FRONT DRIVE SHAFT CARRIER BEARING REPLACEMENT - CONTINUED

0108 00

INSTALLATION

WARNING


NOTE •

Front drive shaft weighs 40 lb (18 kg).

•

Apply a thin coat of clean oil to front drive shaft journal and to carrier bearing bore.

1.

Use lifting equipment to support front drive shaft (1).

2.

Install carrier bearing (6) over front drive shaft (1).

3.

Install spacers (5) and bolts (4) on machine.

4.

Install setscrew (3) in lock ring (2). Tighten setscrew so slot in setscrew aligns with lock ring slot.

5.

Install lock ring (2) on front drive shaft (1).

6.

Install parking brake (WP 0113 00).


7.


8.

Drive machine and verify correct operation of drive shaft carrier bearing (TM 5-3805-291-10).

END OF WORK PACKAGE

0108 00-3/(0108 00-4 Blank)

4 TM 5-3805-291-23-2

FRONT DRIVE SHAFT REPLACEMENT

0109 00


Maintenance Level


Unit





References

Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00)



TM 5-3805-291-10

Drive shaft carrier bearing removed (WP 0108 00) Drawings Required




0109 00-1

TM 5-3805-291-23-2

FRONT DRIVE SHAFT REPLACEMENT - CONTINUED

0109 00

REMOVAL

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Failure to follow this warning may result in injury to personnel.

NOTE Front drive shaft weighs 40 lb (18 kg). 1.

Attach lifting equipment to front drive shaft (1).

2.

With assistance, remove four bolts (2) and two collars (3) from yoke (4).

3.

Carefully remove front drive shaft (1) from machine.

427-C0449


WARNING •


•


1.

Clean U-joints and mating surfaces with solvent cleaning compound.

2.


3.

Inspect U-joints for wear, pitting, cracks, or corrosion and replace if necessary. 0109 00-2

TM 5-3805-291-23-2

FRONT DRIVE SHAFT REPLACEMENT - CONTINUED

0109 00

INSTALLATION

WARNING


CAUTION The front drive shaft must be installed in phase with the front axle assembly yoke, and the center and rear drive shafts. If it is not, serious component damage could occur. Ensure all joint groups, yokes, and lubricating fittings are aligned.

NOTE •

Front drive shaft weighs 40 lb (18 kg).

•


•

Splines should be lubricated with molybdenum or multipurpose grease with machine fully articulated.

1.

Using lifting equipment, carefully position front drive shaft (1) on machine.

2.

With assistance, position front drive shaft (1) on yoke (4) and install two collars (3) and four bolts (2) on front drive shaft. Tighten bolts to 125 ± 11 lb-ft (170 ± 15 Nm).

3.

Install carrier bearing (WP 0108 00).

4.

Drive machine and verify correct operation of front drive shaft (TM 5-3805-291-10).

END OF WORK PACKAGE

0109 00-3/(0109 00-4 Blank)

4 TM 5-3805-291-23-2

REAR DRIVE SHAFT REPLACEMENT

0110 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00)

Equipment Conditions Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Drawings Required TM 5-3805-291-23P, Figure 94

Grease, molybdenum (Item 17, WP 0233 00) Estimated Time to Complete Task


3.0 hr


REMOVAL

NOTE Index mark drive shaft to U-joint to ensure correct installation. 1.

Support rear drive shaft (1) and remove eight bolts (2) and four straps (3) from each end of rear drive shaft.

2.

Slide yoke (4) rearward to increase clearance and carefully remove rear drive shaft (1) from machine.

427-C0453

0110 00-1

TM 5-3805-291-23-2

REAR DRIVE SHAFT REPLACEMENT - CONTINUED CLEANING AND INSPECTION

WARNING •


•


1.

Clean U-joints with a dry rag.

2.

Clean drive shaft with solvent.

3.


4.

Inspect U-joints for wear, pitting, cracks, or corrosion and replace if necessary.

0110 00-2

0110 00

TM 5-3805-291-23-2

REAR DRIVE SHAFT REPLACEMENT - CONTINUED

0110 00

INSTALLATION

CAUTION The rear drive shaft must be installed in phase with the rear axle assembly yoke and the center and front drive shafts. If it is not, serious component damage could occur. Ensure all joint groups, yokes, and lubricating fittings are aligned. 1.

Slide yoke (4) toward rear axle assembly to provide enough clearance for rear drive shaft (1) installation.

2.

Carefully install rear drive shaft (1) on machine.

3.

Slide yoke (4) toward rear drive shaft (1) so rear drive shaft is properly located.

4.

Support rear drive shaft (1) and install four straps (3) and eight bolts (2) on rear drive shaft. Tighten bolts to 110 ± 11 lb-ft (150 ± 15 Nm).

NOTE •


•

Lubricate splines with molybdenum or multipurpose grease with machine fully articulated.

5.

Lubricate rear drive shaft (1).

6.

Drive machine and verify correct operation of rear drive shaft (TM 5-3805-291-10).

END OF WORK PACKAGE

0110 00-3/(0110 00-4 Blank)

427-C0453

2 TM 5-3805-291-23-2

DIFFERENTIAL AND FINAL DRIVE OIL CHANGE

0111 00

THIS WORK PACKAGE COVERS Differential and Final Drive Oil Change







Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked

Materials/Parts Axle oil additive (Item 3, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Oil, lubricating, TO-4 (Item 31, WP 0233 00)

Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figures 95 and 97

Rag, wiping (Item 35, WP 0233 00) Spill containment unit, hazardous material (Item 41, WP 0233 00)

0111 00-1


TM 5-3805-291-23-2

DIFFERENTIAL AND FINAL DRIVE OIL CHANGE - CONTINUED

0111 00

DIFFERENTIAL AND FINAL DRIVE OIL CHANGE


NOTE •


•

The axle housings are equipped with ecology drain valves.

1.

Remove one drain plug (1) from each axle. Attach hose to drain adapter and install adapter in drain valve. Allow oil to drain into container.

2.

Clean and install drain plug (1) for each axle.

3.

Clean area around dipstick/fill plugs (2) on each axle.

4.

Remove the dipstick/fill plugs (2) from each axle.

NOTE Axle capacity is 16.9 gal. (64 L), which includes 0.3 gal. (1 L) of axle oil additive. 5.

Add 1.06 qt (1.0 L) of axle oil additive to each axle.

6.

Fill each axle with oil.

7.

Clean and install level gage/fill plugs (2) on each axle.

427-C0340

8.


9.

Operate machine and drive for a few minutes (TM 5-3805-291-10).

10.

Shut off machine (TM 5-3805-291-10).

11.

Let oil settle for a few minutes.

12.

Check oil level in axle.

13.

Check for leaks.


427-C0341

6 TM 5-3805-291-23-2

PARKING BRAKE ACTUATOR REPLACEMENT

0112 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation, Adjustment INITIAL SETUP Personnel Required




References


WP 0113 00 Equipment Conditions Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10)

Materials/Parts Cap set, protective (Item 6, WP 0233 00)







Hydraulic system pressure relieved (TM 5-3805291-10) Drawings Required TM 5-3805-291-23P, Figure 100



O-ring Pin, cotter

1.0 hr

WARNING •

DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate skin, causing injury to personnel.

•


CAUTION Wipe area clean around all connections to be opened during removal. Cap lines and hoses and plug openings after removing lines. Contamination of system could result in premature failure. 0112 00-1

TM 5-3805-291-23-2

PARKING BRAKE ACTUATOR REPLACEMENT - CONTINUED

0112 00

NOTE •


•


•

Parking brake actuator is located inside loader frame.

REMOVAL 1.

Disconnect hose (1) and remove O-ring (2) from parking brake actuator (3). Discard O-ring.

2.

Remove clevis (4) and cotter pin (5) from yoke assembly (6). Discard cotter pin.

3.

Disconnect yoke assembly (6) from parking brake actuator lever (7).

4.

Remove two nuts (8) and washers (9) from parking brake actuator (3).

5.

Remove parking brake actuator (3) from machine.

427-C0119


WARNING •


•


1.


2.


3.

Inspect all parts for wear, pitting, cracks, or corrosion and replace if necessary. 0112 00-2

TM 5-3805-291-23-2


0112 00

INSTALLATION 1.

Position parking brake actuator (3) on machine.

2.

Install two washers (9) and nuts (8) on parking brake actuator (3).

3.

Connect yoke assembly (6) to parking brake actuator lever (7).

4.

Install clevis (4) and new cotter pin (5) on yoke assembly (6).

5.

Lubricate new O-ring (2) with clean oil and install in hose assembly (1).

6.

Connect hose (1) to parking brake actuator (3).

7.


8.


9.

Check for leaks.


10.


ADJUSTMENT

WARNING •

Personal injury or death can result if two persons are not used in the following procedure.

•

Personal injury or death can result from a parking brake malfunction. Do not operate machine if parking brake does not function correctly.

•

Be sure parking brake components are adjusted correctly before attempting to return machine to service.

•

Personal injury or death can result from sudden machine movement.

•

Sudden movement of machine can cause injury to persons on or near machine.

•

Prevent possible injury by performing procedure that follows before working on machine.

•

Allow only authorized personnel on machine. Keep unauthorized personnel off machine and in clear sight of operator.

Machine Preparation 1.

Disengage parking brake (TM 5-3805-291-10).

CAUTION Be sure to avoid getting any grease or dirt on the brake shoes. Grease and dirt on brake shoes greatly reduces the effectiveness of the parking brake.

2.

Remove parking brake. The parking brake must be disassembled in order to perform adjustment procedure (WP 0113 00). 0112 00-3

TM 5-3805-291-23-2


0112 00

ADJUSTMENT - CONTINUED Adjustment Procedure 1.

Place brake drum (10) on a flat surface. Make sure that large diameter of brake drum is facing upward. Place brake group (11) into brake drum. Make sure that camshaft (12) is facing upward.

2.

Rotate starwheel (13) in order to move brake shoes (14) outward. Rotate starwheel until brake shoes contact brake drum (10). Make sure that brake shoes stay above radius at the bottom of brake drum.

3.

Rotate starwheel (13) so that brake shoes (14) press against brake drum (10). The force of brake shoes against brake drum should be sufficient to hold brake shoes to brake drum when you lift brake group (11) upward.

4.

Lift brake group (11) upward. Place brake drum (10) and brake group on the flat surface.

5.

Rotate starwheel (13) for 15 clicks in order to release the pressure of brake shoes (14) on brake drum (10).

6.

Install parking brake on machine (WP 0113 00).

7.

Apply the parking brake. Actuator shaft (15) should be retracted.

8.

Adjust rod end (16) by turning the actuator shaft (15) in order to achieve dimension (A) of 4.134 in. (105 mm).

9.

Release parking brake in order to extend the actuator shaft (15).

427-C1994

427-C1995

0112 00-4

TM 5-3805-291-23-2


0112 00

ADJUSTMENT - CONTINUED Adjustment Procedure - Continued 10.

Position lever (18) on splined end of camshaft (19). Push lever so the brake camshaft will contact brake shoes. Rotate actuator shaft (15) in order to align rod end (16). Install pin (20). Tighten locknut (17) on actuator shaft (15).

427-C1996

11.

Adjust lever (18) by removing lever from splined shaft (19). Rotate lever about splined shaft (19) until dimension (B) equals 1.38 in. (35 mm).

12.

Install cotter (21) in pin (20).

13.

Install bolt (22).

14.

Apply parking brake (TM 5-3805-291-10).

NOTE Replacement brake shoes must be burnished.

15.

In order to burnish brake shoes, make three successive stops from third speed forward at maximum speed. Allow parking brake to cool to ambient temperature after third stop.

16.

Measure stroke of actuator. If dimension (B) exceeds 1.38 in. (35 mm), repeat steps 9 thru 13.


8 TM 5-3805-291-23-2

PARKING BRAKE MAINTENANCE

0113 00



Maintenance Level


Unit

References


TM 5-3805-291-10




Drawings Required

Pump, hydraulic ram, hand driven (Item 57, WP 0232 00)

Center drive shaft removed (WP 0107 00)


Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

WARNING •


•


NOTE Use a container to catch any oil that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up.

0113 00-1

TM 5-3805-291-23-2

PARKING BRAKE MAINTENANCE - CONTINUED

0113 00

REMOVAL 1.

Disconnect hose (1) and plug opening.

2.

Attach hand hydraulic pump to end of brake actuator (2).

427-C0120

3.

Use hand hydraulic pump to release tension on pin (3).

4.

Remove pin (3) from lever (4).

5.

Remove bolt (5) and washer (6) from lever (4).

6.

Remove lever (4) from machine.

427-C0121

0113 00-2

TM 5-3805-291-23-2


0113 00


Remove eight bolts (7) and washers (8) from brake drum (9).

8.

Remove brake drum (9) from machine.

427-C0122

9.

Remove bolt (10) and washer (11) from yoke retainer (12).

10.

Remove yoke retainer (12) and yoke (13) from machine.

427-C0123

0113 00-3

TM 5-3805-291-23-2


0113 00


Remove return spring (14), retaining spring (15), and brace (16) from brake shoes (17).

12.

Remove brakes shoes (17) from machine.

427-C0124

13.

Remove camshaft (18), four bolts (19), and washers (20) from plate assembly (21).

14.

Remove plate assembly (21) from machine.

427-C0125

0113 00-4

TM 5-3805-291-23-2


0113 00


Remove two nuts (22), washers (23), and pins (24) from plate assembly (21).

16.

Remove bracket (25) from plate assembly (21).

427-C0126


WARNING •


•


1.


2.


3.


4.

Replace brake lining if thickness is less than 0.09 in. (2.3 mm).

INSTALLATION 1.

Install bracket (25) on plate assembly (21).

2.

Install two pins (24), washers (23), and nuts (22) on plate assembly (21).

3.

Install plate assembly (21) on machine.

4.

Install camshaft (18), four washers (20), and bolts (19) on plate assembly (21). Tighten bolts to 177 ± 30 lb-ft (240 ± 40 Nm). 0113 00-5

TM 5-3805-291-23-2


0113 00


Install brake shoes (17) on machine.

6.

Install retaining spring (15), return spring (14), and brace (16) on brake shoes (17).

427-C0124

7.

Install yoke (13) and yoke retainer (12) on machine.

8.

Install washer (11) and bolt (10) on yoke retainer (12). Tighten bolt to 125 ± 11 lb-ft (170 ± 15 Nm).

427-C0123

0113 00-6

TM 5-3805-291-23-2


0113 00


Install brake drum (9) on machine.

10.

Install eight washers (8) and bolts (7) on brake drum (9).

11.

Install lever (4) on machine.

12.

Install washer (6) and bolt (5) on lever (4).

13.

Use hand hydraulic pump to position yoke of brake actuator (2) on lever (4).

14.

Install pin (3) on lever (4).

15.

Remove plug and connect hose (1).

16.

Remove all tooling from machine.

17.

Install center drive shaft (WP 0107 00).

427-C0122

427-C0121

427-C0120


10 TM 5-3805-291-23-2

BRAKE ACCUMULATOR MAINTENANCE

0114 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation, Testing, Charging INITIAL SETUP Materials/Parts - Continued



Test Equipment


Test stand, automotive (Item 87, WP 0232 00) Test set, electronic systems (MSD) (Item 86, WP 0232 00) Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00)

O-ring (12) Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions





Hose (Item 33, WP 0232 00)


Charging kit, pressure (Item 23, WP 0232 00)

Wheels chocked



Materials/Parts Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Nitrogen technical dry cylinder (Item 25, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

0114 00-1

Steering frame lock connected (TM 5-3805-29110) Brake system pressure relieved (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figures 101 and 102 Estimated Time to Complete Task 3.0 hr

TM 5-3805-291-23-2

BRAKE ACCUMULATOR MAINTENANCE - CONTINUED

0114 00

WARNING • DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury to personnel. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • The accumulator is filled with dry nitrogen. DO NOT loosen or remove the valve or cap from the top of the accumulator. Failure to follow this warning may result in injury to personnel.


NOTE •


•


REMOVAL

NOTE Accumulators for both front and rear service brakes are located behind ladder on right side of machine.

1.

Remove two bolts (1) and washers (2) from door (3). Open door.

427-C0142

0114 00-2

TM 5-3805-291-23-2


0114 00


Disconnect six hose assemblies (4) and remove O-rings (5) from fittings (6) on brake accumulators (7). Discard O-rings.

3.

Remove six fittings (6) and O-rings (8) from brake accumulators (7). Discard O-rings.

4.

Remove two bolts (9) and washers (10) from clamps (11).

5.

With assistance, remove two clamps (11) and brake accumulators (7) from panel (12).

427-C1043

0114 00-3

TM 5-3805-291-23-2

BRAKE ACCUMULATOR MAINTENANCE - CONTINUED CLEANING AND INSPECTION

WARNING •


•


1.


2.


3.


4.


0114 00-4

0114 00

TM 5-3805-291-23-2


0114 00

INSTALLATION 1.

Place two brake accumulators (7) and clamps (11) on panel (12).

2.

Install two washers (10) and bolts (9) on clamps (11).


3.

Install six new O-rings (8) and fittings (6) on brake accumulators (7).

4.

Install six new O-rings (5) and connect hose assemblies (4) to fittings (6).

427-C1043

0114 00-5

TM 5-3805-291-23-2


0114 00


Close door (3) and install two washers (2) and bolts (1) on door assembly (3).

427-C1042


6.


7.

Check hydraulic fluid level (TM 5-3805-291-10).

8.


9.


10.

Check for leaks.

0114 00-6

TM 5-3805-291-23-2

BRAKE ACCUMULATOR MAINTENANCE - CONTINUED TESTING 1.

Turn engine start switch to ON position (TM 5-3805-291-10).

2.

Disengage parking brake (TM 5-3805-291-10).

3.

Brake oil pressure indicator (13) should illuminate if brake oil is not at normal operating pressure.

4.

Run engine (TM 5-3805-291-10).

5.

Run engine at half speed for 2 minutes to increase accumulator pressure.

6.

Brake oil pressure indicator (13) should darken.

7.


8.

Turn engine start switch to ON position (TM 5-3805-291-10).

NOTE A minimum of five applications of service brake pedal is required.

9.

Apply and release service brake pedal until brake oil pressure indicator (13) illuminates. This decreases pressure in brake accumulators.

10.

Parking brake indicator (14) will illuminate when brake oil pressure indicator (13) illuminates.

11.

If brake oil pressure indicator (13) illuminates with less than five applications of brake, charge brake accumulator. Refer to Charging in this work package.

0114 00-7

0114 00

TM 5-3805-291-23-2


0114 00

CHARGING

WARNING • DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury to personnel. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. • The accumulator is filled with dry nitrogen. DO NOT loosen or remove the valve or cap from the top of the accumulator. Failure to follow this warning may result in injury to personnel.

NOTE •

To ensure nitrogen charge is correct, each brake accumulator piston must be at bottom of accumulator cylinder. Nitrogen gas pressure varies with temperature. To obtain the most accurate nitrogen charge, temperature of each accumulator must be identical to air temperature around accumulators.

•

The pressures in Table 1 are for ambient air temperature ranging from 20°F to 120°F (-7°C to 49°C). Adjust pressure for other ambient conditions, as required.

1.

Stop engine.

2.

Press brake pedal repeatedly until there is no brake pressure.

3.

Use nitrogen gas charging system to determine pressures when charging accumulators. Table 1. Accumulator Precharge Temperature/Pressure Relationship for 1,000 psi (6,900 kPa) Service Brake Accumulators. Temperature

Pressure

20°F (-7°C)

907 psi (6,250 kPa)

30°F (-1°C)

926 psi (6,380 kPa)

40°F (4°C)

945 psi (6,510 kPa)

50°F (10°C)

964 psi (6,640 kPa)

60°F (16°C)

983 psi (6,770 kPa)

70°F (21°C)

1,000 psi (6,900 kPa)

80°F (27°C)

1,020 psi (7,030 kPa)

90°F (32°C)

1,039 psi (7,160 kPa)

100°F (38°C)

1,058 psi (7,290 kPa)

110°F (43°C)

1,077 psi (7,420 kPa)

120°F (49°C)

1,096 psi (7,550 kPa) 0114 00-8

TM 5-3805-291-23-2


0114 00

CHARGING - CONTINUED 4.

Charge accumulator.

5.

Operate service brakes several times.

NOTE If brake accumulator has less than half of required amount of precharge pressure, accumulator should be charged. Then charge accumulator again after applying service brakes repeatedly to prevent trapping oil in accumulator. Oil in accumulator will give inaccurate precharge reading.

6.

Charge accumulator again.

7.

Apply service brakes 20 to 30 times. This will release any pressure that may be in brake accumulators.

8.

Remove cover (15) from brake accumulator. Remove cap (16) from valve assembly on brake accumulator.

427-C1045

0114 00-9

TM 5-3805-291-23-2


0114 00

CHARGING - CONTINUED 9.

Use 0 to 2,000 psi (0 to 13,800 kPa) pressure gage (17) to check nitrogen charge in brake accumulator.

10.

Install chuck (18) of nitrogen charging valve on brake accumulator.

11.

Open valve (19) and charge line (20) to correct precharge.

12.

Turn valve handle (21) completely in clockwise direction.

13.

If reading on pressure gage is too high, slowly open valve (19) to lower pressure. If reading on pressure gage is too low, use this procedure to charge brake accumulator: 427-C1046

a.

Connect hose from nitrogen cylinder to valve (19).

b.

Close valve (19) and open valve on nitrogen cylinder. Adjust screw (22) on regulator assembly (23) until pressure gage (24) is at correct charging pressure.

c.

Open valve (19) and charge brake accumulator. Then close valve. If pressure gage (17) and pressure gage (24) show same reading and readings do not change, brake accumulator has correct charge.

d.

If pressure reading on gage (17) decreases, open valve (19) and allow more nitrogen to fill brake accumulator.

e.

Repeat this procedure until pressure gage (17) and pressure gage (24) show same reading. Make sure that neither reading changes when valve (19) is closed.

14.

Close valve (19). Close valve on nitrogen cylinder.

15.

Turn valve (21) on chuck (18) in counterclockwise direction. Remove nitrogen fitting equipment.

16.

Repeat steps 1 thru 15 for other brake accumulator.

END OF WORK PACKAGE

0114 00-10

4 TM 5-3805-291-23-2

PARKING BRAKE CONTROL VALVE REPLACEMENT

0115 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Materials/Parts

O-ring (3) Personnel Required MOS 62B, Construction Equipment Repairer (2) References TM 5-3805-291-10

Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

0115 00-1

Equipment Conditions Right rear fender removed (WP 0137 00) Drawings Required TM 5-3805-291-23P, Figure 102 Estimated Time to Complete Task 2.0 hr

TM 5-3805-291-23-2

PARKING BRAKE CONTROL VALVE REPLACEMENT - CONTINUED

0115 00

REMOVAL


NOTE • Tag hoses prior to removal to ensure correct installation. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. 1.

Disconnect three hose assemblies (1) and O-rings (2) from parking brake control valve (3). Discard O-rings.

2.

Disconnect wiring harness connectors (4) from parking brake control valve (3).

3.

Remove two bolts (5), washers (6), and nuts (7) from parking brake control valve (3).

427-C0115

0115 00-2

TM 5-3805-291-23-2

PARKING BRAKE CONTROL VALVE REPLACEMENT - CONTINUED

0115 00


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Position parking brake control valve (3) on machine.

2.

Install two washers (6), nuts (7), and bolts (5) on parking brake control valve (3).

3.

Connect wiring harness connectors (4) to parking brake control valve (3).

4.

Lubricate three new O-rings (2) with thin coat of clean oil. Install new O-rings in hose assemblies (1). Connect hose assemblies to parking brake control valve (3).

5.


6.


7.

Check for leaks.

8.

Install right rear fender (WP 0137 00).

END OF WORK PACKAGE

0115 00-3/(0115 00-4 Blank)

4 TM 5-3805-291-23-2

SERVICE BRAKE CONTROL VALVE REPLACEMENT

0116 00


Materials/Parts - Continued

Unit





O-ring (10)


Personnel Required

Quick disconnect tool - 06 (Item 58, WP 0232 00)

References


Quick disconnect tool - 08 (Item 59, WP 0232 00) Materials/Parts



Front guard removed (WP 0133 00)

Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

Hydraulic tank drained (WP 0148 00) Drawings Required TM 5-3805-291-23P, Figure 102 Estimated Time to Complete Task 2.0 hr

WARNING •


•



TM 5-3805-291-23-2

SERVICE BRAKE CONTROL VALVE REPLACEMENT - CONTINUED

NOTE •


•


REMOVAL 1.

Disconnect five hose assemblies (1) and remove O-rings (2) from fitting assemblies (3). Discard O-rings.

2.

Remove two nuts (4), washers (5), and control valve (6) from machine.

NOTE Note position of fitting assemblies before removal to aid in installation. 3.

Remove five fitting assemblies (3) from control valve (6).

4.

Remove and discard five O-rings (7) from fitting assemblies (3).


WARNING •


•


1.


2.

Dry parts with compressed air. 0116 00-2

0116 00

TM 5-3805-291-23-2

SERVICE BRAKE CONTROL VALVE REPLACEMENT - CONTINUED CLEANING AND INSPECTION - CONTINUED 3.


INSTALLATION 1.

Install five new O-rings (7) in fitting assemblies (3).

2.

Install five fitting assemblies (3) on control valve (6).

3.

Install control valve (6), two washers (5), and nuts (4) on machine.

4.

Install five new O-rings (2) in fitting assemblies (3) and connect hose assemblies (1) to fitting assemblies.

5.


6.

Install front guard (WP 0133 00).

7.


8.

Apply pressure to brake pedal several times.

9.


10.

Check for leaks around control valve.

11.

Adjust hydraulic tank oil level as necessary (TM 5-3805-291-10).

END OF WORK PACKAGE

0116 00-3/(0116 00-4 Blank)

0116 00

14 TM 5-3805-291-23-2

SERVICE BRAKE LINES AND HOSES REPLACEMENT

0117 00





References


WP 0112 00 WP 0114 00 WP 0116 00 WP 0137 00

Materials/Parts Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00) O-ring (61)

WP 0159 00 Equipment Conditions Hydraulic filter access door opened (TM 5-3805291-10) Hydraulic tank drained (WP 0148 00) Drawings Required TM 5-3805-291-23P, Figure 102 Estimated Time to Complete Task 3.0 hr

WARNING •


•


•



0117 00-1

TM 5-3805-291-23-2

SERVICE BRAKE LINES AND HOSES REPLACEMENT - CONTINUED

0117 00

NOTE •


•


REMOVAL 1.

Disconnect hoses and fittings from service brake control valve (WP 0116 00). Remove all associated clips, clamps, and tiedown straps. Discard tiedown straps.

2.

Disconnect hoses (1 and 2) from two fittings (3) and remove hoses from machine. Remove and discard two O-rings (4).

3.

Disconnect hoses (5 and 6) from two fittings (3). Remove and discard two O-rings (7). Remove all associated clips, clamps, and tiedown straps. Discard tiedown straps.

4.

Remove two fittings (3) from partition (8). Remove and discard two O-rings (9).

0117 00-2

TM 5-3805-291-23-2


0117 00


Disconnect hoses (5 and 6) from two fittings (10) and remove hoses from machine. Remove and discard O-rings (11 and 12). Remove all associated clips, clamps, and tiedown straps. Discard tiedown straps.

6.

Disconnect hoses (13 and 14) from two fittings (10). Remove and discard O-rings (15 and 16).

7.

Remove two fittings (10) from bracket (17). Remove and discard two O-rings (18).

8.

Disconnect hose (15) from parking brake actuator (19) and remove hose from machine (WP 0112 00).

427-C1347

0117 00-3

TM 5-3805-291-23-2


0117 00


Disconnect hose (14) from T (20). Remove and discard O-ring (21).

10.

Disconnect hose (22) from T (20). Remove and discard O-ring (23).

11.

Remove T (20) from elbow (24). Remove and discard O-ring (25).

12.

Remove elbow (24) from machine. Remove and discard O-ring (26).

13.

Disconnect tube (22) from fitting (27) and remove hose from machine. Remove and discard O-ring (28).

14.

Remove fitting (27) from machine. Remove and discard O-ring (29).

15.

Repeat steps 9 thru 14 for rear axle.

16.

Disconnect hoses (30, 31, and 32) from T (33) and remove hose (30) from machine. Remove and discard three O-rings (34).

17.

Remove T (33) (with three fittings) from machine.

18.

Disconnect hoses (31, 35, and 36) from valve (37) and remove hose (31) from machine. Remove and discard three O-rings (38).

19.

Remove valve (37) (with three fittings) from machine.

427-C1348

427-C1349

0117 00-4

TM 5-3805-291-23-2


0117 00


Disconnect hose (36) from valve (39) and remove hose from machine. Remove and discard O-ring (40).

21.

Disconnect hose (41) from valve (39). Remove and discard O-ring (42).

22.

Remove left rear fender (WP 0137 00).

23.

Remove associated clips and clamps from machine, disconnect hose (41) from hydraulic tank (43) (WP 0159 00), and remove hose from machine.

24.

Disconnect line (44) from valve (39). Remove and discard O-ring (45). Remove valve (39) (with three fittings) from machine.

25.

Disconnect all hoses and fittings from brake accumulators (WP 0114 00) and remove applicable hoses from machine.

427-C1350

26.

Disconnect hose (46) from fitting (47). Remove and discard O-ring (48).

27.

Remove fitting (47) from sampling valve (49). Remove and discard O-ring (50).

427-C1351

0117 00-5

TM 5-3805-291-23-2


0117 00


Disconnect four hoses (51, 52, and 53) from four fittings (54, 55, and 56) and remove hoses (51 and 53) from machine. Remove and discard four O-rings (57, 58, and 59). Remove all associated clips, clamps, and tiedown straps. Discard tiedown straps.

29.

Remove four fittings (54, 55, and 56) from brake manifold (60). Remove and discard four O-rings (61, 62, and 63).

427-C1352

30.

Disconnect hose (53) from fitting (64) and remove hose from machine. Remove and discard O-ring (65).

31.

Remove fitting (64) from braking/hydraulic fan pump (66). Remove and discard O-ring (67). Remove all associated clips, clamps, and tiedown straps. Discard tiedown straps.

32.


33.

Remove fitting (69) from braking/hydraulic fan pump (66). Remove and discard O-ring (71).

34.

Remove four bolts (72) and washers (73) and disconnect hose (74) from braking/hydraulic fan pump (66). Remove and discard O-ring (75).

35.

Disconnect hose (74) from hydraulic tank (WP 0159 00) and remove hose from machine.

427-C1353

0117 00-6

TM 5-3805-291-23-2

SERVICE BRAKE LINES AND HOSES REPLACEMENT - CONTINUED REMOVAL - CONTINUED 36.

Disconnect hose (68) from coupling (76). Remove and discard O-ring (77).

37.


38.

Remove fitting (79) from coupling (76). Remove and discard O-ring (81).

39.

Disconnect hose (82) from coupling (76). Remove and discard O-ring (83).

40.

Remove coupling (76) from bracket (84). Remove and discard O-ring (85).

41.


427-C1354

0117 00-7

0117 00

TM 5-3805-291-23-2


0117 00


Disconnect hose (82) from elbow (86) and remove hose from machine. Remove and discard O-ring (87).

43.

Remove elbow (86) from fitting (88). Remove and discard O-ring (89).

44.


45.

Disconnect hose (91) from elbow (92). Remove and discard O-ring (93).

46.

Disconnect hose (94) from elbow (92). Remove and discard O-ring (93).

47.

Remove elbow (92) from machine.

48.

Disconnect hose (94) from elbow (95) and remove hose from machine. Remove and discard O-ring (96).

49.

Remove elbow (95) from fitting (97). Remove and discard O-ring (98).

50.


427-C1355

0117 00-8

TM 5-3805-291-23-2

SERVICE BRAKE LINES AND HOSES REPLACEMENT - CONTINUED INSTALLATION


1.

Install new O-ring (99) and fitting (97) on machine.

2.

Install new O-ring (98) and elbow (95) on fitting (97).

3.

Install new O-ring (96) in hose (94) and connect hose to elbow (95).

4.

Install elbow (92) on machine.

5.


6.


7.

Install new O-ring (89) and elbow (86) on fitting (88).

8.

Install fitting (88) on machine.

9.


10.

Connect hose (78) on hydraulic tank (WP 0159 00).

11.

Install new O-ring (85) and coupling (76) on bracket (84).

12.

Install new O-ring (83) and connect hose (82) to coupling (76).

13.

Install new O-ring (81) and fitting (79) on coupling (76).

14.

Install new O-ring (80) and connect hose (78) to fitting (79).

15.

Install new O-ring (77) and connect hose (68) to coupling (76).

427-C1354

0117 00-9

0117 00

TM 5-3805-291-23-2


0117 00


Connect hose (74) to hydraulic tank (WP 0159 00).

17.

Install new O-ring (75) and position hose (74) on machine and install four washers (73) and bolts (72).

18.

Install new O-ring (71) and fitting (69) on braking/hydraulic fan pump (66).

19.

Install new O-ring (70) in fitting (69) and connect hose (68).

20.

Install new O-ring (67) and fitting (64) on braking/hydraulic fan pump (66). Install all associated clips, clamps, and new tiedown straps.

21.


427-C1353

22.

Install four new O-rings (61, 62, and 63) and four fittings (54, 55, and 56) on brake manifold (60).

23.

Install four new O-rings (57, 58, and 59) and connect four hoses (51, 52, and 53) to four fittings (54, 55, and 56). Install all associated clips, clamps, and new tiedown straps.

427-C1352

0117 00-10

TM 5-3805-291-23-2


0117 00


Install new O-ring (50) and fitting (47) on sampling valve (49).

25.

Install new O-ring (48) and connect hose (46) on fitting (47).

26.

Connect hoses and fittings on brake accumulators (WP 0114 00).

427-C1351

27.

Install valve (39) and three fittings on machine, install new O-ring (45), and connect line (44) to valve.

28.

Connect hose (41) to hydraulic tank (WP 0159 00). Install all associated clips and clamps.

29.

Install left rear fender (WP 0137 00).

30.

Install new O-ring (42) and connect hose (41) to valve (39).

31.

Install new O-ring (40) and connect hose (36) to valve (39).

427-C1350

0117 00-11

TM 5-3805-291-23-2


0117 00


Install valve (37) (with three fittings) on machine, install three new O-rings (38), and connect hoses (31, 35, and 36) to valve.

33.

Install T (33) (with three fittings) on machine.

34.

Install three new O-rings (34) and connect hoses (30, 31, and 32) to T (33).

427-C1349

35.

Install new O-ring (29) and fitting (27) on machine.

36.


37.

Install new O-ring (26) and elbow (24) on machine.

38.

Install new O-ring (25) and T (20) on elbow (24).

39.

Install new O-ring (23) and connect hose (22) to T (20).

40.

Install new O-ring (21) and connect hose (14) to T (20).

41.

Repeat steps 35 thru 40 for rear axle.

427-C1348

0117 00-12

TM 5-3805-291-23-2


0117 00


Connect hose (15) to parking brake actuator (19) (WP 0112 00).

427-C1347

43.

Install two new O-rings (18) and fittings (10) on bracket (17).

44.

Install new O-rings (16 and 15) and connect hoses (14 and 13) on fittings (10).

45.

Install two new O-rings (13) and connect hoses (5 and 6) to fittings (10).

0117 00-13

TM 5-3805-291-23-2


0117 00


Install two new O-rings (9) and fittings (3) on partition (8).

47.

Install two new O-rings (9) and connect hoses (6 and 5) to fittings (3). Install all associated clips, clamps, and new tiedown straps.

48.

Install two O-rings (4) and connect hoses (2 and 1) to fittings (3).

49.

Install fittings and connect hoses to service brake control valve (WP 0116 00). Install all associated clips, clamps, and new tiedowns straps.

50.


51.


52.


53.

Check for leaks.

54.

Close hydraulic filter access door (TM 5-3805-291-10).

END OF WORK PACKAGE

0117 00-14

4 TM 5-3805-291-23-2

BRAKE PEDALS REPLACEMENT

0118 00



Unit Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Pin

Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Brake control valve unbolted from brake pedal (WP 0116 00) Drawings Required

Retaining ring

TM 5-3805-291-23P, Figure 103

Personnel Required



0118 00-1

TM 5-3805-291-23-2

BRAKE PEDALS REPLACEMENT - CONTINUED

0118 00

REMOVAL 1.

Disconnect wiring harness connectors (1 and 2).

2.

Remove six bolts (3) and washers (4) from brake pedal assemblies (5 and 6).

3.

Remove brake pedal assemblies (5 and 6) from machine.

4.

Remove six bolts (7) from side cover (8).

5.

Remove pin (9) and retaining ring (10) from shaft (11). Discard pin and retaining ring.

6.

Remove shaft (11) from brake pedal assemblies (5 and 6).

427-C0134

0118 00-2

TM 5-3805-291-23-2

BRAKE PEDALS REPLACEMENT - CONTINUED

0118 00


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Install shaft (11) on brake pedal assemblies (6 and 5).

2.

Install new pin (9) and new retaining ring (10) on shaft (11).

3.

Install six bolts (7) on side cover (8).

4.

Position brake pedal assemblies (6 and 5) on machine.

5.

Install six washers (4) and bolts (3) on brake pedal assemblies (5 and 6).

6.

Connect wiring harness connectors (2 and 1).

7.

Connect brake control valve (WP 0116 00).

END OF WORK PACKAGE

0118 00-3/(0118 00-4 Blank)

4 TM 5-3805-291-23-2

WHEEL AND TIRE ASSEMBLY (FRONT) REPLACEMENT

0119 00



Materials/Parts

Unit



Rag, wiping (Item 35, WP 0233 00) Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions

Pin, shoulder, headless (Item 48, WP 0232 00) Puller, hydraulic (Item 53, WP 0232 00) Pump, hydraulic ram, hand-driven (Item 56, WP 0232 00) Repair tool, special (Item 63, WP 0232 00)

Steering frame lock connected (TM 5-3805-29110) Front fender removed (WP 0136 00) Drawings Required

Stand assembly (Item 78, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00)

TM 5-3805-291-23P, Figures 104 and 105 Estimated Time to Complete Task

Lifting equipment, 2,250-lb capacity

1.5 hr

Multiplier, torque

REMOVAL 1.

Use Pump, hydraulic ram, hand-driven (Item 56, WP 0232 00) and Puller, hydraulic (Item 53, WP 0232 00) to raise front tires off ground.

427-C0192

0119 00-1

TM 5-3805-291-23-2

WHEEL AND TIRE ASSEMBLY (FRONT) REPLACEMENT - CONTINUED

0119 00


Assemble Stand assembly (Item 78, WP 0232 00), Pin, shoulder, headless (Item 48, WP 0232 00), and Repair tool, special (Item 63, WP 0232 00), as shown, to support machine.

427-C0193

WARNING


NOTE Rim and tire weighs 1,500 lb (680 kg).

3.

With assistance, attach lifting equipment on tire and rim (1).

4.

Remove 20 bolts (2) and tire and rim (1) from machine.

427-C0194

0119 00-2

TM 5-3805-291-23-2


0119 00


WARNING •


•


1.


2.


3.


INSTALLATION

WARNING


NOTE

1.

•

Rim and tire weighs 1,500 lb (680 kg).

•

Tighten bolts in criss-cross pattern.

With assistance, use lifting equipment to position tire and rim (1) on machine. Install 20 bolts (2) on rim and tighten to 420 + 60 lb-ft (570 + 80 Nm). Tighten bolts an additional 60 + 5 degrees.

0119 00-3

TM 5-3805-291-23-2


0119 00


Use Pump, hydraulic ram, hand-driven (Item 56, WP 0232 00) and Puller, hydraulic (Item 53, WP 0232 00) to raise machine and remove Stand assembly (Item 78, WP 0232 00), Pin, shoulder, headless (Item 48, WP 0232 00), and Repair tool, special (Item 63, WP 0232 00), as shown, from under machine. Lower machine to ground.

427-C0192

3.

Install front fender (WP 0136 00).


4.


END OF WORK PACKAGE

0119 00-4

427-C0193

4 TM 5-3805-291-23-2

WHEEL AND TIRE ASSEMBLY (REAR) REPLACEMENT

0120 00




Unit



Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions Steering frame lock connected (TM 5-3805-29110) Rear fender removed (WP 0137 00)

Pump, hydraulic (Item 55, WP 0232 00)

Drawings Required

Stand, lift gp (Item 80, WP 0232 00) (2)

TM 5-3805-291-23P, Figures 104 and 105



Wood block, 4 x 4

REMOVAL 1.

Place wood block between rear axle housing (1) and frame (2). Repeat for opposite side of machine. This will prevent axle housing from oscillating.

2.

Position lift stands and hydraulic pump under frame. Raise machine until rear tires/rims (1) are off ground.

427-C0195

0120 00-1

TM 5-3805-291-23-2

WHEEL AND TIRE ASSEMBLY (REAR) REPLACEMENT - CONTINUED

0120 00

REMOVAL - CONTINUED


NOTE Rim and tire weighs 1,500 lb (680 kg). 3.

With assistance, attach lifting equipment on tire and rim (3).

4.

Remove 20 bolts (4) and washers (5) from rim.

5.

Remove tire and rim (3) from machine.

427-C0196


WARNING •


•


1.


2.


3.

Inspect all parts for damage, wear, pitting, cracks, or corrosion and replace if necessary. 0120 00-2

TM 5-3805-291-23-2

WHEEL AND TIRE ASSEMBLY (REAR) REPLACEMENT - CONTINUED

0120 00

INSTALLATION

WARNING


NOTE •

Rim and tire weighs 1,500 lb (680 kg).

•

Tighten bolts in criss-cross pattern.

1.

With assistance, use lifting equipment to position tire and rim (3) on machine. Install 20 bolts (4) and washers (5) on rim and tighten to 420 + 60 lb-ft (570 + 80 Nm). Tighten bolts an additional 60 + 5 degrees.

2.

Lower machine to ground.

3.

Remove block between rear axle housing (1) and frame (2). Repeat for opposite side of machine.

427-C0195

4.



5.



10 TM 5-3805-291-23-2

STEERING COLUMN REPLACEMENT

0121 00






References


WP 0118 00 WP 0122 00 Equipment Conditions Turnlamp lever removed (WP 0066 00)

Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00)

Transmission shift lever removed (WP 0101 00) Steering frame lock connected (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figure 106 Estimated Time to Complete Task

Gasket

2.0 hr

Snap ring

0121 00-1

TM 5-3805-291-23-2

STEERING COLUMN REPLACEMENT - CONTINUED

0121 00

REMOVAL

NOTE

1.

•

Steering wheel, turnlamp lever, and transmission shift lever need not be removed to remove steering column.

•

Tag wiring harnesses prior to removal to ensure correct installation.

Disconnect wiring harness (1) under floor mat on right side of cab.

427-C1146

2.

Disconnect two wiring harnesses (2) under floor mat on left side of cab.

427-C1147

0121 00-2

TM 5-3805-291-23-2


0121 00


Remove 13 screws (3) from upper and lower steering column cowls (4 and 5) and remove cowls from machine.

427-C1153

4.

Remove and discard all associated tiedown straps and disconnect five wiring harnesses (6) under steering column support bracket (7).

427-C1148

5.

Remove nut (8), disconnect ground wire (9), and reinstall nut.

427-C1149

0121 00-3

TM 5-3805-291-23-2


0121 00


Remove two nuts (10) and washers (11) from each side of steering column base (12).

7.

Remove two bolts (13) and washers (14) from steering column base (12).

427-C1150

8.

Remove bolt (15) from center of steering column base (12).

9.

Remove brake pedal assembly (16) (WP 0118 00).

10.

Remove two bolts (17) and washers (18) from steering column base (12).

11.

Remove four nuts (20) and bolts (19) from steering column support bracket (7) and remove steering column (21) from machine.

12.

Remove and discard gasket (22).

427-C1152

427-C1151

0121 00-4

TM 5-3805-291-23-2


0121 00


Remove steering wheel (23) from steering column (21) (WP 0122 00).

14.

Remove two bolts (24) and cover (25) from steering column (21).

427-C1927

15.

Remove two bolts (26), four washers (27), and bracket (28) from steering column (21).

16.

Remove four bolts (29), shift lever (30), and cover (31) from steering column (21).

427-C1928

0121 00-5

TM 5-3805-291-23-2


0121 00


Remove snap ring (32) and pin (33) from steering column (21). Discard snap ring.

18.

Remove two bolts (34) and strut (35) from steering column (21).

427-C1941


WARNING •


•


1.


2.


3.


0121 00-6

TM 5-3805-291-23-2


0121 00

INSTALLATION 1.

Install upper end strut (35) and two bolts (34) on steering column (21).

2.

Install lower end of strut (35), pin (33), and new snap ring (32) on steering column (21).

3.

Install cover (31), shift lever (30), and four bolts (29) on steering column (21).

4.

Install bracket (28), four washer (27), and two bolts (26) on steering column (21).

427-C1928

5.

Install cover (25) and two bolts (24) on steering column (21).

6.

Install steering wheel (23) on steering column (21) (WP 0122 00).

427-C1927

0121 00-7

TM 5-3805-291-23-2


0121 00


Position new gasket (22) on machine.

8.

Position steering column (21) on machine and install four bolts (19) and nuts (20) on steering column support bracket (7).

9.

Install two washers (18) and bolts (17) on steering column base (12).

10.

Install brake pedal assembly (16) (WP 0118 00).

11.

Install bolt (15) in center of steering column base (12).

427-C1152

427-C1151

12.

Install two washers (14) and bolts (13) on steering column base (12).

13.

Install two washers (11) and nuts (10) on each side of steering column base (12).

14.

Remove nut (8), connect ground wire (9), and reinstall nut.

427-C1150

0121 00-8

427-C1149

TM 5-3805-291-23-2


0121 00


Connect five wiring harnesses (6) under steering column support bracket (7), securing wires in place with new tiedown straps as necessary.

427-C1148

16.

Position upper and lower steering column cowls (4 and 5) in cab and install 13 screws (3) in steering column cowls.

427-C1153

0121 00-9

TM 5-3805-291-23-2


0121 00


Connect two wiring harnesses (2) located on left side of cab and install floor mat.

427-C1147

18.

Connect wiring harness (1) located on right side of cab and install floor mat.

427-C1146

19.

If removed, install turnlamp lever (WP 0066 00) and transmission shift lever (WP 0101 00).

WARNING Before operating the machine, secure the steering frame lock in the stowed position. DO NOT operate machine with steering frame lock connected. Steering frame lock must be disconnected and securely stowed. Failure to follow this warning may result in injury or death to personnel. 20.


21.

Verify correct steering column operation (TM 5-3805-291-10).


4 TM 5-3805-291-23-2

STEERING WHEEL REPLACEMENT

0122 00




Unit


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Puller kit, steering wheel (Item 54, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Materials/Parts

Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figure 106 Estimated Time to Complete Task 0.5 hr


REMOVAL 1.


Pry up on horn assembly (1) and set horn assembly aside.

0122 00-1

TM 5-3805-291-23-2

STEERING WHEEL REPLACEMENT - CONTINUED REMOVAL - CONTINUED 2.

Disconnect wiring harness (2) from horn assembly (1). Remove horn assembly from machine.

3.

Remove nut (3) from steering wheel (4).

0122 00-2

0122 00

TM 5-3805-291-23-2

STEERING WHEEL REPLACEMENT - CONTINUED

0122 00


Remove steering wheel (4) with steering puller kit.

483-1308

INSTALLATION 1.

Install steering wheel (4) and nut (3) on steering pillar. Tighten nut to 37 ± 3 lb-ft (50 ± 4 Nm).

2.

Connect wiring harness (2) to horn assembly (1). Install horn assembly on steering wheel (4).

3.

Verify correct steering operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0122 00-3/(0122 00-4 Blank)

4 TM 5-3805-291-23-2

SECONDARY STEERING PUMP AND ELECTRIC MOTOR MAINTENANCE

0123 00

THIS WORK PACKAGE COVERS Removal, Disassembly, Cleaning and Inspection, Assembly, Installation INITIAL SETUP Materials/Parts - Continued


Tag, marker (Item 43, WP 0233 00) Gasket

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)

O-ring (2) Personnel Required MOS 62B, Construction Equipment Repairer References TM 5-3805-291-10 Equipment Conditions

Materials/Parts

Left side panel removed (WP 0133 00)

Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Left side ladder removed (WP 0134 00) Hydraulic tank drained (WP 0148 00) Drawings Required TM 5-3805-291-23P, Figures 75 and 107 Estimated Time to Complete Task 3.0 hr

0123 00-1

TM 5-3805-291-23-2

SECONDARY STEERING PUMP AND ELECTRIC MOTOR MAINTENANCE - CONTINUED

0123 00

REMOVAL

NOTE Tag hoses and wiring harnesses prior to removal to ensure correct installation.

1.

Remove two nuts (1) and washers (2) and disconnect cable assemblies and wiring harness (3) from electric motor (4).

2.

Disconnect two hose assemblies (5) from secondary steering pump (6).

3.

Remove two O-rings (7) from hose assemblies (5). Discard O-rings.

4.

Remove two bolts (8), washers (9), electric motor (4), and secondary steering pump (6) from machine.

427-C0524

0123 00-2

TM 5-3805-291-23-2

SECONDARY STEERING PUMP AND ELECTRIC MOTOR MAINTENANCE - CONTINUED

0123 00

DISASSEMBLY 1.

Remove four bolts (10), washers (11), and bracket (12) from electric motor (4).

2.

Remove two fittings (15) from secondary steering pump (6).

3.

Remove two bolts (13), washers (14), secondary steering pump (6), and gasket (16) from electric motor (4). Discard gasket.

427-C0525


WARNING •


•


1.


2.


3.


4.


ASSEMBLY


1.

Install new gasket (16) between secondary steering pump (6) and electric motor (4) and install two washers (14) and bolts (13).

2.

Install two fittings (15) on secondary steering pump (6).

3.

Position bracket assembly (12) on electric motor (4) and install four washers (11) and bolts (10). 0123 00-3

TM 5-3805-291-23-2

SECONDARY STEERING PUMP AND ELECTRIC MOTOR MAINTENANCE - CONTINUED INSTALLATION 1.

Position electric motor (4) and secondary steering pump (6) on machine and install two washers (9) and bolts (8).

2.

Lubricate two new O-rings (7) with thin coat of clean hydraulic oil and install in hose assemblies (5). Connect hose assemblies to secondary steering pump (6).

3.

Connect cable assemblies and wiring harness (3) to electric motor (4) and install two washers (2) and nuts (1). Tighten nuts to 15 lb-ft (20 Nm).

4.

Install left side panel (WP 0133 00).

5.

Install left side ladder (WP 0134 00).

6.


7.

Run engine and verify correct operation of secondary steering pump and electric motor (TM 5-3805-291-10).

END OF WORK PACKAGE

0123 00-4

0123 00

10 TM 5-3805-291-23-2

STEERING HOSES, LINES, AND FITTINGS REPLACEMENT

0124 00



Unit

References


TM 5-3805-291-10


WP 0125 00 WP 0127 00

Materials/Parts

WP 0128 00

Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00)


Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

Hydraulic tank drained (WP 0148 00) Cab removed (WP 0132 00) Drawings Required TM 5-3805-291-23P, Figures 110 and 111



O-ring (24)

4.0 hr

WARNING •


•


•



TM 5-3805-291-23-2

STEERING HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED

NOTE •


•


REMOVAL 1.

Disconnect five hoses (1 thru 5) and associated fittings from steering metering pump (WP 0128 00).

2.

Remove bolt (6) and washer (7) from clip (8).

3.

Remove bolt (9) and washer (10) from clip (11). Remove clip from machine.

4.

Disconnect hose (1) from elbow (12) and remove hose from machine.

5.

Remove O-ring (13) from hose (1). Discard O-ring.

6.

Disconnect hose (2) from bracket (14) and remove hose from machine.

7.


8.

Disconnect hose (3) from elbow (16) and remove hose and clip (8) from machine.

9.


10.


11.


12.


13.


14.

Remove elbows (12, 14, 16, 18, and 20) from machine.

15.

Remove five O-rings (22 thru 26) from elbows (12, 14, 16, 18, and 20). Discard O-rings.

0124 00-2

0124 00

TM 5-3805-291-23-2


0124 00

REMOVAL - CONTINUED

427-C0528

0124 00-3

TM 5-3805-291-23-2


0124 00


Remove four O-rings (27 thru 30) from lines (31 thru 34). Discard O-rings.

17.

Disconnect hose (35) from line (31).

18.


19.

Disconnect line (31) from fitting (37) and remove line from machine.

20.

Remove O-ring (38) from line (31). Discard O-ring.

21.

Disconnect line (32) and fitting from steering control valve (WP 0127 00).

22.

Disconnect hose (39) from line (33).

23.


24.

Disconnect line (33) from fitting (41).

25.


26.

Disconnect line (34) from elbow (43) and remove line from machine.

27.


28.

Disconnect hose (45) from elbow (43).

29.


30.

Remove elbow (43) from machine.

31.


32.

Disconnect hose (45) and fitting from steering control valve (WP 0127 00) and remove hose and clip (49) from machine.

33.


34.

Disconnect hose (35) and fitting from steering control valve (WP 0127 00) and remove hose and clip (52) from machine.

0124 00-4

TM 5-3805-291-23-2


0124 00

REMOVAL - CONTINUED

427-C0529

0124 00-5

TM 5-3805-291-23-2


0124 00


Disconnect line (53) from fitting (54).

36.


37.

Disconnect line (53) from fitting (56) and remove line from machine.

38.


39.

Remove fittings (54 and 56) from machine.

40.

Remove O-rings (58 and 59) from fittings (54 and 56). Discard O-rings.

41.

Disconnect hoses (60 and 61) and remove associated fittings from steering control valve (WP 0127 00).

42.

Disconnect hoses (60 and 61) and remove associated fittings from steering cylinder (WP 0125 00). Remove hoses from machine.

43.

Repeat steps 41 and 42 for other steering cylinder hoses.

44.

Disconnect hose (62) and remove fitting from hydraulic tank (WP 0159 00).

45.

Disconnect hose (62) and remove fitting from steering control valve (WP 0127 00). Remove hose from machine.

46.

Disconnect pipe (63) and remove fitting from hydraulic tank (WP 0159 00).

47.

Disconnect pipe (63) and remove fitting from steering control valve (WP 0127 00).

48.

Remove two clamps (64) and sleeve (65) from pipe (63).

0124 00-6

TM 5-3805-291-23-2


0124 00

REMOVAL - CONTINUED

427-C1853

INSTALLATION


1.

Install sleeve (65) and two clamps (64) on pipe (63).

2.

Position pipe (63) on machine and connect pipe to steering control valve (WP 0127 00).

3.

Connect pipe (63) to hydraulic tank (WP 0159 00).

4.

Position hose (62) on machine and connect hose to steering control valve (WP 0127 00).

5.


6.

Connect hoses (60 and 61) to steering cylinder (WP 0125 00).

7.

Connect hoses (60 and 61) to steering control valve (WP 0127 00).

8.

Repeat steps 6 and 7 for other steering cylinder hoses.

9.

Install new O-rings (58 and 59) in fittings (54 and 56) and install fittings on machine.

10.

Install new O-ring (57) in line (53) and connect line to fitting (56).

11.

Install new O-ring (55) in line (53) and connect line to fitting (54). 0124 00-7

TM 5-3805-291-23-2


0124 00


Position clip (52) and install washer (51) and bolt (50) on machine.

13.

Route hose (35) through clip (52) and connect hose to steering control valve (WP 0127 00).

14.


15.

Route hose (45) through clip (49) and connect hose to steering control valve (WP 0127 00).

16.

Install elbow (43) on machine.

17.


18.

Install new O-ring (44) in line (34) and connect line to elbow (43).

19.


20.

Install new O-ring (40) in hose (39) and connect hose to line (33).

21.

Connect line (32) and fitting to steering control valve (WP 0127 00).

22.


23.

Install new O-ring (36) in hose (35) and connect hose to line (31).

24.

Install four new O-rings (27 thru 30) in lines (31 thru 34).

427-C0529

0124 00-8

TM 5-3805-291-23-2


0124 00


Install five new O-rings (22 thru 26) in elbows (12, 14, 16, 18, and 20) and install elbows on machine.

26.


27.


28.


29.


30.

Route hose (3) through clip (8).

31.

Install new O-ring (15) in hose (2) and connect hose to bracket (14).

32.

Route hose (2) through clip (8).

33.


34.


35.

Route hose (1) through clips (11 and 8).

36.

Connect five hoses (1 thru 5) to steering metering pump (WP 0128 00).

427-C0528

0124 00-9

TM 5-3805-291-23-2

STEERING HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 37.

Install cab (WP 0132 00).

38.

Fill hydraulic tank to correct level (WP 0148 00).

39.


40.


41.

Check for leaks.

END OF WORK PACKAGE

0124 00-10

0124 00

6 TM 5-3805-291-23-2

STEERING CYLINDERS REPLACEMENT

0125 00




Unit





O-ring (8)


Personnel Required






Rear fenders removed (WP 0137 00)





WARNING •


•


•


0125 00-1

TM 5-3805-291-23-2

STEERING CYLINDERS REPLACEMENT - CONTINUED

0125 00


NOTE •


•


REMOVAL 1.

Disconnect two hose assemblies (1) and remove O-rings (2) from steering cylinder (3). Discard O-rings.

2.

Remove two fittings (4) and O-rings (5) from steering cylinder (3). Discard O-rings.

3.

Remove lubrication line (6) from steering cylinder (3).

427-C0530

0125 00-2

TM 5-3805-291-23-2


0125 00

REMOVAL - CONTINUED

WARNING


NOTE Steering cylinder weighs 95 lb (43 kg). 4.

Attach lifting equipment to steering cylinder (3).

5.

With assistance, remove bolt (7), washer (8), and pin assembly (9).

6.

Remove bolt (10), washer (11), pin assembly (12), and steering cylinder (3) from machine.

7.

Repeat steps 1 thru 6 for other steering cylinder.

427-C0531

0125 00-3

TM 5-3805-291-23-2


0125 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION

WARNING


NOTE •

Steering cylinder weighs 95 lb (43 kg).

•

Apply a thin coat of clean oil to all O-rings before installation.

1.

Attach lifting equipment to steering cylinder (3).

2.

With assistance, position steering cylinder (3) on machine and install pin assembly (12), washer (11), and bolt (10).

3.

Install pin assembly (9), washer (8), and bolt (7) on steering cylinder (3).

0125 00-4

427-C0531

TM 5-3805-291-23-2


0125 00


Install lubrication line (6) on steering cylinder (3).

5.

Install two new O-rings (5) in fittings (4) and install fittings on steering cylinder (3).

6.

Install two new O-rings (2) in hose assemblies (1) and connect hose assemblies to steering cylinder (3).

7.

Repeat steps 1 thru 6 for other steering cylinder.

427-C0530

8.

Install rear fenders (WP 0137 00).

9.

Fill hydraulic system (WP 0148 00).

10.

Run engine and operate machine (TM 5-3805-291-10).

11.

Verify correct operation of steering system (TM 5-3805-291-10).

12.


13.

Check for leaks.


14.


END OF WORK PACKAGE

0125 00-5/(0125 00-6 Blank)

4 TM 5-3805-291-23-2

SECONDARY STEERING VALVE REPLACEMENT

0126 00






Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 2 (Item 71, WP 0232 00) Materials/Parts

Gasket (2) O-ring (2) Personnel Required MOS 62B, Construction Equipment Repairer References


TM 5-3805-291-10

Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00)

Equipment Conditions Cab removed (WP 0132 00) Drawings Required



WARNING •


•


•


•

Hydraulic oils used in performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

0126 00-1

TM 5-3805-291-23-2

SECONDARY STEERING VALVE REPLACEMENT - CONTINUED

0126 00


NOTE •

Tag hoses and wires prior to removal to ensure correct installation.

•


REMOVAL 1.

Disconnect two pressure switches (1) from chassis wiring harness (2).

2.

Remove bolt (3), washer (4), and two clips (5) and position pressure switches (1) aside.

3.

Disconnect hose assembly (6) from fitting (7).

4.

Remove and discard O-ring (8).

5.

Remove eight bolts (9), washers (10), four flange halves (11), and two gaskets (12) from two hose assemblies (13), and remove two hose assemblies. Discard gaskets.

6.

Remove three bolts (14), washers (15), and secondary steering valve (16) from machine.

7.

Remove fitting (7) from secondary steering valve (16).

8.


9.

Remove two pressure switches (1) from secondary steering valve (16).

427-C0526


WARNING •


•


1.


2.


3.


4.

Inspect oil passages to ensure they are clean and unobstructed. 0126 00-2

TM 5-3805-291-23-2

SECONDARY STEERING VALVE REPLACEMENT - CONTINUED

0126 00

INSTALLATION


1.

Install two pressure switches (1) on secondary steering valve (16).

2.

Install new O-ring (17) and fitting (7) on secondary steering valve (16).

3.

Position secondary steering valve (16) on machine and install three washers (15) and bolts (14).

4.

Install two new gaskets (12) and position two hose assemblies (13) and install four flange halves (11), eight washers (10), and bolts (9) on hose assemblies.

5.

Install new O-ring (8) and connect hose assembly (6) to fitting (7).

6.

Position pressure switches (1) and install two clips (5), washer (4), and bolt (3).

7.

Connect two pressure switches (1) to chassis wiring harness (2).

8.


9.

Verify proper operation of secondary steering (TM 5-3805-291-10).

END OF WORK PACKAGE

0126 00-3/(0126 00-4 Blank)

10 TM 5-3805-291-23-2

STEERING CONTROL VALVE MAINTENANCE

0127 00

THIS WORK PACKAGE COVERS Removal, Disassembly, Assembly, Installation


Materials/Parts - Continued Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)






Seal (3)





Materials/Parts

Cab removed (WP 0132 00)

Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)


WARNING •


•


•


•


0127 00-1

TM 5-3805-291-23-2

STEERING CONTROL VALVE MAINTENANCE - CONTINUED

0127 00


NOTE •


•


REMOVAL 1.

Disconnect three hoses (1) and remove O-rings (2) from fittings (3). Discard O-rings.

2.

Remove three fittings (3) and O-rings (4) from steering control valve assembly (5). Discard O-rings.

0127 00-2

TM 5-3805-291-23-2


0127 00


Remove four bolts (6) and washers (7) from two flange halves (8).

4.

Remove two flange halves (8) and O-ring (9) from steering control valve assembly (5). Discard O-ring.

5.

Disconnect two hose assemblies (10).

427-C1173

NOTE Perform steps 6 thru 8 on left side.

6.

Remove seven bolts (11) and washers (12) from upper valve assembly (13).

7.

Remove valve assembly (13) from steering control valve assembly (5).

8.


427-C1174

0127 00-3

TM 5-3805-291-23-2


0127 00


Remove two bolts (15) and washers (16) from flange (17).

10.

Remove flange (17), O-ring (18), spacer block (19), and seal (20) from steering control valve assembly (5). Discard O-ring and seal.

11.

Disconnect face port line (21) from fitting (22).

427-C1175

12.

Remove three bolts (23) and washers (24) from steering control valve assembly (5).

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may cause injury or death to personnel. 427-C1176

NOTE Steering control valve assembly weighs 95 lb (43 kg). 13.

With assistance, remove steering control valve assembly (5) from frame (25).

0127 00-4

TM 5-3805-291-23-2


0127 00

DISASSEMBLY 1.

Remove eight bolts (26), washers (27), and separate manifold (28) from control valve (29).

2.

Remove and discard two seals (30).

3.

Remove four fittings (31) and O-rings (32) from manifold (28). Discard O-rings.

4.

Remove cross-over relief valve (33) and three O-rings (34) from control valve (29). Discard O-rings.

5.

Remove pump backup relief valve (35) and three O-rings (36) from control valve (29). Discard O-rings.

427-C1879

0127 00-5

TM 5-3805-291-23-2


0127 00

DISASSEMBLY - CONTINUED 6.

Remove four bolts (37) and separate selector valve (38) from control valve (29).

7.

Remove three fittings (39) and two O-rings (40) from selector valve (38). Discard O-rings.

8.

Remove four bolts (41) and separate cover (42) from control valve (29).

9.

Remove and discard two O-rings (43).

427-C1880

ASSEMBLY


NOTE Steering control valve assembly weighs 95 lb (43 kg).

0127 00-6

TM 5-3805-291-23-2


0127 00

ASSEMBLY - CONTINUED 1.

Install two new O-rings (43), cover (42), and four bolts (41) on control valve (29).

2.

Install two new O-rings (40) and three fittings (39) on selector valve (38).

3.

Install selector valve (38) and four bolts (37) on control valve (29).

4.

Install three new O-rings (36) and pump backup relief valve (35) on control valve (29).

5.

Install three new O-rings (34) and cross-over relief valve (33) on control valve (29).

6.

Install four new O-rings (32) and fittings (31) on manifold (28).

7.

Install two new seals (30), manifold (28), eight washers (27), and bolts (26) on control valve (29).

427-C1879

0127 00-7

TM 5-3805-291-23-2


0127 00

INSTALLATION 1.

With assistance, position steering control valve assembly (5) on frame (25).

2.

Install three washers (24) and bolts (23) on steering control valve assembly (5).

427-C1176

3.

Connect face port line (21) to fitting (22).


4.

Install new O-ring (18), flange (17), seal (20), and spacer block (19) on steering control valve assembly (5).

5.

Install two washers (16) and bolts (15) on flange (17).

427-C1175

0127 00-8

TM 5-3805-291-23-2


0127 00


Connect two hose assemblies (14).

7.

Position valve assembly (13) on steering control valve assembly (5).

8.

Install seven washers (12) and bolts (11) on upper valve assembly (13).

9.


427-C1174

10.

Install new O-ring (9) and two flange halves (8) on steering control valve assembly (5).

11.

Install four washers (7) and bolts (6) on two flange halves (8).

427-C1173

0127 00-9

TM 5-3805-291-23-2

STEERING CONTROL VALVE MAINTENANCE - CONTINUED INSTALLATION - CONTINUED 12.

Install three new O-rings (4) and fittings (3) on steering control valve assembly (5). Tighten fittings to 37 ± 5 lb-ft (50 ± 7 Nm).

13.

Install three new O-rings (2) in hoses (1) and connect hoses to fittings (3).

14.


15.


16.


17.


18.

Check for steering system leaks.

END OF WORK PACKAGE

0127 00-10

0127 00

4 TM 5-3805-291-23-2

STEERING METERING PUMP REPLACEMENT

0128 00



Unit





O-ring (10)


Personnel Required









Front guard on cab removed (WP 0133 00) Drawings Required TM 5-3805-291-23P, Figures 111 and 114 Estimated Time to Complete Task 2.5 hr

WARNING •


•


•



TM 5-3805-291-23-2

STEERING METERING PUMP REPLACEMENT - CONTINUED

NOTE •


•


REMOVAL 1.

Disconnect five hose assemblies (1) from fittings (3).

2.

Remove five O-rings (2) from hose assemblies (1). Discard O-rings.

NOTE Mark shaft with reference to steering metering pump to aid in installation. 3.

Remove four bolts (4), washers (5), and steering metering pump (6) from machine.

NOTE Note position of fittings before removal to aid in installation. 4.

Remove five fittings (3) and O-rings (7) from steering metering pump (6). Discard O-rings.

0128 00-2

0128 00

TM 5-3805-291-23-2

STEERING METERING PUMP REPLACEMENT - CONTINUED

0128 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION


1.

Install five new O-rings (7) in fittings (3) and install fittings on steering metering pump (6).

2.

Position steering metering pump (6) on machine and install four washers (5) and bolts (4).

3.

Install five new O-rings (2) in hose assemblies (1) and connect hose assemblies to fittings (3).

4.

Install front guard on cab (WP 0133 00).


5.


6.

Run engine and verify correct operation of steering system (TM 5-3805-291-10).

7.

Check for leaks.


22 TM 5-3805-291-23-2

REMOTE LUBRICATION LINES, HOSES, AND FITTINGS REPLACEMENT

0129 00



Unit



Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10)

Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Grease, automotive and artillery, GAA (Item 15, WP 0233 00)

Steering frame lock connected (TM 5-3805-29110) Hood opened (TM 5-3805-291-10) Cab removed (rear lines only) (WP 0132 00) Drawings Required


TM 5-3805-291-23P, Figure 118 Estimated Time to Complete Task 0.5 hr ea


0129 00-1

TM 5-3805-291-23-2

REMOTE LUBRICATION LINES, HOSES, AND FITTINGS REPLACEMENT - CONTINUED

0129 00

REMOVAL


NOTE

1.

•


•


Remove fittings (1, 2, and 3) from adapters (4, 5, and 6).

0129 00-2

TM 5-3805-291-23-2


0129 00


Disconnect lines (7, 8, and 9) from elbows (10, 11, and 12).

3.

Remove elbows (10, 11, and 12) from adapters (4, 5, and 6).

427-C1235

4.

Remove nuts (13, 14, and 15) and adapters (4, 5, and 6) from machine.

427-C1236

0129 00-3

TM 5-3805-291-23-2


0129 00


Remove six nuts (16), washers (17), and nine clips (18) from machine.

NOTE Remove clips from all lines and make note of positions for correct installation.

427-C1237

0129 00-4

TM 5-3805-291-23-2


0129 00


Disconnect line (7) from elbow (19). Remove line from machine.

7.

Remove elbow (19) from pivot pin (20).

8.


9.


427-C1239

0129 00-5

TM 5-3805-291-23-2


0129 00



11.


427-C1240

12.

Disconnect hoses (25, 26, 27, and 28) from elbows (29, 30, 31, and 32).

13.

Remove elbows (29, 30, 31, and 32) from adapters (33, 34, 35, and 36).

0129 00-6

TM 5-3805-291-23-2


0129 00


Remove fittings (37, 38, 39, and 40) from adapters (33, 34, 35, and 36).

15.

Remove nuts (41, 42, 43, and 44) and adapters (33, 34, 35, and 36) from machine.

427-C1242

16.

Remove and discard tiedown strap (45) from machine.

17.

Remove nut (46), washer (47), and clamp (48) from machine.

18.

Remove clamp (48) from hoses (25, 26, 27, and 28).

427-C1243

0129 00-7

TM 5-3805-291-23-2

REMOTE LUBRICATION LINES, HOSES, AND FITTINGS REPLACEMENT - CONTINUED REMOVAL - CONTINUED

NOTE Remove cab (WP 0132 00) for removing rear lines.

19.

Remove three bolts (49), nut (50), four washers (51), and clips (52) from machine.

20.

Remove four clips (52) from hose (25).

21.

Disconnect hose (25) from steering cylinder (53) and remove hose from machine.

427-C1244

0129 00-8

0129 00

TM 5-3805-291-23-2


0129 00


Remove five nuts (54), washers (55), and clamps (56) from machine.

23.

Remove five clamps (56) from hoses (26, 27, and 28).

427-C1245

24.

Disconnect hoses (26, 27, and 28) from fittings (57, 58, and 59).

25.

Remove fittings (57, 58, and 59) from machine.

26.

Disconnect lines (60, 61, and 62) from fittings (63, 64, and 65).

27.

Remove fittings (63, 64, and 65) from machine.

427-C1246

0129 00-9

TM 5-3805-291-23-2

REMOTE LUBRICATION LINES, HOSES, AND FITTINGS REPLACEMENT - CONTINUED REMOVAL - CONTINUED 28.

Remove three nuts (66), washers (67), and four clips (68) from machine.

29.

Remove four clips (68) from lines (60, 61, and 62).

30.

Disconnect line (60) from connector (69). Remove line from machine.

31.

Remove connector (69) from trunnion (70).

32.

Disconnect line (61) from union (71). Remove line from machine.

33.

Remove union (71) from line (72).

34.

Disconnect line (72) from mid-bearing (73) and remove line from machine.

35.

Remove bolt (74), washer (75), clamp (76), spacer (77), and clamp (78) from machine.

427-C1247

36.

Disconnect line (62) from connector (79).

37.

Remove connector (79) from hose (80).

38.

Disconnect hose (80) from steering cylinder (81) and remove hose from machine.

0129 00-10

0129 00

TM 5-3805-291-23-2


0129 00


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Position hose (80) on machine and connect to steering cylinder (81).

2.

Install connector (79) on hose (80).

3.

Connect line (62) to connector (79).

4.

Install clamp (78), spacer (77), clamp (76), washer (75), and bolt (74) on machine.

5.

Connect line (72) to mid-bearing (73).

6.

Install union (71) on line (72).

7.

Connect line (61) to union (71).

8.

Install connector (69) on trunnion (70).

9.

Connect line (60) to connector (69).

10.

Install four clips (68) on lines (60, 61, and 62).

11.

Install four clips (68), three washers (67), and nuts (66) on machine.

0129 00-11

TM 5-3805-291-23-2


0129 00


Install fittings (63, 64, and 65) on machine.

13.

Connect lines (60, 61, and 62) to fittings (63, 64, and 65).

14.

Install fittings (57, 58, and 59) on machine.

15.

Connect hoses (26, 27, and 28) to fittings (57, 58, and 59).

427-C1246

16.

Install five clamps (56) on hoses (26, 27, and 28).

17.

Install five clamps (56), washers (55), and nuts (54) on machine.

427-C1245

0129 00-12

TM 5-3805-291-23-2

REMOTE LUBRICATION LINES, HOSES, AND FITTINGS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 18.

Position hose (25) on machine and connect to steering cylinder (53).

19.

Install four clips (52) on hose (25).

20.

Install four clips (52), washers (51), three bolts (49), and nut (50) on machine.

427-C1244

0129 00-13

0129 00

TM 5-3805-291-23-2


0129 00


Install clamp (48) on hoses (25, 26, 27, and 28).

22.

Install clamp (48), washer (47), and nut (46) on machine.

23.

Install new tiedown strap (45) on machine.

427-C1243

24.

Install adapters (33, 34, 35, and 36) and nuts (41, 42, 43, and 44) on machine.

25.

Install fittings (37, 38, 39, and 40) on adapters (33, 34, 35, and 36).

427-C1242

0129 00-14

TM 5-3805-291-23-2


Install elbows (29, 30, 31, and 32) on adapters (33, 34, 35, and 36).

27.

Connect hoses (25, 26, 27, and 28) to elbows (29, 30, 31, and 32).

0129 00-15

0129 00

TM 5-3805-291-23-2


0129 00


Install elbow (23) on pivot pin (24).

29.

Connect line (9) to elbow (23).

427-C1240

30.


31.


427-C1239

0129 00-16

TM 5-3805-291-23-2



33.


0129 00-17

0129 00

TM 5-3805-291-23-2


0129 00


Install nine clips (18), six washers (17), and nuts (16) on machine.

427-C1237

0129 00-18

TM 5-3805-291-23-2


0129 00


Install adapters (4, 5, and 6) and nuts (13, 14, and 15) on machine.

427-C1236

0129 00-19

TM 5-3805-291-23-2


Install elbows (10,11, and 12) on adapters (4, 5, and 6).

37.

Connect lines (7, 8, and 9) to elbows (10, 11, and 12).

427-C1235

0129 00-20

0129 00

TM 5-3805-291-23-2


0129 00


Install fittings (1, 2, and 3) on adapters (4, 5, and 6).

39.

Fill all lines with GAA until no air is in system.

40.

If removed, install cab (WP 0132 00).


41.


42.

Close hood (TM 5-3805-291-10).


4 TM 5-3805-291-23-2

COUNTERWEIGHT REPLACEMENT

0130 00







Wheels chocked


Brake/stoplight and brackets removed (WP 0070 00)

Materials/Parts


Drawings Required


TM 5-3805-291-23P, Figure 116

Mechanic’s wire



0130 00-1

4.0 hr

TM 5-3805-291-23-2

COUNTERWEIGHT REPLACEMENT - CONTINUED

0130 00


Remove bolt (1) and washer (2) from wiring harness (3).

NOTE Attach nonelectrical wire to wiring harness before removal and secure inside counterweight to aid in installation. 2.

Remove wiring harness (3) from counterweight (4).

3.

Repeat steps 1 and 2 for other side.

WARNING


NOTE Counterweight weighs 2,438 lb (1,106 kg).

4.

Attach lifting equipment to counterweight (4).

5.

With assistance, remove 12 bolts (5) and washers (6) from counterweight (4). Remove counterweight from machine.

0130 00-2

TM 5-3805-291-23-2

COUNTERWEIGHT REPLACEMENT - CONTINUED

0130 00

INSTALLATION

WARNING


NOTE Counterweight weighs 2,438 lb (1,106 kg).

1.

Attach lifting equipment to counterweight (4).

2.

With assistance, position counterweight (4) on machine and install 12 washers (6) and bolts (5).

3.

Route wiring harness (3) through counterweight (4) and install washer (2) and bolt (1).

4.

Install brake/stoplight and brackets (WP 0070 00).

5.

Verify correct operation of brake/taillights (TM 5-3805-291-10).

END OF WORK PACKAGE

0130 00-3/(0130 00-4 Blank)

18 TM 5-3805-291-23-2

CAB DOORS MAINTENANCE

0131 00

THIS WORK PACKAGE COVERS Removal, Disassembly, Cleaning and Inspection, Assembly, Installation (Right Door, Left Upper Door, Left Lower Door) INITIAL SETUP Personnel Required










Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10)


Drawings Required TM 5-3805-291-23P, Figures 126 and 127



Plastic washer (4) Weather stripping (foam and rubber)

4.0 hr

0131 00-1

TM 5-3805-291-23-2

CAB DOORS MAINTENANCE - CONTINUED

0131 00

REMOVAL

WARNING


NOTE Right door weighs 75 lb (32 kg).

1.

With assistance, attach lifting equipment to right door (1) and remove six bolts (2), washers (3), and door from machine.

427-C1089

0131 00-2

TM 5-3805-291-23-2


0131 00

REMOVAL - CONTINUED

WARNING


NOTE

2.

•

Upper left door weighs 66 lb (30 kg).

•

Raise latch to unlock upper left door from lower left door.

With assistance, attach lifting equipment to upper left door (4) and remove six bolts (5), washers (6), and door from machine.

427-C1077

0131 00-3

TM 5-3805-291-23-2


0131 00

REMOVAL - CONTINUED

WARNING


NOTE Lower left door weighs 51 lb (23 kg).

3.

With assistance, attach lifting equipment to lower left door (7) and remove six bolts (8), washers (9), and door from machine.

427-C1078

0131 00-4

TM 5-3805-291-23-2


0131 00

DISASSEMBLY 1.

Remove rubber weather stripping (10) around right door (1). Discard weather stripping.

427-C1088

2.

Remove foam weather stripping (11) on each corner of upper left door (4). Discard weather stripping.

3.

Remove rubber weather stripping (12) from around upper left door (4). Discard weather stripping.

427-C1090

0131 00-5

TM 5-3805-291-23-2


0131 00


Remove foam weather stripping (13) on each corner of lower left door (7). Discard weather stripping.

5.

Remove rubber weather stripping (14) from around lower left door (7). Discard weather stripping.

427-C1087

6.

Remove three bolts (15), washers (16), and handrail (17) from door (7).

427-C1079

0131 00-6

TM 5-3805-291-23-2


0131 00


Remove two bolts (18) and cover (19) from door (7).

427-C1080

8.

