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
only Left Blank.
This page is blank.

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 fly-
ing 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 dan-
ger 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 oxy-
gen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of head-
ache, 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!
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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 bat-
tery 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 compo-
nents. 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-venti-
lated 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.
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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 hazard-
ous 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 slip-
pery. 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 person-
nel.
• 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 per-
sonnel 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 PER-
SONNEL WEARING FULL NBC PROTECTIVE
EQUIPMENT. SEE OPERATOR/MAINTE-
NANCE 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 cool-
ing 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 suit-
able 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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TM 5-3805-291-23-2
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. Page/WP No. Change No.

Front Cover (2 pgs) . . . . . . . . . . . . . . . . . . . . 0 WP 0091 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
Warning Summary (8 pgs) . . . . . . . . . . . . . . 0 WP 0092 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
i thru x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 WP 0093 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0050 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0094 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0051 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0095 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0052 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0096 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0053 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0097 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0054 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0098 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0055 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0099 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0056 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0100 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0057 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0101 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0058 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0102 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0059 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0103 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0060 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0104 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0061 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0105 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0062 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0106 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0063 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0107 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0064 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0108 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0065 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0109 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0066 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0110 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0067 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0111 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0068 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0112 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0069 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0113 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0070 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0114 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0071 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0115 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0072 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0116 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0073 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0117 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0074 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0118 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0075 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0119 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0076 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0120 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0077 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0121 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0078 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0122 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0079 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0123 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0080 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0124 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0081 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0125 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0082 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0126 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0083 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0127 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0084 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0128 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0085 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0129 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0086 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0130 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0087 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0131 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0088 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0132 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0089 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0133 00 (34 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0090 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0134 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
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TM 5-3805-291-23-2

WP 0135 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0187 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0136 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0188 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0137 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0189 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0138 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0190 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0139 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0191 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0140 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0192 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0141 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0193 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0142 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0194 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0143 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0195 00 (24 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0144 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0196 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0145 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0197 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0146 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0198 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0147 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0199 00 (32 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0148 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0200 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0149 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0201 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0150 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0202 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0151 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0203 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0152 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0204 00 (20 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0153 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0205 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0154 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0206 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0155 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0207 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0156 00 (26 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0208 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0157 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0209 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0158 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0210 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0159 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0211 00 (18 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0160 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0212 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0161 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0213 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0162 00 (26 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0214 00 (28 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0163 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0215 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0164 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0216 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0165 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0217 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0166 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0218 00 (14 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0167 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0219 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0168 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0220 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0169 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0221 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0170 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0222 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
CHAPTER 4 title page . . . . . . . . . . . . . . . . . 0 WP 0223 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0171 00 (38 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0224 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0172 00 (12 pgs.) . . . . . . . . . . . . . . . . . . 0 WP 0225 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0173 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0226 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0174 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0227 00 (10 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0175 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0228 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0176 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0229 00 (16 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0177 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 CHAPTER 5 title page . . . . . . . . . . . . . . . . . 0
WP 0178 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0230 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0179 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0231 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0180 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0232 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0181 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0233 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0182 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0234 00 (22 pgs.) . . . . . . . . . . . . . . . . . . 0
WP 0183 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0235 00 (8 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0184 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0236 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0185 00 (6 pgs.) . . . . . . . . . . . . . . . . . . . 0 WP 0237 00 (2 pgs.) . . . . . . . . . . . . . . . . . . . 0
WP 0186 00 (4 pgs.) . . . . . . . . . . . . . . . . . . . 0 Index-1 to Index-16 . . . . . . . . . . . . . . . . . . . 0
B
TM 5-3805-291-23-2

Foldouts (52) . . . . . . . . . . . . . . . . . . . . . . . . . 0 Back cover . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Metric conversion chart. . . . . . . . . . . . . . . . . 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 improve-
ments 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 tacomlcmc.daform2028@us.army.mil. 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 Rearview Camera, Cable, and Display Replacement . . . . . . . . . . . . . . . . . . . . . 0050 00-1
WP 0051 00 Starter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1
WP 0052 00 HVAC Blend Door Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-1
WP 0053 00 Fuse, Relay, Circuit Breaker, and Arc Suppressor Replacement . . . . . . . . . . . . 0053 00-1
WP 0054 00 Instrument Cluster Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-1
WP 0055 00 Instrument Panels and Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
WP 0056 00 Messenger ECM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1
WP 0057 00 Engine Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . 0057 00-1
WP 0058 00 Hood Tilt Actuator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
WP 0059 00 Hood Tilt Switch and Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . 0059 00-1
WP 0060 00 Implement Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . 0060 00-1
WP 0061 00 Main Light Switch and Arctic Heater Switch Replacement . . . . . . . . . . . . . . . . 0061 00-1
WP 0062 00 Power Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0062 00-1
WP 0063 00 Powertrain Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . 0063 00-1
WP 0064 00 Stoplight Limit Switch Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1
WP 0065 00 Turnlamp Flasher Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1
WP 0066 00 Turnlamp Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1
WP 0067 00 Windshield Wiper Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00-1
WP 0068 00 Blackout Drive Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1
WP 0069 00 Dome Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1
WP 0070 00 Stoplight Assembly and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0070 00-1
WP 0071 00 Service Lights and Front Turnlamp Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0071 00-1
WP 0072 00 Worklights Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1
WP 0073 00 Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
WP 0074 00 Boost Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1
WP 0075 00 Brake Pedal Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1
WP 0076 00 Camshaft Speed/Timing Sensor (Secondary) Replacement . . . . . . . . . . . . . . . . 0076 00-1
WP 0077 00 Coolant Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1
WP 0078 00 Crankshaft Speed/Timing Sensor (Primary) Replacement . . . . . . . . . . . . . . . . . 0078 00-1
WP 0079 00 Engine Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
WP 0080 00 Fuel Level Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1
WP 0081 00 Front and Rear Axle Oil Temperature Sensors Replacement . . . . . . . . . . . . . . . 0081 00-1
WP 0082 00 Fuel Temperature Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
WP 0083 00 Hydraulic Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1
WP 0084 00 Intake Manifold Air Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . 0084 00-1
WP 0085 00 Lift Kickout Position Sensor and Mounting Replacement . . . . . . . . . . . . . . . . . 0085 00-1
WP 0086 00 Parking Brake Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
WP 0087 00 Service Brake Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
WP 0088 00 Steering Oil Pressure Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
WP 0089 00 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 Transmission Oil Temperature Sensors Replacement. . . . . . . . . . . . . . . . . . . . . 0092 00-1
WP 0093 00 Transmission Output Speed Sensor Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
WP 0094 00 Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1
WP 0095 00 Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
WP 0096 00 Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1
WP 0097 00 Battery Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1
WP 0098 00 Battery Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1
WP 0099 00 NATO Slave Receptacle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0099 00-1
WP 0100 00 Transmission Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00-1
WP 0101 00 Shift Lever Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1
WP 0102 00 Transmission Oil Cooler Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1
WP 0103 00 Transmission Oil Filler Tube Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
WP 0104 00 Transmission Oil Filter Base, Lines, and Bypass Switch Replacement . . . . . . . 0104 00-1
WP 0105 00 Transmission Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
WP 0106 00 Transmission Test Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . 0106 00-1
Propeller and Propeller Shafts
WP 0107 00 Center Drive Shaft (Slip Joint) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00-1
WP 0108 00 Front Drive Shaft Carrier Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0108 00-1
WP 0109 00 Front Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109 00-1
WP 0110 00 Rear Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1
WP 0111 00 Differential and Final Drive Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1
Brake System
WP 0112 00 Parking Brake Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
WP 0113 00 Parking Brake Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1
WP 0114 00 Brake Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1
WP 0115 00 Parking Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1
WP 0116 00 Service Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
WP 0117 00 Service Brake Lines and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1
WP 0118 00 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 Steering Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00-1
WP 0122 00 Steering Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122 00-1
WP 0123 00 Secondary Steering Pump and Electric Motor Maintenance. . . . . . . . . . . . . . . . 0123 00-1
WP 0124 00 Steering Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0124 00-1
iii
TM 5-3805-291-23-2

Page
Number
Steering System-Continued
WP 0125 00 Steering Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00-1
WP 0126 00 Secondary Steering Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1
WP 0127 00 Steering Control Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1
WP 0128 00 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 Windshield Washer Bottle and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
WP 0145 00 Front Windshield Wipers and Motor Replacement. . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
WP 0146 00 Rear Windshield Wiper and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1
WP 0147 00 Data Plates Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0147 00-1
Hydraulic System
WP 0148 00 Hydraulic System Oil Change and Filter Replacement. . . . . . . . . . . . . . . . . . . . 0148 00-1
WP 0149 00 Quick Coupler Diverter Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1
WP 0150 00 Pilot Oil Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1
WP 0151 00 Ride Control Accumulator Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1
WP 0152 00 Tilt Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1
WP 0153 00 Lift Cylinders Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
WP 0154 00 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

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 Arctic Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1
WP 0162 00 Arctic Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00-1
WP 0163 00 Bristles Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1
WP 0164 00 Broom Hose, Manifold, and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
WP 0165 00 Broom Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1
WP 0166 00 Broom Shields and Springs Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-1
WP 0167 00 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 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1
WP 0172 00 Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
WP 0173 00 Crankshaft Vibration Damper and Pulley Replacement . . . . . . . . . . . . . . . . . . . 0173 00-1
WP 0174 00 Front Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
WP 0175 00 Rear Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
WP 0176 00 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
WP 0177 00 Flywheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
WP 0178 00 Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
WP 0179 00 Intake/Exhaust Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1
WP 0180 00 Rocker Arms and Push Rods Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1
WP 0181 00 Engine Oil Pan Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
WP 0182 00 Engine Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1
WP 0183 00 Piston Cooling Jets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00-1
WP 0184 00 Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1
WP 0185 00 Intake Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
WP 0186 00 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

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 Accessory Support Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0194 00-1
WP 0195 00 Cab Wiring Harness and Fuse/Relay Block Replacement . . . . . . . . . . . . . . . . . 0195 00-1
WP 0196 00 Engine Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1
WP 0197 00 Front Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197 00-1
WP 0198 00 Heater and Air Conditioning Wiring Harness Replacement . . . . . . . . . . . . . . . . 0198 00-1
WP 0199 00 Rear Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
WP 0200 00 Secondary Steering Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
Transmission
WP 0201 00 Transmission Control Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . 0201 00-1
WP 0202 00 Transmission Hydraulic Control Relief Valve Replacement . . . . . . . . . . . . . . . 0202 00-1
WP 0203 00 Transmission Modulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1
WP 0204 00 Transmission and Torque Converter Replacement . . . . . . . . . . . . . . . . . . . . . . . 0204 00-1
WP 0205 00 Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1
WP 0206 00 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 Seat Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00-1
WP 0215 00 Braking and Hydraulic Fan Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00-1
WP 0216 00 Piston Pumps (Steering and Implement/Pilot) Replacement. . . . . . . . . . . . . . . . 0216 00-1
WP 0217 00 Brake Charge and Hydraulic Fan Control Manifold Replacement . . . . . . . . . . . 0217 00-1
WP 0218 00 Main Hydraulic Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00-1
vi
TM 5-3805-291-23-2

Page
Number
Refrigeration and Air Conditioning

WP 0219 00 Electrohydraulic Control (Joystick) Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0219 00-1
WP 0220 00 Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00-1
WP 0221 00 Air Conditioning System Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . 0221 00-1
WP 0222 00 Air Conditioning System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-1
WP 0223 00 Refrigerant Hoses, Lines, Valves, Flanges, and Fittings Replacement. . . . . . . . 0223 00-1
WP 0224 00 Inline Refrigerant Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0224 00-1
WP 0225 00 Refrigerant Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00-1
WP 0226 00 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. Electrical Schematics - Key to Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1/(FP-2 Blank)

Figure 1. 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. Electrical Schematics - Lighting Circuit (Sheet 2 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-7/(FP-8 Blank)
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. Electrical Schematics - Implement Circuit (Sheet 7 of 21) . . . . . . . . . . . . . . . . . . . . . . . FP-17/(FP-18 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 10 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-23/(FP-24 Blank)
Figure 1. Electrical Schematics - Implement Circuit (Sheet 11 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-25/(FP-26 Blank)
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

Page
Number
Electrical - Continued
Figure 1. Electrical Schematics - Transmission Circuit (Sheet 14 of 21) . . . . . . . . . . . . . . . . . . . . FP-31/(FP-32 Blank)
Figure 1. Electrical Schematics - Starting Circuit (Sheet 17 of 21). . . . . . . . . . . . . . . . . . . . . . . . . FP-37/(FP-38 Blank)
Figure 1. Electrical Schematics - Starting Circuit (Sheet 18 of 21). . . . . . . . . . . . . . . . . . . . . . . . . FP-39/(FP-40 Blank)
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 Ser-
vices (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, Mainte-
nance 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 dam-
age 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
Maintenance Level Equipment Conditions

Unit Machine parked on level ground (TM 5-3805-291-
Tools and Special Tools 10)
Tool kit, general mechanic’s, automotive (Item 90, Work tool lowered to ground (TM 5-3805-291-10)
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 5-
3805-291-10)
Rag, wiping (Item 35, WP 0233 00)
Strap, tiedown, electrical components (Item 42, WP Drawings Required
0233 00)
TM 5-3805-291-23P, Figure 54
Locknuts (4)
Personnel Required Estimated Time to Complete Task

