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CHAPTER 1 INTRODUCTION - TM-5-3805-262-20_15
1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS
1-11. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT
Section II. EQUIPMENT DESCRIPTION AND DATA
1-14. Location and Description of Major Components and Plates
b . L o c a t i o n o f I d e n t i f i c a t i o n , I n s t r u c t i o n , a n d W a r r a n t y P l a t e s
b . L o c a t i o n o f I d e n t i f i c a t i o n , I n s t r u c t i o n , a n d W a r r a n t y P l a t e s ( C o n t )
b . L o c a t i o n o f I d e n t i f i c a t i o n , I n s t r u c t i o n , a n d W a r r a n t y P l a t e s ( C o n t )
b. L o c a t i o n o f I d e n t i f i c a t i o n , I n s t r u c t i o n , a n d w a r r a n t y p l a t e s ( C o n t )
1-15. EQUIPMENT DATA
CAPACITIES - TM-5-3805-262-20_25
FUEL SYSTEM - TM-5-3805-262-20_26
AIR CLEANER
1-16. SAFETY, CARE, AND HANDLING
Section III. PRINCIPLES OF OPERATION
4. FUEL TANK AND LINES AND FITTINGS.
1-21. ELECTRICAL SYSTEM
5. BUCKET HEIGHT CIRCUIT.
7. LIGHTS.
1. INSTRUMENT PANEL CLUSTER.
1-23. RIGHT INSTRUMENT PANEL
3. AIR PRESSURE WARNING ALARM.
1-24. TRANSMISSION AND DRIVESHAFTS
1-25. AXLE AND WHEELS
PNEUMATIC SYSTEM
1-27. STEERING SYSTEM
1-28. FRAME AND TOWING ATTACHMENTS
1-29. BODY AND CAB
1-31. HYDRAULIC SYSTEM
1-32. BACK-UP ALARM
2. LOADER BUCKET ASSEMBLY
C H A P T E R 2 M W 2 4 C L O A D E R M A I N T E N A N C E
a. Unloading Instructions (cont)
b. Unpacking
2-2. SERVICING NEW EQUIPMENT
b. Service Check
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - TM-5-3805-262-20_52
Compressed air
TABLE 2-1. PRGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
TABLE 2-1. PRGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES -cont - TM-5-3805-262-20_55
TABLE 2-1. PRGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES -cont - TM-5-3805-262-20_56
Section III. MOVEMENT TO A NEW WORK SITE
2-7. TOWING
2-8. PREPARATION FOR AIR TRANSPORT
a. Preparation Prior to Cab Removal
2-8. PREPARATION FOR AIR TRANSPORT (CONT)
b. Cab Removal (Cont)
a. Preparation Prior to Cab Removal CONT
c. Loading i n A i r c r a f t
e. C a b I n s t a l l a t i o n
e. C a b I n s t a l l a t i o n ( C o n t )
e. C a b I n s t a l l a t i o n ( C o n t )
f. Preparation for Use After Air Transport
f. Preparation for Use After Air Transport CONT
Transporting the MW24C Loader Scoop ROPS
CHAPTER 3 TROUBLESHOOTING
FUEL SYSTEM - TM-5-3805-262-20_72
LIGHT SYSTEMS
FRONT AND REAR AXLES
BODY AND CAB
Section II. TROUBLESHOOTING
3-4. ENGINE TROUBLESHOOTING (CONT)
Step 2. - TM-5-3805-262-20_78
Step 3. - TM-5-3805-262-20_79
3. ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE) - TM-5-3805-262-20_80
Step 2. - TM-5-3805-262-20_81
Step 3. - TM-5-3805-262-20_82
Step 5. - TM-5-3805-262-20_83
Step 6. (Cont)
4. ENGINE STARTS BUT WILL NOT RUN - TM-5-3805-262-20_85
Step 2. - TM-5-3805-262-20_86
Step 4. - TM-5-3805-262-20_87
Step 7. - TM-5-3805-262-20_88
5. ENGINE MISFIRES
Step 2. - TM-5-3805-262-20_90
Step 4. - TM-5-3805-262-20_91
S t e p 4 . ( C o n t ) - TM-5-3805-262-20_92
6. ENGINE STALLS FREQUENTLY OR DOES NOT DEVELOP FULL POWER.
Step 4. - TM-5-3805-262-20_94
Step 5. - TM-5-3805-262-20_95
Step 6. - TM-5-3805-262-20_96
Step 7. - TM-5-3805-262-20_97
S t e p 8 . ( C o n t ) - TM-5-3805-262-20_98
S t e p 8 . ( C o n t ) - TM-5-3805-262-20_99
Step 9. - TM-5-3805-262-20_100
Step 11. - TM-5-3805-262-20_101
7. EXCESSIVE OIL CONSUMPTION - TM-5-3805-262-20_102
Step 3. - TM-5-3805-262-20_103
Step 4. - TM-5-3805-262-20_104
8. ENGINE CRANKS BUT DOES NOT START WHEN COLD START AID IS ACTIVATED
9. LOW ENGINE OIL PRESSURE
Step 2. - TM-5-3805-262-20_107
10. ENGINE WILL NOT SHUT DOWN
11. ENGINE NOISE (LOW AND HIGH RPM)
S t e p 2 . ( C o n t )
3-5. FUEL SYSTEM TROUBLESHOOTING
1. LOW FUEL PRESSURE (Cont).
Step 2. - TM-5-3805-262-20_113
Step 3..
Step 4. - TM-5-3805-262-20_115
Step 6 - TM-5-3805-262-20_116
Step 7. - TM-5-3805-262-20_117
Step 9. - TM-5-3805-262-20_118
Step 10.
2. EXCESSIVE FUEL USAGE
3-6. EXHAUST SYSTEM TROUBLESHOOTING
EXCESSIVE EXHAUST NOISE (Cont)
3-7. COOLING SYSTEM TROUBLESHOOTING
1. ENGINE OVERHEATS (Cont)
Step 6. - TM-5-3805-262-20_125
Step 10
Step 13.
2. ENGINE DOES NOT REACH OPERATING TEMPERATURE
3. COOLING SYSTEM NOT PRESSURIZED (Cont).
3-8. CHARGING SYSTEM TROUBLESHOOTING
2. ALTERNATOR NOT CHARGING BATTERIES (Cont).
3-9. STARTING SYSTEM TROUBLESHOOTING
1. STARTER DOES NOT CRANK (Cont).
Step 6. - TM-5-3805-262-20_134
Step 8. - TM-5-3805-262-20_135
2. STARTER CRANKS CONTINUOUSLY.
Step 2. - TM-5-3805-262-20_137
3. STARTER CRANKS SLOWLY
Step 5.
