Foreword
SAFETY - TM-5-3805-258-24-1_13
SAFETY - TM-5-3805-258-24-1_14
Diesel fuel and all lubricants
Hot hydraulic oil
SERIAL NUMBER LOCATIONS
TIRE INFLATION INFORMATION
MAINTENANCE RECOMMENDATIONS
FUEL SYSTEM - TM-5-3805-258-24-1_20
LUBRICANTS-FUELS-COOLANT
COOLANT SPECIFICATIONS - TM-5-3805-258-24-1_22
RECOMMENDED LUBRICANT VISCOSITIES
LUBRICATION AND MAINTENANCE CHART
LUBRICATION AND MAINTENANCE CHART
LUBRICATION AND MAINTENANCE CHART3.
T R A N S M I S S I O N
FRONT AND REAR DIFFERENTIALS AND FINAL DRIVES
AIR INTAKE SYSTEM
SECONDARY ELEMENT
Cover the air inlet opening
CLEANING AIR CLEANER ELEMENTS
Detergent
ENGINE AIR PRECLEANER - TM-5-3805-258-24-1_35
COOLING SYSTEM - CLEANING
Open the drain valve
Close the drain valve
Inspect the radiator cap gasket
Inspect the valve for damage
FUEL TANK - TM-5-3805-258-24-1_41
BUCKET TEETH - REPLACE TIP
CUTTING EDGE
SEAT BELT
FUSES
ETHER STARTING AID - ETHER CYLINDER
Temporary Removal
ENGINE/TRANSMISSION OIL SAMPLING
ATTACHMENT HITCH
WALK-AROUND INSPECTION
Every 10 Service Hours or Daily
ENGINE CRANKCASE
RADIATOR - TM-5-3805-258-24-1_53
INDICATOR LIGHTS
BUCKET LOWER PINS
TIRES
REAR AXLE TRUNNION BEARINGS
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_59
BUCKET CYLINDER LINKAGE BEARINGS
BATTERIES - TM-5-3805-258-24-1_61
ENGINE CRANKCASE
Apply a light coat
BRAKE FLUID RESERVOIRS
SERVICE BRAKES - TESTING
PARKING BRAKE - TESTING
The parking brake and the brake pressure indicator lights
DRIVE SHAFT SPLINE
FAN AND ALTERNATOR BELTS
FAN BEARING
Every 250 Service Hours or Monthly
FUEL TANK CAP AND FILL SCREEN
Every 500 Service Hours or 3 Months
Move the hydraulic controls
Remove the filter element
Inspect the filler cap seal
TRANSMISSION - TM-5-3805-258-24-1_77
Clean the housing base
PRIMARY FUEL FILTER
Clean the case
FINAL FILTER
PRIMING THE FUEL SYSTEM
ENGINE CRANKCASE BREATHER
TRANSMISSION - TM-5-3805-258-24-1_84
Remove the tube and magnets
Insert the screen
Every 1000 Service Hours or 6 Months
DRIVE SHAFT UNIVERSAL JOINTS
FRAME UPPER AND LOWER PIVOT BEARINGS
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
DIFFERENTIALS AND FINAL DRIVES
Install the differential and final drive drain plugs
Every 2000 Service Hours or 1 Year
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_94
Install a 1 inch NPT pipe nipple
Inspect the drain plug seal
COOLING SYSTEM - CHANGE COOLANT
Open the radiator drain valve
ENGINE VALVE LASH
SPECIFICATIONS SECTION 2
HYDRAULIC SYSTEM INDEX
ENGINE DESIGN
FUEL INJECTION EQUIPMENT
AIR-FUEL RATIO CONTROL
GOVERNOR - TM-5-3805-258-24-1_107
TIMING GEARS - TM-5-3805-258-24-1_108
VALVES
CAMSHAFT - TM-5-3805-258-24-1_110
CYLINDER HEAD
EXHAUST PIPE AND MUFFLER
TURBOCHARGER - TM-5-3805-258-24-1_113
OIL PUMP - TM-5-3805-258-24-1_114
OIL FILTER
WATER PUMP - TM-5-3805-258-24-1_116
RADIATOR - TM-5-3805-258-24-1_117
CYLINDER BLOCK
CYLINDER LINER
CONNECTING ROD
PISTONS AND RINGS
CRANKSHAFT - TM-5-3805-258-24-1_122
BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS
BEARING SURFACE (JOURNAL) FOR CONNECTING RODS
MAIN BEARINGS AND CONNECTING ROD BEARINGS
TIMING GEAR COVER
FLYWHEEL - TM-5-3805-258-24-1_127
FLYWHEEL RUNOUT
FLYWHEEL HOUSING RUNOUT
FLYWHEEL HOUSING BORE
ALTERNATORS
STARTER SOLENOID - TM-5-3805-258-24-1_132
STARTER SOLENOID
TORQUE CONVERTER - TM-5-3805-258-24-1_135
OUTLET RELIEF VALVE FOR TORQUE CONVERTER
SELECTOR AND PRESSURE CONTROL VALVE FOR TRANSMISSION
TRANSMISSION NEUTRALIZER VALVE
TRANSMISSION - TM-5-3805-258-24-1_139
TRANSMISSION (Cont.)