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 0050 00
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
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
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
REMOVAL - CONTINUED
17. Disconnect cab camera cable (30) from rear connector (24).
18. Disconnect cab camera cable (30) from upper connec-

tor (32) and remove cable from machine.
19. Disconnect camera display cable (31) from upper con-
nector (32).
20. Remove nut (33) and upper connector (32) from panel
(34).
0050 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
21. 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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
24. 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
CLEANING AND INSPECTION
WARNING
• Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low-toxic
• 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 per-
sonnel.
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
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
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
TM 5-3805-291-23-2
11. 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
TM 5-3805-291-23-2
15. 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
18. 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 5-3805-
291-10).
21. Install seven clamps (17) on rear camera cable (7) and
hood (6) with washers (18) and bolts (16).
0050 00-13
TM 5-3805-291-23-2
22. 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
10
TM 5-3805-291-23-2
STARTER REPLACEMENT 0051 00

Removal, Installation, Pinion Clearance Adjustment
INITIAL SETUP
Maintenance Level Personnel Required

Unit MOS 62B, Construction Equipment Repairer (2)
Tools and Special Tools References

WP 0013 00
Tool kit, general mechanic’s, automotive (Item 90,
WP 0232 00) Equipment Conditions
Shop equipment, automotive maintenance and Hood opened (TM 5-3805-291-10)
repair: organizational maintenance, common no. Battery cables disconnected from batteries (WP
1 (Item 70, WP 0232 00) 0096 00)
Lifting equipment, 90-lb capacity Drawings Required
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- TM 5-3805-291-23P, Figure 48

ft (Item 98, WP 0232 00) Estimated Time to Complete Task
2.0 hr
Materials/Parts
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 sole-
noid (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
REMOVAL - CONTINUED
6. Remove nut (11), cover (12), and locknut (13) and dis-
connect 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
REMOVAL - CONTINUED
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during pro-
cedure. 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
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
5. 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
7. 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
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
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

Unit TM 5-3805-291-10
Tools and Special Tools Equipment Conditions

Tool kit, general mechanic’s, automotive (Item 90, Machine parked on level ground (TM 5-3805-291-
WP 0232 00) 10)
Shop equipment, automotive maintenance and Work tool lowered to ground (TM 5-3805-291-10)
repair: organizational maintenance, common no. Parking brake engaged (TM 5-3805-291-10)
1 (Item 70, WP 0232 00) Wheels chocked
Materials/Parts Battery disconnect switch in OFF position (TM 5-
3805-291-10)
0233 00) Drawings Required
Primer coating (Item 34, WP 0233 00) TM 5-3805-291-23P, Figure 172
0052 00-1
TM 5-3805-291-23-2
HVAC BLEND DOOR ACTUATOR REPLACEMENT - CONTINUED 0052 00
REMOVAL
1. Remove three screws (1) from tray (2).
2. Remove screw (3) and tray (2) from machine.
0052 00-2
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
5. 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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
7. 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
TM 5-3805-291-23-2
WARNING
sonnel.
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
3. Position cover assembly (5) on machine.
4. Install screw (11) on cover assembly (5).
0052 00-7
TM 5-3805-291-23-2
5. 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
TM 5-3805-291-23-2
8. Install three washers (7) and screws (6) on cover assembly (5).
9. Install three screws (4) on cover assembly (5).
0052 00-9
TM 5-3805-291-23-2
10. 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
10
TM 5-3805-291-23-2
FUSE, RELAY, CIRCUIT BREAKER, AND ARC SUPPRESSOR REPLACEMENT 0053 00

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

Unit TM 5-3805-291-10
Tools and Special Tools
Equipment Conditions
WP 0232 00) Right rear interior cover removed (interior wiring)
(WP 0138 00)
Materials/Parts
Rag, wiping (Item 35, WP 0233 00) Drawings Required
TM 5-3805-291-23P, Figures 51 and 56
Tiestraps
FUSE REMOVAL 0053 00
WARNING
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 0053 00
FUSE REMOVAL - CONTINUED
0053 00-2
TM 5-3805-291-23-2

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

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
FUSE INSTALLATION - CONTINUED

3. Close access door (1).
427-C1071-1
HOOD TILT RELAY REMOVAL 0053 00

1. Remove three bolts (5), washers (6), and panel (7) from machine.
0053 00-5
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
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
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
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)

2
TM 5-3805-291-23-2
INSTRUMENT CLUSTER REPLACEMENT 0054 00

Removal, Installation
INITIAL SETUP

10)
WP 0232 00) Parking brake engaged (TM 5-3805-291-10)
Shop equipment, automotive maintenance and Wheels chocked
repair: organizational maintenance, common no.
1 (Item 70, WP 0232 00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
Materials/Parts
Drawings Required
Tag, marker (Item 43, WP 0233 00) TM 5-3805-291-23P, Figure 50

WARNING
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 instru-

ment 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).
END OF WORK PACKAGE
0054 00-2
14
TM 5-3805-291-23-2
INSTRUMENT PANELS AND SWITCHES REPLACEMENT 0055 00
Cover: Removal, Installation

Instrument Panel: Removal, Installation
Switch: Removal, Installation
12 Volt Socket: Removal, Installation
INITIAL SETUP

10)
Work tool lowered to ground (TM 5-3805-291-10)
WP 0232 00)
Wheels chocked
Rag, wiping (Item 35, WP 0233 00) 3805-291-10)
Tag, marker (Item 43, WP 0233 00) Drawings Required
Lockwasher TM 5-3805-291-23P, Figures 49 and 50
COVER REMOVAL
WARNING
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
WARNING
4. Remove three screws (5) from center switch panel (6).
427-C0077
5. Disconnect wiring harness (7) from wiring harness

(8).
427-C0078
0055 00-3
TM 5-3805-291-23-2

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

9. Remove two screws (12) from cover (11).
10. Disconnect four wiring harnesses (13) from rocker

switches (14) and messenger (15).
427-C0083
0055 00-5
TM 5-3805-291-23-2
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
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
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
INSTRUMENT PANEL REMOVAL
CAUTION
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
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
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).

427-C1519
3. Install switch knob (20) on rotary switch (21) and

tighten setscrew (19).
4. Install applicable panel.
Rocker Switch Removal 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
SWITCH REMOVAL AND INSTALLATION - CONTINUED
Rocker Switch Installation 0055 00
1. Insert switch (24) in panel.

2. Install applicable panel.
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
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 5-3805-
291-10).
0055 00-13
TM 5-3805-291-23-2
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

System Configuration Parameters, Copy Configuration from ECM, Remove Messenger, Install Messenger, Flash
Programming, Copy Configuration (Program ECM)
INITIAL SETUP

Unit WP 0005 00
WP 0006 00
Machine parked on level ground (TM 5-3805-291-
WP 0232 00)
10)
Adapter, test (Item 3, WP 0232 00) Work tool lowered to ground (TM 5-3805-291-10)
Software kit (Item 75, WP 0232 00) Parking brake engaged (TM 5-3805-291-10)
Test set, electronic systems (MSD) (Item 86, WP Wheels chocked
3805-291-10)
Materials/Parts
Drawings Required
TM 5-3805-291-23P, Figure 49
CAUTION
• Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened compo-
nent 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 Descrip-
tion column gives the name of the parameter. The Unit column displays the configuration parameter units. The TT column dis-
plays 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 param-
eters 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 DEFINITION/ RANGE OF DEFAULT

INPUT
DESCRIPTION LOCATION VALUES VALUE
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 9 characters FLASH

part number
ECM software release 5 characters APR07 FLASH

date MONTH YR
(NOV99)
ECM software group 7 characters FLASH

description
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 pack-
age.
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
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 configura-
tion.
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
REMOVE MESSENGER 0056 00
WARNING
NOTE
• Follow troubleshooting procedures in this manual to ensure that replacing the ECM will correct the
problem.
• Ensure that all diagnostic codes are noted before removing ECM.
1. Carefully pry messenger (1) from console (2).
2. Disconnect messenger (1) from wiring harness (3).
0056 00-4
TM 5-3805-291-23-2
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
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 5-3805-
291-10). Check for active diagnostic codes (WP 0006 00).
COPY CONFIGURATION (PROGRAM ECM) 0056 00
1. Highlight the ECM, then click “OK”.
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”.
291-10). 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
System Configuration Parameters, Copy Configuration from ECM, Remove ECM, Install ECM, Flash Programming,
Copy Configuration (Program ECM)
INITIAL SETUP
Unit WP 0005 00
Tools and Special Tools WP 0006 00
Tool kit, general mechanic’s, automotive (Item 90, WP 0096 00

WP 0232 00)
Adapter, test (Item 3, WP 0232 00)
Software kit (Item 75, WP 0232 00)
10)
Test set, electronic systems (MSD) (Item 86, WP
0232 00) Work tool lowered to ground (TM 5-3805-291-10)
Wrench, torque, dial, 3/8” drive, 300 lb-in. (Item Parking brake engaged (TM 5-3805-291-10)
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
CAUTION
nent life.
NOTE
If mission dictates, you may need to remove an ECM from an engine that is not in service. Refer to the fol-
lowing 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

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
eters 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.

INPUT
DESCRIPTION LOCATION VALUES VALUE
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 9 characters FLASH
Part Number
ECM Software Release 5 characters APR07 FLASH
Date MONTH YR
(NOV99)
Description
Full Load Setting Engine Data Plate 2 characters COPY CONFIG
Full Torque Setting Engine Data Plate 2 characters COPY CONFIG
a. Record all diagnostic codes before replacing ECM (WP 0006 00).
b. Copy configuration of the existing ECM to the MSD. Refer to Copy Configuration from ECM in this work pack-
age.
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.
work package.
0057 00-2
TM 5-3805-291-23-2
CAUTION
NOTE
ET lists Engine ECM as “C11-966H”.
tion.
5. The “No data is available” dialogue box is displayed. Press “Yes” to “Load the data from the ECM”.
NOTE
As the data is loading from the ECM, the “Please wait...” message displays, Then the “Loading data from
7. “The current ECM Replacement data...Load from...” message appears. Click the “OK” button.
NOTE
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
REMOVE ECM 00057 00
WARNING
NOTE
• Follow troubleshooting procedures in this manual to ensure replacing the ECM will correct the prob-
lem.
• 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
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 brack-
ets (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).
0057 00-5
TM 5-3805-291-23-2
FLASH PROGRAMMING
1. Turn battery disconnect switch to ON position (TM 5-3805-291-10).

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

4. Insert flash file CD and read the “read me” file. Note the correct ECM flash file and folder name.
5. Select “WinFlash” from the “Utilities” menu in ET. “WinFlash” will attempt to detect an ECM. Read and close the Win-
Flash Quick Help Guide.
NOTE
verify the file and engine being flashed match. Repeat steps 3 thru 10 until the flash programming is com-
pleted and you see “Flash Completed Successfully”.
NOTE
COPY CONFIGURATION (PROGRAM ECM)

5. “Programming Conflict Warning” will appear. Click “OK.”
0057 00-6
TM 5-3805-291-23-2
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”.
0006 00).
Table 2. Engine ECM Replacement.
PARAMETER VALUE
Engine Fan Control 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 950.0 rpm
Machine Hibernating Engine Low Idle Speed Configuration 6,000.0 rpm
END OF WORK PACKAGE
0057 00-7/(0057 00-8 Blank)

6
TM 5-3805-291-23-2
HOOD TILT ACTUATOR REPLACEMENT 0058 00

INITIAL SETUP

10)
Tool kit, general mechanic’s, automotive (Item 90, Parking brake engaged (TM 5-3805-291-10)
WP 0232 00)
Wheels chocked
Shop equipment, automotive maintenance and
repair: organizational maintenance, common no. Battery disconnect switch in OFF position (TM 5-
1 (Item 70, WP 0232 00) 3805-291-10)
Steering frame lock connected (TM 5-3805-291-
Bracket, link (Item 17, WP 0232 00)
10)
Lifting equipment, 600-lb capacity Hood opened (TM 5-3805-291-10)
Materials/Parts Drawings Required
Rag, wiping (Item 35, WP 0233 00) TM 5-3805-291-23P, Figure 57
MOS 62B, Construction Equipment Repairer (2) 1.0 hr
WARNING
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
REMOVAL - CONTINUED
4. 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
REMOVAL - CONTINUED
7. Disconnect connector (12) from chassis wiring har-
ness (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
4. 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
8. 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
INITIAL SETUP
Unit MOS 62B, Construction Equipment Repairer
References
TM 5-3805-291-10
Control box cover removed (Hood Tilt Relay
Materials/Parts Removal in WP 0053 00)
Strap, tiedown, electrical components (Item 42, WP TM 5-3805-291-23P, Figures 56 and 72

0233 00) Estimated Time to Complete Task
Lockwasher 0.5 hr
WARNING
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 lock-
washer.
483-1530
2. Cut and remove tiedown strap (6) from wiring har-

nesses (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).
END OF WORK PACKAGE
0059 00-2
6
TM 5-3805-291-23-2
IMPLEMENT ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT 0060 00
System Configuration Parameters, Copy Configuration from ECM, Remove ECM, Install ECM, Flash Programming,
Copy Configuration (Program ECM)
INITIAL SETUP
Unit WP 0005 00
WP 0006 00
WP 0096 00
Adapter, test (Item 3, WP 0232 00) Machine parked on level ground (TM 5-3805-291-
10)
0232 00) Parking brake engaged (TM 5-3805-291-10)
Wrench, torque, dial, 3/8” drive, 300 lb-in. (Item Lockout switch set (TM 5-3805-291-10)
97, WP 0232 00)
Wheels chocked
CAUTION
nent life.
NOTE
lowing 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 0060 00
values for the parameters are programmed at the factory. Some parameters (such as Joystick Installation Status or Dump Kick-
out 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.
The push-buttons in the Configuration screen are “Change” or “Print”. The Change push-buttons allow you to change
eters from one ECM to the other. Table 1 lists the system configuration parameters, data range, default value, and unit for the
966H Wheel Loader.
Parameter Definition/
Range of Values Default Value Input
Description location

Equipment ID Serial Number 9 characters Blank Customer Defined
Part Number
Date MONTH YR
(NOV99)
Description
b. Copy configuration of the existing ECM to the MSD. Refer to Copy Configuration from ECM in this work
package.
work package.
0060 00-2
TM 5-3805-291-23-2
CAUTION
tion.
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.
NOTE
0060 00-3
TM 5-3805-291-23-2
REMOVE ECM 00060 00
WARNING
NOTE
lem.
1. 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

4. Disconnect upper cab wiring harness (4) from lower
cab wiring harness (5).
6. Remove four bolts (8), washers (9), spacers (10), rear
washers (11), and ground strap (12) from ECM (7).
8. Remove eight mounts (13) from ECM (7).
INSTALL ECM
1. Install eight mounts (13) on ECM (7).
3. Install ground strap (12), four rear washers (11), spac-
ers (10), washers (9), and bolts (8) on ECM (7).
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.

