ForewordSAFETY - TM-5-3805-258-24-1_13SAFETY - TM-5-3805-258-24-1_14Diesel fuel and all lubricants Hot hydraulic oilSERIAL NUMBER LOCATIONSTIRE INFLATION INFORMATIONMAINTENANCE RECOMMENDATIONSFUEL SYSTEM - TM-5-3805-258-24-1_20LUBRICANTS-FUELS-COOLANTCOOLANT SPECIFICATIONS - TM-5-3805-258-24-1_22RECOMMENDED LUBRICANT VISCOSITIESLUBRICATION AND MAINTENANCE CHARTLUBRICATION AND MAINTENANCE CHARTLUBRICATION AND MAINTENANCE CHART3.T R A N S M I S S I O NFRONT AND REAR DIFFERENTIALS AND FINAL DRIVESAIR INTAKE SYSTEMSECONDARY ELEMENTCover the air inlet openingCLEANING AIR CLEANER ELEMENTSDetergentENGINE AIR PRECLEANER - TM-5-3805-258-24-1_35COOLING SYSTEM - CLEANINGOpen the drain valveClose the drain valveInspect the radiator cap gasketInspect the valve for damageFUEL TANK - TM-5-3805-258-24-1_41BUCKET TEETH - REPLACE TIPCUTTING EDGESEAT BELTFUSESETHER STARTING AID - ETHER CYLINDERTemporary RemovalENGINE/TRANSMISSION OIL SAMPLINGATTACHMENT HITCHWALK-AROUND INSPECTIONEvery 10 Service Hours or DailyENGINE CRANKCASERADIATOR - TM-5-3805-258-24-1_53INDICATOR LIGHTSBUCKET LOWER PINSTIRESREAR AXLE TRUNNION BEARINGSHYDRAULIC SYSTEM - TM-5-3805-258-24-1_59BUCKET CYLINDER LINKAGE BEARINGSBATTERIES - TM-5-3805-258-24-1_61ENGINE CRANKCASEApply a light coatBRAKE FLUID RESERVOIRSSERVICE BRAKES - TESTINGPARKING BRAKE - TESTINGThe parking brake and the brake pressure indicator lightsDRIVE SHAFT SPLINEFAN AND ALTERNATOR BELTSFAN BEARINGEvery 250 Service Hours or MonthlyFUEL TANK CAP AND FILL SCREENEvery 500 Service Hours or 3 MonthsMove the hydraulic controlsRemove the filter elementInspect the filler cap sealTRANSMISSION - TM-5-3805-258-24-1_77Clean the housing basePRIMARY FUEL FILTERClean the case FINAL FILTERPRIMING THE FUEL SYSTEMENGINE CRANKCASE BREATHERTRANSMISSION - TM-5-3805-258-24-1_84Remove the tube and magnetsInsert the screenEvery 1000 Service Hours or 6 MonthsDRIVE SHAFT UNIVERSAL JOINTSFRAME UPPER AND LOWER PIVOT BEARINGSROLLOVER PROTECTIVE STRUCTURE (ROPS)DIFFERENTIALS AND FINAL DRIVESInstall the differential and final drive drain plugsEvery 2000 Service Hours or 1 YearHYDRAULIC SYSTEM - TM-5-3805-258-24-1_94Install a 1 inch NPT pipe nippleInspect the drain plug sealCOOLING SYSTEM - CHANGE COOLANTOpen the radiator drain valveENGINE VALVE LASHSPECIFICATIONS SECTION 2HYDRAULIC SYSTEM INDEXENGINE DESIGNFUEL INJECTION EQUIPMENTAIR-FUEL RATIO CONTROLGOVERNOR - TM-5-3805-258-24-1_107TIMING GEARS - TM-5-3805-258-24-1_108VALVESCAMSHAFT - TM-5-3805-258-24-1_110CYLINDER HEADEXHAUST PIPE AND MUFFLERTURBOCHARGER - TM-5-3805-258-24-1_113OIL PUMP - TM-5-3805-258-24-1_114OIL FILTERWATER PUMP - TM-5-3805-258-24-1_116RADIATOR - TM-5-3805-258-24-1_117CYLINDER BLOCKCYLINDER LINERCONNECTING RODPISTONS AND RINGSCRANKSHAFT - TM-5-3805-258-24-1_122BEARING SURFACE (JOURNAL) FOR MAIN BEARINGSBEARING SURFACE (JOURNAL) FOR