Remove clip (20), two plastic washers (21), and rod (22) from latch (23). Discard plastic washers.

9.

Remove two bolts (24), brackets (25), and latch (23) from door (7).

427-C1081

0131 00-7

TM 5-3805-291-23-2


0131 00


Remove clip (26) and rod (22) from latch (27).

11.

Remove three bolts (28) and cover (29) from latch (27).

427-C1082

12.

Remove four bolts (30), latch (27), and spacer (31) from door (7).

427-C1083

0131 00-8

TM 5-3805-291-23-2


0131 00


Remove four bolts (32) and cover (33) from door (7).

427-C1084

14.

Remove four bolts (34) and latch (35) from door (7).

15.

Remove nut (36), bolt (37), and rod (38) from latch (35).

427-C1085

0131 00-9

TM 5-3805-291-23-2


0131 00


Remove nut (39), bolt (40), and rod (38) from handle (41).

17.

Remove bolt (42), washer (43), two plastic washers (44), and handle (41) from door (7). Discard plastic washers.

427-C1086


WARNING •


•


1.


2.


3.


ASSEMBLY 1.

Install handle (41), two new plastic washers (44), washer (43), and bolt (42) on door (7).

2.

Install rod (38), bolt (40), and nut (39) on handle (41).

0131 00-10

TM 5-3805-291-23-2


0131 00


Install rod (38), bolt (37), and nut (36) on latch (35).

4.

Install latch (35) and four bolts (34) on door (7).

427-C1085

5.

Install cover (33) and four bolts (32) on door (7).

427-C1084

0131 00-11

TM 5-3805-291-23-2


0131 00


Install spacer (31), latch (27), and four bolts (30) on door (7).

427-C1083

7.

Install cover (29) and three bolts (28) on latch (27).

8.

Install rod (22) and clip (26) on latch (27).

427-C1082

0131 00-12

TM 5-3805-291-23-2


0131 00


Install latch (23), two brackets (25), and bolts (24) on door (7).

10.

Install rod (22), two new plastic washers (21), and clip (20) on latch (23).

427-C1081

11.

Install cover (19) and two bolts (18) on door (7).

427-C1080

0131 00-13

TM 5-3805-291-23-2


0131 00


Install handrail (17), three washers (16), and bolts (15) on door (7).

427-C1079

13.

Install new rubber weather stripping (14) around lower left door (7).

14.

Install new foam weather stripping (13) on each corner of lower left door (7).

427-C1087

0131 00-14

TM 5-3805-291-23-2


0131 00


Install new rubber weather stripping (12) around upper left door (4).

16.

Install new foam weather stripping (11) on each corner of upper left door (4).

427-C1090

17.

Install new rubber weather stripping (10) around right door (1).

427-C1088

0131 00-15

TM 5-3805-291-23-2


0131 00

INSTALLATION

WARNING


NOTE Right door weighs 70 lb (32 kg).

1.

With assistance, attach lifting equipment to right door (1).

2.

Position door (1) on machine and install six washers (3) and bolts (2) on machine.

427-C1089

0131 00-16

TM 5-3805-291-23-2


0131 00

INSTALLATION - CONTINUED

WARNING


NOTE Lower left door weighs 51 lb (23 kg).

3.

With assistance, attach lifting equipment to lower left door (7).

4.

Position lower left door (7) on machine and install six washers (9) and bolts (8) on machine.

427-C1078

0131 00-17

TM 5-3805-291-23-2


0131 00


WARNING


NOTE Upper left door weighs 66 lb (30 kg). 5.

With assistance, attach lifting equipment to upper left door (4).

6.

Position upper left door (4) on machine and install six washers (6) and bolts (5) on machine.

NOTE Lower latch to lock upper left door to lower left door.

427-C1077

7.

Verify cab door operation.

END OF WORK PACKAGE

0131 00-18

16 TM 5-3805-291-23-2

CAB REMOVE/INSTALL

0132 00



Direct Support




Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00) Quick disconnect tool - 06 (Item 58, WP 0232 00) Quick disconnect tool - 08 (Item 59, WP 0232 00)

Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00) O-ring (4) Personnel Required MOS 62B, Construction Equipment Repairer (3) Equipment Conditions



Multiplier, torque

Drain coolant (WP 0041 00) Drain hydraulic tank (WP 0148 00)

Materials/Parts

Evacuate A/C system (WP 0222 00)

Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00)

0132 00-1

Drawings Required TM 5-3805-291-23P, Figures 120 and 122 Estimated Time to Complete Task 8.0 hr

TM 5-3805-291-23-2

CAB REMOVE/INSTALL - CONTINUED

0132 00

REMOVAL

WARNING



NOTE

1.

•

Tag wires and hoses prior to removal to ensure correct installation.

•


•

Front guard weighs 53 lb (24 kg).

With assistance, remove 10 bolts (1), washers (2), and front guard (3) from machine.

0132 00-2

TM 5-3805-291-23-2


0132 00


Disconnect five hoses (4) from steering metering pump (5).

3.

Disconnect five hoses (6) from service brake control valve (7).

4.

Disconnect two hoses (8) and remove O-rings (9) from fittings (10). Discard O-rings.

0132 00-3

TM 5-3805-291-23-2


0132 00


Disconnect camera cable (22) from connector (11).

6.

Disconnect chassis harness (23) from cab harness (12) at five connections.

7.

Disconnect hose (15) and remove O-ring (14) from coupling (13). Discard O-ring.

8.


9.

Remove four bolts (20), washers (21), and plate (19) from cab.

10.

Loosen clamp (24) and disconnect hose (26) from tube (25).

11.

Loosen clamp (28) and disconnect hose (27) from tube (29).

0132 00-4

TM 5-3805-291-23-2


0132 00

REMOVAL - CONTINUED

NOTE •


•

Washer pumps are located under trap door on fender.

12.

Remove and discard two tiedown straps (31) from washer hoses (32 and 34).

13.

Disconnect hoses (32 and 34) from washer pumps (30 and 33).

0132 00-5

TM 5-3805-291-23-2


0132 00


Remove and discard tiedown strap (37) from hoses (32 and 34).

15.

Push hoses (32 and 34) with grommet (35) through fender (36).

16.

Attach suitable lifting equipment to cab at lift points (A).

483-1066

0132 00-6

TM 5-3805-291-23-2


0132 00


Remove bolt (38), washer (39), and ground strap (40) from left rear cab mount area of machine.

0132 00-7

TM 5-3805-291-23-2


0132 00


Remove four bolts (43), small washers (44), large washers (45), and cab mount bushings (46) from machine.

WARNING


NOTE Cab weighs 3,900 lb (1769 kg). 19.

With assistance, remove cab from machine.

20.

Remove four cab mount bushings (42) and large washers (41) from machine.

0132 00-8

TM 5-3805-291-23-2


0132 00


WARNING

1. 2.

•


•


Clean all parts and surfaces with solvent cleaning compound. Dry parts with compressed air. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble.

3.


0132 00-9

TM 5-3805-291-23-2


0132 00

INSTALLATION 1.

Install four large washers (41) and cab mount bushings (42) on machine.

WARNING


NOTE Cab weighs 3,900 lb (1769 kg). 2.

Attach suitable lifting equipment to cab at lift points (A).

3.

With assistance, position cab over machine.

4.

Lower cab onto machine.

0132 00-10

TM 5-3805-291-23-2


0132 00


NOTE Apply oil to all bolt threads before installation. Failure to do so can result in improper bolt torque. 5.

Install four cab mount bushings (46), large washers (45), four small washers (44), and bolts (43) on machine and tighten to 630 + 75 lb-ft (850 + 100 Nm).

6.

Install ground strap (40), washer (39), and bolt (38) on left rear cab mount area of machine.

0132 00-11

TM 5-3805-291-23-2


0132 00


Push hoses (32 and 34) with grommet (35) through fender (36).

8.

Attach new tiedown strap (37) on hoses (32 and 34).

9.

Connect hoses (32 and 34) to two washer pumps (30 and 33).

10.

Install two new tiedown straps (31) on washer hoses (32 and 34).

0132 00-12

TM 5-3805-291-23-2


0132 00


Connect hose (27) to tube (29) and tighten clamp (28).

12.

Connect hose (26) to tube (25) and tighten clamp (24).

0132 00-13

TM 5-3805-291-23-2


0132 00


Install plate (19), four washers (21), and bolts (20) on cab.

14.

Install new O-ring (17) in hose (18) and connect hose to coupling (16).

15.


16.

Connect chassis harness (23) to cab harness (12) at five connectors.

17.

Connect camera cable (22) to connector (11).

0132 00-14

TM 5-3805-291-23-2


0132 00


Install two new O-rings (9) on hoses (8) and connect to fittings (10).

19.

Connect five hoses (6) to service brake valve (7).

20.

Connect five hoses (4) to steering metering pump (5).

0132 00-15

TM 5-3805-291-23-2


0132 00


WARNING


NOTE Front guard weighs 53 lb (24 kg). 21.

With assistance, install front guard (3), 10 washers (2), and bolts (1) on machine.

22.

Recharge A/C System (WP 0222 00).

23.


24.

Fill coolant (WP 0041 00).


25.

Secure steering frame lock in stowed position (TM 53805-291-10).

26.


27.

Operate until normal operating temperature is reached and verify correct operation of machine (TM 5-3805-291-10).

28.

Shut down machine (TM 5-3805-291-10).


34 TM 5-3805-291-23-2

CHASSIS GUARD, SIDE PANELS, HYDRAULIC SERVICE BOX, CIRCUIT BREAKER BOX, AND BATTERY BOX REPLACEMENT

0133 00


References - Continued

Unit

WP 0098 00


WP 0104 00


WP 0114 00


WP 0155 00


WP 0161 00


WP 0148 00

Equipment Conditions Steering frame lock connected (TM 5-3805-29110)


Ladders removed (WP 0134 00)

Cotter pin

Rear fender removed (WP 0137 00) Side cover removed (WP 0135 00)


Drawings Required

References

TM 5-3805-291-23P, Figures 56, 69, 115, 122, 123, and 165

WP 0053 00 WP 0059 00


WP 0096 00

0.5 hr ea

WP 0097 00

WARNING


REMOVAL 0133 00-1

TM 5-3805-291-23-2

CHASSIS GUARD, SIDE PANELS, HYDRAULIC SERVICE BOX, CIRCUIT BREAKER BOX, AND BATTERY BOX REPLACEMENT - CONTINUED

0133 00

Front Guard

0133 00

NOTE Front guard weighs 53 lb (24 kg).

With assistance, remove 10 bolts (1), washer (2), and front guard (3) from machine.

0133 00-2

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Side Panels

0133 00

1.

Remove five bolts (4), washers (5), and upper panel (6) from machine.

2.

Repeat step 1 for opposite side of machine.

0133 00-3

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Side Panels - Continued

0133 00

3.

Remove two nuts (7), two bolts (8), four washers (9), and lower panel (10) from machine.

4.


NOTE If machine is equipped with arctic heater, hoses have to be removed on left side (WP 0161 00 REMOVAL steps 1 thru 9).

0133 00-4

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Hydraulic Service Box

0133 00

1.

Remove two bolts (11) and washers (12) from panel (13).

2.

Open panel (13) and remove cotter pin (14), washer (15), and bar (16) from panel. Discard cotter pin.

483-1077

0133 00-5

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Hydraulic Service Box - Continued

0133 00

WARNING


3.

With assistance, remove five bolts (17) and washers (18) from panel (13).

4.

Remove panel (13) from box (19).

0133 00-6

TM 5-3805-291-23-2


0133 00


0133 00

WARNING


NOTE Box weighs 100 lb (45 kg).

5.

Remove hydraulic oil filter (WP 0148 00).

6.

Remove brake accumulators (WP 0114 00).

7.

Remove two bolts (20), washers (21), and clamps (22) and disconnect two hoses (23).

8.

Remove hydraulic oil filter bases (WP 0155 00).

9.

Remove transmission oil filter base (WP 0104 00).

0133 00-7

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Hydraulic Service Box - Continued 10.

Remove three bolts (24) and washers (25).

11.

Position panel (26) aside.

0133 00

NOTE Remove and discard tiedown straps. 12.

Disconnect three wiring connectors (27).

13.

Remove two bolts (28), washers (29), three clamps (30), and position hoses (31) aside.

14.

Remove two nuts (32), washers (33), bolts (34), and position block (35) aside.

15.


0133 00-8

TM 5-3805-291-23-2


0133 00


0133 00

16.

With assistance, attach lifting equipment to box (19).

17.

Remove four bolts (37) and washers (38) from box (19).

18.

Remove bolt (39), washer (40), and bracket (41) from box (19) and position aside.

19.

Remove four bolts (42) and washers (43) from box (19).

0133 00-9

TM 5-3805-291-23-2


0133 00


0133 00

20.

Remove two bolts (44), washers (45), and box (19) from machine.

21.

Remove two bolts (46), washers (47), and door (48) from box (19).

22.

Remove two bolts (49), washers (50), and bracket (51) from box (19).

23.

Remove two bolts (52), washers (53), and block (53) from box (18).

0133 00-10

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Circuit Breaker Box

0133 00

1.

Remove battery disconnect switch from circuit breaker box (WP 0098 00).

2.

Remove circuit breakers from circuit breaker box (WP 0053 00).

3.

Remove hood tilt actuator switch from circuit breaker box (WP 0059 00).

4.

Loosen upper bolt (55) and washer (56) on circuit breaker box (57).

5.

Remove lower bolt (58), washer (59), and circuit breaker box (57) from battery box (60).

0133 00-11

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Battery Box

0133 00

1.

Remove batteries from battery box (WP 0096 00).

2.

Remove cables from battery box (WP 0097 00).

3.

Remove upper step and brackets from machine (WP 0134 00).

4.

Remove two bolts (65), washers (66), and clamps (64) from battery box (60).

WARNING


NOTE Battery box weighs 110 lb (50 kg).

5.

With assistance, attach lifting equipment to battery box (60).

6.

Remove bolt (61), washer (62), and clamp (63) from battery box (60).

7.

Remove two bolts (68) and washers (67) from battery box (60).

0133 00-12

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Battery Box - Continued

0133 00

0133 00-13

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Battery Box - Continued

0133 00

8.

Remove two bolts (69) and washers (70) from battery box (60).

9.

Remove four bolts (71), washers (72), and battery box (60) from machine.

0133 00-14

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Battery Box - Continued 10.

0133 00

Remove two bolts (73), washers (74), and door (75) from battery box (60).

0133 00-15

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Front Cover Main Hydraulic Control Valve

0133 00

WARNING


NOTE Stands are assembled from Items 48, 65, 79, and 93 (WP 0232 00). • Stand capacity must be 5,200 lb. Use stand assembly to support lift arms (76). •

1.

0133 00-16

TM 5-3805-291-23-2


0133 00

REMOVAL - CONTINUED Front Cover Main Hydraulic Control Valve - Continued 2.

Remove eight bolts (77), washers (78), and two plates (79) from machine.

3.

Remove three nuts (80), washers (81), and plate (82) from machine.

4.

Remove two rubber covers (83) from machine.

5.

Remove two nuts (84), washers (85), and cover plate (86) from machine.

0133 00-17

0133 00

TM 5-3805-291-23-2


0133 00


WARNING •


•


1.


2.


3.


INSTALLATION Front Cover Main Hydraulic Control Valve

0133 00

1.

Position cover plate (86) on machine and install two washers (85) and bolts (84).

2.

Install two rubber covers (83) on machine.

3.

Install plate (82), three washers (81), and nuts (80) on machine.

4.

Install two plates (79), eight washers (78), and bolts (77) on machine.

0133 00-18

TM 5-3805-291-23-2


0133 00

INSTALLATION-CONTINUED Front Cover Main Hydraulic Control Valve - Continued 5.


6.

Start machine (TM 5-3805-291-10) in order to raise lift arms (76) and remove all tooling.

0133 00

0133 00 Battery Box 1.

0133 00

Install door (75), two washers (74), and bolts (73) on battery box (60).

0133 00-19

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Battery Box - Continued

0133 00

WARNING


NOTE Battery box weighs 110 lb (50 kg). 2.

With assistance, attach lifting equipment to battery box (60) and position battery box on machine. Install four washers (72) and bolts (71) on battery box.

0133 00-20

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Battery Box - Continued 3.

0133 00

Install two washers (70) and bolts (69) on battery box (60).

0133 00-21

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Battery Box - Continued

0133 00

4.


5.

Install clamp (63), bolt (61), and washer (62) on battery box (60).

6.

Install two washers (66), bolts (65), and clamps (64) on battery box (60).

7.

Install batteries in battery box (WP 0096 00).

8.

Install cables in battery box (WP 0097 00).

9.

Install upper step and brackets on machine (WP 0134 00).

0133 00-22

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Circuit Breaker Box

0133 00

1.

Install circuit breaker box (57), washer (59), and lower bolt (58) on battery box (60).

2.

Tighten washer (56) and upper bolt (55) on circuit breaker box (57).

3.

Install battery disconnect switch in circuit breaker box (WP 0098 00).

4.

Install circuit breakers in circuit breaker box (WP 0053 00).

5.

Install hood tilt actuator switch in circuit breaker box (WP 0059 00).

0133 00-23

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Hydraulic Service Box

0133 00

1.

Install block (54), two washers (53), and bolts (52) on hydraulic service box (19).

2.

Install bracket (51), two washers (50), and bolts (49) on hydraulic service box (19).

3.

Install door (48), two washers (47), and bolts (46) on hydraulic service box (19).

0133 00-24

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Hydraulic Service Box - Continued

0133 00


NOTE Box weighs 100 lb (45 kg). 4.

With assistance, attach lifting equipment and install hydraulic service box (19), two washers (45), and bolts (44) on machine.

5.

Install two bolts (42) and washers (43) on box (19).

6.

Install bracket (41), washer (40), and bolt (39) on hydraulic service box (19).

0133 00-25

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Hydraulic Service Box - Continued 7.

0133 00

Install four washers (38) and bolts (37) on hydraulic service box (19).

NOTE Install new tiedown straps. 8.


9.

Position block (35) and install two bolts (34), washers (33), and nuts (32).

10.

Position hoses (31) and install three clamps (30), two washers (29), and bolts (28).

11.

Connect three wiring connectors (27).

0133 00-26

TM 5-3805-291-23-2


0133 00


0133 00

12.

Position panel (26) and install three washers (23) and bolts (24).

13.

Install transmission oil filter base (WP 0104 00).

14.

Install hydraulic oil filter bases (WP 0155 00).

15.

Connect two hose assemblies (23) and install two clamps (22), washers (21), and bolts (20).

0133 00-27

TM 5-3805-291-23-2


0133 00


0133 00

WARNING


16.

Install hydraulic oil filter (WP 0148 00).

17.

Install brake accumulators (WP 0114 00).

18.

With assistance, install panel (13), five washers (18), and bolts (17) on hydraulic service box (19).

0133 00-28

TM 5-3805-291-23-2


0133 00


0133 00

19.

Open panel (13) and install bar (16), washer (15), and new cotter pin (14) on panel.

20.

Install two washers (12) and bolts (11) on panel (13).

0133 00-29

TM 5-3805-291-23-2

CHASSIS GUARD, SIDE PANELS, HYDRAULIC SERVICE BOX, CIRCUIT BREAKER BOX, AND BATTERY BOX REPLACEMENT - CONTINUED INSTALLATION - CONTINUED Side Panels

0133 00

NOTE If machine is equipped with arctic heater, hoses have to be installed on left side (WP 0161 00 INSTALLATION steps 10 thru 18).

1.

Install lower panel (10), four washers (9), two nuts (8), and bolts (7) on machine.

2.


0133 00-30

0133 00

TM 5-3805-291-23-2

CHASSIS GUARD, SIDE PANELS, HYDRAULIC SERVICE BOX, CIRCUIT BREAKER BOX, AND BATTERY BOX REPLACEMENT - CONTINUED INSTALLATION - CONTINUED Side Panels - Continued

0133 00

3.

Install upper panel (6), five washers (5), and bolts (6) on machine.

4.


0133 00-31

0133 00

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Front Guard

0133 00

WARNING


NOTE Front guard weighs 53 lb (24 kg).

1.

With assistance, install front guard (3), 10 washers (2), and bolts (1) on machine.

2.

Install side cover (WP 0135 00).

3.


4.

Install ladders (WP 0134 00).

0133 00-32

TM 5-3805-291-23-2


0133 00

INSTALLATION - CONTINUED Front Guard - Continued

0133 00


5.


6.


7.


8.

Shut off machine (TM 5-3805-291-10).

END OF WORK PACKAGE

0133 00-33/(0133 00-34 Blank)

12 TM 5-3805-291-23-2

HANDRAILS, LADDERS, AND STEPS REPLACEMENT

0134 00



Unit


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Wood block, 4 x 4 in.

Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required




0134 00-1

TM 5-3805-291-23-2

HANDRAILS, LADDERS, AND STEPS REPLACEMENT - CONTINUED

0134 00

REMOVAL


NOTE •

Front handrail weighs 13 lb (6 kg).

•

The following procedure is for the standard configuration. The procedure for arctic configuration is similar.

1.

Remove three bolts (1), washers (2), and front handrail (3) from machine.

2.

Repeat step 1 for opposite side.

NOTE Rear handrail weighs 26 lb (12 kg). 3.

Remove six bolts (4), washers (5), and rear handrail (6) from machine.

4.


0134 00-2

TM 5-3805-291-23-2


0134 00

REMOVAL - CONTINUED

WARNING


NOTE Ladder assembly weighs 28 lb (13 kg). 5.

Remove four bolts (7), washers (8), and ladder (9) from machine.

6.

Remove four bolts (10), washers (11), spacers (12), plates (13), two belts (14), and step (15) from ladder (9).

0134 00-3

TM 5-3805-291-23-2


0134 00

REMOVAL - CONTINUED

WARNING


NOTE

7.

•

Ladder assembly weighs 21 lb (10 kg).

•

Step assembly weighs 27 lb (12 kg).

Remove four bolts (16), washers (17), and ladder (18) from machine.

NOTE Use hydraulic jack and wood block to support step assembly. 8.

Remove 10 bolts (19), washers (20), and 2 brackets (21) from machine.

9.

Remove four bolts (22), washers (23), and step (24) from two brackets (21).

10.

Remove four bolts (25), washers (26), spacers (27), plates (28), two belts (29) from step (24) and step (30).

0134 00-4

TM 5-3805-291-23-2


0134 00

REMOVAL - CONTINUED

WARNING


NOTE Rear step assembly weighs 27 lb (12 kg). 11.

Remove four bolts (31), washers (32), and two brackets (33) from machine.

12.

Remove four bolts (34), washers (35), and step (36) from two brackets (33).

13.

Remove four bolts (37), washers (38), spacers (39), plates (40), two belts (41) from step (36) and step (42).

427-C1063

0134 00-5

TM 5-3805-291-23-2


0134 00


Remove four bolts (43), washers (44), and plate (45) from machine.

15.

Remove four bolts (46), washers (47), and plate (48) from machine.

427-C1207

0134 00-6

TM 5-3805-291-23-2


0134 00


WARNING •

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and lowtoxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel.

•


1.


2.


3.


INSTALLATION 1.

Install plate (48), four washers (47), and bolts (46) on machine.

2.

Install plate (45), four washers (44), and bolts (43) on machine.

0134 00-7

TM 5-3805-291-23-2


0134 00


WARNING


NOTE Rear step assembly weighs 27 lb (12 kg). 3.

Install two belts (41), four plates (40), spacers (39), washers (38), and bolts (37) on step (36) and step (42).

4.

Install step (36), four washers (35), and bolts (34) on two brackets (33).

5.

Install two brackets (33), four washers (32), and bolts (31) on machine.

427-C1063

0134 00-8

TM 5-3805-291-23-2


0134 00


WARNING


NOTE •

Ladder assembly weighs 21 lb (10 kg).

•

Step assembly weighs 27 lb (12 kg).

6.

Install two belts (29), four plates (28), spacers (27), washers (26), and bolts (25) on step (24) and step (30).

7.

Install step (24), four washers (23), and bolts (22) on two brackets (21).

8.

Install 2 brackets (21), 10 washers (20), and bolts (19) on machine.

9.

Install ladder (18), four washers (17), and bolts (16) on machine.

0134 00-9

TM 5-3805-291-23-2


0134 00


WARNING


NOTE Ladder assembly weighs 28 lb (13 kg). 10.

Install step (15), two belts (14), four plates (13), spacers (12), washers (11), and bolts (10) on ladder (9).

11.

Install ladder (9), four washers (8), and bolts (7), on machine.

0134 00-10

TM 5-3805-291-23-2


0134 00



NOTE Rear handrail weighs 26 lb (12 kg). 12.

Install rear handrail (6), six washers (5), and bolts (4) on machine.

13.


NOTE Front handrail weighs 13 lb (6 kg). 14.

Install front handrail (3), three washers (2), bolts (1) on machine.

15.



8 TM 5-3805-291-23-2

SIDE COVERS AND HOOD REPLACEMENT

0135 00


Maintenance Level


Unit




Bracket, link (Item 17, WP 0232 00) Lifting equipment, 600-lb capacity



Drawings Required



TM 5-3805-291-23P, Figures 57 and 123

3.0 hr

Locknut (4)

0135 00-1

TM 5-3805-291-23-2

SIDE COVERS AND HOOD REPLACEMENT - CONTINUED REMOVAL 1.

Open rear door (TM 5-3805-291-10).

2.

Disconnect cable (3) from camera (4).

3.

Remove seven bolts (1), washers (2), clamps (8), and cable (3) from hood (9). Position cable aside.

4.

Remove four locknuts (6), washers (7), and bracket (5) with camera (4) from hood (9). Discard locknuts.

5.

Close rear door (TM 5-3805-291-10).

6.

Open hood (TM 5-3805-291-10).

7.

Remove side cover (10) from machine. Repeat for opposite side.

0135 00-2

0135 00

TM 5-3805-291-23-2

SIDE COVERS AND HOOD REPLACEMENT - CONTINUED REMOVAL 8.

Remove plug (11) from engine hood (9).

9.

Attach link bracket and lifting equipment to support engine hood (9).

0135 00-3

0135 00

TM 5-3805-291-23-2

SIDE COVERS AND HOOD REPLACEMENT - CONTINUED

0135 00


Remove lock pin (12) and pin (14) from hood tilt actuator (13).

WARNING


NOTE Engine hood weighs 400 lb (181 kg).

11.

Remove two bolts (15), washers (16), and spacers (17) from machine. Repeat for opposite side.

0135 00-4

TM 5-3805-291-23-2


0135 00


With assistance, remove engine hood (9) from machine.


WARNING •


•


1.


2.


3.


0135 00-5

TM 5-3805-291-23-2


0135 00

INSTALLATION

WARNING


NOTE Engine hood weighs 400 lb (181 kg).

1.

Attach link bracket and lifting equipment to engine hood (9).

2.

With assistance, position engine hood (9) on machine.

3.

Install two washers (16), bolts (15), and spacers (17) on machine. Repeat for opposite side.

0135 00-6

TM 5-3805-291-23-2

SIDE COVERS AND HOOD REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 4.

Install pin (14) and lock pin (12) in hood tilt actuator (13).

5.

Remove link bracket and lifting equipment from hood (9) and install plug (11) in hood.

6.

Install side cover (10) on machine. Repeat for opposite side.

0135 00-7

0135 00

TM 5-3805-291-23-2


0135 00


Close hood (TM 5-3805-291-10).

8.

Open rear door (TM 5-3805-291-10).

9.

Install bracket (5) with camera (4) on hood (9) with four washers (7) and new locknuts (6).

10.

Install cable (3) on hood (9) with seven clamps (8), washers (2), and bolts (1).

11.

Connect cable (3) to camera (4).

12.

Close rear door (TM 5-3805-291-10).


13.


14.

Open and close hood to verify correct operation of hood and camera (TM 5-3805-291-10).

END OF WORK PACKAGE

0135 00-8

4 TM 5-3805-291-23-2

FRONT FENDERS REPLACEMENT

0136 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation INITIAL SETUP Equipment Conditions

Maintenance Level


Unit




Bracket, link (Item 15, WP 0232 00) (2)




Materials/Parts

Wheels chocked

Drawings Required


TM 5-3805-291-23P, Figure 131

Personnel Required



0.5 hr

NOTE The following procedure is for the right-side front fender. The procedure for the left-side front fender is identical.

REMOVAL 1.

Attach link brackets and lifting equipment to fender (1).

427-C0190

0136 00-1

TM 5-3805-291-23-2

FRONT FENDERS REPLACEMENT - CONTINUED

0136 00

REMOVAL - CONTINUED

WARNING


NOTE Fender weighs 60 lb (27 kg).

2.

With assistance, remove six nuts (2) and washers (3) from fender (1). Remove fender from machine.

427-C0191


WARNING •


•


1.


2.


3.


0136 00-2

TM 5-3805-291-23-2

FRONT FENDERS REPLACEMENT - CONTINUED

0136 00

INSTALLATION


NOTE Fender weighs 60 lb (27 kg).

1.

Attach link brackets and lifting equipment to fender (1).

427-C0190

2.

With assistance, position fender (1) on machine.

3.

Install six washers (3) and nuts (2) on fender (1).

4.

Remove link brackets and lifting equipment from fender.


5.


END OF WORK PACKAGE

0136 00-3/(0136 00-4 Blank)

4 TM 5-3805-291-23-2

REAR FENDERS REPLACEMENT

0137 00






Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Bracket, link (Item 15, WP 0232 00) (3) Lifting equipment, 350-lb capacity

Handrails removed (WP 0134 00) Steering frame lock connected (TM 5-3805-29110) Windshield washer bottle removed (right-hand fender only) (WP 0144 00) Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figure 131




0137 00-1

TM 5-3805-291-23-2

REAR FENDERS REPLACEMENT - CONTINUED

0137 00

REMOVAL

WARNING


NOTE Fender assembly weighs 225 lb (102 kg).

1.

Attach link brackets and lifting equipment to fender assembly (1).

427-C0174

2.

Remove four bolts (2) and washers (3) from fender assembly (1).

427-C0179

0137 00-2

TM 5-3805-291-23-2


0137 00


With assistance, use link brackets and lifting equipment to remove fender assembly (1) from machine.

4.

Repeat steps 1 thru 3 for opposite side of machine.


WARNING •


•


1.


2.


3.


INSTALLATION


NOTE Fender assembly weighs 225 lb (102 kg).

1.

With assistance, use link brackets and lifting equipment to position fender assembly (1) on machine.

2.

Install four washers (3) and bolts (2) on fender assembly (1). 0137 00-3

TM 5-3805-291-23-2


0137 00


Repeat steps 1 and 2 for opposite side of machine.

4.

Install handrails (WP 0134 00).

5.

If removed, install windshield washer bottle (WP 0144 00).


6.


END OF WORK PACKAGE

0137 00-4

10 TM 5-3805-291-23-2

CAB LINERS AND DOME LIGHT REPLACEMENT

0138 00



References

Unit

TM 5-3805-291-10 WP 0063 00


Equipment Conditions Upper instrument panel removed (WP 0055 00) Cab sun visor and mirrors removed (WP 0139 00) Camera monitor removed from machine (WP 0048 00)






3.0 hr

REMOVAL 1.

Remove four bolts (1) from rear shelf (2). Remove shelf from cab.

427-C1068

0138 00-1

TM 5-3805-291-23-2

CAB LINERS AND DOME LIGHT REPLACEMENT - CONTINUED

0138 00


Remove three bolts (3) from left rear panel (4).

427-C1069

3.

Remove three bolts (5) from left rear panel (4).

427-C1070

4.

Remove cab air filter (TM 5-3805-291-10).

5.

Remove bolt (6) from left rear panel (4).

6.

Remove left rear panel (4) from cab.

427-C1076

0138 00-2

TM 5-3805-291-23-2


0138 00


Remove five bolts (7) from right rear panel (8) and strap (9).

8.

Remove right rear panel (8) and strap (9) from cab.

427-C1071

9.

Remove machine ECM (WP 0063 00).

10.

Remove insulation pad (10) from cab.

427-C1075

0138 00-3

TM 5-3805-291-23-2


0138 00


Remove four bolts (11) from upper side panel (12).

12.

Remove four screws (13) and two vents (14) from upper side panel (12).

13.

Pull upper side panel (12) out, disconnect lamp (15) from machine, and remove lamp from upper side panel.

14.

Remove upper side panel (12) from cab.

427-C1072

15.

Remove three bolts (16) and lower side panel (17) from cab.

16.

Repeat steps 11 thru 15 for opposite side of cab.

427-C1073

0138 00-4

TM 5-3805-291-23-2


0138 00


Remove six clips (18) from headliner (19). Remove headliner from cab.

427-C1067

18.

Lift floor covering (20) and remove from cab.

427-C1074

0138 00-5

TM 5-3805-291-23-2


0138 00


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Position floor covering (20) and install in cab.

2.

Position headliner (19) in cab and install six clips (18) on headliner.

427-C1067

427-C1074

0138 00-6

TM 5-3805-291-23-2


0138 00


Install lower side panel (17) and three bolts (16) in cab.

427-C1073

4.

Position upper side panel (12) in cab.

5.

Install lamp (15) in upper side panel (12) and connect lamp to machine.

6.

Install two vents (14) and four screws (13) on upper side panel (12).

7.

Install four bolts (11) on upper side panel (12).

8.

Repeat steps 3 thru 7 for opposite side of cab.

427-C1072

0138 00-7

TM 5-3805-291-23-2


0138 00


Install insulation pad (10) in cab.

10.

Install machine ECM (WP 0063 00).

427-C1075

11.

Install right rear panel (8) and strap (9) in cab.

12.

Install five bolts (7) on right rear panel (8) and strap (9).

427-C1071

0138 00-8

TM 5-3805-291-23-2


0138 00


Position left rear panel (4) in cab and install bolt (6) on panel.

14.

Install cab air filter (TM 5-3805-291-10).

427-C1076

15.

Install three bolts (5) on left rear panel (4).

427-C1070

0138 00-9

TM 5-3805-291-23-2


0138 00


Install three bolts (3) on left rear panel (4).

427-C1069

17.

Position rear shelf (2) in cab and install four bolts (1) on shelf.

427-C1068

18.

Install upper instrument panel (WP 0055 00).

19.

Install cab sun visor and mirrors (WP 0139 00).

20.


21.


END OF WORK PACKAGE

0138 00-10

4 TM 5-3805-291-23-2

CAB SUN VISOR AND MIRRORS REPLACEMENT

0139 00




Unit


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Materials/Parts Detergent, general purpose, liquid (Item 9, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figures 134 and 142

Personnel Required



0.5 hr

REMOVAL 1.

Remove four screws (1) and sun visor (2) from cab.

427-C0303

0139 00-1

TM 5-3805-291-23-2

CAB SUN VISOR AND MIRRORS REPLACEMENT - CONTINUED

0139 00


Remove bolt (3), washer (4), and mirror (5) from bracket (6).

3.

Remove cab liner (WP 0138 00).

4.

Remove bolt (7), washer (8), and bracket (6) from machine.

427-C0177

5.

Remove two nuts (13), washers (14), bolts (11), washers (12), clamps (10), and mirror (15) from bracket.

6.

Remove four bolts (16), washers (17), two clamps (18) and bracket (9) from machine.

7.

Repeat steps 5 and 6 for opposite side of cab.

483-1080-1

0139 00-2

TM 5-3805-291-23-2


0139 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION 1.

Install bracket (9), two clamps (18), four washers (17), and bolts (18) on machine.

2.

Install mirror (15), two clamps (10), washers (12), bolts (11), washers (14), and nuts (13) on bracket (9).

3.

Repeat steps 1 and 2 for opposite side of cab.

483-1080-1

0139 00-3

TM 5-3805-291-23-2


0139 00

INSTALLATION-CONTINUED 4.

Install bracket (6), washer (8), and bolt (7) on machine.

5.

Install cab liner (WP 0138 00).

6.

Install mirror (5), washer (4), and bolt (3) on bracket (6).

7.

Install sun visor (2) and four screws (1) on cab.

427-C0303

END OF WORK PACKAGE

0139 00-4

6 TM 5-3805-291-23-2

SEAT ASSEMBLY REPLACEMENT

0140 00


Maintenance Level


Unit






Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Detergent, general purpose, liquid (Item 9, WP 0233 00)

Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figure 132 Estimated Time to Complete Task


1.5 hr


0140 00-1

TM 5-3805-291-23-2

SEAT ASSEMBLY REPLACEMENT - CONTINUED

0140 00

REMOVAL


NOTE •


•

Use a container to catch any fluid that may drain from hoses or system. Dispose of oil IAW local policy and ordinances. Ensure all spills are cleaned up.

1.

Remove four screws (1) from cover (2).

2.

Remove knob assemblies (3), six washers (4), and cover (2) from machine.

3.

Remove four bolts (5) and washers (6) from armrest assembly (7) and position armrest assembly aside.

427-C0309-1

4.

Disconnect wiring harness assemblies (8).

427-C0316

0140 00-2

TM 5-3805-291-23-2


0140 00


Remove four bolts (9) from seat assembly (10).

427-C0317

WARNING


NOTE •

Seat assembly weighs 90 lb (41 kg).

•

Suspension assembly weighs 75 lb (34 kg).

6.

With assistance, reposition seat assembly (10) and suspension assembly (11), as shown.

7.

Remove bolt (12) and two washers (13) from suspension assembly (11).

8.

With assistance, slide seat assembly (10) forward and remove from suspension assembly (11).

9.

Remove seat assembly (10) from machine.

10.

Remove suspension assembly (11) from machine.

0140 00-3

427-C0318

TM 5-3805-291-23-2


0140 00


WARNING •


•


1.


2.


3.

Inspect all parts for damage, wear, pitting, cracks or corrosion and replace if necessary.

4.


INSTALLATION

WARNING


NOTE •

Seat assembly weighs 90 lb (41 kg).

•

Suspension assembly weighs 75 lb (34 kg).

1.

With assistance, install suspension assembly (11) in machine.

2.

With assistance, slide seat assembly (10) on suspension assembly (11) and install bolt (12) and two washers (13) on suspension assembly.

427-C0318

0140 00-4

TM 5-3805-291-23-2


0140 00


Position seat assembly (10) and install four bolts (9).

427-C0317

4.

Connect wiring harness assemblies (8).

427-C0316

0140 00-5

TM 5-3805-291-23-2


0140 00


Position armrest assembly (7) on seat and install four washers (6) and bolts (5).

6.

Install cover (2), six washers (4), and knob assemblies (3) on machine.

7.

Install four screws (1) on cover (2).

427-C0309-1

8.

Verify seat operation (TM 5-3805-291-10).

END OF WORK PACKAGE

0140 00-6

2 TM 5-3805-291-23-2

SEAT BELT REPLACEMENT

0141 00





Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)


Personnel Required



REMOVAL 1.

Remove bolt (1), washer (2), seat belt assembly (3), and spacer (4) from seat.

2.

Repeat step 1 for opposite side of seat.

427-C0150

0141 00-1

TM 5-3805-291-23-2

SEAT BELT REPLACEMENT - CONTINUED

0141 00


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Install spacer (4), seat belt assembly (3), washer (2), and bolt (1) on seat.

427-C0150

2.

Repeat step 1 for opposite side of seat.

END OF WORK PACKAGE

0141 00-2

2 TM 5-3805-291-23-2

RIFLE RACK REPLACEMENT

0142 00


Maintenance Level




Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)


Personnel Required



0.5 hr

REMOVAL 1.

Remove six bolts (1) and washers (2) from bracket (3).

2.

Remove bracket (3) from machine.

3.

Remove two bolts (4), washers (5), bracket (6), and support (7) from bracket (3).

4.

Remove two bolts (8), washers (9), and cup (10) from bracket (3).

0142 00-1

TM 5-3805-291-23-2

RIFLE RACK REPLACEMENT - CONTINUED

0142 00


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Install two washers (9), bolts (8), and cup (10) on bracket (3).

2.

Install support (7), bracket (6), two washers (5), and bolts (4) on bracket (3).

3.

Position bracket (3) on machine.

4.

Install six washers (2) and bolts (1) on bracket (3).


4 TM 5-3805-291-23-2

TOOLBOX REPLACEMENT

0143 00


Maintenance Level


Unit



Upper left front ladder removed from machine (WP 0130 00)


Drawings Required



TM 5-3805-291-23P, Figure 136

1.0 hr

Lifting equipment, 100-lb capacity Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

0143 00-1

TM 5-3805-291-23-2

TOOLBOX REPLACEMENT - CONTINUED

0143 00

REMOVAL 1.

Attach link brackets and lifting equipment to toolbox (1).

2.

Remove two bolts (2) and washers (3) from toolbox (1).

3.

Remove two bolts (4) and washers (5) from machine.

4.



NOTE Toolbox weighs 67 lb (30 kg). 5.

With assistance, remove toolbox (1) from machine.

6.

Remove brackets and lifting equipment from toolbox (1).

427-C0323

0143 00-2

TM 5-3805-291-23-2

TOOLBOX REPLACEMENT - CONTINUED

0143 00


WARNING •


•


1.


2.


3.


INSTALLATION


NOTE Toolbox weighs 67 lb (30 kg). 1.

With assistance, use link brackets and lifting equipment to position toolbox (1) on machine.

2.

Install two washers (7) and bolts (6) on machine.

3.


4.

Install two washers (3) and bolts (2) on toolbox (1).

5.

Remove brackets and lifting equipment from toolbox (1).

6.

Install left front ladder on machine (WP 0130 00).


12 TM 5-3805-291-23-2

WINDSHIELD WASHER BOTTLE AND HOSES REPLACEMENT

0144 00




Unit


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Hose removed from front wiper arm (if removing hoses) (WP 0145 00) Hose removed from rear wiper arm (if removing hoses) (WP 0146 00) Steering column cover removed (WP 0121 00) Steering frame lock connected (TM 5-3805-29110)


Drawings Required



TM 5-3805-291-23P, Figures 138 and 139 2.0 hr

Tiedown strap (5)

0144 00-1

TM 5-3805-291-23-2

WINDSHIELD WASHER BOTTLE AND HOSES REPLACEMENT - CONTINUED

0144 00

REMOVAL

WARNING Hinged access cover is unassisted and may shut under pressure if not firmly grasped. Failure to follow this warning may result in injury to personnel.

NOTE

1.

•

Hinged access opened.

cover

must

be

•

Tag wires and hoses before removing.

Remove four bolts (1) and washers (2) from washer bottle (3).

NOTE Remove and discard tiedown strap(s). 2.

Lift washer bottle (3) to gain access to two wiring harness connections (4) and hoses (5 and 6).

3.

Disconnect two wiring harness connectors (4) from two washer pumps (7).

4.

Disconnect two hoses (5 and 6) from two washer pumps (7).

5.

Remove washer bottle (3) from machine.

6.

Push hoses (5 and 6) through grommet (8).

427-C1226

0144 00-2

TM 5-3805-291-23-2

WINDSHIELD WASHER BOTTLE AND HOSES REPLACEMENT - CONTINUED REMOVAL - CONTINUED 7.

Remove bolt (9), washer (10), and clip (11) from machine.

8.

Disconnect hoses (5 and 6) from clip (11).

0144 00-3

0144 00

TM 5-3805-291-23-2


0144 00


Remove three bolts (12), washers (13), clips (14), and hose (5) from machine.

10.

Remove three clips (14) from hose (5).

427-C1228

0144 00-4

TM 5-3805-291-23-2


Remove and discard five tiedown straps (15) from hose (6) under cab.

12.

Disconnect hose (16) from fitting (17).

0144 00-5

0144 00

TM 5-3805-291-23-2



14.

Remove nut (18), washer (19), and fitting (17) from machine.

0144 00-6

0144 00

TM 5-3805-291-23-2


0144 00


Remove grommet (20) and hose (6) from machine.


WARNING •


•


1.


2.


3.

Inspect all parts for damage, wear, splits, and cracks and replace if necessary.

INSTALLATION 1.

Install grommet (20) on machine and thread hose (6) through grommet.

0144 00-7

TM 5-3805-291-23-2

WINDSHIELD WASHER BOTTLE AND HOSES REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 2.

Install fitting (17), washer (19), and nut (18) on machine.

3.

Connect hose (6) to fitting (17).

4.


0144 00-8

0144 00

TM 5-3805-291-23-2

WINDSHIELD WASHER BOTTLE AND HOSES REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 5.

Install five new tiedown straps (15) on hose (6) under cab.

0144 00-9

0144 00

TM 5-3805-291-23-2


0144 00


Install three clips (14) on hose (5).

7.

Install three clips (14), washers (13), bolts (12), and hose (5) on machine.

427-C1228

0144 00-10

TM 5-3805-291-23-2


0144 00


Install clip (11) on hoses (5 and 6).

9.

Install clip (11), washer (10), and bolt (9) on machine.

10.

Thread hoses (5 and 6) through grommet (8).

427-C1226

0144 00-11

TM 5-3805-291-23-2


0144 00


Position washer bottle (3) on machine.

12.

Connect hoses (5 and 6) to two washer pumps (7).

13.

Connect two wiring harness connectors (4) to two washer pumps (7).

14.

Install four washers (2) and bolts (1) on washer bottle (3).

15.

Install hose on rear wiper arm, if removed (WP 0146 00).

16.

Install hose on front wiper arm, if removed (WP 0145 00).

17.

Install steering column cover (WP 0121 00).


18.


19.

Verify correct operation of washer system (TM 5-3805-291-10).

END OF WORK PACKAGE

0144 00-12

6 TM 5-3805-291-23-2

FRONT WINDSHIELD WIPERS AND MOTOR REPLACEMENT

0145 00



Unit

References


TM 5-3805-291-10




Drawings Required

Materials/Parts

Instrument panel removed (WP 0055 00)



0145 00-1

TM 5-3805-291-23-2

FRONT WINDSHIELD WIPERS AND MOTOR REPLACEMENT - CONTINUED REMOVAL

NOTE Mark position of wiper to aid in installation.

1.


2.

Loosen four bolts (7) and nuts (6) and remove two wiper arm assemblies (8) from extensions (1).

3.

Loosen four bolts (2) and remove two extensions (1) from wiper motor assembly (3).

0145 00-2

0145 00

TM 5-3805-291-23-2

FRONT WINDSHIELD WIPERS AND MOTOR REPLACEMENT - CONTINUED

0145 00


Disconnect wiring harness assembly (9) inside cab.

5.

Support wiper motor assembly (3).

483-1502-1

6.

Remove two nuts (10) from outside of cab and wiper motor assembly (3) from inside cab.

0145 00-3

TM 5-3805-291-23-2

FRONT WINDSHIELD WIPERS AND MOTOR REPLACEMENT - CONTINUED REMOVAL – CONTINUED 7.

Remove bolt (14), nut (13), washer (12), and blade (11) from wiper arm (8).

INSTALLATION 1.

Install blade (11) on wiper arm (8) with washer (12), nut (13), and bolt (14).

2.

Install wiper motor assembly (3) and two nuts (10) on machine. Tighten nuts to 14 ± 1 lb-ft (19 ± 1 Nm).

0145 00-4

0145 00

TM 5-3805-291-23-2

FRONT WINDSHIELD WIPERS AND MOTOR REPLACEMENT - CONTINUED

0145 00

INSTALLATION – CONTINUED 3.

Connect wiring harness assembly (9) to wiper motor assembly (3).

4.

Install two extensions (1) on wiper motor assembly (3) and tighten four bolts (2).

5.

Install two wiper arm assemblies (8) on extensions (1) with four bolts (7) and nuts (6). Tighten bolts to 10 ± 1.5 lb-ft (14 ± 2 Nm).

6.


0145 00-5

TM 5-3805-291-23-2

FRONT WINDSHIELD WIPERS AND MOTOR REPLACEMENT - CONTINUED 7.

Install instrument panel (WP 0055 00).

8.

Verify proper operation of front windshield wipers (TM 5-3805-291-10).

END OF WORK PACKAGE

0145 00-6

0145 00

6 TM 5-3805-291-23-2

REAR WINDSHIELD WIPER AND MOTOR REPLACEMENT

0146 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Materials/Parts

Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Seat moved forward (TM 5-3805-291-10) Drawings Required


TM 5-3805-291-23P, Figure 139

Gasket



0146 00-1

1.0 hr

TM 5-3805-291-23-2 REAR WINDSHIELD WIPER AND MOTOR REPLACEMENT - CONTINUED REMOVAL 1.

Remove three screws (1) and two screws (2) from interior panel (3).

2.

Remove interior panel (3) from machine.

0146 00-2

0146 00

TM 5-3805-291-23-2 REAR WINDSHIELD WIPER AND MOTOR REPLACEMENT - CONTINUED

0146 00


Disconnect wiring harness assembly (4) from wiper motor assembly (5).

427-C0246

4.

Disconnect hose (6) from wiper arm assembly (8).

5.

Loosen bolt (7) and remove wiper arm assembly (8) from machine.

6.


427-C0249

0146 00-3


0146 00


Support wiper motor assembly (5) inside cab. Remove bolt (10), retaining nut (11), plate (12), gasket (13), and wiper motor assembly from machine. Discard gasket.

427-C0247

8.

Remove bolt (17), nut (16), washer (15), and blade (14) from wiper arm (8).

483-1624

0146 00-4


0146 00

INSTALLATION

CAUTION •

DO NOT operate wiper motor before wiper arm assembly is installed.

•

New wiper motor is preset in parked position. If wiper motor is operated before installation of the wiper arm assembly, misalignment will occur. This can cause damage to wiper motor, wiper arm assembly, and/or window.

•

DO NOT manually rotate wiper arm assembly on shaft.

1.

Install blade (14) on wiper arm (8) with washer (15), nut (16), and bolt (17).

2.

Support wiper motor assembly (5) inside cab.

3.

Install wiper motor assembly (5), new gasket (13), plate (12), bolt (10), and retaining nut (11) on machine. Tighten retaining nut to 14 ± 1 lb-ft (19 ± 1 Nm).

4.

Connect wiring harness assembly (4) to wiper motor assembly (5).

5.

Install cover (9) on machine.

0146 00-5


0146 00

INSTALLATION – CONTINUED

CAUTION Push wiper arm assembly straight onto tapered shaft. If wiper arm assembly is not installed properly, when shaft turns, splines will be improperly formed and damage will occur. 6.

Position wiper arm assembly (8) on tapered shaft 4.3 ± 1.6 in. (110 ± 40 mm) from lower edge of glass. Tighten bolt (7) to 15 ± 2 lb-ft (20 ± 3 Nm).

CAUTION DO NOT use petroleum lubricants on hose ends. DO NOT stretch hose between connection points. This will cause damage to hose. 7.

Connect hose (6) to wiper arm assembly (8).

8.

Install interior panel (3), two screws (2), and three screws (1) on machine.

427-C0244

9.

Verify proper operation of rear windshield wiper (TM 5-3805-291-10).

END OF WORK PACKAGE

0146 00-6

4 TM 5-3805-291-23-2

DATA PLATES REPLACEMENT

0147 00

THIS WORK PACKAGE COVERS Data Plate (Solid Rivet) Replacement, Data Plate (Blind Rivet) Replacement, Decal Replacement



Unit


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 2 (Item 71, WP 0232 00) Materials/Parts Detergent, general purpose, liquid (Item 9, WP 0233 00)

Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figure 144

Rag, wiping (Item 35, WP 0233 00) Rivet, blind (as required)

Estimated Time to Complete Task 0.2 hr ea

Rivet, solid (as required)

0147 00-1

TM 5-3805-291-23-2

DATA PLATES REPLACEMENT - CONTINUED

0147 00

DATA PLATE (SOLID RIVET) REPLACEMENT

WARNING To prevent injury to personnel, wear protective eye covering and gloves.

1.

Using center punch and hammer, mark center of each solid rivet (1) on data plate (2).

2.

Using electric drill and twist drill slightly larger than body diameter of solid rivet (1), drill into four rivet heads until rivet heads can be separated from rivet bodies. Remove four rivet heads from data plate (2).

3.

Remove data plate (2) from machine.

CAUTION DO NOT drill any deeper than necessary to remove rivet body. Failure to comply will result in damage to tractor.

4.

Using twist drill with same diameter as solid rivet (1) bodies, remove four rivet bodies from machine. Discard rivet bodies.

5.

Install new data plate (2) on machine with four new solid rivets (1).

427-C2060

0147 00-2

TM 5-3805-291-23-2

DATA PLATES REPLACEMENT - CONTINUED

0147 00

DATA PLATE (BLIND RIVET) REPLACEMENT

CAUTION DO NOT drill any deeper than necessary to remove rivet. Failure to comply will result in damage to machine.

1.

Using electric drill and twist drill with same diameter as rivet body (3), drill through blind rivet heads and bodies and remove four rivets from data plate (4). Discard rivets.

2.

Remove data plate (4) from machine.

3.

Using blind hand riveter, install new data plate (4) on machine with four new blind rivets (3).

427-C2061

DECAL REPLACEMENT

NOTE Use heat gun, as necessary, for ease in removing decal.

1.

Lift and peel back decal (5) to remove from surface of machine.

2.

Using detergent, clean any adhesive residue from machine surface. Rinse and dry area.

3.

Peel paper backing from new decal (5) and apply to surface of machine.

END OF WORK PACKAGE

0147 00-3/(0147 00-4 Blank)

427-C2062

6 TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL CHANGE AND FILTER REPLACEMENT

0148 00

THIS WORK PACKAGE COVERS Drain and Filter Removal, Cleaning and Inspection, Fill and Filter Installation INITIAL SETUP Maintenance Level

Materials/Parts - Continued Rag, wiping (Item 35, WP 0233 00)

Unit

Filter element (2)


Personnel Required



Nipple, pipe (Item 41, WP 0232 00)


Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10)

Materials/Parts



0148 00-1

Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figures 155 and 163 Estimated Time to Complete Task 0.5 hr

TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL CHANGE AND FILTER REPLACEMENT - CONTINUED

0148 00

DRAIN AND FILTER REMOVAL

NOTE Hydraulic system capacity is 29 gal. (110 L). 1.

Operate machine to warm up hydraulic oil (TM 5-3805-291-10). Stop engine.

2.

Press button on breaker relief valve (1) to remove tank pressure.

3.

Remove padlock (2) from hydraulic filler cap (3).

4.

Remove retaining ring and strainer from hydraulic filler cap (3).

5.

Remove hydraulic filler cap (3) from machine. 427-C0212

6.

Remove two bolts (4) and washers (5) from right-side access door. Open door.

427-C0213

0148 00-2

TM 5-3805-291-23-2


0148 00

DRAIN AND FILTER REMOVAL - CONTINUED 7.

Remove remote hydraulic drain plug (6) from drain valve (7).

8.

Install pipe nipple to unseat drain valve (7) and drain hydraulic fluid into container.

427-C0211

9.

Remove pipe nipple and close hydraulic tank drain valve (7). Install hydraulic drain plug (6) in drain valve.

10.

Remove two hydraulic and case drain filters (8) from mounting bases (9). Discard filters.

427-C1358

0148 00-3

TM 5-3805-291-23-2


0148 00


WARNING •


•


1.


2.


3.


4.


5.

Inspect gasket on hydraulic filler cap and replace if damaged or worn.

FILL AND FILTER INSTALLATION

NOTE Hydraulic system capacity is 29 gal. (110 L). 1.

Apply a thin coat of clean oil to seal on two new filters (8).

NOTE Note positions of index marks on filters in relation to a fixed point on mounting bases. There are index marks on each filter spaced 90 degrees (or 1/4 of a turn) apart. When tightening filters, use rotation index marks as a guide. Then turn filters an additional 1/2 turn. 2.

Install two new filters (8) hand-tight until seals contact mounting bases (9).

3.

Fill hydraulic tank with clean oil until level is at “FULL” mark on sight gage (10). 427-C1358

0148 00-4

TM 5-3805-291-23-2


0148 00

FILL AND FILTER INSTALLATION - CONTINUED 4.

Install hydraulic filler cap (3) on machine.

5.

Run engine for a minimum of 10 seconds. Stop engine and check hydraulic oil level. If necessary, remove hydraulic filler cap (3) and add clean oil until “FULL” mark on sight gage (10) is reached. Install hydraulic filler cap on machine.

6.

Run engine at low idle and cycle work tool so all hydraulic systems are filled with oil. Check oil level. If necessary, remove hydraulic filler cap (3) and add oil until “FULL” mark on sight gage (10) is reached. Stop engine and check oil level and add oil if necessary. Check for leaks.

7.

Install strainer and retaining ring in hydraulic filler cap (3).

8.

Install hydraulic filler cap (3) and padlock (2) on machine.

427-C0216

9.

Close access door and install two washers (5) and bolts (4).

427-C0213


6 TM 5-3805-291-23-2

QUICK COUPLER DIVERTER VALVE REPLACEMENT

0149 00


Maintenance Level


Unit



O-ring (9)


Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10)




0149 00-1

Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figure 150 Estimated Time to Complete Task 1.0 hr

TM 5-3805-291-23-2

QUICK COUPLER DIVERTER VALVE REPLACEMENT - CONTINUED

0149 00

REMOVAL

WARNING •


•


•



NOTE •


•


•

Components are located inside right-front frame rail.

1.

Disconnect hoses (1, 2, 3, and 4) from fittings (5, 6, 7, and 8).

2.

Remove four O-rings (9) from hoses (1, 2, 3, and 4). Discard O-rings.

3.

Remove fittings (5, 6, 7, and 8) from quick coupler diverter valve (10).

4.

Remove four O-rings (11) from fittings (5, 6, 7, and 8). Discard O-rings.

5.

Disconnect T (12) from quick coupler diverter valve (10).

6.

Remove O-ring (13) from T (12). Discard O-ring.

7.

Disconnect wiring harness (14) from quick coupler diverter valve (10).

8.


9.

Remove two bolts (18) from quick coupler diverter valve (10) and remove quick coupler diverter valve from machine.

0149 00-2

TM 5-3805-291-23-2


0149 00

REMOVAL - CONTINUED

427-C1155

0149 00-3

TM 5-3805-291-23-2


0149 00


WARNING •

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and lowtoxic material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or death to personnel.

•


1.


2.


3.


4.


INSTALLATION 1.

Position quick coupler diverter valve (10) on machine and install two bolts (18) on quick coupler diverter valve.

2.

Position clip (17) and install bolt (15) and washer (16) on machine.

3.

Connect wiring harness (14) to quick coupler diverter valve (10).

NOTE Apply a thin coat of clean oil to all O-rings before installation. 4.

Install new O-ring (13) in T (12) and install on quick coupler diverter valve (10).

5.

Install four new O-rings (11) in fittings (5, 6, 7, and 8) and install fittings on quick coupler diverter valve (10).

6.

Install four new O-rings (9) in hoses (1, 2, 3, and 4) and connect hoses to fittings (5, 6, 7, and 8).

7.

Run engine and verify correct operation (TM 5-3805-291-10).

0149 00-4

TM 5-3805-291-23-2


0149 00


427-C1155

END OF WORK PACKAGE

0149 00-5/(0149 00-6 Blank)

8 TM 5-3805-291-23-2

PILOT OIL ACCUMULATOR MAINTENANCE

0150 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation, Test and Charge INITIAL SETUP Maintenance Level


Unit Test Equipment Test stand, automotive (Item 87, WP 0232 00)

Nitrogen technical dry cylinder (Item 25, WP 0233 00)

Hose (Item 33, WP 0232 00)

Rag, wiping (Item 35, WP 0233 00) Personnel Required

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Charging kit, pressure (Item 23, WP 0232 00)

MOS 62B, Construction Equipment Repairer Equipment Conditions Front access cover removed (WP 0218 00) Steering frame lock connected (TM 5-3805-29110) Hydraulic system pressure relieved (TM 5-3805291-10)

Pin, shoulder, headless (Item 48, WP 0232 00) Saddle assembly, lifting block (Item 65, WP 0232 00) Stand assembly (Item 79, WP 0232 00) Tubing assembly set, nonmetallic (Item 93, WP 0232 00)

0150 00-1


TM 5-3805-291-23-2

PILOT OIL ACCUMULATOR MAINTENANCE - CONTINUED

0150 00

REMOVAL

WARNING •


•


•


•


WARNING


NOTE

1.

•

Stands are assembled from Items 48, 65, 79, and 93 (WP 0232 00).

•

Stand capacity must be 5,200 lb (2,359 kg).

Raise lift arms (1) and support with stand assembly.

427-C0596

0150 00-2

TM 5-3805-291-23-2


0150 00

REMOVAL – CONTINUED 2.

Unscrew pilot oil accumulator (2) from block assembly.

427-C0597

0150 00-3

TM 5-3805-291-23-2


0150 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION 1.

Screw pilot oil accumulator (2) on block assembly.

2.

Raise lift arms (1) and remove stand assemblies.

3.

Install front access cover (WP 0178 00).


4.


TEST AND CHARGE Test 1.

Install dial indicating differential pressure gage on hose with quick-disconnect fittings. Connect other end of hose to pressure tap (3).

427-C1139

0150 00-4

TM 5-3805-291-23-2


0150 00

TEST AND CHARGE - CONTINUED Test - Continued 2. 3. 4. 5. 6. 7. 8.

Start engine and run at high idle (TM 5-3805-291-10). Pressure on dial gage should read 510 ± 50 psi (3,515 ± 345 kPa). Stop engine (TM 5-3805-291-10). Turn engine start switch to ON position but do not start engine (TM 5-3805-291-10). Move implement levers through full range of travel to relieve any pressure in system (TM 5-3805-291-10). Turn engine start switch to OFF position (TM 5-3805-291-10). Move joystick to lower boom. Pressure on dial gage should decrease steadily. When pressure is approximately 290 ± 15 psi (2,000 ± 100 kPa), pressure will suddenly drop to zero. Last reading before pressure drop is correct pressure of accumulator charge.

Discharging Pilot Oil Accumulator

NOTE Do not attach hose assembly to T when you are discharging the accumulator.

1.

Remove cap (4) from pilot oil accumulator (2) to locate nitrogen charging valve (5).

2.

Remove protective cap (6) from nitrogen charging valve (5).

3.

Attach hose assembly (7) to nitrogen charging chuck.

4.

Turn T handle (8) on nitrogen charging chuck fully counterclockwise.

5.

Attach hose assembly (7) with nitrogen charging chuck to nitrogen charging valve (5).

WARNING Point open end of hose assembly away from work area and personnel. Failure to follow this warning may result in injury to personnel.

6.

Turn T handle (8) fully clockwise to open nitrogen charging valve (5) and remove pilot oil accumulator (2) from machine.

427-C1142

427-C1141

0150 00-5

TM 5-3805-291-23-2


0150 00

TEST AND CHARGE - CONTINUED Nitrogen Charging Procedure

WARNING •

Injury or death can result from improper accumulator charging.

•

Dry nitrogen is only gas approved for use in accumulator. Charging accumulator with oxygen will cause explosion. This danger will not occur if nitrogen cylinders with standard CGA (Compressed Gas Association, Inc.) Number 580 connections are used.

•

When ordering nitrogen gas, make sure cylinders are equipped with CGA Number 580 connections. DO NOT use color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. Never use an adapter to connect the nitrogen charging group to a valve outlet used on nitrogen, oxygen, or other gas cylinders. MAKE SURE TO USE DRY NITROGEN (99.8% purity).

•

DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid, under pressure, can penetrate skin, causing injury to personnel.

•


1.

Place shift lever in NEUTRAL position.

2.

Place transmission neutralizer lockout in OFF position.

3.

Engage parking brake (TM 5-3805-291-10).

4.

Close valve (9) if open.

5.

Turn T handle (8) on nitrogen charging chuck fully counterclockwise.

427-C1140-2

0150 00-6

TM 5-3805-291-23-2


0150 00

TEST AND CHARGE - CONTINUED Nitrogen Charging Procedure - Continued 6.

Connect nitrogen charging chuck to nitrogen charging valve (5).

427-C1143

7.

Turn T handle (8) fully clockwise.

8.

If reading on pressure gage (10) is too high, slowly open valve (9).

9.

If reading on pressure gage (10) is too low:

10.

a.

Connect hose between nitrogen charging chuck and nitrogen cylinder.

b.

Slowly open valve (9) and charge pilot oil accumulator (2) to 290 ± 15 psi (2,000 ± 100 kPa) at temperature of 70°F (21°C).

c.

Close valve (9).

d.

If readings on pressure gage (10) and pressure gage (11) are identical and steady, pilot oil accumulator (2) is correctly charged.

e.

If reading on pressure gage (10) decreases, open valve (9) until pressure gage (11) readings are equal and do not change.

Close valve (9) on nitrogen cylinder.

0150 00-7

427-C1140-1

TM 5-3805-291-23-2


0150 00

TEST AND CHARGE - CONTINUED Nitrogen Charging Procedure - Continued


11.


12.

Pressurize hydraulic system (TM 5-3805-291-10).

13.


14.


15.


16.

Check for leaks.

END OF WORK PACKAGE

0150 00-8

12 TM 5-3805-291-23-2

RIDE CONTROL ACCUMULATOR MAINTENANCE

0151 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation, Discharging/Charging, Testing Ride Control Diverter Valve INITIAL SETUP Materials/Parts - Continued



Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Bracket, link (Item 15, WP 0232 00)


Charging kit, pressure (Item 23, WP 0232 00)


Test stand, automotive (Item 87, WP 0232 00) (3)




Materials/Parts Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Nitrogen technical dry cylinder (Item 25, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

0151 00-1

Battery disconnect switch in OFF position (TM 53805-291-10) Steering frame lock connected (TM 5-3805-29110) Hydraulic system pressure relieved (TM 5-3805291-10) Drawings Required TM 5-3805-291-23P, Figure 152 Estimated Time to Complete Task 3.0 hr

TM 5-3805-291-23-2

RIDE CONTROL ACCUMULATOR MAINTENANCE - CONTINUED

0151 00

REMOVAL 1.

Discharge ride control accumulator (1) before removing. Refer to Discharging/Charging in this work package.

WARNING •


•


•



NOTE •


•


2.

Disconnect hose assembly (2) from elbow (3).

3.

Remove O-ring (4) from hose assembly (2). Discard O-ring.

427-C1116

0151 00-2

TM 5-3805-291-23-2


0151 00

REMOVAL - CONTINUED

WARNING


NOTE Ride control accumulator weighs 97 lb (44 kg).

4.

Attach lifting equipment to ride control accumulator (1).

5.

With assistance, remove four bolts (5) and washers (6) from ride control accumulator (1) and remove ride control accumulator from machine.

6.

Remove elbow (3) from ride control accumulator (1).

7.

Remove O-ring (7) from elbow (3). Discard O-ring.

427-C1119

0151 00-3

TM 5-3805-291-23-2


0151 00


WARNING •


•


1.


2.

Dry parts with compressed air. Do not wipe parts with rags, which may leave lint deposits on surfaces.

3.


4.


INSTALLATION


1.

Install new O-ring (7) in elbow (3) and install elbow on ride control accumulator (1).

427-C1119

0151 00-4

TM 5-3805-291-23-2


0151 00


WARNING


NOTE Ride control accumulator weighs 97 lb (44 kg).

2.

Attach lifting equipment to ride control accumulator (1).

3.

With assistance, position ride control accumulator (1) on machine and install four washers (6) and bolts (5) on ride control accumulator.

4.

Install new O-ring (4) in hose assembly (2) and connect hose assembly to elbow (3).

427-C1116

0151 00-5

TM 5-3805-291-23-2


0151 00

DISCHARGING/CHARGING

WARNING •

Dry nitrogen is the only gas approved for use in the accumulators. The charging of oxygen gas in an accumulator will cause an explosion. An explosion can be eliminated by using nitrogen gas cylinders with standard CGA (Compressed Gas Association, Inc.) No. 580 connectors. When nitrogen gas is ordered, make sure to order the cylinders with CGA No. 580 connectors.

•

Do not rely on color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. In any application, never use an adapter to connect your nitrogen charging group to a valve outlet used on both nitrogen, oxygen, or other gas cylinders. BE SURE YOU USE DRY NITROGEN (99.8% purity).

•

Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. Injury to personnel can result from hydraulic oil pressure and hot oil.

•

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

•

Make sure all attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filter cap only when the engine is stopped and the filler cap is cooled enough to touch with your bare hand.

•

Sudden movement or accidental starting of the machine can cause injury or death to personnel on or near the machine. To prevent injury or death to personnel, perform the following: a. b. c.

Park the machine on a smooth, level surface. Stop the engine and remove the key. Block the wheels and install the steering frame lock.

0151 00-6

TM 5-3805-291-23-2


0151 00

DISCHARGING/CHARGING - CONTINUED Discharging Ride Control Accumulator 1.

Remove protective cap from nitrogen charging valve (8).

NOTE DO NOT attach hose assembly to T (10) when discharging accumulator.

2.

Attach hose assembly (9) to nitrogen charging chuck (11).

3.

Turn valve handle (12) on nitrogen charging chuck (11) counterclockwise to ensure nitrogen charging valve (8) will not open when nitrogen charging chuck is attached to nitrogen charging valve.

4.

Attach nitrogen charging chuck (11) and hose assembly (9) to nitrogen charging valve (8).

WARNING Point open end of hose assembly away from work area and personnel. Failure to follow this warning may result in injury to personnel.

5.

Place open end of hose assembly (9) away from work area and other personnel.

6.

Turn valve handle (12) on nitrogen charging chuck (11) fully clockwise to open nitrogen charging valve (8). Release all compressed gas from ride control accumulator through hose assembly (9). Remove ride control accumulator from machine.

427-C1121 427-C1122

0151 00-7

TM 5-3805-291-23-2


0151 00

DISCHARGING/CHARGING - CONTINUED Nitrogen Charging Procedure

WARNING

•

Injury or death can result from improper accumulator charging.

•

Dry nitrogen is only gas approved for use in accumulator. Charging accumulator with oxygen will cause explosion. This danger will not occur if nitrogen cylinders with standard CGA (Compressed Gas Association, Inc.) Number 580 connections are used.

•

When ordering nitrogen gas, make sure cylinders are equipped with CGA Number 580 connections. DO NOT use color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. Never use an adapter to connect the nitrogen charging group to a valve outlet used on nitrogen, oxygen, or other gas cylinders. MAKE SURE TO USE DRY NITROGEN (99.8% purity).

•

DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid, under pressure, can penetrate skin, causing injury to personnel.

•


1.

Place shift lever in NEUTRAL position.

2.

Place transmission neutralizer lockout in OFF position.

3.

Engage parking brake (TM 5-3805-291-10).

4.

Start engine (TM 5-3805-291-10) and keep engine running during following steps.

5.

Place ride control switch (13) on instrument panel in ON position.

6.

Move lift control lever to FLOAT position (TM 5-3805-291-10).

0151 00-8

TM 5-3805-291-23-2


0151 00

DISCHARGING/CHARGING - CONTINUED Nitrogen Charging Procedure - Continued 7.

Turn T handle (12) on nitrogen charging chuck (11) counterclockwise. Attach nitrogen charging chuck to nitrogen charging valve (8).

8.

Connect hose assembly (9) between nitrogen charging chuck (11) and T (10).

427-C1121

427-C1122

9.

Install needle valve (14). Install pressure gage (15) on T.

10.

Install nipple (16) on needle valve (14).

11.

Install coupling assembly (18) on hose assembly (17).

12.

Connect hose assembly (17) to nipple (16) on needle valve (14). Place open end of hose assembly away from work area and other personnel.

13.

Open needle valve (14) and turn T handle (12) on nitrogen charging chuck (11) clockwise.

14.

Raise bucket to maximum height to relieve any additional nitrogen from ride control accumulator (TM 5-3805-291-10).

15.

Close needle valve (14).

16.

Lower bucket to ground. Move lift control lever to FLOAT position (TM 5-3805-291-10).

17.

Shut off engine (TM 5-3805-291-10).

18.

Install nipple (19) in hose assembly (17).

19.

Attach open end of hose assembly (17) to coupling assembly (20). Install differential pressure gage (21) in coupling assembly port directly above pressure regulator assembly (22).

20.

Install differential pressure gage (23) in remaining port next to regulator assembly (22).

21.

Install regulator assembly (22) on nitrogen tank valve. Turn valve on nitrogen tank counterclockwise on tank. Adjust screw (24) on regulator assembly to set pressure to charge pressure.

22.

Open needle valve (14). Nitrogen pressure should show on pressure gage (15) within 20 seconds.

427-C1591-1

0151 00-9

TM 5-3805-291-23-2


0151 00

DISCHARGING/CHARGING - CONTINUED Nitrogen Charging Procedure - Continued

NOTE •

To ensure accumulator nitrogen charge is correct, accumulator piston must be at bottom of accumulator cylinder. Nitrogen pressure varies with temperature. To obtain most accurate nitrogen charge, temperature of accumulator should equal outside air temperature. However, temperature of accumulator could be higher than outside air temperature in some cases. If this is case, temperature of accumulator should be used instead of outside air temperature.

•

If nitrogen pressure appears on pressure gage in less time, close pressure regulating screw on regulator assembly and disconnect hose assembly at coupling assembly next to pressure gage. Close needle valve and remove coupling assembly. Repeat steps 6 thru 23. For correct nitrogen charge pressure, see Table 1.

23.

Turn T handle (12) on nitrogen charging chuck (11) fully counterclockwise. Close regulator assembly (22) and needle valve (14). Shut off nitrogen tank. Slowly disconnect hose assembly (17) from needle valve. Open needle valve. Remove nitrogen charging chuck from nitrogen charging valve (8) on ride control accumulator.

24.

Install protective cap on nitrogen charging valve (8).

427-C1121 427-C1122-1

0151 00-10

TM 5-3805-291-23-2


0151 00

DISCHARGING/CHARGING - CONTINUED Nitrogen Charging Procedure - Continued Table 1. 966H Accumulator Precharge Temperature Pressure Relationship for a Typical Ride Control Accumulator with a Precharge of 430 psi (2,960 kPa). Temperature

Pressure

20°F (-7°C)

390 psi (2,960 kPa)

30°F (-1°C)

398 psi (2,745 kPa)

40°F (4°C)

406 psi (2,800 kPa)

50°F (10°C)

414 psi (2,855 kPa)

60°F (16°C)

422 psi (2,910 kPa)

70°F (21°C)

430 psi (2,960 kPa)

80°F (27°C)

438 psi (3,020 kPa)

90°F (32°C)

446 psi (3,075 kPa)

100°F (38°C)

454 psi (3,130 kPa)

110°F (43°C)

462 psi (3,185 kPa)

120°F (49°C)

470 psi (3,240 kPa)


25.


26.

Pressurize hydraulic system (TM 5-3805-291-10).

27.


28.


29.


30.

Check for leaks.

0151 00-11

TM 5-3805-291-23-2

RIDE CONTROL ACCUMULATOR MAINTENANCE - CONTINUED TESTING RIDE CONTROL DIVERTER VALVE

NOTE The following procedure is used to determine whether the diverter valve is operating correctly. Perform this test after the ride control accumulator is charged. 1.


2.

Move ride control switch (13) to OFF position.

3.

Place bucket in full DUMP position. Lift front wheels off ground by moving lift control lever to LOWER position (TM 5-3805-291-10).

4.

With front wheels off ground, place lift control lever in HOLD position. In approximately 5 seconds, ride control switch will switch to ON position. Front wheels should lower to ground.

5.

If wheels do not lower to ground, diverter spool has not shifted to ON position. These conditions are probable causes: a.

Ride control switch is faulty.

b.

Solenoid coil on diverter valve is faulty.

c.

Cartridge valve in diverter valve is faulty.

d.

Diverter valve spool sticks.

e.

Pilot oil passage to ride control diverter valve is blocked.

END OF WORK PACKAGE

0151 00-12

0151 00

12 TM 5-3805-291-23-2

TILT CYLINDERS REPLACEMENT

0152 00






Adapter, shaft puller (Item 11, WP 0232 00)


Inserter end remover, pin (Item 36, WP 0232 00)

Gasket

Nut, plain, round (Item 47, WP 0232 00)

O-ring (3)

Puller, hydraulic (Item 53, WP 0232 00) Pump, hydraulic ram, hand-driven (Item 56, WP 0232 00) Stud, plain (Item 82, WP 0232 00)

Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions

Washer, flat (Item 94, WP 0232 00)

Tilt kickout position sensor removed (WP 0089 00)




Drawings Required

Cleaning compound, solvent, type III (Item 7, WP 0233 00) Grease, automotive and artillery, GAA (Item 15, WP 0233 00)

0152 00-1


TM 5-3805-291-23-2

TILT CYLINDERS REPLACEMENT - CONTINUED

0152 00

REMOVAL

WARNING •


•


•

Hydraulic oils used in the performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.


NOTE • Tag hoses prior to removal to ensure correct installation. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up.

0152 00-2

TM 5-3805-291-23-2


0152 00



2.

Disconnect hose assembly (4) and remove O-ring (5) from tilt cylinder (6). Discard O-ring.

0152 00-3

TM 5-3805-291-23-2


0152 00


Disconnect grease hose assembly (7) from tilt cylinder (6).

4.


5.

Disconnect hose assembly (11) from machine and remove gasket (12). Discard gasket.

427-C0538

0152 00-4

TM 5-3805-291-23-2


0152 00


Remove eight bolts (13) and washers (14) from four flange halves (15).

7.

Disconnect hose assemblies (4 and 11) and remove two O-rings (16) and hose assemblies from machine. Discard O-rings.

WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may result in injury or death to personnel.

NOTE

8.

•

Tilt cylinder weighs 485 lb (220 kg).

•

Tooling weighs 150 lb (68 kg) and consists of a hand-driven hydraulic pump, hydraulic puller, plain stud, nut, washer, and pin inserter/remover.

Attach lifting equipment to tilt cylinder (6).

427-C0535

0152 00-5

TM 5-3805-291-23-2


0152 00

REMOVAL - CONTINUED

NOTE Special tools should be assembled as shown in illustration below.

9.

With assistance, use hydraulic pump assembly to remove pin assembly (17).

427-C0536

10.

Use hydraulic pump assembly to remove rear pin assembly (18).

11.

Remove tilt cylinder (6) from machine.

427-C0537

0152 00-6

TM 5-3805-291-23-2


0152 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION 1.

Lubricate pin bores with GAA before installing tilt cylinder (6).


0152 00-7

TM 5-3805-291-23-2


0152 00


NOTE

2.

•


•

Special tools should be assembled as shown in illustration.

Use lifting equipment to position tilt cylinder (6) on machine.

427-C0537

3.

With assistance, install rear pin assembly (18) on tilt cylinder (6).

4.

Install pin assembly (17) on tilt cylinder (6).

427-C0536

0152 00-8

TM 5-3805-291-23-2


0152 00


Position two new O-rings (16), hose assemblies (11 and 4), and four flange halves (15) on machine and install eight washers (14) and bolts (13) on hose assemblies.

6.

Position new gasket (12), hose assembly (11), and two flange halves (10) on machine and install four washers (9) and bolts (8).

427-C0538

0152 00-9

TM 5-3805-291-23-2

TILT CYLINDERS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 7.

Connect grease hose assembly (7) to tilt cylinder (6).

0152 00-10

0152 00

TM 5-3805-291-23-2

TILT CYLINDERS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 8.

Position new O-ring (5), hose assembly (4), and two flange halves (3) and install four washers (2) and bolts (1). Connect hose assembly to tilt cylinder (6).

9.