0060 00-5
TM 5-3805-291-23-2
FLASH PROGRAMMING - CONTINUED 00060 00
NOTE
NOTE
proceed to the Copy Configuration (Program ECM) in this work package.
5. If the “Programming parameter cannot be programmed...” message appears, select “OK”.
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).
END OF WORK PACKAGE
0060 00-6
4
TM 5-3805-291-23-2
MAIN LIGHT SWITCH AND ARCTIC HEATER SWITCH REPLACEMENT 0061 00

Main Light Switch: Removal, Installation
Arctic Heater Switch: Removal, Installation
INITIAL SETUP

10)
Tools and Special Tools Work tool lowered to ground (TM 5-3805-291-10)
WP 0232 00) Wheels chocked

3805-291-10)
Drawings Required
TM 5-3805-291-23P, Figure 56
WARNING
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 5-3805-291-

10).
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 har-
ness (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 5-3805-291-
10).
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
INITIAL SETUP

10)
WP 0232 00)
Wheels chocked
Cleaning compound, solvent, type III (Item 7, WP 3805-291-10)
WARNING
0062 00-1
TM 5-3805-291-23-2
POWER CONVERTER REPLACEMENT - CONTINUED 0062 00
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
TM 5-3805-291-23-2
WARNING
sonnel.
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
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
12
TM 5-3805-291-23-2
POWERTRAIN ELECTRONIC CONTROL MODULE (ECM) REPLACEMENT 0063 00
System Configuration Parameters, Copy Configuration from ECM (Load from ECM), Remove ECM, Install ECM, Flash
Programming, Copy Configuration (Program ECM)
INITIAL SETUP
Unit WP 0005 00

WP 0232 00)
Software kit (Item 75, WP 0232 00) 10)
Test set, electronic systems (MSD) (Item 86, WP Work tool lowered to ground (TM 5-3805-291-10)
0232 00)
Materials/Parts
Wheels chocked
Drawings Required
0233 00) TM 5-3805-291-23P, Figure 53
CAUTION
nent life.
NOTE
lowing 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
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.
eters 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.

DESCRIPTION LOCATION VALUES VALUE INPUT

Equipment ID Serial Number 9 characters Blank Customer Defined
Transmission Serial Transmission Data 8 characters Blank Customer Defined
Number Plate
Part Number
Date MONTH YR
(NOV99)
Description
b. Copy configuration of the existing ECM to the MSD. Refer to Copy Configuration from ECM in this work
package.
work package.
0063 00-2
TM 5-3805-291-23-2
COPY CONFIGURATION FROM ECM
CAUTION
NOTE
ET lists Powertrain ECM as “Transmission ECM”.
tion.
NOTE
As the data is loading from the ECM, the “Please wait...” message displays, Then the “Loading data from
NOTE
0063 00-3
TM 5-3805-291-23-2
REMOVE ECM 00063 00
WARNING
NOTE
lem.
1. Disconnect battery cables from batteries (WP 0096
00).
427-C0135
427-C0136
0063 00-4
TM 5-3805-291-23-2

427-C0137
5. Remove three screws (6) and washers (7) from cover

assembly (5).
427-C0138
0063 00-5
TM 5-3805-291-23-2

6. Loosen two thumbwheel screws (8) on air filter cover
(9) and remove from cover assembly (5).
427-C0139
427-C0140

427-C0141
0063 00-6
TM 5-3805-291-23-2

10. Remove and discard tiedown strap (12) from wiring harness (13).
12. Remove four bolts (15), washers (16), spacers (17), rear washers (18), and ground strap (19) from ECM (14).
14. Remove eight mounts (20) from ECM (14).
427-C0337
INSTALL ECM
1. Install eight mounts (20) on ECM (14).
3. Install ground strap (19), four rear washers (18), ECM (14), spacers (17), washers (16), and bolts (15) on machine.
7. Attach new tiedown strap (12) to wiring harness (13).
10. Tighten two thumbwheel screws (8) on air filter cover (9).
0063 00-7
TM 5-3805-291-23-2
INSTALL ECM - CONTINUED

11. Install three washers (7) and screws (6) on cover
assembly (5).
427-C0138
427-C0137

427-C0136
0063 00-8
TM 5-3805-291-23-2
INSTALL ECM - CONTINUED
15. Install tray (2) and three screws (1).
427-C0135


NOTE
ET lists Powertrain ECM as “Transmission ECM”.
NOTE
0063 00-9
TM 5-3805-291-23-2
FLASH PROGRAMMING - CONTINUED 00063 00
NOTE
2. Ensure the correct ECM is highlighted, Select “Copy Configuration” from the “Service menu”, then select “ECM
0006 00).
0063 00-10
TM 5-3805-291-23-2
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 3 Seconds
Secondary Steering Installed
Command Control Steering Installation Configuration Not Installed
Integrated Braking System Manual Mode Enabled Status 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 Disabled or Not Installed
Monday Security System Bypass Start Time Disabled or Not Installed
Monday Security System Bypass Stop Time Disabled or Not Installed
Tuesday Security System Bypass Start Time Disabled or Not Installed
Tuesday Security System Bypass Stop Time Disabled or Not Installed
Wednesday Security System Bypass Start Time Disabled or Not Installed
Wednesday Security System Bypass Stop Time Disabled or Not Installed
Thursday Security System Bypass Start Time Disabled or Not Installed
Thursday Security System Bypass Stop Time Disabled or Not Installed
Friday Security System Bypass Start Time Disabled or Not Installed
Friday Security System Bypass Stop Time Disabled or Not Installed
Saturday Security System Bypass Start Time Disabled or Not Installed
Saturday Security System Bypass Stop Time Disabled or Not Installed
END OF WORK PACKAGE
0063 00-11/(0063 00-12 Blank)

4
TM 5-3805-291-23-2
STOPLIGHT LIMIT SWITCH MAINTENANCE 0064 00
Removal, Installation, Adjustment
INITIAL SETUP

10)

1 (Item 70, WP 0232 00) 3805-291-10)


WARNING
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.
427-C0096
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-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

INITIAL SETUP

WP 0232 00) Right rear interior panel removed (WP 0138 00)
repair: organizational maintenance, common no. Drawings Required
1 (Item 70, WP 0232 00)
TM 5-3805-291-23P, Figure 55
Materials/Parts
Rag, wiping (Item 35, WP 0233 00) Estimated Time to Complete Task
Tag, marker (Item 43, WP 0233 00) 0.5 hr
WARNING
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

INITIAL SETUP

10)
3805-291-10)
Materials/Parts
Drawings Required

REMOVAL
WARNING
0066 00-1
TM 5-3805-291-23-2
TURNLAMP SWITCH REPLACEMENT - CONTINUED 0066 00
REMOVAL - CONTINUED
1. 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
REMOVAL - CONTINUED
5. 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).
END OF WORK PACKAGE
0066 00-3/(0066 00-4 Blank)

2
TM 5-3805-291-23-2
WINDSHIELD WIPER SWITCHES REPLACEMENT 0067 00

INITIAL SETUP

10)
WP 0232 00)
Wheels chocked
Materials/Parts
Battery disconnect switch in OFF position (TM 5-
Personnel Required Drawings Required
MOS 62B, Construction Equipment Repairer TM 5-3805-291-23P, Figure 49
References Estimated Time to Complete Task
WP 0055 00 0.3 hr
WARNING
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).
END OF WORK PACKAGE
0067 00-2
2
TM 5-3805-291-23-2
BLACKOUT DRIVE LIGHT REPLACEMENT 0068 00

INITIAL SETUP

10)

3805-291-10)
Drawings Required
Lockwasher
TM 5-3805-291-23P, Figure 58
WARNING
0068 00-1
TM 5-3805-291-23-2
BLACKOUT DRIVE LIGHT REPLACEMENT - CONTINUED 0068 00
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
6
TM 5-3805-291-23-2
DOME LAMP REPLACEMENT 0069 00

INITIAL SETUP

Unit TM 5-3805-291-10

WP 0232 00) 10)
Materials/Parts Work tool lowered to ground (TM 5-3805-291-10)
Cleaning compound, solvent, type III (Item 7, WP Parking brake engaged (TM 5-3805-291-10)
0233 00) Wheels chocked
Rag, wiping (Item 35, WP 0233 00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
Personnel Required
MOS 62B, Construction Equipment Repairer 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

REMOVAL - CONTINUED
5. Disconnect electrical connector (6) and remove dome lamp (3) from cab.
WARNING
sonnel.
1. Clean mating surfaces with solvent cleaning compound.
3. Inspect parts for wear, pitting, cracks, or corrosion and replace if necessary.
0069 00-3
TM 5-3805-291-23-2

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
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)

6
TM 5-3805-291-23-2
STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT 0070 00

INITIAL SETUP

10)

3805-291-10)
Drawings Required
TM 5-3805-291-23P, Figure 58
WARNING
0070 00-1
TM 5-3805-291-23-2
STOPLIGHT ASSEMBLY AND BRACKET REPLACEMENT - CONTINUED 0070 00
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
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
5. Remove two bolts (10) and washers (11) from bracket
(9).
6. Remove bracket (9) from machine.
0070 00-4
TM 5-3805-291-23-2
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
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 5-3805-
291-10).
END OF WORK PACKAGE
0070 00-6
12
TM 5-3805-291-23-2
SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT 0071 00

Service Light: Removal, Installation
Turnlamp: Removal, Installation
Service Light, Housing Assembly, and Wiring Harness: Removal, Installation
INITIAL SETUP

Unit WP 0068 00

WP 0232 00) 10)
1 (Item 70, WP 0232 00)
Wheels chocked
Materials/Parts Battery disconnect switch in OFF position
Rag, wiping (Item 35, WP 0233 00) (TM 5-3805-291-10)
Bulbs Drawings Required
Locknut (2) TM 5-3805-291-23P, Figure 58
WARNING
0071 00-1
TM 5-3805-291-23-2
SERVICE LIGHTS AND FRONT TURNLAMP REPLACEMENT - CONTINUED 0071 00
SERVICE LIGHT REMOVAL 0071 00

NOTE
Procedure describes removal of one ser-
vice 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 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 LIGHT REMOVAL - CONTINUED

10. Remove two screws (18), retainer (17), and light hous-
ing (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
TM 5-3805-291-23-2
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
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
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
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
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
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
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
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 hous-
ing (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

Bulb: Removal, Installation
Lamp Housing: Removal, Installation
INITIAL SETUP

10)

3805-291-10)
Drawings Required
TM 5-3805-291-23P, Figure 59
WARNING
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 hous-
ing (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
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
LAMP HOUSING REMOVAL 0072 00

1. Disconnect wiring harness (10) from lamp housing
(4).
427-C0425

(13).
3. Remove lamp housing (4) from bracket (13).
427-C0426
LAMP HOUSING INSTALLATION

1. Install lamp housing (4) on bracket (13).
3. Connect wiring harness (10) to lamp housing (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

INITIAL SETUP

10)
Materials/Parts Wheels chocked
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Battery disconnect switch in OFF position (TM 5-
00) 3805-291-10)
Oil, lubricating, OE/HDO-15/40 (Item 28, WP Hood opened (TM 5-3805-291-10)
0233 00)
O-ring TM 5-3805-291-23P, Figure 61

WARNING
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 turbo-
charger 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


WP 0232 00) 10)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Parking brake engaged (TM 5-3805-291-10)
00) Wheels chocked
Oil, lubricating, OE/HDO-15/40 (Item 28, WP Battery disconnect switch in OFF position (TM 5-
0233 00) 3805-291-10)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Hood opened (TM 5-3805-291-10)
0233 00)
Drawings Required
TM 5-3805-291-23P, Figure 61
O-ring 0.5 hr
WARNING
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).
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
INITIAL SETUP

Unit
10)
Wheels chocked
WP 0232 00)
Materials/Parts 3805-291-10)

TM 5-3805-291-23P, Figure 65
Personnel Required
Estimated Time to Complete Task
WARNING
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 0075 00
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)