Step 7. - TM-5-3805-262-20_140
3-10. INSTRUMENT PANELS TROUBLESHOOTING
2. OIL PRESSURE WARNING LIGHT DOES NOT OPERATE (Cont)
3. CLUTCH PRESSURE WARNING LIGHT DOES NOT OPERATE (Cont).
4. BRAKE WARNING LIGHT DOES NOT OPERATE (Cont).
5. HYDRAULIC FILTER WARNING LIGHT DOES NOT OPERATE
Step 4. - TM-5-3805-262-20_146
6. VOLTMETER DOES NOT OPERATE
7. INSTRUMENT CLUSTER GAGES DO NOT OPERATE.
8. FUEL LEVEL GAGE DOES NOT OPERATE (Cont).
11. WATER TEMPERATURE GAGE DOES NOT OPERATE
3-11. LIGHT SYSTEMS TROUBLESHOOTING
2. FLOOD LIGHTS DO NOT OPERATE (Cont)
3. FRONT DRIVING LIGHTS DO NOT OPERATE
4. BLACKOUT DRIVING LIGHT DOES NOT OPERATE
5. SERVICE TAIL LIGHTS DO NOT OPERATE (Cont)
6. BLACKOUT TAIL LIGHTS DO NOT OPERATE
7. BLACKOUT STOP LIGHTS DO NOT OPERATE
8. SERVICE STOP LIGHTS DO NOT OPERATE
Step 2. - TM-5-3805-262-20_159
9. VOLTMETER LIGHT OR INSTRUMENT CLUSTER GAGE LIGHTS DO NOT OPERATE.
Step 2. - TM-5-3805-262-20_161
S t e p 5 . ( C o n t )
3-12. SENDING UNITS TROUBLESHOOTING
3. WATER TEMPERATURE SENDING UNIT DOES NOT OPERATE
6. NEUTRAL START SWITCH DOES NOT OPERATE.
7. AIR PRESSURE SENDER DOES NOT OPERATE.
8. PARKING BRAKE SWITCH DOES NOT OPERATE (Cont)
9. HYDRAULIC FILTER SWITCH DOES NOT OPERATE
3-13. BATTERY SYSTEM TROUBLESHOOTING
2. BATTERIES DISCHARGED OR DO NOT MAINTAIN CHARGE (Cont) - TM-5-3805-262-20_170
3-14. TRANSMISSION TROUBLESHOOTING
2. SLOW OR ERRATIC TRANSMISSION SHIFTING
3. HIGH TRANSMISSION OIL TEMPERATURE (CONV TEMP GAGE INDICATES EXCESSIVE TEMPER- ATURE)
Step 3 - TM-5-3805-262-20_174
4. LOSS OF DRIVE IN ALL RANGES
Step 4 - TM-5-3805-262-20_176
5. LOSS OF POWER.
6. LOADER CONTINUES TO MOVE WITH CONTROL LEVER IN N (NEUTRAL)
3-15. PROPELLER SHAFTS TROUBLESHOOTING
Step 4 - TM-5-3805-262-20_180
3-16. FRONT AND REAR AXLES TROUBLESHOOTING
3-17. PARKING BRAKE SYSTEM TROUBLESHOOTING
3-18. SERVICE BRAKE SYSTEM TROUBLESHOOTING
2. POOR BRAKE ACTION (Cont)
3. SERVICE BRAKES GRAB
5. SERVICE BRAKES DO NOT STOP LOADER (AIR SYSTEM OPERATING OKAY)
Step 2 - TM-5-3805-262-20_187
Step 3 - TM-5-3805-262-20_188
Step 4 - TM-5-3805-262-20_189
3-19. AIR BRAKE SYSTEM TROUBLESHOOTING
3. LOW AIR PRESSURE (AIR PRESSURE GAGE INDICATES IN RED ZONE AND LOW AIR PRES- SURE BUZZER SOUNDS).
Step 3
Step 7. - TM-5-3805-262-20_193
Step 9
Step 11
Step 12 - TM-5-3805-262-20_196
Step 13
4. AIR PRESSURE BUILDS UP SLOWLY.
Step 3. - TM-5-3805-262-20_199
Step 7 - TM-5-3805-262-20_200
5. AIR PRESSURE WILL NOT BUILD UP TO NORMAL
6. AIR PRESSURE TOO HIGH OR AIR COMPRESSOR WILL NOT CUT OUT
7. AIR COMPRESSOR FAILS TO MAINTAIN SUFFICIENT AIR PRESSURE (Cont)
Step 5. - TM-5-3805-262-20_204
8. NOISY OPERATION OF AIR COMPRESSOR
Step 3. - TM-5-3805-262-20_206
Step 4. - TM-5-3805-262-20_207
3-20. WHEELS AND TIRES TROUBLESHOOTING
2. NOISY OR BUMPING SOUND WHILE TRAVELING (Cont)
3-21. STEERING SYSTEM TROUBLESHOOTING
1. NO RESPONSE WHEN STEERING WHEEL TURNED (Cont)
2. SLOW OR HARD STEERING (Cont)
Step 5. - TM-5-3805-262-20_213
Step 6 - TM-5-3805-262-20_214
Step 7. - TM-5-3805-262-20_215
3. WRONG RESPONSE TO STEERING WHEEL
5. AUXILIARY STEERING SYSTEM DOES NOT OPERATE
Step 3 - TM-5-3805-262-20_218
Step 6. - TM-5-3805-262-20_219
Step 7. - TM-5-3805-262-20_220
Step 9. - TM-5-3805-262-20_221
Step 12 - TM-5-3805-262-20_222
3-22. FRAME TROUBLESHOOTING
3. EXCESSIVE PLAY AT CHASSIS SPINDLES WHEN TURNING
4. EXCESSIVE NOISE AT REAR CHASSIS TRUNNION (Cont)
3-23. BODY AND CAB TROUBLESHOOTING
4. SEAT WILL NOT ADJUST FORE AND AFT (Cont)
3-24. ACCESSORIES TROUBLESHOOTING
2. WINDSHIELD WIPER MOTOR DOES NOT OPERATE
Step 3 - TM-5-3805-262-20_230
3. WINDSHIELD WIPER ARM DOES NOT MOVE (MOTOR HUMS)
TM-5-3805-262-20_232
4. WIPER ARM DOES NOT RETURN TO PARK POSITION (Cont)
5. WASHER FLUID DOES NOT SPRAY ON WINDSHIELD.
6. CAB HEATER FAN NOT OPERATING
Step 3. - TM-5-3805-262-20_236
Step 5. - TM-5-3805-262-20_237
7. COLD AIR BLOWN FROM CAB HEATER.
8. DEFROSTER MOTOR DOES NOT OPERATE.
Step 3 - TM-5-3805-262-20_240
Step 4. - TM-5-3805-262-20_241
Step 7. - TM-5-3805-262-20_242
9. BOTH REAR DEFOGGER FANS DO NOT OPERATE.
9. BOTH REAR DEFOGGER FANS DO NOT OPERATE (Cont)
Step 5 - TM-5-3805-262-20_245
10. A REAR DEFOGGER FAN DOES NOT OPERATE.
3-25. HYDRAULIC SYSTEM TROUBLESHOOTING
2. HYDRAULIC PUMP LEAKS HYDRAULIC OIL.
3 . BUCKET TILT CYLINDER ASSEMBLIES OPERATION SLUGGISH OR POOR
Step 2. - TM-5-3805-262-20_250
S t e p 4 . ( C o n t ) - TM-5-3805-262-20_251
4. BUCKET DOES NOT RETURN TO DIGGING POSITION.
Step 3. - TM-5-3805-262-20_253
5. BUCKET HEIGHT CONTROL NOT OPERATING PROPERLY.
Step 2. - TM-5-3805-262-20_255
Step 4.
Step 6.
6. LIFT CYLINDER ASSEMBLIES OPERATING SLUGGISHLY OR POORLY (ALL OTHER CYLINDERS OPERATING OKAY)
Step 2. - TM-5-3805-262-20_259
S t e p 4 . ( C o n t ) - TM-5-3805-262-20_260
7. BUCKET CLAMSHELL CYLINDER ASSEMBLIES OPERATING SLUGGISHLY OR POORLY (ALL OTHER CYLINDERS OPERATE PROPERLY)
Step 2 - TM-5-3805-262-20_262
8. ALL CYLINDER ASSEMBLIES OPERATING SLUGGISHLY OR POORLY.
Step 2. - TM-5-3805-262-20_264
Step 2. - TM-5-3805-262-20_265
3-26. SIGNALING DEVICES TROUBLESHOOTING
Step 3. - TM-5-3805-262-20_267
2. TURN SIGNALS DO NOT OPERATE.
3. A TURN SIGNAL LAMP DOES NOT OPERATE.
Section III. TROUBLESHOOTING USING STE/lCE (SIMPLIFIED TEST EQUIPMENT FOR INTERNAL COMBUSTION ENGINES)
3-29. STE/ICE SET-UP PROCEDURES
3-30. ENGINE TROUBLESHOOTING (CONT)
2. ENGINE HARD TO START OR WILL NOT START (NO EXHAUST SMOKE)
Step 2. - TM-5-3805-262-20_274
Step 3. - TM-5-3805-262-20_275
Step 5. - TM-5-3805-262-20_276
S t e p 6 .
3. ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE) - TM-5-3805-262-20_278
Step 2. - TM-5-3805-262-20_279
Step 3. - TM-5-3805-262-20_280
Step 5. - TM-5-3805-262-20_281
S t e p 6 . ( C o n t )
Step 7. - TM-5-3805-262-20_283
4. ENGINE STARTS BUT WILL NOT RUN - TM-5-3805-262-20_284
S t e p 1 . ( C o n t ) - TM-5-3805-262-20_285
Step 2 - TM-5-3805-262-20_286
Step 3. - TM-5-3805-262-20_287
Step 5. - TM-5-3805-262-20_288
S t e p 7 . ( C o n t )
Step 8. - TM-5-3805-262-20_290
5. ENGINE MISFIRES.
Step 2. - TM-5-3805-262-20_292
Step 3 - TM-5-3805-262-20_293
Step 5. - TM-5-3805-262-20_294
6. ENGINE STALLS FREQUENTLY OR DOES NOT DEVELOP FULL POWER
Step 3.
Step 5 - TM-5-3805-262-20_297
S t e p 6 . ( C o n t ).
Step 7 - TM-5-3805-262-20_299
Step 8. - TM-5-3805-262-20_300
Step 9.
S t e p 9 . ( C o n t )
Step 10.
Step 11. - TM-5-3805-262-20_304
7. EXCESSIVE OIL CONSUMPTION - TM-5-3805-262-20_305
S t e p 1 . ( C o n t ) - TM-5-3805-262-20_306
Step 2. - TM-5-3805-262-20_307
Step 4. - TM-5-3805-262-20_308
Step 6. - TM-5-3805-262-20_309
8. LOW ENGINE OIL PRESSURE.
Step 3. - TM-5-3805-262-20_311
S t e p 4 . ( C o n t ) - TM-5-3805-262-20_312
S t e p 4 . ( C o n t ) - TM-5-3805-262-20_313
3-31. FUEL SYSTEM TROUBLESHOOTING
Step 1.
S t e p 1 . ( C o n t ) - TM-5-3805-262-20_316
Step 2. - TM-5-3805-262-20_317
S t e p 2 . ( C o n t )
S t e p 3
Step 5 - TM-5-3805-262-20_320
S t e p 7 . ( C o n t ).
Step 8. - TM-5-3805-262-20_322
Step 9. - TM-5-3805-262-20_323
Step 10. - TM-5-3805-262-20_324
Step 11. - TM-5-3805-262-20_325
3-32. CHARGING SYSTEM TROUBLESHOOTING
Step 2. - TM-5-3805-262-20_327
Step 3. - TM-5-3805-262-20_328
Step 4.
Step 6. - TM-5-3805-262-20_330
Step 7. - TM-5-3805-262-20_331
Step 8. - TM-5-3805-262-20_332
Step 10.
Step 11.
Step 12. (Cont)
3-33. STARTING SYSTEM TROUBLESHOOTING
Step 3. - TM-5-3805-262-20_337
Step 5. - TM-5-3805-262-20_338
Step 7.
Step 9. - TM-5-3805-262-20_340
2. STARTER CRANKS CONTINUOUSLY
S t e p 1 . ( C o n t ).
Step 2. - TM-5-3805-262-20_343
3. STARTER CRANKS SLOWLY (UNDER 200 RPM)
3. STARTER CRANKS SLOWLY (UNDER 200 RPM) (Cont).
Step 2. - TM-5-3805-262-20_346
Step 5. - TM-5-3805-262-20_347
Step 8. - TM-5-3805-262-20_348
Step 9.
Step 11.
Step 12.
Step 13.
Step 15.
Step 16. (Cont).
Step 17.
3-34. BATTERY SYSTEM TROUBLESHOOTING
2. BATTERIES DISCHARGED OR DO NOT MAINTAIN CHARGE (Cont) - TM-5-3805-262-20_357
Step 2. - TM-5-3805-262-20_358
Step 3. - TM-5-3805-262-20_359
Step 4 - TM-5-3805-262-20_360
Step 7.
Step 10. - TM-5-3805-262-20_362
Step 11. - TM-5-3805-262-20_363
Step 12.
CHAPTER 4 ENGINE, FUEL, EXHAUST, AND COOLING SYSTEMS MAINTENANCE
4-1. ENGINE MAINTENANCE
DRAINING ENGINE OIL (SHEET 2 OF 2)
b . O i l F i l t e r .
c. Oil Sampling (SHEET 1 OF 2).
C . Oil Sampling (SHEET 2 OF 2).
d. E x h a u s t M a n i f o l d.
CLEANING AND INSPECTION - TM-5-3805-262-20_372
INSTALLATION - TM-5-3805-262-20_373
4-2. FUEL SYSTEM MAINTENANCE
REMOVAL ( SHEET 2 OF 2) - TM-5-3805-262-20_375
CLEANING - TM-5-3805-262-20_376
INSTALLATION (SHEET 2 OF 2)
b. Electric Fuel Pump.
SERVICING (SHEET 2 OF 2) - TM-5-3805-262-20_379
REMOVAL - TM-5-3805-262-20_380
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_381
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_382
c. Fuel Injection Pump.
d. A i r C l e a n e r
Secondary element assembly
(2) Replacement. - TM-5-3805-262-20_386
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_387
DISASSEMBLY (SHEET 1 OF 2) - TM-5-3805-262-20_388
DISASSEMBLY (SHEET 2 OF 2) - TM-5-3805-262-20_389
CLEANING (SHEET 1 OF 2) - TM-5-3805-262-20_390
INSPECTION - TM-5-3805-262-20_391
REASSEMBLY (SHEET 1 OF 2) - TM-5-3805-262-20_392
REASSEMBLY (SHEET 2 OF 2) - TM-5-3805-262-20_393
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_394
TESTING - TM-5-3805-262-20_395
e. Fuel Tank.
CLEANING - TM-5-3805-262-20_397
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_398
REMOVAL (SHEET 2 OF 2)
INSTALLATION (SHEET 1 OF 2)
INSTALLATION (SHEET 2 OF 2)
f. F u e l F i l t e r s a n d F i l t e r H e a d
SERVICING (SHEET 2 OF 2) - TM-5-3805-262-20_403
BLEEDING AIR FROM FUEL SYSTEM
(2) Filter Head.
(2) Filter Head (cont).
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_407
CLEANING - TM-5-3805-262-20_408
INSPECTION (SHEET 2 OF 2) - TM-5-3805-262-20_409
INSTALLATION (SHEET 1 OF 2)
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_411
g . C o l d S t a r t K i t.
SERVICING (SHEET 2 OF 2) - TM-5-3805-262-20_413
REMOVAL - TM-5-3805-262-20_414
CLEANING - TM-5-3805-262-20_415
INSPECTION - TM-5-3805-262-20_416
INSTALLATION - TM-5-3805-262-20_417
h. A c c e l e r a t o r
h. A c c e l e r a t o r ( c o n t ) - TM-5-3805-262-20_419
h. A c c e l e r a t o r ( c o n t ) - TM-5-3805-262-20_420
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_421
CLEANING - TM-5-3805-262-20_422
INSPECTION (SHEET 2 OF 2) - TM-5-3805-262-20_423
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_424
h. A c c e l e r a t o r ( c o n t ) - TM-5-3805-262-20_425
h. A c c e l e r a t o r ( c o n t ) - TM-5-3805-262-20_426
INSTALLATION ( SHEET 2 OF 2)
ADJUSTMENTS (SHEET 1 OF 2)
ADJUSTMENTS ( SHEET 2 OF 2)
4-3. EXHAUST SYSTEM MUFFLER AND PIPE MAINTENANCE
CLEANING - TM-5-3805-262-20_431
INSPECTION - TM-5-3805-262-20_432
4-4. COOLING SYSTEM MAINTENANCE
a. R a d i a t o r S e r v i c i n g ( c o n t )
FLUSHING
b. Radiator Hoses.