Install tilt kickout position sensor (WP 0089 00).

10.

Run engine and operate tilt cylinder to verify correct operation of tilt cylinder (TM 5-3805-291-10).

11.


12.

Check for leaks.

END OF WORK PACKAGE

0152 00-11/(0152 00-12 Blank)

0152 00

10 TM 5-3805-291-23-2

LIFT CYLINDERS REPLACEMENT

0153 00



Unit



Grease, automotive and artillery, GAA (Item 15, WP 0233 00)





Nut, fastener (Item 43, WP 0232 00) Pin, shoulder, headless (Item 48, WP 0232 00)


Puller, hydraulic (Item 51, WP 0232 00)


Puller, hydraulic (Item 52, WP 0232 00)

O-ring (3)

Pump, hydraulic ram, hand-driven (Item 56, WP 0232 00) Saddle assembly, lifting block (Item 65, WP 0232 00)

Personnel Required MOS 62B Construction Equipment Repairer (2) Equipment Conditions

Stand assembly (Item 79, WP 0232 00)

Front fenders removed (WP 0136 00)

Stud, plain (Item 82, WP 0232 00)


Tube, metallic (Item 92, WP 0232 00) Tubing assembly set, nonmetallic (Item 93, WP 0232 00)

Drawings Required



TM 5-3805-291-23P, Figure 154

3.0 hr


0153 00-1

TM 5-3805-291-23-2

LIFT CYLINDERS REPLACEMENT - CONTINUED

0153 00

REMOVAL

WARNING •


•


•


•


WARNING



NOTE •


•


•

Stands are assembled from Items 48, 65, 79, and 93 (WP 0232 00).

•

Stand capacity must be 5,200 lb (2,359 kg).

0153 00-2

TM 5-3805-291-23-2


0153 00


Support lift arms on stand assemblies.

427-C0394

2.

Release hydraulic system pressure (TM 5-3805-291-10).

3.

Disconnect two hose assemblies (1) and line (2) from lift cylinder (3).

4.

Remove three O-rings (4) from hose assemblies (1) and line (2). Discard O-rings.

427-C1293-1

427-C0395

0153 00-3

TM 5-3805-291-23-2


0153 00

REMOVAL - CONTINUED

WARNING


NOTE Lift cylinder weighs 550 lb (250 kg). 5.

Attach lifting equipment to lift cylinder (3).

6.

With assistance, remove pin assembly (5) from lift cylinder (3).

NOTE Tooling weighs 50 lb (23 kg). 7.

Remove grease fitting (6) from pin assembly (7).

8.

Remove bolt (8), washer (9), and spacer (10) from pin assembly (7).

427-C0438

0153 00-4

TM 5-3805-291-23-2


0153 00


Support hydraulic pump and puller assembly with lifting equipment. With assistance, use puller assembly to remove pin assembly (7) from lift cylinder (3).

427-C0439

0153 00-5

TM 5-3805-291-23-2


0153 00

REMOVAL - CONTINUED

NOTE Pump and puller is assembled from Items 45, 43, 52, 56, 82, and 94 (WP 0232 00). 10.

Use lifting equipment to remove lift cylinder (3) from machine.


WARNING •


•


1.


2.


3.


4.


0153 00-6

TM 5-3805-291-23-2


0153 00

INSTALLATION

WARNING


NOTE Lift cylinder weighs 550 lb (250 kg).

1.

Use lifting equipment to position lift cylinder (3) on machine.

0153 00-7

TM 5-3805-291-23-2


0153 00


NOTE

2.

•

Lubricate bores and pins with grease before installation.

•

Pump and puller is assembled from Items 45, 43, 52, 56, 82, and 94 (WP 0232 00).

With assistance, use hydraulic pump and puller assembly to install pin assembly (7) in lift cylinder (3).

427-C0439

3.

Install washer (9), spacer (10), and bolt (8) in pin assembly (7).

4.

Install grease fitting (6) in pin assembly (7).

427-C0438

0153 00-8

TM 5-3805-291-23-2


0153 00


Install pin assembly (5) in lift cylinder (3).

6.

Lubricate and install three new O-rings (4) in hose assemblies (1) and line (2). Connect hose assemblies and line to lift cylinder (3).

427-C0395

427-C1293-1

0153 00-9

TM 5-3805-291-23-2


0153 00


Raise lift arms and remove stands and associated tooling.

427-C0394


8.


9.

Install front fenders (WP 0136 00).

10.

Run engine and verify correct operation of lift cylinder (TM 5-3805-291-10).

11.


12.

Check for leaks.

END OF WORK PACKAGE

0153 00-10

12 TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL FILTER BASES AND COOLER HOSES, LINES, AND FITTINGS REPLACEMENT

0154 00





References


WP 0117 00


WP 0159 00

Materials/Parts

WP 0155 00 WP 0193 00 Equipment Conditions

Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Hydraulic tank drained (WP 0148 00) Hydraulic filter access door opened (TM 5-3805291-10) Right rear fender removed (WP 0137 00) Drawings Required TM 5-3805-291-23P, Figure 157 Estimated Time to Complete Task

Tag, marker (Item 43, WP 0233 00) O-ring (27)

0.5 hr

0154 00-1

TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL FILTER BASES AND COOLER HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED

0154 00

REMOVAL

WARNING •


•


•



NOTE •


•


0154 00-2

TM 5-3805-291-23-2


0154 00

REMOVAL - CONTINUED Hydraulic Oil Filter Base 1.

Disconnect hose (1) and tube (2) from hydraulic oil filter bases (3) (WP 0155 00). Remove and discard O-ring (4).

2.

Disconnect tube (2) from fitting (5) and remove tube from machine. Remove O-ring (4) from tube. Discard O-ring.

3.

Disconnect hose (6) from fitting (5). Remove O-ring (7) from hose. Discard O-ring.

4.

Remove fitting (5) from machine.

5.


6.

Remove five clips associated with hose (1) and remove hose from hydraulic cooler (WP 0193 00). Remove O-ring (8) from hose. Discard O-ring.

0154 00-3

TM 5-3805-291-23-2


0154 00

REMOVAL - CONTINUED Hydraulic Oil Filter Base - Continued 7.


8.

Remove fitting (12) from machine (WP 0117 00).

9.


427-C1343

Hydraulic Cooler 1.

Remove elbow (13) from T (14). Remove O-ring (15) from T. Discard O-ring.

2.

Disconnect line (16) from elbow (17). Remove O-ring (18) from line. Discard O-ring.

3.

Remove elbow (17) from T (14). Remove O-ring (19) from elbow. Discard O-ring.

4.

Remove T (14) from junction block (20). Remove O-ring (21) from T. Discard O-ring.

5.

Remove two fittings (22) from junction block (20). Remove two O-rings (23) from fittings. Discard O-rings.

427-C1341

0154 00-4

TM 5-3805-291-23-2


0154 00

REMOVAL - CONTINUED Hydraulic Cooler - Continued 6.

Disconnect line (16) from elbow (24). Remove O-ring (25) from line. Discard O-ring.

7.

Remove elbow (24) from fitting (26). Remove O-ring (27) from elbow. Discard O-ring.

8.

Remove fitting (26) from hydraulic cooler (28). Remove O-ring (29) from fitting. Discard O-ring.

427-C1342

Case Drain Filter Base 1.

Disconnect hose (30) and remove two O-rings (31) from fittings (32 and 33). Discard O-rings.

2.


427-C1381

0154 00-5

TM 5-3805-291-23-2


0154 00

REMOVAL - CONTINUED Case Drain Filter Base - Continued 3.

Remove fittings (32 and 37) and two O-rings (38) from case drain oil filter (39). Discard O-rings.

427-C1559

4.


5.

Disconnect hose (44) and remove O-ring (45) from fitting (42). Discard O-ring.

6.

Remove fitting (42) and O-ring (46) from machine. Discard O-ring.

427-C1560

0154 00-6

TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL FILTER BASES AND COOLER HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED REMOVAL - CONTINUED Drain Valve 1.

Remove bolt (47), washer (48), and clip (49) from hose (44).

2.


3.

Remove fitting (51) and O-ring (52) from drain valve (53). Discard O-ring.

0154 00-7

0154 00

TM 5-3805-291-23-2


0154 00

INSTALLATION Drain Valve

NOTE Apply a thin coat of clean oil to all Orings before installation. 1.

Install new O-ring (52) in fitting (51) and install fitting on drain valve (53).

2.

Install new O-ring (50) in hose (44) and connect hose to fitting (51).

3.

Install clip (49), washer (48), and bolt (47) on hose (44).

4.

Install new O-ring (46) in fitting (42) and install fitting on machine.

427-C1560

Case Drain Filter Base 1.


2.

Install two new O-rings (41) in hose (40) and connect hose to fitting (42).

3.

Install two new O-rings (38) in fittings (37 and 32) and install fittings on oil filter (39).

427-C1559

0154 00-8

TM 5-3805-291-23-2


0154 00

INSTALLATION - CONTINUED Case Drain Filter Base - Continued 4.

Install new O-rings (35) in hose (34) and connect hose to fittings (37 and 36).

5.

Install new O-rings (31) in hose (30) and connect hose to fittings (33 and 32).

427-C1381

Hydraulic Cooler 1.

Install new O-ring (29) in fitting (26) and install fitting on radiator (28).

2.

Install new O-ring (27) in elbow (24) and install elbow on fitting (26).

3.


427-C1342

0154 00-9

TM 5-3805-291-23-2


0154 00

INSTALLATION - CONTINUED Hydraulic Cooler - Continued 4.

Install two new O-rings (23) in fittings (22) and install fittings on junction block (20).

427-C1341

5.

Install new O-ring (21) in T (14) and install T in junction block (20).

6.

Install new O-ring (19) in elbow (17) and install elbow on T (14).

7.


8.

Install new O-ring (15) in elbow (13) and install elbow on T (14).

9.

Install fitting (12) on machine (WP 0117 00).

10.


11.


0154 00-10

427-C1343

TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL FILTER BASES AND COOLER HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED Hydraulic Oil Filter Base 1.

Install new O-ring (8) in hose (1) and connect hose to hydraulic cooler (WP 0193 00).

2.


3.

Install fitting (5) on machine.

4.


5.

Install new O-ring (4) in tube (2) and connect tube to fitting (5).

6. 7.

Install new O-ring (4). Connect hose (1) and tube (2) to hydraulic system oil filter bases (3) (WP 0155 00). Install all associated clips.

8. 9. 10. 11. 12. 13.

Install right rear fender (WP 0137 00). Fill hydraulic tank (WP 0148 00). Operate machine and verify correct operation (TM 5-3805-291-10). Shut down engine (TM 5-3805-291-10). Check for leaks. Close hydraulic filter access door (TM 5-3805-291-10).


0154 00

6 TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL FILTER BASES REPLACEMENT

0155 00



Unit

O-ring (8)


Personnel Required



Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

0155 00-1


Hydraulic system pressure relieved (TM 5-3805291-10) Hydraulic oil filters removed from machine (WP 0148 00) Case drain hoses removed from machine (WP 0154 00) Drawings Required TM 5-3805-291-23P, Figures 65 and 155 Estimated Time to Complete Task 1.5 hr

TM 5-3805-291-23-2

HYDRAULIC SYSTEM OIL FILTER BASES REPLACEMENT - CONTINUED

0155 00

REMOVAL Hydraulic Filter Base 1.

0155 00

Disconnect switch (1) and remove two O-rings (2) from hydraulic oil filter base (3). Discard O-rings.

427-C0540

2.

Disconnect two hoses (4) and remove two O-rings (5) from hydraulic oil filter base (3). Discard O-rings.

3.

Remove four bolts (6) and washers (7) from mounting bracket (8) and remove hydraulic oil filter base (3) from machine.

4.

Remove two fittings (9) and O-rings (10) from hydraulic oil filter base (3). Discard O-rings.

5.

Remove cap (11), fluid sampling valve (12), O-ring (13), elbow (14), and O-ring (15) from hydraulic oil filter base (3). Discard O-rings.

0155 00-2

TM 5-3805-291-23-2


0155 00

REMOVAL - CONTINUED Case Drain Filter Base

0155 00

Remove three bolts (16), washers (17), and case drain filter base (18) from machine.

427-C1592


WARNING •


•


1.


2.


3.


4.


TM 5-3805-291-23-2


0155 00

INSTALLATION Case Drain Filter Base

03 00

Install case drain filter base (18), two washers (17), and bolts (16) on machine.

427-C1592

Hydraulic Filter Base

03 00


Install new O-ring (15), elbow (14), new O-ring (13), fluid sampling valve (12), and cap (11) on hydraulic oil filter base (3).

2.

Install two new O-rings (10) and fittings (9) on hydraulic oil filter base (3).

3.

Position hydraulic oil filter base (3) on machine and install four washers (7) and bolts (6) on mounting bracket (8).

4.

Install two new O-rings (5) and connect hoses (4) to hydraulic oil filter base (3).

5.

Install two new O-rings (2) and connect switch (1) to hydraulic oil filter base (3).

0155 00-4

TM 5-3805-291-23-2


0155 00


427-C0540

6.

Install case drain hoses (WP 0154 00).

7.

Install hydraulic oil filters on machine (WP 0148 00).

8.

Check hydraulic system oil level (TM 5-3805-291-10).

9.


10.

Check hydraulic system pressure (TM 5-3805-291-10).

11.


12.

Check for leaks.

END OF WORK PACKAGE

0155 00-5/(0155 00-6 Blank)

26 TM 5-3805-291-23-2

IMPLEMENT HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT

0156 00





References


TM 5-3805-291-10 WP 0149 00 WP 0152 00 WP 0153 00 WP 0157 00

Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00)

WP 0158 00 Equipment Conditions Hydraulic tank drained (WP 0148 00) Side panels removed (WP 0133 00) Drawings Required TM 5-3805-291-23P, Figures 156, 158, 159, 160, and 171 Estimated Time to Complete Task


0.5 hr ea

O-ring (23)

0156 00-1

TM 5-3805-291-23-2

IMPLEMENT HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED

0156 00

REMOVAL

WARNING •


•


•



NOTE •


•


Coupler System

0156 00

1.

Disconnect hoses and remove fittings from pin coupler cylinder (WP 0158 00).

2.

Cut and remove tiedown strap (1) from two lines (2). Discard tiedown strap.

3.

Remove two bolts (3) and clamps (4) from machine.

427-C1274

0156 00-2

TM 5-3805-291-23-2


0156 00

REMOVAL - CONTINUED Coupler System - Continued

0156 00

4.

Disconnect two lines (2) from fittings (5) and remove lines from machine.

5.

Remove two O-rings (6) from lines (2). Discard O-rings.

6.

Disconnect two fittings (5) from valve (7).

7.

Remove two O-rings (8) from fittings (5). Discard O-rings.

8.

Disconnect two lines (9) from fittings (10).

9.


10.

Disconnect two fittings (10) from valve (7).

11.


12.

Remove eight screws (13) and washers (14) from bracket (15) and remove valve (7) from machine.

13.

Remove four bolts (16) and washers (17) from bracket (15) and remove bracket from machine.

427-C1275

0156 00-3

TM 5-3805-291-23-2


0156 00

REMOVAL - CONTINUED Coupler System - Continued 14.

0156 00

Remove bolt (18) and washer (19) from clip (20) and remove clip from machine.

427-C1276

15.


427-C1277

0156 00-4

TM 5-3805-291-23-2


0156 00


0156 00


427-C1278

17.

Disconnect two lines (27) from fittings (28) and remove lines from machine.

18.


19.

Disconnect two lines (30) from fittings (28).

20.


21.

Remove two fittings (28) from machine.

427-C1279

0156 00-5

TM 5-3805-291-23-2


0156 00


0156 00

Remove two bolts (32), washers (33), and clips (34) from machine.

427-C1280

23.


427-C1281

0156 00-6

TM 5-3805-291-23-2


0156 00


0156 00

24.

Remove two tiedown straps (38) from three hoses on quick coupler diverter valve (39). Discard tiedown straps.

25.

Disconnect hoses and remove fittings from quick coupler diverter valve (39) (WP 0149 00). Remove two lines (30) from machine.

427-C1282

26.

Disconnect hose (40) from fitting (41) and remove hose from machine.

27.


28.


29.


30.

Remove fitting (41) from machine.

31.

Remove O-ring (45) from fitting (41). Discard O-ring.

427-C1283

0156 00-7

TM 5-3805-291-23-2


0156 00


0156 00


427-C1284

33.


427-C1285

0156 00-8

TM 5-3805-291-23-2


0156 00


0156 00

34.


35.

Disconnect hose (55) from fitting (56) and remove hose from machine.

36.


37.

Remove fitting (56) from valve (58).

38.


427-C1286

Third Function System

0156 00

1.

Disconnect two hoses from tilt cylinder (60) (WP 0152 00).

2.

Remove four bolts (61), washers (62), two flange halves (63), and hose (64) from machine.

3.


4.

Remove two bolts (66) and washers (67) from bracket (68) and hose (69).

5.

Remove hose (69) from main hydraulic control valve and machine (WP 0157 00).

0156 00-9

TM 5-3805-291-23-2


0156 00

REMOVAL - CONTINUED Third Function System - Continued 6.

Repeat steps 1 thru 5 for other tilt hose.

7.


8.

Remove fitting (71) from bracket (72).

9.

Remove fitting (73) from bracket (72).

0156 00

427-C1289

Tilt System

0156 00

1.

Remove four bolts (74), washers (75), two flange halves (76), and hose (70) from machine.

2.


3.


427-C1290

0156 00-10

TM 5-3805-291-23-2


0156 00

REMOVAL - CONTINUED Tilt System - Continued

0156 00

4.

Remove four bolts (81), washers (82), and two flange halves (83) from hose (84).

5.


6.

Remove bolt (86) and washer (87) from clamp (88). Remove tube assembly (89) from machine.

427-C1291

7.

Remove four bolts (90), washers (91), and two flange halves (92) from hose (93). Remove hose from machine.

8.


9.

Remove hose (95) from main hydraulic control valve (WP 0157 00).

0156 00-11

TM 5-3805-291-23-2


0156 00

REMOVAL - CONTINUED Tilt System - Continued 10.

0156 00

Remove four bolts (96) and washers (97) from bracket (98) and hose (95) and remove hose from machine.

Lift System 1.

0156 00

Remove two hoses (99) and line (100) from lift cylinder (101) (WP 0153 00).

427-C0395-1

0156 00-12

427-C1293

TM 5-3805-291-23-2


0156 00

REMOVAL - CONTINUED Lift System - Continued

0156 00

2.

Remove eight bolts (102), washers (103), two O-rings (104), and hoses (105 and 106) from machine. Discard O-rings.

3.

Remove hoses (107 and 108) from machine (WP 0157 00).

4.

Remove four bolts (109), washers (110), and two clamps (111) from machine.

5.

Repeat steps 1 thru 4 for other side.

427-C1294

0156 00-13

TM 5-3805-291-23-2


0156 00

REMOVAL – CONTINUED Hose Support Brackets

0156 00

1.

Remove four bolts (96), washers (97), and hose (95) from bracket (98).

2.

Remove four bolts (114), washers (115), and bracket (98) from bracket (68).

3.

Remove two bolts (66), washers (67), and hose (69) from bracket (68).

4.

Remove two bolts (113), washers (112), and bracket (68) from machine.

INSTALLATION Hose Support Bracket

0156 00

1.

Install bracket (68) on machine with two washers (112) and bolts (113).

2.

Install hose (69) on bracket (68) with two washers (67) and bolts (66).

3.

Install bracket (98) on bracket (68) with four washers (115) and bolts (114).

4.

Install hose (95) on bracket (98) with four washers (97 and bolts (96).

0156 00-14

TM 5-3805-291-23-2


0156 00

INSTALLATION – CONTINUED Lift System

0156 00

1.

Install hoses (107 and 108) on main hydraulic control valve (WP 0157 00).

2.

Position two clamps (111) on machine and install four washers (110) and bolts (109).

3.

Install two new O-rings (104) in hoses (106 and 105) and position hoses on machine. Install eight washers (103) and bolts (102).

427-C1294


4.

Install line (100) and two hoses (99) on lift cylinder (101) (WP 0153 00).

5.


427-C0395-1

0156 00-15

427-C1293

TM 5-3805-291-23-2


0156 00

INSTALLATION – CONTINUED Tilt System

0156 00

1.

Position hose (95) on bracket and install four washers (97) and bolts (96).

2.

Connect hose (95) to main hydraulic control valve (WP 0157 00).

3.

Install new O-ring (94) in hose (93). Position hose on machine and install two flange halves (92), four washers (91), and bolts (90).

0156 00-16

TM 5-3805-291-23-2


0156 00

INSTALLATION - CONTINUED Tilt System- Continued

0156 00

4.

Position tube assembly (89) on machine and install clamp (88), washer (87), and bolt (86).

5.

Install new O-ring (85) in hose (84) and position hose on machine. Install two flange halves (83), four washers (82), and bolts (81).

427-C1291

6.

Position clamp (80) on machine and install washer (79) and bolt (78).

7.

Install new O-ring (77) in hose (70) and position hose on machine. Install two flange halves (76), four washers (75), and bolts (74).

427-C1290

0156 00-17

TM 5-3805-291-23-2


0156 00

INSTALLATION - CONTINUED Tilt System - Continued 8.

Install fitting (73) on bracket (72).

9.

Install fitting (71) on bracket (72).

10.


0156 00

427-C1289

Third Function System

0156 00

1.

Position hose (69) on bracket (68) and install two washers (67) and bolts (66).

2.

Install two flange halves (63), four washers (62), and bolts (61).

3.

Install hose (69) on machine and main hydraulic control valve (WP 0157 00).

4.

Install new O-ring (65) in hose (64) and connect hose to tilt cylinder (60) (WP 0152 00).

5.


0156 00-18

TM 5-3805-291-23-2


0156 00

INSTALLATION - CONTINUED Coupler System

0156 00

1.

Install new O-ring (59) in fitting (56) and install fitting on valve (58).

2.


3.

Position clip (54) on machine and install washer (53) and bolt (52).

427-C1286

4.


427-C1285

0156 00-19

TM 5-3805-291-23-2


0156 00

INSTALLATION - CONTINUED Coupler System - Continued 5.

0156 00


427-C1284

6.


7.


8.


427-C1283

0156 00-20

TM 5-3805-291-23-2


0156 00

INSTALLATION - CONTINUED Coupler System - Continued

0156 00

9.

Install three fittings on connect hoses to quick coupler diverter valve (39) (WP 0149 00).

10.

Install two new tiedown straps (38) on three hoses.

427-C1282

11.


427-C1281

0156 00-21

TM 5-3805-291-23-2


0156 00


0156 00

Position two clips (34) on machine and install two washers (33) and bolts (32).

427-C1280

13.

Install two fittings (28) on machine.

14.

Install two new O-rings (31) in lines (30) and connect lines to fittings (28).

15.


427-C1279

0156 00-22

TM 5-3805-291-23-2


0156 00


0156 00


427-C1278

17.


427-C1277

0156 00-23

TM 5-3805-291-23-2


0156 00


0156 00


427-C1276

19.

Position bracket (15) on machine and install four washers (17) and bolts (16).

20.

Position valve (7) in bracket (15) and install eight washers (14) and screws (13).

21.

Install two new O-rings (12) in fittings (10) and install fittings in valve (7).

22.


23.

Install two new O-rings (8) in fittings (5) and install fittings on valve (7).

24.


427-C1275

0156 00-24

TM 5-3805-291-23-2


0156 00

INSTALLATION - CONTINUED Coupler System - Continued

0156 00

25.

Position two clamps (4) on machine and install two bolts (3).

26.

Install new tiedown strap (1) on two lines (2).

27.

Install fittings on and connect hoses to pin coupler cylinder (WP 0158 00).

427-C1274

28.


29.


30.


31.

Check for leaks.

32.

Install side panels (WP 0133 00).

END OF WORK PACKAGE

0156 00-25/(0156 00-26 Blank)

12 TM 5-3805-291-23-2

MAIN CONTROL VALVE AND IMPLEMENT PUMP HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT

0157 00


Maintenance Level


Unit

Gasket (11) Tools and Special Tools

O-ring (23)


Personnel Required


References


WP 0156 00 WP 0159 00

Materials/Parts







Front access cover removed (WP 0218 00) Drawings Required TM 5-3805-291-23P, Figure 157 Estimated Time to Complete Task 0.5 hr ea


0157 00-1

TM 5-3805-291-23-2

MAIN CONTROL VALVE AND IMPLEMENT PUMP HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED

0157 00

REMOVAL

WARNING •


•


•



NOTE •


•


0157 00-2

TM 5-3805-291-23-2


0157 00


Disconnect wiring harness (1) from main hydraulic control valve (2).

2.

Remove eight bolts (3), washers (4), and two gaskets (5) from two third function hoses (6) and disconnect hoses from main hydraulic control valve (2). Discard gaskets.

3.

Remove 16 bolts (7), washers (8), and four gaskets (9) from four lift cylinder hoses (10 and 11) and disconnect hoses from main hydraulic control valve (2). Discard gaskets.

4.

Remove eight bolts (12), washers (13), and two gaskets (14) from two tilt cylinder hoses (15) and disconnect hoses from main hydraulic control valve (2). Discard gaskets.

5.

Disconnect hose (16) from main hydraulic control valve (2). Remove O-ring (17) from hose (16). Discard O-ring.

6.

Disconnect tube (18) from main hydraulic control valve (2) and fitting (19). Remove two O-rings (20) from tube. Discard O-rings.

7.

Remove fitting (19) from machine. Remove O-ring (21) from fitting. Discard O-ring.

8.

Remove eight hoses (6, 10, 11, and 15) from machine (WP 0156 00).

0157 00-3

TM 5-3805-291-23-2


0157 00


Disconnect hoses (16, 22, and 23) from main hydraulic control valve (2). Remove three O-rings (24) from hoses. Discard O-rings. Remove hose (16) from machine.

427-C1296

10.

Remove four bolts (25), washers (26), and gasket (27) and disconnect hose (28) from main hydraulic control valve (2). Discard gasket.

11.

Remove four bolts (29), washers (30), and O-ring (31) and disconnect hose (32) from main hydraulic control valve (2). Discard O-ring.

12.


13.

Disconnect hose (36) from fitting (34) (WP 0156 00).

427-C1297

0157 00-4

TM 5-3805-291-23-2


0157 00


Disconnect hose (37) from main hydraulic control valve (2). Remove O-ring (38) from hose. Discard Oring.

15.

Disconnect hose (39) from main hydraulic control valve (2). Remove O-ring (40) from hose. Discard Oring.

427-C1298

16.

Disconnect hose (33) from fitting (41) and remove hose from machine. Remove O-ring (42) from hose. Discard O-ring.

17.


18.

Remove fittings (41 and 43) from valve (45). Remove two O-rings (46) from fittings. Discard O-rings.

19.

Remove two bolts (47) and washers (48) from valve (45) and remove valve from machine. 427-C1299

0157 00-5

TM 5-3805-291-23-2


0157 00


Remove four bolts (49) and washers (50) and disconnect hose (28) from hose (51). Remove hose (28) from machine. Remove O-ring (52) from hose. Discard O-ring.

21.

Remove four bolts (53) and washers (54) and remove hose (32) from coupling (55). Remove grommet (56) from hose.

22.


23.

Disconnect hose (23) from test port (59) and remove hose from machine. Remove O-ring (60) from hose (23). Discard O-ring.

24.

Remove test port (59) from fitting (61). Remove O-ring (62) from test port. Discard O-ring.

427-C1300

0157 00-6

TM 5-3805-291-23-2

MAIN CONTROL VALVE AND IMPLEMENT PUMP HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED REMOVAL - CONTINUED 25.

Disconnect two hoses (63) from fittings (57 and 61). Remove two O-rings (64) from hoses. Discard O-rings.

26.

Remove fittings (57 and 61) from machine. Remove two O-rings (65) from fittings. Discard O-rings.

27.


28.

Remove three clamps (68) from two hoses (63)

29.

Disconnect two hoses (63) from hydraulic tank (WP 0159 00) and remove hoses from machine.

0157 00-7

0157 00

TM 5-3805-291-23-2


0157 00


Remove four bolts (69) and washers (70) and disconnect hose (51) from hose (71). Remove gasket (72) from hose. Discard gasket.

31.


427-C1356

32.

Remove four bolts (73) and washers (74) from hose (55) and disconnect hose from implement pump (75). Remove gasket (76) from hose. Discard gasket.

427-C1357

INSTALLATION


1.

Install new gasket (76) on hose (55) and position hose on implement pump (75). Install four washers (74) and bolts (73).

2.


3.

Install new gasket (72) on hose (71) and connect hose to hose (51). Install four washers (70) and bolts (69). 0157 00-8

TM 5-3805-291-23-2


0157 00


Install three clamps (68) on two hoses (63).

5.


6.

Install two new O-rings (65) in fittings (57 and 61) and install fittings on machine.

7.

Connect two hoses (63) to hydraulic tank (WP 0159 00).

8.

Install two new O-rings (64) in hoses (63) and connect hoses to fittings (57 and 61).

9.

Install new O-ring (62) in test port (59) and install test port on fitting (61).

10.

Install new O-ring (60) in hose (23) and connect hose to test port (59).

11.


12.

Install grommet (56) on hose (32) and position hose on coupling (55). Install four washers (54) and bolts (53).

13.

Install new O-ring (52) on hose (28) and position hose on coupling (51). Install four washers (50) and bolts (49).

427-C1300

0157 00-9

TM 5-3805-291-23-2


0157 00


Position valve (45) on machine and install two washers (48) and bolts (47).

15.

Install two new O-rings (46) in fittings (41 and 43) and install fittings on valve (45).

16.

Install new O-ring (44) in hose (37) and connect hose (37) to fitting (43).

17.


427-C1299

18.

Install new O-ring (40) in hose (39) and connect hose to main hydraulic control valve (2).

19.


427-C1298

20.

Connect hose (36) to fitting (34) (WP 0156 00).

21.


22.

Install new O-ring (31) in hose (32) and position hose on main hydraulic control valve (2). Install four washers (30) and bolts (29).

23.

Install new gasket (27) on hose (28) and position hose on main hydraulic control valve (2). Install four washers (26) and bolts (25).

427-C1297

0157 00-10

TM 5-3805-291-23-2


0157 00


Install three new O-rings (24) in hoses (16, 22, and 23) and connect hoses to main hydraulic control valve (2).

427-C1296

25.

Install eight hoses (6, 10, 11, and 15) on machine (WP 0156 00).

26.


27.

Install two O-rings (20) in tube (18) and connect tube to main hydraulic control valve (2) and fitting (19).

28.


29.

Install two new gaskets (14) on two tilt cylinder hoses (15) on main hydraulic control valve (2). Install eight washers (13) and bolts (12).

30.

Install four new gaskets (9) on four lift cylinder hoses (10 and 11) on main hydraulic control valve (2). Install 16 washers (8) and bolts (7).

31.

Install two new gaskets (5) on two third function hoses (6) on main hydraulic control valve (2). Install eight washers (4) and bolts (3).

32.

Connect wiring harness (1) to main hydraulic control valve (2).

0157 00-11

TM 5-3805-291-23-2

MAIN CONTROL VALVE AND IMPLEMENT PUMP HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 33.

Install front access cover (WP 0218 00).

34.


35.


36.

Check hydraulic system pressure (TM 5-3805-291-10).

37.


38.

Check for leaks.

END OF WORK PACKAGE

0157 00-12

0157 00

6 TM 5-3805-291-23-2

QUICK COUPLER CYLINDER REPLACEMENT

0158 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Materials/Parts Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Equipment Conditions Machine parked on level ground (TM 5-3805-29110) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Work tools removed (TM 5-3805-291-10) Hydraulic system pressure relieved (TM 5-3805291-10) Steering frame lock connected (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figure 162

Tag, marker (Item 43, WP 0233 00) Estimated Time to Complete Task

Cotter pin (2) O-ring (4)

1.5 hr

0158 00-1

TM 5-3805-291-23-2

QUICK COUPLER CYLINDER REPLACEMENT - CONTINUED

0158 00

REMOVAL

WARNING •


•


•



NOTE •


•


1.

Disconnect two hoses (1) from fittings (2).

2.

Remove two O-rings (3) from hoses (1). Discard O-rings.

3.

Remove two cotter pins (4) from retaining pins (5). Discard cotter pins.

4.

Remove two retaining pins (5) from pin coupler cylinder (6) and remove pin coupler cylinder from machine.

0158 00-2

TM 5-3805-291-23-2


0158 00


Remove two fittings (2) from pin coupler cylinder (6).

6.

Remove two O-rings (7) from fittings (2). Discard Orings.

427-C0580


WARNING •


•


1.


2.


3.


4.


0158 00-3

TM 5-3805-291-23-2


0158 00

INSTALLATION


1.

Install two new O-rings (7) in fittings (2) and install fittings on pin coupler cylinder (6).

2.

Position pin coupler cylinder (6) on machine and install two retaining pins (5).

3.

Install two new cotter pins (4) in retaining pins (5).

427-C0580

4.

Install two new O-rings (3) in hoses (1) and connect hoses to fittings (2).

5.

Install bucket (TM 5-3805-291-10).

0158 00-4

TM 5-3805-291-23-2


0158 00



6.


7.

Verify proper operation of pin coupler cylinder (TM 5-3805-291-10).

8.


9.

Check for leaks.

END OF WORK PACKAGE

0158 00-5/(0158 00-6 Blank)

16 TM 5-3805-291-23-2

HYDRAULIC TANK REPLACEMENT

0159 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Component Transfer, Installation INITIAL SETUP Maintenance Level


Unit





O-ring (27)


Gasket (2)

Personnel Required MOS 62B, Construction Equipment Repairer (2) References

Materials/Parts

TM 5-3805-291-10


WP 0160 00


0159 00-1

Equipment Conditions Air cleaner removed (WP 0030 00) Hydraulic tank drained (WP 0148 00) Drawings Required TM 5-3805-291-23P, Figure 163 Estimated Time to Complete Task 4.0 hr

TM 5-3805-291-23-2

HYDRAULIC TANK REPLACEMENT - CONTINUED

0159 00

REMOVAL 1.

Remove two bolts (1) and washers (2) from clamps (3) and remove clamps from machine.

WARNING •


•


•



NOTE •

Tag hoses and tubes prior to removal to ensure correct installation.

•


2.

Position refrigerant dryer (4) and AC accumulator (5) aside.

3.

Remove three bolts (6), six washers (7), and two clips (8) and position cold start injector lines (9) aside.

4.

Remove sound suppression panel (10) from machine.

0159 00-2

TM 5-3805-291-23-2


0159 00


Remove two bolts (11), nuts (12), five washers (13), and clips (14), and position hoses (15) aside.

6.

Remove bolt (16), washer (17), and clamp (18) from hydraulic tank (19).

7.

Remove 20 bolts (20), washers (21), and 10 flange halves (22) from hydraulic tank (19).

8.

Disconnect nine hoses (23) from fittings (24).

9.

Remove nine O-rings (25) from hoses (23). Discard O-rings.

10.

Disconnect five tubes (26) from hydraulic tank (19). Remove five O-rings (27) from tubes. Discard O-rings.

427-C0569 427-C0568

11.

Remove seven fittings (24) from hydraulic tank (19). Remove seven O-rings (28) from fittings. Discard O-rings.

12.

Remove bolt (29) and washer (30) and position line (31) aside.

427-C0570

0159 00-3

TM 5-3805-291-23-2


0159 00


Disconnect wiring harness (32) from hydraulic tank (19) by removing three nuts (33), washers (34), and clamps (35).

14.

Disconnect wiring harness (32) from chassis wiring harness (36).

427-C0572

15.

Remove five bolts (37) and washers (38) from plate (39) and remove plate from machine. Repeat for other side.

427-C0573

0159 00-4

TM 5-3805-291-23-2


0159 00

REMOVAL - CONTINUED

WARNING


NOTE Hydraulic tank weighs 600 lb (272 kg). 16.

Attach lifting equipment to hydraulic tank (19).

17.

With assistance, remove two bolts (40), four washers (41), and two bushings (42) from mount (43). Repeat for other side.

427-C1882

18.

Remove hydraulic tank (19) from machine.

427-C0574

19.

Remove two bushings (42) from mount (43). Repeat for other side. 0159 00-5

TM 5-3805-291-23-2


0159 00


Remove four bolts (44), washers (45), and mount (43) from machine. Repeat for other side.

427-C0575


WARNING •


•


1.


2.


3.


0159 00-6

TM 5-3805-291-23-2


0159 00

COMPONENT TRANSFER

WARNING


NOTE •

1.

Hydraulic tank weighs 600 lb (272 kg).

• Apply a thin coat of clean oil to all O-rings before installation. Remove breather assembly (46) from hydraulic tank (19).

427-C1887

0159 00-7

TM 5-3805-291-23-2


0159 00

COMPONENT TRANSFER - CONTINUED 2.

Remove 24 bolts (47), plate (48), and gasket (49) from hydraulic tank (19). Discard gasket.

3.

Remove cap cover (50) with pin (51) and lever (52) from plate (48).

4.

Remove ring (53), retaining ring (54), gasket (55), plate (56), check ball (57), and cap (58) from cap cover (50). Discard gasket.

5.

Remove strainer element (59) from hydraulic tank (19).

6.

Remove nut (60), plate (61), and screen (62) from hydraulic tank (19).

7.

Remove sight gage (63) (WP 0160 00).

427-C1888

0159 00-8

TM 5-3805-291-23-2


0159 00


Remove two nuts (64), washers (65), and plate (66) from hydraulic tank (19). Repeat for opposite side.

427-C1889

9.

Remove four fittings (67) from hydraulic tank (19).

10.

Remove four O-rings (68) from fittings (67). Discard O-rings.

427-C1890

0159 00-9

TM 5-3805-291-23-2


0159 00


Remove two fittings (69) from hydraulic tank (19).

12.


427-C1891


13.

Install two new O-rings (70) on fittings (69).

14.

Install two fittings (69) on hydraulic tank (19).

15.

Install four new O-rings (68) on fittings (67).

16.

Install four fittings (67) on hydraulic tank (19).

17.

Install plate (66), two washers (65), and nuts (64) on hydraulic tank (19). Repeat for opposite side.

0159 00-10

TM 5-3805-291-23-2


0159 00


Install sight gauge (63) (WP 0160 00).

19.

Install screen (62), plate (61), and nut (60) on hydraulic tank (19).

20.

Install strainer element (59) on hydraulic tank (19).

21.

Install cap (58), check ball (57), plate (56), gasket (55), retaining ring (54), and ring (53) in cap cover (50).

22.

Install lever (52) and pin (51) on cap cover (50) and cap cover on plate (48).

23.

Install gasket (49), plate (48), and 24 bolts (47) on hydraulic tank (19).

427-C1888

0159 00-11

TM 5-3805-291-23-2


0159 00


Install breather assembly (46) on hydraulic tank (19).

427-C1887

INSTALLATION 1.

Position mount (43) on machine and install four washers (45) and bolts (44) on mount. Repeat for other side.

427-C0575

0159 00-12

TM 5-3805-291-23-2


0159 00


Install two bushings (42) on mount (43). Repeat for other side.

427-C1882

3.

Attach lifting equipment to hydraulic tank (19).

4.

With assistance, position hydraulic tank (19) on machine.

427-C0574

5.

Install two bushings (42), four washers (41), and two bolts (40) on mount (43). Repeat for other side.

0159 00-13

TM 5-3805-291-23-2


0159 00


Position plate (39) on machine and install five washers (38) and bolts (37) on plate. Repeat for other side.

427-C0573

7.

Connect wiring harness (32) to chassis wiring harness (36).

8.

Connect wiring harness (32) to hydraulic tank (19) by installing three clamps (35), washers (34), and nuts (33).

427-C0572

0159 00-14

TM 5-3805-291-23-2


0159 00


Install seven new O-rings (28) in fittings (24) and install fittings on hydraulic tank (19).

427-C0570

10.

Position line (31) and install washer (30) and bolt (29).

11.

Install five new O-rings (27) in tubes (26) and connect tubes to hydraulic tank (19).

12.

Install 10 flange halves (22), 20 washers (21), and bolts (20) on hydraulic tank (19).

13.

Install nine new O-rings (25) in hoses (23) and connect hoses to fittings (24).

14.

Install clamp (18), washer (17), and bolt (16) on hydraulic tank (19).

427-C0569

0159 00-15

427-C0568

TM 5-3805-291-23-2


0159 00


Position two hoses (15) and install five washers (13), two bolts (11), nuts (12), and clips (14).

16.

Position sound suppression panel (10) and cold start injector line (9) on machine and install two clips (8), six washers (7), and three bolts (6) on sound suppression panel.

17.

Position AC accumulator (5), refrigerant dryer (4), and two clamps (3) on machine and install two washers (2) and bolts (1) on clamps.

18.


19.


20.

Operate machine and verify correct operation of AC and hydraulic system (TM 5-3805-291-10).

21.


22.

Check for leaks.

END OF WORK PACKAGE

0159 00-16

2 TM 5-3805-291-23-2

SIGHT GAGE REPLACEMENT

0160 00


Maintenance Level


Unit

O-ring (2)


Personnel Required MOS 62B, Construction Equipment Repairer References TM 5-3805-291-10 Equipment Conditions

Materials/Parts Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

0160 00-1

Hydraulic tank drained below level of sight gage (WP 0148 00) Drawings Required TM 5-3805-291-23P, Figure 163 Estimated Time to Complete Task 0.5 hr

TM 5-3805-291-23-2

SIGHT GAGE REPLACEMENT - CONTINUED

0160 00

REMOVAL Remove two bolts (1), O-rings (2), and sight gage (3) from hydraulic tank (4). Discard O-rings.

427-C0392

INSTALLATION 1.

Lubricate and install two new O-rings (2), sight gage (3), and two bolts (1) on hydraulic tank (4).

2.


3.

Run engine and operate machine until normal operating temperature is reached (TM 5-3805-291-10).

4.

Check for normal operation of hydraulic components (TM 5-3805-291-10).

5.


6.

Check for leaks.

END OF WORK PACKAGE

0160 00-2

12 TM 5-3805-291-23-2

ARCTIC HEATER REPLACEMENT

0161 00









Work tool lowered to ground (TM 5-3805-291-10) Wheels chocked Parking brake engaged (TM 5-3805-291-10)

Materials/Parts





Handrails and left side cover removed (WP 0134 00 and WP 0135 00)

Fuel, turbine, aviation (Item 12, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00)

Drawings Required TM 5-3805-291-23P, Figures 124 and 164 Estimated Time to Complete Task


2.3 hr

0161 00-1

TM 5-3805-291-23-2

ARCTIC HEATER REPLACEMENT - CONTINUED

0161 00

REMOVAL

WARNING •

DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing injury or death to personnel or damage to equipment.

•

Fuel used in the performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.


NOTE

1.

•

Tag hoses and wiring prior to removal to ensure correct installation.

•


Close both arctic heater valves (1) on machine.

0161 00-2

TM 5-3805-291-23-2


0161 00


Remove eight bolts (2) and washers (3) and cover (5) from case (4).

3.

Remove three bolts (8), washers (9) and side cover (6) from arctic heater case (7) and machine.

0161 00-3

TM 5-3805-291-23-2


0161 00


Cut and remove tiedown strap (11) from electrical connectors (10).

5.

Disconnect three electrical connectors (10).

6.

Loosen two clamps (13) and disconnect coolant hoses (12 and 15) from fittings (14).

7.

Disconnect fuel hose (18) from fitting (16).

8.


9.


0161 00-4

TM 5-3805-291-23-2


0161 00


Remove four nuts (23) and eight washers (24) from bottom of case (7) and remove arctic heater (22) from machine.

0161 00-5

TM 5-3805-291-23-2


0161 00


Remove bolt (26), washer (27), and two clips (28) from machine.

12.

Loosen clamp (29), disconnect hose (13) from fitting (25), and remove hose from machine.

13.

Loosen clamp (29), disconnect hose (15) from fitting (30), and remove hose from machine.

0161 00-6

TM 5-3805-291-23-2


0161 00


Disconnect arctic heater wiring harness (32) from chassis harness (31) and remove from machine.

15.

Disconnect hose (18) from fuel tank fitting (33) and remove hose from machine.

16.


INSTALLATION

NOTE Apply a thin coat of fuel to all O-rings before installation.

1.

Install new O-ring (34) and connect hose (18) to fuel tank fitting (33).

2.

Position and connect arctic heater wiring harness (32) to chassis harness (31).

3.

Connect hose (15) to fitting (30) and tighten clamp (29).

0161 00-7

TM 5-3805-291-23-2


0161 00



5.

Position two clips (28) on machine and install washer (27) and bolt (26).

0161 00-8

TM 5-3805-291-23-2


0161 00


Position arctic heater (22) in case (7) and install eight washers (24) and four nuts (23) on case.

7.

Install new O-ring (17) and connect fuel hose (18) to fitting (16).

8.

Connect coolant hoses (15 and 12) to fittings (14) and tighten clamps (13).

9.

Connect three electrical connectors (10).

10.

Install new tiedown strap (11) on electrical connectors (10).

11.


0161 00-9

TM 5-3805-291-23-2

ARCTIC HEATER REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 12.

Install side cover (6) on arctic heater case (7) and machine with three bolts (9) and washers (8).

13.

Position cover (5) on case (4) and install eight washers (3) and bolts (2) on cover.

0161 00-10

0161 00

TM 5-3805-291-23-2

ARCTIC HEATER REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 14.

Open both arctic heater valves (1) on machine.

15.

Install left side cover (WP 0135 00) and handrails (WP 0134 00) on machine.

16.

Run engine and verify correct operation of heater system (TM 5-3805-291-10).

END OF WORK PACKAGE

0161 00-11/(0161 00-12 Blank)

0161 00

26 TM 5-3805-291-23-2

ARCTIC HEATER INSTALLATION

0162 00

THIS WORK PACKAGE COVERS Installation



Antifreeze drained (WP 0041 00) Left side ladders removed from machine (WP 0129 00)


Battery box removed from machine (WP 0128 00) Fuel tank removed from machine and fuel hose fittings removed from tank (WP 0033 00)

Materials/Parts Antifreeze (Item 1, WP 0233 00)

Transfer fuel level sending unit (WP 0081 00) to arctic kit fuel tank


Drawings Required

Fuel, turbine, aviation (Item 12, WP 0233 00) O-ring (12)

TM 5-3805-291-23P, Figures 33, 34, 56, 124, 164, 165, 166, and 167

Personnel Required


MOS 62B, Construction Equipment Repairer MOS 44B, Metal Worker

16.0 hr

PARTS LIST Following parts are required for installation of arctic heater on standard 966H machine. Ensure that all parts are available prior to beginning procedure.

PART NUMBER

NOMENCLATURE

QUANTITY

2836489

HEATER ASSEMBLY

1

2802866

HEATER, VEHICULAR CO

1

HOSE, NON METALLIC MAKE FROM HOSE P/N 5P0765, 92.5 INCHES (235 CM)

1

5D1026

CLAMP, HOSE

4

2D3165

ADAPTER STRAIGHT, HO

2

9Y2238

ADAPTER, BRUSHING

2

3K0360

O-RING

7

8T0119

CATCH, ELBOW

2

5P0765-235

0162 00-1

TM 5-3805-291-23-2

ARCTIC HEATER INSTALLATION - CONTINUED PART NUMBER

0162 00

NOMENCLATURE

QUANTITY

8T6639

VALVE, BALL

2

1557321

ADAPTER ASSEMBLY

1

6V1722

BRUSHING, PIPE

1

3D2824

O-RING

1

1671795

ELBOW ASSEMBLY

1

3D2824

O-RING

1

8T3491

ELBOW, HOSE

1

1180911

TEE, PIPE TO BOSS

1

8T4137

BOLT, MACHINE M10X1.5X20-MM

1

8T4121

WASHER, FLAT 11X21X2.5-MM THK

1

6P9299

CLAMP, LOOP

1

2836497

HOSE ASSEMBLY, NONME

1

1488368

ELBOW ASSEMBLY

1

4J5477

O-RING

1

6V8627

ELBOW, TUBE

1

3J1907

O-RING 1

7C4354

FASTENER, POSITIVE L

1

8T4133

NUT, PLAIN, HEXAGON M10X1.15THD

1

5P0765-123

HOSE, NONMETALLIC MAKE FROM HOSE P/N 5P0765, 48.5 INCHES (123 CM)

1

6V2235

FASTENER, POSITIVE L

2

1886185

GROMMET

1

5P1076

WASHER, SHOULDERED A

4

8T4956


4

2836498

BRACKET, MOUNTING

1

8T4224

WASHER, FLAT 8.8X16X2-MM THK

4

2836493

COVER, ACCESS

1

7X7729

WASHER, FLAT 11X25X3-MM THK

12

8T4136


11

4J5477

O-RING

1

COVER, ACCESS

1

2832230

0162 00-2

TM 5-3805-291-23-2


0162 00

NOMENCLATURE

QUANTITY

2364850

HEATER, DIESEL OIL,

1

2847695

GROMMET, BLANK, NONME

1

2836491

PLATE, MOUNTING

1

5P1076

WASHER, SHOULDERED A 13.5X30X4 MM THK

8

8T4139

BOLT, MACHINE M12X1.75X30 MM

8

2802929

BATTERY BOX

1

2G9524

LATCH, HOOD, VEHICULA

3

2921078

PLATE, MOUNTING

1

8T4137


2

8T4121

WASHER, FLAT 11X21X2.5 MM THK

8

2802888

PLATE

1

2802932

COVER, ACCESS

1

8T4133

NUT, PLAIN, HEXAGON M10X1.5 THD

4

3E6602-80.7

SEAL MAKE FROM SEAL P/N 3E6602 80.7 INCHES (205 CM)

2

3E6602-250.4

SEAL MAKE FROM SEAL P/N 3E6602, 98.6 INCHES (250.4 CM)

1

3053159

PAWL

1

2942382

LATCH, DOOR, VEHICULA 5 PIECES

1

2802919

COVER, BATTERY BOX

1

2802881

LADDER, STRAIGHT LH BOARDING LADDER

1

5P1076

WASHER, SHOULDERED A 13.5X30X4 MM THK

4

8T4139


4

1503674

HANDRAIL, VEHICULAR

2

8T4196

SCREW, CAP, M10X1.5X35 MM

8T4121


4

2978744

LEAD, STORAGE BATTER

1

3S2093

STRAP

8

2V1771

GROMMET, NONMETALLIC

2

0919035

SPACER, STRAIGHT

1

HEXAGON

0162 00-3

H

4

TM 5-3805-291-23-2


0162 00

NOMENCLATURE

QUANTITY

6D4246

CLAMP, LOOP

2

8T4121


2

8T4186

BOLT, MACHINE

1

3259333

HARNESS

1

7K1181

STRAP

5

2668944


1

4S1936

CLAMP, LOOP

2

2V8259


2

2978743

CABLE ASSEMBLY, POWE

1

1160080

LEAD, ELECTRICAL

1

2978745

LEAD, STORAGE BATTER

1

5P8245

WASHER, FLAT 13.5X25X.5X3-MM THK

1

8T4192

BOLT, SHOULDER M12X1.75X25 MM

1

8T4191

BOLT, MACHINE

1

1Q1445

SWITCH, HEATER, VEHIC

1

3K0360

O-RING

1

5H8853

O-RING

1

2836490

TANK ASSEMBLY FOR USE WITH ARCTIC HEATER

1

1978743

WIRING HARNESS

1

1342418

MOUNT PLATE

2

9R2613

BOSS

2

0162 00-4

TM 5-3805-291-23-2

ARCTIC HEATER INSTALLATION - CONTINUED

0162 00

INSTALLATION

WARNING •


•


NOTE •

Apply a thin coat of coolant to all coolant fitting O-rings before installation.

•

Apply a thin coat of fuel to fuel line fitting O-rings before installation.

•

When applicable, reuse existing machine hardware for arctic heater installation.

0162 00-5

TM 5-3805-291-23-2


0162 00


Lift off left side cover (1) from machine.

0162 00-6

TM 5-3805-291-23-2


0162 00

INSTALLATION – CONTINUED 2.

Remove two nuts (3), washers (4), bolts (5), washers (6), and rear panel (2) from machine.

0162 00-7

TM 5-3805-291-23-2


0162 00


Attach two mounting bars (9) to arctic heater case (10) with four bolts (12) and washers (11).

4.

Attach side cover (7) on arctic heater case (10) with two bolts (13) and washers (14).

5.

Attach boss (8) to side cover (7) with bolt (15) and washer (16).

6.

Position arctic heater case (10) and side cover (7) on machine level with step plate on counter weight.

7.

Tack weld mounting bars (9) and boss (8) on machine.

8.

Remove bolt (15), washer (16), two bolts (13), washers (14), and side cover (7) from arctic heater case (10) and machine.

9.

Remove four bolts (12), washers (11), and arctic heater case (10) from machine.

10.

Finish welding two mounting bars (9) and boss (8) on machine.

11.

Weld boss (8) on frame.

NOTE Paint all add-on parts as needed to match machine and protect bare metal.

12.

Install arctic heater case (10) on machine with four bolts (12) and washers (11).

0162 00-8

TM 5-3805-291-23-2


0162 00

REMOVAL – CONTINUED

0162 00-9

TM 5-3805-291-23-2


0162 00


Install rear panel for arctic heater application (2) on machine with two washers (4) and nuts (3) and one (inner) washer (6) and bolt (5).

0162 00-10

TM 5-3805-291-23-2


0162 00



NOTE Fuel tank weighs 550 lb (250 kg).

14.

With assistance, use hydraulic jack to position arctic kit fuel tank (17) on machine.

15.

Install eight mounts (21), four spacers (20), washers (19), and bolts (18) on both sides of fuel tank (17).

0162 00-11

TM 5-3805-291-23-2


0162 00


Connect sending unit connector (23) to wiring harness (22).

17.

Install nut (25), washer (26), and sending unit connector (23) on machine.

18.

Install new tiedown strap (27) on sending unit wire (24).

19.

Remove four O-rings (31) from fittings (30). Discard O-rings.

20.

Install four new O-rings (31) on fittings (30).

21.

Install two fittings (30) in arctic kit fuel tank (17).

22.

Connect hose assemblies (28 and 29) to fittings (30).

0162 00-12

TM 5-3805-291-23-2


0162 00


Install fitting (34) with O-ring (35) in fuel tank (17).

24.

Connect hose (32) with O-ring (33) to fitting (34) on fuel tank (17).

0162 00-13

TM 5-3805-291-23-2


0162 00


WARNING Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting equipment used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting equipment. Failure to follow this warning may result in injury or death to personnel

NOTE Arctic kit battery box weighs 110 lb (50 kg).

25.

With assistance, attach lifting equipment to arctic kit battery box (38) and position battery box on machine. Install four washers (36) and bolts (37) on battery box.

0162 00-14

TM 5-3805-291-23-2


0162 00



0162 00-15

TM 5-3805-291-23-2


0162 00



28.

Install clamp (44), bolt (42), and washer (43) on battery box (38).

29.

Install two washers (47), bolts (46), and clamps (45) on battery box (38).

0162 00-16

TM 5-3805-291-23-2


0162 00


Remove plug (49) with O-ring (50) from cylinder head (51).

31.

Install elbow (62) and O-ring (61) in cylinder head (60) and position as shown.

32.

Install fitting (59) and O-ring (63) in elbow (62).

33.

Install valve (58) and O-ring (57) in fitting (59).

34.

Install elbow (56) and O-ring (57) in valve (58) and position as shown.

35.


36.

Install connector (53) in fitting (54).

37.

Connect hose (52) to connector (53) and tighten clamp (64).

0162 00-17

TM 5-3805-291-23-2


0162 00


Loosen clamp (64) and disconnect hose (65) from heater valve (67).

39.

Remove heater valve (67) with O-ring (57) from fitting (66).

40.

Install heater valve (67) and O-ring (57) in T (68).

41.

Install T (68) and O-ring (57) in fitting (66) and position as shown.

42.

Install valve (58) and O-ring (57) in T (68).

43.

Install elbow (56) and O-ring (57) in valve (58).

44.


45.

Install connector (53) in fitting (54).

46.

Connect hose (69) to connector (53) and tighten clamp (64).

0162 00-18

TM 5-3805-291-23-2


0162 00


Route two coolant hoses (69 and 52), fuel hose (32), and arctic heater harness (72) through grommet (71) in rear panel (2).

NOTE Connections for arctic heater harness are placed during production in area under left rear motor mount.

48.

Connect arctic heater harness (72) to machine harness (75).

49.

Secure arctic heater harness (72) and fuel hose (32) to machine with two clamps (70), bolt (74), and washer (73).

0162 00-19

TM 5-3805-291-23-2


0162 00


Install grommet (76) in arctic heater case (10).

51.

Route two coolant hoses (69 and 52), fuel hose (32), and arctic heater harness (72) through grommet (76) in arctic heater case (10).

0162 00-20

TM 5-3805-291-23-2


0162 00


Install arctic heater (77) in arctic heater case (10) with four nuts (78), washers (79), and washers (80).

0162 00-21

TM 5-3805-291-23-2


0162 00


Connect fuel hose (32) with O-ring (83) to fitting (82).

54.


55.


56.

Connect arctic heater (77) to arctic heater harness (72).

57.

Install clamp (84) around hoses (52 and 69), fuel hose, (32), and arctic heater harness (72) and secure to rear panel (2) with bolt (5) and washer (6).

0162 00-22

TM 5-3805-291-23-2


0162 00


Install side cover (7) on arctic heater case (10) and machine with two bolts (13) and washers (14) and bolt (15) and washer (16).

0162 00-23

TM 5-3805-291-23-2


0162 00


Install cover (85) on arctic heater case (10) with eight bolts (15) and washers (16).

60.

Install two handrails (86) on arctic heater case (10) with four washers (88) and bolts (87).

0162 00-24

TM 5-3805-291-23-2


0162 00


Remove bolt (90), washer (92), and clamp (91) with hose (65) from bracket (89).

62.

Install clamp (91) on hose (52).

63.

Install two clamps (91) with hoses (65 and 52) on bracket (89) with bolt (90) and washer (92).

64.

Remove four bolts (96) and cover (95) from control box (94).

65.

Remove plug (93) from top of control box (94).

0162 00-25

TM 5-3805-291-23-2


0162 00


Install arctic heater switch (98) in control box (94) with nut (97).

67.

Connect arctic heater switch (98) to cab harness (99).

68.

Install cover (95) on control box (94) with four bolts (96).

69.

Refill fuel tank to correct level (TM 5-3805-291-10).


70.

Install batteries in battery box (WP 0095 00).

71.

Install cables in battery box (WP 0097 00).

72.

Install left side fender on machine (WP 0133 00).

73.

Install left side ladders on machine (Install new arctic kit ladder on fender and battery box) (WP 0129 00).

74.

Fill coolant to proper level (WP 0041 00).

75.

Run engine and verify correct operation of heater system (TM 5-3805-291-10).

76.

Check for leaks.

END OF WORK PACKAGE

0162 00-26

4 TM 5-3805-291-23-2

BRISTLES REPLACEMENT

0163 00









Materials/Parts

Wheels chocked (TM 5-3805-291-10)

Work tool raised slightly (TM 5-3810-291-10) Drawings Required


TM 5-3805-291-23P, Figure 168

Locknut (12)



0163 00-1

1.0 hr

TM 5-3805-291-23-2

BRISTLES REPLACEMENT - CONTINUED

0163 00

REMOVAL


1.

Remove two locknuts (1), bolts (2), and clamps (3) from hoses (4). Discard locknuts.

427-C1537-1

2.

Remove four locknuts (4) and bolts (5) from bracket (6). Discard locknuts.

427-C1530

0163 00-2

TM 5-3805-291-23-2


0163 00

REMOVAL - CONTINUED

NOTE Bracket and motor weigh approximately 65 lb (29 kg). 3.

Secure bracket (6) with lifting equipment.

4.

With assistance, remove motor (7) from frame (8) and brush (9).

5.


6.

Remove brush (9) from frame (8).

7.

Remove two bolts (10) and collar (11) from brush core (12).

427-C1531

8.

Remove bristles (13) and spacers (14) from brush core (12). Discard worn bristles.

427-C1532

INSTALLATION 1.

Install spacers (14) and new bristles (13) on brush core (12).

2.

Install collar (11) and two bolts (10) on brush core (12).

3.

Install brush (9) on frame (8).

NOTE Bracket and motor weigh approximately 65 lb (29 kg).

4.

Secure brush (9) with lifting equipment.

5.

With assistance, install motor (7) in brush (9).

6.

Install motor on frame (8).

7.

Install four bolts (5) and new locknuts (4) on bracket (6). 0163 00-3

TM 5-3805-291-23-2


0163 00


Install two clamps (3), bolts (2), and new locknuts (1) on hoses (4).

427-C1537-1

NOTE Repeat steps 5 thru 8 for opposite side.

9.

Verify correct operation of broom (TM 5-3805-291-10).

END OF WORK PACKAGE

0163 00-4

6 TM 5-3805-291-23-2

BROOM HOSE, MANIFOLD, AND LINK REPLACEMENT

0164 00

THIS WORK PACKAGE COVERS Hose: Removal, Installation Manifold: Removal, Installation Angle Link: Removal, Installation


Materials/Parts - Continued Locknut (13)

Unit

O-ring (20)

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Materials/Parts

Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions Broom assembly removed (TM 5-3805-291-10) Drawings Required TM 5-3805-291-23P, Figures 168 and 170




0164 00-1

TM 5-3805-291-23-2

BROOM HOSE, MANIFOLD, AND LINK REPLACEMENT - CONTINUED

0164 00

HOSE REMOVAL 1.

Remove two hoses (1) and O-rings (2) from fittings (3). Discard O-rings.

427-C1536

2.

Remove four locknuts (4), bolts (5), two clamps (6), and hoses (1) from bracket (7). Discard locknuts.

3.

Remove two locknuts (8), bolts (9), and clamps (10). Discard locknuts.

427-C1537

0164 00-2

TM 5-3805-291-23-2


0164 00

HOSE REMOVAL - CONTINUED 4.

Remove four bolts (11), two clamps (12), and hoses (1) from frame (13).

427-C1538

5.


6.

Remove two hoses (1) from broom (16).

7.

Repeat steps 1 thru 6 for opposite side.

427-C1539

HOSE INSTALLATION


1.

Install two hoses (1) on broom (16).

2.


3.

Install two hoses (1), clamps (12), and four bolts (11) on frame (13). 0164 00-3

TM 5-3805-291-23-2


0164 00

HOSE INSTALLATION - CONTINUED 4.

Install two clamps (10), bolts (9), and new locknuts (8).

5.

Install two hoses (1), clamps (6), four new locknuts (4), and bolts (5) on bracket (7).

427-C1537

6.


7.

Repeat steps 1 thru 6 for opposite side.

427-C1536

0164 00-4

TM 5-3805-291-23-2


0164 00

MANIFOLD REMOVAL 1.

Remove six hoses (17) and O-rings (18) from fittings (19). Discard O-rings.

2.

Remove six fittings (19) and O-rings (20) from manifold (21). Discard O-rings.

3.

Remove two bolts (22) and manifold (21) from broom (16).

427-C1540

MANIFOLD INSTALLATION


1.

Install manifold (21) and two bolts (22) on broom (16).

2.

Install six new O-rings (20) in fittings (19) and install fittings on manifold (21).

3.

Install six new O-rings (18) in hoses (17) and connect hoses to fittings (19).

ANGLE LINK REMOVAL 1.

Remove locking pin (23) from angle link (24).

427-C1541

0164 00-5

TM 5-3805-291-23-2


0164 00

ANGLE LINK REMOVAL - CONTINUED 2.

Remove locknut (25) and bolt (26) from frame (13). Discard locknut.

3.

Remove angle link (24) from frame (13).

427-C1542

ANGLE LINK INSTALLATION 1.

Position angle link (24) on frame (13).

2.

Install bolt (26) and new locknut (25) on frame (13).

3.

Install locking pin (23) on angle link (24).

427-C1541

4.

Install broom assembly (TM 5-3805-291-10).

5.


END OF WORK PACKAGE

0164 00-6

4 TM 5-3805-291-23-2

BROOM MOTOR REPLACEMENT

0165 00




Unit







Wheels chocked Parking brake engaged (TM 5-3805-291-10)

Materials/Parts

Broom assembly removed (TM 5-3805-291-10)


Drawings Required


TM 5-3805-291-23P, Figure 169



O-ring (4)

1.0 hr

REMOVAL

WARNING •


•



0165 00-1

TM 5-3805-291-23-2

BROOM MOTOR REPLACEMENT - CONTINUED

0165 00

REMOVAL - CONTINUED

NOTE •


•


1.

Disconnect two hydraulic hoses (1) and remove O-rings (2) from fittings (3). Discard O-rings.

2.

Remove two fittings (3) and O-rings (4) from motor (5). Discard O-rings.

427-C1533

3.

Remove bolt (6), washer (7), and carrier (8) from motor shaft (9).

427-C1534

0165 00-2

TM 5-3805-291-23-2

BROOM MOTOR REPLACEMENT - CONTINUED

0165 00


Remove four bolts (10) and washers (11) from motor (5).

5.

Remove motor (5) from bracket (12).

427-C1535

INSTALLATION


1.

Install motor (5) on bracket (12).

2.

Install four washers (11) and bolts (10) on motor (5).

3.

Install carrier (8), washer (7), and bolt (6) on motor shaft (9).

4.

Install two new O-rings (4) in fittings (3) and install fittings on motor (5).

5.

Install two new O-rings (2) in hydraulic hoses (1) and connect two hydraulic hoses to fittings (3).

6.

Operate machine and verify correct operation of broom motor (TM 5-3805-291-10).

7.


8.

Check for leaks.

END OF WORK PACKAGE

0165 00-3/(0165 00-4 Blank)

4 TM 5-3805-291-23-2

BROOM SHIELDS AND SPRINGS REPLACEMENT

0166 00

THIS WORK PACKAGE COVERS Forward Shield: Removal, Installation Aft Shield: Removal, Installation Spring: Removal, Installation



Unit



Broom assembly removed (TM 5-3805-291-10)



Chain come-along (Item 22, WP 0232 00) Materials/Parts Rag, wiping (Item 35, WP 0233 00) Locknut (9)

FORWARD SHIELD REMOVAL 1.

0166 00

Remove locknut (1) and bolt (2) from bracket (3). Discard locknut.

427-C1543

0166 00-1

TM 5-3805-291-23-2

BROOM SHIELDS AND SPRINGS REPLACEMENT - CONTINUED

0166 00

FORWARD SHIELD REMOVAL - CONTINUED 2.

Remove four locknuts (4), bolts (5), and brackets (6) from ribs (7). Discard locknuts.

3.

Remove forward shield (8) from ribs (7).

427-C1544

FORWARD SHIELD INSTALLATION 1.

Install forward shield (8) on ribs (7).

2.

Install four brackets (6), new locknuts (4), and bolts (5) on ribs (7).

3.

Install bolt (2) and new locknut (1) on bracket (3).

427-C1543

0166 00-2

TM 5-3805-291-23-2


0166 00

AFT SHIELD REMOVAL

0166 00

1.

Remove four locknuts (9), bolts (10), and brackets (11) from ribs (13). Discard locknuts.

2.

Remove aft shield (12) from ribs (13).

427-C1545

AFT SHIELD INSTALLATION

0166 00

1.

Install aft shield (12) on ribs (13).

2.

Install four brackets (11), bolts (10), and new locknuts (9) on ribs (13).

0166 00-3

TM 5-3805-291-23-2


0166 00

SPRING REMOVAL

WARNING Spring is under tension. Wear eye protection and use extreme caution when removing spring to avoid injury to personnel.

NOTE The following procedure is for one spring. The procedure can be used for both springs.

1.

Secure spring (14) with come-along.

2.

Remove pin (15) from spring tensioner (16).

3.

Remove link (17) from spring tensioner (16).

4.

Relieve tension on spring (14).

5.

Remove link (17) from spring (14) and remove comealong.

6.

Remove spring (14) from spring hitch (18).

427-C1546

SPRING INSTALLATION 1.

Install spring (14) on spring hitch (18).

2.

Install spring (14) on link (17).

3.

Secure spring (14) with come-along.

4.

Install link (17) on spring tensioner (16).

5.

Install pin (15) in spring tensioner (16).

6.

Relieve tension on spring (14) and remove come-along.

7.

Install broom assembly (TM 5-3805-291-10).

8.



8 TM 5-3805-291-23-2

PALLET FORKS REPAIR

0167 00

THIS WORK PACKAGE COVERS Disassembly, Assembly INITIAL SETUP Maintenance Level


Unit





Tag, marker (Item 43, WP 0233 00) Cotter pin (6)


O-ring (22) Personnel Required



Lifting equipment, 400-lb capacity Lifting equipment, 3,000-lb capacity

Equipment Conditions Pallet fork assembly removed (TM 5-3805-291-10)


Drawings Required

Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)


DISASSEMBLY

WARNING •


•


•



0167 00-1

TM 5-3805-291-23-2

PALLET FORKS REPAIR - CONTINUED

0167 00

DISASSEMBLY - CONTINUED

NOTE •


•


1.

Disconnect two hoses (1) from fittings (2) and remove hoses from pallet fork assembly. Remove two O-rings (3) from hoses. Discard O-rings.

2.

Remove two fittings (2) from valve (4). Remove two O-rings (5) from fittings. Discard O-rings.

3.


4.

Disconnect hoses (9 and 10) from T (11). Remove two O-rings (12) from hoses. Discard O-rings.

5.

Remove fitting (7) and T (11) from valve (4). Remove two O-rings (13) from fitting and T. Discard O-rings.

6.

Remove two bolts (14) from valve (4) and remove valve from pallet fork assembly.

7.

Remove bolt (15) from clamp (16) and remove clamp from pallet fork assembly.

8.

Remove two bolts (17) from clamp (18) and remove clamp from pallet fork assembly.

9.

Disconnect hose (9) from fitting (19) and remove hose from pallet fork assembly. Remove O-ring (12) from hose. Discard O-ring.

10.

Remove fitting (19) from cylinder (20). Remove O-ring (21) from fitting. Discard O-ring.

11.


12.


427-C1377

0167 00-2

TM 5-3805-291-23-2


0167 00


Disconnect hose (6) from elbow (25) and remove hose from pallet fork assembly. Remove O-ring (8) from hose. Discard O-ring.

14.

Remove elbow (25) from valve (26). Remove O-ring (27) from elbow. Discard O-ring.

15.


16.

Remove fitting (29) from valve (26). Remove O-ring (31) from fitting. Discard O-ring.

17.


18.


19.

Disconnect hose (34) from elbow (35). Remove O-ring (36) from hose. Discard O-ring.

20.

Remove elbow (35) from valve (26). Remove O-ring (37) from elbow. Discard O-ring.

21.

Remove two bolts (38) from valve (26) and remove valve from pallet fork assembly.

22.

Loosen nut (39), washer (40), and bolt (41).

23.

Remove and discard two cotter pins (42) and remove pin (43) from pallet fork assembly.

427-C1378

0167 00-3

TM 5-3805-291-23-2


0167 00



25.

Remove fitting (44) from cylinder (23). Remove and discard O-ring (45).

26.

Remove two cotter pins (46) and pin (47) from cylinder (23). Discard cotter pins.

27.

Remove cylinder (23) from pallet fork assembly.

28.

Repeat steps 22, 23, and 27 to remove other cylinder (23).

29.

Remove two bolts (48) and washers (49) from pad (50) and remove pad from pallet fork assembly.

30.

Repeat step 29 for other side.

WARNING


NOTE •

Fork carriage weighs 1,920 lb (871 kg).

•

Tube weighs 260 lb (118 kg).

31.

Attach link bracket to pad (50) with washer (49) and bolt (48). Repeat for opposite side.

32.

Attach lifting equipment to fork carriage (51).

33.

Attach lifting equipment to tube (52).

34.

With assistance, carefully remove tube (52), two tine guides (53), and tines (54) from pallet fork assembly.

427-C1379

0167 00-4

427-C1380

TM 5-3805-291-23-2


0167 00

ASSEMBLY

WARNING


NOTE •

Fork carriage weighs 1,920 lb (871 kg).

•

Tube weighs 260 lb (118 kg).

•

Apply a thin coat of clean oil to all O-rings prior to installation.

1.

Attach lifting equipment to fork carriage (51).

2.

Remove bolt (48), washer (49), and link bracket from pad (50). Repeat for opposite side.

3.

With assistance, carefully install tube (52), two tine guides (53), and tines (54) on pallet fork assembly.

4.

Position pad (50) on pallet fork assembly and install two washers (49) and bolts (48) on pad. Repeat for other side.

5.

Install cylinder (23) on pallet fork assembly.

427-C1378

6.

Install pin (47) and two new cotter pins (46) on cylinder (23).

7.

Install new O-ring (45) in fitting (44) and install fitting on cylinder (23).

8.


9.

Install pin (43) and two new cotter pins (42) on pallet fork assembly.

10.

Tighten nut (39), washer (40), and bolt (41).

11.

Repeat steps 3, 7, and 8 for other cylinder (23).

12.

Position valve (26) on pallet fork assembly and install two bolts (38) on valve. 0167 00-5

TM 5-3805-291-23-2


0167 00


Install new O-ring (37) in elbow (35) and install elbow on valve (26).

14.


15.


16.


17.

Install new O-ring (31) in fitting (29) and install fitting on valve (26).

18.

Install new O-ring (27) in elbow (25) and install elbow on valve (26).

19.


427-C1378

20.


21.


22.


23.

Install new O-ring (12) in hose (9) and connect hose to fitting (19) on pallet fork assembly.

24.

Position clamp (18) on pallet fork assembly and install two bolts (17) on clamp.

25.

Position clamp (16) on pallet fork assembly and install bolt (15) on clamp.

26.

Position valve (4) on pallet fork assembly and install two bolts (14) on valve.

27.

Install two new O-rings (13) in fitting (7) and T (11) and install fitting and T on valve (4).

28.

Install two new O-rings (12) in hoses (9 and 10) and connect hoses to T (11).

0167 00-6

TM 5-3805-291-23-2


0167 00



30.

Install two new O-rings (5) in fittings (2) and install fittings on valve (4).

31.

Install two new O-rings (3) in hoses (1) and connect two hoses to fittings (2).

427-C1377

32.

Install pallet fork assembly on machine (TM 5-3805-291-10).

33.

Operate machine and verify correct operation of pallet fork assembly (TM 5-3805-291-10).

END OF WORK PACKAGE

0167 00-7/(0167 00-8 Blank)

10 TM 5-3805-291-23-2

AIR CONDITIONING/HEATER BLOWER MOTOR REPLACEMENT

0168 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required TM 5-3805-291-23P, Figures 172 and 178 Estimated Time to Complete Task


2.0 hr

REMOVAL 1.


427-C0135

0168 00-1

TM 5-3805-291-23-2

AIR CONDITIONING/HEATER BLOWER MOTOR REPLACEMENT - CONTINUED

0168 00



427-C0136

3.


427-C0137

0168 00-2

TM 5-3805-291-23-2


0168 00



427-C0138

5.


427-C0139

0168 00-3

TM 5-3805-291-23-2


0168 00



427-C0140

7.


8.


427-C0141

0168 00-4

TM 5-3805-291-23-2


0168 00


Disconnect wiring harness (12).

10.

Remove four bolts (13) and washers (14) from machine.

11.

Remove two bolts (15), washers (16), and bracket (17) from machine.

12.

Remove blower motor (18) from machine.

427-C0142


WARNING •


•


1.


2.


3.


INSTALLATION 1.

Position blower motor (18) on machine.

2.

Install bracket (17), two washers (16), and bolts (15) on machine.

3.

Install four washers (14) and bolts (13) on machine.

4.

Connect wiring harness (12). 0168 00-5

TM 5-3805-291-23-2


0168 00



6.


427-C0141

7.


427-C0140

0168 00-6

TM 5-3805-291-23-2


0168 00



9.


427-C0139

10.


427-C0138

0168 00-7

TM 5-3805-291-23-2


0168 00



427-C0137

12.


13.


427-C0136

0168 00-8

TM 5-3805-291-23-2


0168 00


Install three screws (1) on tray (2).

427-C0135

15.


16.

Verify correct operation of blower motor (TM 5-3805-291-10).

17.


END OF WORK PACKAGE

0168 00-9/(0168 00-10 Blank)

6 TM 5-3805-291-23-2

QUICK COUPLER REPLACEMENT

0169 00



Unit


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 1 (Item 70, WP 0232 00) Inserter end remover, pin (Item 36, WP 0232 00) Nut, plain, round (Item 47, WP 0232 00)

Tag, marker (Item 43, WP 0233 00) O-ring (4) Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions Machine parked on level ground (TM 5-3805-29110)

Puller, hydraulic (Item 52, WP 0232 00) Pump, hydraulic ram, hand-driven (Item 56, WP 0232 00)

Work tool removed (TM 5-3805-291-10)


Wheels chocked



Materials/Parts Grease, automotive and artillery, GAA (Item 15, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

0169 00-1


Steering frame lock connected (TM 5-3805-29110) Hydraulic system pressure relieved (TM 5-3805291-10) Drawings Required TM 5-3805-291-23P, Figure 180 Estimated Time to Complete Task 1.5 hr

TM 5-3805-291-23-2

QUICK COUPLER REPLACEMENT - CONTINUED

0169 00

REMOVAL

WARNING •


•


•



NOTE •


•


1.

Cut and remove tiedown strap (1) from two lines (2). Discard tiedown strap.

2.

Remove bolt (3) and clamp (4) from quick coupler (5).

3.

Disconnect two lines (2) from quick coupler (5). Remove and discard O-rings (6).

427-C1274-1

0169 00-2

TM 5-3805-291-23-2


0169 00

REMOVAL - CONTINUED

WARNING


NOTE Tilt link weighs approximately 140 lb (64 kg). 4.

Attach lifting equipment to tilt link (7).

5.


6.

Use puller to remove pin assembly (11) from quick coupler (5).

7.

Attach lifting equipment to quick coupler (5).

8.

Disconnect hose (12) and remove and discard O-ring (13) from quick coupler (5).

9.


10.

Use puller to remove pin assembly (17) from quick coupler (5).

11.

Remove two shims (18) from quick coupler (5).

12.

Repeat steps 8 thru 11 to remove pin assembly from opposite side of quick coupler (5).

WARNING

427-C1923


NOTE Quick coupler weighs approximately 1,020 lb (463 kg).

13.

Use lifting equipment to remove quick coupler (5) from machine. 0169 00-3

TM 5-3805-291-23-2


0169 00

INSTALLATION

WARNING


NOTE Quick coupler weighs approximately 1,020 lb (463 kg).

1.

Use lifting equipment to position quick coupler (5) on machine.

NOTE Apply grease to all of the pin bores prior to pin installation. 2.

Align quick coupler (5) bores with lift arm bores.

3.

Put two shims (18) in position and install pin assembly (17) through bores.

4.

Install spacer (16), washer (15), and bolt (14) that holds pin assembly (17).

5.

Apply a thin coat of clean oil to new O-ring (13), install O-ring, and connect hose (12) to quick coupler (5).

6.

Repeat steps 2 thru 5 to install washers and pin assemblies in opposite side of quick coupler (5).