4
TM 5-3805-291-23-2
CAMSHAFT SPEED/TIMING SENSOR (SECONDARY) REPLACEMENT 0076 00
INITIAL SETUP

Unit
MOS 62B, Construction Equipment Repairer
Tool kit, general mechanic’s, automotive (Item 90, Equipment Conditions
WP 0232 00) Machine parked on level ground (TM 5-3805-291-
Shop equipment, automotive maintenance and 10)
1 (Item 70, WP 0232 00) Work tool lowered to ground (TM 5-3805-291-10)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- Parking brake engaged (TM 5-3805-291-10)
ft (Item 98, WP 0232 00)
Wheels chocked
Materials/Parts
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Battery disconnect switch in OFF position (TM 5-
00) 3805-291-10)
Oil, lubricating, OE/HDO-15/40 (Item 28, WP
Hood opened (TM 5-3805-291-10)
0233 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Drawings Required
0233 00)
0233 00) (3)
O-ring 0.5 hr
WARNING
0076 00-1
TM 5-3805-291-23-2
CAMSHAFT SPEED/TIMING SENSOR (SECONDARY) REPLACEMENT - CONTINUED 0076 00
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
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).
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
INITIAL SETUP
WP 0232 00) Coolant drained below level of sensor (WP 0041
00)
Materials/Parts
Drawings Required
Antifreeze (Item 1, WP 0233 00) TM 5-3805-291-23P, Figure 61
O-ring 0.5 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.
• When servicing this machine, performing maintenance, or disposing of materials such as engine cool-
ant, 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
•
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 O-
ring and coolant temperature sensor (2) on engine.
2. Connect coolant temperature sensor wiring harness
connector (1) to coolant temperature sensor (2).
3. Run engine until normal operating temperature is
reached (TM 5-3805-291-10).
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
INITIAL SETUP

WP 0232 00) 10)
Materials/Parts
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233
Wheels chocked
00)
Oil, lubricating, OE/HDO-15/40 (Item 28, WP 3805-291-10)
0233 00)
Drawings Required
Oil, lubricating, OEA-30, Arctic (Item 29, WP
0233 00) TM 5-3805-291-23P, Figure 61
O-ring 0.5 hr
WARNING
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 crank-
shaft 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).
END OF WORK PACKAGE
0078 00-2
2
TM 5-3805-291-23-2
ENGINE OIL PRESSURE SENSOR REPLACEMENT 0079 00
INITIAL SETUP


WP 0232 00) 10)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Parking brake engaged (TM 5-3805-291-10)
00) Wheels chocked
Oil, lubricating, OE/HDO-15/40 (Item 28, WP Battery disconnect switch in OFF position (TM 5-
0233 00) 3805-291-10)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Hood opened (TM 5-3805-291-10)
0233 00)
Drawings Required
TM 5-3805-291-23P, Figure 61
O-ring 0.5 hr
WARNING
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 connec-
tor (5) from oil pressure sensor wiring harness (6).
4. Remove engine oil pressure switch (7) and O-ring (8)
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).
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

INITIAL SETUP

10)
repair: organizational maintenance, common no. Wheels chocked
3805-291-10)
Materials/Parts
Rag, wiping (Item 35, WP 0233 00) Hood opened (TM 5-3805-291-10)
Gasket cement (Item 14, WP 0233 00) Drawings Required
TM 5-3805-291-23P, Figure 63
0233 00)

WARNING
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
1. Remove and discard tiedown strap (6) from sending

unit wire (3).
2. Remove nut (4), washer (5), and sending unit connec-
tor (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
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

INITIAL SETUP

10)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Battery disconnect switch in OFF position (TM 5-
0233 00) 3805-291-10)
Oil, lubricating, TO-4 (Item 31, WP 0233 00)
Drawings Required
O-ring (2) TM 5-3805-291-23P, Figure 65

WARNING
0081 00-1
TM 5-3805-291-23-2
FRONT AND REAR AXLE OIL TEMPERATURE SENSORS REPLACEMENT - CONTINUED 0081 00
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).
6. Check for leaks.
END OF WORK PACKAGE
0081 00-2
4
TM 5-3805-291-23-2
FUEL TEMPERATURE SENSOR REPLACEMENT 0082 00
INITIAL SETUP

10)
Diesel fuel, DF-1 (Item 10, WP 0233 00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
Fuel oil, diesel, DF-2 (Item 11, WP 0233 00)
Fuel, turbine, aviation (Item 12, WP 0233 00)
O-ring TM 5-3805-291-23P, Figure 61

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)

427-C0254
0082 00-2
TM 5-3805-291-23-2
FUEL TEMPERATURE SENSOR REPLACEMENT - CONTINUED 0082 00
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).
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)

4
TM 5-3805-291-23-2
HYDRAULIC OIL TEMPERATURE SENSOR REPLACEMENT 0083 00
INITIAL SETUP

WP 0232 00) TM 5-3805-291-10
Materials/Parts Equipment Conditions

Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Air cleaner removed (WP 0030 00)
00)
Hydraulic tank drained (WP 0148 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP TM 5-3805-291-23P, Figure 65
0233 00)
O-ring 3.5 hr
WARNING
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
REMOVAL - CONTINUED
4. 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).
10. Check for leaks.
END OF WORK PACKAGE
0083 00-3/(0083 00-4 Blank)

2
TM 5-3805-291-23-2
INTAKE MANIFOLD AIR TEMPERATURE SENSOR REPLACEMENT 0084 00
INITIAL SETUP

10)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- 3805-291-10)
ft (Item 98, WP 0232 00) Hood opened (TM 5-3805-291-10)
Materials/Parts
Drawings Required
TM 5-3805-291-23P, Figure 61
O-ring

WARNING
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 tem-
perature sensor to 15 ± 4 lb-ft (20 ± 5 Nm).
2. Connect connector (1) to intake manifold air temperature sensor (2).
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

INITIAL SETUP

Unit
10)
Wheels chocked
WP 0232 00)

TM 5-3805-291-23P, Figure 64
Personnel Required
WARNING
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
REMOVAL - CONTINUED
8. 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
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
5. 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
8. 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

INITIAL SETUP
Maintenance Level Materials/Parts - Continued

Unit Strap, tiedown, electrical components (Item 42, WP
0233 00)
Tools and Special Tools O-ring
Tool kit, general mechanic’s, automotive (Item 90, Personnel Required
WP 0232 00)
repair: organizational maintenance, common no. Equipment Conditions
1 (Item 70, WP 0232 00) Machine parked on level ground (TM 5-3805-291-
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- 10)
ft (Item 98, WP 0232 00) Work tool lowered to ground (TM 5-3805-291-10)
Materials/Parts
Wheels chocked
00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
TM 5-3805-291-23P, Figure 65
Rag, wiping (Item 35, WP 0233 00) 0.5 hr
WARNING
0086 00-1
TM 5-3805-291-23-2
PARKING BRAKE OIL PRESSURE SWITCH REPLACEMENT - CONTINUED 0086 00
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
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).
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

INITIAL SETUP

Unit
O-ring
WP 0232 00)
Personnel Required
repair: organizational maintenance, common no. MOS 62B, Construction Equipment Repairer
1 (Item 70, WP 0232 00)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- Equipment Conditions
ft (Item 98, WP 0232 00)
Right side cover removed (WP 0135 00)
Materials/Parts
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Drawings Required
00)
TM 5-3805-291-23P, Figure 65
0233 00)
0233 00) 0.5 hr
WARNING
0087 00-1
TM 5-3805-291-23-2
SERVICE BRAKE OIL PRESSURE SWITCH REPLACEMENT - CONTINUED 0087 00
REMOVAL
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).
6. Install right side cover (WP 0135 00).
END OF WORK PACKAGE
0087 00-2
2
TM 5-3805-291-23-2
STEERING OIL PRESSURE SWITCHES REPLACEMENT 0088 00
INITIAL SETUP

0233 00)
Tools and Special Tools O-ring (2)
WP 0232 00)
ft (Item 98, WP 0232 00) Work tool lowered to ground (TM 5-3805-291-10)
Materials/Parts
Wheels chocked
3805-291-10)
TM 5-3805-291-23P, Figure 65
WARNING
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 O-
rings (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).
7. Check for steering fluid leaks.
END OF WORK PACKAGE
0088 00-2
6
TM 5-3805-291-23-2
TILT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT 0089 00

INITIAL SETUP

10)
WP 0232 00)
Wheel chocked

0233 00) TM 5-3805-291-23P, Figure 64
WARNING
0089 00-1
TM 5-3805-291-23-2
TILT KICKOUT POSITION SENSOR AND MOUNTING REPLACEMENT - CONTINUED 0089 00
REMOVAL
1. Remove four bolts (2), washers (3), and cover (1)
from machine.
0089 00-2
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
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)

2
TM 5-3805-291-23-2
TORQUE CONVERTER OIL TEMPERATURE SENSOR REPLACEMENT 0090 00
INITIAL SETUP

References
WP 0232 00) TM 5-3805-291-10

Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Transmission oil drained (WP 0100 00)
00)
0233 00)
TM 5-3805-291-23P, Figure 62
O-ring 0.5 hr
WARNING
0090 00-1
TM 5-3805-291-23-2
TORQUE CONVERTER OIL TEMPERATURE SENSOR REPLACEMENT - CONTINUED 0090 00
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).
7. Check for leaks.
END OF WORK PACKAGE
0090 00-2
4
TM 5-3805-291-23-2
TORQUE CONVERTER OUTPUT SPEED SENSOR REPLACEMENT 0091 00
INITIAL SETUP

References
WP 0232 00) TM 5-3805-291-10
Shop equipment, automotive maintenance and Equipment Conditions

1 (Item 70, WP 0232 00) Left side cover removed (WP 0135 00)

Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 TM 5-3805-291-23P, Figure 62
00)
Seal 1.0 hr
WARNING
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). A
4. Turn torque converter output speed sensor (10) coun-
terclockwise 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).
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
INITIAL SETUP

Unit
0233 00)
Personnel Required
WP 0232 00) MOS 62B, Construction Equipment Repairer
References
Materials/Parts
TM 5-3805-291-10
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Equipment Conditions
00)
Transmission oil drained (WP 0100 00)
Drawings Required
0233 00)
TM 5-3805-291-23P, Figure 62
WARNING
0092 00-1
TM 5-3805-291-23-2
TRANSMISSION OIL TEMPERATURE SENSORS REPLACEMENT - CONTINUED 0092 00
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
TM 5-3805-291-23-2
TRANSMISSION OIL TEMPERATURE SENSORS REPLACEMENT - CONTINUED 0092 00
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).
END OF WORK PACKAGE
0092 00-3/(0092 00-4 Blank)

4
TM 5-3805-291-23-2
TRANSMISSION OUTPUT SPEED SENSOR REPLACEMENT 0093 00
INITIAL SETUP

10)
3805-291-10)
Materials/Parts
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Hood opened (TM 5-3805-291-10)
00)
Drawings Required
TM 5-3805-291-23P, Figure 62
Seal (2)

WARNING
0093 00-1
TM 5-3805-291-23-2
TRANSMISSION OUTPUT SPEED SENSOR REPLACEMENT - CONTINUED 0093 00
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
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

INITIAL SETUP
Maintenance Level Equipment Conditions - Continued

Unit Work tool lowered to ground (TM 5-3805-291-10)
Tools and Special Tools Parking brake engaged (TM 5-3805-291-10)
Tool kit, general mechanic’s, automotive (Item 90, Wheel chocked
WP 0232 00)
Rag, wiping (Item 35, WP 0233 00) Hood opened (TM 5-3805-291-10)
Personnel Required
Drawings Required
TM 5-3805-291-23P, Figure 67
10) 0.3 hr
WARNING
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

INITIAL SETUP

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

3805-291-10)

MOS 62B, Construction Equipment Repairer TM 5-3805-291-23P, Figure 66
10) 0.3 hr
WARNING
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

INITIAL SETUP

Unit
Battery compartment door opened (TM 5-3805-
Tools and Special Tools 291-10)
Tool kit, general mechanic’s, automotive (Item 90, Ladder removed (WP 0134 00)
WP 0232 00)
Materials/Parts TM 5-3805-291-23P, Figure 68
Personnel Required
WARNING
Do not smoke, use open flame, make sparks, or create other ignition sources around batteries. If a bat-
tery 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.
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. 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.
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
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.
0096 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
8. 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
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).
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
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.
WARNING
death to personnel.
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).
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
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).
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).
END OF WORK PACKAGE
0096 00-5/(0096 00-6 Blank)

12
TM 5-3805-291-23-2
BATTERY CABLES REPLACEMENT 0097 00

INITIAL SETUP

Unit Left rear fender removed (WP 0137 00)
Tools and Special Tools Left upper chassis guard panel removed (WP 0133
00)
WP 0232 00) Battery cables disconnected from battery discon-
nect switch (WP 0098 00)
Materials/Parts Battery cables disconnected from batteries (WP
Rag, wiping (Item 35, WP 0233 00) 0096 00)

MOS 62B, Construction Equipment Repairer TM 5-3805-291-23P, Figures 70 and 167
References Estimated Time to Complete Task

TM 5-3805-291-10 2.0 hr
0097 00-1
TM 5-3805-291-23-2
BATTERY CABLES REPLACEMENT - CONTINUED 0097 00
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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
0097 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
6. 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).
483-1343
0097 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
11. 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).
483-1546
0097 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
18. 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
INSTALLATION
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
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
10. 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
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
TM 5-3805-291-23-2
20. Install two clamps (4), spacers (5), large washers (1), small washers (3), and bolts (2) on battery box (6).

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).
END OF WORK PACKAGE
0097 00-11/(0097 00-12 Blank)

4
TM 5-3805-291-23-2
BATTERY DISCONNECT SWITCH REPLACEMENT 0098 00

INITIAL SETUP

Unit TM 5-3805-291-10
Battery cables disconnected from batteries (WP
WP 0232 00)
0096 00)
Materials/Parts
Drawings Required
Lockwasher (4) TM 5-3805-291-23P, Figure 70

WARNING
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 0098 00
REMOVAL - CONTINUED
2. Pull back boots (4) and remove two nuts (7) and lock-
washers (8) from battery disconnect switch (6). Dis-
card lockwashers.
3. Remove two cables (5) from battery disconnect switch
(6).
0098 00-2
TM 5-3805-291-23-2
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 lock-
washer.
0098 00-3
TM 5-3805-291-23-2
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.