CONNECTING RODSMAIN BEARINGS AND CONNECTING ROD BEARINGSTIMING GEAR COVERFLYWHEEL - TM-5-3805-258-24-1_127FLYWHEEL RUNOUTFLYWHEEL HOUSING RUNOUTFLYWHEEL HOUSING BOREALTERNATORSSTARTER SOLENOID - TM-5-3805-258-24-1_132STARTER SOLENOIDTORQUE CONVERTER - TM-5-3805-258-24-1_135OUTLET RELIEF VALVE FOR TORQUE CONVERTERSELECTOR AND PRESSURE CONTROL VALVE FOR TRANSMISSIONTRANSMISSION NEUTRALIZER VALVETRANSMISSION - TM-5-3805-258-24-1_139TRANSMISSION (Cont.)TRANSMISSION OIL FILTER - TM-5-3805-258-24-1_141TRANSMISSION NEUTRALIZER GROUP - TM-5-3805-258-24-1_142TORQUE CONVERTER AND PUMP DRIVE HOUSINGDRIVE SHAFTDIFFERENTIAL AND BEVEL GEARDifferential and Bevel GearFRONT AXLE GROUPRIM GROUPADJUSTMENT OF THE WHEEL BEARINGSFINAL DRIVES, BRAKE AND WHEELSMOUNTING GROUP (ROPS)HYDRAULIC PUMP FOR IMPLEMENT, STEERING AND PILOT SYSTEMSHAND METERING UNIT (HMU)STEERING CYLINDERSSTEERING CONTROL VALVENEUTRALIZER VALVESDIVERTER VALVE FOR SUPPLEMENTAL STEERINGARTICULATED HITCH GROUPARTICULATED HITCH GROUPAIR COMPRESSOR GOVERNORAIR PRESSURE SWITCHBRAKE CONTROL VALVES - TM-5-3805-258-24-1_164AIR/HYDRAULIC CYLINDERSEMERGENCY AND PARKING BRAKE ADJUSTMENTAIR DRYER - TM-5-3805-258-24-1_167WHEEL BRAKES - TM-5-3805-258-24-1_169HYDRAULIC PUMP FOR IMPLEMENT, STEERING AND PILOT SYSTEMSHYDRAULIC SYSTEMFILTER AND TANK GROUPLIFT AND TILT PILOT VALVEATTACHMENT PILOT VALVESELECTOR AND PRESSURE CONTROL VALVECONTROL VALVES FOR LIFT, TILT AND ATTACHMENTMAIN RELIEF VALVEWEAR PLATES, BIT AND CUTTING EDGE GROUPSCONTROL LEVER LINKAGELIFT KICKOUT ADJUSTMENT PROCEDURETILT CYLINDERBUCKET CONTROL GROUPBucket Control Group (Cont.)AIR COMPRESSOR - TM-5-3805-258-24-1_184AIR COMPRESSOR GENERAL TIGHTENING TORQUE FOR BOLTS, NUTS AND TAPERLOCK STUDSLINES, PLUGS AND FITTINGSTORQUES FOR 0THER FITTINGSSYSTEMS OPERATIONHYDRAULIC SYSTEM INDEXFUEL SYSTEM - TM-5-3805-258-24-1_193FUEL INJECTION NOZZLEFUEL TRANSFER PUMP - TM-5-3805-258-24-1_195OIL FLOW FOR FUEL PUMP AND GOVERNORGOVERNOR - TM-5-3805-258-24-1_197Governor ServoDashpotAIR FUEL RATIO CONTROLAIR FUEL RATIO CONTROLAIR INLET AND EXHAUST SYSTEM - TM-5-3805-258-24-1_203CYLINDER HEAD AND VALVESLUBRICATION SYSTEMENGINE LUBRICATION SYSTEMCOOLING SYSTEMCOOLING SYSTEM COMPONENTSBASIC BLOCKELECTRICAL SYSTEMT Y P I C A L S O L E N O I D S C H E M A T I CGENERAL INFORMATIONTORQUE CONVERTERFLOW OF POWER IN TORQUE CONVERTERTORQUE CONVERTER AND PUMP DRIVE HOUSINGTORQUE S Y S T E M S O P E R A T I O N CONVERTER HYDRAULIC SYSTEMRATlO VALVE FOR THE TORQUE CONVERTERTRANSMISSION HYDRAULIC SYSTEMOIL PUMPOIL FILTERPOWER TRAIN OIL COOLERTRANSMISSION - TM-5-3805-258-24-1_222FIRST SPEED FORWARDSECOND SPEED FORWARDTHIRD SPEED FORWARDFOURTH SPEED FORWARDFIRST SPEED REVERSESECOND SPEED REVERSETHIRD SPEED REVERSEFOURTH SPEED REVERSEPLANETARY LUBRICATIONTRANSMISSION HYDRAULIC CONTROLSSELECTOR AND PRESSURE CONTROL VALVE - TM-5-3805-258-24-1_233P 