TRANSMISSION OIL FILTER - TM-5-3805-258-24-1_141
TRANSMISSION NEUTRALIZER GROUP - TM-5-3805-258-24-1_142
TORQUE CONVERTER AND PUMP DRIVE HOUSING
DRIVE SHAFT
DIFFERENTIAL AND BEVEL GEAR
Differential and Bevel Gear
FRONT AXLE GROUP
RIM GROUP
ADJUSTMENT OF THE WHEEL BEARINGS
FINAL DRIVES, BRAKE AND WHEELS
MOUNTING GROUP (ROPS)
HYDRAULIC PUMP FOR IMPLEMENT, STEERING AND PILOT SYSTEMS
HAND METERING UNIT (HMU)
STEERING CYLINDERS
STEERING CONTROL VALVE
NEUTRALIZER VALVES
DIVERTER VALVE FOR SUPPLEMENTAL STEERING
ARTICULATED HITCH GROUP
ARTICULATED HITCH GROUP
AIR COMPRESSOR GOVERNOR
AIR PRESSURE SWITCH
BRAKE CONTROL VALVES - TM-5-3805-258-24-1_164
AIR/HYDRAULIC CYLINDERS
EMERGENCY AND PARKING BRAKE ADJUSTMENT
AIR DRYER - TM-5-3805-258-24-1_167
WHEEL BRAKES - TM-5-3805-258-24-1_169
HYDRAULIC PUMP FOR IMPLEMENT, STEERING AND PILOT SYSTEMS
HYDRAULIC SYSTEM
FILTER AND TANK GROUP
LIFT AND TILT PILOT VALVE
ATTACHMENT PILOT VALVE
SELECTOR AND PRESSURE CONTROL VALVE
CONTROL VALVES FOR LIFT, TILT AND ATTACHMENT
MAIN RELIEF VALVE
WEAR PLATES, BIT AND CUTTING EDGE GROUPS
CONTROL LEVER LINKAGE
LIFT KICKOUT ADJUSTMENT PROCEDURE
TILT CYLINDER
BUCKET CONTROL GROUP
Bucket Control Group (Cont.)
AIR COMPRESSOR - TM-5-3805-258-24-1_184
AIR COMPRESSOR
GENERAL TIGHTENING TORQUE FOR BOLTS, NUTS AND TAPERLOCK STUDS
LINES, PLUGS AND FITTINGS
TORQUES FOR 0THER FITTINGS
SYSTEMS OPERATION
HYDRAULIC SYSTEM INDEX
FUEL SYSTEM - TM-5-3805-258-24-1_193
FUEL INJECTION NOZZLE
FUEL TRANSFER PUMP - TM-5-3805-258-24-1_195
OIL FLOW FOR FUEL PUMP AND GOVERNOR
GOVERNOR - TM-5-3805-258-24-1_197
Governor Servo
Dashpot
AIR FUEL RATIO CONTROL
AIR FUEL RATIO CONTROL
AIR INLET AND EXHAUST SYSTEM - TM-5-3805-258-24-1_203
CYLINDER HEAD AND VALVES
LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM
COOLING SYSTEM
COOLING SYSTEM COMPONENTS
BASIC BLOCK
ELECTRICAL SYSTEM
T Y P I C A L S O L E N O I D S C H E M A T I C
GENERAL INFORMATION
TORQUE CONVERTER
FLOW OF POWER IN TORQUE CONVERTER
TORQUE CONVERTER AND PUMP DRIVE HOUSING
TORQUE S Y S T E M S O P E R A T I O N CONVERTER HYDRAULIC SYSTEM
RATlO VALVE FOR THE TORQUE CONVERTER
TRANSMISSION HYDRAULIC SYSTEM
OIL PUMP
OIL FILTER
POWER TRAIN OIL COOLER
TRANSMISSION - TM-5-3805-258-24-1_222
FIRST SPEED FORWARD
SECOND SPEED FORWARD
THIRD SPEED FORWARD
FOURTH SPEED FORWARD
FIRST SPEED REVERSE
SECOND SPEED REVERSE
THIRD SPEED REVERSE
FOURTH SPEED REVERSE
PLANETARY LUBRICATION
TRANSMISSION HYDRAULIC CONTROLS
SELECTOR AND PRESSURE CONTROL VALVE - TM-5-3805-258-24-1_233
P O W E R T R A I N T R A N S M I S S I O N H Y D R A U L I C C O N T R O LS
OPERATION Starting the Engine (Transmission in Neutral)
Transmission selector lever is in NEUTRAL
Engine Running (Neutral to First Speed Forward)
No. 6 clutch is full of oil
Starting the Engine (Transmission in a Speed and Direction)
Neutralizer Valve
TRANSMISSION NEUTRALIZER GROUP - TM-5-3805-258-24-1_241
Transmission engaged in either FORWARD or REVERSE
OUTPUT TRANSFER GEARS
DIFFERENTIALS
OPERATION Straight FORWARD or REVERSE
NOSPIN DIFFERENTIAL GROUP
TM-5-3805-258-24-1_247
OPERATION OF NOSPIN DIFFERENTIAL
Straight Forward Operation
Forward Turn With No Power
FINAL DRIVES - TM-5-3805-258-24-1_251
AMPLIFIED STEERING SYSTEM
AMPLIFIED STEERING SYSTEM
HAND METERING UNIT (HMU)
The steering wheel
STEERING CONTROL VALVE - TM-5-3805-258-24-1_256
Right Turn Position
Left Turn Position
SUPPLEMENTAL STEERING SYSTEM
DIVERTER VALVE.