427-C1923

0169 00-4

TM 5-3805-291-23-2


0169 00



NOTE Tilt link weighs approximately 140 lb (64 kg).

7.

Use lifting equipment to lower tilt link (7) into position.

8.

Install pin assembly (11) and secure with spacer (10), washer (9), and bolt (8).

9.

Install two new O-rings (6) and connect lines (2) to quick coupler (5).

10.

Install clamp (4) and bolt (3) on two lines (2).

11.

Install new tiedown strap (1) on two lines (2).

427-C1274-1


12.



8 TM 5-3805-291-23-2

BUCKET TIPS AND CUTTING EDGES REPLACEMENT

0170 00

THIS WORK PACKAGE COVERS Bucket Tips: Inspection/Removal, Cleaning, Installation Bucket Cutting Edges: Inspection/Removal, Cleaning, Installation INITIAL SETUP Personnel Required





Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: organizational maintenance, common no. 2 (Item 71, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00) Multiplier, torque Wood block, 4 x 4 in.

Machine parked on level ground (TM 5-3805-29110) Work tool lowered to ground (TM 5-3805-291-10) Wheels chocked Parking brake engaged (TM 5-3805-291-10) Battery disconnect switch in OFF position (TM 53805-291-10) Drawings Required

Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

TM 5-3805-291-23P, Figures 182 and 183 Estimated Time to Complete Task 0.5 hr ea

0170 00-1

TM 5-3805-291-23-2

BUCKET TIPS AND CUTTING EDGES REPLACEMENT - CONTINUED

0170 00

BUCKET TIPS INSPECTION/REMOVAL

WARNING

1.

•


•

Injury to personnel or death can result from the bucket falling. Block the bucket before changing bucket tips.

Check bucket tips for wear. Wear on bucket tip (1) is acceptable. Wear on bucket tips (2 and 3) is unacceptable and bucket tips should be replaced. If bucket tip has hole, replace bucket tip.

427-C1213

0170 00-2

TM 5-3805-291-23-2


0170 00

BUCKET TIPS INSPECTION/REMOVAL - CONTINUED

NOTE •

Perform steps 2 thru 4 for each of eight bucket tips.

•

If tooth pin remover is not available, a hammer and punch can be used.

2.

Align punch with pin (4) in bucket tip (1).

3.

Strike punch until pin (4) hangs out completely from other side of bucket tip (1). Avoid striking bucket (5).

4.

Remove bucket tip (1) from machine.

427-C1214

5.

Some bucket tips (6) have pins (7) that are inserted vertically, as shown.

427-C1215

0170 00-3

TM 5-3805-291-23-2


0170 00

BUCKET TIPS CLEANING

WARNING •


•


1.


2.


BUCKET TIPS INSTALLATION 1.

Fit retainer (8) into retaining washer (9). Install as an assembly in groove on side of adapter (10).

427-C1216

0170 00-4

TM 5-3805-291-23-2


0170 00

BUCKET TIPS INSTALLATION - CONTINUED 2.

Install new bucket tip (1) on adapter (10).

427-C1217

NOTE •

The bucket tip can be rotated by 180 degrees to allow more or less penetration.

•

To correctly install the pin into the retainer, the pin must be driven in from the right side of the tooth. Improper installation of the pin can result in the loss of the bucket tip.

3.

Insert pin (4) through bucket tip (1).

4.

Place punch over bucket tip (1) and locate pin (4) in hole.

5.

Strike punch with a hammer at back to start pin (4).

6.

Strike punch until pin (4) is fully inserted in bucket (5).

7.

After pin (4) is set, make sure retainer (8) fits snugly in pin groove.

427-C1214

0170 00-5

TM 5-3805-291-23-2


0170 00

BUCKET CUTTING EDGES INSPECTION/REMOVAL

NOTE •

Check cutting edges and end bits for wear or damage. Use this procedure to service cutting edges and end bits.

•

If opposite side of cutting edge is not worn, it may be used. End bits are not reversible.

•

If both sides of cutting edge are worn, install new cutting edge.

•

Number of fasteners used on cutting edges is dependent upon the type of bucket (GP or rock).

1.


2.

Raise bucket and place blocking under bucket. Lower bucket onto blocking (TM 5-3805-291-10).

3.

Stop engine (TM 5-3805-291-10).

4.

Remove bolts (12), nuts (13), washers (14), and cutting edges (15) from bucket (16).

5.

Use hammer and punch or pin-master tool to remove two pins (17) and corner edge (18) from bucket (16).

6.

Repeat step 5 for opposite side of bucket (16).

427-C1219

BUCKET CUTTING EDGES CLEANING

WARNING •


•


1.


2.

Dry parts with compressed air. 0170 00-6

TM 5-3805-291-23-2


0170 00

BUCKET CUTTING EDGES INSTALLATION 1.

Use hammer and punch or pin-master tool to install corner edge (18) and two pins (17) on bucket (16).

2.

Repeat step 1 for opposite side of bucket (16).

3.

Install cutting edges (15), washers (14), bolts (12), and nuts (13) on bucket (16). Tighten nuts to 1,700 + 200 lb-ft (2,300 + 300 Nm).

4.


5.

After 3 to 5 hours of operation, check all bolts for proper torque.

END OF WORK PACKAGE

0170 00-7/(0170 00-8 Blank)

TM 5-3805-291-23-2

CHAPTER 4 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS

38 TM 5-3805-291-23-2

ENGINE REPLACEMENT

0171 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Component Transfer, Installation INITIAL SETUP Maintenance Level


Direct Support

Gasket (2) Lockwasher

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Bracket, link (Item 15, WP 0232 00)




Chain come-along (Item 22, WP 0232 00) Nipple, pipe (Item 41, WP 0232 00)

Transmission fluid drained (WP 0100 00)


Air intake hoses and lines removed (WP 0034 00)

Beam, hoisting

Air cleaner removed (WP 0030 00) Side covers removed (WP 0135 00)


AC dryer removed (WP 0224 00)

Multiplier, torque

Oil fill tube removed (WP 0029 00)

Materials/Parts

Cooling system package removed (WP 0190 00)

Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00)

Serpentine belt removed (WP 0048 00) Belt tensioner removed (WP 0047 00) Battery cables disconnected from starter (WP 0051 00) Drawings Required TM 5-3805-291-23P, Figures 1 and 2 Estimated Time to Complete Task 40.5 hr

Maintenance Task Title

Page

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-2 Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-13 Component Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-27 0171 00-1

TM 5-3805-291-23-2

ENGINE REPLACEMENT - CONTINUED

0171 00

REMOVAL


NOTE •


•


1.

Remove three bolts (1) and washers (2) and position accumulator and dryer assembly (3) aside.

2.

Remove three bolts (4), six washers (5), and two clips (6) from cover (7).

3.

Position cold start injector line (8) aside.

4.


427-C0480

5.

Disconnect wiring harness (9) from sensor (10).

6.

Remove five bolts (11), washers (12), spacer (13), and three bracket assemblies (14) from engine (15).

427-C0481

0171 00-2

TM 5-3805-291-23-2


0171 00



8.

Disconnect wiring harness (18) from solenoid (19).

9.

Disconnect three hoses (20) and remove O-rings (21). Discard O-rings.

10.

Remove two bolts (22) and spacers (23) from manifold (24).

11.

Position manifold (24) aside.

427-C0482

12.

Remove bolt (25) and washer (26) from bracket (27).

13.

Remove hose (28) from clamp (29).

427-C0483

0171 00-3

TM 5-3805-291-23-2


0171 00


Disconnect hose (30) and remove O-ring (31) from pump (32). Discard O-ring.

15.

Loosen hose clamp (33) and disconnect hose (34).

427-C0484

16.

Disconnect hose (35) and remove O-ring (36) from filter base (37). Discard O-ring.

427-C0486

17.

Disconnect two wiring harnesses (38).

18.

Remove four bolts (39) and washers (40) from compressor (41).

19.

Position compressor (41) aside.

427-C0485

0171 00-4

TM 5-3805-291-23-2


0171 00


Remove four bolts (42) and washers (43) from piston pump (44).

21.

Remove two flange halves (45) from hose (46).

22.

Disconnect hose (46) from piston pump (44) and remove and discard O-ring (47).

23.

Remove bolt (48), two washers (49), clamps (50), and nut (51).

427-C0491

24.

Remove two bolts (52), washers (53), and four clamps (54) from two brackets (55).

427-C1894

0171 00-5

TM 5-3805-291-23-2


0171 00


Disconnect hose (56) and remove and discard O-ring (57).

427-C1895

26.

Remove bolt (58), two washers (59), and nut (60) from two hose clamps (61).

427-C0492

27.

Remove bolt (62), washer (63), and bracket (64) from engine (15).

427-C1896

0171 00-6

TM 5-3805-291-23-2


0171 00


Remove three bolts (65) and washers (66) from plate (67).

29.

Remove plate (67) from machine.

427-C0494

30.

Remove eight bolts (68) and washers (69) from two tubes (70).

31.

Remove two tubes (70) and gaskets (71) from manifold (72). Discard gaskets.

427-C0495

0171 00-7

TM 5-3805-291-23-2


0171 00


Disconnect wiring harness lead (73) from engine wiring harness (74).

33.

Turn valve (75) to OFF position.

34.

Loosen clamp (76) and disconnect hose (77) from valve (75).

427-C0496

35.

If equipped with arctic heater, turn valve (78) to OFF position.

36.

If equipped with arctic heater, loosen clamp (79) and disconnect hose (80) from valve (78).

427-C1897

37.

Remove chassis wiring harness connector (81) from clip (82).

38.

Disconnect engine wiring harness (74) from chassis wiring harness connector (81).

39.

Remove bolt (83), washer (84), and clamp (85) from frame rail (86).

427-C0497

0171 00-8

TM 5-3805-291-23-2


0171 00


If equipped with arctic heater, disconnect three wiring harnesses (87 and 88).

427-C1898

41.

Turn valve (89) to OFF position.

42.


43.

If equipped with arctic heater, turn valve (92) to OFF position.

44.

If equipped with arctic heater, loosen clamp (93) and disconnect hose (94) from valve (92).

427-C0498

45.

Remove vent (95) from fuel tank (96).

427-C1900

0171 00-9

TM 5-3805-291-23-2


0171 00

REMOVAL - CONTINUED

WARNING


NOTE

46.

•

Sling will support torque converter and transmission during removal of engine. Torque converter and transmission have a combined weight of 2,200 lb (998 kg).

•

A bracket has to be removed in order to attach link bracket to support transmission when removing engine.

With assistance, attach sling to hydraulic tank (97) and torque converter (98).

427-C0500 427-C0499

0171 00-10

TM 5-3805-291-23-2


0171 00

REMOVAL - CONTINUED


NOTE Engine weighs approximately 3,200 lb (1,451 kg). 47.

Attach hoisting beam and lifting equipment to engine (15).

427-C0501

48.

Remove 11 bolts (99) and washers (100) from housing (101).

427-C0502

0171 00-11

TM 5-3805-291-23-2


0171 00


Remove two bolts (102), four washers (103 and 104), and two sleeves (105) from two front mounts (106).

50.

Remove two front mounts (106) from engine support (107).

427-C0504

WARNING


NOTE Engine weighs approximately 3,200 lb (1,451 kg).

51.

With assistance, use hoisting beam and lifting equipment to remove engine (15) from machine.

427-C0501

0171 00-12

TM 5-3805-291-23-2


0171 00


WARNING •


•


1.

Clean all parts and mating surfaces of engine with solvent cleaning compound.

2.


3.


4.


0171 00-13

TM 5-3805-291-23-2


0171 00

COMPONENT TRANSFER

NOTE It is highly recommended that component transfer be done with both engines side-by-side and that old engine not be released until machine is operational.

1.

Remove bolt (108), washer (109), and clamp (110) from engine (15).

2.

Remove two bolts (111), washers (112), and bracket (113) from engine (15).

3.

Remove three nuts (114), washers (115), and brackets (116) from engine (15).

4.


5.

Remove three bolts (120), washers (121), and pump (44) with hoses still attached to engine (15).

NOTE Tag all wiring harnesses and note location of tiedown straps and mounting hardware prior to disconnecting to ensure correct installation.

6.

Disconnect connector (122), cut and discard all tiedown straps (123), and disconnect remaining connections.

7.

Remove four bolts (124), washers (125), and two brackets (126) from engine (15).

8.


427-C1910

0171 00-14

TM 5-3805-291-23-2


0171 00


Remove three bolts (130), washers (131), brackets (132), bracket (133), and wiring harness (134) from engine (15).

10.

Remove two bolts (135), washers (136), spacer (137), and two brackets (138) from engine (15).

427-C1911

11.

Remove two bolts (139), washers (140), and ground cable (141) from engine (15) and alternator.

427-C1912

0171 00-15

TM 5-3805-291-23-2


0171 00


Remove bolt (142), washer (143), clip (144), bolt (145), washer (146), spacer (147), and clip (148) from engine (15).

13.

Remove adapter (149), atomizer (150), and tube (151) as an assembly from engine (15).

427-C1913

14.

Remove adapter and valve assembly (152), loosen hose clamp (153), and disconnect hose (154).

427-C1914

0171 00-16

TM 5-3805-291-23-2


0171 00


Remove nut (155), washer (156), and lockwasher (157) from alternator (158). Discard lockwasher.

16.

Remove five bolts (159), washers (160), clamps (161), two bolts (162), washers (163), fuse holder and cable assembly (164), and starter (165) from engine (15).

427-C1915

17.

Remove bolt (166), washer (167), and pulley (168) from engine (15).

427-C1916

0171 00-17

TM 5-3805-291-23-2


0171 00


Remove three bolts (169), washers (170), and starter (165) from engine (15).

19.

Remove bolt (171), washer (172), and ground cable (173) from engine (15).

427-C1917

20.

If equipped with arctic heater, remove valve (78), elbow (174), and adapter (175) from engine (15).

21.

Remove valve (75) and adapter (176) from engine (15).

427-C1918

0171 00-18

TM 5-3805-291-23-2


0171 00

COMPONENT TRANSFER - CONTINUED

NOTE Only machines equipped with arctic heater have valve (92) and T (177).

22.

Remove valve (92), T (177), and adapter (178) from engine (15).

23.

Remove elbow (179) and adapter (180) from engine (15).

24.

Loosen hose clamp (181) and disconnect hose (182).

427-C1919

25.

Remove three bolts (183), washers (184), spacers (185), and bracket (186) from engine (15).

427-C1920

0171 00-19

TM 5-3805-291-23-2


0171 00


Loosen hose clamp (187) and remove hose (188) and tube (189) from engine (15).

427-C1921

27.

Loosen hose clamp (190) and remove hose (191) from engine (15).

28.

Carefully look over both engines and look for any fittings, hoses, brackets, clips, etc., that may have been overlooked. Transfer those parts as necessary. If possible, verify machine is operational before releasing old engine.

29.

Install hose (191) on engine (15) and tighten hose clamp (190).

427-C1922

30.

Install hose (188) and tube (189) on engine (15) and tighten hose clamp (187).

0171 00-20

TM 5-3805-291-23-2


0171 00


Install bracket (186), three spacers (185), washers (184), and bolts (183) on engine (15).

427-C1920

32.

Connect hose (182) and tighten hose clamp (181).

33.

Install adapter (180) and elbow (179) on engine (15).

NOTE Only machines equipped with arctic heater have valve (92) and T (177).

34.

Install adapter (178), T (177), and valve (92) on engine (15).

427-C1919

0171 00-21

TM 5-3805-291-23-2


0171 00


Install adapter (176) and valve (75) on engine (15).

36.

If equipped with arctic heater, install adapter (175), elbow (174), and valve (78) on engine (15).

427-C1918

37.

Install ground cable (173), washer (172), and bolt (171) on engine (15).

38.

Install starter (165), three washers (170), and bolts (169) on engine (15).

427-C1917

0171 00-22

TM 5-3805-291-23-2


0171 00


Install pulley (168), washer (167), and bolt (166) on engine (15).

427-C1916

40.

Install fuse holder and cable assembly (164), two washers (163), bolts (162), five clamps (161), washers (160), and bolts (159) on engine (15) and starter (165).

41.

Install new lockwasher (157), washer (156), and nut (155) on alternator (158).

427-C1915

0171 00-23

TM 5-3805-291-23-2


0171 00


Install adapter and valve assembly (152), connect hose (154), and tighten hose clamp (153).

427-C1914

NOTE There is an orientation mark on the hex head of the ether atomizer, which is aligned with the pinhole in the atomizer. When installed correctly, this mark should face away from the engine. The atomizer is oriented in this way to ensure thorough mixing of ether with the intake air. This is accomplished by spraying ether against the direction of the incoming air.

43.

Install adapter (149), atomizer (150), and tube (151) as an assembly on engine (15).

44.

Install clip (148), spacer (147), washer (146), bolt (145), clip (144), washer (143), and bolt (142) on engine (15).

427-C1913

0171 00-24

TM 5-3805-291-23-2


0171 00


Install ground cable (141), two washers (140), and bolts (139) on engine (15).

427-C1912

46.

Install two brackets (138), spacer (137), two washers (136), and bolts (135) on engine (15).

47.

Install wiring harness (134), bracket (133), three brackets (132), washers (131), and bolts (130) on engine (15).

427-C1911

0171 00-25

TM 5-3805-291-23-2


0171 00


Install bracket (129), washer (128), and bolt (127) on engine (15).

49.

Install two brackets (126), four washers (125), and bolts (124) on engine (15).

50.

Connect remaining connections, connector (122), and install all new tiedown straps (123).

51.

Install pump (44), with hoses still attached, three washers (121), and bolts (120) on engine (15).

52.


53.

Install three brackets (116), washers (115), and nuts (114) on engine (15).

54.

Install bracket (113), two washers (112), and bolts (111) on engine (15).

55.

Install clamp (110), washer (109), and bolt (108) on engine (15).

427-C1910

0171 00-26

TM 5-3805-291-23-2


0171 00

INSTALLATION

WARNING


NOTE

1.

•


•

Engine weighs approximately 3,200 lb (1,451 kg).

With assistance, use hoisting beam and lifting equipment to position engine (15) in machine.

427-C0501

2.

Install 11 washers (100) and bolts (99) on housing (101).

427-C0502

0171 00-27

TM 5-3805-291-23-2


0171 00


NOTE

3.

•

Raise engine to release tension from come-along.

•

Link bracket has to be removed and a bracket installed where link bracket was removed.

With assistance, remove come-along from torque converter (98) and hydraulic tank (97).

427-C0499

427-C0500

4.

Install two front mounts (106) on engine support (107).

5.

Install two sleeves (105), four washers (104 and 103), and two bolts (102) on front mounts (106). Tighten bolts to 660 ± 75 lb-ft (895 ± 102 Nm).

6.

With assistance, remove lifting equipment from engine.

427-C0504

0171 00-28

TM 5-3805-291-23-2


0171 00


Install vent (95) on fuel tank (96).

427-C1900

8.

If equipped with arctic heater, connect hose (94) to valve (92) and tighten clamp (93).

9.

If equipped with arctic heater, turn valve (92) to ON position.

10.

Connect hose (91) to valve (89) and tighten clamp (90).

11.

Turn valve (89) to ON position.

427-C0498

0171 00-29

TM 5-3805-291-23-2


0171 00


If equipped with arctic heater, connect three wiring harnesses (88 and 87).

427-C1898

13.

Install chassis wiring harness connector (81) in clip (82).

14.

Install clamp (85), washer (84), and bolt (83) on frame rail (86).

15.

Connect engine wiring harness (74) to chassis wiring harness connector (81).

427-C0497

16.

If equipped with arctic heater, connect hose (80) to valve (78) and tighten clamp (79).

427-C1897

0171 00-30

TM 5-3805-291-23-2


0171 00


If equipped with arctic heater, turn valve (78) to ON position.

18.


19.

Turn valve (75) to ON position.

20.

Connect wiring harness lead (73) to engine wiring harness (74).

427-C0496

21.

Place two new gaskets (71) and two tubes (70) on manifold (72).

22.

Install eight washers (69) and bolts (68) on two tubes (70).

427-C0495

0171 00-31

TM 5-3805-291-23-2


0171 00


Place plate (67) on machine.

24.

Install three washers (66) and bolts (65) on plate (67).

427-C0494

25.


427-C1896

0171 00-32

TM 5-3805-291-23-2


0171 00


Place compressor (41) in position and install four washers (40) and bolts (39) on compressor.

27.

Connect two wiring harnesses (38).

427-C0485

28.

Install two hose clamps (61), washers (59), bolt (58), and nut (60).

427-C0492

29.

Install new O-ring (57) and connect hose (56).

427-C1895

0171 00-33

TM 5-3805-291-23-2


0171 00


Install four clamps (54), two washers (53), and bolts (52) on brackets (55).

427-C1894

31.

Install new O-ring (47) and connect hose (46) to piston pump (44).

32.

Install two flange halves (45) on hose (46) and secure with four washers (43) and bolts (42).

33.

Install nut (51), two clamps (50), washers (49), and bolt (48).

427-C0491

0171 00-34

TM 5-3805-291-23-2


0171 00


Install new O-ring (36) in hose (35).

35.

Connect hose (35) to filter base (37).

427-C0486

36.

Connect hose (34) and tighten hose clamp (33).

37.

Install new O-ring (31) in hose (30).

38.

Install hose (30) on pump (32).

427-C0484

39.

Place hose (28) in clamp (29).

40.

Install washer (26) and bolt (25) on bracket (27).

427-C0483

0171 00-35

TM 5-3805-291-23-2


0171 00


Place manifold (24) on engine (15).

42.

Install two spacers (23) and bolts (22) on manifold (24).

43.

Install three new O-rings (21) and connect hoses (20).

44.

Connect wiring harness (18) to solenoid (19).

45.

Connect wiring harness (16) to sensor (17).

427-C0482

46.

Install three bracket assemblies (14), spacer (13), five washers (12), and bolts (11) on engine (15).

47.


427-C0481

0171 00-36

TM 5-3805-291-23-2


0171 00


Place cover (7) on machine.

49.

Position cold start injector line (8) on cover (7) and install two clips (6), six washers (5), and three bolts (4) on cover.

50.

Install accumulator and dryer assembly (3), three washers (2), and bolts (1).

427-C0480

51.

Install AC dryer (WP 0224 00).

52.

Install belt tensioner (WP 0047 00).

53.

Install serpentine belt (WP 0048 00).

54.

Connect battery cables to starter (WP 0051 00).

55.

Fill engine oil (TM 5-3805-291-10).

56.

Install cooling system package (WP 0190 00).

57.

Install oil fill tube (WP 0029 00).

58.


59.


60.

Install air intake hoses and lines (WP 0034 00).

61.

Fill transmission fluid to correct level (TM 5-3805-291-10).

62.

Fill hydraulic fluid to correct level (WP 0100 00).

63.


64.


65.

Check for leaks.


12 TM 5-3805-291-23-2

CYLINDER HEAD REPLACEMENT

0172 00



Materials/Parts - Continued Gasket (2)

Direct Support

O-ring (4)

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00)

Seal Personnel Required MOS 62B, Construction Equipment Repairer (2) References WP 0041 00 Equipment Conditions Muffler removed (WP 0040 00) Air cleaner removed (WP 0030 00)



Materials/Parts

Thermostat housing removed (WP 0044 00)

Antiseize compound (Item 2, WP 0233 00)

Accessory drive mechanism removed (WP 0194 00)

Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

Valve cover and base removed (WP 0024 00) Rocker arm assembly and pushrods removed (WP 0180 00) Fuel injectors removed (WP 0187 00) Steering frame lock connected (TM 5-3805-29110) Drawings Required

Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00)


0172 00-1

TM 5-3805-291-23-2

CYLINDER HEAD REPLACEMENT - CONTINUED

0172 00

REMOVAL


NOTE • Tag hoses and wiring harnesses prior to removal to ensure correct installation. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up. • Remove and discard all associated tiedown straps. 1.


2.

Disconnect wiring harnesses (4 and 5) from sensors (6 and 7).

3.

Remove nut (8), washer (9), and bracket (10) from cylinder head (11).

4.

Remove bolt (12), washer (13), and clip (14) from cylinder head (11).

5.

Remove three bolts (15), washer (16), and two brackets (17) from cylinder head (11).

427-C1905

0172 00-2

TM 5-3805-291-23-2


0172 00


Remove bolt (18), washer (19), two clips (20), and spacer (21) from cylinder head (11).

7.

Remove ether start aid (22) from cylinder head (11).

8.

With assistance, remove three bolts (23) and washers (24) from bracket (25).

9.

Position bracket (25) with fuel filter bases (26) aside.

427-C1906

10.

Loosen two clamps (27) from hoses (28) and remove hoses from fittings (29).

11.

Remove two fittings (29) from cylinder head (11).

12.


13.

Disconnect sensor (31) from wiring harness (32).

14.

Remove two bolts (33), washers (34), and brackets (35) from cylinder head (11).

427-C1907

0172 00-3

TM 5-3805-291-23-2


0172 00


Remove two bolts (36) and washers (37) from oil tube (38).

16.

Remove oil tube (38) and gasket (39) from turbocharger (40). Discard gasket.

17.

Remove two bolts (41) and washers (42) from oil tube (43).

18.

Remove oil tube (43) and gasket (44) from turbocharger (40). Discard gasket.

427-C0544


NOTE Cylinder head weighs approximately 500 lb (227 kg).

19.

Attach lifting equipment to cylinder head (11).

20.

Remove 34 cylinder head bolts (45) from cylinder head (11).

21.

Remove cylinder head (11) and gasket (46) from engine. Discard gasket. 0172 00-4

TM 5-3805-291-23-2


0172 00

REMOVAL - CONTINUED

427-C0546

0172 00-5

TM 5-3805-291-23-2


0172 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION 1.

Install new cylinder head gasket (46) on engine.

WARNING


NOTE •

Cylinder head weighs approximately 500 lb (227 kg).

•

Lubricate all cylinder head bolt threads, underside of bolt heads, and washers on bolts inside valve cover with antiseize compound prior to assembly.

•


2.

Attach lifting equipment to cylinder head (11) and position on engine.

3.

Install 34 cylinder head bolts (45).

4.

Tighten cylinder head bolts (45) in sequence as follows:

NOTE Lubricate the bolt threads, the underside of the bolt heads, and the washers with 6V-4876 Lubricant prior to assembly.

0172 00-6

TM 5-3805-291-23-2


0172 00

INSTALLATION - CONTINUED a.

Tighten bolt (1) through bolt (26) in numerical sequence as shown to 125 ± 7 lb-ft (170 ± 10 Nm).

b.

Tighten bolt (1) through bolt (26) again in numerical sequence as shown to 125 ± 7 lb-ft (170 ± 10 Nm).

c.

Place a mark on bolt (1) through bolt (26). Rotate bolt (1) through bolt (26) in numerical sequence. Rotate bolts clockwise 120 ± 5 degrees (1/3 turn).

d.

Loosen bolt (1) through bolt (26) until washers are loose under bolt heads.

e.


f.

Tighten bolt (1) through bolt (26) again in numerical sequence as shown to 125 ± 7 lb-ft (170 ± 10 Nm).

g.

Place a mark on bolt (1) through bolt (26). Rotate bolt (1) through bolt (26) in numerical sequence. Rotate bolts clockwise 120 ± 5 degrees (1/3 turn).

h.


427-C0546

0172 00-7

TM 5-3805-291-23-2


0172 00


NOTE •

Lubricate the bores for the cup plugs with 6V-6640 Sealant prior to installing the cup plugs.

•

The cup plugs are measured from the head face to the top edge of the plug. Depth of installation should be 0.049 ± 0.010 in. (1.25 ± 0.25 mm).

•

Minimum permissible thickness of cylinder head is 6.4901 in. (164.85 mm).

•

Maximum permissible thickness of cylinder head is 6.502 in. (165.15 mm).

•

The flatness of the cylinder head should be within 0.006 in. (0.15 mm). The flatness should also be a maximum of 0.002 in. (0.05 mm) for any 5.906 in. (150.00 mm) span.

5.

Install new gasket (44) on oil tube (43).

6.

Place oil tube (43) on turbocharger (40) and install two washers (42) and bolts (41) on oil tube (43).

7.

Install new gasket (39) on oil tube (38).

8.

Place oil tube (38) on turbocharger (40) and install two washers (37) and bolts (36) on oil tube.

427-C0544

0172 00-8

TM 5-3805-291-23-2


0172 00


Position two brackets (35) on cylinder head (11) and install washers (34) and bolts (33) on brackets.

10.

Connect sensor (31) to wiring harness (32).

11.

Install two new O-rings (30) on fittings (29).

12.

Install two fittings (29) on cylinder head (11).

13.

Install two hoses (28) on fittings (29) and tighten clamps (27).

427-C1907

14.

With assistance, place bracket (25) with fuel filter bases (26) in position and install three washers (24) and bolts (23) on bracket.

15.

Install ether start aid (22) on cylinder head (11).

16.

Install spacer (21), two clips (20), washer (19), and bolt (18) on cylinder head (11).

427-C1906

0172 00-9

TM 5-3805-291-23-2


0172 00


Install two brackets (17), three washers (16), and bolts (15) on cylinder head (11).

18.

Install clip (14), washer (13), and bolt (12) on cylinder head (11).

19.

Place bracket (10) in position and install washer (9) and nut (8) on bracket.

20.

Connect wiring harnesses (5 and 4) to sensors (7 and 6).

21.

Install two new O-rings (2) in hoses (1).

22.

Connect two hoses (1) to fittings (3).

427-C1905

0172 00-10

TM 5-3805-291-23-2


0172 00


Install fuel injectors (WP 0187 00).

24.

Install rocker arms/pushrods (WP 0180 00).

25.

Install valve mechanism cover and base (WP 0024 00).

26.

Install accessory drive (WP 0194 00).

27.

Install thermostat housing (WP 0044 00).

28.


29.


30.

Install muffler (WP 0040 00).

31.


32.


33.


34.

Check for leaks.


35.


END OF WORK PACKAGE

0172 00-11/(0172 00-12 Blank)

6 TM 5-3805-291-23-2

CRANKSHAFT VIBRATION DAMPER AND PULLEY REPLACEMENT

0173 00

THIS WORK PACKAGE COVERS Removal, Inspection, Installation INITIAL SETUP Maintenance Level


Direct Support


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Lifting equipment, 90-lb capacity

Cooling system package removed (WP 0190 00) Serpentine belt removed (WP 0048 00) Steering frame lock connected (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figure 5

Materials/Parts



0173 00-1

TM 5-3805-291-23-2

CRANKSHAFT VIBRATION DAMPER AND PULLEY REPLACEMENT - CONTINUED

0173 00

REMOVAL

WARNING


NOTE The crankshaft vibration damper and pulley weighs approximately 60 lb (27 kg).

1.

Attach lifting equipment to crankshaft vibration damper (1) and pulley (2).

2.

Remove six bolts (3) from crankshaft vibration damper (1).

3.

Remove crankshaft vibration damper (1) and pulley (2) from engine (4).

427-C0547-1

0173 00-2

TM 5-3805-291-23-2


0173 00


Remove eight bolts (5) from pulley (2).

5.

Remove pulley (2) from crankshaft vibration damper (1).

427-C0548

INSPECTION

CAUTION Damage to vibration damper or failure of vibration damper will increase vibrations. This will result in damage to crankshaft. Replace damper if any of these conditions exist: • • • • •

Damper is dented, cracked, or fluid is leaking from damper. Paint on damper is discolored from excessive heat. Damper is bent. Bolt holes are worn or there is loose fit for bolts. Engine has had a crankshaft failure due to torsional forces.

Inspect crankshaft vibration damper (1) for signs of leakage and signs of damage to case. Either of these conditions can cause weight to contact the case. This contact can affect damper operation.

0173 00-3

TM 5-3805-291-23-2


0173 00

INSTALLATION

WARNING


NOTE Crankshaft vibration damper and pulley weighs approximately 60 lb (27 kg).

1.

Install pulley (2) on crankshaft vibration damper (1).

2.

Install eight bolts (5) on pulley (2).

427-C0548

0173 00-4

TM 5-3805-291-23-2


0173 00


Attach lifting equipment to crankshaft vibration damper (1) and pulley (2).

4.

Position crankshaft vibration damper (1) and pulley (2) on engine (4).

5.

Install six bolts (3) on crankshaft vibration damper (1).

427-C0547-1

6.


7.



8.

Secure steering frame lock in the stowed position (TM 5-3805-291-10).

9. 10. 11.

Inspect vibration damper for signs of damage.

Run engine and verify there is no vibration (TM 5-3805-291-10). Shut down engine (TM 5-3805-291-10).

END OF WORK PACKAGE

0173 00-5/(0173 00-6 Blank)

4 TM 5-3805-291-23-2

FRONT MAIN SEAL REPLACEMENT

0174 00


Maintenance Level Direct Support



References


TM 5-3805-291-10

Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00)


Materials/Parts

Crankshaft vibration damper removed (WP 0173 00) Drawings Required



Rag, wiping (Item 35, WP 0233 00) Seal

10.5 hr

0174 00-1

TM 5-3805-291-23-2

FRONT MAIN SEAL REPLACEMENT - CONTINUED

0174 00

REMOVAL 1.

Remove five nuts (1) and washers (2) from front main seal (3).

2.

Remove front main seal (3) from crankshaft (4). Discard seal.

427-C0553


WARNING •


•


1.


2.


3.


4.


0174 00-2

TM 5-3805-291-23-2

FRONT MAIN SEAL REPLACEMENT - CONTINUED

0174 00

INSTALLATION

NOTE Leave the shipping sleeve in place when installing front main seal. The front main seal must be installed dry.

1.

Position new front main seal (3) on crankshaft (4).

2.

Push front main seal (3) into place. This will dislodge shipping sleeve.

3.

Install five washers (2) and nuts (1) on front main seal (3). Tighten nuts in numerical sequence as shown.

427-C0554

4.

Install crankshaft vibration damper (WP 0173 00).

5.


6.


7.

Check for leaks.

END OF WORK PACKAGE

0174 00-3/(0174 00-4 Blank)

4 TM 5-3805-291-23-2

REAR MAIN SEAL REPLACEMENT

0175 00



Gasket


O-ring (2)

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00)

Seal Personnel Required MOS 62B, Construction Equipment Repairer References

Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Gasket cement (Item 14, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

TM 5-3805-291-10 WP 0176 00 Equipment Conditions Flywheel removed (WP 0177 00) Drawings Required TM 5-3805-291-23P, Figure 6 Estimated Time to Complete Task

Rag, wiping (Item 35, WP 0233 00) Sealing compound (Item 38, WP 0233 00)

39.0 hr

0175 00-1

TM 5-3805-291-23-2

REAR MAIN SEAL REPLACEMENT - CONTINUED

0175 00

REMOVAL Rear Main Seal 1.

Remove nine bolts (1) and washers (2) from rear main seal (3).

2.

Remove rear main seal (3) from crankshaft (4). Discard rear main seal.

427-C0550

3.

Remove O-ring (5) from crankshaft (4). Discard O-ring.

427-C0551

Rear Main Seal Carrier 1.

Remove flywheel housing (WP 0176 00).

2.

Remove O-ring (6), rear seal carrier (7), and gasket (8) from engine. Discard O-ring and gasket. 0175 00-2

TM 5-3805-291-23-2


0175 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION


Rear Main Seal Carrier 1.

Install new gasket (8), rear seal carrier (7), and new O-ring (6) on engine.

2.

Install flywheel housing (WP 0176 00).

0175 00-3

TM 5-3805-291-23-2


0175 00

INSTALLATION - CONTINUED Rear Main Seal

NOTE

1.

•

Leave the shipping sleeve in place when installing rear main seal. The rear main seal must be installed dry.

•

Use an alternating sequence when tightening the front and rear seal bolts.

•

Three bottom bolts are M6x1x20 mm. Six top bolts are size M6x1x30 mm.

• Use sealing compound on bolts before installation. Position new rear main seal (3) and new O-ring (5) on crankshaft (4).

2.

Push rear main seal (3) into place. This will dislodge shipping sleeve.

3.

Install nine washers (2) and bolts (1) on rear main seal (3). Tighten bolts in numerical sequence as shown.

4.

Install flywheel (WP 0177 00).

427-C0552

5.


6.


7.

Check for leaks.

END OF WORK PACKAGE

0175 00-4

6 TM 5-3805-291-23-2

FLYWHEEL HOUSING REPLACEMENT

0176 00

THIS WORK PACKAGE COVERS Removal, Cleaning, Installation, Inspection INITIAL SETUP Maintenance Level

Materials/Parts - Continued Gasket cement (Item 14, WP 0233 00)

Direct Support


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Diesel engine repair stand, 6,000-lb (Item 25, WP 0232 00) Diesel engine repair stand, adapter plate (Item 26, WP 0232 00) Indicator, dial (Item 35, WP 0232 00)

Personnel Required MOS 62B, Construction Equipment Repairer (2) References TM 5-3805-291-10 Equipment Conditions Engine removed (WP 0171 00) Starter removed (WP 0051 00) Flywheel removed (WP 0177 00) Drawings Required


TM 5-3805-291-23P, Figure 9


0176 00-1


TM 5-3805-291-23-2

FLYWHEEL HOUSING REPLACEMENT - CONTINUED

0176 00

REMOVAL

WARNING


NOTE Flywheel housing weighs mately 137 lb (62 kg).

approxi-

1.

Support engine on engine stand.

2.

Attach lifting equipment to flywheel housing (1).

3.

Remove four bolts (2), two washers (3), and bracket (4).

4.

Remove 12 bolts (5) and washers (6) from flywheel housing (1).

5.

With assistance, remove flywheel housing (1) from engine.

427-C1944

427-C0559

0176 00-2

TM 5-3805-291-23-2


0176 00

CLEANING

WARNING •


•


1.

Remove all gasket material from mounting surfaces.

2.


3.


INSTALLATION


CAUTION Installation of flywheel housing on engine must be completed within 10 minutes of application of gasket cement. Failure to do so could result in damage to equipment.

NOTE Flywheel housing weighs approximately 137 lb (62 kg). 1.

Attach lifting equipment to flywheel housing (1).

2.

Apply gasket cement to face of engine.

3.

With assistance, position flywheel housing (1) on rear of engine.

4.

Install 12 washers (6) and bolts (5) on flywheel housing (1).

5.

Install bracket (4), two washers (3), and four bolts (2).

6.

Check flywheel runout as necessary. 0176 00-3

TM 5-3805-291-23-2


0176 00

INSPECTION

NOTE Flywheel inspection is in WP 0177 00.

Face Runout (Axial Eccentricity) 1.

Attach dial indicator to flywheel (7) so anvil of dial indicator contacts face of flywheel housing (1).

2.

Use rubber mallet and tap crankshaft toward rear before dial indicator is read at each point.

3.

Turn flywheel (7) while dial indicator is set at 0.00 in. (0.0 mm) at location (A).

4.

Read dial indicator at locations (B, C, and D).

5.

Difference between lower measurements and higher measurements at all four points must not be more than 0.015 in. (0.38 mm), which is maximum permissible face runout (axial eccentricity) of flywheel housing.

427-C0560

427-C0561

Bore Runout (Radial Eccentricity) 1.

Attach dial indicator to flywheel (7) so anvil of dial indicator contacts bore of flywheel housing (1).

2.

While dial indicator is in position at location (C), adjust dial indicator to 0.00 in. (0.0 mm).

3.

Push crankshaft upward against top of bearing.

4.

Write measurements for bearing clearance on line 1 in column (C) of chart.

427-C0562

0176 00-4

TM 5-3805-291-23-2


0176 00

INSPECTION - CONTINUED Bore Runout (Radial Eccentricity) - Continued

NOTE Write measurements for dial indicator with correct notations. This notation is necessary for making calculations in chart correctly.

5.

Divide measurements from step 4 by two. Write this number on line 1 in columns (B and D) of chart.

6.

Turn flywheel to put dial indicator at position (A).

7.

Adjust dial indicator to 0.00 in. (0.0 mm).

8.

Turn flywheel counterclockwise to put dial indicator at position (B).

9.

Write measurements on line 2 under B in chart.

10.

Turn flywheel counterclockwise to put to dial indicator at position (C).

11.

Write measurement on line 2 under C in chart.

12.

Turn flywheel counterclockwise to put to dial indicator at position (D).

13.

Write measurement on line 2 under D in chart.

14.

Total each column. Write result of column C on line 3.

15.

Subtract smaller number from larger number in column B and column D of chart.

16.

Write result of step 15 on line 3. Result is horizontal eccentricity (out of round). Line 3 in column C is vertical eccentricity.

427-C0563

0176 00-5

TM 5-3805-291-23-2


0176 00

INSPECTION - CONTINUED Bore Runout (Radial Eccentricity) - Continued 17.

Find intersection of eccentricity lines (vertical and horizontal) in illustration below.

18.

If point of intersection is in “Acceptable” range, bore is in alignment. If point of intersection is in “Not Acceptable” range, flywheel housing must be changed. (1)

Total vertical eccentricity.

(2)

Total horizontal eccentricity.

(3)

Acceptable value.

(4)

Unacceptable value.

427-C0564

19.

Install flywheel (WP 0177 00).

20.

Install starter (WP 0051 00)

21.

Install engine (WP 0171 00).

22.


23.

Inspect for flywheel interference.

24.


END OF WORK PACKAGE

0176 00-6

4 TM 5-3805-291-23-2

FLYWHEEL REPLACEMENT

0177 00

THIS WORK PACKAGE COVERS Removal, Installation, Inspection INITIAL SETUP Maintenance Level


Direct Support

Stud (M16x2x180 mm)

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Bracket, link (Item 16, WP 0232 00)

Personnel Required MOS 62B, Construction Equipment Repairer (2) References TM 5-3805-291-10 Equipment Conditions

Diesel engine repair stand, 6,000-lb (Item 25, WP 0232 00) Diesel engine repair stand, adapter plate (Item 26, WP 0232 00) Indicator, dial (Item 35, WP 0232 00)

Engine removed (WP 0171 00) Drawings Required TM 5-3805-291-23P, Figure 8 Estimated Time to Complete Task 38.0 hr


0177 00-1

TM 5-3805-291-23-2

FLYWHEEL REPLACEMENT - CONTINUED

0177 00

REMOVAL

WARNING


NOTE Flywheel weighs approximately 75 lb (34 kg). 1.

Remove two bolts (2) and washers (3) from 3 o’clock and 9 o’clock positions and install studs in crankshaft (6).

2.

Remove six bolts (4) and washers (5) from flywheel (1).

3.

With assistance, remove flywheel (1) from crankshaft (6).

4.

Remove two studs from crankshaft (6).

427-C0555

0177 00-2

TM 5-3805-291-23-2


0177 00

INSTALLATION

WARNING


NOTE Flywheel weighs approximately 75 lb (34 kg). 1.

With assistance, install flywheel (1) over studs on crankshaft (6).

2.

Install six washers (5) and bolts (4) on flywheel (1). Tighten bolts evenly to 220 ± 30 lb-ft (300 ± 40 Nm).

3.

Install two studs on crankshaft (6) at 9 o’clock and 3 o’clock positions.

4.

Install two washers (3) and bolts (2) on flywheel (1).

5.

Check flywheel runout (refer to Inspection in this work package).

INSPECTION Face Runout (Axial Eccentricity)

0177 00

NOTE •

Find top center position for No. 1 Piston.

•

Always put force on crankshaft in same direction before dial indicator is read. This will remove any crankshaft end clearance.

1.

Install dial indicator on bell housing (6) as shown.

2.

Set dial indicator to read 0.00 in. (0.0 mm).

3.

Turn flywheel (1) at intervals of 90 degrees and read dial indicator.

4.

Take measurements at all four points. Difference between lower measurements and higher measurements at all four points must not be more than 0.0005 in. (0.013 mm), which is maximum permissible face runout (axial eccentricity) of flywheel (1).

427-C0556

0177 00-3

TM 5-3805-291-23-2


0177 00

INSPECTION - CONTINUED Bore Runout (Radial Eccentricity)

0177 00

NOTE • •

Find top center position for No. 1 Piston. Always put force on crankshaft in same direction before dial indicator is read. This will remove any crankshaft end clearance.

1.

Install dial indicator on bell housing (6) as shown.

2.

Adjust universal attachment so dial indicator makes contact with flywheel (1).

3.

Set dial indicator to read 0.00 in. (0.0 mm).

4.

Turn flywheel (1) at intervals of 90 degrees and read dial indicator.

5.

Take measurements at all four points. Difference between lower measurements and higher measurements at all four points must not be more than 0.006 in. (0.15 mm), which is maximum permissible bore runout (radial eccentricity) of flywheel (1).

427-C0557

6.

To find runout (eccentricity) of pilot bearing bore (7), install dial indicator on bell housing (6) as shown and repeat steps 1 thru 5.

7.

Runout (eccentricity) of pilot bearing bore (7) for pilot bearing in flywheel (1) must not exceed 0.005 in. (0.13 mm).

8.

Install engine (WP 0171 00).

427-C0558

9.

Run engine to verify there is no flywheel interference (TM 5-3805-291-10).

10.

Shut down engine and inspect for flywheel interference (TM 5-3805-291-10).


4 TM 5-3805-291-23-2

FRONT COVER REPLACEMENT

0178 00



Direct Support

References

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00)

TM 5-3805-291-10 Equipment Conditions Fuel transfer pump removed (WP 0188 00) Accessory mechanism removed (WP 0194 00) Front main seal removed (WP 0174 00)



Gasket

0178 00-1

TM 5-3805-291-23-2

FRONT COVER REPLACEMENT - CONTINUED

0178 00

REMOVAL 1.

Remove 18 bolts (1) and washers (2) from front cover (3).

2.

Remove two studs (4) and washers (5) from front cover (3).

3.

Remove front cover (3) and gasket (6) from front housing (7). Discard gasket.

427-C0565


WARNING •


•


1.


2.


3.


4.


TM 5-3805-291-23-2

FRONT COVER REPLACEMENT - CONTINUED INSTALLATION 1.

Position new gasket (6) and front cover (3) on front housing (7).

2.

Install two washers (5) and studs (4) on front cover (3).

3.

Install 18 washers (2) and bolts (1) on front cover (3).

4.

Install front main seal (WP 0174 00).

5.

Install accessory mechanism (WP 0194 00).

6.

Install fuel transfer pump (WP 0188 00).

7.


8.


9.

Check for leaks.

END OF WORK PACKAGE

0178 00-3/(0178 00-4 Blank)

0178 00

6 TM 5-3805-291-23-2

INTAKE/EXHAUST VALVE LASH ADJUSTMENT

0179 00

THIS WORK PACKAGE COVERS Intake Valve Adjustment, Exhaust Valve Adjustment INITIAL SETUP Materials/Parts

Maintenance Level


Direct Support

Personnel Required




References



Pinion turning tool (Item 49, WP 0232 00)

Drawings Required

WP 0187 00

Valve cover removed (WP 0024 00)

TM 5-3805-291-23P, Figure 10

Timing pin (Item 89, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)

0179 00-1


TM 5-3805-291-23-2

INTAKE/EXHAUST VALVE LASH ADJUSTMENT - CONTINUED

0179 00

INTAKE VALVE ADJUSTMENT

WARNING •

To prevent possible injury to personnel, DO NOT use starter to turn flywheel.

•

Hot engine can cause burns. Allow additional time for engine to cool before measuring valve clearance.

NOTE There is no lash adjustment for injector rocker arms. Setting is done via fuel injectors (WP 0187 00).

1.

Put No. 1 piston at top center position on compression stroke:

CAUTION Never turn engine using crankshaft vibration damper. Crankshaft vibration damper is a precision part. Major engine failure may be caused by damage to crankshaft vibration damper.

a.

Remove two bolts (1) and cover (2) from flywheel housing (3).

NOTE Timing hole is located approximately 5.0 to 6.0 in. (127 to 152 mm) above turning hole in flywheel housing.

b.

Remove plug (4) from timing hole.

c.

Install timing pin with timing pin adapter in timing hole.

0179 00-2

TM 5-3805-291-23-2


0179 00

INTAKE VALVE ADJUSTMENT - CONTINUED

NOTE Direction of engine rotation is counterclockwise, as the engine is viewed from the flywheel end. Turn flywheel in direction of engine rotation. • If flywheel is turned beyond point of engagement with timing pin, flywheel must be turned clockwise approximately 30 degrees. Then turn flywheel counterclockwise until timing pin engages hole in flywheel. This procedure removes play from gears when No. 1 piston is at top-center position. d. Turn flywheel until timing pin engages with hole in flywheel. •

427-C0600

Table 1. Intake Valve Lash Adjustment. Inlet Valves

Exhaust Valves

Valve Lash

0.0150 ± 0.0031 in. (0.38 ± 0.08 mm)

0.0252 ± 0.0031 in. (0.64 ± 0.08 mm)

Cylinders

1-2-4

1-3-5

TC Compression Stroke (1)

(1)

Position for No. 1 cylinder

0179 00-3

TM 5-3805-291-23-2


0179 00

INTAKE VALVE ADJUSTMENT - CONTINUED 2.

Adjust valve lash according to Table 1. a.

Lightly tap rocker arm (5) at top of adjustment screw (6). This will ensure lifter roller seats.

427-C1040

b.

Loosen adjustment locknut (7).

c.

Place appropriate feeler gage between rocker arm (5) and valve bridge (8).

427-C1041

d.

Turn adjustment screw (6) in clockwise direction. Slide feeler gage between rocker arm (5) and valve bridge (8). Continue turning adjustment screw until a slight drag is felt on feeler gage.

e.

Tighten adjustment locknut (7) to 22 ± 5 lb-ft (30 ± 7 Nm).

NOTE DO NOT allow adjustment screw to turn while you are tightening adjustment locknut.

f.

Recheck valve lash after tightening adjustment locknut (7).

0179 00-4

TM 5-3805-291-23-2


0179 00

EXHAUST VALVE ADJUSTMENT 1.

Put No. 6 piston at top center position on compression stroke.

Table 2. Exhaust Valve Lash Adjustment. Inlet Valves

Exhaust Valves

Valve Lash

0.0150 ± 0.0031 in. (0.38 ± 0.08 mm)

0.0252 ± 0.0031 in. (0.64 ± 0.08 mm)

Cylinders

3-5-6

2-4-6

TC Compression Stroke (1)

(1)

2.

Position for No. 6 cylinder 360 ° from TC Compression Stroke

Adjust valve lash according to Table 2. a.

Lightly tap rocker arm (5) at top of adjustment screw (6). This will ensure lifter roller seats.

b.

Loosen adjustment locknut (7).

c.

Place appropriate feeler gage between rocker arm (5) and valve bridge (8).

d.

Turn adjustment screw (6) in clockwise direction. Slide feeler gage between rocker arm (5) and valve bridge (8). Continue turning adjustment screw until a slight drag is felt on feeler gage.

e.

Tighten adjustment locknut (7) to 22 ± 5 lb-ft (30 ± 7 Nm).

NOTE DO NOT allow adjustment screw to turn while you are tightening adjustment locknut.

f.

Recheck valve lash after tightening adjustment locknut (7).

3.

Remove timing pin with timing pin adapter from timing hole.

4.

Install plug (4) in timing hole.

5.

Install cover (2) and two bolts (1) on flywheel housing (3).

427-C0600

0179 00-5

TM 5-3805-291-23-2

INTAKE/EXHAUST VALVE LASH ADJUSTMENT - CONTINUED EXHAUST VALVE ADJUSTMENT - CONTINUED 6.

Install valve cover (WP 0024 00).

7.


8.


9.

Check for leaks.

END OF WORK PACKAGE

0179 00-6

0179 00

4 TM 5-3805-291-23-2

ROCKER ARMS AND PUSH RODS MAINTENANCE

0180 00

THIS WORK PACKAGE COVERS Removal, Disassembly, Cleaning and Inspection, Assembly, Installation INITIAL SETUP Maintenance Level

Personnel Required

Direct Support



References


TM 5-3805-291-10 WP 0179 00 WP 0187 00 Equipment Conditions

Bushing driver set (Item 19, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Materials/Parts

Valve cover removed (WP 0024 00) Drawings Required TM 5-3805-291-23P, Figure 10




NOTE The following procedures remove and install one valve mechanism. There are three valve mechanisms on engine.

REMOVAL 1.

Remove four bolts (1) from rocker arm shaft (2).

2.

Remove rocker arm shaft (2) and four pushrods (3) from cylinder head (4).

427-C0900

0180 00-1

TM 5-3805-291-23-2

ROCKER ARMS AND PUSH RODS MAINTENANCE - CONTINUED

0180 00

DISASSEMBLY

NOTE Place identification mark on all components for assembly purposes. Inner stands have offset holes.

1.

Remove two outer stands (6) from rocker arm shaft (2).

2.

Remove six rocker arms (7) and two inner stands (5) from rocker arm shaft (2).

NOTE Bearing bore diameter should not exceed 1.3405 ± 0.0006 in. (34.050 ± 0.015 mm).

3.

Check bearing bore diameter.

4.

If bearing bore diameter is out of specification, use bushing driver to remove six bearings (8) from rocker arms (7). 427-C0901


WARNING •


•


1.


2.


3.


4.


0180 00-2

TM 5-3805-291-23-2

ROCKER ARMS AND PUSH RODS MAINTENANCE - CONTINUED

0180 00

ASSEMBLY 1.

If removed, use bushing driver to install six bearings (8) in rocker arms (7).

NOTE Inner stands have offset holes.

2.

Install two inner stands (5) and six rocker arms (7) on rocker arm shaft (2).

3.

Install two outer stands (6) on rocker arm shaft (2).

INSTALLATION 1.

Place four pushrods (3) and rocker arm shaft (2) in position on cylinder head (4).

2.

Install four bolts (1) on rocker arm shaft (2).

3.

Tighten locknuts to 40 ± 7 lb-ft (55 ± 10 Nm).

4.

Adjust fuel injector lash (WP 0187 00).

5.

Adjust intake and exhaust valve lash (WP 0179 00).

427-C0900

6.

Install valve cover (WP 0024 00).

7.


8.


9.

Check for leaks.

END OF WORK PACKAGE

0180 00-3/(0180 00-4 Blank)

6 TM 5-3805-291-23-2

ENGINE OIL PAN MAINTENANCE

0181 00

THIS WORK PACKAGE COVERS Removal, Disassembly, Cleaning and Inspection, Assembly, Installation INITIAL SETUP Materials/Parts – Continued


Gasket O-ring (2)


Personnel Required


References

Materials/Parts




Engine oil drained (WP 0025 00)


Fuel tank removed (WP 0032 00)


Rear axle removed (WP 0208 00)


0181 00-1

TM 5-3805-291-23-2

ENGINE OIL PAN MAINTENANCE - CONTINUED

0181 00

REMOVAL 1.


2.

Remove valve (2) and O-ring (4) from oil pan (3). Discard O-ring.

3.

Remove nut (11), washer (12), and clip (6) from stud (13).

4.

Remove nut (14), washer (15), bracket (16), spacer (17), stud bolt (18), washer (19), and spacer (20) from oil pan (3).

5.

Remove 13 bolts (8), washers (9) and spacers (10) from oil pan (3) and then remove oil pan and gasket (7) from machine. Discard gasket.

0181 00-2

TM 5-3805-291-23-2


0181 00

DISASSEMBLY 1.


2.

Remove two bolts (21), washers (22), oil pickup tube (23), and O-ring (26) from machine. Discard O-ring.


WARNING •


•


1.

Remove all gasket material from mounting surfaces.

2.


3.


4.


ASSEMBLY


1.

Install oil pickup tube (23), new O-ring (26), two washers (22), and bolts (21) on machine.

2.

Install two washers (24) and bolts (25) on machine. 0181 00-3

TM 5-3805-291-23-2


0181 00

INSTALLATION 1.

Install new gasket (7) and oil pan (3) on machine.

2.

Install 13 spacers (10) washers (9) and bolts (8) on oil pan (3).

3.

Install clip (6) on stud (13) with nut (11) and washer (12).

4.

Install spacer (20), washer (19), stud bolt (18), spacer (17), bracket (16), washer (15), and nut (14) on oil pan (4).

5.

Install O-ring (4) on valve (2).

6.

Install valve (2) in oil pan (3).

7.


0181 00-4

TM 5-3805-291-23-2

ENGINE OIL PAN MAINTENANCE - CONTINUED INSTALLATION – CONTINUED 8.

Install rear axle (WP 0208 00).

9.

Install fuel tank (WP 0032 00).

10.

Fill engine with recommended engine oil (WP 0025 00).

11.


12.


13.

Check for leaks.

END OF WORK PACKAGE

0181 00-5/(0181 00-6 Blank)

0181 00

6 TM 5-3805-291-23-2

ENGINE OIL PUMP REPLACEMENT

0182 00



Direct Support Tools and Special Tools



O-ring (7) Personnel Required MOS 62B, Construction Equipment Repairer References TM 5-3805-291-10

Materials/Parts


Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)

0182 00-1

Oil pan removed (WP 0181 00) Drawings Required TM 5-3805-291-23P, Figure 19 Estimated Time to Complete Task 19.0 hr

TM 5-3805-291-23-2

ENGINE OIL PUMP REPLACEMENT - CONTINUED

0182 00

REMOVAL

WARNING •


•


•


•


1.

Remove four bolts (1) and washers (2) from tube assembly flange halves (3).

2.

Remove two tube assemblies (3) and O-rings (4) from elbow (5). Discard O-rings.

427-C1027

0182 00-2

TM 5-3805-291-23-2


0182 00


Remove four bolts (6) and washers (7) from elbow (5).

4.

Remove elbow (5) from two couplings (8).

5.

Remove two couplings (8) and four O-rings (9) from oil pump (10). Discard O-rings.

6.

Remove two bolts (11) and washers (12) from oil pump (10).

7.

Remove oil pump (10) from engine.

8.

Remove O-ring (13) from oil pump (10). Discard O-ring.

427-C1028

0182 00-3

TM 5-3805-291-23-2


0182 00


WARNING •


•


1.


2.


3.


4.


5.

Inspect distance between face of gear (15) and housing (16). Distance should be 1.158 ± 0.020 in. (29.41 ± 0.50 mm).

6.

If distance is not within specification, replace oil pump.

427-C1039

0182 00-4

TM 5-3805-291-23-2


0182 00

INSTALLATION


1.

Install new O-ring (13) on oil pump (10).

2.

Place oil pump (10) on engine.

3.

Install two washers (12) and bolts (11) on oil pump (10).

4.

Install four new O-rings (9) on two couplings (8).

5.

Install two couplings (8) on oil pump (10).

6.

Install elbow (5) on two couplings (8).

7.

Install four washers (7) and bolts (6) on elbow (5).

427-C1028

0182 00-5

TM 5-3805-291-23-2


0182 00


Install two new O-rings (4) on tube assemblies (3).

9.

Install two tube assemblies (3) on elbow (5).

10.

Install four washers (2) and bolts (1) on tube assembly flange halves (3).

427-C1027

11.

Install engine oil pan (WP 0181 00).

12.


13.


14.

Check for leaks.

END OF WORK PACKAGE

0182 00-6

2 TM 5-3805-291-23-2

PISTON COOLING JETS REPLACEMENT

0183 00


Personnel Required

Direct Support



References

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)

TM 5-3805-291-10 Equipment Conditions Oil pan removed (WP 0181 00) Drawings Required TM 5-3805-291-23P, Figure 14 Estimated Time to Complete Task


16.5 hr

REMOVAL

CAUTION Special care must be taken not to bend piston cooling jets. Piston cooling jets are precision aligned with coolant passage in pistons. Bent condition could result in engine damage.

NOTE There is only one position for each cooling jet. Notch in bottom of piston allows clearance for piston cooling jet when piston is at bottom dead center.

1.

Remove six bolts (1) and washers (2) from piston cooling jets (3).

2.

Remove six piston cooling jets (3) from piston caps (4).

427-C1026

0183 00-1

TM 5-3805-291-23-2

PISTON COOLING JETS REPLACEMENT - CONTINUED

0183 00

INSTALLATION

CAUTION Special care must be taken not to bend piston cooling jets. Piston cooling jets are precision aligned with coolant passage in pistons. Bent condition could result in engine damage.

NOTE There is only one position for each cooling jet. Notch in bottom of piston allows clearance for piston cooling jet when piston is at bottom dead center.

1.

Place six piston cooling jets (3) in position on piston caps (4).

2.

Install six washers (2) and bolts (1) on piston cooling jets (3).

NOTE Ensure piston cooling jet is properly seated in cylinder block before applying torque.

3.

Tighten bolts (1) to 26 ± 2 lb-ft (35 ± 3 Nm).

427-C1026

4.

Install engine oil pan (WP 0181 00).

5.


6.


7.

Check for leaks.

END OF WORK PACKAGE

0183 00-2

2 TM 5-3805-291-23-2

EXHAUST MANIFOLD REPLACEMENT

0184 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Materials/Parts

References TM 5-3805-291-10 Equipment Conditions Turbocharger removed (WP 0031 00) Drawings Required TM 5-3805-291-23P, Figure 21

Antiseize compound (Item 2, WP 0233 00) Estimated Time to Complete Task

Rag, wiping (Item 35, WP 0233 00) Gasket (6)

4.0 hr

0184 00-1

TM 5-3805-291-23-2

EXHAUST MANIFOLD REPLACEMENT - CONTINUED

0184 00

REMOVAL 1.

Remove 12 nuts (1), washers (2), and spacers (3) from studs (4).

2.

Remove manifold (5) and six gaskets (6) from studs (4). Discard gaskets.

3.

If necessary, remove 12 studs (4) from manifold (5).

427-C1029

INSTALLATION 1.

If removed, apply antiseize compound to stud threads and install 12 studs (4) on machine.

2.

Tighten studs (4) to 26 ± 4 lb-ft (35 ± 5 Nm).

3.

Position six new gaskets (6) and manifold (5) on studs (4).

4.

Apply antiseize compound to 12 nuts (1).

NOTE The exhaust manifold gaskets have tabs. Tabs should point to oil pan.

5.

Install 12 spacers (3), washers (2), and nuts (1) on studs (4).

6.

Tighten nuts (1) to 41 ± 7 lb-ft (55 ± 10 Nm).

7.

Install turbocharger (WP 0031 00).

8.


9.


10.

Check for leaks.


6 TM 5-3805-291-23-2

INTAKE MANIFOLD REPLACEMENT

0185 00



Gasket O-ring (3)

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Personnel Required MOS 62B, Construction Equipment Repairer References TM 5-3805-291-10 Equipment Conditions Air intake assembly hoses removed (WP 0034 00) Ether atomizer removed, if necessary (WP 0037 00) Drawings Required TM 5-3805-291-23P, Figure 21 Estimated Time to Complete Task 3.0 hr

0185 00-1

TM 5-3805-291-23-2

INTAKE MANIFOLD REPLACEMENT - CONTINUED

0185 00

REMOVAL

WARNING •


•


•


•


1.

Remove bolt (1) and washer (2) from bracket (3).

2.

Position two hoses (4) with clamps (5) aside.

3.

Remove nut (6), washer (7), and bracket (8) from stud (9).

4.

Disconnect two wiring harnesses (10) from sensors (11).

427-C1030

0185 00-2

TM 5-3805-291-23-2


0185 00


Remove O-ring (12) from manifold (13). Discard O-ring.

6.

Remove two studs (14) and washers (15) from manifold (13).

7.

Remove bolt (16), washer (17), and bracket (18) from manifold (13).

8.

Remove nine bolts (19) and washers (20) from manifold (13).

9.

Remove manifold (13) and gasket (21) from engine. Discard gasket.

10.

Remove two plugs (22) and O-rings (23) from manifold (13). Discard O-rings.

427-C1031


WARNING •


•


1.


2.


3.


4.

Inspect oil passages in air intake manifold to ensure they are clean and unobstructed. 0185 00-3

TM 5-3805-291-23-2


0185 00

INSTALLATION

NOTE Apply a thin coat of clean oil to all O-rings prior to installation. 1.

Install two new O-rings (23) and plugs (22) on manifold (13).

2.

Place new gasket (21) and manifold (13) on engine.

3.

Install nine washers (20) and nine bolts (19) on manifold (13).

4.

Place bracket (18) in position on manifold (13).

5.

Install washer (17) and bolt (16) on manifold (13).

6.

Install two washers (15) and studs (14) on manifold (13).

7.

Install new O-ring (12) on manifold (13).

427-C1031

0185 00-4

TM 5-3805-291-23-2


0185 00


Connect two wiring harnesses (10) to sensors (11).

9.

Place bracket (8) in position on stud (9).

10.

Install washer (7) and nut (6) on stud (9).

11.

Install bracket (3), two clamps (5), and hoses (4) on machine.

12.

Install washer (2) and bolt (1) on stud (4).

427-C1030

13.

Install air intake assembly hoses (WP 0034 00).

14.

Install ether atomizer, if removed (WP 0037 00).

15.


16.


17.

Check for leaks.

END OF WORK PACKAGE

0185 00-5/(0185 00-6 Blank)

4 TM 5-3805-291-23-2

IDLER GEARS REPLACEMENT

0186 00




Direct Support

References


TM 5-3805-291-10 WP 0013 00 Equipment Conditions Front cover removed (WP 0178 00) Drawings Required



REMOVAL 1.

Align timing marks (1) on idler gear (2), crankshaft gear (3), and camshaft gear (4).

427-C0566

0186 00-1

TM 5-3805-291-23-2

IDLER GEARS REPLACEMENT - CONTINUED

0186 00


Remove bolt (5), bearing and shaft assembly (6), and gear (7) from engine (8).

3.

Remove bolt (9), bearing and shaft assembly (10), and idler gear (2) from engine (8).

4.

Remove bolt (11), bearing (12), and gear (13) from engine (8).

427-C0567


WARNING •


•


1.


2.


3.


4.


0186 00-2

TM 5-3805-291-23-2

IDLER GEARS REPLACEMENT - CONTINUED

0186 00

INSTALLATION

CAUTION •

Make sure the timing marks on the gears are in alignment. If timing gear is installed backward, engine will not start.

•

Check for proper alignment of camshaft gear and timing reference ring on camshaft assembly. Inspect key between timing reference ring and camshaft gear. Check teeth on timing ring. Teeth should not be defaced. Teeth should have sharp clean edges and teeth should be free of contaminants. Failure to follow this caution may result in engine damage.

NOTE Electronic injection timing must be calibrated after reassembly of the front gear train. Refer to Troubleshooting, Engine Speed/Timing Sensor - Calibration (WP 0013 00).

1.

Install gear (13), bearing (12), and bolt (11) on engine (8).

2.

Install idler gear (2), bearing and shaft assembly (10), and bolt (9) in engine (8).

3.

Install gear (7), bearing and shaft assembly (6), and bolt (5) in engine (8).

4.

Ensure timing marks (1) on camshaft gear (4), crankshaft gear (3), and idler gear (2) are aligned.

427-C0566

5.

Install front cover (WP 0178 00).

6.


7.


8.

Check for leaks.


6 TM 5-3805-291-23-2

FUEL INJECTORS AND WIRING HARNESS MAINTENANCE

0187 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Installation, Testing, Adjustment, Injector Trim File, Exchanging Injectors INITIAL SETUP Materials/Parts - Continued



Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Adapter, test (Item 3, WP 0232 00)

Strap, tiedown, electrical components (Item 42, WP 0233 00) O-ring (3) Personnel Required MOS 62B, Construction Equipment Repairer References

Software kit (Item 75, WP 0232 00) Test set, electronic systems (MSD) (Item 86, WP 0232 00) Wrench, torque, dial, 1/4” drive, 30 lb-in. (Item 96, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00) Diesel fuel, DF-1 (Item 10, WP 0233 00)

TM 5-3805-291-10 WP 0010 00 WP 0011 00 WP 0179 00 Equipment Conditions Rocker arms removed (WP 0180 00) Drawings Required TM 5-3805-291-23P, Figures 24 and 78

Fuel oil, diesel, DF-2 (Item 11, WP 0233 00)



3.0 hr


0187 00-1

TM 5-3805-291-23-2

FUEL INJECTORS AND WIRING HARNESS MAINTENANCE - CONTINUED

0187 00

REMOVAL 1.

Disconnect wiring harness (1) from electronic fuel injector (2).

2.

Disconnect wiring harness (1) from connector (3).

NOTE •

Harness removal is not required when injectors are replaced.

•

Trace routing of wiring harness and remove/install mounting hardware and tiedown straps.

3.

Remove all associated clips and tiedown straps and remove wiring harness (1) from machine. Discard tiedown straps, if removed.

4.

Remove bolt (4) from fuel injector clamp (5).

5.

Position pry bar under fuel injector clamp (5) and remove electronic fuel injector (2) from machine.

6.

Remove and discard three O-rings (8) from electronic fuel injector (2).

427-C0440


WARNING •


•


1.


2.


3.


4.


TM 5-3805-291-23-2


0187 00

INSTALLATION 1.

Evacuate as much fuel and oil as possible from cylinder head before installing injector. Several evacuations may be necessary.

2.

Use brush to clean injector seating (6) and tip bore (7).


3.

Install three new O-rings (8) on electronic fuel injector (2).

427-C0441

4.

Lubricate bore lightly with 50/50 mix of clean engine oil and Grease, multipurpose (Item 18, WP 0233 00).

NOTE

5.

•

Injector confirmation code may not need to be programmed into engine Electronic Control Module (ECM) when injectors are exchanged for testing purposes only.

•

When an electronic fuel injector is replaced, the new electronic injector code must be programmed into the engine’s personality module software by using the calibration menu on the Electronic Service Tool. If the new electronic injector code is not entered, the characteristics of the previous electronic fuel injector are assumed.

•

If it is not possible to immediately reprogram the electronic injector code into the personality module software, the engine will not be severely harmed. The new electronic injector code should be reprogrammed as quickly as possible in order to optimize engine performance.

Program E-Trim value of each new injector into engine control module. E-Trim value is a 12-digit alphanumeric code that is supplied with data sheet that comes with new injectors. Injector Confirmation Code is a 4-digit numeric code. Both codes are located on top of electronic fuel injector (2). Use this menu to program E-Trim value: •

ECM Summary Screen

•

Service Menu

•

Calibration

•

Injector Code Calibration

427-C0442

0187 00-3

TM 5-3805-291-23-2


0187 00


Install electronic fuel injector (2) and fuel injector clamp (5).

7.

Install bolt (4) in fuel injector clamp (5) and tighten to 41 ± 7 lb-ft (55 ± 10 Nm).

NOTE Trace routing of wiring harness and remove/install mounting hardware and tiedown straps. 8.

Connect wiring harness (1) to connector (3).

9.

Connect wiring harness (1) to electronic fuel injector (2) and tighten wiring harness to 22 ± 2 lb-in. (2.50 ± 0.25 Nm).

427-C0440

10.

Install rocker arms (WP 0180 00).

CAUTION DO NOT run engine until rocker arm assemblies are installed and adjusted properly, including rocker arm adjustments for injectors. Doing so will cause engine damage.

11.


TESTING 1.

Check for air in fuel, if this procedure has not already been performed (WP 0011 00).

WARNING

The electronic unit injector system uses 90 to 120V. To prevent injury to personnel, make sure electronic unit injector system is not powered and unit injector solenoids are disconnected.

2.

Remove valve cover and look for broken parts. Repair or replace any broken parts. Inspect all wiring to solenoids. Look for loose connections. Also look for frayed wires or broken wires. Ensure connector for fuel injector solenoid is properly connected. Perform a pull test on wires. Inspect posts of the solenoid for arcing. If arcing or evidence of arcing is found, remove the cap assembly. Clean the connecting posts, reinstall cap assembly, and tighten solenoid nuts to 22 + 2 lb-in. (2.50 + 0.25 Nm).

3.

Check the valve lash setting for the cylinder of the suspect fuel injector (WP 0179 00).

4.

Ensure bolt that holds the fuel injector is tightened to correct torque. If necessary, loosen bolt that holds fuel injector and tighten bolt to 41 + 7 lb-ft (55 + 10 Nm).

5.

Remove suspect fuel injector and check for signs of exposure to coolant. Exposure to coolant will cause rust to form on injector. If fuel injector shows signs of exposure to coolant, remove injector sleeve and inspect. Replace injector sleeve if injector sleeve is damaged. Check fuel injector for an excessive brown discoloration that extends beyond injector tip. If excessive discoloration is found, check quality of the fuel. Replace seals on injector and reinstall the injector.

6.

If problem is not resolved, replace suspect injector with new injector. 0187 00-4

TM 5-3805-291-23-2


0187 00

ADJUSTMENT

WARNING ECM emits high voltage. To prevent injury to personnel, make sure ECM is not powered and unit injector solenoids are disconnected.

CAUTION Operation of engine with improper adjustment of electronic fuel injector can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life.

NOTE Adjust electronic fuel injector at same interval as valve lash adjustment (WP 0179 00).

1.

Put No. 1 piston at top center position on compression stroke (WP 0010 00).

2.

Cylinders 3, 5, and 6 can be adjusted with cylinder 1 at TC compression stroke.

3.

Loosen jamnut (9).

4.

Turn adjustment screw (10) until screw makes contact with electronic fuel injector (2).

5.

Turn adjustment screw (10) through 180 degrees in clockwise direction.

6.

Tighten jamnut (9) to 41 + 7 lb-ft (55 + 10 Nm).

7.

Rotate engine in normal operating direction by 360 degrees. Cylinder 1 will now be at TC exhaust stroke.

8.

Cylinders 1, 2, and 4 can be adjusted with cylinder 1 at TC exhaust stroke.

9.

Loosen jamnut (9).

10.

Turn adjustment screw (10) until screw makes contact with electronic fuel injector (2).

11.

Turn adjustment screw (10) through 180 degrees in clockwise direction.

12.

Tighten jamnut (9) to 41 + 7 lb-ft (55 + 10 Nm).

INJECTOR TRIM FILE 1.

Electronic Technician (ET) is used to load injector trim files into ECM.

2.

Injector trim files must be loaded into ECM if any of these conditions occur: a.

An injector is replaced.

b.

ECM is replaced.

c.

“Injector Trim” is displayed below 268-02 diagnostic code on ET.

d.

Injectors are exchanged between cylinders. 0187 00-5

427-C0444

TM 5-3805-291-23-2


0187 00

EXCHANGING INJECTORS Exchanging injectors can help determine if combustion problem is in injector or in cylinder. If two injectors that are currently installed in engine are exchanged between cylinders, injector trim files can also be exchanged. Press “Exchange” button at bottom of “Injector Trim Calibration” screen on ET. Select two injectors to be exchanged and press “OK” button. Tattletale for injectors that were exchanged will increase by one.

NOTE Injector serial number and injector confirmation code are located on injector. ET may require entry of injector confirmation code during this process. ET will prompt you for code, if necessary.

1.

Record injector serial number and injector confirmation code for each injector (2).

2.

Connect ET to diagnostic tool connector.

3.

Select these menu options on ET: a.

Service

b.

Calibrations

c.

Injector Trim Calibration

4.

Select appropriate cylinder.

5.

Click “Change” button.

6.

Select appropriate injector trim file from PC (on CD).

7.

Click “Open” button.

8.

If you are prompted by ET, enter injector confirmation code into field.

9.

Click “OK” button. Injector trim file is loaded into ECM.

10.

Repeat steps 1 thru 9 for each cylinder, as required.

END OF WORK PACKAGE

0187 00-6

427-C0442

4 TM 5-3805-291-23-2

FUEL TRANSFER PUMP REPLACEMENT

0188 00


Materials/Parts - Continued Tag, marker (Item 43, WP 0233 00)

Direct Support

O-ring (5)


Personnel Required MOS 62B, Construction Equipment Repairer References TM 5-3805-291-10 Equipment Conditions

Materials/Parts

Side cover removed (WP 0135 00)

Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Fuel, turbine, aviation (Item 12, WP 0233 00)



2.0 hr

WARNING •


•



NOTE •


•


0188 00-1

TM 5-3805-291-23-2

FUEL TRANSFER PUMP REPLACEMENT - CONTINUED

0188 00

REMOVAL 1.

Disconnect two tube assemblies (1) from fittings (2).

2.


3.

Remove two fittings (2) from fuel transfer pump (4).

4.


5.

Remove two bolts (6) and washers (7) from fuel transfer pump (4).

6.

Remove fuel transfer pump (4) and O-ring (8) from machine. Discard O-ring.

427-C0443


WARNING •


•


1.


2.


3.


0188 00-2

TM 5-3805-291-23-2

FUEL TRANSFER PUMP REPLACEMENT - CONTINUED INSTALLATION

NOTE Apply a thin coat of clean fuel to all O-rings before installation.

1.

Install new O-ring (8) and position fuel transfer pump (4) on machine.

2.

Install two washers (7) and bolts (6) on fuel transfer pump (4).

3.

Install two new O-rings (5) and fittings (2) on fuel transfer pump (4).

4.

Install two new O-rings (3) and connect tube assemblies (1) to fittings (2).

5.


6.


7.

Check for leaks.

8.


END OF WORK PACKAGE

0188 00-3/(0188 00-4 Blank)

0188 00

10 TM 5-3805-291-23-2

AFTERCOOLER REPLACEMENT

0189 00



Maintenance Level


Direct Support



Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions Engine compartment shield removed (WP 0212 00) Cooling system package removed (WP 0190 00)




Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figures 31 and 42

Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00)



REMOVAL 1.

Remove two bolts (1) and washers (2) from brace (3).

2.

Remove brace (3) from cooling assembly (4).

3.

Repeat steps 1 and 2 for opposite side.

427-C0156

0189 00-1

TM 5-3805-291-23-2

AFTERCOOLER REPLACEMENT - CONTINUED

0189 00


Remove nut (5), washer (6), and bolt (7) from two clamps (8).

5.

Position hose (9) aside.

427-C0157

6.

Remove clamp (10) from hose (11). Disconnect hose from coolant tank (12).

7.

Remove two bolts (13) and washers (14) from cooling assembly (4).

8.

Remove two bolts (15) and washers (16) from cooling assembly (4).

9.

Remove coolant tank (12) from cooling assembly (4).

427-C0159

0189 00-2

TM 5-3805-291-23-2


0189 00


Remove clamp (17) from upper hose (18).

11.

Disconnect upper hose (18) from aftercooler (19).

427-C0160


NOTE Fan assembly weighs 225 lb (102 kg).

12.

With assistance, attach link brackets and lifting equipment to fan assembly (20).

427-C0161

0189 00-3

TM 5-3805-291-23-2


0189 00


Remove four bolts (21) and washers (22) from fan assembly (20). Repeat for opposite side.

14.

Remove fan assembly (20) from cooling assembly (4).

427-C0162

15.

Remove clamp (23) from lower hose (24). Disconnect hose from aftercooler (19).

16.

Remove four bolts (25) and washers (26) from cooling assembly (4).

17.

Remove brace (27) from cooling assembly (4).

427-C0163

18.

Remove two bolts (28), washers (29), and four rubber mounts (30) from bottom of aftercooler (19).

427-C0164

0189 00-4

TM 5-3805-291-23-2


0189 00

REMOVAL - CONTINUED

WARNING


NOTE Aftercooler weighs 27 lb (12 kg).

19.

With assistance, attach lifting equipment to aftercooler (19).

427-C0165

20.

Remove two bolts (31) and washers (32) from aftercooler (19).

21.

Remove two bolts (33) and washers (34) from bracket (35). Remove bracket from cooling assembly (4).