8. Verify correct battery disconnect switch operation (TM 5-3805-291-10).
END OF WORK PACKAGE
0098 00-4
2
TM 5-3805-291-23-2
NATO SLAVE RECEPTACLE REPLACEMENT 0099 00

INITIAL SETUP

Unit TM 5-3805-291-10
Battery cables disconnected from batteries and
WP 0232 00)
NATO slave receptacle (WP 0097 00)
Materials/Parts
Drawings Required

WARNING
0099 00-1
TM 5-3805-291-23-2
NATO SLAVE RECEPTACLE REPLACEMENT - CONTINUED 0099 00
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
6
TM 5-3805-291-23-2
TRANSMISSION SERVICE 0100 00

Draining, Filling
INITIAL SETUP

References
WP 0232 00) WP 0105 00
Nipple, pipe (Item 41, WP 0232 00) 10)

Cleaning compound, solvent, type III (Item 7, WP Parking brake engaged (TM 5-3805-291-10)
0233 00)
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Wheels chocked
Oil, lubricating, OEA-30, Arctic (Item 29, WP 3805-291-10)
0233 00)
Oil, lubricating, TO-4 (Item 31, WP 0233 00) Drawings Required
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) Estimated Time to Complete Task
O-ring (2) 1.0 hr
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 ordi-
nances. Ensure all spills are cleaned up.
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
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 mate-
rial. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-venti-
lated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury
NOTE
Check bottom of strainer to ensure cor-
rect 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
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.
WARNING
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
FILLING - CONTINUED
10. Slowly operate transmission controls (TM 5-3805-291-10).
11. Check transmission for leaks.
13. Check transmission fluid level (TM 5-3805-291-10).
END OF WORK PACKAGE
0100 00-5/(0100 00-6 Blank)

4
TM 5-3805-291-23-2
SHIFT LEVER REPLACEMENT 0101 00

INITIAL SETUP

Unit TM 5-3805-291-10
WP 0232 00) Steering wheel removed (WP 0122 00)
Materials/Parts Steering column cover removed (WP 0121 00)

TM 5-3805-291-23P, Figure 85
0233 00)

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
REMOVAL - CONTINUED
2. 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 5-3805-291-
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

INITIAL SETUP

Unit Spill containment unit, hazardous material (Item
41, WP 0233 00)
Tools and Special Tools Tag, marker (Item 43, WP 0233 00)
Tool kit, general mechanic’s, automotive (Item 90, O-ring (4)
WP 0232 00) Seal
Shop equipment, automotive maintenance and Personnel Required
1 (Item 70, WP 0232 00)
Materials/Parts
Cleaning compound, solvent, type III (Item 7, WP 10)
0233 00) Side covers removed from machine (WP 0135 00)
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Oil cooler lines removed from oil cooler (WP 0205
00) 00)

0233 00) TM 5-3805-291-23P, Figure 91
Oil, lubricating, TO-4 (Item 31, WP 0233 00) Estimated Time to Complete Task
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 open-
ings 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 pol-
icy 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).
4. Remove clamp (10) from tube (6).
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 O-
rings and seal.
8. Disconnect test probe (20) from tube (7).
427-C0338
0102 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
9. 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
sonnel.
1. Clean all parts and surfaces with solvent cleaning compound.

0102 00-3
TM 5-3805-291-23-2
INSTALLATION
NOTE
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
4. 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).
10. Instal clamp (10) on tube (6).
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).
WARNING

17. Start machine (TM 5-3805-291-10).
18. Run engine until operating temperature is reached and verify correct operation of machine (TM 5-3805-291-10).
END OF WORK PACKAGE
0102 00-5/(0102 00-6 Blank)

4
TM 5-3805-291-23-2
TRANSMISSION OIL FILLER TUBE REPLACEMENT 0103 00

INITIAL SETUP
Unit Rag, wiping (Item 35, WP 0233 00)

Tools and Special Tools 41, WP 0233 00)
Gasket (2)
WP 0232 00) Personnel Required
Materials/Parts
References
Cap set, protective (Item 6, WP 0233 00)
TM 5-3805-291-10
0233 00) Equipment Conditions
Transmission oil drained (WP 0100 00)
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233
00) Drawings Required
Oil, lubricating, TO-4 (Item 31, WP 0233 00) 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 transmis-
sion 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
sonnel.
1. Clean all parts and mating surfaces with solvent cleaning compound.
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).
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
INITIAL SETUP

Unit
41, WP 0233 00)
O-ring (12)
Shop equipment, automotive maintenance and MOS 62B, Construction Equipment Repairer
1 (Item 70, WP 0232 00)
ft (Item 98, WP 0232 00)
Materials/Parts Parking brake engaged (TM 5-3805-291-10)

Wheels chocked
3805-291-10)
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Steering frame lock connected (TM 5-3805-291-
00) 10)
0233 00)
TM 5-3805-291-23P, Figures 65 and 92
CAUTION
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
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
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.
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
WARNING
sonnel.
INSTALLATION
NOTE
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
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
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
WARNING

23. Start machine (TM 5-3805-291-10).
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

INITIAL SETUP

10)
Materials/Parts
Cleaning compound, solvent, type III (Item 7, WP Work tool lowered to ground (TM 5-3805-291-10)
0233 00)
00) Wheels chocked
Oil, lubricating, OEA-30, Arctic (Item 29, WP Battery disconnect switch in OFF position (TM 5-
0233 00) 3805-291-10)
Drawings Required
Spill containment unit, hazardous material (Item TM 5-3805-291-23P, Figure 92
41, WP 0233 00)
Filter element Estimated Time to Complete Task
O-ring (2) 0.2 hr
0105 00-1
TM 5-3805-291-23-2
TRANSMISSION OIL FILTER ELEMENT REPLACEMENT - CONTINUED 0105 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
• 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.
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
sonnel.
INSTALLATION
NOTE
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).
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
INITIAL SETUP

Unit
41, WP 0233 00)
Tools and Special Tools Strap, tiedown, electrical components (Item 42, WP
0233 00)
Tool kit, general mechanic’s, automotive (Item 90, Tag, marker (Item 43, WP 0233 00)
WP 0232 00)
O-ring (36)
Personnel Required
1 (Item 70, WP 0232 00)
Materials/Parts
Hydraulic filter access door opened (TM 5-3805-
Cap set, protective (Item 6, WP 0233 00) 291-10)
Hydraulic system pressure relieved (TM 5-3805-
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 291-10)
00)
0233 00)
TM 5-3805-291-23P, Figure 92
Oil, lubricating, TO-4 (Item 31, WP 0233 00) Estimated Time to Complete Task
WARNING
hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escap-
ing hydraulic fluid under pressure can penetrate the skin, causing 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
CAUTION
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 0106 00
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
7. Remove six fittings (11) from machine. Remove and
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).
12. Close access door (TM 5-3802-291-10).
END OF WORK PACKAGE
0106 00-3/(0106 00-4 Blank)

4
TM 5-3805-291-23-2
CENTER DRIVE SHAFT (SLIP JOINT) REPLACEMENT 0107 00

INITIAL SETUP

Unit Grease, multipurpose (Item 18, WP 0233 00)
Tools and Special Tools Rag, wiping (Item 35, WP 0233 00)
Shop equipment, automotive maintenance and MOS 62B, Construction Equipment Repairer (2)
1 (Item 70, WP 0232 00) Equipment Conditions
Wrench, torque, click, ratcheting, 1/2” drive, 250 Steering frame lock connected (TM 5-3805-291-
lb-ft (Item 99, WP 0232 00) 10)
Grease, molybdenum (Item 17, WP 0233 00) 1.0 hr
0107 00-1
TM 5-3805-291-23-2
CENTER DRIVE SHAFT (SLIP JOINT) REPLACEMENT - CONTINUED 0107 00
REMOVAL
WARNING
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
sonnel.
1. Clean U-joints and mating surfaces with solvent cleaning compound.

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
machine with steering frame lock connected. Failure to lock steering frame lock into the stowed posi-
tion before operating can result in loss of steering and injury or death to personnel.
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

INITIAL SETUP

WP 0232 00) Steering frame lock connected (TM 5-3805-291-
repair: organizational maintenance, common no. Parking brake removed (WP 0113 00)
1 (Item 70, WP 0232 00)

00) Estimated Time to Complete Task
0108 00-1
TM 5-3805-291-23-2
FRONT DRIVE SHAFT CARRIER BEARING REPLACEMENT - CONTINUED 0108 00
REMOVAL
WARNING
cedure. 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).
WARNING

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

INITIAL SETUP

Unit Grease, multipurpose (Item 18, WP 0233 00)

WP 0232 00) MOS 62B, Construction Equipment Repairer (2)
repair: organizational maintenance, common no. References
1 (Item 70, WP 0232 00) TM 5-3805-291-10
Wrench, torque, click, ratcheting, 1/2” drive, 250 Equipment Conditions
lb-ft (Item 99, WP 0232 00)
Drive shaft carrier bearing removed (WP 0108 00)
Lifting equipment, 60-lb capacity
Drawings Required
Materials/Parts
TM 5-3805-291-23P, Figure 94
Grease, molybdenum (Item 17, WP 0233 00) 3.0 hr
0109 00-1
TM 5-3805-291-23-2
FRONT DRIVE SHAFT REPLACEMENT - CONTINUED 0109 00
REMOVAL
WARNING
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
sonnel.
1. Clean U-joints and mating surfaces with solvent cleaning compound.

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).
• Lubricate all grease fittings with multipurpose grease.
• Splines should be lubricated with molybdenum or multipurpose grease with machine fully articu-
lated.
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

INITIAL SETUP

1 (Item 70, WP 0232 00)
Wrench, torque, click, ratcheting, 1/2” drive, 250 Parking brake engaged (TM 5-3805-291-10)
lb-ft (Item 99, WP 0232 00)
Wheels chocked
Materials/Parts
Drawings Required
0233 00) TM 5-3805-291-23P, Figure 94
Grease, molybdenum (Item 17, WP 0233 00)
Grease, multipurpose (Item 18, WP 0233 00) Estimated Time to Complete Task
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 care-
fully remove rear drive shaft (1) from machine.
427-C0453
0110 00-1
TM 5-3805-291-23-2
REAR DRIVE SHAFT REPLACEMENT - CONTINUED 0110 00
WARNING
sonnel.
1. Clean U-joints with a dry rag.
2. Clean drive shaft with solvent.
0110 00-2
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 all grease fittings with
multipurpose grease.
• Lubricate splines with molybdenum 427-C0453
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)

2
TM 5-3805-291-23-2
DIFFERENTIAL AND FINAL DRIVE OIL CHANGE 0111 00

Differential and Final Drive Oil Change
INITIAL SETUP

WP 0232 00) 10)
1 (Item 70, WP 0232 00) Parking brake engaged (TM 5-3805-291-10)

Axle oil additive (Item 3, WP 0233 00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
TM 5-3805-291-23P, Figures 95 and 97
41, WP 0233 00) 1.0 hr
0111 00-1
TM 5-3805-291-23-2
DIFFERENTIAL AND FINAL DRIVE OIL CHANGE - CONTINUED 0111 00
DIFFERENTIAL AND FINAL DRIVE OIL CHANGE
CAUTION
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.
• 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 427-C0341
8. Start machine (TM 5-3805-291-10).