INSPECTION - TM-5-3805-262-20_437
REMOVAL - TM-5-3805-262-20_438
INSTALLATION - TM-5-3805-262-20_439
c. R a d i a t o r G r i l l e
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_441
CLEANING AND INSPECTION - TM-5-3805-262-20_442
INSTALLATION - TM-5-3805-262-20_443
d. Radiator and Guard.
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_445
CLEANING - TM-5-3805-262-20_446
INSPECTION - TM-5-3805-262-20_447
INSTALLATION (SHEET 1 OF 3) - TM-5-3805-262-20_448
INSTALLATION (SHEET 2 OF 3) - TM-5-3805-262-20_449
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_450
e. T h e r m o s t a t s
CLEANING - TM-5-3805-262-20_452
INSTALLATION - TM-5-3805-262-20_453
f. W a t e r M a n i f o l d
CLEANING - TM-5-3805-262-20_455
INSPECTION - TM-5-3805-262-20_456
INSTALLATION (SHEET 2 OF 2)
g. Water Pump.
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_459
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_460
CLEANING AND INSPECTION - TM-5-3805-262-20_461
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_462
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_463
h. F a n A s s e m b l y
CLEANING AND INSPECTION - TM-5-3805-262-20_465
CHAPTER 5 ELECTRICAL SYSTEM MAINTENANCE
5-1. ALTERNATOR DRIVE BELTS MAINTENANCE
a. I n s p e c t i o n cont
b. Replacement. - TM-5-3805-262-20_470
CLEANING AND INSPECTION - TM-5-3805-262-20_471
5-2. ALTERNATOR MAINTENANCE
TESTING (SHEET 2 OF 2) - TM-5-3805-262-20_473
TESTING (SHEET 1 OF 2)
TESTING (SHEET 2 OF 2) - TM-5-3805-262-20_475
b. Replacement. - TM-5-3805-262-20_476
REMOVAL (SHEET 2 OF 3) - TM-5-3805-262-20_477
REMOVAL (SHEET 3 OF 3) - TM-5-3805-262-20_478
CLEANING - TM-5-3805-262-20_479
INSTALLATION (SHEET 2 OF 3) - TM-5-3805-262-20_480
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_481
5-3. STARTER MAINTENANCE
a. S t a r t e r (cont).
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_484
a. S t a r t e r ( c o n t )
CLEANING - TM-5-3805-262-20_486
INSPECTION AND REPAIR - TM-5-3805-262-20_487
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_488
a. S t a r t e r ( c o n t ) - TM-5-3805-262-20_489
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_490
a. S t a r t e r ( c o n t ) - TM-5-3805-262-20_491
b. Circuit Breakers and Relays.
REMOVAL (SHEET 2 OF 4) - TM-5-3805-262-20_493
REMOVAL (SHEET 3 OF 4) - TM-5-3805-262-20_494
CLEANING - TM-5-3805-262-20_495
INSPECTION TESTING, AND REPAIR (SHEET 2 OF 2)
INSTALLATION (SHEET 2 OF 4) - TM-5-3805-262-20_497
INSTALLATION (SHEET 3 OF 4) - TM-5-3805-262-20_498
INSTALLATION (SHEET 4 OF 4) - TM-5-3805-262-20_499
5-4. INSTRUMENT PANELS MAINTENANCE
REMOVAL ( SHEET 2 OF 3) - TM-5-3805-262-20_501
a. Left-hand Instrument Panel (cont). - TM-5-3805-262-20_502
REMOVAL ( SHEET 3 OF 3) - TM-5-3805-262-20_503
a. Left-hand Instrument Panel (cont)
DISASSEMBLY - TM-5-3805-262-20_505
INSPECTION, TESTING, AND REPAIR (SHEET 1 OF 2)
INSPECTION, TESTING, AND REPAIR (SHEET 2 OF 2) - TM-5-3805-262-20_507
a. Left-hand Instrument Panel (cont). - TM-5-3805-262-20_508
REASSEMBLY - TM-5-3805-262-20_509
a. Left-hand Instrument Panel (cont) - TM-5-3805-262-20_510
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_511
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_512
a. Left-hand Instrument Panel (cont) - TM-5-3805-262-20_513
b. Right-hand Instrument Panel - TM-5-3805-262-20_514
b. Right-hand Instrument Panel - TM-5-3805-262-20_515
b. Right-hand Instrument Panel - TM-5-3805-262-20_516
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_517
b. Right-hand Instrument Panel (cont). - TM-5-3805-262-20_518
DISASSEMBLY - TM-5-3805-262-20_519
CLEANING - TM-5-3805-262-20_520
INSPECTION , TESTING, AND REPAIR (SHEET 1 OF 5)
INSPECTION, TESTING, AND REPAIR (SHEET 2 OF 5)
INSPECTION , TESTING, AND REPAIR (SHEET 3 OF 5)
INSPECTION, TESTING, AND REPAIR (SHEET 4 OF 5)
INSPECTION, TESTING, AND REPAIR (SHEET 5 OF 5)
b. Right-hand Instrument Panel (cont). - TM-5-3805-262-20_526
REASSEMBLY - TM-5-3805-262-20_527
b. Right-hand Instrument Panel (cont)
INSTALLATION ( SHEET 1 OF 2) - TM-5-3805-262-20_529
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_530
c. Hourmeter/Tachometer.
CLEANING - TM-5-3805-262-20_532
INSTALLATION - TM-5-3805-262-20_533
5-5. RETURN-TO-DIG AND BUCKET HEIGHT SWITCHES MAINTENANCE
REMOVAL (SHEET 2 OF 3) - TM-5-3805-262-20_535
REMOVAL ( SHEET 3 OF 3) - TM-5-3805-262-20_536
CLEANING - TM-5-3805-262-20_537
INSTALLATION (SHEET 1 OF 3) - TM-5-3805-262-20_538
5-5. RETURN-TO-DIG AND BUCKET HEIGHT SWITCHES MAINTENANCE (CONT)
INSTALLATION (SHEET 2 OF 3) - TM-5-3805-262-20_540
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_541
5-6. AUXILIARY STEERING ELECTRiCAL SYSTEM MAINTENANCE
REMOVAL ( SHEET 2 OF 2) - TM-5-3805-262-20_543
CLEANING - TM-5-3805-262-20_544
INSPECTION AND REPAIR (SHEET 2 OF 4)
INSPECTION AND REPAIR (SHEET 3 OF 4)
INSPECTION AND REPAIR (SHEET 4 OF 4)
a. Relay Socket Assembly (cont)
INSTALLATION - TM-5-3805-262-20_549
b. Auxiliary Steering Cables and Harness.
b. Auxiliary Steering Cables and Harness. cont
b. Auxiliary Steering Cables and Harness (cont).
CLEANING - TM-5-3805-262-20_553
INSPECTION AND REPAIR
b. Auxiliary Steering Cables and Harness (cont) - TM-5-3805-262-20_555
b. Auxiliary Steering Cables and Harness (cont) - TM-5-3805-262-20_556
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_557
5-7. LIGHT SYSTEMS MAINTENANCE
a. Front Flood and Driving L i g h t s.cont
a. Front Flood and Driving L i g h t s ( c o n t )
CLEANING - TM-5-3805-262-20_561
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_562
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_563
b. Blackout Driving Light.
REMOVAL - TM-5-3805-262-20_565
INSPECTION AND REPAIR - TM-5-3805-262-20_566
INSTALLATION - TM-5-3805-262-20_567
c. Rear Flood Lights.
CLEANING - TM-5-3805-262-20_569
INSTALLATION - TM-5-3805-262-20_570
d. Stop and Tail Lights.
CLEANING - TM-5-3805-262-20_572
INSTALLATION - TM-5-3805-262-20_573
e. Blackout Stop and Tail Lights.