DIVERTER VALVE SCHEMATIC
AIR SYSTEM AND BRAKES
BRAKE SYSTEM
WARNING SYSTEM
AIR SUPPLY FOR THE AIR SYSTEM
AIR RESERVOIR
AIR CIRCUIT FOR THE EMERGENCY AND PARKING BRAKE
L O C A T I O N O F T H E C O N T R O L K N OB
QUICK RELEASE VALVE FOR EMERGENCY AND PARKING BRAKE
EMERGENCY AND PARKING BRAKE
E M E R G E N C Y A N D P A R K I N G B R A KE
AIR CIRCUIT FOR THE WHEEL BRAKES
BRAKE CONTROL VALVES - TM-5-3805-258-24-1_274
AIR HORNS AND VALVE
Operation
AIR PRESSURE SWITCH FOR STOP LIGHTS
A I R C Y L I N D E R
HYDRAULIC CIRCUIT FOR THE WHEEL BRAKES
BRAKE FLUID RESERVOIRS
M A S T E R C Y L I N D E R
WHEEL BRAKES - TM-5-3805-258-24-1_282
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_283
R I G H T S I D E O F T R A N S M I S S I ON
R I G H T S I D E O F M A C H I N E
HYDRAULIC PUMP WITH THREE SECTIONS
Operation Of The Pilot Pump Section
ONE-WAY CHECK VALVES
SELECTOR AND PRESSURE CONTROL VALVE - TM-5-3805-258-24-1_289
LIFT AND TILT PILOT VALVE
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_291
LOWER Position With Engine Off
DUMP Position With Engine Off
OPEN or RAISE Position
SEQUENCE VALVE - TM-5-3805-258-24-1_295
SHUTTLE VALVE
Tilt Valve Spool
Lift Valve Spool
RAISE Operation
Make-Up Valves
COUPLING HITCH ATTACHMENT CONTROL VALVE
RELIEF VALVES
Relief Valves For Tilt And Attachment Cylinders
BUCKET POSITIONER
TILT BACK Operation
DUMP Operation
LOWER Operation
OPEN or RAISE Position
AIR COMPRESSOR OPERATION
TYPICAL AIR COMPRESSOR SYSTEM
AIR GOVERNOR
AIR COMPRESSOR LUBRICATION
PROTECTIVE ITEMS
BACK-UP ALARM - TM-5-3805-258-24-1_316
OPERATOR COMFORT ITEMS
CONTROL GROUPS
STEERING CONTROL GROUP
INSTRUMENT PANEL - TM-5-3805-258-24-1_321
Service Meter
Fuel Level Indicator
FUSE AND CIRCUIT BREAKER PANEL
RELAY PANEL
Main Power Relay
TROUBLESHOOTING METHODS
OPERATORS STATION ELECTRICAL SYSTEM
CODES AND ABBREVIATIONS
ELECTRICAL COMPONENTS LOCATION AND IDENTIFICATION
E L E C T R I C A L S Y S T E M
INDIVIDUAL CIRCUIT DESCRIPTION
OPERATOR PANEL
B. Alternator
C. Parking Brake (Transmission in Neutral)
TRANSMISSION IN NEUTRAL
2. Indicator and Master Fault Light
B. Engine Coolant Temperature
C. Transmission Oil Temperature
3. Indicator, Master Fault Light and Fault Alarm
B. Low Brake Oil Pressure
Brake Oil Pressure Circuit
C. Engine Oil Pressure
Engine Oil Pressure Circuit
D. Transmission Neutralizer (With Transmission in Gear)
TRANSMISSION IN FORWARD
Power To Operator Panel
F U E L P R E S S U R E S W I T CH
MAIN POWER CIRCUIT
Main Power Circuit
START SYSTEM
1. Start Circuit
STARTER SOLENOID - TM-5-3805-258-24-1_354
INDIVIDUAL CIRCUIT DESCRIPTION
ENGINE STOP SYSTEM
Stop Circuit
SERVICE METER
S e r v i c e M e t e r C i r c u i t
BACK-UP ALARM - TM-5-3805-258-24-1_360
I N D I V I D U A L C I R C U I T D E S C R I P T I ON
Jumper bar
CIGAR LIGHTER
STOP LIGHTS
Tail Light Circuit
REAR FLOOD LIGHTS
FRONT FLOOD LIGHTS
MAIN STEERING INDICATOR
PARKING LIGHTS
S P E E D O M E T ER
TESTING AND ADJUSTING SECTION 4
AIR SYSTEM AND BRAKE INDEX
POWER TRAIN TROUBLESHOOTING INDEX
FUEL SYSTEM
E X T R A V A L V E
Nozzle Preparation for Test
Il. Flush the Nozzle
IV. Orifice Restriction Test
FUEL INJECTION LINES
Installation of Fuel Injection Pumps
F U E L P U M P I N S T A L L A T I ON
FINDING TOP CENTER COMPRESSION
CHECKING TIMING BY FUEL FLOW METHOD.
ASSEMBLING ROD AND ADAPTER
6 V 2 0 2 3 F L O W C H E C K I N G A D A P T E R G R O UP
CHECKING TIMING BY TIMING PIN METHOD
Remove timing gear cover
T R A N S D U C E R I N P O S I T I ON
GOVERNOR ADJUSTMENT FOR AIR FUEL RATIO CONTROL
B R A C K E T A S S E M B L Y I N S T A L L ED
RACK SETTING PROCEDURE
I N D I C A T O R B R A C K E T I N S T A L L E D
MEASURING ENGINE SPEED
GOVERNOR ADJUSTMENTS
Checking Balance Point
GOVERNOR CABLE ADJUSTMENT
AIR INLET AND EXHAUST SYSTEM - TM-5-3805-258-24-1_399
CRANKCASE (CRANKSHAFT COMPARTMENT) PRESSURE
PROCEDURE FOR MEASURING CAMSHAFT LOBES
LUBRICATION SYSTEM
Crankcase Oil Level
COOLING SYSTEM
Checking Filler Cap and Relief Valve
Testing Radiator and Cooling System for Leaks
V-BELT TENSION CHART
BASIC BLOCK
CYLINDER BLOCK
Bore Runout (radial eccentricity) of the Flywheel Housing
Face Runout (axial eccentricity) of the Flywheel
C H E C K I N G B O R E R U N O U T O F T H E F L Y W H E E L
ELECTRICAL SYSTEM - TM-5-3805-258-24-1_414
STARTING SYSTEM
Pinion Clearance Adjustment
NOSPIN NOSPIN DIFFERENTIAL TEST (Before Installation) After the NoSpin differential has been assembled and before it is installed in the machine, make a test of the operation of the differential as follows: 1. Install the NoSpin differential in the case. 2. Put the case in a stand or a vise to keep it from rotation. 3. Install both axles in the case. TM 5-3805-258-24-1 T E S T I N G A N D A D J U S T I N G DIFFERENTIAL
TORQUE CONVERTER - TM-5-3805-258-24-1_418
LOCATION OF THE PRESSURE TAPS - TM-5-3805-258-24-1_419
TORQUE CONVERTER PRESSURE CHART
POWER SHIFT TRANSMISSION
LOCATION OF THE PRESSURE TAPS - TM-5-3805-258-24-1_422
TRANSMISSION PRESSURE CHART
T R A N S M I S S I O N S E L E C T O R A N D P R E S S U RE C O N T R O L V A L V E
TRANSMISSION CONTROL LINKAGE ADJUSTMENTS
S P E E D C O N T R O L L I N K A GE
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_427
PRESSURE TEST OF STEERING SYSTEM
NEUTRALIZER VALVE
AIR SYSTEM AND BRAKES
AIR COMPRESSOR GOVERNOR
CONTROL VALVE FOR EMERGENCY AND PARKING BRAKE
H E A D A S S E M B L Y O F W H E E L B R A KE
Correction
HOT OR DRAGGING BRAKES
Too Little Master Cylinder Stroke
EMERGENCY AND PARKING BRAKE ADJUSTMENT
HYDRAULIC SYSTEM.