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.
END OF WORK PACKAGE
0111 00-2
6
TM 5-3805-291-23-2
PARKING BRAKE ACTUATOR REPLACEMENT 0112 00

Removal, Cleaning and Inspection, Installation, Adjustment
INITIAL SETUP

WP 0232 00)
repair: organizational maintenance, common no. Machine parked on level ground (TM 5-3805-291-
1 (Item 70, WP 0232 00) 10)
Cap set, protective (Item 6, WP 0233 00) Parking brake engaged (TM 5-3805-291-10)
Cleaning compound, solvent, type III (Item 7, WP Wheels chocked
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 3805-291-10)
00) Steering frame lock connected (TM 5-3805-291-
Oil, lubricating, OE/HDO-15/40 (Item 28, WP 10)
0233 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP 291-10)
0233 00)
Drawings Required
O-ring Estimated Time to Complete Task

Pin, cotter 1.0 hr
WARNING
ing hydraulic fluid under pressure can penetrate skin, causing injury to personnel.
CAUTION
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 park-

ing brake actuator (3). Discard O-ring.
2. Remove clevis (4) and cotter pin (5) from yoke assem-
bly (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
sonnel.
0112 00-2
TM 5-3805-291-23-2
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).
9. Check for leaks.
WARNING
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
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. 427-C1994
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-C1995
0112 00-4
TM 5-3805-291-23-2
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 park-
ing 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.
END OF WORK PACKAGE
0112 00-5/(0112 00-6 Blank)

8
TM 5-3805-291-23-2
PARKING BRAKE MAINTENANCE 0113 00
INITIAL SETUP
References
TM 5-3805-291-10
WP 0232 00)
Center drive shaft removed (WP 0107 00)
repair: organizational maintenance, common no. Drawings Required
1 (Item 70, WP 0232 00) TM 5-3805-291-23P, Figure 100
Pump, hydraulic ram, hand driven (Item 57, WP Estimated Time to Complete Task
0232 00) 4.0 hr
Wrench, torque, click, ratcheting, 1/2” drive, 250
lb-ft (Item 99, WP 0232 00)
Materials/Parts

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
REMOVAL - CONTINUED
7. 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
REMOVAL - CONTINUED
11. 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
REMOVAL - CONTINUED
15. Remove two nuts (22), washers (23), and pins (24)
from plate assembly (21).
16. Remove bracket (25) from plate assembly (21).
427-C0126
WARNING
sonnel.
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
5. 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
9. 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). 427-C0122
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-C0121
427-C0120
END OF WORK PACKAGE
0113 00-7/(0113 00-8 Blank)

10
TM 5-3805-291-23-2
BRAKE ACCUMULATOR MAINTENANCE 0114 00

Removal, Cleaning and Inspection, Installation, Testing, Charging
INITIAL SETUP

Test Equipment Tag, marker (Item 43, WP 0233 00)
Test stand, automotive (Item 87, WP 0232 00)
O-ring (12)
0232 00) Personnel Required
MOS 62B, Construction Equipment Repairer (2)
10)
1 (Item 70, WP 0232 00)
Adapter, test (Item 3, WP 0232 00) Work tool lowered to ground (TM 5-3805-291-10)
Hose (Item 33, WP 0232 00) Parking brake engaged (TM 5-3805-291-10)
Charging kit, pressure (Item 23, WP 0232 00)
Wheels chocked
0233 00)
Nitrogen technical dry cylinder (Item 25, WP 0233 Brake system pressure relieved (TM 5-3805-291-
00) 10)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Drawings Required

00)
Oil, lubricating, OE/HDO-15/40 (Item 28, WP TM 5-3805-291-23P, Figures 101 and 102
0233 00)
0233 00) 3.0 hr
0114 00-1
TM 5-3805-291-23-2
BRAKE ACCUMULATOR MAINTENANCE - CONTINUED 0114 00
WARNING
• 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.
CAUTION
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
REMOVAL - CONTINUED
2. 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
WARNING
sonnel.
0114 00-4
TM 5-3805-291-23-2
INSTALLATION
1. Place two brake accumulators (7) and clamps (11) on panel (12).
2. Install two washers (10) and bolts (9) on clamps (11).
NOTE
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
5. Close door (3) and install two washers (2) and bolts
(1) on door assembly (3).
427-C1042
WARNING

7. Check hydraulic fluid level (TM 5-3805-291-10).
0114 00-6
TM 5-3805-291-23-2
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.
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
TM 5-3805-291-23-2
CHARGING
WARNING
• 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
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
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 pre-
charge.
12. Turn valve handle (21) completely in clockwise direc-

tion.
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

INITIAL SETUP

WP 0232 00)
repair: organizational maintenance, common no. MOS 62B, Construction Equipment Repairer (2)
1 (Item 70, WP 0232 00)
References
Materials/Parts
TM 5-3805-291-10
Cleaning compound, solvent, type III (Item 7, WP Equipment Conditions
0233 00) Right rear fender removed (WP 0137 00)
Oil, lubricating, OE/HDO-15/40 (Item 28, WP TM 5-3805-291-23P, Figure 102
0233 00)
0233 00) 2.0 hr
0115 00-1
TM 5-3805-291-23-2
PARKING BRAKE CONTROL VALVE REPLACEMENT - CONTINUED 0115 00
REMOVAL
CAUTION
NOTE
• Use a container to catch any fluid that may drain from hoses or system. Dispose of fluid IAW local policy
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
sonnel.
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).
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
INITIAL SETUP

WP 0232 00)
1 (Item 70, WP 0232 00)
Quick disconnect tool - 06 (Item 58, WP 0232 00) References
Quick disconnect tool - 08 (Item 59, WP 0232 00) TM 5-3805-291-10
Materials/Parts
Front guard removed (WP 0133 00)
0233 00) Hydraulic tank drained (WP 0148 00)
Drawings Required
00)
0233 00)
0233 00) 2.0 hr
WARNING
CAUTION
0116 00-1
TM 5-3805-291-23-2
SERVICE BRAKE CONTROL VALVE REPLACEMENT - CONTINUED 0116 00
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
sonnel.
0116 00-2
TM 5-3805-291-23-2
SERVICE BRAKE CONTROL VALVE REPLACEMENT - CONTINUED 0116 00
CLEANING AND INSPECTION - CONTINUED

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.
6. Install front guard (WP 0133 00).
8. Apply pressure to brake pedal several times.
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)

14
TM 5-3805-291-23-2
SERVICE BRAKE LINES AND HOSES REPLACEMENT 0117 00

INITIAL SETUP

References
WP 0232 00) WP 0112 00
Shop equipment, automotive maintenance and WP 0114 00
1 (Item 70, WP 0232 00) WP 0116 00
Materials/Parts WP 0137 00
Cap set, protective (Item 6, WP 0233 00) WP 0159 00
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Equipment Conditions
00)
Oil, lubricating, OE/HDO-15/40 (Item 28, WP Hydraulic filter access door opened (TM 5-3805-
0233 00) 291-10)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Hydraulic tank drained (WP 0148 00)
0233 00)
Strap, tiedown, electrical components (Item 42, WP TM 5-3805-291-23P, Figure 102
0233 00)
Tag, marker (Item 43, WP 0233 00) Estimated Time to Complete Task
O-ring (61) 3.0 hr
WARNING
CAUTION
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
REMOVAL - CONTINUED
5. 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
REMOVAL - CONTINUED
9. Disconnect hose (14) from T (20). Remove and
discard O-ring (21).
10. Disconnect hose (22) from T (20). Remove and

11. Remove T (20) from elbow (24). Remove and discard

O-ring (25).
12. Remove elbow (24) from machine. Remove and

13. Disconnect tube (22) from fitting (27) and remove

hose from machine. Remove and discard O-ring (28).
427-C1348
14. Remove fitting (27) from machine. Remove and
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-C1349
0117 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
20. Disconnect hose (36) from valve (39) and remove
21. Disconnect hose (41) from valve (39). Remove and
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

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
REMOVAL - CONTINUED
28. 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

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. Disconnect hose (68) from fitting (69). Remove and

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
427-C1353
35. Disconnect hose (74) from hydraulic tank

(WP 0159 00) and remove hose from machine.
0117 00-6
TM 5-3805-291-23-2
REMOVAL - CONTINUED
36. Disconnect hose (68) from coupling (76). Remove and discard O-ring (77).
37. Disconnect hose (78) from fitting (79). Remove and discard O-ring (80).
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. Disconnect hose (78) from hydraulic tank (WP 0159 00) and remove hose from machine.
427-C1354
0117 00-7
TM 5-3805-291-23-2
REMOVAL - CONTINUED
42. 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. Remove fitting (88) from machine. Remove and discard O-ring (90).
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. Remove fitting (97) from machine. Remove and discard O-ring (99).
427-C1355
0117 00-8
TM 5-3805-291-23-2
INSTALLATION
NOTE
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.
7. Install new O-ring (89) and elbow (86) on fitting (88).
8. Install fitting (88) on machine.
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
TM 5-3805-291-23-2
16. 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. Install new O-ring (65) and connect hose (53) to
fitting (64).
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
24. 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.
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
32. 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. Install new O-ring (28) and connect hose (22) to fit-
ting (27).
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
42. 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
46. 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.
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

INITIAL SETUP

10)
WP 0232 00)
Wheels chocked
0233 00) Brake control valve unbolted from brake pedal (WP
Rag, wiping (Item 35, WP 0233 00) 0116 00)
Pin Drawings Required
Retaining ring TM 5-3805-291-23P, Figure 103
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
sonnel.
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
INITIAL SETUP
Maintenance Level Materials/Parts

Unit Cleaning compound, solvent, type III (Item 7, WP
0233 00)
Tool kit, general mechanic’s, automotive (Item 90, Rag, wiping (Item 35, WP 0233 00)
WP 0232 00)
Personnel Required
repair: organizational maintenance, common no. MOS 62B, Construction Equipment Repairer (2)
2 (Item 71, WP 0232 00)
Pin, shoulder, headless (Item 48, WP 0232 00) Equipment Conditions
Puller, hydraulic (Item 53, WP 0232 00) Steering frame lock connected (TM 5-3805-291-
Pump, hydraulic ram, hand-driven (Item 56, WP 10)
0232 00)
Front fender removed (WP 0136 00)
Repair tool, special (Item 63, WP 0232 00)
Stand assembly (Item 78, WP 0232 00) Drawings Required
Wrench, torque, click, ratcheting, 1/2” drive, 250 TM 5-3805-291-23P, Figures 104 and 105
lb-ft (Item 99, WP 0232 00)
Lifting equipment, 2,250-lb capacity Estimated Time to Complete Task
Multiplier, torque 1.5 hr
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
REMOVAL - CONTINUED
2. 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
WARNING
sonnel.
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 (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
2. 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 427-C0193
3. Install front fender (WP 0136 00).
WARNING
END OF WORK PACKAGE
0119 00-4
4
TM 5-3805-291-23-2
WHEEL AND TIRE ASSEMBLY (REAR) REPLACEMENT 0120 00
INITIAL SETUP

Unit
0233 00)
Personnel Required

repair: organizational maintenance, common no. Steering frame lock connected (TM 5-3805-291-
2 (Item 71, WP 0232 00) 10)
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
Lifting equipment, 2,250-lb capacity
Wood block, 4 x 4 1.5 hr
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
WARNING
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
sonnel.

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
WARNING
END OF WORK PACKAGE
0120 00-3/(0120 00-4 Blank)

10
TM 5-3805-291-23-2
STEERING COLUMN REPLACEMENT 0121 00
INITIAL SETUP

WP 0118 00
WP 0232 00)
1 (Item 70, WP 0232 00)
Turnlamp lever removed (WP 0066 00)
Materials/Parts
Transmission shift lever removed (WP 0101 00)
0233 00) Steering frame lock connected (TM 5-3805-291-
Rag, wiping (Item 35, WP 0233 00) 10)

0233 00)
TM 5-3805-291-23P, Figure 106
Gasket Estimated Time to Complete Task
Snap ring 2.0 hr
0121 00-1
TM 5-3805-291-23-2
STEERING COLUMN REPLACEMENT - CONTINUED 0121 00
REMOVAL
NOTE
• 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.
1. 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
REMOVAL - CONTINUED
3. 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
REMOVAL - CONTINUED
6. 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
REMOVAL - CONTINUED
13. 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
REMOVAL - CONTINUED
17. 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
sonnel.
0121 00-6
TM 5-3805-291-23-2
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
7. 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-C1149
427-C1150
0121 00-8
TM 5-3805-291-23-2
15. 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 col-
umn cowls.
427-C1153
0121 00-9
TM 5-3805-291-23-2
17. 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
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.
21. Verify correct steering column operation (TM 5-3805-291-10).
END OF WORK PACKAGE
0121 00-10
4
TM 5-3805-291-23-2
STEERING WHEEL REPLACEMENT 0122 00
INITIAL SETUP

Tool kit, general mechanic’s, automotive (Item 90, 10)
WP 0232 00)
Shop equipment, automotive maintenance and Parking brake engaged (TM 5-3805-291-10)
Wheels chocked
1 (Item 70, WP 0232 00)
Puller kit, steering wheel (Item 54, WP 0232 00) 3805-291-10)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- Drawings Required
ft (Item 98, WP 0232 00)
TM 5-3805-291-23P, Figure 106
Materials/Parts Estimated Time to Complete Task
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 0122 00
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
TM 5-3805-291-23-2
STEERING WHEEL REPLACEMENT - CONTINUED 0122 00
REMOVAL - CONTINUED
4. 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

Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
INITIAL SETUP

Unit Tag, marker (Item 43, WP 0233 00)
Tools and Special Tools Gasket
WP 0232 00)
Personnel Required
1 (Item 70, WP 0232 00) References
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- TM 5-3805-291-10
ft (Item 98, WP 0232 00)
Materials/Parts
Left side panel removed (WP 0133 00)
Left side ladder removed (WP 0134 00)
00) Hydraulic tank drained (WP 0148 00)
Oil, lubricating, OE/HDO-15/40 (Item 28, WP Drawings Required
0233 00)
TM 5-3805-291-23P, Figures 75 and 107
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
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 steer-
ing pump (6), and gasket (16) from electric motor (4).
Discard gasket.
427-C0525
WARNING
sonnel.
ASSEMBLY
CAUTION
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
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). Con-
nect 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).
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
10
TM 5-3805-291-23-2
STEERING HOSES, LINES, AND FITTINGS REPLACEMENT 0124 00
INITIAL SETUP