REMOVAL - TM-5-3805-262-20_575
e. Blackout Stop and Tail Lights (cont)
INSPECTION AND REPAIR - TM-5-3805-262-20_577
5-8. SENDING UNITS AND WARNING SWITCHES MAINTENANCE
CLEANING (SHEET 2 OF 2) - TM-5-3805-262-20_579
INSPECTION, TESTING, AND REPAIR - TM-5-3805-262-20_580
INSTALLATION ( SHEET 2 OF 2)
b. F u e l L e v e l S e n d i n g U n i t
REMOVAL - TM-5-3805-262-20_583
INSPECTION, TESTING, AND REPAIR - TM-5-3805-262-20_584
INSTALLATION - TM-5-3805-262-20_585
c. Water Temperature Sending U n i t
CLEANING (SHEET 2 OF 2) - TM-5-3805-262-20_587
INSPECTION, TESTING, AND REPAIR - TM-5-3805-262-20_588
INSTALLATION - TM-5-3805-262-20_589
d. Converter Temperature Sending Unit.
REMOVAL - TM-5-3805-262-20_591
INSPECTION, TESTING, AND REPAIR - TM-5-3805-262-20_592
INSTALLATION - TM-5-3805-262-20_593
e. Clutch Pressure Switch
e. Clutch Pressure Switch cont
CLEANING - TM-5-3805-262-20_596
INSTALLATION - TM-5-3805-262-20_597
f. N e u t r a l S t a r t S w i t c h
REMOVAL - TM-5-3805-262-20_599
INSPECTION, TESTING, AND REPAIR - TM-5-3805-262-20_600
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_601
g. A i r P r e s s u r e S e n d e r.
REMOVAL - TM-5-3805-262-20_603
INSPECTION, TESTING, AND REPAIR - TM-5-3805-262-20_604
INSTALLATION - TM-5-3805-262-20_605
5-9. BATTERIES AND CABLES MAINTENANCE
SERVICING (SHEET 2 OF 2) - TM-5-3805-262-20_607
VOLTAGE TEST
LOAD TEST
SPECIFIC GRAVITY CHECK (SHEET 1 OF 2)
SPECIFIC GRAVITY CHECK (SHEET 2 OF 2)
CHARGING (SHEET 1 OF 2)
CHARGING (SHEET 2 OF 2)
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_614
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_615
CLEANING - TM-5-3805-262-20_616
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_617
a. B a t t e r i e s ( c o n t )
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_619
b. Slave Receptacle.
CLEANING - TM-5-3805-262-20_621
INSPECTION - TM-5-3805-262-20_622
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_623
c. B a t t e r y C a b l e s
5-9 BATTERIES AND CABLES MAINTENANCE (CONT)
c. B a t t e r y Cables (cont)
CLEANING - TM-5-3805-262-20_627
INSPECTION - TM-5-3805-262-20_628
c. B a t t e r y Cables (cont)
c. B a t t e r y C a b l e s ( c o n t )
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_631
5-10. WIRING HARNESS MAINTENANCE
a. Front Wiring Harness. CONT
TESTING (SHEET 2 OF 2) - TM-5-3805-262-20_634
REPAIR (SHEET 2 OF 3) - TM-5-3805-262-20_635
a. Front Wiring Harness. CONT
REPAIR (SHEET 3 OF 3) - TM-5-3805-262-20_637
b. Rear Wiring Harness.
TESTING (SHEET 2 OF 2) - TM-5-3805-262-20_639
REPAIR (SHEET 1 OF 3)
REPAIR (SHEET 2 OF 3) - TM-5-3805-262-20_641
b. Rear Wiring Harness (cont)
REPAIR (SHEET 3 OF 3) - TM-5-3805-262-20_643
c. Blackout Lights Wiring Harness.
TESTING (SHEET 2 OF 2) - TM-5-3805-262-20_645
REPAIR (SHEET 2 OF 3) - TM-5-3805-262-20_646
REPAIR (SHEET 3 OF 3)
d. Cab Upper Wiring Harness.
TESTING - TM-5-3805-262-20_649
REPAIR (SHEET 1 OF 2) - TM-5-3805-262-20_650
REPAIR (SHEET 2 OF 2) - TM-5-3805-262-20_651
e. Cab Lower Wiring Harness
TESTING - TM-5-3805-262-20_653
REPAIR (SHEET 1 OF 2) - TM-5-3805-262-20_654
REPAIR (SHEET 2 OF 2) - TM-5-3805-262-20_655
f. Cab Console Wiring Harness
TESTING - TM-5-3805-262-20_657
REPAIR (SHEET 1 OF 2) - TM-5-3805-262-20_658
REPAIR (SHEET 2 OF 2) - TM-5-3805-262-20_659
CHAPTER 6 POWER TRAIN MAINTENANCE
a. T r a n s m i s s i o n
a. T r a n s m i s s i o n ( c o n t )
( 2 ) S e r v i c i n g.
OIL LEVEL CHECK (SHEET 2 OF 2)
DRAINING AND REFILLING OIL (SHEET 1 OF 3)
DRAINING AND REFILLING OIL (SHEET 2 OF 3)
OIL FILTER REPLACEMENT (SHEET 1 OF 2)
OIL FILTER REPLACEMENT (SHEET 2 OF 2)
b. Control Valve Linkage.
REMOVAL (SHEET 1 OF 3) - TM-5-3805-262-20_671
REMOVAL (SHEET 2 OF 3)
CLEANING - TM-5-3805-262-20_673
INSPECTION - TM-5-3805-262-20_674
INSTALLATION (SHEET 2 OF 4) - TM-5-3805-262-20_675
INSTALLATION (SHEET 3 OF 4) - TM-5-3805-262-20_676
INSTALLATION (SHEET 4 OF 4) - TM-5-3805-262-20_677
ADJUSTMENT (1) (2) (3) (SHEET 1 OF 3)
ADJUSTMENT (SHEET 2 OF 3)
ADJUSTMENT (SHEET 3 OF 3)
c. Transmission Pump and Oil Filter and Lines.
REMOVAL - TM-5-3805-262-20_682
c. Transmission Pump and Oil Filter and Lines (cont)
INSPECTION - TM-5-3805-262-20_684
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_685
d. Transmission Cooler Lines
REMOVAL - TM-5-3805-262-20_687
d. Transmission Cooler Lines (cont)
INSTALLATION - TM-5-3805-262-20_689
e. Oil Sampling (SHEET 1 OF 2)
SHEET 2 OF 2 - TM-5-3805-262-20_691
6-2. DRIVE SHAFTS MAINTENANCE
SHEET 2 OF 2 - TM-5-3805-262-20_693
(2) Replacement. - TM-5-3805-262-20_694
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_695
(2) Replacement (cont) - TM-5-3805-262-20_696
INSTALLATION - TM-5-3805-262-20_697
b. Center Drive Shaft and Support Bearing
SHEET 2 OF 2 - TM-5-3805-262-20_699
(2) Replacement - TM-5-3805-262-20_700
CENTER DRIVE SHAFT - TM-5-3805-262-20_701
b. Center Drive S h a f t a nd Support Bea r i ng (cont)
CENTER DRIVE SHAFT - TM-5-3805-262-20_703
c. R e a r D r i v e S h a f t.
REMOVAL - TM-5-3805-262-20_705
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_706
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_707
6-3. FRONT AND REAR AXLES MAINTENANCE
DRAINING AND REFILLINAG OIL (SHEET 1 OF 2)
DRAINING AND REFILLING OIL (SHEET 2 OF 2)
BREATHER SERVICE
CHAPTER 7 BRAKE SYSTEM MAINTENANCE
7-1. PARKING BRAKE MAINTENANCE
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_715
CLEANING - TM-5-3805-262-20_716
INSPECTION AND REPAIR - TM-5-3805-262-20_717
a. Parking Brake (cont)
INSTALLATION - TM-5-3805-262-20_719
b. Parking Brake C h a m b e r.