22.

Remove aftercooler (19) from cooling assembly (4).

427-C0166

0189 00-5

TM 5-3805-291-23-2


0189 00


WARNING •


•


1.


2.


3.


INSTALLATION


NOTE Aftercooler weighs 27 lb (12 kg).

1.

With assistance, attach lifting equipment to aftercooler (19).

2.

Position aftercooler (19) on cooling assembly (4).

427-C0167

0189 00-6

TM 5-3805-291-23-2


0189 00


Install bracket (35) on cooling assembly (4). Install two washers (34) and bolts (33) on bracket.

4.

Install two washers (32) and bolts (31) on aftercooler (19).

427-C0166

5.

Install four rubber mounts (30), two washers (29), and bolts (28) on bottom of aftercooler (19).

427-C0164

6.

Install brace (27) on cooling assembly (4).

7.

Install four washers (26) and bolts (25) on cooling assembly (4).

8.

Connect lower hose (24) to aftercooler (19). Install clamp (23) on lower hose.

427-C0163

0189 00-7

TM 5-3805-291-23-2


0189 00


WARNING


NOTE Fan assembly weighs 225 lb (102 kg).

9.

With assistance, attach link brackets and lifting equipment to fan assembly (20).

427-C0161

10.

Position fan assembly (20) on cooling assembly (4) and install four washers (22) and bolts (21) on fan assembly. Repeat for opposite side.

427-C0162

0189 00-8

TM 5-3805-291-23-2


0189 00


Connect upper hose (18) to aftercooler (19) and install clamp (17) on upper hose.

427-C0160

12.

Position coolant tank (12) on cooling assembly (4).

13.

Install two washers (16) and bolts (15) on cooling assembly (4).

427-C0159

14.

Install two washers (14) and bolts (13) on cooling assembly (4).

15.

Connect hose (11) to coolant tank (12) and install two clamps (10) on hose.

0189 00-9

TM 5-3805-291-23-2


0189 00


Position hose (9) in clamp (8) and install nut (5), washer (6), and bolt (7) on clamps.

427-C0157

17.

Install brace (3) on cooling assembly (4) and secure with two washers (2) and bolts (1). Repeat for opposite side.

427-C0156

18.


19.

Install engine compartment shield (WP 0212 00).


20.

Secure steering frame lock in the stowed position (TM 5-3805-291-10).

21.

Check coolant level (TM 5-3805-291-10).

22.


23.

Check for leaks.


14 TM 5-3805-291-23-2

COOLING SYSTEM PACKAGE (RADIATOR, FAN, AFTERCOOLER, AND OIL COOLER) REPLACEMENT

0190 00


Maintenance Level




Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Bracket, link (Item 17, WP 0232 00) (2)

O-ring (2) Seal Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions


Oil check tube removed (WP 0029 00)

Materials/Parts

Engine coolant drained (WP 0041 00)


Hydraulic fluid drained (WP 0148 00)

Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00)

Radiator access door opened (TM 5-3805-291-10) Steering frame lock connected (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figures 17, 28, 31, 40, 42, and 45 Estimated Time to Complete Task


8.0 hr

WARNING •

DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant may result in serious burns.

•

DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Loosen cap to first stop and let any pressure out of cooling system, then remove cap. Failure to follow this warning may result in serious burns to personnel.

•

Wear effective eye, hand, and skin protection when handling coolants. Failure to do so may result in injury to personnel.

•

Engine coolant used in the performance of maintenance can be very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

0190 00-1

TM 5-3805-291-23-2

COOLING SYSTEM PACKAGE (RADIATOR, FAN, AFTERCOOLER, AND OIL COOLER) REPLACEMENT - CONTINUED

0190 00


NOTE • •

Tag hoses, lines, and wires prior to removal to ensure correct installation. Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy and ordinances. Ensure all spills are cleaned up.

REMOVAL 1.

Disconnect hose assembly (1) from elbow (2).

427-C0217

0190 00-2

TM 5-3805-291-23-2


0190 00


Remove bolt (3), washer (4), and clamp (5) from cooling package (6) and position hose aside.

427-C0218

3.

Remove two bolts (7) and washers (8) from both sides of AC condenser (9). Position AC condenser aside.

427-C0219

4.

Close rear door and open engine hood (TM 5-3805-291-10).

5.


427-C0220

0190 00-3

TM 5-3805-291-23-2


0190 00


Loosen clamp (11) and disconnect tube (12) from hose (13).

427-C0221

7.

Remove two bolts (14), washers (15), oil fill tube (16), and seal (17) from engine. Set dipstick tube (18) aside. Discard seal.

8.

Disconnect hydraulic hose assembly (19) from fitting (20).

9.

Remove O-ring (21) from fitting (20) on hydraulic hose assembly (19). Discard O-ring.

10.

Remove bolt, (22), washer (23), clamp (24), spacer (25), clamp (26), two washers (27), and nut (28) from machine.

427-C0223

0190 00-4

TM 5-3805-291-23-2


0190 00


Loosen clamp (29) and disconnect hose (30) from aftercooler (31).

427-C0224

12.

Remove bolt (32), washer (33), nut (34), and two clamps (35) from two hoses (36).

13.

Loosen top clamp (37) and disconnect tube (38) from coolant hose (39) (left side of machine).

427-C0226

0190 00-5

TM 5-3805-291-23-2


0190 00


Disconnect hydraulic hose assembly (40) from fitting (41) and position hydraulic hose assembly aside.

15.


16.

Loosen clamp (43) and disconnect hose (44) from water pump (45).

17.

Loosen clamp (46) and disconnect hose (47) from fitting (48).

NOTE Preform step 18 only if equipped with arctic heater. 18.

Loosen clamp (49) and disconnect hose assembly (50) from fitting (51). Set hose assembly aside.

427-C0230

19.

Loosen two clamps (52) and disconnect tube (53) from rubber sleeve (54).

20.

Remove fuel cap (TM 5-3805-291-10).

427-C0261

0190 00-6

TM 5-3805-291-23-2


0190 00

REMOVAL - CONTINUED


NOTE Cooling system package weighs 900 lb (408 kg).

21.

Install two link brackets and attach lifting equipment to cooling package (6).

427-C0262

22.

With assistance, remove four bolts (55) and washers (56) from each side of cooling package (6).

23.

Remove cooling package (6) from machine.

427-C0263

0190 00-7

TM 5-3805-291-23-2


0190 00

INSTALLATION


NOTE Cooling system package weighs 900 lb (408 kg).

1.

Install two link brackets and attach lifting equipment to cooling package (6). Position cooling package on machine.

2.

Install four washers (56) and bolts (55) on each side of cooling package (6).

427-C0263

3.

Install fuel cap (TM 5-3805-291-10).

4.

Connect tube (53) to rubber sleeve (54) and tighten two clamps (52).

427-C0261

0190 00-8

TM 5-3805-291-23-2


0190 00


NOTE Perform step 5 only if equipped with arctic heater. 5.

Connect hose assembly (50) to fitting (51) and tighten clamp (49).

6.


7.

Connect hose (44) to water pump (45) and tighten clamp (43).

NOTE Apply a thin coat of clean oil to all Orings and seals before installation. 8.

Install new O-ring (42) in hydraulic hose assembly (40) and connect hydraulic hose assembly to fitting (41).

427-C0230

9.

Connect tube (38) to coolant hose (39) and tighten clamp (37).

10.

Install two clamps (35), nut (34), washer (33), and bolt (32) on two hoses (36).

427-C0226

0190 00-9

TM 5-3805-291-23-2


0190 00


Connect hoses (30) to aftercooler (31) and tighten clamp (29).

427-C0224

12.

Install nut (28), two washers (27), clamp (26), spacer (25), clamp (24), washer (23), and bolt (22) on machine.

13.

Install new O-ring (21) in hose assembly (19) and connect hose assembly to fitting (20).

14.

Install new seal (17), oil fill tube (16), two washers (15), and bolts (14) on engine.

427-C0223

0190 00-10

TM 5-3805-291-23-2


0190 00


Connect tube (12) to hose (13) and tighten clamp (11).

427-C0221

16.

Install panel (10) on machine.

427-C0220

17.

Close engine hood and open rear door (TM 5-3805291-10).

18.

Position AC condenser (9) and install two washers (8) and bolts (7) on each side of AC condenser.

427-C0219

0190 00-11

TM 5-3805-291-23-2


0190 00


Install clamp (5), washer (4), and bolt (3) on cooling package (6).

427-C0218

20.

Connect hose assembly (1) to elbow (2).

427-C0217

21.

Close radiator access door (TM 5-3805-291-10).

22.

Fill engine coolant to correct level (WP 0041 00).

23.

Fill hydraulic fluid to correct level (WP 0148 00).

24.

Install oil check tube (WP 0029 00).

0190 00-12

TM 5-3805-291-23-2


0190 00



25.


26.


27.


28.

Check for leaks.

END OF WORK PACKAGE

0190 00-13/(0190 00-14 Blank)

10 TM 5-3805-291-23-2

RADIATOR REPLACEMENT

0191 00




Direct Support



Personnel Required

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Bracket, link (Item 16, WP 0232 00)

MOS 62B, Construction Equipment Repairer References TM 5-3805-291-10 Equipment Conditions Cooling system drained (WP 0041 00)


Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figure 40

Antifreeze (Item 1, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00)


REMOVAL 1.

Loosen clamp (1) and disconnect hose (2) from aftercooler (3).

427-C1929

0191 00-1

TM 5-3805-291-23-2

RADIATOR REPLACEMENT - CONTINUED

0191 00


Remove bolt (4) and washer (5) from clamp (6) and position hose (7) aside.

427-C1930

3.

Remove three bolts (8), washers (9), clip (10), and baffle plate (11) from cooling package (12).

427-C1931

0191 00-2

TM 5-3805-291-23-2


0191 00


Loosen clamp (13) and remove hose (14) from radiator (15).

427-C1932

5.

Remove four bolts (16) and washers (17) from radiator top support (18). Repeat for opposite side.

6.

Remove two bolts (19) and washers (20) from surge tank (21).

7.

Remove three bolts (22), washers (23), and bracket (24) from radiator top support (18).

8.

Remove four bolts (25), washers (26), and bracket (27) from radiator top support (18).

9.

Remove radiator top support (18) from cooling package (12).

427-C0264

0191 00-3

TM 5-3805-291-23-2


0191 00


Remove two bolts (28), washers (29), and left plate (30) from cooling package (12).

11.

Remove four bolts (31), washers (32), and right plate (33) from cooling package (12).

12.

Remove two bolts (34) and washers (35) from radiator bottom support (36).

427-C1933

13.

Loosen two clamps (37) and position hoses (38) aside.

427-C1934

0191 00-4

TM 5-3805-291-23-2


0191 00

REMOVAL - CONTINUED

WARNING


NOTE Radiator weighs 56 lb (25 kg).

14.

Attach link brackets and lifting equipment to radiator (15).

15.

With assistance, remove radiator (15) from cooling package (12).


WARNING •


•


1.


2.


3.


4.


0191 00-5

TM 5-3805-291-23-2


0191 00

INSTALLATION

WARNING


NOTE Radiator weighs 56 lb (25 kg).

1.

With assistance, install link brackets and lifting equipment on radiator (15).

2.

Install radiator (15) in cooling package (12).

3.

Connect two hoses (38) to radiator (15) and tighten clamps (37).

427-C1934

0191 00-6

TM 5-3805-291-23-2


0191 00


Install two washers (35) and bolts (34) on radiator bottom support (36).

5.

Install right plate (33), four washers (32), and bolts (31) on cooling package (12).

6.

Install left plate (30), two washers (29), and bolts (28) on cooling package (12).

427-C1933

7.

Position radiator top support (18) on cooling package (12). Install four washers (17) and bolts (16) on cooling package. Repeat for opposite side.

8.

Close hood and open hood side and radiator screen access doors (TM 5-3805-291-10).

9.

Install bracket (27), four washers (26), and bolts (25) on radiator top support (18).

10.

Install bracket (24), three washers (23), and bolts (22) on radiator top support (18).

11.

Install two washers (20) and bolts (19) on surge tank (21).

427-C0264

0191 00-7

TM 5-3805-291-23-2


0191 00


Install hose (14) on radiator (15) and tighten clamp (13).

427-C1932

13.

Install baffle plate (11), clip (10), three washers (9), and bolts (8) on cooling package (12).

427-C1931

0191 00-8

TM 5-3805-291-23-2


0191 00


Position hose (7) and install washer (5) and bolt (4) on clamp (6).

427-C1930

15.

Connect hose (2) to aftercooler (3) and tighten clamp (1).

427-C1929

16.

Fill cooling system slowly (WP 0041 00).

17.


18.


19.

Check for leaks.

END OF WORK PACKAGE

0191 00-9/(0191 00-10 Blank)

12 TM 5-3805-291-23-2

FAN HYDRAULIC MOTOR AND FAN GROUP REPLACEMENT

0192 00






Rag, wiping (Item 35, WP 0233 00) O-ring (3)


Personnel Required


References

Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00) Lifting equipment, 400-lb capacity


TM 5-3805-291-10 Equipment Conditions Radiator top tank removed (WP 0042 00)

Puller set, mechanical



Engine coolant drained (WP 0041 00) Drawings Required


TM 5-3805-291-23P, Figure 45



REMOVAL 1.

Loosen two clamps (1) and remove hose (2) and tube (3) from cooling package (4).

427-C0267

0192 00-1

TM 5-3805-291-23-2

FAN HYDRAULIC MOTOR AND FAN GROUP REPLACEMENT - CONTINUED

0192 00


Remove bolt (5) and washer (6) from each side of cooling package (4) and remove shield and brace assembly (7) from cooling package.

427-C0269

3.

Disconnect hydraulic hose (8) from fitting (9). Remove and discard O-ring (10).

427-C1946

0192 00-2

TM 5-3805-291-23-2


0192 00


Disconnect two hydraulic hoses (11) from fittings (12). Remove and discard two O-rings (13).

427-C1947

5.

Attach two link brackets and lifting equipment to fan group (14).

427-C0270

0192 00-3

TM 5-3805-291-23-2


0192 00

REMOVAL - CONTINUED


NOTE Fan group weighs 255 lb (116 kg). 6.

With assistance, remove four bolts (15) and washers (16) from both sides of fan group (14).

427-C0370

NOTE Position fan group on cribbing. 7.

Remove four bolts (17) and washers (18) from shield (19).

427-C0371

0192 00-4

TM 5-3805-291-23-2


0192 00


Remove eight bolts (20), washers (21), and shield (19) from guard (22).

427-C0372

9.

Remove eight bolts (23), washers (24), and fan (25) from guard (22).

427-C0373

10.

Remove nut (26) and washer (27) from fan motor shaft (28).

427-C0375

0192 00-5

TM 5-3805-291-23-2


0192 00


Using puller adapter, remove hub (29) from motor housing (30).

427-C0376

12.

Remove two bolts (31), washers (32), and fan motor (33) from guard (22).

427-C0377

0192 00-6

TM 5-3805-291-23-2


0192 00


WARNING •


•


1.


2.


3.


INSTALLATION


1.

Position fan motor (33) on guard (22) and install two washers (32) and bolts (31).

2.

Position hub (29) on motor housing (30) and install washer (27) and nut (26) on fan motor shaft (28). Tighten nut to 148 ± 22 lb-ft (200 ± 30 Nm).

427-C0375

0192 00-7

TM 5-3805-291-23-2


0192 00


Position fan (25) on guard (22) and install eight washers (24) and bolts (23).

427-C0373

4.

Position shield (19) and install eight washers (21) and bolts (20) on guard (22).

427-C0372

5.

Position guard (22) and install four washers (18) and bolts (17) on shield (19).

427-C0371

0192 00-8

TM 5-3805-291-23-2


0192 00


Attach two link brackets and lifting equipment to fan group (14).

427-C0270

WARNING


NOTE Fan group weighs 255 lb (116 kg).

7.

With assistance, install four washers (16) and bolts (15) on both sides of fan group (14).

427-C0370

0192 00-9

TM 5-3805-291-23-2


0192 00


Install two new O-rings (13) and connect hydraulic hoses (11) to fittings (12).

427-C1947

9.

Install new O-ring (10) and connect hydraulic hose (8) to fitting (9).

427-C1946

0192 00-10

TM 5-3805-291-23-2


0192 00


Position shield and brace assembly (7) on cooling package (4) and install washer (6) and bolt (5) on each side of cooling package.

427-C0269

11.

Install tube (3) and hose (2) on cooling package (4) and tighten two clamps (1).

427-C0267

0192 00-11

TM 5-3805-291-23-2

FAN HYDRAULIC MOTOR AND FAN GROUP REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 12.


13.

Install radiator top tank (WP 0042 00).

14.


15.


16.

Check for leaks.

END OF WORK PACKAGE

0192 00-12

0192 00

4 TM 5-3805-291-23-2

HYDRAULIC OIL COOLER REPLACEMENT

0193 00


Maintenance Level


Direct Support



O-ring (2) Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions Hydraulic system drained (WP 0148 00)

Materials/Parts

Cooler assembly unlatched (TM 5-3805-291-10)






TM 5-3805-291-23P, Figure 46



WARNING



NOTE •

Hydraulic and axle cooler core weighs 19 lb (9 kg).

•


•


0193 00-1

TM 5-3805-291-23-2

HYDRAULIC OIL COOLER REPLACEMENT - CONTINUED

0193 00

REMOVAL 1.

Disconnect hose assembly (1) and remove O-ring (2) from fitting (3). Discard O-ring.

2.

Disconnect hose assembly (4) and remove O-ring (5) from fitting (6). Discard O-ring.

3.

Remove three bolts (7), washers (8), and nuts (9) from cooler assembly (10).

4.

Remove hydraulic oil cooler (11) from cooler assembly (10).

427-C0325

5.

Remove two bolts (12), washers (13), and nuts (14) from cooler assembly (10).

427-C0324

0193 00-2

TM 5-3805-291-23-2


0193 00


WARNING •


•


1.


2.


3.


INSTALLATION

WARNING


NOTE •

Hydraulic and axle oil cooler core weighs 19 lb (9 kg).

•


1.

Position hydraulic oil cooler (11) on cooler assembly (10).

2.

Install two washers (13), bolts (12), and nuts (14) on cooler assembly (10).

3.

Install three washers (8), bolts (7), and nuts (9) on cooler assembly (10).

4.

Install new O-ring (5) in hose assembly (4). Connect hose assembly to fitting (6).

5.

Install new O-ring (2) in hose assembly (1). Connect hose assembly to fitting (3).

0193 00-3

TM 5-3805-291-23-2


0193 00



6.


7.

Fill hydraulic system (WP 0148 00).

8.


9.

Run machine until operating temperature is reached (TM 5-3805-291-10).

10.


11.

Check for leaks.

END OF WORK PACKAGE

0193 00-4

4 TM 5-3805-291-23-2

ACCESSORY SUPPORT BRACKETS REPLACEMENT

0194 00

THIS WORK PACKAGE COVERS Removal, Cleaning and Inspection, Transfer, Installation INITIAL SETUP Personnel Required

Maintenance Level


Direct Support





Serpentine belt removed (WP 0048 00)


Alternator removed (WP 0046 00)

Materials/Parts

AC compressor removed (WP 0221 00) Steering frame lock connected (TM 5-3805-29110) Drawings Required

Cleaning compound, solvent, type III (Item 7, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)


REMOVAL 1.

Remove four bolts (1), washers (2), two brackets (3), clip (4), and spacer (5) from bracket (6).

2.

Position wiring harness (7) and battery cable (8) aside.

427-C1901

0194 00-1

TM 5-3805-291-23-2

ACCESSORY SUPPORT BRACKETS REPLACEMENT - CONTINUED

0194 00

REMOVAL - CONTINUED


NOTE •

Side bracket weighs 23 lb (10 kg).

•

Accessory mechanism weighs 45 lb (20 kg).

3.

Remove four bolts (9), washers (10), and bracket (6) from engine.

4.

Remove two nuts (11) and washers (12) from accessory mechanism (13).

5.

Remove two bolts (14) and washers (15) from accessory mechanism (13).

6.

Remove accessory mechanism (13) from engine.

427-C1902


WARNING •


•

Particles blown by compressed air are hazardous. DO NOT exceed 15 psi (103 kPa) nozzle pressure when drying parts with compressed air. DO NOT direct compressed air against human skin. Failure to follow this warning may result in injury to personnel. Make sure air stream is directed away from user and other personnel in the area. To prevent injury, user must wear protective goggles or face shield.

1.


2.


3.

Inspect all parts for damage, wear, pitting, cracks or corrosion and replace if necessary. 0194 00-2

TM 5-3805-291-23-2


0194 00

TRANSFER If accessory mechanism (13) is to be replaced, remove four bolts (16), three pulleys (17), and belt tensioner (18) and install on new accessory mechanism. INSTALLATION


NOTE •

Side bracket weighs 23 lb (10 kg).

•

Accessory mechanism weighs 45 lb (20 kg).

1.

Position accessory mechanism (13) on engine.

2.

Install two washers (15) and bolts (14) on accessory mechanism (13).

3.

Install two washers (12) and nuts (11) on accessory mechanism (13).

4.

Position bracket (6) on engine and install four washers (10) and bolts (9) on bracket.

5.

Position wiring harness (7) and battery cable (8) on engine.

6.

Install spacer (5), clip (4), two brackets (3), four washers (2), and bolts (1) on bracket (6).

427-C1901

7.

Install alternator (WP 0046 00).

8.

Install AC compressor (WP 0221 00).

9.


10.

Install cooling package (WP 0190 00). 0194 00-3

TM 5-3805-291-23-2


0194 00


WARNING Before operating the machine, secure the steering frame lock in the stowed position. DO NOT operate machine with steering frame lock connected. Steering frame lock must be disconnected and securely stowed. Failure to follow this warning may result in injury or death to personnel.

11.


12.


13.

Run until operating temperature is reached and verify correct operation of machine (TM 5-3805-291-10).

14.


15.

Check for leaks.

END OF WORK PACKAGE

0194 00-4

24 TM 5-3805-291-23-2

CAB WIRING HARNESS AND FUSE/RELAY BLOCK REPLACEMENT

0195 00

THIS WORK PACKAGE COVERS Removal, Fuse/Relay Block Removal, Fuse/Relay Block Installation, Installation INITIAL SETUP Maintenance Level


Direct Support

References

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Materials/Parts

TM 5-3805-291-10 Equipment Conditions Cab wiring harness disconnected from turnlamp switch (WP 0066 00) Cab wiring harness disconnected from instrument and switch panels (WP 0055 00) Interior panels removed from machine (WP 0138 00)


Drawings Required



TM 5-3805-291-23P, Figure 73

4.0 hr

Lockwasher (16)

0195 00-1

TM 5-3805-291-23-2

CAB WIRING HARNESS AND FUSE/RELAY BLOCK REPLACEMENT - CONTINUED

0195 00

REMOVAL


NOTE •


•

Note location of all tiedown straps and fasteners to ensure correct installation.

1.

Remove two tiedown straps (1) and cover (2) from machine. Discard tiedown straps.

2.

Loosen three setscrews (3) on chassis harness (4) and disconnect chassis harness from machine.

3.

Remove six screws (5) from machine.

4.

Remove eight bolts (6) and washers (7) from machine.

427-C1427

5.

Disconnect upper cab wiring harness (8) from lamp housing (9).

427-C0425-1

0195 00-2

TM 5-3805-291-23-2


0195 00


Disconnect shift lever (10) from lower cab wiring harness (11).

427-C0349-1

7.

Disconnect lower cab wiring harness (11) from wiper motor assembly (12).

427-C1948

0195 00-3

TM 5-3805-291-23-2


0195 00


Disconnect lower cab wiring harness (11) from signal flasher (13).

427-C1949

9.

Disconnect lower cab wiring harness (11) from wiper motor assembly (14).

427-C1950

0195 00-4

TM 5-3805-291-23-2


0195 00


Disconnect heater/AC wiring harness (15) from lower cab wiring harness (11).

427-C1951

11.

Remove and discard tiedown straps (16) from lower cab wiring harness (11).

12.

Disconnect cab wiring harness (11) from powertrain ECM (17).

13.

Remove bolt (18), washer (19), and ground strap (20) from powertrain ECM (17).

427-C1952

0195 00-5

TM 5-3805-291-23-2


0195 00


Remove three nuts (21) and washers (22) from fuse/ relay block (23).

15.

Disconnect lower cab wiring harness (11) from fuse/ relay block (23).

427-C1428

16.

Remove fuse/relay block. Refer to fuse/relay block removal in this WP. Disconnect upper cab wiring harness (8) from lower cab wiring harness (11).

17.

Remove three nuts (24), washers (25), and lower cab wiring harness (11) from bracket (26).

0195 00-6

TM 5-3805-291-23-2


0195 00


Disconnect lower cab wiring harness (11) from implement ECM (27).

19.

Remove bolt (28), washer (29), and ground strap (30) from implement ECM (27).

427-C1953

20.

Remove two nuts (31), washers (32), and lower cab wiring harness (11) from relay block (33).

427-C1430

0195 00-7

TM 5-3805-291-23-2


0195 00


Remove and discard tiedown strap (34) from lower cab wiring harness (11).

22.

Remove bolt (35), washer (36), and alarm (37) from clamp (38).

23.

Disconnect alarm (37) from lower cab wiring harness (11).

24.

Remove clamp (38) from lower cab wiring harness (11).

427-C1431

25.

Remove two nuts (39), washers (40), and ground connections (41) from machine.

427-C1432

26.


27.


427-C1433

0195 00-8

TM 5-3805-291-23-2


0195 00


Remove two tiedown straps (45) from lower cab wiring harness (11). Discard tiedown straps.

29.

Disconnect lower cab wiring harness (11) from pilot operated control harness (46).

427-C1434

30.

Remove four tiedown straps (47) from lower cab wiring harness (11). Discard tiedown straps.

31.


32.


33.

Remove lower cab wiring harness (11) from machine.

427-C1435

0195 00-9

TM 5-3805-291-23-2


0195 00


Remove tiedown strap (51) from upper cab wiring harness (8). Discard tiedown strap.

35.

Remove nut (52), washer (53), and two ground connections (54) from machine.

36.

Remove four bolts (55) and washers (56) from clamps (57).

37.

Remove four clamps (57) from worklight harness (58).

427-C1436

0195 00-10

TM 5-3805-291-23-2


0195 00


Remove seven tiedown straps (59) from upper cab wiring harness (8). Discard tiedown straps.

39.

Remove eight nuts (60), lockwashers (61), washers (62), bushings (63), four grommets (64), screws (65), and upper cab wiring harness (8) from machine. Discard lockwashers.

427-C1437

0195 00-11

TM 5-3805-291-23-2


0195 00


Remove six tiedown straps (66) from fog lamp harness (58). Discard tiedown straps.

41.

Remove eight nuts (67), lockwashers (68), washers (69), bushings (70), four grommets (71), screws (72), and fog lamp harness (58) from machine. Discard lockwashers.

427-C1438

0195 00-12

TM 5-3805-291-23-2

CAB WIRING HARNESS AND FUSE/RELAY BLOCK REPLACEMENT - CONTINUED FUSE/RELAY BLOCK REMOVAL Remove four bolts (73), washers (74), and fuse/relay block (23).

FUSE/RELAY BLOCK INSTALLATION Install fuse/relay block (23), four washers (74), and bolts (73).

0195 00-13

0195 00

TM 5-3805-291-23-2


0195 00

INSTALLATION 1.

Position fog lamp harness (58) on machine and install four screws (72), grommets (71), eight bushings (70), washers (69), new lockwashers (68), and nuts (67).

2.

Install six new tiedown straps (66) on fog lamp harness (58).

427-C1438

0195 00-14

TM 5-3805-291-23-2


0195 00


Position upper cab wiring harness (8) on machine and install four screws (65), grommets (64), eight bushings (63), washers (62), new lockwashers (61), and nuts (60).

4.

Install seven new tiedown straps (59) on upper cab wiring harness (8).

427-C1437

0195 00-15

TM 5-3805-291-23-2


0195 00


Install four clamps (57) on worklight harness (58).

6.

Install four washers (56) and bolts (55) on clamps (57).

7.

Install two ground connections (54), washer (53), and nut (52) on machine.

8.

Install new tiedown strap (51) on upper cab wiring harness (8).

427-C1436

0195 00-16

TM 5-3805-291-23-2


0195 00


Install lower cab wiring harness (11) on machine.

10.

Install clamp (50) on lower cab wiring harness (11).

11.


12.

Install four new tiedown straps (47) on lower cab wiring harness (11).

427-C1435

13.

Connect lower cab wiring harness (11) to pilot operated control harness (46).

14.

Install two new tiedown straps (45) on lower cab wiring harness (11).

427-C1434

0195 00-17

TM 5-3805-291-23-2


0195 00



16.


427-C1433

17.

Install two ground connections (41), washers (40), and nuts (39) on machine.

427-C1432

18.


19.

Connect alarm (37) to lower cab wiring harness (11).

20.

Install alarm (37), washer (36), and bolt (35) on clamp (38).

21.

Install new tiedown strap (34) on lower cab wiring harness (11).

427-C1431

0195 00-18

TM 5-3805-291-23-2


0195 00


Install lower cab wiring harness (11), two washers (32), and nuts (31) on relay block (33).

427-C1430

23.

Install ground strap (30), washer (29), and bolt (28) on implement ECM (27).

24.

Connect lower cab wiring harness (11) to implement ECM (27).

427-C1953

0195 00-19

TM 5-3805-291-23-2


0195 00


Install lower cab wiring harness (11), three washers (25), and nuts (24) on bracket (26).

26.

Connect upper cab wiring harness (8) to lower cab wiring harness (11).

27.

Install fuse/relay block refer to fuse/relay block installation in this WP. Connect lower cab wiring harness (11) to fuse/relay block (23).

28.

Install three washers (22) and nuts (21) on fuse/relay block (23).

427-C1428

0195 00-20

TM 5-3805-291-23-2


0195 00


Install ground strap (20), washer (19), and bolt (18) on powertrain ECM (17).

30.

Connect lower cab wiring harness (11) to powertrain ECM (17).

31.

Install new tiedown straps (16) on lower cab wiring harness (11).

427-C1952

32.

Connect heater/AC wiring harness (15) to lower cab wiring harness (11).

427-C1951

0195 00-21

TM 5-3805-291-23-2


0195 00


Connect lower cab wiring harness (11) to wiper motor assembly (14).

427-C1950

34.

Connect lower cab wiring harness (11) to signal flasher (13).

427-C1949

35.

Connect lower cab wiring harness (11) to wiper motor assembly (12).

427-C1948

0195 00-22

TM 5-3805-291-23-2


0195 00


Connect shift lever (10) to lower cab wiring harness (11).

427-C0349-1

37.

Connect upper cab wiring harness (8) to lamp housing (9).

427-C0425-1

0195 00-23

TM 5-3805-291-23-2


0195 00


Install eight washers (7) and bolts (6) on machine.

39.

Install six screws (5) on machine.

40.

Connect chassis harness (4) to machine and tighten three setscrews (3) on chassis harness.

41.

Install cover (2) and two new tiedown straps (1) on machine.

427-C1427

42.

Install interior panels on machine (WP 0138 00).

43.

Connect cab wiring harness to instrument and switch panels (WP 0055 00).

44.

Connect cab wiring harness to turnlamp switch (WP 0066 00).

45.


46.

Run machine and verify correct operation of cab wiring harness (TM 5-3805-291-10).

47.


END OF WORK PACKAGE

0195 00-24

8 TM 5-3805-291-23-2

ENGINE WIRING HARNESS REPLACEMENT

0196 00


References TM 5-3805-291-10

Direct Support



Battery cables disconnected from batteries (WP 0096 00) Wiring harness disconnected from fuel injector harness (WP 0187 00)

Materials/Parts Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00)

Wiring harness disconnected from engine ECM (WP 0057 00) Drawings Required TM 5-3805-291-23P, Figure 74

Personnel Required



0196 00-1

TM 5-3805-291-23-2

ENGINE WIRING HARNESS REPLACEMENT - CONTINUED REMOVAL


NOTE •


•


•

Some nuts, bolts, and components in illustrations removed for clarity.

1.

Remove and discard tiedown straps (1) from engine wiring harness (2).

2.

Disconnect engine wiring harness (2) from crankshaft position sensor lead (3).

3.

Disconnect engine wiring harness (2) from camshaft position sensor lead (4).

4.

Disconnect engine wiring harness (2) from coolant temperature sensor (5).

5.

Disconnect engine wiring harness (2) from atmospheric air sensor lead (6).

6.

Disconnect engine wiring harness (2) from alternator (7).

7.

Disconnect engine wiring harness (2) from fuel pump (8).

8.

Disconnect engine wiring harness (2) from fuel pump pressure sensor lead (9).

9.

Disconnect engine wiring harness (2) from fuel pump temperature sensor (10).

10.

Disconnect engine wiring harness (2) from fuel pump differential pressure switch lead (11).

11.

Disconnect engine wiring harness (2) from intake air pressure sensor lead (12).

12.

Disconnect engine wiring harness (2) from intake air temperature sensor (13).

13.

Disconnect engine wiring harness (2) from engine oil pressure sensor lead (14).

0196 00-2

0196 00

TM 5-3805-291-23-2

ENGINE WIRING HARNESS REPLACEMENT - CONTINUED

0196 00

REMOVAL - CONTINUED

427-C0329

0196 00-3

TM 5-3805-291-23-2


0196 00


Remove two bolts (15), washers (16), and clamps (17) from machine.

15.

Disconnect engine wiring harness (2) from AC compressor (18).

427-C0330

16.

Disconnect engine wiring harness (2) from turbocharger inlet pressure sensor lead (19).

17.

Disconnect engine wiring harness (2) from torque converter oil pressure sensor (20).

18.

Disconnect engine wiring harness (2) from service brake oil pressure sensor lead (21).

19.

Remove bolt (22), washer (23), and clamp (24) from engine wiring harness (2) on right side of engine.

20.

Remove bolt (25), washer (26), and clamp (27) from engine wiring harness (2) on left side of machine.

21.

Disconnect engine wiring harness (2) from chassis wiring harness on left side of machine.

22.

Remove engine wiring harness (2) from machine.

0196 00-4

TM 5-3805-291-23-2


0196 00

REMOVAL - CONTINUED

427-C0331

INSTALLATION 1.

Position engine wiring harness (2) on machine.

2.

Connect engine wiring harness (2) to chassis wiring harness on left side of machine.

3.

Install washer (26), bolt (25), and clamp (27) on engine wiring harness (2) on left side of machine.

4.

Install washer (23), bolt (22), and clamp (24) on engine wiring harness (2) on right side of engine.

5.

Connect engine wiring harness (2) to service brake oil pressure sensor lead (21).

6.

Connect engine wiring harness (2) to torque converter oil pressure sensor (20).

7.

Connect engine wiring harness (2) to turbocharger inlet pressure sensor lead (19).

8.

Connect engine wiring harness (2) to AC compressor (18).

9.

Install two washers (16), bolts (15), and clamps (17) on machine.

0196 00-5

TM 5-3805-291-23-2

ENGINE WIRING HARNESS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 10.

Connect engine wiring harness (2) to engine oil pressure sensor lead (14).

11.

Connect engine wiring harness (2) to intake air temperature sensor (13).

12.

Connect engine wiring harness (2) to intake air pressure sensor lead (12).

13.

Connect engine wiring harness (2) to fuel pump differential pressure switch lead (11).

14.

Connect engine wiring harness (2) to fuel pump temperature sensor (10).

15.

Connect engine wiring harness (2) to fuel pump pressure sensor lead (9).

16.

Connect engine wiring harness (2) to fuel pump (8).

17.

Connect engine wiring harness (2) to alternator (7).

18.

Connect engine wiring harness (2) to atmospheric air sensor lead (6).

19.

Connect engine wiring harness (2) to coolant temperature sensor (5).

20.

Connect engine wiring harness (2) to camshaft position sensor lead (4).

21.

Connect engine wiring harness (2) to crankshaft position sensor lead (3).

22.

Attach new tiedown straps (1) to engine wiring harness (2).

0196 00-6

0196 00

TM 5-3805-291-23-2


0196 00


427-C0329

23.

Connect wiring harness to engine ECM (WP 0057 00).

24.

Connect wiring harness to fuel injector harness (WP 0187 00).

25.


26.


27.


28.


END OF WORK PACKAGE

0196 00-7/(0196 00-8 Blank)

6 TM 5-3805-291-23-2

FRONT CHASSIS WIRING HARNESS REPLACEMENT

0197 00



TM 5-3805-291-10




Front harness disconnected from blackout drive lights (WP 0068 00) Front harness disconnected from service lights and turnlamps (WP 0071 00)






3.0 hr

0197 00-1

TM 5-3805-291-23-2

FRONT CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED

0197 00

REMOVAL


NOTE •


•


•

Nuts, bolts, and components in illustrations removed for clarity.

1.

Disconnect front wiring harness (1) from chassis wiring harness (2).

2.

Remove 24 tiedown straps (3) from front wiring harness (1). Discard tiedown straps.

3.

Disconnect wiring harness (1) from lighting harness connector (4).

4.

Disconnect wiring harness (1) from tilt harness connector (5).

5.

Disconnect wiring harness (1) from two horns (6).

6.

Disconnect wiring harness (1) from lift position sensor (7).

7.

Disconnect wiring harness (1) from quick coupler harness connector (8).

8.

Disconnect wiring harness (1) from front axle temperature sensor (9).

9.

Disconnect wiring harness (1) from tilt cylinder anti-drift sensor (10).

10.

Disconnect wiring harness (1) from tilt and lift solenoid (11).

11.

Disconnect wiring harness (1) from pilot solenoid (12).

12.

Remove two bolts (13), washers (14), plate (15), and clamp (16) from front wiring harness (1).

13.

Remove two bolts (17), washers (18), plate (19), and clamp (20) from front wiring harness (1).

14.


15.


16.

Remove nut (27), two washers (28), clip (29), and washer (30) from machine.

17.

Remove three nuts (31), washers (32), clips (33), and washers (34) from machine.

18.

Remove six nuts (35), washers (36), clips (37), and washers (38) from machine.

19.

Remove nut (39) and washer (40) from machine.

20.


21.

Remove two nuts (43) and washers (44) from machine.

22.


23.

Remove front wiring harness (1) from machine. 0197 00-2

TM 5-3805-291-23-2


0197 00

REMOVAL - CONTINUED

427-C0334

0197 00-3

TM 5-3805-291-23-2

FRONT CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED INSTALLATION 1.

Position front wiring harness (1) on machine.

2.

Install washer (46) and nut (45) on machine.

3.

Install two washers (44) and nuts (43) on machine.

4.


5.


6.

Install six washers (38), clips (37), washers (36), and nuts (35) on machine.

7.

Install three washers (34), clips (33), washers (32), and nuts (31) on machine.

8.

Install washer (30), clip (29), two washers (28), and nut (27) on machine.

9.


10.


11.

Install clamp (20), plate (19), two washers (18), and bolts (17) on front wiring harness (1).

12.

Install clamp (16), plate (15), two washers (14), and bolts (13) on front wiring harness (1).

13.

Connect wiring harness (1) to pilot solenoid (12).

14.

Connect wiring harness (1) to tilt and lift solenoid (11).

15.

Connect wiring harness (1) to tilt cylinder anti-drift sensor (10).

16.

Connect wiring harness (1) to front axle temperature sensor (9).

17.

Connect wiring harness (1) to quick coupler harness connector (8).

18.

Connect wiring harness (1) to lift position sensor (7).

19.

Connect wiring harness (1) to two horns (6).

20.

Connect wiring harness (1) to tilt harness connector (5).

21.

Connect wiring harness (1) to lighting harness connector (4).

22.

Install 24 new tiedown straps (3) on front wiring harness (1).

23.

Connect front wiring harness (1) to chassis wiring harness (2).

0197 00-4

0197 00

TM 5-3805-291-23-2


0197 00


427-C0334

24.

Connect front wiring harness to service lights and turnlamps (WP 0071 00).

25.

Connect front wiring harness to blackout drive lights (WP 0068 00).

26.

Operate machine and verify correct operation of all components (TM 5-3805-291-10).

END OF WORK PACKAGE

0197 00-5/(0197 00-6 Blank)

4 TM 5-3805-291-23-2

HEATER AND AIR CONDITIONING WIRING HARNESS REPLACEMENT

0198 00



TM 5-3805-291-10

Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts

Equipment Conditions Battery cables disconnected from battery (WP 0096 00) Left rear interior panel removed (WP 0138 00)

Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00)



1.5 hr

0198 00-1

TM 5-3805-291-23-2

HEATER AND AIR CONDITIONING WIRING HARNESS REPLACEMENT - CONTINUED

0198 00

REMOVAL


NOTE •


•


•


1.

Disconnect heater/AC wiring harness (1) from cab wiring harness (2).

2.

Remove tiedown strap (3) from heater/AC wiring harness (1). Discard tiedown strap.

3.

Disconnect heater/AC wiring harness (1) from blower motor (4).

427-C1198

0198 00-2

TM 5-3805-291-23-2

HEATER AND AIR CONDITIONING WIRING HARNESS REPLACEMENT - CONTINUED

0198 00


Remove bolt (5) and washer (6) from heater/AC assembly (7).

5.

Remove clip (8) from heater/AC wiring harness (1).

6.

Disconnect heater/AC wiring harness (1) from sensor (9).

7.

Disconnect heater/AC wiring harness (1) from temperature switch (10).

8.

Remove grommet (11) from heater/AC assembly (7).

9.

Disconnect three wires from heater/AC assembly (7).

10.

Remove heater/AC wiring harness (1) from heater/AC assembly (7).

427-C1199

INSTALLATION 1.

Position heater/AC wiring harness (1) on heater/AC assembly (7).

2.

Connect three wires to heater/AC assembly (7).

3.

Install grommet (11) on heater/AC assembly (7).

4.

Connect heater/AC wiring harness (1) to temperature switch (10).

5.

Connect heater/AC wiring harness (1) to sensor (9).

6.

Install clip (8) on heater/AC wiring harness (1).

7.

Install washer (6) and bolt (5) on heater/AC assembly (7).

8.

Connect heater/AC wiring harness (1) to blower motor (4).

9.

Install new tiedown strap (3) on heater/AC wiring harness (1).

10.

Connect heater/AC wiring harness (1) to cab wiring harness (2).

11.

Install left rear interior panel (WP 0138 00).

12.

Connect battery cables to battery (WP 0096 00).

13.


14.

Run machine and verify correct operation of AC and heater systems (TM 5-3805-291-10).

15.



32 TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT

0199 00





References TM 5-3805-291-10 Equipment Conditions Cab removed (WP 0132 00) Chassis wiring harness disconnected from hydraulic oil temperature sensor (WP 0083 00)

Materials/Parts Rag, wiping (Item 35, WP 0233 00) Strap, tiedown, electrical components (Item 42, WP 0233 00) Tag, marker (Item 43, WP 0233 00)


Grommet (6)

4.0 hr

Lockwasher

0199 00-1

TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED

0199 00

REMOVAL


NOTE

1.

•


•


Disconnect chassis wiring harness (1) from bypass switch (2).

427-C1954

2.

Disconnect chassis wiring harness (1) from parking brake oil pressure switch (3).

427-C1955

0199 00-2

TM 5-3805-291-23-2


0199 00


At bottom of hydraulic tank (4), disconnect chassis wiring harness (1) from oil temperature sensor (5).

4.

Remove chassis wiring harness nut (6) and lockwasher (7) from starter solenoid (8). Discard lockwasher.

5.

Disconnect chassis wiring harness (1) from starter solenoid (8).

427-C1957

0199 00-3

TM 5-3805-291-23-2


0199 00


Disconnect chassis wiring harness (1) from primary steering switch (9).

7.

Disconnect chassis wiring harness (1) from secondary steering switch (10).

427-C1958

8.

Disconnect chassis wiring harness (1) from jumper lead (11) of fuel level sending unit.

427-C1959

0199 00-4

TM 5-3805-291-23-2


0199 00


Disconnect chassis wiring harness (1) from ether start aid atomizer assembly (12).

427-C1960

10.

Disconnect chassis wiring harness (1) from hood tilt actuator connector (13).

427-C1961

0199 00-5

TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED REMOVAL - CONTINUED 11.

Disconnect chassis wiring harness (1) from backup alarm connector (14).

12.


13.

Remove clamp (17) from chassis wiring harness (1).

0199 00-6

0199 00

TM 5-3805-291-23-2


0199 00

REMOVAL - CONTINUED

NOTE For chassis wiring harness replacement, attach guide wire to wiring harness prior to removal from machine. Secure one end of guide wire to damaged lamp housing. Remove other end from damaged chassis wiring harness. 14.

Disconnect chassis wiring harness (1) from five connectors (18) of rear lamp.

15.

Disconnect chassis wiring harness (1) from temperature sensor (19).

427-C1964

0199 00-7

TM 5-3805-291-23-2


0199 00


Disconnect two chassis wiring harness connectors (1) from two washer pumps (20).

17.

Remove three bolts (21), washers (22), and clamps (23) from chassis wiring harness (1).

427-C1439-2

0199 00-8

TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED REMOVAL - CONTINUED

NOTE Steps 18 thru 21 will remove parking brake, oil filter, and washer pump wiring harness.

18.

Remove and discard eight tiedown straps (24) from chassis wiring harness (1).

19.

Remove nut (25) and washer (26) from clip (27).

20.

Remove clip (27) from chassis wiring harness (1).

21.

Remove two grommets (28) from chassis wiring harness (1). Discard grommets.

0199 00-9

0199 00

TM 5-3805-291-23-2


0199 00


Remove and discard tiedown strap (29) from chassis wiring harness (1).

23.


24.


25.

Remove three nuts (33) and washers (34) from clips (35).

26.

Remove three clips (35) from chassis wiring harness (1).

427-C1441

0199 00-10

TM 5-3805-291-23-2


Remove and discard nine tiedown straps (36) from chassis wiring harness (1).

28.

Remove two nuts (37) and washers (38) from clips (39).

29.

Remove two clips (39) from chassis wiring harness (1).

30.

Remove bolt (40) and washer (41) from two clips (42).

31.


32.

Remove nut (43), washer (44), and clamp (45) from clip (46).

33.

Remove clip (46) and clamp (45) from chassis wiring harness (1).

34.


35.


0199 00-11

0199 00

TM 5-3805-291-23-2


Remove three bolts (50), washers (51) and cover (53) from box (52).

0199 00-12

0199 00

TM 5-3805-291-23-2


Remove and discard four tiedown straps (64) from chassis wiring harness (1).

38.

Remove nuts (55), washers (56), and chassis wiring harness (1) from circuit breaker block (57).

39.

Remove nut (67) and chassis wiring harness (1) from main relay (58).

40.

Disconnect chassis wiring harness (1) from main relay connector (66).

41.

Remove nut (59) and chassis wiring harness (1) from start relay (65).

42.

Disconnect chassis wiring harness (1) from start relay connector (63).

43.

Disconnect chassis wiring harness (1) from hood tilt relay (54).

44.

Disconnect chassis wiring harness (1) from emergency cut-off switch (61).

45.

Disconnect chassis wiring harness (1) from hood tilt switch (60).

46.

Disconnect chassis wiring harness (1) from arc suppressor (62).

0199 00-13

0199 00

TM 5-3805-291-23-2


Remove and discard three tiedown straps (68) from chassis wiring harness (1).

48.

Remove four nuts (69) and washers (70) from clips (71).

49.

Remove four clips (71) from chassis wiring harness (1).

50.


51.


52.

Remove two bolts (75), washers (76), clips (77), and bracket (78) from machine.

53.


54.

Disconnect jumper harness (79) of secondary steering wiring harness from chassis wiring harness (1).

0199 00-14

0199 00

TM 5-3805-291-23-2


Remove and discard seven tiedown straps (80) from chassis wiring harness (1).

56.

Remove nut (81) and washer (82) from clips (83 and 84).

57.

Remove clips (83 and 84) from chassis wiring harness (1).

58.


59.


60.

Disconnect chassis wiring harness (1) from engine wiring harness (88).

61.


62.

Remove two bolts (91) and washers (92) from clips (93).

63.


0199 00-15

0199 00

TM 5-3805-291-23-2


Remove and discard 14 tiedown straps (94) from chassis wiring harness (1).

65.

Remove two bolts (95) and washers (96) from clips (97).

66.


67.

Remove chassis wiring harness (1) and four grommets (98) from machine. Discard grommets.

0199 00-16

0199 00

TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED INSTALLATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Position four new grommets (98) and chassis wiring harness (1) on machine. Install two clips (97) on chassis wiring harness (1). Install two washers (96) and bolts (95) on clips (97). Install 14 new tiedown straps (94) on chassis wiring harness (1). Install two clips (93) on chassis wiring harness (1). Install two washers (92) and bolts (91) on clips (93). Install chassis wiring harness (1), washer (90), and nut (89) on machine. Connect engine wiring harness (88) to chassis wiring harness (1). Install clip (87) on chassis wiring harness (1). Install washer (86) and nut (85) on clip (87). Install clips (83 and 84) on chassis wiring harness (1). Install washer (82) and nut (81) on clips (83 and 84). Install seven new tiedown straps (80) on chassis wiring harness (1).

0199 00-17

0199 00

TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 14.

Connect jumper harness (79) of secondary steering wiring harness to chassis wiring harness (1).

15.

Install clip (77) on chassis wiring harness (1).

16.

Install bracket (78), clip (77), two washers (76), and bolts (75) on machine.

17.

Install two clips (74) on chassis wiring harness (1).

18.

Install two washers (73) and bolts (72) on clip (74).

19.

Install four clips (71) on chassis wiring harness (1).

20.

Install four washers (70) and nuts (69) on clips (71).

21.

Install three new tiedown straps (68) on chassis wiring harness (1).

0199 00-18

0199 00

TM 5-3805-291-23-2


Connect chassis wiring harness (1) to arc suppressor (62).

23.

Connect chassis wiring harness (1) to hood tilt switch (60).

24.

Connect chassis wiring harness (1) to emergency cut-off switch (61).

25.

Connect chassis wiring harness (1) to hood tilt relay (54).

26.

Connect chassis wiring harness (1) to start relay connector (63).

27.

Connect chassis wiring harness (1) to start relay (65) with nut (59).

28.

Connect chassis wiring harness (1) to main relay connector (66).

29.

Connect chassis wiring harness (1) to main relay (58) with nut (67).

30.

Install chassis wiring harness (1), washer (56), and nut (55) on circuit breaker block (57).

31.

Install four new tiedown straps (64) on chassis wiring harness (1).

0199 00-19

0199 00

TM 5-3805-291-23-2


Install three washers (51), bolts (50), and cover (53) on box (52).

0199 00-20

0199 00

TM 5-3805-291-23-2



34.

Install washer (48) and bolt (47) on clip (49).

35.

Install clip (46) and clamp (45) on chassis wiring harness (1).

36.

Install clamp (45), washer (44), and nut (43) on clip (46).

37.


38.

Install washer (41) and bolt (40) on two clips (42).

39.


40.

Install two washers (38) and nuts (37) on clips (39).

41.

Install nine new tiedown straps (36) on chassis wiring harness (1).

0199 00-21

0199 00

TM 5-3805-291-23-2


0199 00


Install three clips (35) on chassis wiring harness (1).

43.

Install three nuts (33) and washers (34) on clips (35).

44.


45.


46.

Install new tiedown strap (29) on chassis wiring harness (1).

427-C1441

0199 00-22

TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED

NOTE Steps 47 thru 50 will install parking brake, oil filter, and washer pump wiring harness.

47.

Install two new grommets (28) on chassis wiring harness (1).

48.


49.

Install washer (26) and nut (25) on clip (27).

50.

Install eight new tiedown straps (24) on chassis wiring harness (1).

0199 00-23

0199 00

TM 5-3805-291-23-2


0199 00


Install three clamps (23), washers (22), and bolts (21) on chassis wiring harness (1).

427-C1439-2

52.

Connect two chassis wiring harness connectors (1) to two washer pumps (20).

0199 00-24

TM 5-3805-291-23-2


0199 00


Connect chassis wiring harness (1) to temperature sensor (19).

427-C1964

54.

Install bolt (15) and washer (16) on clamp (17).

55.

Install clamp (17) on chassis wiring harness (1).

0199 00-25

TM 5-3805-291-23-2

REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED INSTALLATION - CONTINUED

NOTE For chassis wiring harness replacement, attach guide wire to wiring harness prior to removal from machine. Secure one end of guide wire to damaged lamp housing. Remove other end from damaged chassis wiring harness. 56.

Connect chassis wiring harness (1) to five connectors (18) of rear lamp.

0199 00-26

0199 00

TM 5-3805-291-23-2


Connect chassis wiring harness (1) to backup alarm connector (14).

0199 00-27

0199 00

TM 5-3805-291-23-2


0199 00


Connect chassis wiring harness (1) to hood tilt actuator connector (13).

427-C1961

59.

Connect chassis wiring harness (1) to ether start aid atomizer assembly (12).

427-C1960

0199 00-28

TM 5-3805-291-23-2


0199 00


Connect chassis wiring harness (1) to jumper lead (11) of fuel level sending unit.

427-C1959

61.

Connect chassis wiring harness (1) to primary steering switch (9).

62.

Connect chassis wiring harness (1) to secondary steering switch (10).

427-C1958

0199 00-29

TM 5-3805-291-23-2


0199 00


Install chassis wiring harness nut (6) and new lockwasher (7) on starter solenoid (8).

64.

Connect chassis wiring harness (1) to starter solenoid (8).

427-C1957

65.

At bottom of hydraulic tank (4), connect chassis wiring harness (1) to oil temperature sensor (5).

0199 00-30

TM 5-3805-291-23-2


0199 00


Connect chassis wiring harness (1) to parking brake oil pressure switch (3).

427-C1955

67.

Connect chassis wiring harness (1) to bypass switch (2).

427-C1954

68. 69. 70. 71. 72.

Connect chassis wiring harness to hydraulic oil temperature sensor (WP 0083 00). Install cab (WP 0132 00). Start machine (TM 5-3805-291-10). Run machine until normal operating temperature is reached and verify correct operation of chassis wiring harness (TM 5-3805-291-10). Shut down machine (TM 5-3805-291-10).


4 TM 5-3805-291-23-2

SECONDARY STEERING WIRING HARNESS REPLACEMENT

0200 00



Direct Support

References


TM 5-3805-291-10


Equipment Conditions Battery cables disconnected from battery (WP 0096 00)

Materials/Parts

Drawings Required




0200 00-1

TM 5-3805-291-23-2

SECONDARY STEERING WIRING HARNESS REPLACEMENT - CONTINUED

0200 00

REMOVAL


NOTE •


•


•


1.

Remove and discard three tiedown straps (1) from secondary steering wiring harness (2).

2.

Remove bolt (3), washer (4), and spacer (5) from clip (6).

3.

Remove clip (6) from secondary steering wiring harness (2).

4.

Remove five bolts (7) and washers (8) from clips (9).

5.

Remove five clips (12) from secondary steering wiring harness (2).

6.

Disconnect secondary steering wiring harness (2) from secondary steering pump (10).

7.

Disconnect secondary steering wiring harness (2) from arc suppressor (11).

8.

Disconnect secondary steering wiring harness (2) from switch (12).

9.

Disconnect secondary steering wiring harness (2) from switch (13).

10.

Disconnect secondary steering wiring harness (2) from wiring assembly (14).

11.

Remove secondary steering wiring harness (2) from machine.

0200 00-2

TM 5-3805-291-23-2


0200 00

REMOVAL - CONTINUED

427-C0328

INSTALLATION 1.

Position secondary steering wiring harness (2) on machine.

2.

Connect secondary steering wiring harness (2) to wiring assembly (14).

3.

Connect secondary steering wiring harness (2) to switch (13).

4.

Connect secondary steering wiring harness (2) to switch (12).

5.

Connect secondary steering wiring harness (2) to arc suppressor (11).

6.

Connect secondary steering wiring harness (2) to secondary steering pump (10).

7.

Install five clips (1) on secondary steering wiring harness (2).

8.

Install five washers (8) and bolts (7) on clips (9).

9.

Install clip (6) on secondary steering wiring harness (2).

10.

Install spacer (5), washer (4), and bolt (3) on clip (6).

11.

Attach three new tiedown straps (1) to secondary steering wiring harness (2). 0200 00-3

TM 5-3805-291-23-2


0200 00


Connect battery cables to battery (WP 0096 00).

13.


14.


15.


END OF WORK PACKAGE

0200 00-4

4 TM 5-3805-291-23-2

TRANSMISSION CONTROL WIRING HARNESS REPLACEMENT

0201 00


Maintenance Level


Direct Support

References


TM 5-3805-291-10 Equipment Conditions Cab removed (WP 0132 00)

Materials/Parts

Drawings Required




0201 00-1

TM 5-3805-291-23-2

TRANSMISSION CONTROL WIRING HARNESS REPLACEMENT - CONTINUED

0201 00

REMOVAL


NOTE •


•


•


1.


2.

Remove clip (3) from transmission control wiring harness (4).

3.

Remove tiedown strap (5) from transmission control wiring harness (4). Discard tiedown strap.

4.


5.

Remove bolt (9) from clip (10).

6.

Remove clip (10) from transmission control wiring harness (4).

7.

Remove nine tiedown straps (11) from three plates (12). Discard tiedown straps.

427-C1197

0201 00-2

TM 5-3805-291-23-2

TRANSMISSION CONTROL WIRING HARNESS REPLACEMENT - CONTINUED

0201 00


Remove three bolts (13) and plates (12) from machine.

9.

Remove bolt (14) from clip assembly (15).

10.

Remove clip assembly (15) from transmission control wiring harness (4).

11.

Disconnect transmission control wiring harness (4) from torque converter output speed sensor (16).

12.

Disconnect transmission control wiring harness (4) from six modulating valves (17).

13.

Disconnect transmission control wiring harness (4) from two transmission output speed sensors (18).

14.

Disconnect transmission control wiring harness (4) from oil temperature sensor (19).

15.

Remove transmission control wiring harness (4) from machine.

INSTALLATION 1.

Position transmission control wiring harness (4) on machine.

2.

Connect transmission control wiring harness (4) to oil temperature sensor (19).

3.

Connect transmission control wiring harness (4) to two transmission output speed sensors (18).

4.

Connect transmission control wiring harness (4) to six modulating valves (17).

5.

Connect transmission control wiring harness (4) to torque convertor output speed sensor (16).

6.

Install clip assembly (15) on transmission control wiring harness (4).

7.

Install bolt (14) on clip assembly (15).

8.

Install three plates (12) and bolts (13) on machine.

9.

Position transmission control wiring harness (4) on three plates (12) and install nine new tiedown straps (11) on plates.

10.

Install clip (10) on transmission control wiring harness (4).

11.

Install bolt (9) on clip (10).

12.


13.

Position transmission control wiring harness (4) on clip (3) and install new tiedown strap (5) on transmission control wiring harness.

14.

Install clip (3) on transmission control wiring harness (4).

15.


16.


17.


18.

Drive and verify correct operation of machine (TM 5-3805-291-10).

19.



4 TM 5-3805-291-23-2

TRANSMISSION HYDRAULIC CONTROL RELIEF VALVE REPLACEMENT

0202 00





Oil, lubricating, refrigerant compressor: Synthetic Ester (Item 30, WP 0233 00)

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)

Rag, wiping (Item 35, WP 0233 00) Tag, marker (Item 43, WP 0233 00) O-ring (4) Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions

Materials/Parts


Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)

0202 00-1

Steering frame lock connected (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figure 85 Estimated Time to Complete Task 4.0 hr

TM 5-3805-291-23-2

TRANSMISSION HYDRAULIC CONTROL RELIEF VALVE REPLACEMENT - CONTINUED

0202 00

REMOVAL


NOTE •


•


•

The transmission hydraulic control relief valve is located on the left rear side of the transmission housing.

1.

Disconnect hose assembly (1) and remove O-ring (2) from transmission (3). Discard O-ring.

2.

Disconnect hose assembly (4) and remove O-ring (5) from transmission (3). Discard O-ring.

3.

Remove four bolts (6), washers (7), transmission hydraulic control relief valve (8), and O-ring (9) from transmission (3). Discard O-ring.

4.

Remove torque converter inlet relief valve (10) and O-ring (11) from transmission (3). Discard O-ring.

427-C1002

427-C1003

0202 00-2

TM 5-3805-291-23-2

TRANSMISSION HYDRAULIC CONTROL RELIEF VALVE REPLACEMENT - CONTINUED

0202 00

INSTALLATION


1.

Install new O-ring (11) and torque converter inlet relief valve (10) on transmission (3).

2.

Install new O-ring (9), transmission hydraulic control relief valve (8), four washers (7), and bolts (6) on transmission (3). Tighten bolts to 22 ± 3 lb-ft (30 ± 4 Nm).

3.

Install new O-ring (5) and connect hose assembly (4) to transmission (3).

4.

Install new O-ring (2) and connect hose assembly (1) to transmission (3).

5.



6.


7.


8.


9.


10.


11.

Check for leaks.

END OF WORK PACKAGE

0202 00-3/(0202 00-4 Blank)

4 TM 5-3805-291-23-2

TRANSMISSION MODULATING VALVE REPLACEMENT

0203 00




Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Materials/Parts

O-ring (6) Personnel Required MOS 62B, Construction Equipment Repairer References

Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)

WP 0014 00 Equipment Conditions Cab removed (WP 0132 00) Steering frame lock connected (TM 5-3805-29110) Drawings Required


TM 5-3805-291-23P, Figure 85

Oil, lubricating, refrigerant compressor: Synthetic Ester (Item 30, WP 0233 00)



8.0 hr

0203 00-1

TM 5-3805-291-23-2

TRANSMISSION MODULATING VALVE REPLACEMENT - CONTINUED

0203 00

REMOVAL

WARNING •


•



NOTE •


•


1.

Disconnect wiring harness assembly (1) from modulating valve (2).

2.

Disconnect hose assembly (3) from modulating valve (2).

3.


4.

Remove two bolts (5), washers (6), and modulating valve (2) from transmission (7).

5.

Repeat steps 1 thru 4 for remaining five modulating valves. On some valves, wiring harness bracket (8) will need to be positioned aside.

427-C1594-2

0203 00-2

TM 5-3805-291-23-2

TRANSMISSION MODULATING VALVE REPLACEMENT - CONTINUED

0203 00


WARNING •


•


1.


2.


3.


INSTALLATION


1.

Install modulating valve (2), two washers (6), and bolts (5) on transmission (7). Tighten bolts to 22 + 2 lb-ft (30 + 4 Nm). On some modulating valves, wiring harness bracket (8) will need to be positioned on valve before installation of washers and bolts.

2.

Install new O-ring (4) on hose assembly (3).

3.

Connect hose assembly (3) to modulating valve (2).

4.

Connect wiring harness assembly (1) to modulating valve (2).

5.

Repeat steps 1 thru 4 for remaining five modulating valves.

6.


7.

Perform Fill Time for Transmission Clutch (MSD) Calibration (WP 0014 00).


8.


9.


10.

Operate machine and verify correct operation of transmission system (TM 5-3805-291-10).

11.



20 TM 5-3805-291-23-2

TRANSMISSION AND TORQUE CONVERTER REPLACEMENT

0204 00



Personnel Required

Direct Support



References WP 0205 00 Equipment Conditions




Transmission oil drained (WP 0100 00)

Lever puller hoist (Item 37, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00) Beam, hoisting

Transmission cooler lines removed (WP 0102 00) Fill tube removed (WP 0103 00) Handrails removed (WP 0134 00)

Bolt, 19 mm, 8 cm Lifting equipment, 3,500-lb capacity

Implement piston pump removed (WP 0216 00)

Multiplier, torque

Hydraulic tank removed (WP 0159 00)

Wood block, 2 x 4 x 6 in. (2)

Steering control valve removed (WP 0127 00)

Materials/Parts Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00)

Secondary steering control valve removed (WP 0126 00) Center drive shaft removed (WP 0107 00)


Rear drive shaft removed (WP 0110 00)




Drawings Required

Paint, heat resisting (Item 32, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

TM 5-3805-291-23P, Figure 87



O-ring (7) Preformed packing

24.0 hr

0204 00-1

TM 5-3805-291-23-2

TRANSMISSION AND TORQUE CONVERTER REPLACEMENT - CONTINUED

0204 00

REMOVAL Transmission Assembly

0204 00

WARNING •


•


CAUTION •

Wipe area clean around all connections to be opened during removal. Cap lines and hoses and plug openings after removing lines. Contamination of system could result in premature failure.

NOTE

1.

•


•


Disconnect test port line (1) from fitting (2). Remove O-ring (3) from line assembly. Discard O-ring.

427-C0975

0204 00-2

TM 5-3805-291-23-2


0204 00

REMOVAL - CONTINUED Transmission Assembly - Continued

0204 00

2.


3.


427-C0348-1

0204 00-3

TM 5-3805-291-23-2


0204 00


0204 00

4.

Disconnect hose assembly (10) from modulating valve (11).

5.


6.

Repeat steps 4 and 5 for remaining modulating valves.

427-C1594-1

7.

Remove bolt (13), washer (14), and bracket (15) from torque converter (16).

8.

Install link bracket on torque converter (16) using 19 mm bolt.

427-C1935

0204 00-4

TM 5-3805-291-23-2


0204 00

REMOVAL - CONTINUED Transmission Assembly - Continued 9.

0204 00

Remove four bolts (17), washers (18), and brackets (19 and 20) from transmission assembly (21). Remove two bolts (22) and washers (23) from transmission assembly and reposition bracket (20) on transmission assembly installed with two bolts and washers, as shown.

427-C0983

10.

427-C0984

Attach lifting equipment to transmission assembly (21) and torque converter (16).

427-C1936

0204 00-5

TM 5-3805-291-23-2


0204 00


0204 00

WARNING


NOTE Combined transmission assembly weighs 2,200 lb (998 kg).

11.

Remove bolt (24) and washers (25 and 26) from bracket assembly (27). Repeat for opposite side.

12.

Relieve tension of transmission mounts with lifting equipment.

13.

Remove five bolts (28) and washers (29) from lower torque converter assembly (16).

WARNING


NOTE Engine weighs 3,200 lb (1,451 kg).

14.

Raise engine slightly and insert wood block between flywheel housing and axle as shown.

15.

Lower engine to rest on wood block.

427-C0986 427-C1937

0204 00-6

TM 5-3805-291-23-2


0204 00


0204 00

WARNING


NOTE Each bracket assembly weighs 70 lb (32 kg).

16.

Remove four bolts (30) and washers (31) from bracket assembly (27).

17.

With assistance, remove bracket assembly (27).

18.


19.

Remove six bolts (28) and washers (29) from upper torque converter (16).

427-C0987

0204 00-7

TM 5-3805-291-23-2


0204 00


0204 00

WARNING



20.

With assistance, remove torque converter and transmission assembly from machine.

427-C0999

NOTE Not required for class III leak. 21.

Replace oil cooler (WP 0205 00) in event of major failure of transmission.

427-C1936

0204 00-8

TM 5-3805-291-23-2


0204 00

REMOVAL - CONTINUED Torque Converter 1.

0204 00

Position torque converter (16) on wood blocks as shown.

427-C0988


NOTE Torque converter weighs 420 lb (191 kg).

2.

Attach link brackets and lifting equipment to torque converter (16).

427-C0989

0204 00-9

TM 5-3805-291-23-2


0204 00

REMOVAL - CONTINUED Torque Converter - Continued

0204 00

NOTE Note lengths and locations of bolts and washers for proper reassembly.

3.

Remove 12 bolts (32) and washers (33) from torque converter (16) and transmission (21).

427-C0990

4.

With assistance, remove torque converter (16) from transmission (21).

427-C0991

Torque Converter Disassembly 1. Remove bolt (34), retainer (35), and gear (36) from torque converter (37). 2.

Remove torque converter (37) from housing (38).

3.

Remove ring (39), and O-ring (40), and preformed packing (41) from torque converter (37). Discard O-rings.

4.

Remove eight bolts (42), washers (43), and housing (44).

5.

Remove bolt (45), washer (46), and shaft (47).

6.

Remove gear (48) and bearing (49).

7.

Remove plug (51) and O-ring (50). Discard O-ring.

8.

Remove cap (52) and coupling (53). 0204 00-10

0204 00

TM 5-3805-291-23-2


0204 00

REMOVAL - CONTINUED

0204 00

Torque Converter Disassembly - Continued

0204 00

0204 00-11

TM 5-3805-291-23-2


0204 00


WARNING •


•


1.


2.


3.


INSTALLATION Torque Converter Assembly

0204 00

1.

Install coupling (53) and cap (52).

2.

Install new O-ring (50) and plug (51).

3.

Install bearing (49) and gear (48).

4.

Install shaft (47), washer (46), and bolt (45).

5.

Install housing (44), eight washers (43) and bolts (42).

6.

Install new preformed packing (41), new O-ring (40), and ring (39) on torque converter (37).

7.

Install torque converter (37) in housing (38).

8.

Install gear (36), retainer (35), and bolt (34) on torque converter (37).

0204 00-12

TM 5-3805-291-23-2


0204 00

INSTALLATION-CONTINUED Torque Converter Assembly-Continued

0204 00

0204 00-13

TM 5-3805-291-23-2


0204 00

INSTALLATION - CONTINUED Torque Converter

0204 00

WARNING


NOTE Torque converter weighs 420 lb (191 kg).

1.

Attach link brackets and lifting equipment to torque converter (16).

427-C0989

2.

With assistance, install torque converter (16) on transmission (21).

NOTE Note lengths and locations of bolts and washers during reassembly.

0204 00-14

TM 5-3805-291-23-2


0204 00

INSTALLATION - CONTINUED Torque Converter - Continued 3.

0204 00

Install 12 washers (33) and bolts (32) on torque converter (16) and transmission (21). .

427-C0990

Transmission Assembly 1.

0204 00

Install link bracket with 19 mm bolt on top of torque converter.

WARNING



0204 00-15

TM 5-3805-291-23-2


0204 00

INSTALLATION - CONTINUED Transmission Assembly - Continued 2.

0204 00

With assistance, use lifting equipment to position torque converter and transmission assembly in machine.

427-C0999

NOTE Each bracket assembly weighs 70 lb (32 kg).

3.

With assistance, position bracket assembly (27) on machine.

4.

Install four washers (31) and bolts (30) on bracket assembly (27) and tighten bolts to 400 ± 50 lb-ft (542 ± 68 Nm).

5.


427-C0987

0204 00-16

TM 5-3805-291-23-2


0204 00

INSTALLATION - CONTINUED Transmission Assembly - Continued

0204 00

6.

Install six washers (29) and bolts (28) on upper torque converter (16).

7.

Install five washers (29) and bolts (28) on lower torque converter (16).

427-C0986

8.

Raise engine slightly to remove block of wood.

427-C1937

9.

Install washers (26 and 25) and bolt (24) on bracket (27) and tighten bolt to 660 ± 75 lb-ft (895 ± 102 Nm).

10.

Remove lifting equipment from transmission assembly.

0204 00-17

TM 5-3805-291-23-2


0204 00


0204 00

11.

Remove two bolts (22) and washers (23) from transfer gear assembly (21) and reposition bracket (20) on transfer gear assembly to side location, as shown.

12.

Install two washers (23) and bolts (22) on transfer gear assembly (21). Install bracket (19), four washers (18), and bolts (17) on transfer gear assembly.

427-C0983

13.

427-C0984

Install bracket (15), washer (14), and bolt (13) on torque converter (16).

427-C1935

0204 00-18

TM 5-3805-291-23-2


0204 00


0204 00


14.


15.

Connect hose assembly (10) to modulating valve (11).

427-C1594-1

16.

Install new O-ring (8) on hose (7) and connect hose to elbow (9).

17.

Install new O-ring (5) on hose (4) and connect hose to elbow (6).

427-C0348-1

0204 00-19

TM 5-3805-291-23-2


0204 00

INSTALLATION - CONTINUED Transmission Assembly - Continued 18.

0204 00

Install new O-ring (3) in test port line (1) and connect line assembly to fitting (2).

427-C0975

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Install rear oil cooler line (WP 0102 00). Install handrails (WP 0134 00). Install fill tube (WP 0103 00). Install rear drive shaft (WP 0110 00). Install center drive shaft (WP 0107 00). Install secondary steering control valve (WP 0126 00). Install steering control valve (WP 0127 00). Install hydraulic tank (WP 0159 00). Install implement piston pump (WP 0216 00). Install cab (WP 0132 00). Refill transmission with clean oil (WP 0100 00).


30. 31. 32. 33. 34. 35.

Secure steering frame lock in stowed position (TM 5-3805-291-10). Start machine (TM 5-3805-291-10). Run engine until operating temperature is reached and verify correct operation of machine (TM 5-3805-291-10). Shut down engine (TM 5-3805-291-10). Check oil level (TM 5-3805-291-10). Check transmission for leaks.


4 TM 5-3805-291-23-2

TRANSMISSION OIL COOLER REPLACEMENT

0205 00




Direct Support



O-ring (2)


Personnel Required MOS 62B, Construction Equipment Repairer (2) References TM 5-3805-291-10

Lifting equipment, 100-lb capacity Materials/Parts



Side covers removed (WP 0135 00) Air cleaner removed (WP 0030 00)


Turbocharger removed (WP 0031 00)

Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Oil, lubricating, refrigerant compressor: Synthetic Ester (Item 30, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Spill containment unit, hazardous material (Item 41, WP 0233 00)

Engine oil cooler removed (WP 0027 00) Drawings Required TM 5-3805-291-23P, Figure 89 Estimated Time to Complete Task 7.5 hr



TM 5-3805-291-23-2

TRANSMISSION OIL COOLER REPLACEMENT - CONTINUED

0205 00

NOTE • •

Transmission oil cooler weighs 52 lb (24 kg). Tag hoses prior to removal to ensure correct installation.

•


REMOVAL 1.

Remove four bolts (1) and washers (2) from tube assembly (3). Repeat for opposite side of transmission oil cooler (4).

2.

Remove tube assembly (3) and O-ring (5) from transmission oil cooler (4). Discard O-ring. Repeat for opposite side of transmission oil cooler.

3.

Attach lifting equipment and remove two bolts (6) and washers (7) from bracket (8).

427-C0326

4.

Remove bolt (9), washer (10), and clip (11) from bracket (12). Position wiring harness (13) aside.

5.


6.


7.

With assistance, remove transmission oil cooler (4) from machine.

427-C1945

0205 00-2

TM 5-3805-291-23-2

TRANSMISSION OIL COOLER REPLACEMENT - CONTINUED

0205 00


WARNING •


•


1.


2.


3.


INSTALLATION


NOTE Transmission oil cooler weighs 52 lb (24 kg).

1.

Attach lifting equipment and position transmission oil cooler (4) on machine.

2.


3.


4.

Position wiring harness (13) and clip (11) on bracket (12) and secure with washer (10) and bolt (9).

5.


6.

Lubricate and install new O-ring (5) and tube assembly (3) on transmission oil cooler (4). Repeat for opposite side of transmission oil cooler.

7.

Install four washers (2) and bolts (1) on tube assembly (3). Repeat for opposite side of transmission oil cooler (4). 0205 00-3

TM 5-3805-291-23-2

TRANSMISSION OIL COOLER REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 8.

Install engine oil cooler (WP 0027 00).

9.

Install turbocharger (WP 0031 00).

10.


11.


12.


13.

Run machine until operating temperature is reached (TM 5-3805-291-10).

14.


15.

Check for leaks.

END OF WORK PACKAGE

0205 00-4

0205 00

4 TM 5-3805-291-23-2

TRANSMISSION OIL PUMP (GEAR PUMP) REPLACEMENT

0206 00


Materials/Parts - Continued Oil, lubricating, TO-4 (Item 31, WP 0233 00)

Direct Support



O-ring (3) Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions Implement piston pump removed (WP 0216 00)




Drawings Required


TM 5-3805-291-23P, Figure 90



0206 00-1

8.0 hr

TM 5-3805-291-23-2

TRANSMISSION OIL PUMP (GEAR PUMP) REPLACEMENT - CONTINUED

0206 00

REMOVAL


NOTE •


•


1.

Remove bolt (1), washer (2), and clip (3) from bracket (4).

2.

Position wiring harness (5) aside.

427-C1000

3.

Remove four bolts (6), washers (7), two flange halves (8), and disconnect hose assembly (9).

4.


5.

Remove two bolts (11) and disconnect tube assembly (12).

6.


7.

Remove bolt (14), washer (15), and disconnect sensor (16).

8.

Remove bolt (17) and bracket (18).

427-C1967

0206 00-2

TM 5-3805-291-23-2


0206 00


Attach lifting equipment to oil pump (19).

WARNING


NOTE Oil pump weighs 80 lb (36 kg). 10.

Remove seven bolts (20) and three washers (21) from oil pump (19).

11.

Remove oil pump (19) and O-ring (22) from torque converter (23). Discard O-ring.

427-C1001

INSTALLATION 1.

Attach lifting equipment to oil pump (19).

WARNING


NOTE •

Oil pump weighs 80 lb (36 kg).

•


2.

Lubricate new O-ring (22) with clean oil and install O-ring and oil pump (19) on torque converter (23).

3.

Install three washers (21) and seven bolts (20) on oil pump (19). 0206 00-3

TM 5-3805-291-23-2


0206 00


Install bracket (18) and bolt (17).

5.

Connect sensor (16) and install washer (15) and bolt (14).

6.

Lubricate new O-ring (13) with clean oil and install on tube assembly (12).

7.

Install two bolts (11) on tube assembly (12).

8.

Lubricate new O-ring (10) and install on hose assembly (9).

9.

Connect hose assembly (9), two flange halves (8), four washers (7), and bolts (6).

427-C1967

10.

Position wiring harness (5) and install bracket (4), clip (3), washer (2), and bolt (1).

11.

Install implement piston pump (WP 0216 00).

427-C1000


12.


13.


14.


15.


16.


17.

Check transmission for leaks.


8 TM 5-3805-291-23-2

FRONT AXLE REPLACEMENT

0207 00



Direct Support



Oil, lubricating, TO-4 (Item 31, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Pin, shoulder, headless (Item 48, WP 0232 00)

Tag, marker (Item 43, WP 0233 00) O-ring Personnel Required

Saddle assembly, lifting block (Item 65, WP 0232 00) Stand assembly (Item 78, WP 0232 00)

MOS 62B, Construction Equipment Repairer (2) References TM 5-3805-291-10

Stand assembly (Item 79, WP 0232 00)

WP 0015 00

Tubing assembly set, nonmetallic (Item 93, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00)

WP 0111 00 Equipment Conditions Front tires and rims removed (WP 0119 00)


Axle temperature sensor removed (WP 0081 00)

Multiplier, torque

Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figures 95 and 96



WARNING • DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing injury to personnel. • At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel.


TM 5-3805-291-23-2

FRONT AXLE REPLACEMENT - CONTINUED

0207 00

NOTE • Tag hoses and wires prior to removal to ensure correct installation. • Use a container to catch any fluid that may drain from hoses or system. Dispose of fluids IAW local policy and ordinances. Ensure all spills are cleaned up. REMOVAL 1.

Support machine frame with suitable support equipment.

2.

Use machine hydraulics to position lift arms (1) on stands, as shown.