VISUAL CHECKS
Lift And Tilt Cylinder Drift Tests
PRESSURE TEST OF PILOT SYSTEM
F R O N T O F L O A D E R F R A ME
Pilot Pressure For Lower And Float
Final Check
Dump Stem Adjustment
ADJUSTMENT PROCEDURE FOR THE ATTACHMENT PILOT VALVE
RELIEF VALVE TESTS
Relief Valve For Head End Of Tilt Cylinder
HYDRAULIC OIL TEMPERATURE (TOO HOT)
CONTROL LEVER LINKAGE ADJUSTMENT
Move the tilt control lever to the TILT BACK detent position
LIFT KICKOUT ADJUSTMENT PROCEDURE
TESTING AND ADJUSTING
The cut out pressure setting
TROUBLESHOOTING
1. ENGINE CRANKSHAFT WILL NOT TURN WHEN START SWITCH IS ON
3. MISFIRING OR RUNNING ROUGH
5. SUDDEN CHANGES IN ENGINE SPEED (rpm)
7. TOO MUCH VIBRATION
10. OIL IN COOLING SYSTEM
14. LITTLE MOVEMENT OF ROCKER ARM AND TOO MUCH VALVE CLEARANCE
17. LITTLE OR NO VALVE CLEARANCE
21. TOO MUCH WHITE OR BLUE SMOKE
23. ENGINE USES TOO MUCH LUBRICATION OIL
25. STARTER MOTOR DOES NOT TURN
29. ALTERNATOR HAS NOISE
POWER TRAIN TROUBLESHOOTING
CHECK LIST DURING OPERATION
CHECK LIST DURING OPERATION -CONT - TM-5-3805-258-24-1_471
CHECK LIST DURING OPERATION -CONT - TM-5-3805-258-24-1_472
STEERING SYSTEM TROUBLESHOOTING
PERFORMANCE TESTS -CONT
TROUBLESHOOTING THE ELECTRONIC MONITORING SYSTEM
TEST I
PROBLEM A. ALL Indicator OFF; Master Fault Light OFF
PROBLEM B: Only the Indicators Are ON That Are Normally ON With the Engine OFF
PROBLEM C: ALL Indicators Are ON; Master Fault Light is OFF
9 5 0 B O P E R A T O R S S T A T I O N - TM-5-3805-258-24-1_480
PROBLEM D: Fault Alarm is ON When It Must Be OFF
9 5 0 B O P E R A T O R ' S S T A T I O N
TEST II
POSSIBLE PROBLEMS
PROBLEM A: ALL Indicators ON
PROBLEM B: An Indicator That Must Be ON is NOT ON
PROBLEM C: An Indicator That Must Be OFF, Is ON.
PROBLEM D: The Master Fault Light Is NOT ON But Was ON In Test I
TEST Ill
PROBLEM A: One Or More Indicators Are ON
Low Fuel Level Indicator
Parking Brake Indicator
Engine Oil Pressure Indicator
Brake Air Pressure Indicator
Brake Oil Pressure Indicator
PROBLEM B: Alternator Indicator ON
TEST IV
PROBLEM A: All Indicators, Master Fault Light And Fault Alarm OFF
9 5 0 B O P E R A T O R S S T A T I O N - TM-5-3805-258-24-1_499
9 5 0 B O P E R A T O R S S T A T I O N
950B KICKOUTS
Lift Kickout
Troubleshooting the Lift Kickout Circuit on the Machine
Bench Test of 9G117 Switch Assembly
Bucket Positioner
B u c k e t P o s i t i o n e r S w i t c h
B u c k e t P o s i t i o n e r S c h e m a t ic
Troubleshooting the Bucket Positioner Circuit on the Machine
Bench Test of the 9G116 Bucket Positioner Switch Assembly
Other Methods of Failure
DIODES
Damage to a switch
DIODE ASSEMBLY CIRCUIT DESCRIPTION
1 V 9 6 3 3 D i o d e A s s e m b ly
STANDARD HYDRAULIC SYSTEM IN TILT BACK POSITION
STANDARD HYDRAULIC SYSTEM IN RAISE POSITION
STANDARD HYDRAULIC SYSTEM IN LOWER POSITION (ENGINE OFF)
OPTIOINAL HYDRAULIC SYSTEM IN CLOSE OR LOWER POSITION
CONNECTOR IDENTIFICATION
FO-6. SCHEMATIC
FO-7. SCHEMATIC
LIGHTING AND WARNING SYSTEM SCHEMATIC
FO-8. SCHEMATIC
FO-9. SCHEMATIC
FO-10. SCHEMATIC
SAFETY - TM-5-3805-258-24-1_13
SAFETY - TM-5-3805-258-24-1_14
Diesel fuel and all lubricants
Hot hydraulic oil
SERIAL NUMBER LOCATIONS
TIRE INFLATION INFORMATION
MAINTENANCE RECOMMENDATIONS
FUEL SYSTEM - TM-5-3805-258-24-1_20
LUBRICANTS-FUELS-COOLANT
COOLANT SPECIFICATIONS - TM-5-3805-258-24-1_22
RECOMMENDED LUBRICANT VISCOSITIES
LUBRICATION AND MAINTENANCE CHART
LUBRICATION AND MAINTENANCE CHART
LUBRICATION AND MAINTENANCE CHART3.