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 LSOPERATION Starting the Engine (Transmission in Neutral)Transmission selector lever is in NEUTRALEngine Running (Neutral to First Speed Forward)No. 6 clutch is full of oilStarting the Engine (Transmission in a Speed and Direction)Neutralizer ValveTRANSMISSION NEUTRALIZER GROUP - TM-5-3805-258-24-1_241Transmission engaged in either FORWARD or REVERSEOUTPUT TRANSFER GEARSDIFFERENTIALSOPERATION Straight FORWARD or REVERSENOSPIN DIFFERENTIAL GROUPTM-5-3805-258-24-1_247OPERATION OF NOSPIN DIFFERENTIALStraight Forward OperationForward Turn With No PowerFINAL DRIVES - TM-5-3805-258-24-1_251AMPLIFIED STEERING SYSTEMAMPLIFIED STEERING SYSTEMHAND METERING UNIT (HMU)The steering wheelSTEERING CONTROL VALVE - TM-5-3805-258-24-1_256Right Turn PositionLeft Turn PositionSUPPLEMENTAL STEERING SYSTEMDIVERTER VALVE.DIVERTER VALVE SCHEMATICAIR SYSTEM AND BRAKESBRAKE SYSTEMWARNING SYSTEMAIR SUPPLY FOR THE AIR SYSTEMAIR RESERVOIRAIR CIRCUIT FOR THE EMERGENCY AND PARKING BRAKEL O C A T I O N O F T H E C O N T R O L K N OBQUICK RELEASE VALVE FOR EMERGENCY AND PARKING BRAKEEMERGENCY AND PARKING BRAKEE M E R G E N C Y A N D P A R K I N G B R A KEAIR CIRCUIT FOR THE WHEEL BRAKESBRAKE CONTROL VALVES - TM-5-3805-258-24-1_274AIR HORNS AND VALVEOperationAIR PRESSURE SWITCH FOR STOP LIGHTSA I R C Y L I N D E RHYDRAULIC CIRCUIT FOR THE WHEEL BRAKESBRAKE FLUID RESERVOIRSM A S T E R C Y L I N D E R WHEEL BRAKES - TM-5-3805-258-24-1_282HYDRAULIC SYSTEM - TM-5-3805-258-24-1_283R I G H T S I D E O F T R A N S M I S S I ONR I G H T S I D E O F M A C H I N EHYDRAULIC PUMP WITH THREE SECTIONSOperation Of The Pilot Pump SectionONE-WAY CHECK VALVESSELECTOR AND PRESSURE CONTROL VALVE - TM-5-3805-258-24-1_289LIFT AND TILT PILOT VALVEHYDRAULIC SYSTEM - TM-5-3805-258-24-1_291LOWER Position With Engine OffDUMP Position With Engine OffOPEN or RAISE PositionSEQUENCE VALVE - TM-5-3805-258-24-1_295SHUTTLE VALVETilt Valve SpoolLift Valve SpoolRAISE OperationMake-Up ValvesCOUPLING HITCH ATTACHMENT CONTROL VALVERELIEF VALVESRelief Valves For Tilt And Attachment CylindersBUCKET POSITIONERTILT BACK OperationDUMP OperationLOWER OperationOPEN or RAISE PositionAIR COMPRESSOR OPERATIONTYPICAL AIR COMPRESSOR SYSTEMAIR GOVERNORAIR COMPRESSOR LUBRICATIONPROTECTIVE ITEMSBACK-UP ALARM - TM-5-3805-258-24-1_316OPERATOR COMFORT ITEMSCONTROL GROUPSSTEERING CONTROL GROUPINSTRUMENT PANEL - TM-5-3805-258-24-1_321Service MeterFuel Level IndicatorFUSE AND CIRCUIT BREAKER PANELRELAY PANELMain Power RelayTROUBLESHOOTING METHODSOPERATORS STATION ELECTRICAL SYSTEMCODES AND ABBREVIATIONSELECTRICAL COMPONENTS LOCATION AND IDENTIFICATIONE L E C T R I C A L S Y S T E M INDIVIDUAL CIRCUIT DESCRIPTIONOPERATOR PANELB. AlternatorC. Parking Brake (Transmission in Neutral)TRANSMISSION IN NEUTRAL2. Indicator and