427-C1032

3.

Remove two bolts (2) and washers (3) from guard (4).

4.

Remove guard (4) from machine.

427-C1034

0207 00-2

TM 5-3805-291-23-2


0207 00



6.


7.

Support front drive shaft (10) on stand.

8.

Remove four bolts (11) and washers (12) from straps (13).

9.

Remove two straps (13) from yoke (14).

10.

Slide drive shaft (10) away from yoke (14).

427-C1035

0207 00-3

TM 5-3805-291-23-2


0207 00

REMOVAL - CONTINUED


NOTE Axle weighs approximately 3,395 lb (1,540 kg). 11.

With assistance, attach lifting equipment to each side of axle (15).

427-C1036

12.

Remove two bolts (16), washers (17), and covers (18) from each side of machine.

427-C1037

0207 00-4

TM 5-3805-291-23-2


0207 00


Remove eight bolts (19) and washers (20) from axle (15).

14.

Use lifting equipment to lower axle (15) from machine.

427-C1038


WARNING •


•


1.


2.


3.


4.


0207 00-5

TM 5-3805-291-23-2


0207 00

INSTALLATION

WARNING


NOTE Axle weighs approximately 3,395 lb (1,540 kg).

1.

With assistance, attach lifting equipment to each side of axle (15), as shown.

427-C1036

2.

Use lifting equipment to raise axle (15) to machine.

3.

Install eight washers (20) and bolts (19) on axle (15). Tighten bolts to 1,328 ± 148 lb-ft (1,800 ± 200 Nm).

4.

Place covers (18) in position on each side of machine.

5.

Install two washers (17) and bolts (16) on each cover (18).

427-C1037

0207 00-6

TM 5-3805-291-23-2


0207 00


Slide front drive shaft (10) into yoke (14).

7.

Install two straps (13) on yoke (14).

8.

Install four washers (12) and bolts (11) on straps (13). Tighten bolts to 125 ± 11 lb-ft (170 ± 15 Nm).

9.

Remove support from front drive shaft (10).

10.


11.

Lubricate and install new O-ring (6) on hose (5).

12.


427-C1035

13.

Place guard (4) in position on machine.

14.

Install two washers (3) and bolts (2) on guard (4).

427-C1034

0207 00-7

TM 5-3805-291-23-2


0207 00


Raise lift arms (1) in order to remove stands.

427-C1032

16.

Install axle temperature sensor (WP 0081 00).

17.

Refill axle oil to correct level (WP 0111 00).

18.

Install front tires and rims (WP 0119 00).

19.

Drive machine to verify correct axle operation (TM 5-3805-291-10).

20.


21.

Check for leaks.

22.

If new axle was installed, record new disc thickness in ECM. Refer to Service Brake Wear Indicator (New Brake Disc) Check (WP 0015 00).

END OF WORK PACKAGE

0207 00-8

10 TM 5-3805-291-23-2

REAR AXLE REPLACEMENT

0208 00


Maintenance Level


Direct Support

References


TM 5-3805-291-10

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, machine shop, field maintenance, heavy, less power (Item 69, WP 0232 00)

WP 0015 00 Equipment Conditions Rear axle drained (WP 0111 00)


Rear drive shaft removed (WP 0110 00)


Rear tires and rims removed (WP 0120 00)

Multiplier, torque

Axle temperature sensor removed (WP 0081 00) Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figure 97




10.0 hr

Oil, lubricating, TO-4 (Item 31, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Tag, marker (Item 43, WP 0233 00) O-ring (4)

WARNING •


•



TM 5-3805-291-23-2

REAR AXLE REPLACEMENT - CONTINUED

0208 00

NOTE •


•


REMOVAL 1.

Disconnect tube assembly (1) and remove O-ring (2) from oscillating axle (3). Discard O-ring.

427-C0454

2.

Disconnect two tube assemblies (4) and remove two O-rings (5) from oscillating axle (3). Discard O-rings.

3.

Disconnect hose assembly (6) and remove O-ring (7) from oscillating axle (3). Discard O-ring.

427-C0455

0208 00-2

TM 5-3805-291-23-2


0208 00


Remove two bolts (8) and washers (9) from guard (10). Remove guard from machine.

427-C0457

5.

Disconnect wiring harness (11).

427-C0458

0208 00-3

TM 5-3805-291-23-2


0208 00


Fasten retainer around oscillating axle (3), front axle support (12), and yoke (13) to prevent front axle support and yoke from falling.

427-C0510


NOTE Oscillating axle weighs 3,600 lb (1,635 kg).

7.

Fasten lifting equipment to each side of oscillating axle (3).

427-C0511

0208 00-4

TM 5-3805-291-23-2


0208 00


Remove two nuts (14) and washers (15) from rear axle support (16) and machine frame.

9.


427-C0512

10.

With assistance, remove two nuts (17) and washers (18) from front axle support (12) and machine frame.

11.


12.

Remove oscillating axle (3) from machine.

427-C0513

0208 00-5

TM 5-3805-291-23-2


0208 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION 1.

Fasten retainer around oscillating axle (3), front axle support (12), and yoke (13). This will prevent front axle support and yoke from falling as oscillating axle is being installed.

427-C0510

0208 00-6

TM 5-3805-291-23-2


0208 00



NOTE

2.

•

Oscillating axle weighs 3,600 lb (1,635 kg).

•


Fasten lifting equipment to each side of oscillating axle (3) and position axle on machine.

427-C0511

3.

With assistance, install two washers (18) and nuts (17) in front axle support (12) and machine frame. Tighten nuts to 740 ± 90 lb-ft (1,000 ± 125 Nm).

4.


427-C0513

0208 00-7

TM 5-3805-291-23-2


0208 00


Install two washers (15) and nuts (14) in rear axle support (16) and machine frame.

6.


427-C0512

7.

Connect wiring harness (11).

427-C0458

0208 00-8

TM 5-3805-291-23-2


0208 00


Position guard (10) on machine and install two washers (9) and bolts (8) on guard.

427-C0457

9.

Install new O-ring (7) and connect hose assembly (6) to oscillating axle (3).

10.

Install two new O-rings (5) and connect two tube assemblies (4) to oscillating axle (3).

427-C0455

0208 00-9

TM 5-3805-291-23-2


0208 00


Install new O-ring (2) and connect tube assembly (1) to oscillating axle (3).

427-C0454

12.

Install axle temperature sensor (WP 0081 00).

13.

Install rear tires and rims (WP 0120 00).

14.

Install rear drive shaft (WP 0110 00).

15.

Fill rear axle (WP 0111 00).

16.

Operate machine at all speeds to verify correct operation of rear axle (TM 5-3805-291-10).

17.


18.

If new axle was installed, record new disc thickness in ECM. Refer to Service Brake Wear Indicator (New Brake Disc) Check (WP 0015 00).

END OF WORK PACKAGE

0208 00-10

8 TM 5-3805-291-23-2

REAR AXLE TRUNNION REPLACEMENT

0209 00




Direct Support

Bearing


Lip seal


Personnel Required


References




TM 5-3805-291-10

Rear axle removed (WP 0208 00)


Drawings Required

Gasket cement (Item 14, WP 0233 00)


TM 5-3805-291-23P, Figures 98 and 99

14.0 hr


REMOVAL

NOTE Mark bolts and hole locations to ensure correct assembly.

1.

Remove six bolts (1), washers (2), and cover (3) from rear support (4).

427-C0514

0209 00-1

TM 5-3805-291-23-2

REAR AXLE TRUNNION REPLACEMENT - CONTINUED

0209 00


Remove thrust washer (5), four bolts (6), washers (7), plate (8), and thrust washer (9) from end of trunnion (10).

427-C0515


NOTE Rear support weighs 100 lb (45 kg).

3.

Attach lifting equipment to rear support (4).

4.

With assistance, remove rear support (4) from trunnion (10).

427-C0516

0209 00-2

TM 5-3805-291-23-2


0209 00


Remove lip seal (11) and sleeve bearing (12) from rear support (4). Discard lip seal and bearing.

427-C0517

WARNING


NOTE Trunnion weighs 53 lb (24 kg).

6.

Attach lifting equipment to trunnion (10).

7.

With assistance, remove 12 bolts (13), washers (14), and trunnion (10) from rear axle housing (15).

427-C0518

0209 00-3

TM 5-3805-291-23-2


0209 00


WARNING •


•


1.


2.


3.


4.


INSTALLATION 1.

Apply gasket cement to mating surface between trunnion (10) and axle housing (15).

WARNING


NOTE Trunnion weighs 53 lb (24 kg).

2.

Attach lifting equipment to trunnion (10).

3.

With assistance, position trunnion (10) on rear axle housing (15) and install 12 washers (14) and bolts (13). Tighten bolts to 220 ± 30 lb-ft (300 ± 40 Nm).

427-C0518

0209 00-4

TM 5-3805-291-23-2


0209 00


Use press and driver to install new sleeve bearing (12) in the rear support (4).

427-C0519

427-C0520

NOTE The seal must be installed so that the sealing lip is facing toward the outside of the rear support, as shown.

5.

Use driver to install new lip seal (11) in rear support (4).

427-C0521

0209 00-5

TM 5-3805-291-23-2


0209 00



NOTE Rear support weighs 100 lb (45 kg).

6.

Attach lifting equipment to rear support (4).

7.

With assistance, install rear support (4) on trunnion (10).

427-C0516

8.

Lubricate thrust washers (5 and 9) with grease.

9.

Install thrust washer (9), plate (8), thrust washer (5), four washers (7), and bolts (6) on trunnion (10). Tighten bolts to 420 ± 60 lb-ft (570 ± 80 Nm).

427-C0515

0209 00-6

TM 5-3805-291-23-2


0209 00


NOTE Be sure to install the correct bolt in each bolt’s original hole.

10.

Install cover (3), six washers (2), and bolts (1) on rear support (4). Tighten bolts to 220 ± 30 lb-ft (300 ± 40 Nm).

427-C0514

11.

Install oscillating rear axle (WP 0208 00).

12.

Operate machine and verify correct operation of rear axle assembly (TM 5-3805-291-10).

13.


14.

Check for leaks.

END OF WORK PACKAGE

0209 00-7/(0209 00-8 Blank)

4 TM 5-3805-291-23-2

STEERING NEUTRALIZER VALVE REPLACEMENT

0210 00









Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Battery disconnect switch in OFF position (TM 53805-291-10)


Wheels chocked




Steering frame lock connected (TM 5-3805-29110) Drawings Required TM 5-3805-291-23P, Figure 109




2.0 hr

WARNING •


•


•


•



0210 00-1

TM 5-3805-291-23-2

STEERING NEUTRALIZER VALVE REPLACEMENT - CONTINUED

0210 00

NOTE •


•


•

The following procedure is for the right steering cylinder. The procedure for the left is identical.

REMOVAL 1.


2.

Remove fitting (3) and O-ring (4) from steering neutralizer valve (5). Discard O-ring.

3.

Disconnect tube (6) and remove O-ring (7) from fitting (8). Discard O-ring.

4.


5.

Disconnect tube (10) and remove O-ring (11) from fitting (12). Discard O-ring.

6.


7.

Remove two bolts (14) and washers (15) from steering neutralizer valve (5). 427-C1171

8.

Remove steering neutralizer valve (5) from frame (16).

INSTALLATION 1.

Position steering neutralizer valve (5) on frame (16).

2.

Install two washers (15) and bolts (14) on steering neutralizer valve (5).


3.

Install new O-ring (13) and fitting (12) on steering neutralizer valve (5).

4.

Install new O-ring (11) and connect tube (10) to fitting (12).

5.


6.

Install new O-ring (7) and connect tube (6) to fitting (8).

7.


8.

Install new O-ring (2) and connect hose (1) to fitting (3). 0210 00-2

TM 5-3805-291-23-2

STEERING NEUTRALIZER VALVE REPLACEMENT - CONTINUED

0210 00



9.


10.


11.


12.


13.

Check for leaks.

END OF WORK PACKAGE

0210 00-3/(0210 00-4 Blank)

18 TM 5-3805-291-23-2

SEPARATE FRONT LOADER FRAME AND REAR FRAME

0211 00

THIS WORK PACKAGE COVERS Separation, Connection INITIAL SETUP Maintenance Level

Materials/Parts Antiseize compound (Item 2, WP 0233 00)

Direct Support




Shop equipment, machine shop, field maintenance, heavy, less power (Item 69, WP 0232 00)


Adapter, mechanical puller (Item 8, WP 0232 00)



Tag, marker (Item 43, WP 0233 00) Bearing (4)

Bushing driver set (Item 20, WP 0232 00)

Bearing cup (4)

Driver plate (Item 27, WP 0232 00) (2)

Bearing sleeve (2)

Head (Item 32, WP 0232 00)

Lip seal (4)

Nut (Item 42, WP 0232 00)

Personnel Required

Nut, plain, hexagon (Item 44, WP 0232 00)


Puller, hydraulic (Item 51, WP 0232 00) Pump, hydraulic (Item 55, WP 0232 00)

References

Pump, hydraulic ram, hand driven (Item 57, WP 0232 00)

TM 5-3805-291-10

Remover, bearing and bushing (Item 61, WP 0232 00)


WP 0016 00

Screw, cap hexagon head (Item 66, WP 0232 00)


Spacer, sleeve (Item 76, WP 0232 00)


Spacer, sleeve (Item 77, WP 0232 00)

Center drive shaft removed (WP 0107 00)

Stand, lift gp (Item 80, WP 0232 00)

Front wiring harness disconnected from chassis wiring harness (WP 0197 00)

Stud, plain (Item 81, WP 0232 00) Wrench, torque, click, ratcheting, 1/2” drive, 250 lb-ft (Item 99, WP 0232 00)

Hydraulic hose assemblies disconnected from front frame (WP 0156 00) Drawings Required

Bottle jack

TM 5-3805-291-23P, Figure 117

Lifting equipment, 75,000-lb capacity Multiplier, torque


Wood block 12 x 12 x 24-in. (2)

14.0 hr

0211 00-1

TM 5-3805-291-23-2

SEPARATE FRONT LOADER FRAME AND REAR FRAME - CONTINUED

0211 00

SEPARATION

WARNING



NOTE

1. 2.

•


•


• Machine without cab weighs 50,044 lb (22,700 kg). Remove bolt (1), washer (2), and pin assembly (3) from frame (4).

Position steering cylinder (5) aside. Repeat for remaining steering cylinder.

427-C1004

0211 00-2

TM 5-3805-291-23-2


0211 00

SEPARATION - CONTINUED 3.

Use Pump, hydraulic (Item 55, WP 0232 00) and Stand, lift gp (Item 80, WP 0232 00) as shown to support rear frame.

427-C1005

4.

Position two 12 x 12 x 24-in. wood blocks under front of rear frame.

427-C1006

5.

Attach lifting equipment to loader frame.

427-C1007

0211 00-3

TM 5-3805-291-23-2


0211 00


Attach Pump, hydraulic ram, hand driven (Item 57, WP 0232 00) to end of brake actuator (6).

427-C1013-1

7.

Remove six bolts (7), washers (8), two bolts (9), and washers (10) from plate (11).

8.

Remove plate (11) and shim (12) from frame (4).

427-C1008

0211 00-4

TM 5-3805-291-23-2


0211 00

SEPARATION - CONTINUED

NOTE Use lifting equipment to relieve pressure from pin assembly during removal.

9.

Use bottle jack to remove pin (13).

427-C1009

10.

Remove spacer (14) from lower hitch (15).

427-C1010

0211 00-5

TM 5-3805-291-23-2


0211 00


Remove bolt (16) and washer (17) from pin assembly (18).

427-C1011

NOTE Use lifting equipment to relieve pressure from pin during removal.

12.

Use bottle jack to remove pin assembly (18) from upper hitch (19).

427-C1012

0211 00-6

TM 5-3805-291-23-2


0211 00


Apply pressure to end of brake actuator (6) to release parking brake.

427-C1013-1

14.

Separate loader frame from rear frame.

15.

Use two 12 x 12 x 24-in. wood blocks to support loader frame and rear frame.

427-C1015

16.

Mark position of caps (20 and 21).

17.

Remove six bolts (22) and washers (23) from cap (20).

18.

Remove cap (20), shim (24), and cap (21) from upper hitch (19) of loader frame.

427-C1016

0211 00-7

TM 5-3805-291-23-2


0211 00


Remove and discard lip seal (25) from cap (20).

20.


427-C1017

21.

Use Puller, hydraulic (Item 51, WP 0232 00), Pump, hydraulic (Item 55, WP 0232 00), Stud, plain (Item 81, WP 0232 00), Nut, plain, hexagon (Item 44, WP 0232 00), Adapter, mechanical puller (Item 8, WP 0232 00), and Spacer, sleeve (Item 76, WP 0232 00) to remove bearing cups (27 and 28) and bearings (29 and 30) from upper hitch (19) of loader frame. Discard bearing cups and bearings.

427-C1018

0211 00-8

TM 5-3805-291-23-2


0211 00


Use Puller, hydraulic (Item 51, WP 0232 00), Pump, hydraulic (Item 55, WP 0232 00), Stud, plain (Item 81, WP 0232 00), Nut, plain, hexagon (Item 44, WP 0232 00), Adapter, mechanical puller (Item 9, WP 0232 00), and Spacer, sleeve (Item 76, WP 0232 00) to remove bearing sleeve (31) from upper hitch (19) of rear frame. Discard bearing sleeve.

427-C1019

23.

Use Puller, hydraulic (Item 51, WP 0232 00), Pump, hydraulic (Item 55, WP 0232 00), Stud, plain (Item 81, WP 0232 00), Nut, plain, hexagon (Item 44, WP 0232 00), Adapter, mechanical puller (Item 9, WP 0232 00), and Spacer, sleeve (Item 76, WP 0232 00) to remove bearing sleeve (32) from the upper hitch (19) of rear frame. Discard bearing sleeve.

427-C1020

0211 00-9

TM 5-3805-291-23-2


0211 00


Mark position of caps (33 and 34).

25.

Remove eight bolts (35) and washers (36) from cap (33).

26.

Remove caps (33 and 34) and shims (37) from lower hitch (15) of rear frame.

27.


28.


427-C1022

427-C1021

29.

Use Puller, hydraulic (Item 51, WP 0232 00), Pump, hydraulic (Item 55, WP 0232 00), Stud, plain (Item 81, WP 0232 00), Nut, plain, hexagon (Item 44, WP 0232 00), Spacer, sleeve (Item 77, WP 0232 00), Remover, bearing and bushing (Item 61, WP 0232 00), and Head (Item 32, WP 0232 00) to remove bearing cups (40 and 41) and bearings (42 and 43) from lower hitch (15) of rear frame. Discard bearing cups and bearings.

30.

Adjust hitch as necessary (WP 0016 00).

427-C1023

0211 00-10

TM 5-3805-291-23-2


0211 00

CONNECTION

NOTE •

Apply antiseize compound to all bores when connecting frames. Lubricate all pin bores, seals, and pins with grease before installation.

•

The following steps are for assembling lower hitch bearings.

1.

Position cap (34) and install four washers (36) and bolts (35) equally spaced on cap. Ensure cap is seated firmly against frame of machine.

2.

Lower temperature of lower bearing cup (41) and use Bushing driver set (Item 19, WP 0232 00) to install so lower bearing cup makes contact with cap (34).

3.

Apply clean oil to new lower bearing (43) and install in new lower bearing cup (41).

4.

Apply clean oil to new upper bearing (42) and install next to lower bearing (43).

5.

Lower temperature of new upper bearing cup (40) and use Bushing driver set (Item 19, WP 0232 00) to install so upper bearing cup makes contact with upper bearing (42).

6.

Remove four bolts (35) and washers (36) from cap (34).

7.

Remove cap (34) from machine.

8.

Position shims (37) on lower hitch (15).

9.

Install caps (33 and 34), four washers (36), and bolts (35) on lower hitch (15).

10.

Install 1/4 NC x 3 3/4-in. bolt, two 1/4 NC nuts, and two driver plates. Use torque wrench to measure rolling torque. Adjust number of shims (37) to achieve rolling torque of 70 to 204 lb-in. (8 to 23 Nm).

11.

Remove four bolts (35) and washers (36) from caps (33 and 34).

12.

Remove caps (33 and 34) from machine.

427-C1024

427-C1050

0211 00-11

TM 5-3805-291-23-2


0211 00

CONNECTION - CONTINUED 13.

Use Bushing driver set (Item 20, WP 0232 00) to install new lip seal (38) in cap (33).

14.


427-C1051

15.

Position required number of shims (37) on lower hitch (15).

16.

Position caps (33 and 34), as marked, on lower hitch (15).

17.

Install eight washers (36) and bolts (35) on cap (33).

427-C1052

0211 00-12

TM 5-3805-291-23-2


0211 00

CONNECTION - CONTINUED

NOTE The following steps are for assembling upper hitch bearings.

18.

Position cap (21) and install three washers (23) and bolts (22) equally spaced on cap. Ensure cap is seated firmly against frame of machine. Apply grease to bores.

19.

Lower temperature of new lower bearing cup (28) and use Bushing driver set (Item 20, WP 0232 00) to install so lower bearing cup makes contact with cap (21).

20.

Apply clean oil to new lower bearing (30) and install in lower bearing cup (28).

21.

Apply clean oil to new upper bearing (29) and install next to lower bearing (28).

22.

Lower temperature of new upper bearing cup (27) and use Bushing driver set (Item 20, WP 0232 00) to install so upper bearing cup makes contact with upper bearing (29).

427-C1053

23.

Remove three bolts (22) and washers (23) from cap (21).

24.

Remove cap (21) from machine.

25.

Position shims (24) on upper hitch (19).

26.

Position caps (20 and 21) and install three washers (23) and bolts (22) evenly spaced on cap (21).

27.

Install 1/4 NC x 3 3/4-in. bolt, two 1/4 NC nuts, and two driver plates. Use torque wrench to measure rolling torque. Adjust number of shims (24) to achieve rolling torque of 124 to 18 lb-in. (14 to 2 Nm).

28.

Remove three bolts (22), washers (23), and caps (20 and 21) from upper hitch (19).

427-C1054

0211 00-13

TM 5-3805-291-23-2


0211 00



30.


427-C1017

31.

Position required number of shims (24) on upper hitch (19).

32.

Position caps (20 and 21) on upper hitch (19).

33.

Install six washers (23) and bolts (22) on cap (20).

427-C1016

34.

Lower temperature of bearing sleeves (32 and 31) and install in upper hitch (19).

427-C1055

0211 00-14

TM 5-3805-291-23-2


0211 00


With assistance, attach lifting equipment to front frame and apply slight lifting tension.

427-C1007

WARNING


NOTE Machine without cab weighs 50,044 lb (22,700 kg).

36.

Remove two 12 x 12 x 24-in. wood blocks from front frame.

37.

Position front frame and rear frame.

427-C1056

0211 00-15

TM 5-3805-291-23-2


0211 00


Use Pump, hydraulic (Item 55, WP 0232 00) and Stand, lift gp (Item 80, WP 0232 00) as shown, and lifting equipment to align pin bores.

427-C1005

39.

Install pin assembly (18) on machine.

40.

Install washer (17) and bolt (16) on pin assembly (18).

427-C1011

41.

Install pin (13) on lower hitch (15).

427-C1057

0211 00-16

TM 5-3805-291-23-2


0211 00


Install spacer (14) on lower hitch (15).

427-C1010

43.

Install plate (11), two washers (10), and bolts (9) on frame (4). Tighten bolts to 390 ± 50 lb-ft (530 ± 70 Nm).

44.

Use feeler gage to measure distance between machine and plate (11). Check completely around lower hitch mount plate and record minimum measurement.

45.

Remove two bolts (9), washers (10), and plate (11).

46.

Install shims (12) under plate (11). Thickness of shims should equal measurement from step 44.

47.

Install two washers (10) and bolts (9) and tighten to 390 ± 50 lb-ft (530 ± 70 Nm).

48.

Install six washers (8) and bolts (7) on plate (11) and tighten to 75 ± 15 lb-ft (100 ± 20 Nm). 427-C1008

49.

Remove 12 x 12 x 24-in. wood blocks from rear frame.

427-C1058

0211 00-17

TM 5-3805-291-23-2


0211 00


Position steering cylinder (5) on frame (4).

51.

Install pin assembly (3), washer (2), and bolt (1) on frame (4). Repeat for remaining steering cylinder.

427-C1004

52.

Connect hydraulic hose assemblies to front frame (WP 0156 00).

53.

Install center drive shaft (WP 0107 00).

54.


55.


56.

Connect front wiring harness to chassis wiring harness (WP 0197 00).

57.


58.


59.


60.

Check for leaks.

END OF WORK PACKAGE

0211 00-18

10 TM 5-3805-291-23-2

ENGINE COMPARTMENT SHIELD REPLACEMENT

0212 00






Tag, marker (Item 43, WP 0233 00) O-ring (6) Personnel Required MOS 62B, Construction Equipment Repairer (2) References

Materials/Parts

TM 5-3805-291-10



Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00)

0212 00-1

Cooling system package removed (WP 0190 00) Drawings Required TM 5-3805-291-23P, Figure 124 Estimated Time to Complete Task 9.5 hr

TM 5-3805-291-23-2

ENGINE COMPARTMENT SHIELD REPLACEMENT - CONTINUED

0212 00

REMOVAL


NOTE •


•


1.


2.

Remove grommet (4) from engine compartment shield (5).

3.

Remove hose (6) from engine compartment shield (5) and position aside.

0212 00-2

427-C0304

TM 5-3805-291-23-2


0212 00


Remove hose (7) and O-ring (8) from fitting (9). Discard O-ring.

5.

Remove two fittings (9) and O-rings (10) from adapters (11). Discard O-rings.

6.


7.


427-C0305

8.

Remove four bolts (18), washers (19), and plate (20).

427-C1968

0212 00-3

TM 5-3805-291-23-2


0212 00


Loosen clamp (21) on hose (22).

10.

Remove tube (23) from hose (22) and engine compartment shield (5).

427-C0306

11.

Remove two bolts (24), washers (25), and nut (26) from engine compartment shield (5). Repeat for opposite side.

427-C0307

0212 00-4

TM 5-3805-291-23-2


0212 00


Remove two bolts (27), washers (28), and nuts (29) from engine compartment shield (5). Repeat for opposite side.

13.

Remove engine compartment shield (5) from cooling assembly (30).

427-C0308


WARNING •


•


1.


2.


3.


0212 00-5

TM 5-3805-291-23-2


0212 00

INSTALLATION 1.

Position engine compartment shield (5) on cooling assembly (30).

2.

Install two washers (28), bolts (27), and nuts (29) on engine compartment shield (5). Repeat for opposite side.

427-C0308

3.

Install two washers (25), bolts (24), and nuts (26) on engine compartment shield (5). Repeat for opposite side.

427-C0307

0212 00-6

TM 5-3805-291-23-2


0212 00


Connect tube (23) through engine compartment shield (5) to hose (22).

5.

Tighten clamp (21) on hose (22).

427-C0306

6.

Install plate (20), four washers (19), and bolts (18).


Install new O-ring (16) and hose (15) on fitting (17).

427-C1968

0212 00-7

TM 5-3805-291-23-2


0212 00



9.

Install two new O-rings (10) and fittings (9) on adapters (11).

10.


427-C0305

11.

Install hose (6) through engine compartment shield (5).

12.

Install grommet (4) on engine compartment shield (5).

13.


427-C0304

0212 00-8

TM 5-3805-291-23-2

ENGINE COMPARTMENT SHIELD REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 14.


15.


16.


17.


18.

Check for leaks.

END OF WORK PACKAGE

0212 00-9/(0212 00-10 Blank)

0212 00

4 TM 5-3805-291-23-2

WINDSHIELD FRONT/REAR AND DOORS GLASS REPLACEMENT

0213 00



Direct Support


Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Materials/Parts



Drawings Required



TM 5-3805-291-23P, Figure 130

1.5 hr ea

Twine, 20 ft

0213 00-1

TM 5-3805-291-23-2

WINDSHIELD FRONT/REAR AND DOORS GLASS REPLACEMENT - CONTINUED

0213 00

REMOVAL


NOTE Front glass weighs 43 lb (19 kg).

1.

With assistance, support windshield (1) and peal back seal (2).

2.

With assistance, apply small amount of pressure to windshield (1) from inside cab to release windshield from seal (2).

3.

Remove windshield (1) from machine.

NOTE Weights for remaining glass sections are as follows:

4.

•

Side glass - 6 lb (2.6 kg).

•

Right door glass - 44 lb (20 kg).

•

Left door glass - 42 lb (19 kg).

•

Rear glass - 28 lb (13.6 kg).

Repeat steps 1 thru 3 for cab side glass, door glass, and rear glass. 0213 00-2

TM 5-3805-291-23-2

WINDSHIELD FRONT/REAR AND DOORS GLASS REPLACEMENT - CONTINUED

0213 00


WARNING •


•


1.


2.


3.

Inspect all parts for damage, wear, pitting, and splits and replace if necessary.

INSTALLATION 1.

Install new seal on machine.

2.

Install rope inside channel around perimeter of seal (2), with ends of rope overlapping.

427-C1450

3.

With assistance, position windshield (1) on machine.

4.

With another person applying pressure to outside of windshield (1), slowly pull rope from inside cab as seal (2) seals around perimeter of glass opening. Pressure should be uniformly applied around windshield as rope is being pulled from seal.

427-C1451

5.

Repeat steps 1 thru 4 for remaining glass sections.


28 TM 5-3805-291-23-2

SEAT ASSEMBLY REPAIR

0214 00

THIS WORK PACKAGE COVERS Disassembly, Cleaning and Inspection, Assembly INITIAL SETUP Materials/Parts - Continued


Lockwasher


O-ring (2)

Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00) Wood block, 2 x 4 in. x 1 ft

Personnel Required MOS 62B, Construction Equipment Repairer (2) References TM 5-3805-291-10 Equipment Conditions Seat removed from machine (WP 0140 00)


Seat belts removed from seat (WP 0141 00) Drawings Required TM 5-3805-291-23P, Figure 132



Cotter pin (2)

DISASSEMBLY Seat Assembly 1.

0214 00

Remove five screws (1) and lower cushion (2) from seat assembly (3).

427-C1248

0214 00-1

TM 5-3805-291-23-2

SEAT ASSEMBLY REPAIR - CONTINUED

0214 00

DISASSEMBLY - CONTINUED Seat Assembly - Continued 2.

0214 00

Remove nut (4), bolt (5), and arm rest (6) from seat assembly (3).

427-C1249

3.

Pull down on cushion (7) to release cushion from seat assembly (3).

427-C1400

0214 00-2

TM 5-3805-291-23-2


0214 00

DISASSEMBLY - CONTINUED Seat Assembly - Continued

0214 00

4.

Loosen nut (8) and spacer (9) on rod (10) and slide rod to release backrest (11) from left side of seat assembly (3).

5.

Remove backrest (11) from seat assembly (3).

427-C1401

6.

Remove clip (12) and rod (13) from seat assembly (3).

427-C1402

0214 00-3

TM 5-3805-291-23-2


0214 00


0214 00

WARNING Spring is under tension. Wear eye protection and use extreme caution when removing spring to avoid injury to personnel.

7.

Remove two cotter pins (14) from pins (15). Discard cotter pins.

8.

Remove bar (16) from seat assembly (3).

427-C1404

9.

Remove bolt (17), washer (18), bolt (19), washer (20), and bracket (21) from seat assembly (3).

427-C1405

0214 00-4

TM 5-3805-291-23-2


0214 00


0214 00

WARNING

Spring is under tension. Wear eye protection and use extreme caution when removing spring to avoid injury to personnel.

10.

Remove spring (22) and pawl (23) from seat assembly (3).

11.

Remove bolt (24) and washer (25) from gear (26).

12.

Use large screwdriver or prybar to remove gear (26) from seat assembly (3).

427-C1406

13.

Remove three nuts (27) and bolts (28) from seat assembly (3).

14.

Repeat step 13 for opposite side of seat assembly (3).

15.

Remove bracket (29) and rod (30) from seat assembly (3).

427-C1407

0214 00-5

TM 5-3805-291-23-2


0214 00

DISASSEMBLY - CONTINUED Seat Assembly - Continued 16.

0214 00

Remove two springs (31) and handle (32) from seat assembly (3).

427-C1408

17.

Remove two springs (33) and rods (34 and 35) from latches (36 and 37).

18.

Remove rod (34) from handle (38). Remove handle from seat assembly (3).

427-C1409

0214 00-6

TM 5-3805-291-23-2


0214 00


0214 00

19.

Remove nut (39) and latch (36) from seat assembly (3).

20.

Remove nut (40) and latch (37) from seat assembly (3).

427-C1410

Suspension Assembly

0214 00

WARNING Prior to disassembly, release air pressure in air spring. Failure to follow this procedure could result in injury to personnel.

1.

Pull knob (41) to release all air pressure.

2.

Remove 24 clips (42) and boot (43) from suspension assembly (44).

427-C1411

0214 00-7

TM 5-3805-291-23-2


0214 00

DISASSEMBLY - CONTINUED Suspension Assembly - Continued

0214 00

3.

Loosen setscrew on knob (41) and remove knob, nut (45), lockwasher (46), and plate (47) from air valve switch (48). Discard lockwasher.

4.

Remove four nuts (49) and two shafts (50) from suspension assembly (44).

427-C1412

5.

Remove and discard tiedown strap (51) from two wiring connectors (52).

6.

Disconnect two wiring connectors (52) from upper housing assembly (53).

427-C1413

0214 00-8

TM 5-3805-291-23-2


0214 00


0214 00

7.

Lift upper housing (53) and remove air valve switch (48) from housing.

8.

Remove upper housing (53) from lower housing (54).

427-C1414

9.

Disconnect two wiring connectors (52) from air valve switch (48).

10.

Remove hose (55) and O-ring (56) from air valve switch (48). Discard O-ring.

427-C1415

0214 00-9

TM 5-3805-291-23-2


0214 00

DISASSEMBLY - CONTINUED Suspension Assembly - Continued 11.

0214 00

Raise scissor assembly (57) and install wood block to keep in raised position.

427-C1416

12.

Remove nut (58), washer (59), bolt (60), washer (61), and bearing (62) from shock absorber (63).

13.

Remove nut (64), bolt (65), washer (66), and bearing (67) from shock absorber (63).

14.

Repeat steps 12 and 13 for second shock absorber.

427-C1417

0214 00-10

TM 5-3805-291-23-2


0214 00


0214 00

15.

Remove two bolts (68), rod (69), and toggle assembly (70) from scissor assembly (57).

16.

Remove screw (71) in order to remove spring assembly (72) from lower housing (54).

427-C1419

427-C1418

17.

Remove two nuts (73) and rod (74) from scissor assembly (57).

18.

Remove two nuts (75) and rod (76) from scissor assembly (57).

19.

Remove scissor assembly (57) from lower housing assembly (54).

20.

Remove two tether straps (77) from scissor assembly (57).

427-C1420

0214 00-11

TM 5-3805-291-23-2


0214 00


0214 00

WARNING


21.

Remove two nuts (78), rod (79), and toggle assembly (80) from scissor assembly (57).

427-C1421

22.

Remove hose (81) and O-ring (82) from spring assembly (83). Discard O-ring.

23.

Remove bolt (84) and spring assembly (83) from scissor assembly (57).

427-C1422

0214 00-12

TM 5-3805-291-23-2


0214 00

DISASSEMBLY - CONTINUED Suspension Assembly - Continued 24.

0214 00

Remove two bolts (85) and compressor assembly (86) from scissor assembly (57).

427-C1423

25.

Remove compressor assembly (86) from mount (87).

427-C1424

0214 00-13

TM 5-3805-291-23-2


0214 00


WARNING •


•


1.


2.


3.


ASSEMBLY

0214 00

Suspension Assembly

0214 00


1.

Install and firmly seat compressor assembly (86) in mount (87).

427-C1424

0214 00-14

TM 5-3805-291-23-2


0214 00

ASSEMBLY - CONTINUED

0214 00

Suspension Assembly - Continued

0214 00

2.

Install compressor assembly (86) and two bolts (85) on scissor assembly (57).

427-C1423

3.

Install spring assembly (83) and bolt (84) on scissor assembly (57).

4.

Install new O-ring (82) and connect hose (81) to spring assembly (83).

427-C1422

0214 00-15

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

5.

Install toggle assembly (80), rod (79), and two nuts (78) on scissor assembly (57).

427-C1421

6.

Install two tether straps (77) on scissor assembly (57).

7.

Install scissor assembly (57) on lower housing assembly (54).

8.

Install rod (76) and two nuts (75) on scissor assembly (57).

9.

Install rod (74) and two nuts (73) on scissor assembly (57).

10.

Install wood block to keep scissor assembly (57) raised.

427-C1420

0214 00-16

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

11.

Install spring assembly (72) and screw (71) on lower housing (54).

12.

Install toggle assembly (70), rod (69), and two bolts (68) on scissor assembly (57). Tighten bolts to 11 + 2 lb-ft (15 + 3 Nm).

427-C1419 427-C1418

13.

Install bearing (67), washer (66), bolt (65), and nut (64) on shock absorber (63).

14.

Install bearing (62), washer (61), bolt (60), washer (59), and nut (58) on shock absorber (63).

15.

Repeat steps 13 and 14 for second shock absorber.

427-C1417

0214 00-17

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

16.

Remove wood block from scissor assembly (57).

427-C1416

17.

Connect two wiring connectors (52) to air valve switch (48).

18.

Install new O-ring (56) and connect hose (55) to air valve switch (48).

427-C1415

0214 00-18

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

19.

Position air valve switch (48) on upper housing (53).

20.

Install upper housing (53) on lower housing (54).

427-C1414

21.

Connect two wiring connectors (52) to upper housing assembly (53).

22.

Install new tiedown strap (51) on two wiring connectors (52).

427-C1413

0214 00-19

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

23.

Install two shafts (50) and four nuts (49) on suspension assembly (44). Tighten nuts to 15 + 4 lb-ft (20 + 5 Nm).

24.

Install plate (47), new lockwasher (46), nut (45), and knob (41) on air valve switch (48). Tighten setscrew on knob.

427-C1412

25.

Install boot (43) on suspension assembly (44) and install 24 clips (42) on boot.

427-C1425

0214 00-20

TM 5-3805-291-23-2


0214 00


0214 00

Seat Assembly

0214 00

1.

Install latch (37) and nut (40) on seat assembly (3).

2.

Install latch (36) and nut (39) on seat assembly (3).

427-C1410

WARNING


3.

Position handle (38) on seat assembly (3) and install rod (34) on handle.

4.

Install rods (35 and 34) and springs (33) on latches (37 and 36).

427-C1409

0214 00-21

TM 5-3805-291-23-2


0214 00


0214 00

Seat Assembly - Continued

0214 00

5.

Install handle (32) and two springs (31) on seat assembly (3).

427-C1408

6.

Install bracket (29) and rod (30) on seat assembly (3).

7.

Install three bolts (28) and nuts (27) on seat assembly (3).

8.

Repeat steps 6 and 7 for opposite side of seat assembly (3).

427-C1407

0214 00-22

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

WARNING


9.

Install gear (26), washer (25), and bolt (24) on seat assembly (3).

10.

Install pawl (23) and spring (22) on seat assembly (3).

427-C1406

11.

Install bracket (21), washer (20), bolt (19), washer (18), and bolt (17) on seat assembly (3).

427-C1405

0214 00-23

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

12.

Install bar (16) on seat assembly (3).

13.

Install two new cotter pins (14) on pins (15).

427-C1404

WARNING


14.

Install rod (13) and clip (12) on seat assembly (3).

427-C1402

0214 00-24

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

15.

Position backrest (11) on seat assembly (3). Front tooth on leg of backrest should engage first tooth of side gear (26), as shown.

427-C1426

16.

With backrest (11) in position, slide rod (10) to secure backrest to left side of seat assembly (3) and tighten spacer (9) and nut (8) on rod.

427-C1401

0214 00-25

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

17.

Install cushion (7) on seat assembly (3), bottom first, then onto seat back.

427-C1400

18.

Install arm rest (6), bolt (5), and nut (4) on seat assembly (3).

427-C1249

0214 00-26

TM 5-3805-291-23-2


0214 00


0214 00


0214 00

19.

Install lower cushion (2) and five screws (1) on seat assembly (3).

427-C1248

20.

Install seat belts on seat (WP 0141 00).

21.

Install seat in machine (WP 0140 00).

22.


23.

Verify correct operation of seat assembly (TM 5-3805-291-10).

24.


END OF WORK PACKAGE

0214 00-27/(0214 00-28 Blank)

10 TM 5-3805-291-23-2

BRAKING AND HYDRAULIC FAN PUMP REPLACEMENT

0215 00






Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Materials/Parts

Gasket O-ring (8) Personnel Required MOS 62B, Construction Equipment Repairer References


TM 5-3805-291-10


0215 00-1

Equipment Conditions Hydraulic tank drained (WP 0148 00) Drawings Required TM 5-3805-291-23P, Figure 146 Estimated Time to Complete Task 4.0 hr

TM 5-3805-291-23-2

BRAKING AND HYDRAULIC FAN PUMP REPLACEMENT - CONTINUED

0215 00

REMOVAL

WARNING •


•


•



NOTE

1.

•


•



0215 00-2

TM 5-3805-291-23-2


0215 00


Disconnect hose assemblies (2 and 3) from fittings (4 and 5).

3.


427-C0586

4.

Remove four bolts (7), washers (8), and spacers (9) from bracket (10).

427-C0587

0215 00-3

TM 5-3805-291-23-2


0215 00


Remove three bolts (11), washers (12), and gasket (13), and disconnect hose assembly (14) from piston pump (15). Discard gasket.

427-C0588

6.

Disconnect hose assembly (16) from fitting (17).

7.


427-C0589

0215 00-4

TM 5-3805-291-23-2


0215 00


Remove bolt (19), washer (20), and bracket (21) from piston pump (15).

427-C0590

9.

Disconnect oil fill tube (22) from block (23) and position oil fill tube aside.

427-C0591

0215 00-5

TM 5-3805-291-23-2


0215 00


Remove three bolts (24) and washers (25) from piston pump (15). Remove piston pump from machine.

11.

Remove three fittings (26) from piston pump (15). Remove four O-rings (27) from fittings. Discard O-rings.

427-C0593

427-C0592


WARNING •


•


1.

Scrape all gasket material from mating surfaces and clean with solvent cleaning compound.

2.


3.


4.


0215 00-6

TM 5-3805-291-23-2


0215 00

INSTALLATION


1.

Install four new O-rings (27) in fittings (26). Install fittings on piston pump (15).

2.

Position piston pump (15) on machine and install three washers (25) and bolts (24).

3.

Position oil fill tube (22) on machine and connect oil fill tube to block (23).

427-C0591

4.

Position bracket (21) on piston pump (15) and install washer (20) and bolt (19) on bracket.

427-C0590

0215 00-7

TM 5-3805-291-23-2


0215 00


Install two new O-rings (18) and connect hose assembly (16) to fitting (17).

427-C0589

6.

Install new gasket (13), three washers (12), and bolts (11), and connect hose assembly (14) to piston pump (15).

427-C0588

7.

Position bracket (10) on machine and install four spacers (9), washers (8), and bolts (7).

427-C0587

0215 00-8

TM 5-3805-291-23-2


0215 00


Install two new O-rings (6) and connect hose assemblies (3 and 2) to fittings (5 and 4).

427-C0586

9.

Install panel (1) on machine.

0215 00-9

TM 5-3805-291-23-2

BRAKING AND HYDRAULIC FAN PUMP REPLACEMENT - CONTINUED INSTALLATION - CONTINUED 10.

Refill hydraulic tank (WP 0148 00).

11.

Run engine and verify correct operation of braking and hydraulic fan pump (TM 5-3805-291-10).

12.

Shut engine down and check for leaks (TM 5-3805-291-10).

END OF WORK PACKAGE

0215 00-10

0215 00

12 TM 5-3805-291-23-2

PISTON PUMPS (STEERING AND IMPLEMENT/PILOT) REPLACEMENT

0216 00







Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Lifting equipment, 360-lb capacity


Materials/Parts







0216 00-1

Hydraulic service box removed (WP 0133 00) Drawings Required TM 5-3805-291-23P, Figures 108 and 145 Estimated Time to Complete Task 10.0 hr

TM 5-3805-291-23-2

PISTON PUMPS (STEERING AND IMPLEMENT/PILOT) REPLACEMENT - CONTINUED

0216 00

REMOVAL

WARNING •


•


•



NOTE •


•


Piston Pump (Steering)

0216 00

1.

Disconnect three hose assemblies (1) from piston steering pump (2). Remove and discard three O-rings (3).

2.

Remove four bolts (4), washers (5), and two flange halves (6) and disconnect hose assembly (7) from piston steering pump (2). Remove and discard O-ring (8).

3.

Disconnect tube assembly (9) from piston steering pump (2). Remove and discard O-ring (10).

4.

Remove four bolts (11), washers (12), and two flange halves (13) and disconnect tube assembly (14) from piston steering pump (2). Remove and discard O-ring (15).

5.

Loosen clamp (16) and disconnect tube assembly (14) from hose (17).

427-C0577

0216 00-2

TM 5-3805-291-23-2


0216 00

REMOVAL - CONTINUED Piston Pump (Steering) - Continued 6.

0216 00

Attach lifting equipment to piston steering pump (2).

WARNING


NOTE Piston steering pump weighs 120 lb (54 kg).

7.

With assistance, remove two bolts (18) and washers (19) from piston steering pump (2).

8.

Remove two bolts (20), washers (21), and piston steering pump (2) from machine.

427-C0578

0216 00-3

TM 5-3805-291-23-2


0216 00

REMOVAL - CONTINUED Piston Pump (Steering) - Continued

0216 00

9.

Remove coupling (22) from piston steering pump (2).

10.


11.

Remove two fittings (24) from piston steering pump (2).

12.


427-C0579

Piston Pump (Implement/Pilot)

0216 00

1.

Disconnect two hose assemblies (26) from fittings (27).

2.


3.

Remove four bolts (29), washers (30), and two flange halves (31).

4.

Remove tube (32) from hydraulic tank (33).

5.


6.

Remove four bolts (35), washers (36), and flange (37).

7.

Disconnect tube (38) from piston implement pump (39).

8.


0216 00-4

TM 5-3805-291-23-2


0216 00

REMOVAL - CONTINUED Piston Pump (Implement/Pilot) - Continued

0216 00

WARNING


NOTE Piston implement pump weighs 235 lb (107 kg).

9.

Loosen clamp (41) and disconnect tube (38) from hose (42).

10.

Remove four bolts (43), washer (44), and two flange halves (45).

11.

Disconnect tube (46) from hydraulic tank (33).

12.


427-C0582 427-C1886

0216 00-5

TM 5-3805-291-23-2


0216 00

REMOVAL - CONTINUED Piston Pump (Implement/Pilot) - Continued

0216 00

13.

Attach lifting equipment to piston implement pump (39).

14.

With assistance, remove four bolts (48) and washers (49) from piston implement pump (39). Remove piston implement pump from machine.

427-C0583

15.

Remove coupling (50) and O-ring (51) from piston implement pump (39). Discard O-ring.

16.

Remove two fittings (27) and O-rings (52) from piston implement pump (39). Discard O-rings.

427-C0584

0216 00-6

TM 5-3805-291-23-2


0216 00


WARNING •


•


1.


2.


3.


4.


0216 00-7

TM 5-3805-291-23-2


0216 00

INSTALLATION Piston Pump (Implement/Pilot)

0216 00

NOTE Apply a thin coat of clean hydraulic oil to all O-rings before installation.

1.

Install two new O-rings (52) in fittings (27). Install fittings on piston implement pump (39).

2.

Install new O-ring (51) and coupling (50) on piston implement pump (39).

WARNING


NOTE Piston implement pump weighs 235 lb (107 kg).

3.

Attach lifting equipment to piston implement pump (39).

427-C0584

0216 00-8

TM 5-3805-291-23-2


0216 00

INSTALLATION - CONTINUED Piston Pump (Implement/Pilot) - Continued 4.

0216 00

With assistance, position piston implement pump (39) on machine and install four washers (49) and bolts (48) on piston implement pump.

427-C0583

5.

Install new O-ring (47) on tube (46).

6.

Install tube (46), two flange halves (45), four washers (44), and bolts (43) on hydraulic tank (33).

7.

Connect tube (38) to hose (42) and tighten clamp (41).

8.

Install new O-ring (40) and connect tube (38) to piston implement pump (39).

9.

Install flange (37), four washers (36), and bolts (35) on tube (38).

10.

Install new O-ring (34) on tube (32).

11.

Connect tube (32), two flange halves (31), four washers (30), and bolts (29) to hydraulic tank (33).

12.

Install two new O-rings (28) and connect hose assemblies (26) to fittings (27).

427-C0582 427-C1886

0216 00-9

TM 5-3805-291-23-2


0216 00

INSTALLATION - CONTINUED Piston Pump (Steering)

0216 00


Install two new O-rings (25) in fittings (24). Install fittings on piston steering pump (2).

2.

Install new O-ring (23) on coupling (22). Install coupling on piston steering pump (2).

427-C0579

WARNING


NOTE Piston steering pump weighs 120 lb (54 kg).

3.

Attach lifting equipment to piston steering pump (2).

4.

With assistance, position piston steering pump (2) and install two washers (21) and bolts (20).

5.

Install two washers (19) and bolts (18) on piston steering pump (2).

427-C0578

0216 00-10

TM 5-3805-291-23-2


0216 00

INSTALLATION - CONTINUED Piston Pump (Steering) - Continued

0216 00

6.

Connect tube assembly (14) to hose (17) and tighten clamp (16).

7.

Install new O-ring (15) and connect tube assembly (14) to piston steering pump (2).

8.

Install two flange halves (13), four washers (12), and bolts (11) on piston steering pump (2).

9.

Install new O-ring (10) on tube assembly (9).

10.

Install two flange halves (6), four washers (5), and bolts (4) on piston steering pump (2).

11.

Install three new O-rings (3) and connect hose assemblies (1) to piston steering pump (2).

427-C0577

12.


13.

Install hydraulic service box (WP 0133 00).

14.


15.

Check hydraulic oil level (TM 5-3805-291-10).

16.

Run engine and verify correct operation of piston pumps (TM 5-3805-291-10).

17.


18.

Check for leaks.

END OF WORK PACKAGE

0216 00-11/(0216 00-12 Blank)

6 TM 5-3805-291-23-2

BRAKE CHARGE AND HYDRAULIC FAN CONTROL MANIFOLD REPLACEMENT

0217 00


Maintenance Level


Direct Support



O-ring (14) Personnel Required MOS 62B, Construction Equipment Repairer Equipment Conditions Hydraulic system pressure relieved (TM 5-3805291-10)




Hood opened (TM 5-3805-291-10) Right side cover removed (WP 0135 00) Drawings Required



WARNING •


•


•


•


0217 00-1

TM 5-3805-291-23-2

BRAKE CHARGE AND HYDRAULIC FAN CONTROL MANIFOLD REPLACEMENT - CONTINUED

0217 00


NOTE •


•


REMOVAL 1.

Disconnect engine wiring harness (1) from demand fan solenoid (2).

2.


3.

Remove two fittings (5) and O-rings (6) from control manifold (7). Discard O-rings.

0217 00-2

TM 5-3805-291-23-2


0217 00



5.

Remove two fittings (10) and O-rings (11) from control manifold (7). Discard O-rings.

427-C1102

6.

Disconnect three hoses (12) and remove O-rings (13) from fittings (14). Discard O-rings.

7.

Remove three fittings (14) and O-rings (15) from control manifold (7). Discard O-rings.

427-C1103

0217 00-3

TM 5-3805-291-23-2


0217 00


Remove two bolts (16) and spacers (17) from control manifold (7).

9.

Remove control manifold (7) from engine (18).

427-C1104

INSTALLATION


CAUTION Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

1.

Position control manifold (7) on engine (18).

2.

Install two spacers (17) and bolts (16) on control manifold (7).

0217 00-4

TM 5-3805-291-23-2


0217 00


3.

Install three new O-rings (15) and fittings (14) on control manifold (7).

4.

Install three new O-rings (13) and connect hoses (12) to fittings (14).

427-C1103

5.

Install two new O-rings (11) and fittings (10) on control manifold (7).

6.

Install two new O-rings (9) and connect hoses (8) to fittings (10).

427-C1102

0217 00-5

TM 5-3805-291-23-2

BRAKE CHARGE AND HYDRAULIC FAN CONTROL MANIFOLD REPLACEMENT - CONTINUED 7.

Install two new O-rings (6) and fittings (5) on control manifold (7).

8.

Install two new O-rings (4) and connect hoses (3) to fittings (5).

9.

Connect engine wiring harness (1) to demand fan solenoid (2).

10.

Install right side cover (WP 0135 00).

11.

Close hood (TM 5-3805-291-10).

0217 00


12.


13.


14.


15.

Check for leaks.

END OF WORK PACKAGE

0217 00-6

14 TM 5-3805-291-23-2

MAIN HYDRAULIC CONTROL VALVE REPLACEMENT

0218 00

THIS WORK PACKAGE COVERS Main Hydraulic Control Valve: Removal, Cleaning and Inspection, Installation Solenoid Valve: Removal, Installation










Lever puller hoist (Item 37, WP 0232 00) (2)

Strap, tiedown, electrical components (Item 42, WP 0233 00) O-ring (20)

Pin, shoulder, headless (Item 48, WP 0232 00) Saddle assembly, lifting block (Item 65, WP 0232 00) Shackle assembly (Item 67, WP 0232 00)

Personnel Required MOS 62B, Construction Equipment Repairer (2) Equipment Conditions

Stand assembly (Item 78, WP 0232 00) Tube, metallic (Item 92, WP 0232 00) Wrench, torque, click, ratcheting, 3/8” drive, 75 lbft (Item 98, WP 0232 00)

Hydraulic system pressure relieved (TM 5-3805291-10) Wheels chocked Hydraulic tank drained (WP 0148 00)

Materials/Parts

Drawings Required

Cap set, protective (Item 6, WP 0233 00) Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00)

0218 00-1


TM 5-3805-291-23-2

MAIN HYDRAULIC CONTROL VALVE REPLACEMENT - CONTINUED

0218 00

MAIN HYDRAULIC CONTROL VALVE REMOVAL

WARNING •


•


•



NOTE

1.

•


•


Use stand assembly to support lift arms (1).

427-C0599

0218 00-2

TM 5-3805-291-23-2


0218 00

MAIN HYDRAULIC CONTROL VALVE REMOVAL - CONTINUED 2.

Remove eight bolts (2), washers (3), and two plates (4) from machine.

3.

Remove three nuts (5), washers (6), and plates (7) from machine.

4.

Remove two rubber covers (8) from machine.

5.

Remove two nuts (9), washers (10), and cover plate (11) from machine.

427-C1105

6.

Remove eight bolts (12) and washers (13) from two tube assemblies (14).

7.

Remove two O-rings (15) from tube assemblies (14). Discard O-rings.

8.

Remove 24 bolts (16), washers (17), and 12 flange halves (18) and disconnect eight tube assemblies (19) from main hydraulic control valve (20).

9.

Remove six O-rings (21) from eight tube assemblies (19). Discard O-rings.

427-C1106

0218 00-3

TM 5-3805-291-23-2


0218 00

MAIN HYDRAULIC CONTROL VALVE REMOVAL - CONTINUED 10.

Disconnect two hose assemblies (22) from main hydraulic control valve (20).

11.


427-C1107

12.

Disconnect hose assembly (24) from main hydraulic control valve (20).

13.


14.


15.

Remove two O-rings (27) from hose assembly (26). Discard O-ring.

16.


17.


18.

Remove eight bolts (30), washers (31), and four flange halves (32) from main hydraulic control valve (20). Disconnect two hoses (33) from main hydraulic control valve.

19.


20.

Disconnect 12 connectors (35) from main hydraulic control valve (20). 427-C1108

0218 00-4

TM 5-3805-291-23-2


0218 00

MAIN HYDRAULIC CONTROL VALVE REMOVAL - CONTINUED

NOTE Remove and discard all associated tiedown straps.

21.

Attach link bracket to main hydraulic control valve (20).

22.

Remove five bolts (36) and washers (37) from front and rear of main hydraulic control valve (20).

23.

Install lever puller hoist on main hydraulic control valve (20) and tilt link (38), as shown.

427-C1109

0218 00-5

427-C1110

TM 5-3805-291-23-2


0218 00

MAIN HYDRAULIC CONTROL VALVE REMOVAL - CONTINUED

WARNING


NOTE Main hydraulic control valve weighs 525 lb (238 kg).

24.

Attach two link brackets to main hydraulic control valve (20).

25.

Attach lever puller hoist to link bracket and tilt cylinder (39).

26.

With assistance, remove main hydraulic control valve (20) from machine.

427-C1112

427-C1111

0218 00-6

TM 5-3805-291-23-2


0218 00

MAIN HYDRAULIC CONTROL VALVE CLEANING AND INSPECTION

WARNING •


•


1.


2.


3.


4.


0218 00-7

TM 5-3805-291-23-2


0218 00

NOTE The following procedure is for the lower solenoid valve. The procedure for the other implement solenoid valve is identical.

SOLENOID VALVE REMOVAL 1.

Remove solenoid valve (40) from main hydraulic control valve (20).

2.

Remove three O-rings (41) from solenoid valve (40). Discard O-rings.

SOLENOID VALVE INSTALLATION 1.

Lubricate three new O-rings (41) with clean lubricating oil and install on solenoid valve (40).

2.

Install solenoid valve (40) in main hydraulic control valve (20). Tighten bolt on solenoid valve to 70 ± 4 lb-ft (95 ± 5 Nm).

427-C1823b

0218 00-8

TM 5-3805-291-23-2


0218 00

MAIN HYDRAULIC CONTROL VALVE INSTALLATION

WARNING


NOTE •

Main hydraulic control valve weighs 525 lb (238 kg).

•


1.

Attach link bracket to main hydraulic control valve (20).

2.

Attach lever puller hoist to link bracket and tilt cylinder (39).

427-C1112

0218 00-9

TM 5-3805-291-23-2


0218 00

MAIN HYDRAULIC CONTROL VALVE INSTALLATION - CONTINUED 3.

With assistance, attach shackle assembly to front frame of machine. Attach lever puller hoist and link bracket to shackle assembly and position main hydraulic control valve (20) on machine.

427-C1113

4.

Install five washers (37) and bolts (36) on front and rear of main hydraulic control valve (20).

427-C1109

0218 00-10

TM 5-3805-291-23-2


0218 00


Connect 12 connectors (35) to main hydraulic control valve (20).

6.

Install two new O-rings (34) in hose assemblies (33) and connect hose assemblies to main hydraulic control valve (20).

7.

Install four flange halves (32), eight washers (31), and bolts (30) on main hydraulic control valve (20).

8.


9.


10.

Install new O-ring (25) in hose assembly (24) and connect hose assembly to main hydraulic control valve (20).

11.


427-C1108

427-C1107

0218 00-11

TM 5-3805-291-23-2


0218 00


Install six new O-rings (21) in eight tube assemblies (19) and connect tube assemblies to main hydraulic control valve (20).

13.

Install 12 flange halves (18), 24 washers (17), and bolts (16) on main hydraulic control valve (20).

14.

Install two new O-rings (15) on tube assemblies (14).

15.

Install eight washers (13) and bolts (12) on two tube assemblies (14).

427-C1106

16.

Position cover plate (11) on machine and install two washers (10) and bolts (9).

17.

Install two rubber covers (8) on machine.

18.

Install plate (7), three washers (6), and nuts (5) on machine.

19.

Install two plates (4), eight washers (3), and bolts (2) on machine.

427-C1105

0218 00-12

TM 5-3805-291-23-2


0218 00



21.

Start machine (TM 5-3805-291-10) in order to raise lift arms (1) and remove all tooling.

427-C0599

22.

Operate machine and verify correct operation of main hydraulic control valve (TM 5-3805-291-10).

23.


24.

Check for leaks.

END OF WORK PACKAGE

0218 00-13/(0218 00-14 Blank)

2 TM 5-3805-291-23-2

ELECTROHYDRAULIC CONTROL (JOYSTICK) REPLACEMENT

0219 00






Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Materials/Parts Rag, wiping (Item 35, WP 0233 00)

Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10) Steering frame lock connected (TM 5-3805-29110)

Tag, marker (Item 43, WP 0233 00) Personnel Required

Drawings Required


TM 5-3805-291-23P, Figure 151


0219 00-1


TM 5-3805-291-23-2

ELECTROHYDRAULIC CONTROL (JOYSTICK) REPLACEMENT - CONTINUED

0219 00

REMOVAL

NOTE Tag wiring harnesses prior to removal to ensure correct installation.

1.

Lift boot (1) high enough to expose four bolts (2) on electrohydraulic control (3).

2.

Remove four bolts (2) from electrohydraulic control (3) and position electrohydraulic control as far forward as possible.

427-C0594

3.

Disconnect two wiring harnesses (4).

4.

Remove electrohydraulic control (3) and two wiring harnesses (4) from machine.

427-C0595

INSTALLATION 1.

Position electrohydraulic control (3) as shown and connect two wiring harnesses (4).

2. 3.

Position electrohydraulic control (3) on machine and install four bolts (2). Adjust boot (1) to cover four bolts (2) on electrohydraulic control (3).


4. 5. 6.

Secure steering frame lock in stowed position (TM 5-3805-291-10). Run engine and verify correct operation of electrohydraulic control (TM 5-3805-291-10). Shut down engine (TM 5-3805-291-10).


2 TM 5-3805-291-23-2

HEATER CORE REPLACEMENT

0220 00




Direct Support





AC system recovered (WP 0222 00)


Lower housing removed from heater assembly (WP 0227 00) Drawings Required

Materials/Parts

TM 5-3805-291-23P, Figure 176



Heater core

4.0 hr

REMOVAL

CAUTION •


•

Use two line wrenches to avoid damage to fittings.

•

Care must be taken to ensure fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

•

Dispose of all fluids according to local regulations and mandates.

NOTE •


•

Refrigerant is odorless. As a result, all of it may leak away and not be noticed until system stops cooling. All vehicle refrigerant systems lose some refrigerant depending on the condition of system. Higher loss rates signal a need to locate and repair leaks.

•

Leaks are most often found at the compressor hose connections and at various fittings and joints in system. If unapproved replacement hoses are installed, refrigerant can be lost through hose permeation.

0220 00-1

TM 5-3805-291-23-2

HEATER CORE REPLACEMENT - CONTINUED

0220 00


Remove foam insert (1) from upper housing assembly (2).

2.

Remove heater core (3) from upper housing assembly (2). Discard heater core.

427-C1186

INSTALLATION 1.

Install new heater core (3) in upper housing assembly (2).

2.

Install foam insert (1) in upper housing (2).

3.

Install lower housing on heater assembly (WP 0227 00).


4.


5.


6.


7.

Checks for coolant leaks.

8.

Charge AC system (WP 0222 00).

9.

Verify correct operation of AC system (TM 5-3805-291-10).

END OF WORK PACKAGE

0220 00-2

4 TM 5-3805-291-23-2

AIR CONDITIONING SYSTEM COMPRESSOR REPLACEMENT

0221 00



Personnel Required

Direct Support

MOS 52C, Utilities Equipment Repairer




Hood opened and side cover removed (TM 5-3805291-10)


Steering frame lock connected (TM 5-3805-29110) AC refrigerant recovered (WP 0222 00)

Materials/Parts

Serpentine belt removed (WP 0048 00)

Cap set, protective (Item 6, WP 0233 00) Oil, lubricating, refrigerant compressor: Synthetic Ester (Item 30, WP 0233 00)





4.0 hr

REMOVAL

WARNING When servicing this machine, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-872-3845.


0221 00-1

TM 5-3805-291-23-2

AIR CONDITIONING SYSTEM COMPRESSOR REPLACEMENT - CONTINUED REMOVAL - CONTINUED

NOTE •


•


1.


2.


3.

Remove four bolts (6) and washers (7) from AC compressor (8).

4.

Remove AC compressor (8) from engine (9).

5.

Drain and measure old compressor oil.

INSTALLATION 1.

Fill compressor with amount of new oil equal to that drained from old compressor.

2.

Position AC compressor (8) on engine (9).

3.

Install four washers (7) and bolts (6) on AC compressor (8). 0221 00-2

0221 00

TM 5-3805-291-23-2

AIR CONDITIONING SYSTEM COMPRESSOR REPLACEMENT - CONTINUED

0221 00


NOTE Apply a thin coat of clean refrigerant oil to all O-rings prior to installation.

4.

Install two new O-rings (4) and hoses (3) on fittings (5).

5.


6.


7.

Recharge AC system (WP 0222 00).

8.

Install side cover (TM 5-3805-291-10).

9.

Close engine hood (TM 5-3805-291-10).


10.


11.


12.

Verify AC system operation (TM 5-3805-291-10).

13.


END OF WORK PACKAGE

0221 00-3/(0221 00-4 Blank)

8 TM 5-3805-291-23-2

AIR CONDITIONING SYSTEM SERVICE

0222 00

THIS WORK PACKAGE COVERS Recovery, Evacuation, Charging







Hood opened (TM 5-3805-291-10) Machine parked on level ground (TM 5-3805-29110)



Reclaimer, refrigerant R-134a (Item 60, WP 0232 00)


Materials/Parts

Wheels chocked

Oil, lubricating, refrigerant compressor: Synthetic Ester (Item 30, WP 0233 00) Rag, wiping (Item 35, WP 0233 00) Tetrafluoroethane, technical (Refrigerant, R-134a) (Item 46, WP 0233 00)

Battery disconnect switch in OFF position (TM 53805-291-10) Estimated Time to Complete Task

RECOVERY

2.0 hr

0222 00

WARNING •

Take care to prevent refrigerant from touching your skin or eyes. Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Use protective gloves and goggles. Serious injury or blindness may result if you come in contact with liquid refrigerant.

•

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

•

DO NOT work in an area where refrigerant may contact an open flame or burning material such as a cigarette. When refrigerant contacts extreme heat, refrigerant breaks down into poisonous phosgene gas which, if breathed, causes severe respiratory irritation. DO NOT breathe fumes from an open flame leak detector.

0222 00-1

TM 5-3805-291-23-2

AIR CONDITIONING SYSTEM SERVICE - CONTINUED

0222 00

RECOVERY - CONTINUED

NOTE •

Refrigerant capacity is 5.5 lb (2.4 kg).

•

Ensure both valves on manifold gage set are closed.

•

Ensure the red and blue valves on the recovery station lines are fully closed prior to installing on machine AC system. Connections will feel loose when valves are open.

•

Record amount of refrigerant recovered from system.

1.

Install manifold gage set (1) by connecting low pressure hose (2) to suction port (3) of AC compressor (4), and high pressure hose (5) to discharge port (6) of AC compressor.

2.

Attach charging hose (7) of manifold gage set (1) to inlet (8) on recovery station (9).

3.

Open both valves on refrigerant tank (10).

427-C1194

0222 00-2

TM 5-3805-291-23-2


0222 00

RECOVERY - CONTINUED 4.

Slowly open low pressure valve (11) and high pressure valve (12) on manifold gage set (1) to release air from charging hose (7).

5.

Plug recovery station (9) into electrical outlet and turn ON power switch at control panel (13).

6.

Press “Compressor Start” button on control panel (13). When “Compressor On” light is lit, compressor (14) will start. When recovery is complete, compressor will shut off automatically.

7.

Open accumulator pressurizing valve (15) and allow oil from compressor (14) to flow into accumulator (16).

CAUTION DO NOT allow complete loss of pressure in accumulator. Doing so will damage accumulator.

8.

Slowly open oil drain valve (17) and drain oil into measuring container. Close valve when oil finishes draining.

NOTE Refrigerant oil capacity is 11 oz (325 ml).

9.

If 6 to 8 oz (177 to 237 ml) of oil from compressor (14) was lost during recovery, new oil must be added.

EVACUATION

0222 00

1.

After refrigerant is recovered from system, ensure low pressure valve (11) and high pressure valve (12) are closed.

2.

Disconnect charging hose (7) of manifold gage set (1) from recovery station inlet (8).

0222 00-3

TM 5-3805-291-23-2


0222 00

EVACUATION - CONTINUED 3.

Check oil level in vacuum pump (18).

4.

Plug vacuum pump (18) into electrical outlet.

5.

Connect charging hose (7) to inlet fitting on vacuum pump (18).

6.

Open low pressure valve (11) and high pressure valve (12) on manifold gage set (1).

7.

Turn on vacuum pump (18).

427-C1195

0222 00-4

TM 5-3805-291-23-2


0222 00

EVACUATION - CONTINUED

NOTE Vented exhaust valve must remain closed until vacuum pump has started.

8.

Open vented exhaust valve (19).

NOTE Between 28 and 29 in. Hg (95 and 98 kPa) is the required pressure specification at sea level. For every 1,000 ft (305 m) above sea level, decrease required specification by 1 in. Hg (3 kPa).

9.

Operate vacuum pump (18) until low pressure gage (20) indicates pressure between 28 and 29 in. Hg (95 and 98 kPa), then close vented exhaust valve (19). Operate vacuum pump for a minimum of 90 minutes after closing vented exhaust valve.

NOTE Maximum vacuum loss in 5 minutes must not exceed 2 in. Hg (7 kPa). Excessive vacuum loss may indicate a system leak.

10.

Close low pressure valve (11) and high pressure valve (12).

11.

Turn off vacuum pump (18).

0222 00-5

TM 5-3805-291-23-2


0222 00

CHARGING

0222 00

1.

Connect charging hose (7) from manifold gage set (1) directly to refrigerant tank valve (21) on top of refrigerant tank (10) and hand tighten.

2.

Open refrigerant tank valve (21).

3.

Loosen charging hose (7) at manifold gage set (1) for 2 to 3 seconds, then hand tighten charging hose again to purge air from line.

NOTE Correct refrigerant charging is determined by weight only and never by gage pressure.

4.

Position refrigerant tank (10) on scale (22). Check weight of refrigerant tank periodically. Weight should decrease over time.

5.

Open high pressure valve (12) on manifold gage set (1) to allow liquid refrigerant to charge system.

6.

When refrigerant reaches system capacity, close refrigerant tank valve (21) and high pressure valve (12).

7.

Record amount of refrigerant added to system.

8.

Disconnect charging hose (7) from refrigerant tank (10).

9.

While compressor (4) is still operating, close high pressure valve (23) on compressor and disconnect high pressure hose (5) from system. Open valves (11 and 12) on manifold gage set (1). Close low pressure valve (24) on compressor and disconnect low pressure hose (2) from system. Cap charging valves.

0222 00-6

TM 5-3805-291-23-2


0222 00

CHARGING - CONTINUED

427-C1196

10.

Start engine and run AC on highest cool setting (TM 5-3805-291-10).

11.

Check for correct operation of AC system (TM 5-3805-291-10).

12.

Check for leaks.

13.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0222 00-7/(0222 00-8 Blank)

16 TM 5-3805-291-23-2

REFRIGERANT HOSES, LINES, VALVES, FLANGES, AND FITTINGS REPLACEMENT

0223 00



Personnel Required MOS 52C, Utilities Equipment Repairer

Direct Support



Discharge AC system (WP 0222 00)


Hoses removed from compressor (WP 0221 00)

Hoses removed from heater core (WP 0220 00) Hoses removed from evaporator (WP 0227 00) Tube removed from inline dryer (WP 0224 00)

Materials/Parts

Tube removed from accumulator (WP 0225 00)


Hoses removed from condenser (WP 0226 00)

Oil, lubricating, refrigerant compressor: Synthetic Ester (Item 30, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Steering frame lock connected (TM 5-3805-29110) Drawings Required

Tag, marker (Item 43, WP 0233 00) Tetrafluoroethane, technical (Refrigerant, R-134a) (Item 46, WP 0233 00)


O-ring (8)

6.0 hr

REMOVAL

WARNING •


•


•


0223 00-1

TM 5-3805-291-23-2

REFRIGERANT HOSES, LINES, VALVES, FLANGES, AND FITTINGS REPLACEMENT - CONTINUED

0223 00

REMOVAL - CONTINUED

CAUTION •


•


NOTE •


•


•

Refrigerant is odorless. As a result, all of it may leak away and not be noticed until system stops cooling. All vehicle refrigerant systems lose some refrigerant depending on the condition of the system. Higher loss rates signal a need to locate and repair leaks.

•

Leaks are most often found at the compressor hose connections and at various fittings and joints in the system. If unapproved replacement hoses are installed, refrigerant can be lost through hose permeation.

•


1.

Remove nine bolts (1), washers (2), and clips (3) from hoses (4 and 5).

2.

Remove hoses (4 and 5) from machine.

427-C1250

0223 00-2

TM 5-3805-291-23-2


0223 00


Remove two bolts (6), washers (7), and clips (8) from hose (9).

4.

Disconnect hose (9) from fittings (10 and 11).

5.

Remove two O-rings (12) from hose (9). Discard O-rings.

6.

Remove hose (9) from machine.

427-C1251

0223 00-3

TM 5-3805-291-23-2


0223 00



8.


9.

Remove three bolts (19), washers (20), and clips (21) from hoses (13 and 16).

10.


427-C1252

0223 00-4

TM 5-3805-291-23-2


0223 00



12.


13.

Remove jamnuts (26 and 27) from couplings (15 and 18).

14.

Remove couplings (15 and 18) and gasket (28) from rear cab wall.

15.

Remove bolt (29), washer (30), and clips (31 and 32) from hoses (22 and 24).

16.

Remove hoses (22 and 24) from cab.

427-C1253

0223 00-5

TM 5-3805-291-23-2


0223 00


Disconnect hose (33) from hose (34).

18.

Disconnect hose (35) from hose (36).

19.

Remove nut (37), two washers (38), bolt (39), and spacer (40) from clip (41).

20.

Remove clip (42) from hoses (33 and 35).

21.

Remove bolt (43) and washer (44) from clips (45 and 46).

22.

Remove clips (45 and 46) from hoses (33 and 35).

23.

Remove hoses (33 and 35) from cab.

427-C1255

0223 00-6

TM 5-3805-291-23-2


0223 00


Remove hoses (34 and 36) from rear cab wall.

25.

Disconnect hose (34) from shutoff valve (47).

26.

Disconnect hose (36) from shutoff valve (48).

27.

Remove bolt, (49), washer (50), and clip (51) from machine.

28.

Remove three bolts (52), washers (53), and clips (54) from hoses (34 and 36).

29.


427-C1256

0223 00-7

TM 5-3805-291-23-2


0223 00


Remove shutoff valve (47) and O-ring (55) from machine. Discard O-ring.

31.

Remove shutoff valve (48) and O-ring (56) from machine. Discard O-ring.

427-C1259

INSTALLATION


1.

Install new O-ring (56) and shutoff valve (48) on machine.

2.

Install new O-ring (55) and shutoff valve (47) on machine.

0223 00-8

TM 5-3805-291-23-2


0223 00


Install three clips (54) on hoses (36 and 34) and position hoses on machine.

4.

Install three washers (53) and bolts (52) on machine.

5.


6.

Connect hose (34) to shutoff valve (48).

7.

Connect hose (36) to shutoff valve (47).

8.

Install hoses (36 and 34) on rear cab wall.

427-C1256

0223 00-9

TM 5-3805-291-23-2


0223 00


Position hoses (35 and 33) in cab.

10.

Install clips (46 and 45) on hoses (35 and 33).

11.

Install washer (44) and bolt (43) on clips (46 and 45).

12.

Install clip (42) on hoses (35 and 33).

13.

Install bolt (39), two washers (38), spacer (40), and nut (37) on clip (41).

14.

Connect hose (35) to hose (36).

15.

Connect hose (33) to hose (34).

427-C1255

0223 00-10

TM 5-3805-291-23-2


0223 00


Position hoses (24 and 22) in cab.

17.

Install clips (32 and 31), washer (30), and bolt (29) on hoses (24 and 22).

18.

Install gasket (28) and couplings (18 and 15) on rear cab wall.

19.

Install jamnuts (26 and 27) on couplings (18 and 15).

20.


21.


427-C1253

0223 00-11

TM 5-3805-291-23-2


0223 00


Position hoses (16 and 13) on machine.

23.

Install three clips (21), washers (20), and bolts (19) on hoses (16 and 13).

24.


25.


427-C1252

0223 00-12

TM 5-3805-291-23-2


0223 00


Position hose (9) on machine.

27.

Install two new O-rings (12) on hose (9).

28.

Connect hose (9) to fittings (11 and 10).

29.

Install two clips (8), washers (7), and bolts (6) on hose (9).

427-C1251

0223 00-13

TM 5-3805-291-23-2


0223 00


Position hoses (5 and 4) on machine.

31.

Install nine clips (3), washers (2), and bolts (1) on hoses (5 and 4).

427-C1250

32.

Connect hoses to compressor (WP 0221 00).

33.

Connect hoses to evaporator (WP 0227 00).

34.

Connect tube to inline dryer (WP 0224 00).

35.

Connect tube to accumulator (WP 0225 00).

36.

Connect hoses to condenser (WP 0226 00).

37.

Connect hoses to heater core (WP 0220 00).

38.


39.

Install side cover (TM 5-3805-291-10).

40.

Close engine hood (TM 5-3805-291-10).

0223 00-14

TM 5-3805-291-23-2


0223 00



41.


42.


43.


44.


END OF WORK PACKAGE

0223 00-15/(0223 00-16 Blank)

4 TM 5-3805-291-23-2

INLINE REFRIGERANT DRYER REPLACEMENT

0224 00


Personnel Required

Direct Support





Steering frame lock connected (TM 5-3805-29110) Side cover removed (WP 0135 00)

Materials/Parts

AC refrigerant serviced (WP 0222 00)






3.0 hr

REMOVAL

WARNING •


•


•


•


0224 00-1

TM 5-3805-291-23-2

INLINE REFRIGERANT DRYER REPLACEMENT - CONTINUED

0224 00

REMOVAL - CONTINUED

CAUTION •


•


NOTE

1.

•


•


•


•


•


Disconnect tube (1) and remove O-ring (2) from inline refrigerant dryer (3). Discard O-ring.

0224 00-2

TM 5-3805-291-23-2


0224 00


Disconnect tube (4) and remove O-ring (5) from inline refrigerant dryer (3). Discard O-ring.

427-C1190

3.

Remove nut (6), bolt (7), and washer (8) from mounting bracket (9).

4.

Remove two bolts (10) and washers (11) from mounting bracket (9).

5.

Remove mounting bracket (9) and inline refrigerant dryer (3) from engine (12).

427-C1191

INSTALLATION 1.

Position inline refrigerant dryer (3) and mounting bracket (9) on engine (12).

2.

Install two washers (11) and bolts (10) on mounting bracket (9).

3.

Install washer (8), bolt (7), and nut (6) on mounting bracket (9).


4.

Install new O-ring (5) in tube (4) and connect tube to inline refrigerant dryer (3). 0224 00-3

TM 5-3805-291-23-2


0224 00


Install new O-ring (2) in tube (1) and connect tube to inline refrigerant dryer (3).


6.


7.

Run engine until normal temperature is reached (TM 5-3805-291-10).

8.


9.


10.


11.


12.

Close hood (TM 5-3805-291-10).