Tool kit, general mechanic’s, automotive (Item 90, TM 5-3805-291-10

WP 0232 00) WP 0125 00
Materials/Parts WP 0127 00

WP 0159 00
00) Equipment Conditions
Oil, lubricating, OE/HDO-15/40 (Item 28, WP Hydraulic tank drained (WP 0148 00)
0233 00)
Cab removed (WP 0132 00)
O-ring (24) 4.0 hr
WARNING
CAUTION
0124 00-1
TM 5-3805-291-23-2
STEERING HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED 0124 00
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.
8. Disconnect hose (3) from elbow (16) and remove hose and clip (8) from machine.
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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
427-C0528
0124 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
16. Remove four O-rings (27 thru 30) from lines (31 thru 34). Discard O-rings.
17. Disconnect hose (35) from line (31).
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).
24. Disconnect line (33) from fitting (41).
26. Disconnect line (34) from elbow (43) and remove line from machine.
28. Disconnect hose (45) from elbow (43).
30. Remove elbow (43) from machine.
32. Disconnect hose (45) and fitting from steering control valve (WP 0127 00) and remove hose and clip (49) from machine.
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
REMOVAL - CONTINUED
427-C0529
0124 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
35. Disconnect line (53) from fitting (54).
37. Disconnect line (53) from fitting (56) and remove line from machine.
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
REMOVAL - CONTINUED
427-C1853
INSTALLATION
NOTE
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).
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).
0124 00-7
TM 5-3805-291-23-2
12. 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).
15. Route hose (45) through clip (49) and connect hose to steering control valve (WP 0127 00).
16. Install elbow (43) on machine.
18. Install new O-ring (44) in line (34) and connect line to elbow (43).
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).
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
25. Install five new O-rings (22 thru 26) in elbows (12, 14, 16, 18, and 20) and install elbows on machine.
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).
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
37. Install cab (WP 0132 00).
38. Fill hydraulic tank to correct level (WP 0148 00).
END OF WORK PACKAGE
0124 00-10
6
TM 5-3805-291-23-2
STEERING CYLINDERS REPLACEMENT 0125 00
INITIAL SETUP

WP 0232 00)
1 (Item 70, WP 0232 00)
Lifting equipment, 150-lb capacity Equipment Conditions
Materials/Parts Hydraulic tank drained (WP 0148 00)
Cap set, protective (Item 6, WP 0233 00) Rear fenders removed (WP 0137 00)
Cleaning compound, solvent, type III (Item 7, WP Steering frame lock connected (TM 5-3805-291-
0233 00) 10)
Drawings Required
00)
0233 00)
0233 00) 3.0 hr
WARNING
0125 00-1
TM 5-3805-291-23-2
STEERING CYLINDERS REPLACEMENT - CONTINUED 0125 00
CAUTION
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
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
WARNING
sonnel.
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 427-C0531
steering cylinder (3).
0125 00-4
TM 5-3805-291-23-2
4. 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).
WARNING
END OF WORK PACKAGE
0125 00-5/(0125 00-6 Blank)

4
TM 5-3805-291-23-2
SECONDARY STEERING VALVE REPLACEMENT 0126 00
INITIAL SETUP

Tool kit, general mechanic’s, automotive (Item 90, Gasket (2)
WP 0232 00)
O-ring (2)
repair: organizational maintenance, common no. Personnel Required
2 (Item 71, WP 0232 00)
Materials/Parts
References
TM 5-3805-291-10
0233 00) Equipment Conditions
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Cab removed (WP 0132 00)
0233 00)
0233 00) 3.0 hr
WARNING
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.
• Hydraulic oils used in performance of maintenance can be very slippery. Immediately wipe up any
0126 00-1
TM 5-3805-291-23-2
SECONDARY STEERING VALVE REPLACEMENT - CONTINUED 0126 00
CAUTION
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). 427-C0526

9. Remove two pressure switches (1) from secondary
steering valve (16).
WARNING
sonnel.
0126 00-2
TM 5-3805-291-23-2
SECONDARY STEERING VALVE REPLACEMENT - CONTINUED 0126 00
INSTALLATION
NOTE
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).
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
Removal, Disassembly, Assembly, Installation
INITIAL SETUP

Unit Oil, lubricating, OEA-30, Arctic (Item 29, WP
0233 00)
WP 0232 00)
O-ring (19)
Shop equipment, automotive maintenance and Seal (3)
1 (Item 70, WP 0232 00) Personnel Required
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- MOS 62B, Construction Equipment Repairer (2)
ft (Item 98, WP 0232 00) Equipment Conditions
Lifting equipment, 150-lb capacity Hydraulic system pressure relieved (TM 5-3805-
291-10)
Materials/Parts
Drawings Required
00) TM 5-3805-291-23P, Figure 114
0233 00) 3.0 hr
WARNING
0127 00-1
TM 5-3805-291-23-2
STEERING CONTROL VALVE MAINTENANCE - CONTINUED 0127 00
CAUTION
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
REMOVAL - CONTINUED
3. 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).
427-C1174
0127 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
9. 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 steer-
ing 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 con-
dition 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 per-
sonnel.
427-C1176
NOTE
Steering control valve assembly weighs 95 lb (43 kg).
13. With assistance, remove steering control valve assem-
bly (5) from frame (25).
0127 00-4
TM 5-3805-291-23-2
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
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
WARNING
death to personnel.
NOTE
Steering control valve assembly weighs 95 lb (43 kg).
0127 00-6
TM 5-3805-291-23-2
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
INSTALLATION
1. With assistance, position steering control valve assem-
bly (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).

NOTE
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
6. 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).
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
12. Install three new O-rings (4) and fittings (3) on steer-
ing 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).

18. Check for steering system leaks.
END OF WORK PACKAGE
0127 00-10
4
TM 5-3805-291-23-2
STEERING METERING PUMP REPLACEMENT 0128 00

INITIAL SETUP

WP 0232 00) O-ring (10)
1 (Item 70, WP 0232 00) MOS 62B, Construction Equipment Repairer
Quick disconnect tool - 06 (Item 58, WP 0232 00) Equipment Conditions

Quick disconnect tool - 08 (Item 59, WP 0232 00) Steering frame lock connected (TM 5-3805-291-
Materials/Parts 10)
Cap set, protective (Item 6, WP 0233 00) Hydraulic system pressure relieved (TM 5-3805-
Cleaning compound, solvent, type III (Item 7, WP 291-10)
0233 00) Front guard on cab removed (WP 0133 00)
0233 00)
0233 00) 2.5 hr
WARNING
CAUTION
0128 00-1
TM 5-3805-291-23-2
STEERING METERING PUMP REPLACEMENT - CONTINUED 0128 00
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
TM 5-3805-291-23-2
STEERING METERING PUMP REPLACEMENT - CONTINUED 0128 00
WARNING
sonnel.
INSTALLATION
NOTE
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).
WARNING
6. Run engine and verify correct operation of steering system (TM 5-3805-291-10).
7. Check for leaks.
END OF WORK PACKAGE
0128 00-3/(0128 00-4 Blank)

22
TM 5-3805-291-23-2
REMOTE LUBRICATION LINES, HOSES, AND FITTINGS REPLACEMENT 0129 00

INITIAL SETUP

WP 0232 00)
Cleaning compound, solvent, type III (Item 7, WP Steering frame lock connected (TM 5-3805-291-
0233 00) 10)
Grease, automotive and artillery, GAA (Item 15,
WP 0233 00) Cab removed (rear lines only) (WP 0132 00)

Tag, marker (Item 43, WP 0233 00) 0.5 hr ea
0129 00-1
TM 5-3805-291-23-2
REMOTE LUBRICATION LINES, HOSES, AND FITTINGS REPLACEMENT - CONTINUED 0129 00
REMOVAL
CAUTION
NOTE
1. Remove fittings (1, 2, and 3) from adapters
(4, 5, and 6).
0129 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
2. 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
REMOVAL - CONTINUED
5. 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
REMOVAL - CONTINUED
6. Disconnect line (7) from elbow (19). Remove line
from machine.
7. Remove elbow (19) from pivot pin (20).

from machine.
427-C1239
0129 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
from machine.
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
REMOVAL - CONTINUED
14. 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
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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
22. 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
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
TM 5-3805-291-23-2
WARNING
sonnel.
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
12. 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
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
TM 5-3805-291-23-2
21. 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
26. 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
TM 5-3805-291-23-2
28. Install elbow (23) on pivot pin (24).

29. Connect line (9) to elbow (23).
427-C1240

427-C1239
0129 00-16
TM 5-3805-291-23-2

0129 00-17
TM 5-3805-291-23-2
34. Install nine clips (18), six washers (17), and nuts (16)
on machine.
427-C1237
0129 00-18
TM 5-3805-291-23-2
35. 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
36. 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
TM 5-3805-291-23-2
38. 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).
WARNING
42. Close hood (TM 5-3805-291-10).
END OF WORK PACKAGE
0129 00-21/(0129 00-22 Blank)

4
TM 5-3805-291-23-2
COUNTERWEIGHT REPLACEMENT 0130 00

INITIAL SETUP

10)
1 (Item 70, WP 0232 00) 3805-291-10)
Lifting equipment, 3,700-lb capacity Brake/stoplight and brackets removed (WP 0070
00)
Materials/Parts
Mechanic’s wire TM 5-3805-291-23P, Figure 116

0130 00-1
TM 5-3805-291-23-2
COUNTERWEIGHT REPLACEMENT - CONTINUED 0130 00
REMOVAL - CONTINUED
1. Remove bolt (1) and washer (2) from wiring harness
(3).
NOTE
Attach nonelectrical wire to wiring har-
ness 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

(Right Door, Left Upper Door, Left Lower Door)
INITIAL SETUP

WP 0232 00) 10)
1 (Item 70, WP 0232 00)
Wheels chocked
Drawings Required
0233 00)
Plastic washer (4) Estimated Time to Complete Task

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
REMOVAL - CONTINUED
WARNING
NOTE
• Upper left door weighs 66 lb (30 kg).
• Raise latch to unlock upper left door from lower left door.
2. 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
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
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
4. 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
7. 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
10. 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
13. 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
16. 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
sonnel.
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
3. 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
6. 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
9. 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
12. 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 cor-
ner of lower left door (7).
427-C1087
0131 00-14
TM 5-3805-291-23-2
15. 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
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
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
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

INITIAL SETUP

Direct Support Oil, lubricating, OE/HDO-15/40 (Item 28, WP
0233 00)
Tools and Special Tools Oil, lubricating, OEA-30, Arctic (Item 29, WP
0233 00)
WP 0232 00) Rag, wiping (Item 35, WP 0233 00)
0233 00)
1 (Item 70, WP 0232 00) Tag, marker (Item 43, WP 0233 00)
O-ring (4)
lb-ft (Item 99, WP 0232 00) Personnel Required
Quick disconnect tool - 06 (Item 58, WP 0232 00) MOS 62B, Construction Equipment Repairer (3)
Quick disconnect tool - 08 (Item 59, WP 0232 00) Equipment Conditions

10)
Multiplier, torque Drain coolant (WP 0041 00)
Materials/Parts Drain hydraulic tank (WP 0148 00)

Evacuate A/C system (WP 0222 00)
Drawings Required
0233 00) TM 5-3805-291-23P, Figures 120 and 122
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Estimated Time to Complete Task
00) 8.0 hr
0132 00-1
TM 5-3805-291-23-2
CAB REMOVE/INSTALL - CONTINUED 0132 00
REMOVAL
WARNING
CAUTION
NOTE
• Tag wires and hoses prior to removal to ensure correct installation.
• Front guard weighs 53 lb (24 kg).
1. With assistance, remove 10 bolts (1), washers (2), and

front guard (3) from machine.
0132 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
2. 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)

0132 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
5. 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.
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
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
REMOVAL - CONTINUED
14. 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
REMOVAL - CONTINUED
17. 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
REMOVAL - CONTINUED
18. 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
WARNING
sonnel.
2. 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.
0132 00-9
TM 5-3805-291-23-2
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
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
7. 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
11. 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
13. 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).
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
18. 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
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).
24. Fill coolant (WP 0041 00).
WARNING
25. Secure steering frame lock in stowed position (TM 5-

3805-291-10).
26. Start machine (TM 5-3805-291-10).
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).
END OF WORK PACKAGE
0132 00-16
34
TM 5-3805-291-23-2
CHASSIS GUARD, SIDE PANELS, HYDRAULIC SERVICE BOX, CIRCUIT

BREAKER BOX, AND BATTERY BOX REPLACEMENT 0133 00

INITIAL SETUP
Maintenance Level References - Continued

Unit WP 0098 00
WP 0104 00
WP 0232 00) WP 0114 00
1 (Item 70, WP 0232 00) WP 0148 00
Lifting equipment, 150-lb capacity WP 0161 00
Materials/Parts
Strap, tiedown, electrical components (Item 42, WP Ladders removed (WP 0134 00)
0233 00)
Cotter pin Rear fender removed (WP 0137 00)
Personnel Required Side cover removed (WP 0135 00)

Drawings Required
References
TM 5-3805-291-23P, Figures 56, 69, 115, 122, 123,
WP 0053 00 and 165
WP 0059 00
WP 0096 00 Estimated Time to Complete Task
WP 0097 00 0.5 hr ea
WARNING
REMOVAL
0133 00-1
TM 5-3805-291-23-2

BREAKER BOX, AND BATTERY BOX REPLACEMENT - CONTINUED 0133 00
Front Guard 0133 00
NOTE
With assistance, remove 10 bolts (1), washer (2), and
front guard (3) from machine.
0133 00-2
TM 5-3805-291-23-2

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

REMOVAL - CONTINUED
Side Panels - Continued 0133 00
3. Remove two nuts (7), two bolts (8), four washers (9),
and lower panel (10) from machine.
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

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

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

REMOVAL - CONTINUED
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

REMOVAL - CONTINUED
10. Remove three bolts (24) and washers (25).

11. Position panel (26) aside.
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.
0133 00-8
TM 5-3805-291-23-2

REMOVAL - CONTINUED
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

REMOVAL - CONTINUED
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

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

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

REMOVAL - CONTINUED
Battery Box - Continued 0133 00
0133 00-13
TM 5-3805-291-23-2

REMOVAL - CONTINUED
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

REMOVAL - CONTINUED
10. Remove two bolts (73), washers (74), and door (75)
from battery box (60).
0133 00-15
TM 5-3805-291-23-2

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.
1. Use stand assembly to support lift arms (76).
0133 00-16
TM 5-3805-291-23-2

REMOVAL - CONTINUED
Front Cover Main Hydraulic Control Valve - Continued 0133 00
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
TM 5-3805-291-23-2

WARNING
sonnel.