Master Fault LightB. Engine Coolant TemperatureC. Transmission Oil Temperature3. Indicator, Master Fault Light and Fault AlarmB. Low Brake Oil PressureBrake Oil Pressure CircuitC. Engine Oil PressureEngine Oil Pressure CircuitD. Transmission Neutralizer (With Transmission in Gear)TRANSMISSION IN FORWARDPower To Operator PanelF U E L P R E S S U R E S W I T CHMAIN POWER CIRCUITMain Power CircuitSTART SYSTEM1. Start CircuitSTARTER SOLENOID - TM-5-3805-258-24-1_354INDIVIDUAL CIRCUIT DESCRIPTIONENGINE STOP SYSTEMStop CircuitSERVICE METERS e r v i c e M e t e r C i r c u i tBACK-UP ALARM - TM-5-3805-258-24-1_360I 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 ONJumper barCIGAR LIGHTERSTOP LIGHTSTail Light CircuitREAR FLOOD LIGHTSFRONT FLOOD LIGHTSMAIN STEERING INDICATORPARKING LIGHTSS P E E D O M E T ERTESTING AND ADJUSTING SECTION 4AIR SYSTEM AND BRAKE INDEXPOWER TRAIN TROUBLESHOOTING INDEXFUEL SYSTEME X T R A V A L V ENozzle Preparation for TestIl. Flush the NozzleIV. Orifice Restriction TestFUEL INJECTION LINESInstallation of Fuel Injection PumpsF U E L P U M P I N S T A L L A T I ONFINDING TOP CENTER COMPRESSIONCHECKING TIMING BY FUEL FLOW METHOD.ASSEMBLING ROD AND ADAPTER6 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 UPCHECKING TIMING BY TIMING PIN METHODRemove timing gear cover T R A N S D U C E R I N P O S I T I ONGOVERNOR ADJUSTMENT FOR AIR FUEL RATIO CONTROLB R A C K E T A S S E M B L Y I N S T A L L EDRACK SETTING PROCEDUREI N D I C A T O R B R A C K E T I N S T A L L E DMEASURING ENGINE SPEEDGOVERNOR ADJUSTMENTSChecking Balance PointGOVERNOR CABLE ADJUSTMENTAIR INLET AND EXHAUST SYSTEM - TM-5-3805-258-24-1_399CRANKCASE (CRANKSHAFT COMPARTMENT) PRESSUREPROCEDURE FOR MEASURING CAMSHAFT LOBESLUBRICATION SYSTEMCrankcase Oil LevelCOOLING SYSTEMChecking Filler Cap and Relief ValveTesting Radiator and Cooling System for LeaksV-BELT TENSION CHARTBASIC BLOCKCYLINDER BLOCKBore Runout (radial eccentricity) of the Flywheel HousingFace Runout (axial eccentricity) of the FlywheelC 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 LELECTRICAL SYSTEM - TM-5-3805-258-24-1_414STARTING SYSTEMPinion Clearance AdjustmentNOSPIN 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 DIFFERENTIALTORQUE CONVERTER - TM-5-3805-258-24-1_418LOCATION OF THE PRESSURE TAPS - TM-5-3805-258-24-1_419TORQUE CONVERTER PRESSURE CHARTPOWER SHIFT TRANSMISSIONLOCATION OF THE PRESSURE TAPS - TM-5-3805-258-24-1_422TRANSMISSION PRESSURE CHARTT 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 ETRANSMISSION CONTROL LINKAGE ADJUSTMENTSS P E E D C O N T R O L L I N K A GEHYDRAULIC SYSTEM - TM-5-3805-258-24-1_427PRESSURE TEST OF STEERING SYSTEMNEUTRALIZER VALVEAIR SYSTEM AND BRAKESAIR COMPRESSOR GOVERNORCONTROL VALVE FOR EMERGENCY AND PARKING BRAKEH E A D A S S E M B L Y O F W H E E L B R A KECorrectionHOT OR