END OF WORK PACKAGE

0224 00-4

4 TM 5-3805-291-23-2

REFRIGERANT ACCUMULATOR REPLACEMENT

0225 00


Personnel Required

Direct Support





Steering frame lock connected (TM 5-3805-29110) Side cover removed (WP 0135 00)

Materials/Parts

AC refrigerant recovered (WP 0222 00)






3.0 hr

REMOVAL

WARNING •


•


•


•


0225 00-1

TM 5-3805-291-23-2

REFRIGERANT ACCUMULATOR REPLACEMENT - CONTINUED

0225 00

REMOVAL - CONTINUED

CAUTION •


•


NOTE

1.

•


•


•


•


•


Disconnect tube (1) and remove O-ring (2) from refrigerant accumulator (3). Discard O-ring.

0225 00-2

TM 5-3805-291-23-2

REFRIGERANT ACCUMULATOR REPLACEMENT - CONTINUED

0225 00


Disconnect tube (4) and remove O-ring (5) from refrigerant accumulator (3). Discard O-ring.

3.

Remove bolt (6) and washer (7) from mounting bracket (8).

4.

Remove mounting bracket (8) and refrigerant accumulator (3) from hydraulic tank (9).

5.

Drain and measure old oil from refrigerant accumulator (3).

427-C1188

INSTALLATION

NOTE Do not add oil if compressor was also changed.

1.

Fill new refrigerant accumulator (3) with amount of new oil equal to that drained from old refrigerant accumulator.

2.

Position refrigerant accumulator (3) and mounting bracket (8) on hydraulic tank (9).

3.

Install washer (7) and bolt (6) on mounting bracket (8).


4.

Install new O-ring (5) in tube (4) and connect tube to refrigerant accumulator (3).

5.

Install new O-ring (2) in tube (1) and connect tube to refrigerant accumulator (3).


6.


7.


8.


9.


10.


11.


12.

Close hood (TM 5-3805-291-10).


6 TM 5-3805-291-23-2

AIR CONDITIONING SYSTEM CONDENSER REPLACEMENT

0226 00


Personnel Required

Direct Support



Equipment Conditions Steering frame lock connected (TM 5-3805-29110)


Radiator screen access door opened (TM 5-3805291-10)

Materials/Parts

AC refrigerant recovered (WP 0222 00)



Rag, wiping (Item 35, WP 0233 00) Estimated Time to Complete Task


4.0 hr

O-ring (2)

REMOVAL

WARNING •


•


•


•


0226 00-1

TM 5-3805-291-23-2

AIR CONDITIONING SYSTEM CONDENSER REPLACEMENT - CONTINUED

0226 00

REMOVAL - CONTINUED

CAUTION •


•


NOTE •


•


•


•


•


1.

Disconnect two hose assemblies (1) and remove Orings (2) from condenser (3). Discard O-rings.

2.


0226 00-2

TM 5-3805-291-23-2


0226 00



4.

Remove refrigerant condenser (3) from mounting brackets (6 and 9).

427-C1193


WARNING •


•


1.


2.


3.


0226 00-3

TM 5-3805-291-23-2


0226 00

INSTALLATION


1.

Position refrigerant condenser (3) on mounting brackets (9 and 6).

2.


427-C1193

3.


4.

Install two new O-rings (2) in hose assemblies (1) and connect hose assemblies to refrigerant condenser (3).

0226 00-4

TM 5-3805-291-23-2


0226 00



5.


6.


7.


8.

Close radiator screen access door (TM 5-3805-291-10).

9.


10.


END OF WORK PACKAGE

0226 00-5/(0226 00-6 Blank)

10 TM 5-3805-291-23-2

EVAPORATOR CORE REPLACEMENT

0227 00



Personnel Required MOS 52C, Utilities Equipment Repairer

Direct Support

References




Steering frame lock connected (TM 5-3805-29110) Outside cab filter removed (TM 5-3805-291-10) AC system discharged (WP 0222 00)

Materials/Parts

AC refrigerant R-134a recovered (WP 0222 00)


Coolant drained (WP 0041 00)

Oil, lubricating, refrigerant compressor: Synthetic Ester (Item 30, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

AC/heater blower motor removed (WP 0168 00) Drawings Required


TM 5-3805-291-23P, Figure 177

Evaporator core


O-ring (2)

4.0 hr

REMOVAL

CAUTION •


•


•

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

•

Dispose of all fluids according to local regulations and mandates.

0227 00-1

TM 5-3805-291-23-2

EVAPORATOR CORE REPLACEMENT - CONTINUED

0227 00

REMOVAL - CONTINUED

NOTE

1.

•

Tag hoses and wiring harnesses prior to removal to ensure correct installation.

•


•


•



427-C1177

2.

Loosen two clamps (3) and disconnect two coolant hoses (4) from heater core (5).

3.

Remove bolt (6), washer (7), and spacer (8) from clip (9).

427-C1178

0227 00-2

TM 5-3805-291-23-2


0227 00


Disconnect hose assemblies (10 and 11) and remove two O-rings (12) from evaporator core (13). Discard O-rings.

427-C1179

5.

Remove two bolts (14) from HVAC assembly (15).

427-C1180

0227 00-3

TM 5-3805-291-23-2


0227 00


Remove bolt (16) from HVAC assembly (15).

7.

Remove HVAC assembly (15) from cab.

427-C1181

8.

Remove probe (17) and disconnect connector (18) from thermostatic switch.

9.

Remove bolt (19) and washer (20).

427-C1969

0227 00-4

TM 5-3805-291-23-2


0227 00


Remove two bolts (21) and cover (22).

427-C1183

11.

Remove eight screws (23) securing upper housing assembly (24) to lower housing assembly (25).

427-C1184

0227 00-5

TM 5-3805-291-23-2


0227 00


Separate upper housing assembly (24) from lower housing assembly (25) as shown.

13.

Remove evaporator core (13) from lower housing assembly (25). Discard evaporator core.

427-C1185

INSTALLATION

NOTE Installing heater core in lower housing assembly (WP 0220 00) may ease installation.

1.

Install new evaporator core (13) in lower housing assembly (25).

2.

Install lower housing assembly (25) on upper housing assembly (24) as shown.

3.

Install eight screws (23) securing upper housing assembly (24) to lower housing assembly (25).

427-C1184

0227 00-6

TM 5-3805-291-23-2


0227 00


Install cover (22) and two bolts (21).

427-C1183

5.

Install washer (20) and bolt (19).

6.

Connect connector (18) to thermostatic switch and install probe (17).

427-C1969

0227 00-7

TM 5-3805-291-23-2


0227 00


Position HVAC assembly (15) in cab.

8.

Install bolt (16) in HVAC assembly (15).

427-C1181

9.

Install two bolts (14) on HVAC assembly (15).

427-C1180

0227 00-8

TM 5-3805-291-23-2


0227 00


Install two new O-rings (12) and connect hose assemblies (11 and 10) to evaporator core (13).

427-C1179

11.

Install spacer (8), washer (7), and bolt (6) on clip (9).

12.

Connect two coolant hoses (4) to heater core (5). Tighten clamps (3).

427-C1178

0227 00-9

TM 5-3805-291-23-2


0227 00


Connect wiring harness (2) to wiring harness (1).

427-C1177

14.

Install AC/heater blower motor (WP 0168 00).

15.

Install outside cab filter (TM 5-3805-291-10).


16.


17.


18.


19.


20.

Check for coolant leaks.

21.


22.


END OF WORK PACKAGE

0227 00-10

16 TM 5-3805-291-23-2

BUCKET TILT LEVER AND LINK REPLACEMENT

0228 00



Tools and Special Tools - Continued Sleeve, assembly (Item 73, WP 0232 00)

Direct Support

Sleeve assembly (Item 74, WP 0232 00) Tools and Special Tools







Washer, flat (Item 95, WP 0232 00) (4)

Jack stand Materials/Parts Cleaning compound, solvent, type III (Item 7, WP 0233 00)

Adapter, puller (Item 10, WP 0232 00)


Adapter, threaded (Item 12, WP 0232 00) Bushing driver set (Item 20, WP 0232 00)


Extractor, screw (Item 28, WP 0232 00)

Lip seal (6)



Nut, fastener (Item 43, WP 0232 00)


Nut, plain, hexagon (Item 45, WP 0232 00) Nut, plain, round (Item 46, WP 0232 00)




Puller, hydraulic (Item 52, WP 0232 00) Pump, hydraulic ram, hand driven (Item 57, WP 0232 00) (2) Remover, bearing and bushing (Item 61, WP 0232 00)

Tilt kickout position sensor removed (WP 0089 00) Drawings Required TM 5-3805-291-23P, Figure 181 Estimated Time to Complete Task 6.0 hr

Rod, threaded end (Item 64, WP 0232 00) (4)

0228 00-1

TM 5-3805-291-23-2

BUCKET TILT LEVER AND LINK REPLACEMENT - CONTINUED

0228 00

REMOVAL Tilt Link

0228 00

WARNING


NOTE Bucket tilt link weighs 140 lb (64 kg).

1.

Attach lifting equipment to bucket tilt link (1).

2.

With assistance, remove bolt (2), washer (3), and spacer (4) from forward pin assembly (5).

0228 00-2

TM 5-3805-291-23-2


0228 00

REMOVAL - CONTINUED Tilt Link - Continued

0228 00

NOTE Items 36, 47, 52, 57, 82, and 94 (WP 0232 00) are assembled to make puller assembly as shown.

3.

Using puller assembly, remove forward pin assembly (5) from machine.

427-C1124

4.

Remove bolt (6), washer (7), and spacer (8) from rear pin assembly (9).

427-C1125

NOTE Items 7, 36, 47, 52, 57, and 94 (WP 0232 00) are assembly to make puller assembly as shown. 5.

Using puller assembly, remove rear pin assembly (9) from machine.

427-C1126

0228 00-3

TM 5-3805-291-23-2


0228 00

REMOVAL - CONTINUED Tilt Link - Continued

0228 00


NOTE •

Bucket tilt link weighs 140 lb (64 kg).

•

Note direction of tilt link to aid in installation.

6.

Use lifting equipment to remove bucket tilt link (1) from machine.

7.

Remove lip seal (10) from each side of bucket tilt link (1). Repeat this step for opposite end of bucket tilt link. Discard four lip seals.

427-C1127

NOTE Items 10, 36, 46, 52, 57, and 82 (WP 0232 00) are assembled to make puller assembly as shown. 8.

Using puller assembly, remove bearing (11) from bucket tilt link (1). Repeat this step for opposite end of bucket tilt link.

427-C1128

0228 00-4

TM 5-3805-291-23-2


0228 00

REMOVAL - CONTINUED Tilt Lever 1.

0228 00

Place jack stand under bucket tilt link (1).

427-C1128

2.


427-C1130

WARNING


NOTE •


•

Tooling weighs 75 lb (34 kg).

0228 00-5

TM 5-3805-291-23-2


0228 00

REMOVAL - CONTINUED Tilt Lever - Continued

0228 00

NOTE Items 36, 43, 52, 57, 82, and 94 (WP 0232 00) are assembled to make puller assembly as shown. 3.

Use lifting equipment to support rod end of tilt cylinder (16).

4.

With assistance, install puller assembly on tilt cylinder (16) to remove pin assembly (15).

5.

Start engine and retract tilt cylinder (16). Lower rod end of tilt cylinder onto lift arm assembly. 427-C1131

6.

Place pin assembly (15) through pin bore of tilt lever (17).

WARNING


NOTE

7.

•

Tilt lever weighs 840 lb (380 kg).

•

Tooling weighs 75 lb (34 kg).

Use lifting equipment to support tilt lever (17).

427-C1132

0228 00-6

TM 5-3805-291-23-2


0228 00

REMOVAL - CONTINUED Tilt Lever - Continued 8.

0228 00

With assistance, remove bolt (18), washer (19), and spacer (20) from pin assembly (21).

427-C1133

NOTE

9.

•

Perform steps 9 and 10 on left side of machine.

•

Items 7, 36, 46, 52, 57, and 94 (WP 0232 00) are assembled to make puller assembly as shown.

Using puller assembly, remove pin assembly (21) from machine.

427-C1134

10.


427-C1135

0228 00-7

TM 5-3805-291-23-2


0228 00


0228 00

NOTE Items 12, 28, 46, 52, 57, 64, 82, and 95 (WP 0232 00) are assembled to make puller assembly as shown. 11.

Using puller assembly, remove pin assembly (25) from machine.

12.

Remove tilt lever (17) from machine.

427-C1136

13.

Remove lip seal (26) from center bore on each side of tilt lever (17). Discard two lip seals.

427-C1137

0228 00-8

TM 5-3805-291-23-2


0228 00


0228 00

NOTE Items 43, 47, 52, 57, 82, 94, and 95 (WP 0232 00) are assembled to make puller assembly as shown. 14.

Using puller assembly, remove bearing (27) from tilt lever (17).

427-C1138


WARNING •


•


1.


2.


3.


0228 00-9

TM 5-3805-291-23-2


0228 00

INSTALLATION Tilt Lever

0228 00

NOTE •

Before installation, lubricate bore, pins, and lip seals with grease cartridge.

•

Items 43, 47, 52, 57, 73, 82, and 94 (WP 0232 00) are assembled to make puller assembly as shown.

1.

Lower temperature of bearing (27) for tilt lever (17).

2.

Using puller assembly, install bearing (27) in tilt lever (17) to a depth of 0.39 ± 0.04 in. (10.0 ± 1.0 mm).

427-C1138

3.

Use bushing driver set to install new lip seal (26) in side of tilt lever (17). Make sure lip of seal is facing out.

4.

Repeat step 3 for lip seal (26) on opposite side of tilt lever (17).

WARNING


0228 00-10

TM 5-3805-291-23-2


0228 00

INSTALLATION - CONTINUED Tilt Lever - Continued

0228 00

NOTE Tilt lever weighs 840 lb (380 kg).

5.

With assistance, use lifting equipment to position tilt lever (17) on machine.

427-C1137

CAUTION Aligning bores of tilt lever and lift arm is important. Improper alignment can damage lip seals during installation of pin assembly.

6.

With assistance, carefully install pin assembly (25) in tilt lever (17).

7.

Install spacer (24), washer (23), and bolt (22) in pin assembly (25).

427-C1135

0228 00-11

TM 5-3805-291-23-2


0228 00

INSTALLATION - CONTINUED Tilt Lever - Continued

0228 00

CAUTION Aligning bores of tilt lever and bucket tilt link is important. Improper alignment can damage lip seals during installation of pin assembly.

NOTE Perform steps 8 and 9 on right side of machine. 8.

Install pin assembly (21) on machine.

9.

Install spacer (20), washer (19), and bolt (18) in pin assembly (21).

427-C1133

WARNING


NOTE Tilt cylinder weighs 485 lb (220 kg).

10.

Use lifting equipment to raise rod end of tilt lever (17).

11.

Start engine (TM 5-3805-291-10) and extend tilt lever (17).

12.

With assistance, align bore of tilt lever (17) with pin bore of tilt cylinder (16) and install pin assembly (15) in pin bore.

427-C1132

0228 00-12

TM 5-3805-291-23-2


0228 00

INSTALLATION - CONTINUED Tilt Lever - Continued 13.

0228 00

Install spacer (14), washer (13), and bolt (12) to secure pin assembly (15) to tilt cylinder (16).

427-C1130

14.

Remove jack stand.

15.

Install tilt kickout position sensor (WP 0089 00).

0228 00-13

TM 5-3805-291-23-2


0228 00

INSTALLATION - CONTINUED Tilt Link

0228 00

NOTE Items 10, 36, 47, 52, 57, 82, and 94 (WP 0232 00) are assembled to make puller assembly as shown. 1.

Lower temperature of all bearings (11) before installation.

2.

Using puller assembly, install bearing (11) in bucket tilt link (1) to a depth of 0.39 ± 0.04 in. (10.0 ± 1.0 mm). Repeat this step for opposite end of bucket tilt link.

427-C1128

3.

Use bushing driver set to install new lip seal (10) in each side of bucket tilt link (1). Repeat this step for opposite end of bucket tilt link.

427-C1127

WARNING


NOTE Bucket tilt link weighs 140 lb (64 kg).

0228 00-14

TM 5-3805-291-23-2


0228 00

INSTALLATION - CONTINUED Tilt Link - Continued

0228 00

4.

With assistance, use lifting equipment to position bucket tilt link (1) on machine.

5.

Apply grease to all pin bores.

6.

Install spacer (8), washer (7), and bolt (6) in rear pin assembly (9).

427-C1125

7.

Install spacer (4), washer (3), and bolt (2) on bucket tilt link (1) in forward pin assembly (5).


8.


9.

Operate machine and verify correct operation of bucket tilt system (TM 5-3805-291-10).


16 TM 5-3805-291-23-2

BUCKET LIFT ARMS REPLACEMENT

0229 00


INITIAL SETUP Materials/Parts



Tools and Special Tools Tool kit, general mechanic’s, automotive (Item 90, WP 0232 00) Shop equipment, automotive maintenance and repair: field maintenance, basic, less power (Item 68, WP 0232 00) Adapter, mechanical puller (Item 5, WP 0232 00) Adapter, mechanical puller (Item 6, WP 0232 00)

Cleaning compound, solvent, type III (Item 7, WP 0233 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00) Oil, lubricating, OE/HDO-15/40 (Item 28, WP 0233 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00) Rag, wiping (Item 35, WP 0233 00)

Adapter, puller (Item 10, WP 0232 00) Bushing driver set (Item 19, WP 0232 00)


Bushing driver set (Item 20, WP 0232 00)

Lip seal (6)


O-ring (6)


Personnel Required

Pin, shoulder, headless (Item 48, WP 0232 00) (2) Puller, hydraulic (Item 52, WP 0232 00) Pump, hydraulic ram, hand driven (Item 57, WP 0232 00) Saddle assembly, lifting block (Item 65, WP 0232 00) (2) Sleeve (Item 72, WP 0232 00)

MOS 62B, Construction Equipment Repairer (2) Equipment Conditions Bucket removed (TM 5-3805-291-10) Bucket tilt link and lever removed (WP 0228 00) Tilt cylinder removed (WP 0152 00)

Stand assembly (Item 79, WP 0232 00) (2)

Lift kickout position sensor and mounting bracket removed (WP 0085 00)


Quick coupler removed (WP 0169 00)

Tubing assembly set, nonmetallic (Item 93, WP 0232 00) (2)




Lifting equipment, 4,600-lb capacity Wood block (2)

8.0 hr

0229 00-1

TM 5-3805-291-23-2

BUCKET LIFT ARMS REPLACEMENT - CONTINUED

0229 00

REMOVAL 1.

Raise lift arm (1) until front pin assembly (2) bores and rear pin assembly (3) bores are level.

2.

Install Pin, shoulder, headless (Item 48, WP 0232 00), Saddle assembly, lifting block (Item 65, WP 0232 00), Stand assembly (Item 79, WP 0232 00), and Tubing assembly set, nonmetallic (Item 93, WP 0232 00) under lift arm (1).

427-C1166

3.

Attach lifting equipment to lift cylinder (4) on lift arm (1).

4.


WARNING



5.

With assistance, place blocking between lift cylinder (4) and loader frame (8) and lower lift cylinder onto blocking.

6.

Repeat steps 4 and 5 on opposite side of machine.

427-C1167

0229 00-2

TM 5-3805-291-23-2


0229 00

REMOVAL - CONTINUED

NOTE Tag wiring harnesses prior to removal to ensure correct installation.

7.

Disconnect two wiring harnesses (12) from lighting assembly (9).

8.

Remove four bolts (10) and washers (11) from lighting assembly (9) and position aside.

WARNING •


•


•



0229 00-3

TM 5-3805-291-23-2


0229 00

REMOVAL - CONTINUED

NOTE •


•


9.

Disconnect tube assembly (13) from fitting (14).

10.

Remove fitting (14) from lift arm (1). Remove two O-rings (15) from fitting. Discard O-rings.

11.

Repeat steps 7 thru 10 for other side of machine.

427-C1169

12.

Remove four bolts (16) and washers (17) and disconnect hose assembly (18) from fitting (19).

13.


14.

Repeat steps 12 and 13 for other side of machine.

427-C1170

0229 00-4

TM 5-3805-291-23-2


0229 00


Remove four bolts (21) and washers (22) and disconnect hose assembly (23) from fitting (24).

16.


17.

Remove all associated clips and brackets securing wiring harness (26) to lift arm (1).

18.

Position wiring harness (26) aside.

427-C1262

WARNING


NOTE Lift arm weighs 3,065 lb (1,390 kg).

19.

Attach lifting equipment to lift arm (1).

427-C1263

0229 00-5

TM 5-3805-291-23-2


0229 00


With assistance, remove bolt (27), washer (28), and spacer (29) from rear pin assembly (3).

427-C1272

WARNING


NOTE Rear pin assembly and tooling weighs 75 lb (34 kg).

21.

With assistance, use lifting equipment to support puller assembly. Using Sleeve (Item 72, WP 0232 00), Nut, plain, round (Item 47, WP 0232 00), Puller, hydraulic (Item 52, WP 0232 00), and Stud, plain (Item 82, WP 0232 00), remove pin assembly (3).

22.

Repeat steps 20 and 21 for front pin assembly.

0229 00-6

TM 5-3805-291-23-2


0229 00

REMOVAL - CONTINUED



23.

With assistance, use lifting equipment to remove lift arm (1) from machine and place on wood blocks.

427-C1264

24.

Remove three lip seals (30) from each side of lift arm (1). Discard lip seals.

427-C1265

0229 00-7

TM 5-3805-291-23-2


0229 00


Use Adapter, mechanical puller (Item 6, WP 0232 00), Nut, plain, round (Item 47, WP 0232 00), Puller, hydraulic (Item 52, WP 0232 00), Sleeve (Item 72, WP 0232 00), and Stud, plain (Item 82, WP 0232 00) to remove two bearings (31) from bucket end of lift arm (1).

427-C1266

26.

Use Adapter, mechanical puller (Item 5, WP 0232 00), Nut, plain, round (Item 47, WP 0232 00), Puller, hydraulic (Item 52, WP 0232 00), Pump, hydraulic ram, hand driven (Item 57, WP 0232 00), Sleeve (Item 72, WP 0232 00), and Stud, plain (Item 82, WP 0232 00) to remove two bearings (32) from lift cylinder pin bores (33).

427-C1267

27.

Use Adapter, puller (Item 10, WP 0232 00), Nut, plain, round (Item 47, WP 0232 00), Puller, hydraulic (Item 52, WP 0232 00), Pump, hydraulic ram, hand driven (Item 57, WP 0232 00), Sleeve (Item 72, WP 0232 00), and Stud, plain (Item 82, WP 0232 00) to remove two bearings (34) from loader frame end of lift arm (1).

28.

Repeat steps 25 thru 27 on opposite side of lift arm.

427-C1268

0229 00-8

TM 5-3805-291-23-2


0229 00


WARNING •


•


1.


2.


3.


4.


0229 00-9

TM 5-3805-291-23-2


0229 00

INSTALLATION

NOTE Lower temperature of bearings for lift arm prior to installation.

1.

Use Adapter, puller (Item 10, WP 0232 00), Nut, plain, round (Item 47, WP 0232 00), Puller, hydraulic (Item 52, WP 0232 00), Pump, hydraulic ram, hand driven (Item 57, WP 0232 00), Stud, plain (Item 82, WP 0232 00), and Washer, flat (Item 94, WP 0232 00) to install two bearings (34) into loader frame end of lift arm (1). Install bearings to a depth of 0.37 ± 0.04 in. (9.5 ± 1.0 mm).

427-C1269

2.

Use Adapter, mechanical puller (Item 5, WP 0232 00), Nut, plain, round (Item 47, WP 0232 00), Puller, hydraulic (Item 52, WP 0232 00), Pump, hydraulic ram, hand driven (Item 57, WP 0232 00), Stud, plain (Item 82, WP 0232 00), and Washer, flat (Item 94, WP 0232 00) to install two bearings (32) into lift cylinder pin bores (33). Install bearings to a depth of 0.37 ± 0.04 in. (9.5 ± 1.0 mm).

427-C1270

0229 00-10

TM 5-3805-291-23-2


0229 00


Use Adapter, mechanical puller (Item 6, WP 0232 00), Nut, plain, round (Item 47, WP 0232 00), Puller, hydraulic (Item 52, WP 0232 00), Pump, hydraulic ram, hand driven (Item 57, WP 0232 00), Stud, plain (Item 82, WP 0232 00), and Washer, flat (Item 94, WP 0232 00) to install two bearings (31) into bucket end of lift arm (1). Install bearings to a depth of 0.37 ± 0.04 in. (9.5 ± 1.0 mm).

4.

Repeat steps 1 thru 3 on opposite side of lift arm.

427-C1271

5.

Use Bushing driver set (Item 19, WP 0232 00) and Bushing driver set (Item 20, WP 0232 00) to install three new lip seals (30) into each side of lift arm (1).

427-C1265

0229 00-11

TM 5-3805-291-23-2


0229 00


WARNING



6.

With assistance, use lifting equipment to position lift arm (1) on machine.

427-C1263

7.

With assistance, install rear pin assembly (3), spacer (29), washer (28), and bolt (27) on lift arm (1). Repeat for other side of machine.

427-C1272

0229 00-12

TM 5-3805-291-23-2


0229 00


Use lifting equipment to lower lift arm (1) onto Pin, shoulder, headless (Item 48, WP 0232 00), Saddle assembly, lifting block (Item 65, WP 0232 00), Stand assembly (Item 79, WP 0232 00), and Tubing assembly set, nonmetallic (Item 93, WP 0232 00).

427-C1273


9.

Install all associated clips and brackets to secure wiring harness (26) to lift arm (1).

10.


11.

Install four washers (22) and bolts (21) to connect hose assembly (23) to fitting (24).

427-C1262

0229 00-13

TM 5-3805-291-23-2


0229 00


Install new O-ring (20) in hose assembly (18) and install four washers (17) and bolts (16) to connect hose assembly to fitting (19).

427-C1170

13.

Install two new O-rings (15) in fitting (14).

14.

Install fitting (14) on lift arm (1).

15.

Connect tube assembly (13) to fitting (14).

427-C1169

0229 00-14

TM 5-3805-291-23-2


0229 00


Position lighting assembly (9) on machine and install four washers (11) and bolts (10).

17.

Connect two wiring harnesses (12) to lighting assembly (9).

427-A1581

0229 00-15

TM 5-3805-291-23-2


0229 00




18.

Use lifting equipment to position lift cylinder (4) on machine.

19.

With assistance, install pin assembly (2), spacer (7), washer (6), and bolt (5) on machine.

20.

Remove blocking from loader frame (8) that was used to support lift cylinder (4).

21.

Repeat steps 18 thru 20 for other side of lift cylinder (4).

22.

Raise lift arm (1) and remove stand assembly.

427-C1167

23.

Install lift kickout position sensor and mounting bracket (WP 0085 00).

24.

Install tilt cylinder (WP 0152 00).

25.

Install quick coupler (WP 0169 00).

26.

Install bucket tilt link and lever (WP 0228 00).

27.

Install bucket (TM 5-3805-291-10).

28.

Run engine and verify correct operation of bucket lift arms (TM 5-3805-291-10).

29.


30.

Check for leaks.


TM 5-3805-291-23-2

CHAPTER 5 SUPPORTING INFORMATION

2 TM 5-3805-291-23-2

REFERENCES

0230 00

SCOPE This work package lists all publication indexes, forms, field manuals, technical bulletins, technical manuals, and other publications referenced in this manual and which apply to maintenance of the 966H Wheel Loader. PUBLICATION INDEXES The following indexes should be consulted frequently for latest changes or revisions and for new publications relating to material covered in this technical manual. Consolidated Army Publications and Forms Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30 Functional Users Manual for the Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . PAM 750-8 FORMS

NOTE Refer to PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual, for instructions on the use of maintenance forms.

Accident Identification Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 518 Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404, DA Form 5988-E Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407 Motor Vehicle Accident Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 91 Product Quality Deficiency Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 368 Recommended Changes to Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028 Report of Discrepancy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SF Form 364 Uncorrected Fault Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2408-14 Vehicles and Spare Engines, Processing and Deprocessing Record for Shipment, Storage, and Issue of . . . . . . DD Form 1397 FIELD MANUALS Army Motor Transport Units and Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 55-30 Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-70 Desert Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 90-3 First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 4-25.11 Multiservice Tactics, Techniques, and Procedures for Chemical, Biological, Radiological, and Nuclear Contamination Avoidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-11.3 Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-71 Operations and Maintenance of Ordnance Materiel in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 9-207 Recovery and Battlefield Damage Assessment and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 9-43-2 Rigging Techniques, Procedures, and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 5-125 TECHNICAL BULLETINS WD CARC Spot Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0242 Color, Marking, and Camouflage Painting of Military Vehicles, Construction Equipment and Materials Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0209 Solder and Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB SIG 222 0230 00-1

TM 5-3805-291-23-2

REFERENCES - CONTINUED

0230 00

TECHNICAL BULLETINS - CONTINUED Use of Antifreeze Multi-Engine Type Cleaning Compounds, and Test Kit in Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651 Warranty Bulletin for the 9666H Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TB 5-3805-291-14 TECHNICAL MANUALS Decontamination system, Sorbent: M100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 3-4230-236-10 Inspection, Care, and Maintenance of Antifriction Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214 Materials Used for Cleaning, Preserving, Abrading and Cementing Ordnance Materiel, and Related Materiels Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247 Operator’s and Organizational Maintenance Manual Including RPSTL for STE/ICE-R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-4910-571-12&P Operator’s Manual for the 966H Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3805-291-10 Operator’s, Unit, Direct Support, and General Support Maintenance Manual for Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-6140-200-14 Painting Instructions for Army Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0139 Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) . . . . . . . . . . TM 750-244-3 Transportability Guidance for the 966H Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3805-291-14 Unit, Direct Support, and General Support Including Depot Maintenance RPSTL for the 966H Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 5-3805-291-23P OTHER PUBLICATIONS Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASME Y14.38-2007 Army Medical Department Expendable/Durable Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CTA 8-100 Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items) . . . . . . . . . . . . . . . . . . . . .CTA 50-970 Fuels and Lubricants Standardization Policy for Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-12 Operator’s Circular for Welding Theory and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TC 9-237 END OF WORK PACKAGE

0230 00-2

4 TM 5-3805-291-23-2

MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION

0231 00

THE ARMY MAINTENANCE SYSTEM MAC 1.

This introduction provides a general explanation of all maintenance and repair functions authorized at the two maintenance levels under the Two-Level Maintenance System concept.

2.

The MAC immediately following this introduction designates overall authority and responsibility for the performance of maintenance functions on the identified end item or component. The application of the maintenance functions to the end item or component shall be consistent with the capacities of the designated maintenance levels, which are shown in the MAC (WP 0232 00) in column (4) as: Field - includes subcolumns: C - Operator/Crew O - Unit D - Direct Support Sustainment - includes subcolumns: H - General Support D - Depot

3.

The tools and test equipment requirements (immediately following the MAC) list the tools and test equipment (both special tools and common tool sets) required for each maintenance function as referenced from the MAC.

4.

The remarks (immediately following the tools and test equipment requirements) contain supplemental instructions and explanatory notes for a particular maintenance function.

MAINTENANCE FUNCTIONS Maintenance functions are limited to and defined as follows: 1.

Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or electrical characteristics with established standards through examination (e.g., by sight, sound, or feel).

2.

Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical characteristics of an item and comparing those characteristics with prescribed standards on a scheduled basis, i.e., load testing of lift equipment and hydrostatic testing of pressure hoses.

3.

Service. Operations required periodically to keep an item in proper operating condition; e.g., to clean (includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants, chemical fluids, or gases.

4.

Adjust. To maintain or regulate, within prescribed limits, by bringing into proper position, or by setting the operating characteristics to specified parameters.

5.

Align. To adjust specified variable elements of an item to bring about optimum or desired performance.

6.

Calibrate. To determine and cause corrections to be made or to be adjusted on instruments of test, measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared.

7.

Remove/Install. To remove and install the same item when required to perform service or other maintenance functions. Install may be the act of emplacing, seating, or fixing into position a spare, repair part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or system.

8.

Replace. To remove an unserviceable item and install a serviceable counterpart in its place. “Replace” is authorized by the MAC and assigned maintenance level is shown as the third position code of the Source, Maintenance, and Recoverability (SMR) code.

9.

Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, disassembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part, subassembly, module (component or assembly), end item, or system. 0231 00-1

TM 5-3805-291-23-2

MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED

0231 00

MAINTENANCE FUNCTIONS - CONTINUED

NOTE The following definitions are applicable to the “repair” maintenance function: •

Services - Inspect, test, service, adjust, align, calibrate, and/or replace.

•

Fault location/troubleshooting - The process of investigating and detecting the cause of equipment malfunctioning; the act of isolating a fault within a system or Unit Under Test (UUT).

•

Disassembly/assembly - The step-by-step breakdown (taking apart) of a spare/functional group coded item and to the level of its least component, that is assigned a SMR code for the level of maintenance under consideration (i.e., identified as maintenance significant).

•

Actions - Weld, grind, rivet, straighten, face, machine, and/or resurface.

10.

Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely serviceable/operational condition as required by maintenance standards in appropriate technical publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition.

11.

Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours/ miles, etc.) considered in classifying Army equipment/components.

EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 1.

Column (1) - Group Number. Column (1) lists Functional Group Code numbers, the purpose of which is to identify maintenance significant components, assemblies, subassemblies, and modules with the Next Higher Assembly (NHA).

2.

Column (2) - Component/Assembly. Column (2) contains the item names of components, assemblies, subassemblies, and modules for which maintenance is authorized.

3.

Column (3) - Maintenance Function. Column (3) lists the functions to be performed on the item listed in Column (2). (For a detailed explanation of these functions refer to Maintenance Functions outlined above).

4.

Column (4) - Maintenance Level. Column (4) specifies each level of maintenance authorized to perform each function listed in column (3), by indicating work time required (expressed as manhours in whole hours or decimals) in the appropriate subcolumn. This work time figure represents the active time required to perform that maintenance function at the indicated level of maintenance. If the number or complexity of the tasks within the listed maintenance function varies at different maintenance levels, appropriate work time figures are to be shown for each level. The work time figure represents the average time required to restore an item (assembly, subassembly, component, module, end item, or system) to a serviceable condition under typical field operating conditions. This time includes preparation time (including any necessary disassembly/assembly time), troubleshooting/fault location time, and quality assurance time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the MAC. The symbol designations for the various maintenance levels are as follows: Field: C - Operator/Crew Maintenance O - Unit Maintenance D - Direct Support Maintenance Sustainment: H - General Support Maintenance D - Depot Maintenance 0231 00-2

TM 5-3805-291-23-2

MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION - CONTINUED

0231 00

EXPLANATION OF COLUMNS IN THE MAC, TABLE 1 - CONTINUED

NOTE The “L” maintenance level is not included in column (4) of the MAC. Functions to this level of maintenance are identified by a work time figure in the “H” column of column (4) and an associated reference code is used in the REMARKS CODE column (6). This code is keyed to the remarks and the SRA complete repair application is explained there.

5.

Column (5) - Tools and Equipment Reference Code. Column (5) specifies, by code, those common tool sets (not individual tools), common Test, Measurement, and Diagnostic Equipment (TMDE), special tools, special TMDE, and special support equipment required to perform the designated function. Codes are keyed to the entries in the tools and test equipment table.

6.

Column (6) - Remarks Code. When applicable, this column contains a letter code, in alphabetical order, which is keyed to the remarks table entries (Table 3).

EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS, TABLE 2 1.

Column (1) - Tool or Test Equipment Reference Code. The tool and test equipment reference code correlates with a code used in column (5) of the MAC.

2.

Column (2) - Maintenance Level. The lowest level of maintenance authorized to use the tool or test equipment.

3.

Column (3) - Nomenclature. Name or identification of the tool or test equipment.

4.

Column (4) - National Stock Number (NSN). The NSN of the tool or test equipment.

5.

Column (5) - Tool Number. The manufacturer's part number, model number, or type number.

EXPLANATION OF COLUMNS IN THE REMARKS, TABLE 3 1.

Column (1) - Remarks Code. The code recorded in column (6) of the MAC.

2.

Column (2) - Remarks. This column lists information pertinent to the maintenance function being performed as indicated in the MAC.

END OF WORK PACKAGE

0231 00-3/(0231 00-4 Blank)

22 TM 5-3805-291-23-2

MAINTENANCE ALLOCATION CHART (MAC)

0232 00

Table 1. Maintenance Allocation Chart (MAC) for 966H Loader. (1)

(2)

(3)

(4) MAINTENANCE LEVEL FIELD

GROUP NUMBER

01

0100

COMPONENT/ ASSEMBLY

MAINTENANCE FUNCTION

UNIT C

O

DS

GS

DEPOT

F

H

D

0103

Engine

Test

Engine Assembly

Inspect Service Replace

1.0 0.3 0.1

Inspect Replace

3,13,49,68,75, 84,86,87,89,90

0.7

70,90 15,22, 41,68,90,99

40.5 60

E B B A D

0.3 0.8

70,90

Crankcase, Block, and Cylinder Head Cylinder Block

Inspect Replace Repair

Cylinder Head Assembly

Inspect Replace

D D D

0.7 20.0 8.0 0.5 22.5

68,90,98,99

A

Rebuild

8.0

D

Crankshaft


0.5 14.5 1.5

D D D

Front Main Seal

Replace

10.5

68,90

Rear Main Seal

Replace

39.0

68,90

Vibration Damper and Pulley

Inspect Replace

0.3 9.0

68,90 68,90

Inspect

38.0

Replace

38.0

25,26, 68,90 25,26, 68,90

Inspect Replace

42.0 42.0

Crankshaft

Flywheel Flywheel

Flywheel Housing 0104

TOOLS AND EQUIPMENT REMARKS REF CODE CODE

ENGINE

Engine Mounts

0102

(6)

SUSTAINMENT

Rebuild

0101

(5)

Piston, Connecting Rods Inspect Replace

25,26,68,90 25,26,68,90 0.5 8.0

0232 00-1

D D

TM 5-3805-291-23-2

MAINTENANCE ALLOCATION CHART (MAC) - CONTINUED

0232 00

Table 1. Maintenance Allocation Chart (MAC) for 966H Loader - Continued. (1)

(2)

(3)


GROUP NUMBER

COMPONENT/ ASSEMBLY

01

ENGINE - Continued

0105

Valves, Camshaft, and Timing System


Camshaft

Inspect Replace

Front Cover

Replace

Housing (Front)

Replace

Intake/Exhaust Valves

Adjust

UNIT C

O

DS

GS

DEPOT

F

H

D

0109


0.5 3.5 27.0

D D 68,90

48.0 3.0

D 49,68,89,90,98

4.0 5.0

B D

Rocker Arm Group

Replace

Valve Cover and Base

Replace

1.5

70,90

19,68,90,98

Crankcase Breather

Service Replace

0.7 0.7

70,90 70,90

Oil Cooler Core

Inspect Replace

0.1 2.0

70,90

Oil Filler Tube and Dipstick Tube

Inspect Replace

0.01 0.7

70,90

Oil Filter

Replace

0.3

70,90

B

Oil Filter Base

Replace

1.5

70,90

A

Oil Pan and Gasket

Replace Repair

16.0 16.0

68,90 68,90

A

Oil Pump

Replace

19.0

68,90

Piston Cooling Jets

Replace

16.5

68,90,98

Engine Lubrication System

Turbocharger Oil Lines Replace 0108

(6)

SUSTAINMENT

Replace

0106

(5)

B B A B

0.5

70,90

Manifolds Exhaust Manifold

Replace

4.0

68,90

Intake Manifold

Replace

3.0

68,90

Replace

15.0

68,90

Accessory Driving Mechanisms Idler Gears

0232 00-2

A

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

03

COMPONENT/ ASSEMBLY

0302

0304

0305

Fuel Injector

C

O

SUSTAINMENT DS

GS

DEPOT

F

H

D


Inspect

1.0

Test

1.0

21,70,84, 87,88,90 21,70,84, 87,88,90

Test

3.0

Adjust

3.0

Replace

3.0

3,68,75, 86,90,96,98 3,68,75, 86,90,96,98 3,68,75, 86,90,96,98

E E

B

Fuel Pumps Filter Lines and Fittings Replace

2.0

70,90

Fuel Priming Pump

Replace

2.0

70,90

Fuel Transfer Pump

Replace

Secondary Fuel Filter Base

Replace

Air Cleaner Assembly

2.0 2.0


0.2 0.3

Inspect Replace

0.1

68,90

A

70,90 B B

2.0

17,70,90

Turbocharger After Cooler

B 11.0

17,68,90

After Cooler (Air Intake) Air Lines

Replace

3.0

70,90

Turbocharger

Inspect Replace

0.5 0.5

70,90,98 70,90,98

0.5 3.0

70,90

4.0

70,90

0.5

70,90

Turbocharger Air Lines Inspect Replace 0306

UNIT

(6)

FUEL SYSTEM Fuel System

0301


(5)

0.03

B

Tanks, Lines, Fittings, and Headers Fuel Tank Fuel Tank Lines, Fittings, and Hoses

Inspect Replace

0.1

Inspect Replace

0.03

B B

0232 00-3

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

03 0309

COMPONENT/ ASSEMBLY

0401

05

Throttle Pedal

0503

DEPOT

F

H

D


Service Replace

0.1

Replace

0.5

70,90

B B

0.5

70,90

B

Inspect Replace

1.5

90

0.5 0.5

70,90,96 70,90

0.5

70,90,98

0.5

70,90,98

0.5 1.0 1.0

70,85,88,90 70,90

0.1

Replace Repair

B

Muffler and Pipes Exhaust Pipes and Clamps

Inspect Replace

0.1

Muffler

Inspect Replace

0.1

B B

COOLING SYSTEM Inspect Test Service

0.2 0.2

E B,E B

Radiator or Heat Exchanger Fan Shroud

Replace

Radiator


0.1

Inspect Replace

0.01

11.0

5,17,68,90

2.0

70,90 16,68,90

0.3 0.2

B B

Water Manifold, Headers, Thermostats, and Housings Cooling System Lines

B 2.0

70,90

Replace

1.5

70,90

Top Tank

Replace

1.0

70,90

Water Pump

Test Replace

0.5 1.0

70,87,90 70,90

Thermostat 0504

GS

EXHAUST SYSTEM

Cooling System

0501

O

DS

Engine Starting Aids Cold (Ether) Starting Aid

04

C

SUSTAINMENT

Fuel Filter Elements

Secondary Fuel Filter

0312

UNIT

(6)

FUEL SYSTEM Continued Primary Fuel Filter

0311


(5)

0232 00-4

B

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

COMPONENT/ ASSEMBLY

05

COOLING SYSTEM Continued

0505

Fan Assembly Hydraulic Motor, Fan

0507

Hydraulic Oil Cooler


Inspect Replace

UNIT C

O

H

D

11.5

5,17,68,90

11.0

5,17,68,90,98

2.5

68,90

A B

Test

0.3

1,2,3,4,14,18, 40,50,62,75, 83,86,90,91,97, 98 14.5

E

68,90

Replace

2.0

70,90,98,99

Belt Tensioner and Idler Replace Pulleys

1.0

70,90,98

Serpentine Belt

Inspect Replace

0.2 0.5

90 90

Adjust Replace

2.0 1.5

70,90 70,90,98

Replace

1.0

90

Fuse, Relay, and Circuit Replace Breakers

0.3

90

Instrument Cluster

Replace

0.2

70,90

Instrument Panels


1.0 1.0

90 90

2.0

3,75,86,90

A

B

Starting Motor Starter Instrument Panel Fuse/Relay Block

Messenger ECM 0608

F


Generator, Alternator

Alternator

0607

DEPOT

0.1

Accessory Support Brackets

0603

GS

ELECTRICAL SYSTEM Electrical System

0601

DS

B

Replace 06

(6)

SUSTAINMENT

0.03

Replace Inspect

(5)

Replace

0.1

B

Miscellaneous Items

0232 00-5

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

06

COMPONENT/ ASSEMBLY

C

O

SUSTAINMENT DS

GS

DEPOT

F

H

D


Replace

0.5

90

Engine Electronic Replace Control Module (ECM)

2.0

3,75,86,90

0.2 1.0

70,90 17,70,90

0.5

90

Implement Electronic Calibrate Control Module (ECM) Replace

1.0 2.0

3,75,86,90 3,75,86,90,97

Main Light Switch

Replace

0.2

90

Power Converter

Replace

1.0

70,90

Power Train Electronic Replace Control Module (ECM)

2.0

3,75,86,90

Rear Camera

Replace

5.0

98

Stoplight Limit Switch

Adjust Replace

0.5 0.5

70,90 70,90

Hood Tilt Actuator

Service Replace

Hood Tilt Switch

Replace

0.2

Turnlamp Flasher

Replace

0.5

70,90

Turnlamp Switch

Replace

0.5

70,90

Wiper Switch

Replace

0.3

90

0.2

90

0.5

90

0.5

70,90

0.5

90

0.3

70,90

0.2 0.1

90 90

B,C

E

Lights Blackout Drive

Inspect Replace

0.02

Dome Light

Replace

Service Lights

Inspect Replace

0.02

Inspect Replace

0.02

Inspect Replace

0.02


0.02

Stoplight Turnlamps Worklights

0610

UNIT

(6)

ELECTRICAL SYSTEM - Continued ARC Suppressor

0609


(5)

B B B B B B

Sending Units, Sensors, and Warning Switches

0232 00-6

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

06

0611

COMPONENT/ ASSEMBLY

UNIT C

O

(6)

SUSTAINMENT DS

GS

DEPOT

F

H

D


ELECTRICAL SYSTEM - Continued Brake Pedal Position Sensor

Replace

0.5

90

Engine Speed/Timing Sensors

Replace

0.5

70,90,98

Fuel Level Sending Unit Replace

1.0

70,90

Hydraulic Oil Temperature Sensor

Replace

3.5

90

Kickout and Position Sensors

Adjust Replace

1.0

90

Pressure Sensor/ Switches

Replace

0.5

70,90,98

Temperature Sensors/ Switches

Replace

0.5

70,90,98

Throttle Position Sensor Replace

0.5

70,90

Transmission Oil Filter Replace Bypass Switch

0.5

90

Transmission Sensors

0.5 0.5

70,90 70,90

0.3

90

0.3

90

0.5

98

0.2 0.2 0.5 1.2

90 90 90

0.5

70,90

2.0

90

0.5

90

0.3

Adjust Replace

Horns and Alarms Backup Alarm Electric Horn Quick Coupler Alarm

0612


(5)

Inspect Replace

0.02

Inspect Replace

0.02

Replace

B B

Batteries and Storage Batteries

Inspect Service Test Replace

Battery Box

Replace

Battery Cables

Inspect Replace

Battery Disconnect Switch

Replace

0.2

0.2

B B F

B

0232 00-7

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

06

COMPONENT/ ASSEMBLY

07

C

O

SUSTAINMENT DS

GS

DEPOT

F

H

D


Inspect Replace

0.02

B 0.5

90

Hull or Chassis Wiring Harness Cab Harnesses

Replace

4.0

68,90

A

Engine and Engine ECM Harnesses

Replace

4.0

90

A

Front Chassis Harness

Replace

3.0

90

A

Fuel Injector Wiring Harness

Replace

1.0

90

A

Heater and Air Conditioning Harness

Replace

1.5

90

A

Rear Chassis Harness

Replace

4.0

68,90

A

Secondary Steering Harness

Replace

2.0

90

A

Transmission Control Harness

Replace

4.0

90

A

3,12,75,86,87, 90,95 3,12,75,86,87, 90,95 3,12,75,86,87, 90,95

E

TRANSMISSION Transmission

0705

UNIT

(6)

ELECTRICAL SYSTEM - Continued NATO Slave Receptacle

0613


(5)

Test

1.0

Adjust

1.0

Calibrate

1.0

Transmission Shifting Components Modulating Valve

Replace

8.0

90,98

Relief Valve (Transmission Hydraulic Control)

Replace

4.0

68,90,98

Shift Lever

Replace

2.8

0232 00-8

90

E E

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

07 0710

COMPONENT/ ASSEMBLY


UNIT C

O

DS

GS

DEPOT

F

H

D

Transmission Assembly with Torque Converter


0.02 1.0

41,70,90 17,37,68,90,99

24.0

D

60.0

Inspect Replace

B B A

0.3

B 1.3

17,37,68,90

Coolers, Pumps, and Motors Fill Tube

Inspect Replace

0.01

B 0.5

90

Magnetic Screen

Service

1.0

Oil Filter Base

Replace

2.5

70,90,98

Test Oil Lines and Fittings

Replace

3.0

70,90

Transmission Filter Element

Replace

0.2

90

Transmission Oil Cooler

Replace

B

Transmission Oil Cooler Lines

Replace

7.5

B

68,90,98

1.5

Transmission Oil Pump Replace (Gear Pump) Repair

0900


TRANSMISSION Continued

Transmission Mounts

09

(6)

SUSTAINMENT

Rebuild

0721

(5)

70,90 8.0

68,90 1.0

A D

PROPELLER AND PROPELLER SHAFTS Propeller Shafts Carrier Bearing

Replace

Drive Shaft (Front)

Inspect Replace

0.01

Drive Shaft (Rear)

Inspect Replace

0.01

Slip Joint (Center)


0.01 0.03

1.3

70,90

3.0

70,90,99

B A

3.0

70,90,99

B A B B,C

2.2

0232 00-9

70,90,99

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

10 1000

COMPONENT/ ASSEMBLY


UNIT C

O

0.01

0.1 0.5

1100

DS

GS

DEPOT

F

H

D

Front Axle


70,90 70,90 48,65,68,78,79, 90,93,99

10.0 40.0

B B,C A D

REAR AXLE Rear Axle

Inspect Service Replace Rebuild

0.01

70,71,90 70,90 69,90,99

B B,C A D

14.0

68,90

A

1.0

30,34,69,75,86, 87,90 30,34,69,75,86, 87,90 30,69,75,86,90

B,E

0.1 0.5 10.0 42.0

Replace

BRAKES Brakes System

1201


FRONT AXLE

Axle Trunnion Group 12

(6)

SUSTAINMENT

Rebuild

11

(5)

Parking Brake

Test

0.1

Adjust

1.0

Inspect

1.0

Test Inspect Replace

0.1

Parking Brake Actuator Replace 1202

Service Brake Discs

1204

Hydraulic Brake System Brake Accumulator

B 4.0 4.0

66,70,90,99 57,70,90,99

4.0

70,90

Inspect

Test

0.3

0.1

B,E

0.5

3,30,69,70,75, 86,90

B

3,33,23,70,75, 86,87,90 3,33,23,70,75, 86,87,90 3,33,23,70,75, 86,87,90

B

Service

0.5

Replace

3.0

Parking Brake Control Valve

Replace

2.0

70,90

Service Brake Control Valve

Replace

2.0

70,90

0232 00-10

A

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

12

COMPONENT/ ASSEMBLY


UNIT C

13 1311

1313 14 1401

1410

Service Brake Pedal

Inspect Replace

0.01

SUSTAINMENT DS

GS

DEPOT

F

H

D


Wheel and Tire Assembly Inspect Service Replace

0.1 0.2

Tire

Inspect Replace

0.1

Inspect

0.1

3.0

70,90

1.0

90

1.5

48,53,55,56,63, 71,78,80,90,99

1.5

90

B

WHEEL AND TRACK B

B F

STEERING Steering System

B

Test

1.0

31,48,65,72,79, 87,90,93,97,98

E

Adjust

1.0

31,48,65,72,79, 87,90,93,97,98

E

Steering Column

Replace

2.0

70,90

Steering Wheel

Inspect Replace

0.5

54,70,90,98

0.01

B

Hydraulic Pump or Fluid Motor Secondary Steering Replace Pump/Motor Assembly Repair

1.5 1.5

9.5

70,90,98 70,90,98 68,90

Steering Neutralizer Valve

Replace

2.0

Steering Pump

Repair

10.0

68,90 4.0

1411

(6)

BRAKES - Continued Service Brake Lines and Replace Hoses

1206

O

(5)

Steering Hoses, Lines, and Fittings

Replace

4.0

0232 00-11

90

A A,D

A D

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

14 1412

1414

15 1501

COMPONENT/ ASSEMBLY


UNIT C

O

(5)

(6)

SUSTAINMENT DS

GS

DEPOT

F

H

D


STEERING Continued Steering Cylinders

Inspect Service Replace Repair

0.1 0.1 3.0

70,90 4.0

B B,C A D

Steering System Valves Steering Control Valve Replace Repair

1.5 1.5

70,90,98 70,90,98

Steering Metering Pump Replace

2.5

70,90

Secondary Steering Valve

Replace

3.0

78,90

Hydraulic Service Box

Replace

0.5

70,90

Steering Frame Lock

Inspect

4.0

70,90

A

FRAME, TOWING, AND ATTACHMENTS Frame Assembly 0.01

1502

Counterweight

Replace

1503

Articulation Pivot Pin


0.02 0.2


0.01 0.4

Remote Lubrication Lines and Fittings 18

BODY, CAB, HOOD

1801

Body, Cab, Hood, and Hull Cab Assembly

Replace

Chassis Guards

Replace

Door Assembly


B B,C 14.0

9,20,32, 42,44,51,55,57, 61,66,69,76,77, 80,81,90,97

0.2

B

0.5

70,90

8.0

44, 64, 72, 70,90,99

0.5

70,90

1.0 3.0

70,90 70,90

0.01

B

0232 00-12

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

18

1802

COMPONENT/ ASSEMBLY

UNIT C

Engine Compartment Shield

Replace

Hood and Side Guards

Replace

Ladders, Steps, and Hand Rails

Inspect Replace

0.02

ROPS

Inspect Replace

0.03

2202

DS

GS

DEPOT

F

H

D

9.5

Front Fenders

Replace

Glass

Inspect Replace


68,90

3.0

17,70,90

3.0

70,90

0.2 1.0

90

0.5

15,90

B

0.01

B C

B 1.5

68,90

Replace

1.2

15,70,90

Cabliners

Replace

3.0

70,90

Seat Assembly


0.1 1.5

70,90,98 68,90

Inspect Replace

0.2

Upholstery, Seats, and Carpets B 4.5

Sunvisor and Mounting Replace

22

SUSTAINMENT

Fenders, Windshield and Glass

Seat Belt

1808

O

(6)

BODY, CAB, HOOD Continued

Rear Fenders 1806


(5)

0.2

90

0.5

70,90

B B

Stowage Racks, Boxes, Straps, Carrying Cases, Cable Reels, Hose Reels, etc. Rifle Rack

Replace

0.5

90

Tool Box

Replace

1.0

15,70,90

BODY ACCESSORY ITEMS Accessory Items Cab Air Filter


0.1 0.3 0.3 0232 00-13

B B B

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

22

COMPONENT/ ASSEMBLY

Washer Bottle Windshield Wipers Wiper Motor

24

Data Plates

2402

C

O

SUSTAINMENT DS

GS

DEPOT

F

H

D


Inspect Replace

0.1

Service Replace

0.1

Inspect Replace

0.5

Replace Inspect Replace

70,90

B

0.5 B 2.0

90

0.3

70,90,98

1.0

70,90,98

0.2

78,90

B

0.2

B

HYDRAULIC AND FLUID SYSTEMS Test

1.0

3,24,33,48, 65,68,72,75,79, 86,87,90,93,97

E

Calibrate

1.0

3,24,33,48, 65,68,72,75,79, 86,87,90,93,97

E

Adjust

1.0

3,24,33,48, 65,68,72,75,79, 86,87,90,93,97

E

Hydraulic Brake and Fan Pump

Replace Repair

4.0

68,90

A D

Hydraulic Pump (Implement)

Replace Repair

10.0

68,90

A D

Replace

2.0

68,90

A

Main Hydraulic Control Replace Valve Repair

12.0

17,37,48,65,67, 68,78,90,92,98

A

Hydraulic Systems

2401

UNIT

(6)

BODY ACCESSORY ITEMS - Continued Mirrors and Mounting

2210


(5)

Hydraulic Pump 7.0 7.0

Hydraulic Control Valves Brake and Fan Control Valve (Manifold)

Quick Coupler Diverter Replace Valve

12.0 1.0

0232 00-14

D 70,90

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

24

2403

COMPONENT/ ASSEMBLY

UNIT C

O

Accumulators

Tilt Cylinder

Test

1.0

Replace

3.0

Inspect Replace

0.2


0.03 0.1

2407 2408

DS

GS

DEPOT

F

H

D


Lift Cylinders


15,33,23,48,65, 70,79,87,90, 93 15,33,23,48,65, 70,79,87,90, 93 90

4.0

11,36,47,53,56, 70,82,90,94

3.0

B A B B,C A D

6.0 0.03 0.4

Repair 2406

SUSTAINMENT

0.5

Repair 2405

(6)

HYDRAULIC AND FLUID SYSTEMS Continued

Electro-Hydraulic Joy Stick 2404


(5)

36,43,48,51,52, 56,65,70,79,82, 90,92,93,94 2.0

B B,C A

D

Hydraulic Filters, Lines, and Fittings Filters

Replace

Hoses, Lines, and Fittings

Inspect Replace

Hydraulic Filter Base Coupler Cylinder

0.2

90

B

0.5

70,90

Replace

1.5

70,90

A

Replace Repair

1.5

70,90

A D

0.04

2.0

Tanks and Reservoirs Cap, Filler

Replace

0.1

Hydraulic Tank


0.2

Inspect Replace

0.02

Sight Gage

0.5 4.0

41,70,90 70,90

0.5

70,90

B B A B

0232 00-15

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

33 3303

COMPONENT/ ASSEMBLY

52

5200

Arctic Kit

Sweeper Bristles

C

O

SUSTAINMENT DS

GS

DEPOT

F

H

D


Test Replace Install

0.3

Replace Inspect Replace

B 2.3 16.0

70,90 98

0.5

70,90

1.0

70,90

0.2

B

Broom Manifold and Hoses

Replace

1.0

70,90

Broom Motor

Replace

1.0

70,90

Broom Shields and Springs

Replace

1.0

22,70,90

Pallet Forks

Inspect Repair

4.0

15,70,90

0.02

B

REFRIGERATION AND AIR CONDITIONING COMPONENTS (HVAC) Air Conditioning

Test Service

2.0 2.0

38,39,60,68,90 60,68,90

E

Replace

4.0

68,90

A

Replace

6.0

68,90

Accumulator

Replace

3.0

68,90

B

Dryer

Replace

3.0

68,90

B

Replace

4.0

68,90

Replace

4.0

68,90

4.0

68,90

Compressor 5217

Refrigerant Hoses, Valves, Flanges and Fittings

5221

Refrigerant Accumulator

5230

UNIT

(6)

SPECIAL PURPOSE KITS

Battery Box (Arctic) 3307


(5)

Condenser Heater Core

5241

Evaporator Core

Replace

5243

Blower Motor

Replace

2.0

70,90

Blower Motor Resistor

Replace

0.5

90

HVAC Blend Door Actuator

Replace

1.5

70,90

0232 00-16

TM 5-3805-291-23-2


0232 00


(2)

(3)


GROUP NUMBER

COMPONENT/ ASSEMBLY

74

CRANES, SHOVELS AND EARTH MOVING EQUIPMENT

7436

7437

Bucket Lift Arms


UNIT C

Replace

Bucket Linkage Tilt Lever

Service Replace

0.1

Quick Coupler


0.03 0.3

Inspect Service Replace Repair

0.02 0.2 0.1

Loader Buckets

O

(5)

(6)

SUSTAINMENT DS

GS

DEPOT

F

H

D


8.0

5,6,10,19,20, 36,47,48,52,57, 65,68,72,79,82, 90,93,94

6.0

7,10,13,20, 36,43,45,46,47, 52,57,61,64,68, 73,74,82,90,94, 95

A

B B,C 1.5

36,47,52,56,70, 82,90 B B,C A

0.5

0232 00-17

71,90,99

TM 5-3805-291-23-2


0232 00

Table 2. Tools and Test Equipment Requirements for 966H Loader. (1)

(2)

(3)

ITEM MAINTENANCE NO. LEVEL

ITEM NAME

(4)

(5)

NATIONAL STOCK NUMBER

PART NUMBER/ CAGEC

2 2

$GDSWHUFDEOHEUHDNRXW $GDSWHUFDEOHEUHDNRXW

; ;

2

$GDSWHUWHVW

2

$GDSWHUFRQQHFWRU

9

)

$GDSWHUPHFKDQLFDOSXOOHU

3

)


3

)


3

)


3

)


8

)

$GDSWHUSXOOHU

3

2

$GDSWHUVKDIWSXOOHU

)

)

$GDSWHUWKUHDGHG

7

)

$GDSWHUWLPLQJSLQ

2

$PPHWHU

2

%UDFNHWOLQN

)

%UDFNHWOLQN

2

%UDFNHWOLQN

2

&DEOHDVVHPEO\VHWEUHDNRXW7

)

%XVKLQJGULYHUVHW

3

)

%XVKLQJGULYHUVHW

3

2

7HVWLQJ,&37SHWUROH

8

)

&KDLQFRPHDORQJ

)

&KDUJLQJNLWSUHVVXUH

2

&RXSOLQJKRVH

9

)

'LHVHOHQJLQHUHSDLUVWDQGOE

8

)

'LHVHOHQJLQHUHSDLUVWDQGDGDSWHUSODWH

8

)

'ULYHUSODWH

3

)

([WUDFWRUVFUHZ

8

2

)LOWHUIOXLG

3

)

*DJHEORFN

2

*DJHSUHVVXUHGLIIHUHQWLDOGLDOLQGLFDWLQJ

8

)

+HDG

)

8

)7

0232 00-18

TM 5-3805-291-23-2


0232 00

Table 2. Tools and Test Equipment Requirements for 966H Loader - Continued.

(1)

(2)

(3)


ITEM NAME

(4)

(5)


PART NUMBER/ CAGEC

) )

+RVH ,QGLFDWRUSRLQW0XOWL7DFK

8

)

,QGLFDWRUGLDO

16.7&6

2

,QVHUWHUHQGUHPRYHUSLQ

9

)

/HYHUSXOOHUKRLVW

8

)

/HDNGHWHFWLRQODPS

)

/HDNGHWHFWRUUHIULJHUDQWJDV

2

0XOWLPHWHU

)/8.(

2

1LSSOHSLSH

9

)

1XW

$

2

1XWIDVWHQHU

3

)

1XWSODLQKH[DJRQ

%

)

1XWSODLQKH[DJRQ

7

)

1XWSODLQURXQG

3

2

1XWSODLQURXQG

8

)

3LQVKRXOGHUKHDGOHVV

6

)

3LQLRQWXUQLQJWRRO

6

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0232 00-19

TM 5-3805-291-23-2 MAINTENANCE ALLOCATION CHART (MAC) - CONTINUED

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0232 00-20

TM 5-3805-291-23-2 MAINTENANCE ALLOCATION CHART (MAC) - CONTINUED

0232 00


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2 2

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Table 3. Remarks for the 966H Loader. Remarks Code

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0232 00-21/(0232 00-2 Blank)

6 TM 5-3805-291-23-2

EXPENDABLE AND DURABLE ITEMS LIST

0233 00

SCOPE This work package lists expendable and durable items you will need to maintain the 966H Wheel Loader. This listing is for informational purposes only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable Items. EXPLANATION OF COLUMNS 1.

Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the narrative instructions to identify the item [e.g., Use Antifreeze (Item 1, WP 0233 00)].

2.

Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item. C - Operator/Crew O - Unit Maintenance F - Direct Support Maintenance

3.

Column (3) - National Stock Number. This is the National Stock Number assigned to the item which you can use to requisition it.

4.

Column (4) - Description, CAGEC, and Part Number. This provides the other information you need to identify the item.

5.

Column (5) - Unit of Measure (U/M). This column shows the physical measurement or count of an item, such as gallon, dozen, gross, etc.

0233 00-1

TM 5-3805-291-23-2

EXPENDABLE AND DURABLE ITEMS LIST - CONTINUED

0233 00

Table 1. Expendable and Durable Items List for 966H Loader. 0(1)

0(2)

0(3)

0(4)

0(5)

ITEM NUMBER

LEVEL


DESCRIPTION, CAGEC, AND PART NUMBER

U/M

1

O 1

Antifreeze 6850-01-383-4068 6850-01-441-3257 6850-01-383-3918

1

(1QK63) 6724354 (1 Gallon Bottle) (58536) A-A52624 (5 Gallon Can) (58536) A-A52621 (55 Gallon Drum)

GAL CN DR

2

F

Antiseize compound (11083) 4C-5598

2

3

O

Axle oil additive 1U-9891

3

4

O

8135-00-132-9589

Barrier material, grease proofed, flexible (81349) MIL-B-121

4

RO

5

O

6840-00-300-6373

Biocide, fuel preservative (0U7J1) BIOBOR JF

5

QT

6

O

5340-00-450-5718

Cap set, protective Dust and Moisture Seal (19207) 10935405

6

EA

7

O

Cleaning compound, solvent, type III (81349) MIL-PRF-680

7

7

8

6850-01-474-2318 6850-01-474-2320 6850-01-474-2321 O

8 9

O

10

C

12

C C

9140-00-286-5294 9130-01-031-5816

8 EA 9

1 Gallon Can Diesel fuel, DF-1 (81346) ASTM D 975

9140-00-286-5286 9140-00-286-5287 9140-00-286-5288

GAL GAL GAL

50 Sheet Package Detergent, general purpose, liquid

6850-01-159-4844

10

11

Cloth, abrasive (80204) ANSI B74.18 5350-00-584-4654

9

1 Gallon Can 5 Gallon Can 55 Gallon Drum

GAL 10

Bulk 5 Gallon Can 55 Gallon Drum

GL CN DR

Fuel oil, diesel, DF-2 ASTM D 975 (81346)

11

Fuel, turbine, aviation (81349) MIL-T-83133 GR JP-8

12

0233 00-2

EA

GAL GL

TM 5-3805-291-23-2


0233 00

Table 1. Expendable and Durable Items List for 966H Loader - Continued. 0(1)

0(2)

0(3)

0(4)

0(5)

ITEM NUMBER

LEVEL



U/M

13

O

14

F

15

C 15

8040-01-437-6864

9150-01-197-7688 9150-01-197-7690 9150-01-197-7692 9150-01-197-7693

16

O

17

13

Gasket cement 1U-8846 (11083)

14

Grease, automotive and artillery, GAA

15

2-1/4 Ounce Tube (81349) M-10924-A 1-3/4 Pound Can (81349) M-10924-C 35 Pound Can (81349) M-10924-E 14 Ounce Cartridge (81349) M-10924-B

OZ LB LB OZ

Grease, electrically conductive (53711) 5190179

16

O

Grease, molybdenum 5P-0960

17

18

O

Grease, multipurpose 1P-0808

18

19

O

Insulating sleeving, electrical (11530) 08-196485-06

19

19 20

9150-01-361-8919

Flux, soldering (58536) A-A-51145TY FORM A

5970-00-815-1295 O

20

250 Foot Spool (11530) 08-196485-06 Insulating varnish, electrical (75037) 1602

5970-00-476-6717

OZ

FT 20

13 Ounce Aerosol Can

CN

21

O

9150-00-111-0208

Lubricating oil, engine (81349) MIL-PRF-21260

21

GAL

22

O

9150-01-293-7696

Lubricating oil, engine, preservative (81349) M21260-3-15W40

22

GAL

23

O

5935-01-507-0644

Maintenance kit, electrical connector (11083) 190-8900

23

EA

24

O

Nitrate test strips

24

6850-01-154-3653 25

O

6803-00-782-2641

100 Strip Package Nitrogen technical dry cylinder (58536) A-A-59503-1B1187

0233 00-3

PK 25

CYL

TM 5-3805-291-23-2


0233 00


0(2)

0(3)

0(4)

0(5)

ITEM NUMBER

LEVEL



U/M

25

25

25

25

25

25

25

25

25

25

26

C

Oil, lubricating, OE/HDO-40 9150-00-188-9862

27

C 27

28

C 28

29

O

(81349) MIL-PRF-2104 55 Gallon Drum Oil, lubricating, OE/HDO-5/40 (81349) MIL-PRF-2104

9150-01-524-9155

O

DR 27

55 Gallon Drum Oil, lubricating, OE/HDO-15/40 (81349) MIL-PRF-2104

9150-01-152-4117 9150-01-152-4118 9150-01-152-4119

26

DR 28 QT GAL GAL

1 Quart Can 5 Gallon Can 55 Gallon Drum Oil, lubricating, OEA-30, Arctic

29

29

9150-00-402-4478

1 Quart Can (81349) MIL-L-46167

29

9150-00-402-2372

5 Gallon Can (81349) MIL-PRF-46167

GAL

29

9150-00-491-7197

55 Gallon Drum (81349) MIL-PRF-46167

GAL

30

F

30 31

9150-01-524-4276

9150-01-410-8972 O

Oil, lubricating, refrigerant compressor: Synthetic Ester (59595) Capella HFC-68NA

QT

30

1 Quart Can Oil, lubricating, TO-4

QT 31

31

9150-00-402-2372

5 Gallon Can (11083) 8T-9576

GAL

31

9150-00-491-7197

55 Gallon Drum (11083) 8T-9577

GAL

32

O

Paint, heat resisting

32

33

O

Petrolatum, technical (81348) V-P-236

33

33

9150-00-250-0926

7.5 lb Can

0233 00-4

CN

TM 5-3805-291-23-2


0233 00


0(2)

0(3)

0(4)

0(5)

ITEM NUMBER

LEVEL



U/M

34

O

8010-01-359-9245

35

Primer coating (80244) GG00265

34

O

Rag, wiping (64067) 7920-00-205-1711

35

36

F

Refrigerant dye

36

37

O

2815-01-521-1638

Repair kit, diesel engine (11083) 175-3700

37

EA

38

O

8030-01-509-1597

Sealing compound (11083) 9S-3263

38

OZ

39

O

6810-00-297-0092

Sodium bicarbonate, technical (81346) ASTM D 928

39

BG

40

O

Solder, lead-tin alloy, rosin core (81346) SN60WRP2 0.032 1LB

40

40 41

O

3439-00-555-4629

1 Pound Spool

4235-01-510-1292

Spill containment unit, hazardous material

41 42

LB 41

20 in. x 20 in., box of 4 (1BW54) B-1400-rdp O

Strap, tiedown, electrical components

42

43

GA

42

O 43

44

O

45

O

46

F

4 in. Length, Black, Pck of 100 (96906) MS3367-4-0 6 in. Length, Black, Pck of 100 (96906) MS3367-1-0 13.35 in. Minimum Length, black, Pck of 100 (96906) MS3367-2-1 Tag, marker (64067) 9905-00-537-8954

9905-00-537-8954

42

43

Pack of 50

EA

Tape, duct - Roll

44

RL

7510-00-040-5895

Tape, pressure sensitive adhesive (81755) P5113-3

45

RL

6830-01-439-0614

Tetrafluoroethane,technical(Refrigerant,R-134a) 46

END OF WORK PACKAGE

0233 00-5/(0233 00-6 Blank)

43 LB CYL

22 TM 5-3805-291-23-2

TORQUE LIMITS

0234 00

SCOPE This work package lists standard torque values and provides general information for applying torque. Special torque values and tightening sequences are indicated in maintenance procedures for applicable components. GENERAL 1.

Always use torque values listed in (Tables 1 thru 6) when maintenance procedure does not show a specific torque value. a.

(Tables 1 thru 3) provides torque limits for SAE standard fasteners.

b.

(Tables 4 thru 6) provides torque limits for metric fasteners.

2.

Unless otherwise indicated, standard torque tolerance shall be r10 percent.

3.

Torque values listed are based on clean, dry threads. Reduce torque by 10 percent when engine oil is used as lubricant. If new plated capscrews are used, reduce torque by 20 percent.

4.

If maintenance procedures do not specify a tightening order, use the following guides: a.

Unless otherwise specified, lubricate threads of fasteners with oil (OE/HDO-10 or OEA-30).

b.

When tightening fasteners above 30 lb-ft (41 Nm), use torque pattern only to tighten to 70 percent of final value (multiply final value by 0.7). Repeat pattern until final value is reached.

c.

Tighten circular patterns using circular torque pattern and tighten straight patterns using straight torque pattern.

8

1

5 12

10 4

3 11

9 6

2

7

CIRCULAR TORQUE PATTERN

9

7

5 3 1 2 4 6 STRAIGHT TORQUE PATTERN

0234 00-1

8

TM 5-3805-291-23-2

TORQUE LIMITS - CONTINUED

0234 00

METRIC (ISO) FASTENERS

CAUTION If replacement capscrews are of higher grade than originally supplied, use torque specifications for original. This will prevent equipment damage due to over-torquing.

NOTE The following tables have recommended standard torque values for metric nuts and bolts for use on Caterpillar engines.

ENGLISH (SAE) FASTENERS

Table 1. English (SAE) Nuts and Bolts.

427-C2063

Thread Size (mm)

Torque

1/4

9 ± 2 lb-ft (12 ± 3 Nm)

5/16

18 ± 4 lb-ft (24 ± 8 Nm)

3/8

35 ± 7 lb-ft (47 ± 9 Nm)

7/16

50 ± 11 lb-ft (68 ± 15 Nm)

1/2

75 ± 15 lb-ft (101 ± 20 Nm)

9/16

120 ± 22 lb-ft (163 ± 30 Nm)

5/8

160 ± 30 lb-ft (217 ± 41 Nm)

3/4

275 ± 37 lb-ft (373 ± 50 Nm)

7/8

460 ± 60 lb-ft (624 ± 81 Nm)

1

660 ± 75 lb-ft (895 ± 102 Nm)

1 1/8

960 ± 110 lb-ft (1,302 ± 149 Nm)

1 1/4

1,320 ± 150 lb-ft (1,790 ± 203 Nm)

1 3/8

1,780 ± 220 lb-ft (2,413 ± 298 Nm)

1 1/2

2,280 ± 260 lb-ft (3,091 ± 353 Nm)

0234 00-2

TM 5-3805-291-23-2


0234 00

ENGLISH (SAE) FASTENERS - CONTINUED Table 2. English (SAE) Taperlock Studs. Thread Size (mm)

Torque

1/4

6 ± 2 lb-ft (8 ± 3 Nm)

5/16

13 ± 4 lb-ft (18 ± 5 Nm)

3/8

26 ± 4 lb-ft (35 ± 5 Nm)

7/16

33 ± 7 lb-ft (45 ± 9 Nm)

1/2

48 ± 7 lb-ft (65 ± 9 Nm)

5/8

80 ± 15 lb-ft (108 ± 20 Nm)

3/4

125 ± 22 lb-ft (169 ± 30 Nm)

7/8

190 ± 30 lb-ft (258 ± 41 Nm)

1

300 ± 44 lb-ft (407 ± 60 Nm)

1 1/8

390 ± 44 lb-ft (529 ± 60 Nm)

1 1/4

550 ± 60 lb-ft (746 ± 81 Nm)

1 3/8

700 ± 90 lb-ft (949 ± 122 Nm)

1 1/2

880 ± 110 lb-ft (1,193 ± 149 Nm)

ENGLISH (SAE) MACHINE SCREWS

427-C2064

Table 3. English (SAE) Machine Screws. Thread Size (mm)

Torque

0-80

0.9 ± 0.1 lb-in. (0.10 ± 0.01 Nm)

1-64

1.3 ± 0.1 lb-in. (0.15 ± 0.01 Nm)

2-56

2.2 ± 0.2 lb-in. (0.25 ± 0.02 Nm)

3-48

3.1 ± 0.4 lb-in. (0.35 ± 0.05 Nm)

4-40

4.4 ± 0.4 lb-in. (0.50 ± 0.05 Nm)

5-40

6.2 ± 0.4 lb-in. (0.70 ± 0.05 Nm)

6-32

8.0 ± 0.9 lb-in. (0.90 ± 0.10 Nm)

8-32

15.0 ± 2.2 lb-in. (1.69 ± 0.25 Nm)

10-24

19.9 ± 2.2 lb-in. (2.25 ± 0.25 Nm)

12-24

30.0 ± 5.3 lb-in. (3.40 ± 0.60 Nm) 0234 00-3

TM 5-3805-291-23-2


0234 00

METRIC (ISO) FASTENERS

427-C2065

Table 4. Metric (ISO) Nuts and Bolts. Thread Size (mm)

Torque

M6

9 ± 2 lb-ft (12 ± 3 Nm)

M8

21 ± 5 lb-ft (28 ± 7 Nm)

M10

41 ± 7 lb-ft (55 ± 9 Nm)

M12

75 ± 15 lb-ft (101 ± 20 Nm)

M14

120 ± 22 lb-ft (163 ± 30 Nm)

M16

175 ± 30 lb-ft (237 ± 41 Nm)

M20

340 ± 44 lb-ft (461 ± 60 Nm)

M24

590 ± 75 lb-ft (800 ± 102 Nm)

M30

1,180 ± 150 lb-ft (1,600 ± 203 Nm)

M36

2,000 ± 220 lb-ft (2,712 ± 298 Nm)

Table 5. Metric (ISO) Taperlock Studs. Thread Size (mm)

Torque

M6

71 ± 27 lb-ft (96 ± 37 Nm)

M8

13 ± 4 lb-ft (18 ± 5 Nm)

M10

26 ± 4 lb-ft (35 ± 5 Nm)

M12

48 ± 7 lb-ft (65 ± 9 Nm)

M16

80 ± 15 lb-ft (108 ± 20 Nm)

M20

125 ± 22 lb-ft (169 ± 30 Nm)

M24

300 ± 44 lb-ft (408 ± 60 Nm)

M30

550 ± 60 lb-ft (746 ± 81 Nm)

M36

880 ± 110 lb-ft (1,193 ± 149 Nm)

0234 00-4

TM 5-3805-291-23-2


0234 00

METRIC (ISO) FASTENERS - CONTINUED

427-C2064

Table 6. Metric (ISO) Machine Screws. Thread Size (mm)

Torque

M1.6

0.9 ± 0.1 lb-in. (0.10 ± 0.01 Nm)

M2

1.3 ± 0.1 lb-in. (0.15 ± 0.01 Nm)

M2.5

3.1 ± 0.4 lb-in. (0.35 ± 0.05 Nm)

M3

4.4 ± 0.4 lb-in. (0.50 ± 0.05 Nm)

M4

15.0 ± 2.2 lb-in. (1.69 ± 0.25 Nm)

M5

19.9 ± 2.2 lb-in. (2.25 ± 0.25 Nm)

GROUND ENGAGING TOOL (G.E.T.) FASTENERS Ground Engaging Tools (G.E.T.) are secured by many types of bolts. Refer to (Table 7) for correct torque for following combinations of fasteners for G.E.T.: •

Plow bolts and nuts.

•

Hex head bolt and nuts. Table 7. Ground Engaging Tool (G.E.T.) Fasteners.

Thread Size In.

(1)

Torque (1) lb-ft

Nm

5/8 in.

200 ± 30

271 ± 41

3/4 in.

350 ± 45

475 ± 61

7/8 in.

550 ± 65

746 ± 88

1 in.

850 ± 110

1,152 ± 149

1 1/4 in.

1,700 ± 220

2,305 ± 298

These values are only for Caterpillar bolts for cutting edges.