CLEANING
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_722
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_723
c. Parking Brake Valve
REMOVAL - TM-5-3805-262-20_725
CLEANING AND INSPECTION - TM-5-3805-262-20_726
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_727
d. Parking Brake Linkage
ADJUSTMENT - TM-5-3805-262-20_729
7-2. SERVICE BRAKE SYSTEM MAINTENANCE
ADJUSTMENT - TM-5-3805-262-20_731
a. Disk Brakes
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_733
CLEANING - TM-5-3805-262-20_734
INSPECTION - TM-5-3805-262-20_735
INSTALLATION - TM-5-3805-262-20_736
b. H y d r a u l i c R e s e r v o i r.
(2) Replacement. - TM-5-3805-262-20_738
REMOVAL - TM-5-3805-262-20_739
7-2. SERVICE BRAKE SYSTEM MAINTENANCE (CONT)
INSTALLATION - TM-5-3805-262-20_741
c. C a l i p e r s
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_743
BLEEDING AIR FROM BRAKE SYSTEM (SHEET 1 OF 2)
BLEEDING AIR FROM BRAKE SYSTEM (SHEET 2 OF 2)
d. Hoses, Lines and Fittings
INSPECTION (SHEET 2 OF 2) - TM-5-3805-262-20_747
(2) Front Brakes Hoses, Lines, and Fittings
d. H o s e s , L i n e s, a n d F i t t i n g s ( c o n t )
REMOVAL (SHEET 2 OF 2)
d. H o s e s . L i n e s, a n d F i t t i n g s ( c o n t ) - TM-5-3805-262-20_751
d. H o s e s . L i n e s, a n d F i t t i n g s ( c o n t ) - TM-5-3805-262-20_752
CLEANING - TM-5-3805-262-20_753
d. H o s e s , L i n e s , a n d F i t t i n g s ( c o n t )
INSTALLATION (SHEET 2 OF 2)
(3) Rear Brakes Hoses, Lines, and Fittings
d. H o s e s , L i n e s, a n d F i t t i n g s ( c o n t )
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_758
d. H o s e s , L i n e s, a n d F i t t i n g s ( c o n t )
CLEANING - TM-5-3805-262-20_760
INSPECTION - TM-5-3805-262-20_761
d. Hoses, L i n e s , a n d F i t t i n g s ( c o n t )
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_763
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_764
a. B r a k e A c t u a t o r s
INSTALLATION - TM-5-3805-262-20_766
b. Service Brake Treadle and Valve and Declutch Treadle and Valve
INSTALLATION - TM-5-3805-262-20_768
OPERATING TEST
c. A i r R e s e r v o i r
INSPECTION - TM-5-3805-262-20_771
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_772
CLEANING - TM-5-3805-262-20_773
INSPECTION (SHEET 2 OF 3)
INSPECTION (SHEET 3 OF 3) - TM-5-3805-262-20_775
INSTALLATION ( SHEET 1 OF 2) - TM-5-3805-262-20_776
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_777
d. Pressure Protection Valve
REMOVAL - TM-5-3805-262-20_779
e. Double Check Valve and Stop Light Switch.
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_781
CLEANING, INSPECTION, AND REPAIR - TM-5-3805-262-20_782
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_783
f. H o s e s , L i n e s , a n d F i t t i n g s.
f. H o s e s , L i n e s , a n d F i t t i n g s. CONT
f. H o s e s , L i n e s, a n d F i t t i n g s ( c o n t ).
INSPECTION (SHEET 2 OF 2)
(2) Replacement. - TM-5-3805-262-20_788
f. H o s e s , L i n e s , a n d F i t t i n g s CONT
REMOVAL (SHEET 2 OF 3) - TM-5-3805-262-20_790
f. H o s e s , L i n e s , a n d F i t t i n g s CONT
REMOVAL (SHEET 3 OF 3) - TM-5-3805-262-20_792
f. H o s e s , L i n e s , a n d F i t t i n g s CONT - TM-5-3805-262-20_793
CLEANING - TM-5-3805-262-20_794
INSPECTION AND REPAIR - TM-5-3805-262-20_795
INSTALLATION (SHEET 1 OF 3) - TM-5-3805-262-20_796
f. H o s e s , L i n e s , a n d F i t t i n g s CONT - TM-5-3805-262-20_797
INSTALLATION (SHEET 2 OF 3) - TM-5-3805-262-20_798
f. H o s e s , L i n e s , a n d F i t t i n g s CONT - TM-5-3805-262-20_799
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_800
f. H o s e s , L i n e s , a n d F i t t i n g s CONT - TM-5-3805-262-20_801
g. Air Compressor Assembly
REMOVAL (SHEET 2 OF 4) - TM-5-3805-262-20_803
REMOVAL (SHEET 3 OF 4) - TM-5-3805-262-20_804
REMOVAL (SHEET 4 OF 4) - TM-5-3805-262-20_805
INSTALLATION (SHEET 1 OF 4) - TM-5-3805-262-20_806
INSTALLATION (SHEET 2 OF 4) - TM-5-3805-262-20_807
INSTALLATION ( SHEET 3 OF 4)
INSTALLATION (SHEET 4 OF 4) - TM-5-3805-262-20_809
(2) Air Compressor Drive Belt
ADJUSTMENT - TM-5-3805-262-20_811
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_812
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_813
ADJUSTMENT (SHEET 1 OF 2)
TESTING - TM-5-3805-262-20_815
h. Air Compressor Lines.
INSPECTION (SHEET 2 OF 3)
h. Air Compressor Lines (cont).
INSPECTION (SHEET 3 OF 3) - TM-5-3805-262-20_819
(2) Replacement - TM-5-3805-262-20_820
REMOVAL (SHEET 1 OF 4)
REMOVAL (SHEET 2 OF 4)
REMOVAL (SHEET 3 OF 4) - TM-5-3805-262-20_823
REMOVAL (SHEET 4 OF 4) - TM-5-3805-262-20_824
CLEANING - TM-5-3805-262-20_825
INSTALLATION (SHEET 1 OF 5) - TM-5-3805-262-20_826
INSTALLATION (SHEET 2 OF 5) - TM-5-3805-262-20_827
INSTALLATION (SHEET 3 OF 5)
INSTALLATION (SHEET 4 OF 5) - TM-5-3805-262-20_829
INSTALLATION (SHEET 5 OF 5) - TM-5-3805-262-20_830
i. A l c o h o l E v a p o r a t o r
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_832
DISASSEMBLY - TM-5-3805-262-20_833
CLEANING (SHEET 2 OF 2) - TM-5-3805-262-20_834
REASSEMBLY - TM-5-3805-262-20_835
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_836
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_837
CHAPTER 8 WHEELS AND STEERING SYSTEM MAINTENANCE
8-1. WHEELS AND TIRES MAINTENANCE
SERVICING (ADDING AIR)
REMOVAL - TM-5-3805-262-20_842
DISASSEMBLY - TM-5-3805-262-20_843
CLEANING, INSPECTION, AND REPAIR - TM-5-3805-262-20_844
REASSEMBLY (SHEET 1 OF 2) - TM-5-3805-262-20_845
REASSEMBLY (SHEET 2 OF 2) - TM-5-3805-262-20_846
INSTALLATION - TM-5-3805-262-20_847
8-2. STEER INGSYSTEM MAINTENANCE
b. H o s e s , L i n e s, a n d F i t t i n g s
(1) Inspection (SHEET 2 OF 3)
SHEET 3 OF 3 - TM-5-3805-262-20_851
(2) Replacement. - TM-5-3805-262-20_852
b. H o s e s , L i n e s, a n d F i t t i n g s ( c o n t ) - TM-5-3805-262-20_853
REMOVAL (SHEET 2 OF 5) - TM-5-3805-262-20_854
REMOVAL (SHEET 3 OF 5) - TM-5-3805-262-20_855
(2) Replacement (cont) - TM-5-3805-262-20_856
REMOVAL (SHEET 4 OF 5) - TM-5-3805-262-20_857
b. H o s e s , L i n e s, a n d F i t t i n g s ( c o n t )
CLEANING - TM-5-3805-262-20_859
INSPECTION - TM-5-3805-262-20_860
INSTALLATION (SHEET 1 OF 5) - TM-5-3805-262-20_861
INSTALLATION (SHEET 2 OF 5) - TM-5-3805-262-20_862
INSTALLATION (SHEET 3 OF 5) - TM-5-3805-262-20_863
INSTALLATION (SHEET 4 OF 5) - TM-5-3805-262-20_864
INSTALLATION (SHEET 5 OF 5)
c. Auxiliary Steering System.