T R A N S M I S S I O N
FRONT AND REAR DIFFERENTIALS AND FINAL DRIVES
AIR INTAKE SYSTEM
SECONDARY ELEMENT
Cover the air inlet opening
CLEANING AIR CLEANER ELEMENTS
Detergent
ENGINE AIR PRECLEANER - TM-5-3805-258-24-1_35
COOLING SYSTEM - CLEANING
Open the drain valve
Close the drain valve
Inspect the radiator cap gasket
Inspect the valve for damage
FUEL TANK - TM-5-3805-258-24-1_41
BUCKET TEETH - REPLACE TIP
CUTTING EDGE
SEAT BELT
FUSES
ETHER STARTING AID - ETHER CYLINDER
Temporary Removal
ENGINE/TRANSMISSION OIL SAMPLING
ATTACHMENT HITCH
WALK-AROUND INSPECTION
Every 10 Service Hours or Daily
ENGINE CRANKCASE
RADIATOR - TM-5-3805-258-24-1_53
INDICATOR LIGHTS
BUCKET LOWER PINS
TIRES
REAR AXLE TRUNNION BEARINGS
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_59
BUCKET CYLINDER LINKAGE BEARINGS
BATTERIES - TM-5-3805-258-24-1_61
ENGINE CRANKCASE
Apply a light coat
BRAKE FLUID RESERVOIRS
SERVICE BRAKES - TESTING
PARKING BRAKE - TESTING
The parking brake and the brake pressure indicator lights
DRIVE SHAFT SPLINE
FAN AND ALTERNATOR BELTS
FAN BEARING
Every 250 Service Hours or Monthly
FUEL TANK CAP AND FILL SCREEN
Every 500 Service Hours or 3 Months
Move the hydraulic controls
Remove the filter element
Inspect the filler cap seal
TRANSMISSION - TM-5-3805-258-24-1_77
Clean the housing base
PRIMARY FUEL FILTER
Clean the case
FINAL FILTER
PRIMING THE FUEL SYSTEM
ENGINE CRANKCASE BREATHER
TRANSMISSION - TM-5-3805-258-24-1_84
Remove the tube and magnets
Insert the screen
Every 1000 Service Hours or 6 Months
DRIVE SHAFT UNIVERSAL JOINTS
FRAME UPPER AND LOWER PIVOT BEARINGS
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
DIFFERENTIALS AND FINAL DRIVES
Install the differential and final drive drain plugs
Every 2000 Service Hours or 1 Year
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_94
Install a 1 inch NPT pipe nipple
Inspect the drain plug seal
COOLING SYSTEM - CHANGE COOLANT
Open the radiator drain valve
ENGINE VALVE LASH
SPECIFICATIONS SECTION 2
HYDRAULIC SYSTEM INDEX
ENGINE DESIGN
FUEL INJECTION EQUIPMENT
AIR-FUEL RATIO CONTROL
GOVERNOR - TM-5-3805-258-24-1_107
TIMING GEARS - TM-5-3805-258-24-1_108
VALVES
CAMSHAFT - TM-5-3805-258-24-1_110
CYLINDER HEAD
EXHAUST PIPE AND MUFFLER
TURBOCHARGER - TM-5-3805-258-24-1_113
OIL PUMP - TM-5-3805-258-24-1_114
OIL FILTER
WATER PUMP - TM-5-3805-258-24-1_116
RADIATOR - TM-5-3805-258-24-1_117
CYLINDER BLOCK
CYLINDER LINER
CONNECTING ROD
PISTONS AND RINGS
CRANKSHAFT - TM-5-3805-258-24-1_122
BEARING SURFACE (JOURNAL) FOR MAIN BEARINGS
BEARING SURFACE (JOURNAL) FOR CONNECTING RODS
MAIN BEARINGS AND CONNECTING ROD BEARINGS
TIMING GEAR COVER
FLYWHEEL - TM-5-3805-258-24-1_127
FLYWHEEL RUNOUT
FLYWHEEL HOUSING RUNOUT
FLYWHEEL HOUSING BORE
ALTERNATORS
STARTER SOLENOID - TM-5-3805-258-24-1_132
STARTER SOLENOID
TORQUE CONVERTER - TM-5-3805-258-24-1_135
OUTLET RELIEF VALVE FOR TORQUE CONVERTER
SELECTOR AND PRESSURE CONTROL VALVE FOR TRANSMISSION
TRANSMISSION NEUTRALIZER VALVE
TRANSMISSION - TM-5-3805-258-24-1_139
TRANSMISSION (Cont.)