0234 00-5

TM 5-3805-291-23-2


0234 00

PLOW BOLTS

WARNING Personal injury can result when installing plow bolts. Appropriate safety equipment must be worn when striking plow bolts. To avoid injury to your eyes and ears, wear protective glasses, and hearing protection during this procedure.

427-C2066

1.

Clean all surfaces that had contact with bolt. Remove all occurrences of the following conditions: rust, paint, nicks, and burrs.

2.

Tighten nut to correct torque. Refer to (Table 7).

3.

Use hammer to bolt head. Bolt head must be struck with significant force.

NOTE Bolt head may be recessed below mounting surface. Use suitable punch to transfer hammer blow to bolt head.

4.

Tighten nut to correct torque. Refer to (Table 7).

INSTALLATION OF FITTINGS

NOTE Tightening sequence of the fasteners that attach tube assembly or hose assembly to the machine is very critical to proper function of machine. Sealing surfaces of tube assembly or hose assembly should be secured squarely. Sealing surfaces of the tube assembly or hose assembly should be tightened to the serviced component (control valve, cylinder, hydraulic motor, etc.). Perform this procedure prior to final tightening of any clamps or slips that are used to fasten the tube assembly or hose assembly to machine.

Fittings have different connections. Fittings may have two completely different ends. Use proper torque for end of fitting. The following list contains some common types of fittings: •

Straight Thread O-Ring (STOR)

•

Adjustable Straight Thread O-Ring (STOR)

•

O-Ring Face Seal (ORFS)

•

Tapered Pipe Thread (NPT and NPTF)

•

37 Degree Flare Fitting

•

45 Degree Flare Fitting

•

45 Degree Inverted Flare Fitting

•

Split Flange Coupling 0234 00-6

TM 5-3805-291-23-2


0234 00

INSTALLATION OF SPLIT FLANGE COUPLINGS 1.

For a metal tube to hose installation, install the tube and tighten all bolts finger tight at rigid end.

2.

Install hose and tighten all bolts finger tight.

3.

Put hose in a position where hose does not make contact with machine or other hoses.

4.

Tighten bolts on both connections to proper torque. Follow the prescribed torque sequence for split-flange connections. Add measurement of gap (A) to measurement of gap (B). Total must not exceed 0.16 in. (4.0 mm).

427-C2067

5.


6.

Move implement control levers to all positions.

7.

Look at hose during movement of implement. Ensure hose is not making contact with machine or other hoses.

NOTE For hoses that cross an articulation hitch, check for contact during articulation. For hoses that connect to the steering system, check for contact during steering.

8.

Shut off engine (TM 5-3805-291-10).

9.

If hose contacts other hoses or machine during test, loosen bolts and reposition hose. Repeat steps 3 thru 8 until there is no contact.

0234 00-7

TM 5-3805-291-23-2


0234 00

INSTALLATION OF ADJUSTABLE STOR FITTINGS This type of fitting is used in many applications. One end of the fitting will be an adjustable STOR fitting. Other end will be different. Always use same installation procedure for STOR end. Adjustable STOR fittings should be positioned before tightening. 1.

Put locknut (3), backup washer (4), and O-ring seal (5) as far back on fitting body (2) as possible. Hold these components in this position. Turn fitting into mating part. Turn the fitting until backup washer contacts the surface of mating part.

2.

Put fitting assembly in correct position. Loosen fitting (1) until the correct assembly position is achieved. Do not loosen the fitting more than 360 degrees. Install tube or hose hand tight to verify the orientation of fitting. Tighten locknut (3) to torque that is shown on correct chart for fitting.

427-C2068

0234 00-8

TM 5-3805-291-23-2


0234 00

INSTALLATION OF ADJUSTABLE STOR FITTINGS - CONTINUED

NOTE If fitting is not adjustable, hex bolt/nuts on body replaces locknut. To install this type of fitting, tighten hex bolt/nuts against face of the mating part.

427-C2069

Table 8. Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials. Nominal Outer Diameter of the Tube

Thread Size (In.)

Standard Torque

.125 in. (3.18 mm)

5/16 - 24

70 ± 9 lb-in. (95 ± 12 Nm)

.188 in. (4.76 mm)

3/8 - 24

9 ± 1 lb-ft (12 ± 1 Nm)

.250 in. (6.35 mm)

7/16 - 20

16 ± 1 lb-ft (22 ± 1 Nm)

.312 in. (7.94 mm)

1/2 - 20

22 ± 2 lb-ft (30 ± 3 Nm)

.375 in. (9.52 mm)

9/16 - 18

35 ± 4 lb-ft (47 ± 5 Nm)

.500 in. (12.70 mm)

3/4 - 16

60 ± 6 lb-ft (81 ± 8 Nm)

.625 in. (15.88 mm)

7/8 - 14

105 ± 10 lb-ft (142 ± 14 Nm)

.750 in. (19.05 mm)

1 1/16 - 12

140 ± 11 lb-ft (190 ± 15 Nm)

.875 in. (22.22 mm)

1 3/16 - 12

185 ± 15 lb-ft (250 ± 20 Nm)

1.000 in. (25.40 mm)

1 5/16 - 12

220 ± 22 lb-ft (298 ± 30 Nm)

1.250 in. (31.75 mm)

1 5/8 - 12

260 ± 26 lb-ft (353 ± 35 Nm)

1.500 in. (38.10 mm)

1 7/16 - 12

305 ± 30 lb-ft (413 ± 40 Nm)

2.000 in. (50.80 mm)

2 1/2 - 12

320 ± 30 lb-ft (434 ± 41 Nm)

Note: Use 50 percent of the torque values from Table 8 when the fitting of the port material is nonferrous.

0234 00-9

TM 5-3805-291-23-2


0234 00


427-C2070

Table 9. Straight Thread O-Ring Plugs (Hex Bolt/Nut Drive). Thread Size (In.)

Torque

5/16

80 ± 9 lb-in. (9.0 ± 1.0 Nm)

3/8

12.5 ± 1.1 lb-ft (17 ± 1.5 Nm)

7/16

17 ± 1 lb-ft (23 ± 1 Nm)

1/2

21 ± 2 lb-ft (28 ± 3 Nm)

9/16

25 ± 2 lb-ft (34 ± 3 Nm)

3/4

44 ± 4 lb-ft (60 ± 5 Nm)

7/8

85 ± 7 lb-ft (115 ± 9 Nm)

1 1/16

103 ± 10 lb-ft (140 ± 14 Nm)

1 3/16

140 ± 14 lb-ft (190 ± 19 Nm)

1 5/16

155 ± 15 lb-ft (210 ± 20 Nm)

1 5/8

215 ± 18 lb-ft (292 ± 24 Nm)

1 7/8

240 ± 22 lb-ft (325 ± 30 Nm)

2 1/2

310 ± 30 lb-ft (420 ± 41 Nm)

0234 00-10

TM 5-3805-291-23-2


0234 00


427-C2071

Table 10. Straight Thread O-Ring Plugs (Socket Drive). Thread Size (In.)

Torque

5/16

44 ± 9 lb-in. (5.0 ± 1.0 Nm)

3/8

97 ± 9 lb-in. (132 ± 1.0 Nm)

7/16

12 ± 1 lb-ft (16 ± 1.4 Nm)

1/2

15 ± 1 lb-ft (20 ± 1 Nm)

9/16

26 ± 3 lb-ft (35 ± 4.0 Nm)

3/4

52 ± 5 lb-ft (70 ± 7 Nm)

7/8

73 ± 7 lb-ft (99 ± 9 Nm)

1 1/16

125 ± 11 lb-ft (169 ± 15 Nm)

1 3/16

160 ± 15 lb-ft (217 ± 20 Nm)

1 5/16

200 ± 18 lb-ft (271 ± 24 Nm)

1 5/8

250 ± 20 lb-ft 339 ± 27 Nm)

1 7/8

275 ± 25 lb-ft (373 ± 34 Nm)

2 1/2

305 ± 30 lb-ft (414 ± 41 Nm)

0234 00-11

TM 5-3805-291-23-2


0234 00


427-C2072

NOTE Plug (A), plug (B), and plug (C) are used with gasket. Conical seal plug (D) does not use gasket.

Table 11. Drain Plugs with Straight Threads. Plug Type

A

B

C

D

Thread Size (In.)

Torque

1/2 - 13

15 ± 4 lb-ft (20 ± 5 Nm)

5/8 - 11

26 ± 4 lb-ft (35 ± 5 Nm)

3/4 -12 3/4 -16

37 ± 4 lb-ft (50 ± 5 Nm)

7/8 - 14 1 1/8 - 12

52 ± 11 lb-ft (70 ± 15 Nm)

1 5/16 - 12 1 1/2 - 12

66 ± 11 lb-ft (89 ± 15 Nm)

2 - 12

92 ± 11 lb-ft (125 ± 15 Nm)

1 1/8 - 12

52 ± 11 lb-ft (70 ± 15 Nm)

1 5/16 - 12

66 ± 11 lb-ft (89 ± 15 Nm)

1/2 - 20

97 ± 35 lb-ft (131 ± 47 Nm)

7/8 - 14

41 ± 5 lb-ft (56 ± 7 Nm)

1 3/8 - 13

66 ± 11 lb-ft (90 ± 15 Nm)

1 1/12 - 12

92 ± 11 lb-ft (125 ± 15 Nm)

0234 00-12

TM 5-3805-291-23-2


0234 00


427-C2073

Table 12. Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies). Thread Size (In.)

Torque

7/8

92 ± 11 lb-ft (125 ± 15 Nm)

1 1/16

130 ± 11 lb-ft (176 ± 15 Nm)

1 3/16

185 ± 15 lb-ft (250 ± 20 Nm)

1 1/4

185 ± 15 lb-ft (250 ± 20 Nm)

1 5/16

275 ± 15 lb-ft (372 ± 20 Nm)

1 5/8

310 ± 20 lb-ft (420 ± 27 Nm)

1 7//8

390 ± 25 lb-ft (529 ± 34 Nm)

2 1/2

665 ± 40 lb-ft (902 ± 54 Nm)

0234 00-13

TM 5-3805-291-23-2


0234 00

O-RING FACE SEAL FITTINGS

427-C2074

O-ring face seal fitting (OFRS fitting): (1)

O-ring face seal connector

(2)

O-ring groove

(3)

O-ring seal

(4)

Nut for O-ring face seal Table 13. Ferrous ORFS Fitting. Thread Size (In.)

Standard Torque for Nut (3)

9/16 - 18

18 ± 2 lb-ft (24 ± 3 Nm)

11/16 - 16

30 ± 3 lb-ft (41 ± 4 Nm)

13/16 - 16

41 ± 4 lb-ft (56 ± 5 Nm)

1 - 14

65 ± 6 lb-ft (88 ± 8 Nm)

1 3/16 - 12

90 ± 11 lb-ft (122 ± 15 Nm)

1 7/16 - 12

120 ± 11 lb-ft (163 ± 15 Nm)

1 11/16 -12

150 ± 15 lb-ft (203 ± 20 Nm)

2 - 12

180 ± 15 lb-ft (244 ± 20 Nm)

0234 00-14

TM 5-3805-291-23-2


0234 00

BULKHEAD NUTS

BULKHEAD CONNECTOR (ORFS) (1) AND BULKHEAD NUT (2) 427-C2075

NOTE

• The bulkhead connector (1) may have different connections. Type of fluid connection does not affect torque for nut (2). • When you assemble the fluid connection, do not use bulkhead nut as leverage for backup wrench. Use the hex bolt on body of connector for leverage.

Table 14. Bulkhead Nuts. Thread Size (In.)

Torque

5/16

53 ± 9 lb-in. (6 ± 1 Nm)

3/8

71 ± 9 lb-in. (8 ± 1 Nm)

7/16

10 ± 1 lb-ft (14 ± 1.3 Nm)

1/2

13 ± 1.4 lb-ft (18 ± 2 Nm)

9/16

16 ± 1.4 lb-ft (22 ± 2 Nm)

11/16

23 ± 2 lb-ft (31 ± 3 Nm)

3/4

27 ± 3 lb-ft (37 ± 4 Nm)

13/16

30 ± 3 lb-ft (41 ± 4 Nm)

7/8

32 ± 3 lb-ft (43 ± 4 Nm)

1

45 ± 4 lb-ft (61 ± 5 Nm)

1 1/16

52 ± 5 lb-ft (70 ± 7 Nm)

1 3/16

67 ± 7 lb-ft (91 ± 9 Nm)

1 5/16

83 ± 7 lb-ft (113 ± 9 Nm)

1 7/16

92 ± 9 lb-ft (125 ± 12 Nm)

1 5/8

110 ± 11 lb-ft (149 ± 15 Nm)

1 11/16

110 ± 11 lb-ft (149 ± 15 Nm)

1 7/8

115 ± 11 lb-ft (156 ± 15 Nm)

2

125 ± 13 lb-ft (169 ± 18 Nm)

2 1/2

160 ± 15 lb-ft (217 ± 20 Nm) 0234 00-15

TM 5-3805-291-23-2


0234 00

FLARE FITTINGS 37 Degree Flare Fittings

427-C2076

(1) 37 Degree Flare Fitting (2) Swivel Nuts Table 15. Nuts for 37 Degree Flare Fittings. Nominal Outer Diameter of the Tube

Thread Size (In.)

Standard Torque

.125 in. (3.18 mm)

5/16

44 ± 13 lb-in. (5.0 ± 1.5 Nm)

.188 in. (4.76 mm)

3/8

100 ± 15 lb-in. (11 ± 2 Nm)

.250 in. (6.35 mm)

7/16

12 ± 3 lb-ft (16 ± 4 Nm)

.312 in. (7.94 mm)

1/2

15 ± 4 lb-ft (20 ± 5 Nm)

.375 in. (9.52 mm)

9/16

18 ± 4 lb-ft (24 ± 5 Nm)

.375 in. (9.52 mm)

5/8

26 ± 4 lb-ft (35 ± 5 Nm)

.500 in. (12.70 mm)

3/4

37 ± 5 lb-ft (50 ± 7 Nm)

.625 in. (15.88 mm)

7/8

48 ± 5 lb-ft (65 ± 7 Nm)

.750 in. (19.05 mm)

1 1/16

75 ± 7 lb-ft (102 ± 9 Nm)

.875 in. (22.22 mm)

1 3/16

90 ± 7 lb-ft (122 ± 9 Nm)

1.000 in. (25.40 mm)

1 5/16

100 ± 11 lb-ft (136 ± 15 Nm)

1.250 in. (31.75 mm)

1 5/8

135 ± 11 lb-ft (183 ± 15 Nm)

1.500 in. (38.10 mm)

1 7/8

165 ± 11 lb-ft (224 ± 15 Nm)

2.000 in. (50.80 mm)

2 1/2

240 ± 22 lb-ft (325 ± 30 Nm)

Note: Use 50 percent of torque values from Table 15 when the fitting or port material is nonferrous.

0234 00-16

TM 5-3805-291-23-2


0234 00

FLARE FITTINGS - CONTINUED 45 Degree Flare and 45 Degree Inverted Flare Fittings (1) 45 Degree Inverted Flare Fittings (2) 45 Degree Flare Fittings

427-C2077

Table 16. 45 Degree Flare Fittings and 45 Degree Inverted Flare Fittings. Nominal Outer Diameter of the Tube

Thread Size (In.)

Standard Torque

.125 in. (3.18 mm)

5/16

44 ± 13 lb-in. (5.0 ± 1.5 Nm)

.188 in. (4.76 mm)

3/8

70 ± 13 lb-in. (8.0 ± 1.5 Nm)

.250 in. (6.35 mm)

7/16

100 ± 15 lb-in. (11 ± 2 Nm)

.312 in. (7.94 mm)

1/2

13 ± 2 lb-ft (18 ± 3 Nm)

.375 in. (9.52 mm)

5/8

22 ± 2 lb-ft (30 ± 3 Nm)

.375 in. (9.52 mm)

5/8

26 ± 4 lb-ft (35 ± 5 Nm)

.438 in. (11.11 mm)

11/16

22 ± 2 lb-ft (30 ± 3 Nm)

.500 in. (12.70 mm)

3/4

28 ± 3 lb-ft (38 ± 4 Nm)

.625 in. (15.88 mm)

7/8

37 ± 4 lb-ft (50 ± 5 Nm)

.750 in. (19.05 mm)

1 1/16

65 ± 6 lb-ft (88 ± 8 Nm)

.875 in. (22.22 mm)

1 1/4

75 ± 7 lb-ft (102 ± 9 Nm)

0234 00-17

TM 5-3805-291-23-2


0234 00

AIR CONDITIONING FITTINGS

(1) O-RING SEAL

(2) 45 DEGREE FLARE FITTING

427-C2078

Table 17. Air Conditioning Fittings. Thread Size (In.)

O-Ring Fitting End

45 Degree Flare Fitting End

Torque

Torque for Steel Tubes

Torque for Aluminum Tubes

5/8 - 18

10 ± 3 lb-ft (14 ± 4 Nm)

22 ± 2 lb-ft (30 ± 3 Nm)

17 ± 2 lb-ft (23 ± 3 Nm)

3/4 - 16

20 ± 3 lb-ft (27 ± 4 Nm)

38 ± 4 lb-ft (52 ± 5 Nm)

24 ± 4 lb-ft (33 ± 5 Nm)

7/8 - 14 1 - 14

30 ± 3 lb-ft (41 ± 4 Nm)

44 ± 5 lb-ft (60 ± 7 Nm)

28 ± 3 lb-ft (38 ± 4 Nm)

1 1/16 - 14

33 ± 4 lb-ft (45 ± 5 Nm)

55 ± 6 lb-ft (75 ± 8 Nm)

37 ± 4 lb-ft (50 ± 5 Nm)

0234 00-18

TM 5-3805-291-23-2


0234 00

TAPERED PIPE THREAD FITTINGS Torque is based on diameter of thread. Torque values are identical for coarse and fine threads.

NOTE The following table has recommended standard torque value for tapered pipe thread fitting for use on Caterpillar engines.

Table 18. Tapered Pipe Thread Fittings. Diameter of the Pipe Thread (In.)

Standard Torque Threads with 5P-3413 Pipe Sealant

Threads without Pipe Sealant

1/16

90 lb-in. (10 Nm)

90 lb-in. (10 Nm)

1/8

12 lb-ft (16 Nm)

12 lb-ft (16 Nm)

1/4

15 lb-ft (20 Nm)

18 lb-ft (24 Nm)

3/8

26 lb-ft (35 Nm)

33 lb-ft (45 Nm)

1/2

33 lb-ft (45 Nm)

44 lb-ft (60 Nm)

3/4

44 lb-ft (60 Nm)

55 lb-ft (75 Nm)

1

55 lb-ft (75 Nm)

65 lb-ft (88 Nm)

1 1/4

65 lb-ft (88 Nm)

80 lb-ft (108 Nm)

1 1/2

80 lb-ft (108 Nm)

95 lb-ft (129 Nm)

2

95 lb-ft (129 Nm)

120 lb-ft (163 Nm)

Note: Use 50 percent of torque values from Table 18 when fitting, plug, or port material is nonferrous. Use 50 percent of torque values from Table 18 when tapered thread is mating with straight thread.

0234 00-19

TM 5-3805-291-23-2


0234 00

MISCELLANEOUS FITTINGS Hi-Duty Tube Fittings (Shear Sleeve)

427-C2079

Put nut (1) over tube and push tube into counterbore of fitting body as far as possible. Turn nut with wrench until small decrease in torque is felt. Small decrease in torque indicates that sleeve (2) has been broken off of the nut. Hold tube to prevent tube from turning. Tighten nut for an additional 1 1/2 turns. SAE Flareless Fittings

427-C2080

Put nut (1) and sleeve (2) over tube. Head end of sleeve should be next to nut. Head end has shoulder. Push tube into counterbore of fitting body as far as possible. Turn nut clockwise until sleeve grips tube. Sleeve must stop all movement of tube. Tighten nut until sudden increase in torque is felt. Next, tighten fitting for an additional 1/6 to 1/3 turn to seat sleeve. Flex Fittings

427-C2081

Put nut (1) and sleeve (2) over tube and push tube into counterbore of fitting body as far as possible. Tighten nut until nut is against hex part of fitting body.

0234 00-20

TM 5-3805-291-23-2


0234 00

HOSE CLAMPS Worm Drive Band Type Clamps

427-C2082

Table 19. Worm Drive Band Type Clamps. Width (A) of Clamp

Torque for New Hose

0.31 in. (7.9 mm)

8 ± 2 lb-in. (0.9 ± 0.2 Nm)

0.53 in. (13.5 mm)

40 ± 4 lb-in. (4.5 ± 0.5 Nm)

0.63 in. (15.9 mm)

65 ± 4 lb-in. (7.3 ± 0.5 Nm)

Width (A) of Clamp

Torque for Reused Hose(1)

0.31 in. (7.9 mm)

6 ± 2 lb-in. (0.7 ± 0.2 Nm)

0.53 in. (13.5 mm)

27 ± 4 lb-in. (3.0 ± 0.5 Nm)

0.63 in. (15.9 mm)

40 ± 4 lb-in. (4.5 ± 0.5 Nm)

(1)

Use this value when hose is re-used. However, clamp may be new or reused.

0234 00-21

TM 5-3805-291-23-2


0234 00

HOSE CLAMPS - CONTINUED Constant Torque Hose Clamps

427-C2083

Use a constant torque hose clamp instead of any worm drive band type clamp. Ensure constant torque hose clap is the same size as worm drive band type clamp. Because of extreme temperature changes, hose will heat set. Heat setting can cause worm drive band type clamps to become loose. Loose hose clamps can result in leaks. There have been reports of component failures that have been caused by loosened worm drive band type clamps. Constant torque hose clamp will help prevent these failures. Use a torque wrench for proper installation of all constant torque hose clamps. There are two types of constant torque hose clamps: Belleville washer (1) and T bolt and spring (4). When constant torque hose clamp of Belleville washer (1) is assembled correctly, Belleville washers (2) are nearly collapsed flat. The proper torque for screw (3) is based on diameter (B) of clamp. Refer to the following table for the correct torque. Diameter (B)

Standard Torque

2 in. (Up to 50.8 mm)

65 ± 5 lb-in. (7.3 ± 0.6 Nm)

2 in. (Greater than 50.8 mm)

95 ± 10 lb-in. (11 ± 1 Nm)

The correct torque for constant torque hose clamp (T bolt and spring) (4) is 60 ± 10 lb-in. (7 ± 1 Nm). END OF WORK PACKAGE

0234 00-22

8 TM 5-3805-291-23-2

PREPARATION FOR STORAGE OR SHIPMENT

0235 00

THIS WORK PACKAGE COVERS Preparation for Return to Service from Long-Term Storage

Preparation for Short-Term Storage Preparation for Return to Service from Short-Term Storage

Preparation for Shipment

Preparation for Long-Term Storage



Unit



Tag, marker (Item 43, WP 0233 00) Tape, pressure sensitive adhesive (Item 45, WP 0233 00) Lubricating oil, engine, preservative (Item 22, WP 0233 00) Personnel Required

Materials/Parts Barrier material, grease proofed, flexible (Item 4, WP 0233 00) Biocide, fuel preservative (Item 5, WP 0233 00)

MOS 62B, Construction Equipment Repairer (2) References TB 750-651


TM 9-6140-200-14


WP 0019 00


WP 0020 00

Lubricating oil, engine (Item 21, WP 0233 00)

WP 0025 00

Lubricating oil, engine, preservative (Item 22, WP 0233 00)

WP 0030 00

Nitrate test strips (Item 24, WP 0233 00) Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00)

WP 0024 00

WP 0033 00 WP 0035 00 WP 0036 00


WP 0041 00


WP 0051 00

Paint, heat resisting (Item 32, WP 0233 00)

WP 0048 00 WP 0096 00 WP 0097 00

Primer coating (Item 34, WP 0233 00)

WP 0100 00

Rag, wiping (Item 35, WP 0233 00) Sodium bicarbonate, technical (Item 39, WP 0233 00) 0235 00-1

WP 0111 00 WP 0187 00

TM 5-3805-291-23-2

PREPARATION FOR STORAGE OR SHIPMENT - CONTINUED

0235 00



8.0 hr

Work tool lowered to ground (TM 5-3805-291-10) Parking brake engaged (TM 5-3805-291-10) Wheels chocked Battery disconnect switch in OFF position (TM 53805-291-10)

PREPARATION FOR SHORT-TERM STORAGE

0235 00

NOTE Short-term storage is storage for 90 days or less.

1.

Thoroughly clean machine.

2.

Perform all Operator PMCS (TM 5-3805-291-10).

3.

Fill fuel tank completely to prevent condensation from forming (TM 5-3805-291-10).

4.

Perform Unit PMCS (WP 0019 00 and WP 0020 00).

5.

Schedule next PMCS on ULLS-G (Unit Level Logistics System – Ground).

6.

Store machine in a dry, protected area with work tools lowered to ground (TM 5-3805-291-10).

7.

If storage exceeds 30 days, disconnect battery cables (WP 0096 00) and secure away from contact with battery terminals using Strap, tiedown, electrical components (Item 42, WP 0233 00). Place a sign that says “BATTERIES ARE DISCONNECTED” in driver’s compartment. Maintain batteries IAW TM 9-6140-200-14.

WARNING •

To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. Do not smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will cause instant heating, damage to equipment, and injury to personnel.

•

Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these procedures may result in injury or death to personnel. a. b. c. d.

Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Seek medical attention immediately. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia.

0235 00-2

TM 5-3805-291-23-2


0235 00

PREPARATION FOR SHORT-TERM STORAGE - CONTINUED 8.

Remove batteries (WP 0096 00) and clean batteries, clamps, supports, retainers, and battery box using acid swabbing brush and a solution of 1/2 lb (0.23 kg) of Sodium bicarbonate, technical (Item 39, WP 0233 00), to 1 gal. (3.8 L) of water. Flush with clean water and dry (TM 9-6140-200-14). Place batteries back in battery boxes.

9.

Check engine coolant to ensure coolant has correct mixture for expected temperatures (WP 0020 00).

10.

Seal all openings in engine, including air intake, exhaust outlet, and crankcase breather tube, with Tape, pressure sensitive adhesive (Item 45, WP 0233 00).

11.

Ensure battery disconnect switch is in OFF position (TM 5-3805-291-10).

12.

Fill in DD Form 1397, Vehicles and Spare Engines, Processing and Deprocessing Record for Shipment, Storage and Issue of, completely and attach to a conspicuous part of machine.

13.

Inflate tires to 60 psi (414 kPa) for front and 40 psi (275 kPa) for rear with dry air (TM 5-3805-291-10). Annotate air pressure and/or if nitrogen was used on DA Form 2258, Depreservation Guide for Vehicles and Equipment.

PREPARATION FOR RETURN TO SERVICE FROM SHORT-TERM STORAGE

0235 00

1.

Inflate tires to 60 psi (414 kPa) for front and 40 psi (275 kPa) for rear with dry air (TM 5-3805-291-10).

2.

Remove tape from all engine openings, including air intake, exhaust outlet, and crankcase breather tube.

3.

If disconnected, connect battery cables (WP 0096 00).

4.

Check coolant level in radiator (TM 5-3805-291-10).

5.

Ensure fuel tank is full (TM 5-3805-291-10).

6.

Start engine and perform machine warm-up (TM 5-3805-291-10). Verify proper operation of all gages, switches, and lights.

7.

Operate machine without a load and check engine, transmission, brakes, steering, and electrical accessories for proper operation (TM 5-3805-291-10).

PREPARATION FOR LONG-TERM STORAGE

0235 00

NOTE Long-term storage is storage for more than 90 days.

1.

Thoroughly clean machine.

2.


3.


4.

Schedule next PMCS on ULLS-G.

5.

Inspect machine for corrosion. Use touch-up paint where necessary to prevent rust (TB 43-0242, CARC Spot Painting).

6.

Where practical, store hydraulic cylinders in fully retracted position, which is normal locked/stored position for equipment. Fill hydraulic systems to operating level (TM 5-3805-291-10). Coat exposed surfaces of hydraulic cylinder with Grease, automotive and artillery, GAA (Item 15, WP 0233 00). Wrap Barrier material, grease proofed, flexible (Item 4, WP 0233 00), around greased surfaces and secure wrap with Tape, pressure sensitive adhesive (Item 45, WP 0233 00). Place a tag on cylinder requiring grease to be cleaned off exposed surface prior to use. This is necessary to prevent cylinder seal from being damaged by contaminated grease. 0235 00-3

TM 5-3805-291-23-2


0235 00

PREPARATION FOR LONG-TERM STORAGE - CONTINUED

NOTE If machine has accumulated a very low amount of hours (250 hours or less) since its last scheduled lubrication service, do not drain and refill transmission and differential; skip step 7 and proceed to step 8.

7.

Drain and refill transmission (WP 0100 00) and differential (WP 0109 00).

8.

Transmission and differential shall be filled to operating level with operational oil, as specified. Operate through all ranges for a minimum of 1 minute at a sufficient speed to assure lubricant coverage of all internal parts and surfaces. Transmissions shall be stored in neutral position. The soldier will annotate DA Form 2258 to indicate the grade and type of oil used.

9.

Preserve engine as follows:

CAUTION If an engine is not used for prolonged periods, oil can run off the cylinder walls, piston rings, main bearings, connecting rod bearings, crankshaft, gears, and other parts that normally get lubrication. This lack of lubricant allows corrosion to start on the metal, especially in areas of high humidity (water content in the air).

a.

First, clean engine of all dirt, rust, grease, and oil. Inspect exterior of engine and paint areas that have paint damage with Paint, heat resisting (Item 32, WP 0233 00).

b.

Remove any dirt from air cleaner. Check all seals and gaskets and filter element for damage (WP 0030 00).

c.

Drain and refill crankcase with Lubricating oil, engine, preservative (Item 22, WP 0233 00) and change oil filter(s) (WP 0025 00). The soldier shall prepare a tag for each engine and attach it to or near to lube oil files; “THIS CRANKCASE IS FILLED TO OPERATING LEVEL WITH PRESERVATIVE LUBRICATING OIL GOOD FOR OPERATION UNTIL THE FIRST REQUIRED OIL CHANGE-DO NOT DRAIN-CHECK OIL LEVEL-IF LOW, FILL TO OPERATING LEVEL WITH OPERATION OIL.” To insure continuous preservation qualities of oil, oil shall be changed after 50 hours of operation.

NOTE If the engine crankcase is full, drain enough engine oil to add the mixture.

d.

Remove air filter element (WP 0030 00). Place emergency shutdown switch in OFF position (TM 5-3805-291-10) and turn engine at cranking speed. Add a coating of Lubricating oil, engine, preservative (Item 22, WP 0233 00) into air intake or turbocharger inlet. Install air filter element and completely enclose element with dark plastic bags, sealing it with Tape, pressure sensitive adhesive (Item 45, WP 0233 00). Reinstall air filter covers. Put Tape, pressure sensitive adhesive (Item 45, WP 0233 00) over all openings to seal oil vapors in engine.

e.

Apply a coating of Lubricating oil, engine, preservative (Item 22, WP 0233 00) into exhaust openings. The minimum application volume is 1.4 oz (40 ml). Seal exhaust pipe, including drain holes in muffler, with Tape, pressure sensitive adhesive (Item 45, WP 0233 00).

f.

Replace both primary and secondary fuel filters (WP 0035 00 and WP 0036 00). Apply a spray of Lubricating oil, engine, preservative (Item 22, WP 0233 00) to prevent rust in fuel tank. Add 2 oz (50 ml) of Biocide, fuel preservative (Item 5, WP 0233 00) to fuel. Apply a small amount of oil to threads on fuel tank filler neck, and install cap (TM 5-3805-291-10). Seal all openings to tank with Tape, pressure sensitive adhesive (Item 45, WP 0233 00), to prevent evaporation of fuel and preservative.

g.

Remove fuel injectors (WP 0187 00) and apply 1 oz (30 ml) of Lubricating oil, engine, preservative (Item 22, WP 0233 00) into each cylinder. Rotate crankshaft by hand slowly; this will put oil on cylinder walls. Reinstall fuel injectors. 0235 00-4

TM 5-3805-291-23-2


0235 00

PREPARATION FOR LONG-TERM STORAGE - CONTINUED h.

Remove starter (WP 0049 00) and spray a thin amount of Lubricating oil, engine, preservative (Item 22, WP 0233 00) on flywheel, ring gear teeth, and starter pinion. Install starter to keep in oil vapors.

NOTE Install all covers and make sure that tape has been installed over all openings: air intake, exhaust, flywheel housing, crankcase breather, dipstick tubes, etc.

i.

Attach a tag to engine with a notation of date machine was preserved, saying “THIS CRANKCASE IS FILLED TO OPERATING LEVEL WITH PRESERVATIVE LUBRICATING OIL GOOD FOR OPERATION UNTIL THE FIRST REQUIRED OIL CHANGE - DO NOT DRAIN - CHECK OIL LEVEL - IF LOW, FILL TO OPERATING LEVEL WITH OPERATIONAL OIL.”

j.

Inspect outside of engine every two or three months for corrosion. If engine shows signs of corrosion on outside at check period, repeat this procedure.

10.

Check engine coolant to ensure coolant has correct mixture for expected temperatures (TB 750-651).

11.

Remove serpentine belt (WP 0048 00) after completing engine preservation. Coat unpainted surfaces of pulley grooves with a Primer coating (Item 34, WP 0233 00). Tag machine indicating “BELT REMOVED, INSTALL PRIOR TO STARTING ENGINE” and attach annotated DA Form 2258.

12.

Ensure battery disconnect switch is in OFF position (TM 5-3805-291-10).

13.

Remove batteries (WP 0096 00) and tape all battery cable ends with Tape, pressure sensitive adhesive (Item 45, WP 0233 00). Clean batteries, clamps, supports, retainers, and battery box using acid swabbing brush and a solution of 1/2 lb (0.23 kg) of Sodium bicarbonate, technical (Item 39, WP 0233 00) to 1 gal. (3.8 L) of water. Flush with clean water and dry (TM 9-6140-200-14). Store batteries where they can be checked periodically and recharged. Discharged batteries will be damaged if they are stored in below freezing temperatures. Secure battery cables to battery box with Strap, tiedown, electrical components (Item 42, WP 0233 00).

14.

Completely drain fuel tank (WP 0033 00) and fill or fog tank with Lubricating oil, engine (Item 21, WP 0233 00). Coat filler cap and drain plug with same oil and reinstall.

15.

Place blocking under axles to remove weight from tires.

16.

Fill in Form DD 1397, Vehicles and Spare Engines, Processing and Deprocessing Record for Shipment, Storage and Issue of, completely and attach to a conspicuous part of machine.

17.

Inflate tires to 60 psi (414 kPa) for front and 40 psi (275 kPa) for rear with dry air (TM 5-3805-291-10). Dry nitrogen may be considered for long-term outside storage. Annotate air pressure and/or if nitrogen was used on DA Form 2258.

PREPARATION FOR RETURN TO SERVICE FROM LONG-TERM STORAGE

0235 00

1.

Inflate tires to 60 psi (414 kPa) for front and 40 psi (275 kPa) for rear with dry air (TM 5-3805-291-10).

2.

Remove blocking from under axles.

3.

Remove tape from battery cable ends and install batteries fully charged (WP 0096 00).

4.

Fill hydraulic systems to operating level (TM 5-3805-291-10). Remove barrier material, tape, and tags from cylinders.

5.

Fill fuel tank with Diesel fuel, DF-1 (Item 10, WP 0233 00); Fuel oil, diesel, DF-2 (Item 11, WP 0233 00); or Fuel, turbine, aviation (Item 12, WP 0233 00) (TM 5-3805-291-10).

6.

Check oil and hydraulic fluid levels in engine crankcase, transmission, and hydraulic reservoir (TM 5-3805-291-10).

7.

Check oil level in front and rear axles (WP 0111 00).

8.

Check coolant level in radiator (TM 5-3805-291-10). 0235 00-5

TM 5-3805-291-23-2


0235 00

PREPARATION FOR RETURN TO SERVICE FROM LONG-TERM STORAGE - CONTINUED 9.

Prepare engine for operation as follows: a.

Remove all outside protective covers.

b.

Change engine oil and filter (WP 0025 00).

c.

Install serpentine belt (WP 0048 00). Replace as necessary.

d.

Replace fuel filter elements (WP 0035 00 and WP 0036 00).

e.

Remove plastic covers from air cleaner elements.

CAUTION If an engine is not used for prolonged periods, oil can run off the cylinder walls, piston rings, main bearings, connecting rod bearings, crankshaft, gears, and other parts that normally get lubrication. This lack of lubricant allows corrosion to start on the metal, especially in areas of high humidity (water content in the air).

f.

Turn engine in normal direction of rotation (TM 5-3805-291-10) by hand to make sure there are no hydraulic locks or excessive resistance.

g.

Before starting engine, remove valve cover (WP 0024 00) and put a large amount of engine oil [Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00); Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00); or Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00)] on camshaft, cam followers, and valve mechanism to prevent damage to mechanism.

h.

Before starting engine, test coolant mixture for proper nitrite and conditioner level with Nitrate test strips (Item 24, WP 0233 00). Drain and fill coolant, if necessary (WP 0041 00).

i.

Prime engine with clean diesel fuel before starting (TM 5-3805-291-10).

CAUTION The engine must have adequate lubrication during the first few seconds of operation. A “dry start” (without adequate lubrication) can cause bearing damage. To prevent the possibility of a “dry start” and bearing damage during the first seconds of operation, pressure lubricate the engine.

j.

k.

To get immediate lubrication, and to prevent damage to engine in the first few seconds after starting, pressure lubricate engine as follows: (1)

Fill main oil passages with oil under pressure. Sources of clean oil under pressure, such as a service shop central oil supply, can be used for pressure lubrication.

(2)

Use a clean source of oil.

(3)

Put correct amount of engine oil in crankcase.

(4)

Connect oil source to engine’s main oil passage.

(5)

Do not exceed an oil pressure of 35 ± 5 psi (242 ± 35 kPa).

(6)

Fill crankcase with correct oil: Oil, lubricating, OEA-30, Arctic (Item 29, WP 0233 00); Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 00); or Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00). Amount of oil used in pressure lubrication procedure must be subtracted from refill capacity given in TM 5-3805291-10. Maintain oil level between ADD and FULL marks on dipstick.

Check condition of ALL rubber hoses. Replace damaged hoses as necessary. 0235 00-6

TM 5-3805-291-23-2


0235 00

PREPARATION FOR RETURN TO SERVICE FROM LONG-TERM STORAGE - CONTINUED 10.

On the first day of returning to operation, check entire engine several times for leaks and correct operation. The quality of oil control components used in engines is such that, following engine storage, only an operational check at initial start is necessary before operation. This operational check ensures correct pressures and temperatures are kept in lubrication, cooling, and fuel systems, and leaks are detected. To be sure of a safe, uniform check at initial start, use this procedure: (1)

Place emergency shutdown switch in OFF position (TM 5-3805-291-10) and crank engine until engine oil pressure is present.

(2)

Place emergency shutdown switch in ON position (TM 5-3805-291-10), start engine, and allow it to run for 10 minutes at low idle speed (TM 5-3805-291-10).

(3)

Operate engine for 15 minutes at half-load and three-quarter rated speed (TM 5-3805-291-10).

(4)

Operate engine for 30 minutes at rated load and speed (TM 5-3805-291-10).

(5)

Check frequently for leaks such as oil, coolant, and fuel during first few hours of operation. Repair any leaks as soon as they are detected.

PREPARATION FOR SHIPMENT

0235 00

1.


2.


3.

Schedule next PMCS on ULLS-G (Unit Level Logistics System – Ground).

4.

Seal exhaust stack opening and engine air cleaner precleaner opening with Tape, pressure sensitive adhesive (Item 45, WP 0233 00).

5.

Consult shipping and transportation data on data plate (TM 5-3805-291-10).

6.

Refer to TM 5-3805-291-10 for Transport Procedures.

END OF WORK PACKAGE

0235 00-7/(0235 00-8 Blank)

6 TM 5-3805-291-23-2

NOMENCLATURE CROSS-REFERENCE LIST

0236 00

Table 1. 966H Nomenclature Cross-Reference List. Manual

Schematic

24

+24V

+V

+ BATTERY

ANTI-DRIFT DUMP SOLENOID

DUMP ANTIDRIFT SOLENOID

ANTI-DRIFT LOWER SOLENOID

LOWER ANTIDRIFT SOLENOID

ARC SUPPRESSOR START RLY

START RELAY ARC SUPPRESSOR

AUX LFT PROP SOLENOID

AUXILIARY THIRD FUNCTION REARWARD SOLENOID

AUX LWR PROP SOLENOID

AUXILIARY THIRD FUNCTION FORWARD SOLENOID

AUXILIARY HE SOLENOID

AUX 3RD FUNCTION FWD SOLENOID

AUXILIARY RE SOLENOID

THIRD REARWARD SOLENOID

BOOST PRESSURE SENSOR

INTAKE MANIFOLD PRESSURE SENSOR

BAT -

BATTERY - (4)

CAL

CALIBRATE

CAN A-

CAN DATA LINK -

CAN A+

CAN DATA LINK +

CLUTCH 1 (REVERSE)

CLUTCH SOLENOID 1 (REVERSE)

CLUTCH 1 REV


CLUTCH 1 REVERSE


CLUTCH 2 (FORWARD)

CLUTCH SOLENOID 2 (FORWARD)

CLUTCH 2 FORWARD


CLUTCH 2-FWD


CLUTCH 3 (FOURTH GEAR)

CLUTCH SOLENOID 3 (SPEED 4)

CLUTCH 3 (SPEED 4)


CLUTCH 3-4TH

CLUTCH SOLENOID 3 (4TH GEAR)

CLUTCH 4 (SPEED 3)


CLUTCH 4 (THIRD GEAR)


CLUTCH 5 (SECOND GEAR)


CLUTCH 5 (SPEED 2)


CLUTCH 5-2ND

CLUTCH SOLENOID 5 (2ND GEAR)

CLUTCH 6 (FIRST GEAR)


CLUTCH 6 (SPEED 1)


0236 00-1

TM 5-3805-291-23-2

NOMENCLATURE CROSS-REFERENCE LIST - CONTINUED

0236 00

Table 1. 966H Nomenclature Cross-Reference List - Continued. Manual

Schematic

CLUTCH 6-1ST

CLUTCH SOLENOID 6 (1ST GEAR)

CONVERTER OUTPUT SPD SNSR-

TC OUT SPEED SENSOR -

CONVERTER OUTPUT SPD SNSR+

TC OUT SPEED SENSOR +

COOLING FAN

DEMAND FAN

DIRECTION SW (FORWARD)

DIRECTION SWITCH FORWARD

DIRECTION SW (NEUTRAL)

DIRECTION SWITCH NEUTRAL

DIRECTION SW (REVERSE)

DIRECTION SWITCH REVERSE

DRIFT REDUCTION

ANTI-DRIFT

DRIFT REDUCTION SOLENOID

ANTI-DRIFT SOLENOID

DRIFT SOLENOID

LOWER ANTI-DRIFT SOLENOID

DUMP SOL

DUMP SOLENOID

DUMP SOLENOID

DUMP PROPORTIONAL SOLENOID

ENGINE COOLANT TEMPERATURE (SENSOR RETURN)

COOLANT TEMPERATURE SENSOR (GROUND)

ENGINE COOLANT TEMPERATURE SENSOR

COOLANT TEMPERATURE SENSOR

ENGINE OIL PRESSURE (ECM)

ENGINE OIL PRESSURE SENSOR SIGNAL

ENGINE SPD TACH WIRE (ENGINE)

ENGINE SPD SIGNAL TO TRANSMISSION

ENGINE START SWITCH

KEY START SWITCH

ETHER INJECTION SOLENOID (ECM)

ETHER ON RELAY

FWD

FORWARD

FWD SW IP

FORWARD SWITCH IP

GND

GROUND

HEADLAMP

SERVICE LIGHT

HMU 1 OR UPSHIFT SW (N/C)

HMU 1 OR UPSHIFT SWITCH (N/C)

HMU 2 OR UPSHIFT SW (N/O)

HMU 2 OR UPSHIFT SWITCH (N/O)

HMU 3 OR DOWNSHIFT (N/C)

HMU 3 OR UDOWNSHIFT SWITCH (N/C)

HMU 4 OR DOWNSHIFT (N/O)

HMU 4 OR UDOWNSHIFT SWITCH (N/O)

HORN

HORN HIGH

HORN

HORN LOW

ID CODE 2 (GROUND)

IDENTIFICATION CODE 2

ID CODE ENABLE

ECM LOC CODE ENABLE

IGNITION SWITCH

ENGINE START SWITCH

0236 00-2

TM 5-3805-291-23-2


0236 00


Schematic

IMAGE 427 C1616 XMSN OIL TEMP SENSOR (ECM)

TRANSMISSION OIL TEMPERATURE SENSOR

IMAGE NUMBER 427-C0700 “THROTTLE POSITION SENSOR” DIGITAL RETURN

THROTTLE POSITION SENSOR GROUND

IMAGE NUMBER 427-C0705 ENGINE SHUTDOWN SWITCH (RUN POSITION)

EMERGENCY SHUTDOWN SWITCH

IMPL LOCKOUT SW (NC)

IMPLEMENT LOCKOUT SWITCH (NC)

IMPL LOCKOUT SW (NO)

IMPLEMENT LOCKOUT SWITCH (NO)

IMPLEMENT CONTROL DOWNSHIFT SWITCH (N/O)

ELECTROHYDRAULIC CONTROL DOWNSHIFT (N/O)

INTAKE MANIFOLD AIR TEMPERATURE SENSOR

INTAKE AIR TEMPERATURE SENSOR

INTAKE MANIFOLD AIR TEMPERATURE (SENSOR RETURN)

INTAKE AIR TEMPERATURE SENSOR (GROUND)

JOYSTICK CONTROL POSITION SENSOR

JOYSTICK POSITION SENSOR

JUNCTION BLOCK

FUSE BOX

KICKOUT SET SW LIFT

KICKOUT SET SWITCH LIFT

KICKOUT SET SWITCH

BUCKET KICKOUT SET SWITCH LIFT

KICKOUT SET SW TILT

KICKOUT SET SWITCH TILT

LEFT PEDAL POSITION SENSOR

LEFT HAND BRAKE PEDAL SENSOR

LIFT LVR POS SENS

LIFT LEVER POSITION SENSOR

LOWER SOL

LOWER SOLENOID

NEUT SW IP

NEUTRAL SWITCH IP

PARA 5 (C) (1) LIFT LINKAGE ROTARY POSITION SENSOR

SCHEMATIC REFERS TO THIS SENSOR AS THE LIFT POSITION SENSOR

PARA 5 D. (1) TILT LINKAGE ROTARY POSITION SENSOR

SCHEMATIC REFERS TO THIS SENSOR AS THE TILT POSITION SENSOR

PARKING BRAKE SOLENOID

PARKING BRAKE ACTUATOR SOLENOID

PARK BRAKE SW-DISENGAGED

PARK BRAKE PRESSURE SWITCH DISENGAGE

PARK BRAKE SW-ENGAGED

PARK BRAKE PRESSURE SWITCH ENGAGE

PARKING BRAKE SWITCH (DISENGAGED)

PARK BRAKE PRESSURE SWITCH DISENGAGE

PARKING BRAKE SWITCH (ENGAGED)

PARK BRAKE PRESSURE SWITCH ENGAGE

PILOT PROPORTIONING

PILOT HYDRAULIC SUPPLY

PILOT SOL

PILOT HYD SUPPLY SOLENOID

PILOT SOLENOID

PILOT HYDRAULIC SUPPLY

PILOT SOLENOID RETURN

PILOT HYD SUPPLY SOLENOID RTN

0236 00-3

TM 5-3805-291-23-2


0236 00


Schematic

POSITION SENSOR LIFT LINKAGE

ROTARY LIFT POSITION SENSOR

POSITION SENSOR TILT LINKAGE

ROTARY TILT POSITION SENSOR

PRESSURE SENSOR +5 VDC (PIN 3)

ANALOG SENSOR POWER

PRIM STER PRESSURE SW (N/C)

PRIMARY STEER PRESSURE SWITCH (N/C)

PRIM STER PRESSURE SW (N/O)

PRIMARY STEER PRESSURE SWITCH (N/O)

PRIMARY SPEED/TIMING -

CRANKSHAFT (PRIMARY) SPEED TIMING SENSOR

PRIMARY SPEED/TIMING - (ECM)

CRANKSHAFT SPEED TIMING SENSOR

PRIMARY SPEED/TIMING +

CRANKSHAFT (PRIMARY) SPEED TIMING SENSOR

PRIMARY SPEED/TIMING + (ECM)

CRANKSHAFT SPEED TIMING SENSOR

PRIMARY STEERING PRESS SW

PRIMARY STEERING PRESSURE SWITCH

PRIMARY STEERING PRESSURE SWITCH (N/C)

PRIMARY STEER PRESSURE SWITCH (N/C)

PRIMARY STEERING PRESSURE SWITCH (N/O)

PRIMARY STEER PRESSURE SWITCH (N/O)

PROPORTIONAL RETURN

AUXILIARY SOLENOID RETURN

RACK SOL

RACKBACK SOLENOID

RACK SOLENOID

RACKBACK SOLENOID

RACK SOLENOID

RACKBACK PROPORTIONAL SOLENOID

RACKBACK SOLENOID

RACKBACK PROPORTIONAL SOLENOID

RAISE SOL

RAISE SOLENOID

RAISE SOLENOID

RAISE PROPORTIONAL SOLENOID

REMOTE INPUT 1(FNR)

REMOTE FNR INPUT 1

REMOTE INPUT 4 (FNR)

REMOTE FNR INPUT 4

REMOTE INPUT 6 (FNR)

REMOTE FNR INPUT 6

RETURN FOR SPD CLUTCH 4 & REV

RETURN FOR SPEED CLUTCHES 4 & REVERSE

RETURN FOR SPD CLUTCHES 1-3

RETURN FOR SPEED CLUTCHES 1-3

REV SW IP

REVERSE SWITCH IP

RIDE CNTL SOL 1

RIDE CONTROL SOLENOID #1

RIDE CNTL SOL 2


RIDE CNTL SOL 3


RIDE CNTL SOL ON/OFF #1

RIDE CONTROL SOLENOID ON/OFF#1





RIDE CNTL/AXLE COOLER RET

RIDE CONTROL/AXLE COOLER RETURN

0236 00-4

TM 5-3805-291-23-2


0236 00


Schematic

RIDE CONTROL SOLENOID 1 (ON/OFF)

RIDE CONTROL SOLENOID ON/OFF #1





RIDE CONTROL SW

RIDE CONTROL SWITCH

RIDE CONTROL SW (AUTO)

RIDE CONTROL SWITCH (AUTO)

RIDE CONTROL SW (ON)

RIDE CONTROL SWITCH (ON)

ROT LIFT POS SENS

ROTARY LIFT POSITION SENSOR

ROT TILT POS SENS

ROTARY TILT POSITION SENSOR

ROTARY LIFT LINKAGE POSITION SENSOR

LIFT POSITION SENSOR

ROTARY TILT LINKAGE POSITION SENSOR

TILT POSITION SENSOR

SEC GEAR

SECOND GEAR

SEC SPEED/TIMING -

CAMSHAFT (SECONDARY) SPEED TIMING SENSOR

SEC SPEED/TIMING +

CAMSHAFT (SECONDARY) SPEED TIMING SENSOR

SEC STEER INTIMED RELAY

SECONDARY STEER INTIMED RELAY

SEC STEERING PRES SW (N/C)

SECONDARY STEER PRESSURE SWITCH (N/C)

SEC STEERING PRES SW (N/O)

SECONDARY STEER PRESSURE SWITCH (N/O)

SEC STEERING PRESSURE SW (N/C)


SEC STEERING PRESSURE SW (N/O)


SECONDARY SPEED/TIMING - (ECM)

CAMSHAFT SPEED TIMING SENSOR

SECONDARY SPEED/TIMING + (ECM)

CAMSHAFT SPEED TIMING SENSOR

SECONDARY STEERING INTERMEDIATE RELAY

SECONDARY STEERING INTMED RELAY

SECONDARY STEERING PRESS SW

PRIMARY STEERING PRESSURE SWITCH

SECONDARY STEERING PRESSURE SWITCH (N/C)


SECONDARY STEERING PRESSURE SWITCH (N/O)


SENSOR OUTPUT SPEED (LEADING)

TRANSMISSION OUTPUT SPEED SENSOR

SENSOR OUTPUT SPEED (TRAILING)

TRANSMISSION OUTPUT SPEED SENSOR

SOL RETURN

PROPORTIONAL RETURN

START RELAY

STARTER RELAY

START RELAY/BACKUP ALM RET

START RELAY/RETURN

THIRD HE SOLENOID

AUX 3RD FUNCTION FWD SOLENOID

THIRD RE SOLENOID

THIRD REARWARD SOLENOID

TILT LVR POS SENS

TILT LEVER POSITION SENSOR

0236 00-5

TM 5-3805-291-23-2

NOMENCLATURE CROSS-REFERENCE LIST - CONTINUED Table 1. 966H Nomenclature Cross-Reference List - Continued. Manual

Schematic

TORQUE CONVERTER OUTPUT SPEED SENSOR (-)

TC OUT SPEED SENSOR -

TORQUE CONVERTER OUTPUT SPEED SENSOR (+)

TC OUT SPEED SENSOR +

TRANSMISSION DIRECTION CONTROL SWITCH (FORWARD)

DIRECTION SWITCH FORWARD

TRANSMISSION DIRECTION CONTROL SWITCH (NEUTRAL)

DIRECTION SWITCH NEUTRAL

TRANSMISSION DIRECTION CONTROL SWITCH (REVERSE)

DIRECTION SWITCH REVERSE

TRANSMISSION OUTPUT SPEED SENSOR (-)

TOS SENSOR (A) -

TRANSMISSION OUTPUT SPEED SENSOR (+)

TOS SENSOR (A) +

TURBO INLET PRESSURE SENSOR

ATMOSPHERIC PRESSURE SENSOR

END OF WORK PACKAGE

0236 00-6

0236 00

2 TM 5-3805-291-23-2

SCHEMATICS INTRODUCTION

0237 00

INTRODUCTION This work package contains schematic diagrams for the 966H Wheel Loader. Electrical FO-1.

Electrical Schematics - Key to Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1/(FP-2 Blank)

FO-1.

Electrical Schematics - Key to Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-3/(FP-4 Blank)

FO-1.


FO-1.


FO-1.

Electrical Schematics - Accessories Circuit (Sheet 3 of 21) . . . . . . . . . . . . . . . . . . . . . . . FP-9/(FP-10 Blank)

FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.


FO-1.

Electrical Schematics - Power Distribution Circuit (Sheet 19 of 21). . . . . . . . . . . . . . . . FP-41/(FP-42 Blank)

FO-1.

Electrical Schematics - Messenger Circuit (Sheet 20 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-43/(FP-44 Blank)

FO-1.

Electrical Schematics - Legend (Sheet 21 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-45/(FP-46 Blank)

Hydraulic FO-2.

Hydraulic Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-47/(FP-48 Blank)

FO-2.

Hydraulic Schematic (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-49/(FP-50 Blank)

FO-2.

Hydraulic Schematic Legend (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-51/(FP-52 Blank)


TM 5-3805-291-23-2

INDEX Subject

Work Package/Page

Numerics 12V Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0055 00-12

A Accessory Support Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0194 00-1

Accumulator Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ride Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0114 00-1 0150 00-1 0225 00-1 0151 00-1

Actuator Hood Tilt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0058 00-1 0112 00-1

Aft Shield Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0166 00-3 0166 00-3

Aftercooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0189 00-1

Air Conditioning System Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0168 00-1 0222 00-6 0221 00-1 0226 00-1 0222 00-3 0222 00-1 0222 00-1 0198 00-1

Arc Suppressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0053 00-1

Arctic Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0061 00-3 0061 00-3

Arctic Heater Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0061 00-1

Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0073 00-1

Axle Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0207 00-1 0208 00-1

0161 00-1

B Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0094 00-1

Bases, Hydraulic System Oil Filter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0155 00-1

Index-1

TM 5-3805-291-23-2

INDEX - Continued Subject

Work Package/Page

B - Continued Battery Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0096 00-1 0097 00-1 0098 00-1

Belt, Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0141 00-1

Blackout Drive Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0068 00-1

Boost Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0074 00-1

Bore Runout (Radial Eccentricity) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0177 00-4

Brake Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance, Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedal Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0114 00-1 0217 00-1 0113 00-1 0075 00-1 0118 00-1 0215 00-1 0117 00-1 0117 00-1

Braking and Hydraulic Fan Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0215 00-1

Bristles Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0163 00-1

Broom Hose, Manifold, and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shields and Springs and Links Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0164 00-1 0165 00-1 0166 00-1

Bucket Lift Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Lever and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tips and Cutting Edges Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0229 00-1 0228 00-1 0170 00-1

C Cab Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dome Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Visor and Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-2

0053 00-7 0138 00-1 0131 00-1 0132 00-1 0138 00-1 0132 00-1 0139 00-1 0195 00-1

TM 5-3805-291-23-2


Work Package/Page

C - Continued Camshaft Speed/Timing Sensor (Secondary) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0076 00-1

Carrier Bearing Replacement, Front Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0108 00-1

Case Drain Filter Base Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0155 00-3

Center Drive Shaft (Slip Joint) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0107 00-1

Chassis Battery Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Service Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear, Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0133 00-1 0133 00-1 0133 00-1 0133 00-1 0199 00-1 0133 00-1

Circuit Breaker Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0053 00-7 0053 00-7 0053 00-1

Cluster, Instrument Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0054 00-1

Compressor, Air Conditioning System, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0221 00-1

Condenser, Air Conditioning System, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0226 00-1

Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0077 00-1

Cooling Jets, Piston, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0183 00-1

Cooling System Package (Radiator, Fan, Aftercooler, and Oil Cooler) Replacement . . . . . . . .

0190 00-1

Core Evaporator, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0227 00-1 0220 00-1

Counterweight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0130 00-1

Coupler Quick, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0169 00-1 0156 00-2

Cover, Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0178 00-1

Crankshaft Speed/Timing Sensor (Primary) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration Damper and Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0078 00-1 0173 00-1

Cutting Edges Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0170 00-1

Index-3

TM 5-3805-291-23-2


Work Package/Page

C - Continued Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Coupler, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0172 00-1 0153 00-1 0158 00-1 0152 00-1

D Data Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0147 00-1

Differential and Final Drive Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0111 00-1

Disconnect Switch Replacement, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0098 00-1

Dome Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0069 00-1

Dome Light Replacement, Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0138 00-1

Door Cab, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0131 00-1 0213 00-1

Drive Light Replacement, Blackout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0068 00-1

Dryer, Inline Refrigerant, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0224 00-1

E Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0123 00-1

Electro-Hydraulic Control (Joystick) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0219 00-1

Electronic Control Module (ECM) Engine, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0057 00-1 0060 00-1 0063 00-1

Engine Compartment Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake/Exhaust Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0212 00-1 0057 00-1 0179 00-1 0181 00-1 0079 00-1 0182 00-1 0171 00-1 0055 00-13 0196 00-1

Evaporator Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0227 00-1

Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0184 00-1 0179 00-1

Index-4

TM 5-3805-291-23-2


Work Package/Page

E - Continued Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0233 00-1

F Fan Group Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0192 00-1 0192 00-1 0190 00-1

Fender Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0136 00-1

Filter Bases, Hydraulic System Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Element Replacement, Transmission Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0155 00-1 0105 00-1 0148 00-1

Flasher, Turnlamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0065 00-1

Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0176 00-1 0177 00-1

Forks, Pallet, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0167 00-1

Forward Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0166 00-1

Front Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Carrier Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loader Frame, Separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turnlamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0207 00-1 0197 00-1 0178 00-1 0108 00-1 0109 00-1 0136 00-1 0211 00-1 0174 00-1 0071 00-1

Fuel Injector and Wiring Harness Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Level Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0187 00-1 0080 00-1 0082 00-1 0188 00-1

Fuse Relay, Circuit Breaker, and Arc Suppressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0053 00-1 0053 00-1 0053 00-1

G Gear, Idler, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-5

0186 00-1

TM 5-3805-291-23-2


Work Package/Page

H Handrails, Ladders, and Steps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0134 00-1

Head, Cylinder, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0172 00-1

Heater Arctic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0161 00-1 0168 00-1 0220 00-1 0198 00-1

Hood Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Relay Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0135 00-1 0058 00-1 0053 00-5 0059 00-1 0059 00-1

Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0095 00-1

Hose Manifold, Link, and Broom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Washer Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0164 00-1 0144 00-1

Hoses, Lines, and Fittings Hydraulic System Oil Filter Bases and Cooler, Replacement . . . . . . . . . . . . . . . . . . . . . . Implement Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Implement Pump Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Lubrication, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves, Flanges, and Refrigerant, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0154 00-1 0156 00-1 0157 00-1 0157 00-1 0129 00-1 0223 00-1

Housing, Flywheel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0176 00-1

HVAC Blend Door Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0052 00-1

Hydraulic Fan Control Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Base Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-6

0217 00-1 0215 00-1 0155 00-2 0218 00-1 0193 00-1 0083 00-1 0159 00-1

TM 5-3805-291-23-2


Work Package/Page

H - Continued Hydraulic System Oil Change and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Bases and Cooler Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . Filter Bases Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0148 00-1 0154 00-1 0155 00-1

I Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0186 00-1

Implement Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Hydraulic Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

0060 00-1 0156 00-1 0157 00-1

Inline Refrigerant Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0224 00-1

Instrument Cluster Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0054 00-1 0055 00-1 0055 00-1

Intake Manifold Air Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0084 00-1 0185 00-1 0179 00-1

J Joystick Electro-Hydraulic Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0219 00-1

L Ladders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0134 00-1

Lever Replacement, Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0101 00-1

Lift Arms Replacement, Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0229 00-1 0153 00-1 0156 00-12

Light Blackout Drive, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0068 00-1 0072 00-1

Liner, Cab, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0138 00-1

Lines, Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0102 00-1 0104 00-1

Index-7

TM 5-3805-291-23-2


Work Package/Page

M Main Control Valve Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0157 00-1 0218 00-1

Main Light Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0061 00-2 0061 00-2 0061 00-1

Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0231 00-1 0232 00-1

Manifold Exhaust Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0184 00-1 0185 00-1

Messenger Configuration Parameters, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copy Configuration (Program ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copy Configuration From ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECM, Copy Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0056 00-2 0056 00-6 0056 00-3 0056 00-1 0056 00-3 0056 00-5 0056 00-2

Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0139 00-1

Motor Broom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Hydraulic Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Windshield Wiper, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0165 00-1 0192 00-1 0145 00-1 0146 00-1

N NATO Slave Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0099 00-1

Nomenclature Cross-Reference List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0236 00-1

O Oil Change, Differential and Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooler, Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooler, Transmission, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pan Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch Replacement, Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-8

0111 00-1 0190 00-1 0193 00-1 0205 00-1 0148 00-1 0181 00-1 0086 00-1

TM 5-3805-291-23-2


Work Package/Page

O - Continued Oil - Continued Pump (Gear Pump), Transmission, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors, Front and Rear Axle Temperature Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0206 00-1 0182 00-1 0081 00-1 0081 00-1

P Pallet Forks Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0167 00-1

Panel Box Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0053 00-7

Parking Brake Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0112 00-1 0115 00-1 0113 00-1 0086 00-1

Pilot Oil Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0150 00-1

Piston Cooling Jets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Implement/Pilot Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement (Steering and Implement/ Pilot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0216 00-4 0216 00-1 0216 00-2

Plates, Data, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0147 00-1

Power Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0062 00-1

Powertrain Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .

0063 00-1

Preparation for Long-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return to Service from Long-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return to Service from Short-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0235 00-3 0235 00-5 0235 00-3 0235 00-7 0235 00-2 0235 00-1

Pulley, Crankshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0173 00-1

Pump, Fuel Transfer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0188 00-1

Push Rods Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0180 00-1

Index-9

0183 00-1

TM 5-3805-291-23-2


Work Package/Page

Q Quick Coupler Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diverter Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0158 00-1 0149 00-1 0169 00-1

R Rack, Rifle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0142 00-1

Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0191 00-1

Rear Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame, Separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0208 00-1 0209 00-1 0110 00-1 0137 00-1 0211 00-1 0175 00-1

Rearview Camera, Cable, and Display Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0050 00-1

Receptacle Replacement, NATO Slave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0099 00-1

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0230 00-1

Refrigerant Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoses, Lines, Valves, Flanges, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . .

0225 00-1 0223 00-1

Relay Hood Tilt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0053 00-5 0053 00-1

Relief Valve, Transmission Hydraulic Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

0202 00-1

Remote Lubrication Lines, Hoses, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .

0129 00-1

Ride Control Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0151 00-1

Rifle Rack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0142 00-1

Rocker Arms and Push Rods Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0180 00-1 0055 00-11

Rotary Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0055 00-11

S Seal, Main Front Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-10

0174 00-1 0175 00-1

TM 5-3805-291-23-2


Work Package/Page

S - Continued Seat Assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0214 00-1 0214 00-1 0140 00-1 0141 00-1 0214 00-7

Secondary Steering Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0123 00-1 0126 00-1 0200 00-1

Sensor (Primary) Crankshaft Speed/Timing, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Atmospheric Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boost Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pedal Position, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft Speed/Timing (Secondary), Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Oil Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Manifold Air Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Kickout Position and Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tilt Kickout Position and Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0078 00-1 0073 00-1 0074 00-1 0075 00-1 0076 00-1 0077 00-1 0079 00-1 0082 00-1 0083 00-1 0084 00-1 0085 00-1 0089 00-1 0090 00-1 0091 00-1 0092 00-1 0093 00-1

Separate Front Loader Frame and Rear Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0211 00-1

Service Light Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0071 00-2 0071 00-1 0100 00-1

Service Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lines and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0116 00-1 0117 00-1 0087 00-1

Index-11

TM 5-3805-291-23-2


Work Package/Page

S - Continued Shaft Replacement Center Drive (Slip Joint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0107 00-1 0109 00-1 0110 00-1

Shield Engine Compartment Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0212 00-1 0166 00-1

Shift Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0101 00-1

Shipment, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0235 00-7

Side Covers Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0135 00-1

Sight Gage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0160 00-1

Springs, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0166 00-1

Start Switch Removal, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0055 00-13

Starter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0051 00-1

Steering Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutralizer Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Pump and Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0121 00-1 0127 00-1 0125 00-1 0124 00-1 0128 00-1 0210 00-1 0088 00-1 0123 00-1 0126 00-1

Steps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0134 00-1

Stoplight Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0070 00-1 0070 00-1 0064 00-1

Storage Long-term, Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short-term, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0235 00-3 0235 00-2

Sun Visor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0139 00-1

Support Brackets, Accessory, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0194 00-1

Suspension, Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0214 00-7

Index-12

TM 5-3805-291-23-2


Work Package/Page

T - Continued Switch 12V, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arctic Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Disconnect, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Start, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Light Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake, Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement, Transmission Oil Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Brake Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight, Limit, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turnlamp, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0055 00-12 0061 00-3 0061 00-3 0098 00-1 0055 00-13 0055 00-1 0061 00-2 0061 00-2 0086 00-1 0104 00-1 0055 00-11 0055 00-11 0087 00-1 0088 00-1 0064 00-1 0066 00-1 0067 00-1

T Tank, Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0159 00-1

Test Lines, and Fittings,Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0106 00-1

Third Function System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0156 00-9

Tilt Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Link Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0152 00-1 0228 00-5 0228 00-2 0156 00-10

Tire Assembly Replacement Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0119 00-1 0120 00-1

Toolbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0143 00-1

Torque Converter Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0090 00-1 0091 00-1 0204 00-9 0204 00-1 0234 00-1

Index-13

TM 5-3805-291-23-2


Work Package/Page

T - Continued Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Control Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filler Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Base, Lines, and Bypass Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump (Gear Pump) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0204 00-2 0201 00-1 0202 00-1 0203 00-1 0102 00-1 0205 00-1 0103 00-1 0104 00-1 0105 00-1 0206 00-1 0092 00-1 0093 00-1 0204 00-1 0100 00-1 0106 00-1

Trunnion, Rear Axle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0209 00-1

Tube Replacement, Transmission Oil Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0103 00-1

Turnlamp Flasher Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0065 00-1 0071 00-9 0066 00-1

V Valve Lash, Intake/Exhaust, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Hydraulic Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Coupler Diverter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Brake Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Neutralizer, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Modulating, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0179 00-1 0218 00-1 0115 00-1 0149 00-1 0116 00-1 0210 00-1 0203 00-1

Vibration Damper, Crankshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0173 00-1

Visor, Sun, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0139 00-1

W Wheel Replacement Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index-14

0119 00-1 0120 00-1

TM 5-3805-291-23-2


Work Package/Page

W - Continued Windshield Front Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wipers Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front/Rear and Doors Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Washer Hoses, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiper Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0145 00-1 0145 00-1 0213 00-1 0146 00-1 0146 00-1 0144 00-1 0144 00-1 0067 00-1

Wiring Harness Cab, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Chassis Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injector, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater and Air Conditioning, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Chassis, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Steering, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0195 00-1 0196 00-1 0197 00-1 0187 00-1 0198 00-1 0199 00-1 0059 00-1 0200 00-1 0201 00-1

Worklights Bulb Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lamp Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0072 00-2 0072 00-4 0072 00-1

Index-15/(Index-16 Blank)

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form) (Include ZIP Code)

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

Date you filled out this form.

FROM: (Activity and location) (Include ZIP Code)

U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630

Your mailing address

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS Title )LHOG0DLQWHQDQFH0DQXDO,QFOXGHV PUBLICATION/FORM NUMBER DATE

TM ITEM NO.

PAGE NO.

PARAGRAPH

LINE NO. *

-DQ

FIGURE TABLE NO. NO.

8QLWDQG'6PDLQWHQDQFH IRU+ /RDGHU+HDY\7\SH,DQG,,

RECOMMENDED CHANGES AND REASON (Provide exact wording of recommended changes, if possible).

3DUWQXPEHUVXSSOLHGIRULWHPLVLQFRUUHFW

TYPED NAME, GRADE OR TITLE

Your Name DA FORM 2028, FEB 74

*Reference to line numbers within the paragraph or subparagraph. TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature

Your Signature

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

USAPPC V3.00

TO: (Forward direct to addressee listed in publication)

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630 PUBLICATION NUMBER

TM

PAGE NO.

COLM NO.

LINE NO.


DATE Date you filled out this form

Your address

PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE )LHOG0DLQW0DQXDOZ8QLW '60DLQW DATE

-DQ

NATIONAL STOCK REFERENCE FIGURE ITEM NO. NO. NO. NUMBER

IRU+/RDGHU+HDY\7\SH,DQG,,

TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

SAMPLE

PART III – REMARKS

(Any general remarks or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)


Your Name

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

Your Signature USAPPC V3.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM). For use of this form, see AR 25-30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code)

DATE


U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630

PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS

PUBLICATION/FORM NUMBER ITEM NO.

PAGE NO.

PARAGRAPH

LINE NO. *

TITLE )LHOG0DLQWHQDQFH0DQXDO,QFOXGHV8QLWDQG'6

DATE

TM

-DQ FIGURE TABLE NO. NO.

0DLQWHQDQFH IRU+/RDGHU+HDY\7\SH,DQG,,


*Reference to line numbers within the paragraph or subparagraph. TYPED NAME, GRADE OR TITLE

DA FORM 2028, FEB 74


SIGNATURE


USAPPC V3.00


DATE



PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS TITLE )LHOG0DLQWHQDQFH0DQXDOZ8QLWDQG'6 DATE

TM

PAGE NO.

COLM NO.

LINE NO.

-DQ

NATIONAL STOCK REFERENCE FIGURE NO. NO. NUMBER



ITEM NO.

0DLQWHQDQFHIRU+/RDGHU+HDY\7\SH,,,


RECOMMENDED ACTION



SIGNATURE

USAPPC V3.00



DATE

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630 PUBLICATION/FORM NUMBER TM

ITEM NO.

PAGE NO.

PARAGRAPH

LINE NO. *

DATE -DQ FIGURE NO.

TABLE NO.

TITLE

)LHOG0DLQWHQDQFH0DQXDO,QFOXGHV8QLWDQG'6 0DLQWHQDQFH IRU+/RDGHU+HDY\7\SH,DQG,,





SIGNATURE


USAPPC V3.00



DATE



TM

PAGE NO.

COLM NO.

LINE NO.



-DQ


ITEM NO.

0DLQWHQDQFHIRU+/RDGHU+HDY\7\SH,DQG,,


RECOMMENDED ACTION



SIGNATURE

USAPPC V3.00



DATE

TO: (Forward to proponent of publication or form) (Include ZIP Code) FROM: (Activity and location) (Include ZIP Code)

U. S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS 1 Rock Island Arsenal, Rock Island, IL 61299-7630 PUBLICATION/FORM NUMBER TM

ITEM NO.

PAGE NO.

PARAGRAPH

LINE NO. *

DATE -DQ FIGURE NO.

TABLE NO.

TITLE

)LHOG0DLQWHQDQFH0DQXDO,QFOXGHV8QLWDQG'6 0DLQWHQDQFH IRU+/RDGHU+HDY\7\SH,DQG,,





SIGNATURE


USAPPC V3.00



DATE



TM

PAGE NO.

COLM NO.

LINE NO.



-DQ


ITEM NO.

0DLQWHQDQFHIRU+/RDGHU+HDY\7\SH,DQG,,


RECOMMENDED ACTION



SIGNATURE

USAPPC V3.00

By Order of the Secretary of the Army: GEORGE W. CASEY, JR. General, United States Army Chief of Staff Official:

0

DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: , requirements for TM 5-3805-291-23-2.

TM 5-3805-291-23-2

483-1607

FO-1. Electrical Schematics - Key to Components FP-1/(FP-2 Blank)

TM 5-3805-291-23-2

483-1608

FO-1. Electrical Schematics - Key to Harnesses. FP-3/(FP-4 Blank)

TM 5-3805-291-23-2

483-1586

FO-1. Electrical Schematics - Lighting Circuit (Sheet 1 of 21) FP-5/(FP-6 Blank)

TM 5-3805-291-23-2

483-1587

FO-1. Electrical Schematics - Lighting Circuit (Sheet 2 of 21) FP-7/(FP-8 Blank)

TM 5-3805-291-23-2

483-1588

FO-1. Electrical Schematics - Accessories Circuit (Sheet 3 of 21) FP-9/(FP-10 Blank)

TM 5-3805-291-23-2

483-1589


TM 5-3805-291-23-2

483-1590


TM 5-3805-291-23-2

483-1591


TM 5-3805-291-23-2

483-1592

FO-1. Electrical Schematics - Implement Circuit (Sheet 7 of 21) FP-17/(FP-18 Blank)

TM 5-3805-291-23-2

483-1593


TM 5-3805-291-23-2

483-1594


TM 5-3805-291-23-2

483-1595


TM 5-3805-291-23-2

483-1596


TM 5-3805-291-23-2

483-1597

FO-1. Electrical Schematics - Engine Circuit (Sheet 12 of 21) FP-27/(FP-28 Blank)

TM 5-3805-291-23-2

483-1598

FO-1. Electrical Schematics - Engine Circuit (Sheet 13 of 21) FP-29/(FP-30 Blank)

TM 5-3805-291-23-2

483-1599

FO-1. Electrical Schematics - Transmission Circuit (Sheet 14 of 21) FP-31/(FP-32 Blank)

TM 5-3805-291-23-2

483-1600

FO-1. Electrical Schematics - Transmission Circuit (Sheet 15 of 21). FP-33/(FP-34 Blank)

TM 5-3805-291-23-2

483-1601

FO-1. Electrical Schematics - Transmission Circuit (Sheet 16 of 21). FP-35/(FP-36 Blank)

TM 5-3805-291-23-2

483-1602

FO-1. Electrical Schematics - Starting Circuit (Sheet 17 of 21). FP-37/(FP-38 Blank)

TM 5-3805-291-23-2

483-1603

FO-1. Electrical Schematics - Starting Circuit (Sheet 18 of 21). FP-39/(FP-40 Blank)

TM 5-3805-291-23-2

483-1604

FO-1. Electrical Schematics - Power Distribution Circuit (Sheet 19 of 21). FP-41/(FP-42 Blank)

TM 5-3805-291-23-2

483-1605

FO-1. Electrical Schematics - Messenger Circuit (Sheet 20 of 21). FP-43/(FP-44 Blank)

TM 5-3805-291-23-2

427-C2057-23

FO-1. Electrical Schematics - Legend (Sheet 21 of 21). FP-45/(FP-46 Blank)

TM 5-3805-291-23-2

427-C1981-2

FO-2. Hydraulic Component Locator. FP-47/(FP-48 Blank)

TM 5-3805-291-23-2

427-C1981-1

FO-2. Hydraulic Schematic (Sheet 1 of 2). FP-49/(FP-50 Blank)

TM 5-3805-291-23-2

427-C1981-3

FO-2. Hydraulic Schematic Legend (Sheet 2 of 2). FP-51/(FP-52 Blank)

THE METRIC SYSTEM AND EQUIVALENTS Linear Measure

Square Measure

1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles

1 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet 1 Sq Kilometer = 1,000,000 Sq Meters = 0.0386 Sq Miles

Weights

Cubic Measure

1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Pounds 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons

1 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet Temperature

Liquid Measure 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces

5/9 (°F - 32) = °C 212° Fahrenheit is equivalent to 100° Celsius 90° Fahrenheit is equivalent to 32.2° Celsius 32° Fahrenheit is equivalent to 0° Celsius 9/5 C° +32 = F°

APPROXIMATE CONVERSION FACTORS To Change

To

Multiply By

To Change

To

Multiply By

Inches

Centimeters

2.540

Centimeters

Inches

0.394

Feet

Meters

0.305

Meters

Feet

3.280

Yards

Meters

0.914

Meters

Yards

1.094

Miles

Kilometers

1.609

Kilometers

Miles

0.621

Sq Inches

Sq Centimeters

6.451

Sq Centimeters

Sq Inches

0.155

Sq Feet

Sq Meters

0.093

Sq Meters

Sq Feet

10.764

Sq Yards

Sq Meters

0.836

Sq Meters

Sq Yards

1.196

Sq Miles

Sq Kilometers

2.590

Sq Kilometers

Sq Miles

0.386

Acres

Sq Hectometers

0.405

Sq Hectometers

Acres

2.471

Cubic Feet

Cubic Meters

0.028

Cubic Meters

Cubic Feet

35.315

Cubic Yards

Cubic Meters

0.765

Cubic Meters

Cubic Yards

1.308

Fluid Ounces

Milliliters

29.573

Milliliters

Fluid Ounces

0.034

Pints

Liters

0.473

Liters

Pints

2.113

Quarts

Liters

0.946

Liters

Quarts

1.057

Gallons

Liters

3.785

Liters

Gallons

0.264

Ounces

Grams

28.349

Grams

Ounces

0.035

Pounds

Kilograms

0.454

Kilograms

Pounds

2.205

Short Tons

Metric Tons

0.907

Metric Tons

Short Tons

1.102

Pound-Feet

Newton-Meters

1.356

Newton-Meters

Pound-Feet

0.738

Pounds per Sq Inch

Kilopascals

6.895

Kilopascals

Pounds per Sq Inch

0.145

Miles per Gallon

Kilometers per Liter

0.425

Kilometers per Liter

Miles per Gallon

2.354

Miles per Hour

Kilometers per Hour

1.609

Kilometers per Hour

Miles per Hour

0.621

PIN: 085667-000

TM 5-3805-291-23-2

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