(2) Replacement. - TM-5-3805-262-20_867
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_868
CLEANING - TM-5-3805-262-20_869
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_870
INSTALLATION ( SHEET 2 OF 2)
d. Hydraulic Oil Cooler
REMOVAL ( SHEET 2 OF 3) - TM-5-3805-262-20_873
CLEANING - TM-5-3805-262-20_874
INSPECTION - TM-5-3805-262-20_875
INSTALLATION ( SHEET 2 OF 3) - TM-5-3805-262-20_876
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_877
e. S t e e r i n g H y d r a u l i c F i l t e r
SHEET 2 OF 2 - TM-5-3805-262-20_879
(2) Removal.
REMOVAL - TM-5-3805-262-20_881
CLEANING AND INSPECTION
INSTALLATION (SHEET 2 OF 3) - TM-5-3805-262-20_883
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_884
CHAPTER 9 FRAME AND TOWING ATTACHMENTS AND BODY AND CAB MAINTENANCE
9-1. CHASSIS ASSEMBLIES MAINTENANCE
SHEET 2 OF 2 - TM-5-3805-262-20_887
b. Rear Chassis Assembly (SHEET 1 OF 2 )
SHEET 2 OF 2 - TM-5-3805-262-20_889
c. Trunnion Grease Hoses.
REMOVAL - TM-5-3805-262-20_891
d. T r a n s p o r t / S e r v i c e L i n k.
REMOVAL - TM-5-3805-262-20_893
REMOVAL - TM-5-3805-262-20_894
9-2. ENGINE HOODS AND PANELS MAINTENANCE
CLEANING - TM-5-3805-262-20_896
INSTALLATION - TM-5-3805-262-20_897
REMOVAL - TM-5-3805-262-20_898
CLEANING AND INSPECTION (SHEET 1 OF 2) - TM-5-3805-262-20_899
CLEANING AND INSPECTION (SHEET 2 OF 2)
INSTALLATION - TM-5-3805-262-20_901
c. E n g i ne Hoods and Side Support s
CLEANING AND INSPECTION - TM-5-3805-262-20_903
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_904
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_905
d. Hood Support
CLEANING AND INSPECTION - TM-5-3805-262-20_907
9-3. FENDERS MAINTENANCE
CLEANING AND INSPECTION - TM-5-3805-262-20_909
b. Rear Fenders.
CLEANING AND INSPECTION - TM-5-3805-262-20_911
b. Rear Fenders (cont)
INSTALLATION - TM-5-3805-262-20_913
9-4. SEAT ASSEMBLY MAINTENANCE
b. S e a t S u p p o r t A s s e m b l y
CLEANING AND INSPECTION - TM-5-3805-262-20_916
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_917
c. S e a t B e l t .
INSTALLATION - TM-5-3805-262-20_919
CHAPTER 10 ACCESSORY ITEMS AND DATA PLATES MAINTENANCE
10-1. AIR HORN VALVE ASSEMBLY MAINTENANCE
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_923
DISASSEMBLY - TM-5-3805-262-20_924
REASSEMBLY - TM-5-3805-262-20_925
INSTALLATION ( SHEET 2 OF 3) - TM-5-3805-262-20_926
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_927
10-2. AIR HORN ASSEMBLY MAINTENANCE
DISASSEMBLY - TM-5-3805-262-20_929
INSPECTION - TM-5-3805-262-20_930
INSTALLATION - TM-5-3805-262-20_931
10-3. WINDSHIELD WIPER AND ARM MAINTENANCE
10-4. WINDSHIELD WIPER MOTOR MAINTENANCE
DISASSEMBLY - TM-5-3805-262-20_934
INSPECTION - TM-5-3805-262-20_935
REASSEMBLY - TM-5-3805-262-20_936
INSTALLATION - TM-5-3805-262-20_937
b. Front Wiper Switch and Circuit Breaker.
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_939
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_940
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_941
10-5. WINDSHIELD WASHER MAINTENANCE
10-5. WINDSHIELD WASHER MAINTENANCE (CONT)
CLEANING - TM-5-3805-262-20_944
INSPECTION - TM-5-3805-262-20_945
10-5. WINDSHIELD WASHER MAINTENANCE (CONT)
INSTALLATION - TM-5-3805-262-20_947
10-6. CAB HEATER SYSTEM MAINTENANCE
a. H e a t e r. CONT
a. H e a t e r ( c o n t )
CLEANING - TM-5-3805-262-20_951
INSPECTION - TM-5-3805-262-20_952
REASSEMBLY - TM-5-3805-262-20_953
a. H e a t e r ( c o n t ).
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_955
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_956
b. H o s e s , Lines, a n d F i t t i n g s
b. H o s e s , L i n e s , a n d F i t t i n g s ( c o n t )
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_959
CLEANING - TM-5-3805-262-20_960
INSPECTION - TM-5-3805-262-20_961
b. H o s e s , L i n e s, a n d F i t t i n g s ( c o n t ) - TM-5-3805-262-20_962
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_963
b. H o s e s , L i n e s , a n d F i t t i n g s ( c o n t )
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_965
c. H e a t e r C o n t r o l V a l v e
INSTALLATION - TM-5-3805-262-20_967
d. Heater Fan Switch and Circuit Breaker
d. Heater Fan Switch and Circuit Breaker CONT
d. Heater Fan Switch and Circuit Breaker (cont).
INSTALLATION - TM-5-3805-262-20_971
a. D e f r o s t e r M o t o r
a. D e f r o s t e r M o t o r CONT
CLEANING - TM-5-3805-262-20_974
INSPECTION - TM-5-3805-262-20_975
a. Defroster Motor (cont).
INSTALLATION - TM-5-3805-262-20_977
b. Defroster Switch and Circuit Breaker.
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_979
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_980
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_981
10-8. CAB DEFOGGER FANS MAINTENANCE
DISASSEMBLY - TM-5-3805-262-20_983
CLEANING - TM-5-3805-262-20_984
REASSEMBLY (SHEET 2 OF 2) - TM-5-3805-262-20_985
10-8. CAB DEFOGGER FANS MAINTENANCE (CONT)
10-9. CAB DOME LIGHT MAINTENANCE
b. Dome Light and Switch
INSTALLATION - TM-5-3805-262-20_989
10-10. MIRRORS MAINTENANCE
b. O u t s i d e M i r r o r s .