DRAGGING BRAKESToo Little Master Cylinder StrokeEMERGENCY AND PARKING BRAKE ADJUSTMENTHYDRAULIC SYSTEM.VISUAL CHECKSLift And Tilt Cylinder Drift TestsPRESSURE TEST OF PILOT SYSTEMF R O N T O F L O A D E R F R A MEPilot Pressure For Lower And FloatFinal CheckDump Stem AdjustmentADJUSTMENT PROCEDURE FOR THE ATTACHMENT PILOT VALVERELIEF VALVE TESTSRelief Valve For Head End Of Tilt CylinderHYDRAULIC OIL TEMPERATURE (TOO HOT)CONTROL LEVER LINKAGE ADJUSTMENTMove the tilt control lever to the TILT BACK detent positionLIFT KICKOUT ADJUSTMENT PROCEDURETESTING AND ADJUSTINGThe cut out pressure settingTROUBLESHOOTING1. ENGINE CRANKSHAFT WILL NOT TURN WHEN START SWITCH IS ON3. MISFIRING OR RUNNING ROUGH5. SUDDEN CHANGES IN ENGINE SPEED (rpm)7. TOO MUCH VIBRATION10. OIL IN COOLING SYSTEM14. LITTLE MOVEMENT OF ROCKER ARM AND TOO MUCH VALVE CLEARANCE17. LITTLE OR NO VALVE CLEARANCE21. TOO MUCH WHITE OR BLUE SMOKE23. ENGINE USES TOO MUCH LUBRICATION OIL25. STARTER MOTOR DOES NOT TURN29. ALTERNATOR HAS NOISEPOWER TRAIN TROUBLESHOOTINGCHECK LIST DURING OPERATIONCHECK LIST DURING OPERATION -CONT - TM-5-3805-258-24-1_471CHECK LIST DURING OPERATION -CONT - TM-5-3805-258-24-1_472STEERING SYSTEM TROUBLESHOOTINGPERFORMANCE TESTS -CONTTROUBLESHOOTING THE ELECTRONIC MONITORING SYSTEMTEST IPROBLEM A. ALL Indicator OFF; Master Fault Light OFFPROBLEM B: Only the Indicators Are ON That Are Normally ON With the Engine OFFPROBLEM C: ALL Indicators Are ON; Master Fault Light is OFF9 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_480PROBLEM D: Fault Alarm is ON When It Must Be OFF9 5 0 B O P E R A T O R ' S S T A T I O NTEST IIPOSSIBLE PROBLEMSPROBLEM A: ALL Indicators ONPROBLEM B: An Indicator That Must Be ON is NOT ONPROBLEM C: An Indicator That Must Be OFF, Is ON.PROBLEM D: The Master Fault Light Is NOT ON But Was ON In Test ITEST IllPROBLEM A: One Or More Indicators Are ONLow Fuel Level IndicatorParking Brake IndicatorEngine Oil Pressure IndicatorBrake Air Pressure IndicatorBrake Oil Pressure IndicatorPROBLEM B: Alternator Indicator ONTEST IVPROBLEM A: All Indicators, Master Fault Light And Fault Alarm OFF9 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_4999 5 0 B O P E R A T O R S S T A T I O N950B KICKOUTSLift KickoutTroubleshooting the Lift Kickout Circuit on the MachineBench Test of 9G117 Switch AssemblyBucket PositionerB u c k e t P o s i t i o n e r S w i t c hB u c k e t P o s i t i o n e r S c h e m a t icTroubleshooting the Bucket Positioner Circuit on the MachineBench Test of the 9G116 Bucket Positioner Switch AssemblyOther Methods of FailureDIODESDamage to a switchDIODE ASSEMBLY CIRCUIT DESCRIPTION1 V 9 6 3 3 D i o d e A s s e m b lySTANDARD 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. SCHEMATICFO-7. SCHEMATICLIGHTING AND WARNING SYSTEM SCHEMATICFO-8. SCHEMATICFO-9. SCHEMATICFO-10. SCHEMATIC