TRANSMISSION OIL FILTER - TM-5-3805-258-24-1_141
TRANSMISSION NEUTRALIZER GROUP - TM-5-3805-258-24-1_142
TORQUE CONVERTER AND PUMP DRIVE HOUSING
DRIVE SHAFT
DIFFERENTIAL AND BEVEL GEAR
Differential and Bevel Gear
FRONT AXLE GROUP
RIM GROUP
ADJUSTMENT OF THE WHEEL BEARINGS
FINAL DRIVES, BRAKE AND WHEELS
MOUNTING GROUP (ROPS)
HYDRAULIC PUMP FOR IMPLEMENT, STEERING AND PILOT SYSTEMS
HAND METERING UNIT (HMU)
STEERING CYLINDERS
STEERING CONTROL VALVE
NEUTRALIZER VALVES
DIVERTER VALVE FOR SUPPLEMENTAL STEERING
ARTICULATED HITCH GROUP
ARTICULATED HITCH GROUP
AIR COMPRESSOR GOVERNOR
AIR PRESSURE SWITCH
BRAKE CONTROL VALVES - TM-5-3805-258-24-1_164
AIR/HYDRAULIC CYLINDERS
EMERGENCY AND PARKING BRAKE ADJUSTMENT
AIR DRYER - TM-5-3805-258-24-1_167
WHEEL BRAKES - TM-5-3805-258-24-1_169
HYDRAULIC PUMP FOR IMPLEMENT, STEERING AND PILOT SYSTEMS
HYDRAULIC SYSTEM
FILTER AND TANK GROUP
LIFT AND TILT PILOT VALVE
ATTACHMENT PILOT VALVE
SELECTOR AND PRESSURE CONTROL VALVE
CONTROL VALVES FOR LIFT, TILT AND ATTACHMENT
MAIN RELIEF VALVE
WEAR PLATES, BIT AND CUTTING EDGE GROUPS
CONTROL LEVER LINKAGE
LIFT KICKOUT ADJUSTMENT PROCEDURE
TILT CYLINDER
BUCKET CONTROL GROUP
Bucket Control Group (Cont.)
AIR COMPRESSOR - TM-5-3805-258-24-1_184
AIR COMPRESSOR
GENERAL TIGHTENING TORQUE FOR BOLTS, NUTS AND TAPERLOCK STUDS
LINES, PLUGS AND FITTINGS
TORQUES FOR 0THER FITTINGS
SYSTEMS OPERATION
HYDRAULIC SYSTEM INDEX
FUEL SYSTEM - TM-5-3805-258-24-1_193
FUEL INJECTION NOZZLE
FUEL TRANSFER PUMP - TM-5-3805-258-24-1_195
OIL FLOW FOR FUEL PUMP AND GOVERNOR
GOVERNOR - TM-5-3805-258-24-1_197
Governor Servo
Dashpot
AIR FUEL RATIO CONTROL
AIR FUEL RATIO CONTROL
AIR INLET AND EXHAUST SYSTEM - TM-5-3805-258-24-1_203
CYLINDER HEAD AND VALVES
LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM
COOLING SYSTEM
COOLING SYSTEM COMPONENTS
BASIC BLOCK
ELECTRICAL SYSTEM
T Y P I C A L S O L E N O I D S C H E M A T I C
GENERAL INFORMATION
TORQUE CONVERTER
FLOW OF POWER IN TORQUE CONVERTER
TORQUE CONVERTER AND PUMP DRIVE HOUSING
TORQUE S Y S T E M S O P E R A T I O N CONVERTER HYDRAULIC SYSTEM
RATlO VALVE FOR THE TORQUE CONVERTER
TRANSMISSION HYDRAULIC SYSTEM
OIL PUMP
OIL FILTER
POWER TRAIN OIL COOLER
TRANSMISSION - TM-5-3805-258-24-1_222
FIRST SPEED FORWARD
SECOND SPEED FORWARD
THIRD SPEED FORWARD
FOURTH SPEED FORWARD
FIRST SPEED REVERSE
SECOND SPEED REVERSE
THIRD SPEED REVERSE
FOURTH SPEED REVERSE
PLANETARY LUBRICATION
TRANSMISSION HYDRAULIC CONTROLS
SELECTOR AND PRESSURE CONTROL VALVE - TM-5-3805-258-24-1_233
P O W E R T R A I N T R A N S M I S S I O N H Y D R A U L I C C O N T R O LS
OPERATION Starting the Engine (Transmission in Neutral)
Transmission selector lever is in NEUTRAL
Engine Running (Neutral to First Speed Forward)
No. 6 clutch is full of oil
Starting the Engine (Transmission in a Speed and Direction)
Neutralizer Valve
TRANSMISSION NEUTRALIZER GROUP - TM-5-3805-258-24-1_241
Transmission engaged in either FORWARD or REVERSE
OUTPUT TRANSFER GEARS
DIFFERENTIALS
OPERATION Straight FORWARD or REVERSE
NOSPIN DIFFERENTIAL GROUP
TM-5-3805-258-24-1_247
OPERATION OF NOSPIN DIFFERENTIAL
Straight Forward Operation
Forward Turn With No Power
FINAL DRIVES - TM-5-3805-258-24-1_251
AMPLIFIED STEERING SYSTEM
AMPLIFIED STEERING SYSTEM
HAND METERING UNIT (HMU)
The steering wheel
STEERING CONTROL VALVE - TM-5-3805-258-24-1_256
Right Turn Position
Left Turn Position
SUPPLEMENTAL STEERING SYSTEM
DIVERTER VALVE.