INSTALLATION - TM-5-3805-262-20_992
10-11. DATA PLATES AND DECALS MAINTENANCE
a. D a t a P l a t e s ( c o n t ) - TM-5-3805-262-20_994
a. D a t a P l a t e s ( c o n t ) - TM-5-3805-262-20_995
a. D a t a P l a t e s ( c o n t ) - TM-5-3805-262-20_996
a. D a t a P l a t e s ( c o n t ) - TM-5-3805-262-20_997
a. D a t a P l a t e s ( c o n t ) - TM-5-3805-262-20_998
a. D a t a P l a t e s ( c o n t ) - TM-5-3805-262-20_999
REMOVAL - TM-5-3805-262-20_1000
BEFORE STARTING ENGINE
CHAPTER 11 SYSTEM MAINTENANCE
INSPECTION (SHEET 1 OF 2)
INSPECTION (SHEET 2 OF 2) - TM-5-3805-262-20_1005
REMOVAL (SHEET 1 OF 5)
REMOVAL (SHEET 2 OF 5) - TM-5-3805-262-20_1007
REMOVAL (SHEET 3 OF 5) - TM-5-3805-262-20_1008
REMOVAL (SHEET 4 OF 5) - TM-5-3805-262-20_1009
REMOVAL (SHEET 5 OF 5) - TM-5-3805-262-20_1010
INSTALLATION (SHEET 2 OF 4) - TM-5-3805-262-20_1011
INSTALLATION (SHEET 3 OF 4) - TM-5-3805-262-20_1012
INSTALLTION (SHEET 4 OF 4)
11-2. RETURN-TO-DIG CONTROL MAINTENANCE
REMOVAL - TM-5-3805-262-20_1015
CLEANING AND INSPECTION - TM-5-3805-262-20_1016
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_1017
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1018
ADJUSTMENT - TM-5-3805-262-20_1019
11-3. LINES AND FITTINGS MAINTENANCE
DIAGRAM
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_1022
CLEANING - TM-5-3805-262-20_1023
INSTALLATION (SHEET 2 OF 4) - TM-5-3805-262-20_1024
INSTALLATION (SHEET 3 OF 4) - TM-5-3805-262-20_1025
INSTALLATION (SHEET 4 OF 4) - TM-5-3805-262-20_1026
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1027
b. Hydraulic Pump to Reservoir (cont). - TM-5-3805-262-20_1028
CLEANING (SHEET 1 OF 2) - TM-5-3805-262-20_1029
b. Hydraulic Pump to Reservoir (cont)
INSPECTION - TM-5-3805-262-20_1031
b. Hydraulic Pump to Reservoir (cont). - TM-5-3805-262-20_1032
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1033
REMOVAL (SHEET 1 OF 3) - TM-5-3805-262-20_1034
DIAGRAM - TM-5-3805-262-20_1035
REMOVAL (SHEET 2 OF 3) - TM-5-3805-262-20_1036
REMOVAL (SHEET 3 OF 3) - TM-5-3805-262-20_1037
CLEANING - TM-5-3805-262-20_1038
INSPECTION - TM-5-3805-262-20_1039
INSTALLATION (SHEET 1 OF 3) - TM-5-3805-262-20_1040
INSTALLATION (SHEET 2 OF 3) - TM-5-3805-262-20_1041
c. Control Valve Asembly to Loader Bucket Assembly (cont)
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_1043
d. Control Valve Assembly to Bucket Tilt Cylinder Assemblies.
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1045
d. Control Valve Assembly to Bucket Tilt Cylinder Assemblies (cont) - TM-5-3805-262-20_1046
CLEANING - TM-5-3805-262-20_1047
INSPECTION - TM-5-3805-262-20_1048
DIAGRAM - TM-5-3805-262-20_1049
d. Control Valve Assembly to Bucket Tilt Cylinder Assemblies (cont) - TM-5-3805-262-20_1050
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1051
e. Control Valve Assembly to Lift Cylinder Assemblies.
REMOVAL ( SHEET 1 OF 2)
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_1054
CLEANING - TM-5-3805-262-20_1055
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_1056
DIAGRAM - TM-5-3805-262-20_1057
e. Control Valve Assembly to Lift Cylinder Assemblies (cont).
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1059
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1060
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_1061
CLEANING - TM-5-3805-262-20_1062
INSTALLATION (SHEET 1 OF 3) - TM-5-3805-262-20_1063
INSTALLATION (SHEET 2 OF 3)
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_1065
11-4. LIFT CYLINDER ASSEMBLIES MAINTENANCE
PRELIMINARY PROCEDURE
REMOVAL (SHEET 1 OF 3) - TM-5-3805-262-20_1068
REMOVAL (SHEET 2 OF 3) - TM-5-3805-262-20_1069
REMOVAL ( SHEET 3 OF 3) - TM-5-3805-262-20_1070
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_1071
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1072
11-5. BUCKET CLAM CYLINDER ASSEMBLIES MAINTENANCE
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1074
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_1075
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_1076
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1077
11-6. HYDRAULIC RESERVOIR MAINTENANCE
INSPECTION (SHEET 2 OF 2) - TM-5-3805-262-20_1079
OIL CHECK
c. Draining and Refilling (SHEET 1 OF 3).
c. D r a i n i n g and Refilling (SHEET 2 OF 3).
SHEET 3 OF 3
11-7. HYDRAULIC FILTER MAINTENANCE
SHEET 2 OF 2.
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1086
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_1087
CLEANING - TM-5-3805-262-20_1088
INSTALLATION (SHEET 1 OF 3) - TM-5-3805-262-20_1089
INSTALLATION (SHEET 2 OF 3) - TM-5-3805-262-20_1090
INSTALLATION (SHEET 3 OF 3) - TM-5-3805-262-20_1091
CHAPTER 12 SIGNALING DEVICES AND LOADER BUCKET ASSEMBLY MAINTENANCE
12-1. SIGNALING DEVICES MAINTENANCE
REMOVAL - TM-5-3805-262-20_1095
CLEANING - TM-5-3805-262-20_1096
INSPECTION, TESTING, AND REPAIR (SHEET 2 OF 2) - TM-5-3805-262-20_1097
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1098
b. T u r n S i g n a l S w i t c h B u l b
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1100
DIAGRAM - TM-5-3805-262-20_1101
REMOVAL (SHEET 2 OF 2) - TM-5-3805-262-20_1102
CLEANING - TM-5-3805-262-20_1103
INSPECTION, REPAIR, AND TESTING
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_1105
c. Turn Signal Switch and Flasher (cont)
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1107
d. Turn Signal Lamp Assemblies Bulb
REMOVAL - TM-5-3805-262-20_1109
INSTALLATION - TM-5-3805-262-20_1110
12-2. BUCKET LIFT ARMS AND PIVOT ASSEMBLIES MAINTENANCE
12-3. LOADER BUCKET ASSEMBLY MAINTENANCE
REMOVAL (SHEET 2 OF 3) - TM-5-3805-262-20_1113
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_1114
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1115
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1116
INSTALLATION - TM-5-3805-262-20_1117
REMOVAL - TM-5-3805-262-20_1118
INSTALLATION - TM-5-3805-262-20_1119
REMOVAL (SHEET 1 OF 2) - TM-5-3805-262-20_1120
INSTALLATION (SHEET 1 OF 2) - TM-5-3805-262-20_1121
INSTALLATION (SHEET 2 OF 2) - TM-5-3805-262-20_1122
APPENDIX A REFERENCES - TM-5-3805-262-20_1123
REFERENCES -CONT - TM-5-3805-262-20_1124
REFERENCES -CONT - TM-5-3805-262-20_1125
APPENDIX B MAINTENANCE ALLOCATION CHART
B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II
B-4. EXPLANATION OF COLUMNSIN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1130
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1131
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1132
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1133
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1134
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1135
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1136
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1137
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1138
SECTION II MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1139
SECTION II. MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1140
SECTION II. MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1141
SECTION II. MAINTENANCE ALLOCATION CHART - TM-5-3805-262-20_1142
SECTION III. TOOL AND TEST EQUIPMENT REQUIREMENTS
TOOL AND TEST EQUIPMENT REQUIREMENTS -CONT - TM-5-3805-262-20_1144
TOOL AND TEST EQUIPMENT REQUIREMENTS -CONT - TM-5-3805-262-20_1145
Section IV. REMARKS
APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST -CONT
APPENDIX D MANUFACTURED ITEMS LIST
Figure D-1. Hoses and Tubing
Figure D-2. Trim
APPENDIX E HYDRAULIC, PNEUMATIC, AND ELECTRICAL DIAGRAMS
E-5. TROUBLESHOOTING LOGIC TREE
FIGURE E-1. LOGIC TREE TROUBLESHOOTING TECHNIQUES
Figure E-2. Electrical Symbols (Sheet 1 of 2 )
Figure E-2. Electrical Symbols (Sheet 2 of 2)
APPENDIX F TORQUE LIMITS
Table F-1. Torque Limits for Dry Fasteners
Table F-2. Torque Limits for Wet Fasteners
APPENDIX G METRIC CONVERSIONS
G L O S S A R Y
List Of Abbreviations (Cont) - TM-5-3805-262-20_1168
List Of Abbreviations (Cont) - TM-5-3805-262-20_1169
ALPHABETICAL INDEX
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