DIVERTER VALVE SCHEMATIC
AIR SYSTEM AND BRAKES
BRAKE SYSTEM
WARNING SYSTEM
AIR SUPPLY FOR THE AIR SYSTEM
AIR RESERVOIR
AIR CIRCUIT FOR THE EMERGENCY AND PARKING BRAKE
L O C A T I O N O F T H E C O N T R O L K N OB
QUICK RELEASE VALVE FOR EMERGENCY AND PARKING BRAKE
EMERGENCY AND PARKING BRAKE
E M E R G E N C Y A N D P A R K I N G B R A KE
AIR CIRCUIT FOR THE WHEEL BRAKES
BRAKE CONTROL VALVES - TM-5-3805-258-24-1_274
AIR HORNS AND VALVE
Operation
AIR PRESSURE SWITCH FOR STOP LIGHTS
A I R C Y L I N D E R
HYDRAULIC CIRCUIT FOR THE WHEEL BRAKES
BRAKE FLUID RESERVOIRS
M A S T E R C Y L I N D E R
WHEEL BRAKES - TM-5-3805-258-24-1_282
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_283
R I G H T S I D E O F T R A N S M I S S I ON
R I G H T S I D E O F M A C H I N E
HYDRAULIC PUMP WITH THREE SECTIONS
Operation Of The Pilot Pump Section
ONE-WAY CHECK VALVES
SELECTOR AND PRESSURE CONTROL VALVE - TM-5-3805-258-24-1_289
LIFT AND TILT PILOT VALVE
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_291
LOWER Position With Engine Off
DUMP Position With Engine Off
OPEN or RAISE Position
SEQUENCE VALVE - TM-5-3805-258-24-1_295
SHUTTLE VALVE
Tilt Valve Spool
Lift Valve Spool
RAISE Operation
Make-Up Valves
COUPLING HITCH ATTACHMENT CONTROL VALVE
RELIEF VALVES
Relief Valves For Tilt And Attachment Cylinders
BUCKET POSITIONER
TILT BACK Operation
DUMP Operation
LOWER Operation
OPEN or RAISE Position
AIR COMPRESSOR OPERATION
TYPICAL AIR COMPRESSOR SYSTEM
AIR GOVERNOR
AIR COMPRESSOR LUBRICATION
PROTECTIVE ITEMS
BACK-UP ALARM - TM-5-3805-258-24-1_316
OPERATOR COMFORT ITEMS
CONTROL GROUPS
STEERING CONTROL GROUP
INSTRUMENT PANEL - TM-5-3805-258-24-1_321
Service Meter
Fuel Level Indicator
FUSE AND CIRCUIT BREAKER PANEL
RELAY PANEL
Main Power Relay
TROUBLESHOOTING METHODS
OPERATORS STATION ELECTRICAL SYSTEM
CODES AND ABBREVIATIONS
ELECTRICAL COMPONENTS LOCATION AND IDENTIFICATION
E L E C T R I C A L S Y S T E M
INDIVIDUAL CIRCUIT DESCRIPTION
OPERATOR PANEL
B. Alternator
C. Parking Brake (Transmission in Neutral)
TRANSMISSION IN NEUTRAL
2. Indicator and Master Fault Light
B. Engine Coolant Temperature
C. Transmission Oil Temperature
3. Indicator, Master Fault Light and Fault Alarm
B. Low Brake Oil Pressure
Brake Oil Pressure Circuit
C. Engine Oil Pressure
Engine Oil Pressure Circuit
D. Transmission Neutralizer (With Transmission in Gear)
TRANSMISSION IN FORWARD
Power To Operator Panel
F U E L P R E S S U R E S W I T CH
MAIN POWER CIRCUIT
Main Power Circuit
START SYSTEM
1. Start Circuit
STARTER SOLENOID - TM-5-3805-258-24-1_354
INDIVIDUAL CIRCUIT DESCRIPTION
ENGINE STOP SYSTEM
Stop Circuit
SERVICE METER
S e r v i c e M e t e r C i r c u i t
BACK-UP ALARM - TM-5-3805-258-24-1_360
I N D I V I D U A L C I R C U I T D E S C R I P T I ON
Jumper bar
CIGAR LIGHTER
STOP LIGHTS
Tail Light Circuit
REAR FLOOD LIGHTS
FRONT FLOOD LIGHTS
MAIN STEERING INDICATOR
PARKING LIGHTS
S P E E D O M E T ER
TESTING AND ADJUSTING SECTION 4
AIR SYSTEM AND BRAKE INDEX
POWER TRAIN TROUBLESHOOTING INDEX
FUEL SYSTEM
E X T R A V A L V E
Nozzle Preparation for Test
Il. Flush the Nozzle
IV. Orifice Restriction Test
FUEL INJECTION LINES
Installation of Fuel Injection Pumps
F U E L P U M P I N S T A L L A T I ON
FINDING TOP CENTER COMPRESSION
CHECKING TIMING BY FUEL FLOW METHOD.
ASSEMBLING ROD AND ADAPTER
6 V 2 0 2 3 F L O W C H E C K I N G A D A P T E R G R O UP
CHECKING TIMING BY TIMING PIN METHOD
Remove timing gear cover
T R A N S D U C E R I N P O S I T I ON
GOVERNOR ADJUSTMENT FOR AIR FUEL RATIO CONTROL
B R A C K E T A S S E M B L Y I N S T A L L ED
RACK SETTING PROCEDURE
I N D I C A T O R B R A C K E T I N S T A L L E D
MEASURING ENGINE SPEED
GOVERNOR ADJUSTMENTS
Checking Balance Point
GOVERNOR CABLE ADJUSTMENT
AIR INLET AND EXHAUST SYSTEM - TM-5-3805-258-24-1_399
CRANKCASE (CRANKSHAFT COMPARTMENT) PRESSURE
PROCEDURE FOR MEASURING CAMSHAFT LOBES
LUBRICATION SYSTEM
Crankcase Oil Level
COOLING SYSTEM
Checking Filler Cap and Relief Valve
Testing Radiator and Cooling System for Leaks
V-BELT TENSION CHART
BASIC BLOCK
CYLINDER BLOCK
Bore Runout (radial eccentricity) of the Flywheel Housing
Face Runout (axial eccentricity) of the Flywheel
C H E C K I N G B O R E R U N O U T O F T H E F L Y W H E E L
ELECTRICAL SYSTEM - TM-5-3805-258-24-1_414
STARTING SYSTEM
Pinion Clearance Adjustment
NOSPIN NOSPIN DIFFERENTIAL TEST (Before Installation) After the NoSpin differential has been assembled and before it is installed in the machine, make a test of the operation of the differential as follows: 1. Install the NoSpin differential in the case. 2. Put the case in a stand or a vise to keep it from rotation. 3. Install both axles in the case. TM 5-3805-258-24-1 T E S T I N G A N D A D J U S T I N G DIFFERENTIAL
TORQUE CONVERTER - TM-5-3805-258-24-1_418
LOCATION OF THE PRESSURE TAPS - TM-5-3805-258-24-1_419
TORQUE CONVERTER PRESSURE CHART
POWER SHIFT TRANSMISSION
LOCATION OF THE PRESSURE TAPS - TM-5-3805-258-24-1_422
TRANSMISSION PRESSURE CHART
T R A N S M I S S I O N S E L E C T O R A N D P R E S S U RE C O N T R O L V A L V E
TRANSMISSION CONTROL LINKAGE ADJUSTMENTS
S P E E D C O N T R O L L I N K A GE
HYDRAULIC SYSTEM - TM-5-3805-258-24-1_427
PRESSURE TEST OF STEERING SYSTEM
NEUTRALIZER VALVE
AIR SYSTEM AND BRAKES
AIR COMPRESSOR GOVERNOR
CONTROL VALVE FOR EMERGENCY AND PARKING BRAKE
H E A D A S S E M B L Y O F W H E E L B R A KE
Correction
HOT OR DRAGGING BRAKES
Too Little Master Cylinder Stroke
EMERGENCY AND PARKING BRAKE ADJUSTMENT
HYDRAULIC SYSTEM.
VISUAL CHECKS
Lift And Tilt Cylinder Drift Tests
PRESSURE TEST OF PILOT SYSTEM
F R O N T O F L O A D E R F R A ME
Pilot Pressure For Lower And Float
Final Check
Dump Stem Adjustment
ADJUSTMENT PROCEDURE FOR THE ATTACHMENT PILOT VALVE
RELIEF VALVE TESTS
Relief Valve For Head End Of Tilt Cylinder
HYDRAULIC OIL TEMPERATURE (TOO HOT)
CONTROL LEVER LINKAGE ADJUSTMENT
Move the tilt control lever to the TILT BACK detent position
LIFT KICKOUT ADJUSTMENT PROCEDURE
TESTING AND ADJUSTING
The cut out pressure setting
TROUBLESHOOTING
1. ENGINE CRANKSHAFT WILL NOT TURN WHEN START SWITCH IS ON
3. MISFIRING OR RUNNING ROUGH
5. SUDDEN CHANGES IN ENGINE SPEED (rpm)
7. TOO MUCH VIBRATION
10. OIL IN COOLING SYSTEM
14. LITTLE MOVEMENT OF ROCKER ARM AND TOO MUCH VALVE CLEARANCE
17. LITTLE OR NO VALVE CLEARANCE
21. TOO MUCH WHITE OR BLUE SMOKE
23. ENGINE USES TOO MUCH LUBRICATION OIL
25. STARTER MOTOR DOES NOT TURN
29. ALTERNATOR HAS NOISE
POWER TRAIN TROUBLESHOOTING
CHECK LIST DURING OPERATION
CHECK LIST DURING OPERATION -CONT - TM-5-3805-258-24-1_471
CHECK LIST DURING OPERATION -CONT - TM-5-3805-258-24-1_472
STEERING SYSTEM TROUBLESHOOTING
PERFORMANCE TESTS -CONT
TROUBLESHOOTING THE ELECTRONIC MONITORING SYSTEM
TEST I
PROBLEM A. ALL Indicator OFF; Master Fault Light OFF
PROBLEM B: Only the Indicators Are ON That Are Normally ON With the Engine OFF
PROBLEM C: ALL Indicators Are ON; Master Fault Light is OFF
9 5 0 B O P E R A T O R S S T A T I O N - TM-5-3805-258-24-1_480
PROBLEM D: Fault Alarm is ON When It Must Be OFF
9 5 0 B O P E R A T O R ' S S T A T I O N
TEST II
POSSIBLE PROBLEMS
PROBLEM A: ALL Indicators ON
PROBLEM B: An Indicator That Must Be ON is NOT ON
PROBLEM C: An Indicator That Must Be OFF, Is ON.
PROBLEM D: The Master Fault Light Is NOT ON But Was ON In Test I
TEST Ill
PROBLEM A: One Or More Indicators Are ON
Low Fuel Level Indicator
Parking Brake Indicator
Engine Oil Pressure Indicator
Brake Air Pressure Indicator
Brake Oil Pressure Indicator
PROBLEM B: Alternator Indicator ON
TEST IV
PROBLEM A: All Indicators, Master Fault Light And Fault Alarm OFF
9 5 0 B O P E R A T O R S S T A T I O N - TM-5-3805-258-24-1_499
9 5 0 B O P E R A T O R S S T A T I O N
950B KICKOUTS
Lift Kickout
Troubleshooting the Lift Kickout Circuit on the Machine
Bench Test of 9G117 Switch Assembly
Bucket Positioner
B u c k e t P o s i t i o n e r S w i t c h
B u c k e t P o s i t i o n e r S c h e m a t ic
Troubleshooting the Bucket Positioner Circuit on the Machine
Bench Test of the 9G116 Bucket Positioner Switch Assembly
Other Methods of Failure
DIODES
Damage to a switch
DIODE ASSEMBLY CIRCUIT DESCRIPTION
1 V 9 6 3 3 D i o d e A s s e m b ly
STANDARD HYDRAULIC SYSTEM IN TILT BACK POSITION
STANDARD HYDRAULIC SYSTEM IN RAISE POSITION
STANDARD HYDRAULIC SYSTEM IN LOWER POSITION (ENGINE OFF)
OPTIOINAL HYDRAULIC SYSTEM IN CLOSE OR LOWER POSITION
CONNECTOR IDENTIFICATION
FO-6. SCHEMATIC
FO-7. SCHEMATIC
LIGHTING AND WARNING SYSTEM SCHEMATIC
FO-8. SCHEMATIC
FO-9. SCHEMATIC
FO-10. SCHEMATIC
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Integrated Publishing, Inc. - A (SDVOSB) Service Disabled Veteran Owned Small Business
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