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

INSTALLATION-CONTINUED
Front Cover Main Hydraulic Control Valve - Continued 0133 00

6. Start machine (TM 5-3805-291-10) in order to raise lift arms (76) and remove all tooling.
0133 00
Battery Box 0133 00
1. Install door (75), two washers (74), and bolts (73) on

battery box (60).
0133 00-19
TM 5-3805-291-23-2

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

3. Install two washers (70) and bolts (69) on battery box
(60).
0133 00-21
TM 5-3805-291-23-2

4. Install two washers (67) and bolts (68) on battery box (60).
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

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

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
0133 00-24
TM 5-3805-291-23-2

WARNING
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
0133 00-25
TM 5-3805-291-23-2

7. Install four washers (38) and bolts (37) on hydraulic

service box (19).
NOTE
Install new tiedown straps.
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

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

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

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

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.
0133 00-30
TM 5-3805-291-23-2

Side Panels - Continued 0133 00
3. Install upper panel (6), five washers (5), and bolts (6)
on machine.
0133 00-31
TM 5-3805-291-23-2

Front Guard 0133 00
WARNING
NOTE
1. With assistance, install front guard (3), 10 washers (2),
2. Install side cover (WP 0135 00).
4. Install ladders (WP 0134 00).
0133 00-32
TM 5-3805-291-23-2

Front Guard - Continued 0133 00
WARNING

6. Start machine (TM 5-3805-291-10).
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

INITIAL SETUP

WP 0232 00)
Wheels chocked
1 (Item 70, WP 0232 00)
Wood block, 4 x 4 in. 3805-291-10)
Cleaning compound, solvent, type III (Item 7, WP TM 5-3805-291-23P, Figures 128 and 166
0134 00-1
TM 5-3805-291-23-2
HANDRAILS, LADDERS, AND STEPS REPLACEMENT - CONTINUED 0134 00
REMOVAL
WARNING
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.
0134 00-2
TM 5-3805-291-23-2
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
REMOVAL - CONTINUED
WARNING
NOTE
• Ladder assembly weighs 21 lb (10 kg).
• Step assembly weighs 27 lb (12 kg).
7. 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).
plates (28), two belts (29) from step (24) and step (30).
0134 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
WARNING
NOTE
Rear step assembly weighs 27 lb (12 kg).
11. Remove four bolts (31), washers (32), and two brack-
ets (33) from machine.
12. Remove four bolts (34), washers (35), and step (36)
from two brackets (33).
plates (40), two belts (41) from step (36) and step (42).
427-C1063
0134 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
14. 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
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 gog-
gles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Fail-
ure 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 pres-
sure 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.
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
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
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
WARNING
NOTE
Ladder assembly weighs 28 lb (13 kg).
10. Install step (15), two belts (14), four plates (13), spac-
ers (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
WARNING
NOTE
Rear handrail weighs 26 lb (12 kg).
12. Install rear handrail (6), six washers (5), and bolts (4) on machine.
NOTE
Front handrail weighs 13 lb (6 kg).
14. Install front handrail (3), three washers (2), bolts (1)
on machine.
END OF WORK PACKAGE
0134 00-11/(0134 00-12 Blank)

8
TM 5-3805-291-23-2
SIDE COVERS AND HOOD REPLACEMENT 0135 00

INITIAL SETUP


WP 0232 00)
Bracket, link (Item 17, WP 0232 00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
Materials/Parts 10)
Cleaning compound, solvent, type III (Item 7, WP Drawings Required

0233 00) TM 5-3805-291-23P, Figures 57 and 123
Locknut (4) 3.0 hr
0135 00-1
TM 5-3805-291-23-2
SIDE COVERS AND HOOD REPLACEMENT - CONTINUED 0135 00
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
TM 5-3805-291-23-2
REMOVAL
8. Remove plug (11) from engine hood (9).
9. Attach link bracket and lifting equipment to support

engine hood (9).
0135 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
10. Remove lock pin (12) and pin (14) from hood tilt actu-
ator (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
REMOVAL - CONTINUED
12. With assistance, remove engine hood (9) from
machine.
WARNING
sonnel.
0135 00-5
TM 5-3805-291-23-2
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
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
TM 5-3805-291-23-2
7. 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).
WARNING

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

INITIAL SETUP

10)
Bracket, link (Item 15, WP 0232 00) (2) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
Lifting equipment, 90-lb capacity Steering frame lock connected (TM 5-3805-291-
10)
Materials/Parts
Drawings Required
TM 5-3805-291-23P, Figure 131
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
sonnel.
0136 00-2
TM 5-3805-291-23-2
FRONT FENDERS REPLACEMENT - CONTINUED 0136 00
INSTALLATION
WARNING
NOTE
Fender weighs 60 lb (27 kg).

(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.
WARNING
END OF WORK PACKAGE
0136 00-3/(0136 00-4 Blank)

4
TM 5-3805-291-23-2
REAR FENDERS REPLACEMENT 0137 00

INITIAL SETUP

Handrails removed (WP 0134 00)
WP 0232 00)
Shop equipment, automotive maintenance and Steering frame lock connected (TM 5-3805-291-
repair: organizational maintenance, common no. 10)
1 (Item 70, WP 0232 00) Windshield washer bottle removed (right-hand
Bracket, link (Item 15, WP 0232 00) (3) fender only) (WP 0144 00)
Drawings Required
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).
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
REMOVAL - CONTINUED
3. 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
sonnel.
INSTALLATION
WARNING
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
3. 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).
WARNING
END OF WORK PACKAGE
0137 00-4
10
TM 5-3805-291-23-2
CAB LINERS AND DOME LIGHT REPLACEMENT 0138 00
INITIAL SETUP

Unit TM 5-3805-291-10

WP 0232 00)
Upper instrument panel removed (WP 0055 00)
repair: organizational maintenance, common no. Cab sun visor and mirrors removed (WP 0139 00)
1 (Item 70, WP 0232 00)
Camera monitor removed from machine (WP 0048
Materials/Parts 00)
Drawings Required
0233 00)
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
REMOVAL - CONTINUED
2. 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
REMOVAL - CONTINUED
7. 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
REMOVAL - CONTINUED
11. 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
REMOVAL - CONTINUED
17. 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
WARNING
sonnel.

INSTALLATION
1. Position floor covering (20) and install in cab.
2. Position headliner (19) in cab and install six clips (18) on headliner.
427-C1074 427-C1067
0138 00-6
TM 5-3805-291-23-2
3. 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
9. 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
13. 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
16. 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).
END OF WORK PACKAGE
0138 00-10
4
TM 5-3805-291-23-2
CAB SUN VISOR AND MIRRORS REPLACEMENT 0139 00
INITIAL SETUP
Unit WP 0138 00

10)
WP 0232 00)
1 (Item 70, WP 0232 00)
Wheels chocked
3805-291-10)
Detergent, general purpose, liquid (Item 9, WP
0233 00)
Drawings Required

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
REMOVAL - CONTINUED
2. 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
WARNING
sonnel.
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
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

INITIAL SETUP


WP 0232 00) 10)
1 (Item 70, WP 0232 00)
Wheels chocked
0233 00)
Drawings Required
0233 00) TM 5-3805-291-23P, Figure 132
0140 00-1
TM 5-3805-291-23-2
SEAT ASSEMBLY REPLACEMENT - CONTINUED 0140 00
REMOVAL
CAUTION
NOTE
• Use a container to catch any fluid that may drain from hoses or system. Dispose of oil IAW local
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
REMOVAL - CONTINUED
5. 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 sus-

pension assembly (11), as shown.
7. Remove bolt (12) and two washers (13) from suspen-

sion assembly (11).
8. With assistance, slide seat assembly (10) forward and

remove from suspension assembly (11).
427-C0318
9. Remove seat assembly (10) from machine.
10. Remove suspension assembly (11) from machine.
0140 00-3
TM 5-3805-291-23-2
WARNING
sonnel.
3. Inspect all parts for damage, wear, pitting, cracks or corrosion and replace if necessary.
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 suspen-
sion assembly (11) and install bolt (12) and two wash-
ers (13) on suspension assembly.
427-C0318
0140 00-4
TM 5-3805-291-23-2
3. 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
5. Position armrest assembly (7) on seat and install four
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

INITIAL SETUP

10)
WP 0232 00)
Wheels chocked
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
sonnel.

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

INITIAL SETUP

10)
WP 0232 00)
Wheels chocked
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
sonnel.
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).
END OF WORK PACKAGE
0142 00-2
4
TM 5-3805-291-23-2
TOOLBOX REPLACEMENT 0143 00

INITIAL SETUP


Tool kit, general mechanic’s, automotive (Item 90, Upper left front ladder removed from machine (WP
WP 0232 00) 0130 00)
Shop equipment, automotive maintenance and Drawings Required
1 (Item 70, WP 0232 00) TM 5-3805-291-23P, Figure 136
Bracket, link (Item 15, WP 0232 00) (2) Estimated Time to Complete Task
Lifting equipment, 100-lb capacity 1.0 hr
Materials/Parts
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.
WARNING
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
sonnel.

INSTALLATION
WARNING
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.
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).
END OF WORK PACKAGE
0143 00-3/(0143 00-4 Blank)

12
TM 5-3805-291-23-2
WINDSHIELD WASHER BOTTLE AND HOSES REPLACEMENT 0144 00
INITIAL SETUP

Hose removed from front wiper arm (if removing
hoses) (WP 0145 00)
WP 0232 00)
Hose removed from rear wiper arm (if removing
Materials/Parts hoses) (WP 0146 00)
Cleaning compound, solvent, type III (Item 7, WP Steering column cover removed (WP 0121 00)
0233 00)
0233 00) TM 5-3805-291-23P, Figures 138 and 139
Tiedown strap (5) 2.0 hr
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
• Hinged access cover must be
opened.
• Tag wires and hoses before remov-
ing.
1. 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 har-
ness 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
REMOVAL - CONTINUED
machine.
8. Disconnect hoses (5 and 6) from clip (11).
0144 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
9. 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
REMOVAL - CONTINUED
11. Remove and discard five tiedown straps (15) from
hose (6) under cab.
12. Disconnect hose (16) from fitting (17).
0144 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
14. Remove nut (18), washer (19), and fitting (17) from
machine.
0144 00-6
TM 5-3805-291-23-2
REMOVAL - CONTINUED
15. Remove grommet (20) and hose (6) from machine.
WARNING
sonnel.

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
2. Install fitting (17), washer (19), and nut (18) on
machine.
3. Connect hose (6) to fitting (17).
0144 00-8
TM 5-3805-291-23-2
5. Install five new tiedown straps (15) on hose (6) under
cab.
0144 00-9
TM 5-3805-291-23-2
6. 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
8. 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
11. 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).
WARNING

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

INITIAL SETUP

Unit
References
TM 5-3805-291-10
Tool kit, general mechanic’s, automotive (Item 90, Equipment Conditions
WP 0232 00)
Instrument panel removed (WP 0055 00)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb-
Drawings Required
ft (Item 98, WP 0232 00)
TM 5-3805-291-23P, Figure 139
Materials/Parts
0145 00-1
TM 5-3805-291-23-2
FRONT WINDSHIELD WIPERS AND MOTOR REPLACEMENT - CONTINUED 0145 00
REMOVAL
NOTE
Mark position of wiper to aid in installation.
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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
4. 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
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
TM 5-3805-291-23-2
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).
0145 00-5
TM 5-3805-291-23-2
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
6
TM 5-3805-291-23-2
REAR WINDSHIELD WIPER AND MOTOR REPLACEMENT 0146 00

INITIAL SETUP

10)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- 3805-291-10)
ft (Item 98, WP 0232 00) Seat moved forward (TM 5-3805-291-10)
Materials/Parts
Drawings Required
TM 5-3805-291-23P, Figure 139
Gasket

0146 00-1
TM 5-3805-291-23-2
REAR WINDSHIELD WIPER AND MOTOR REPLACEMENT - CONTINUED 0146 00
REMOVAL
1. Remove three screws (1) and two screws (2) from interior panel (3).
2. Remove interior panel (3) from machine.
0146 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
3. 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.
427-C0249
0146 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
7. 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
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
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
Data Plate (Solid Rivet) Replacement, Data Plate (Blind Rivet) Replacement, Decal Replacement
INITIAL SETUP

WP 0232 00) 10)
3805-291-10)
Rivet, blind (as required) Estimated Time to Complete Task
Rivet, solid (as required) 0.2 hr ea
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. Dis-
card 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.
427-C2062
END OF WORK PACKAGE
0147 00-3/(0147 00-4 Blank)

6
TM 5-3805-291-23-2
HYDRAULIC SYSTEM OIL CHANGE AND FILTER REPLACEMENT 0148 00

Drain and Filter Removal, Cleaning and Inspection, Fill and Filter Installation
INITIAL SETUP

Filter element (2)
10)
Nipple, pipe (Item 41, WP 0232 00)
Materials/Parts Parking brake engaged (TM 5-3805-291-10)
00)
Drawings Required
TM 5-3805-291-23P, Figures 155 and 163
0233 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Estimated Time to Complete Task
0233 00) 0.5 hr
0148 00-1
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
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
WARNING
sonnel.
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
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
END OF WORK PACKAGE
0148 00-5/(0148 00-6 Blank)

6
TM 5-3805-291-23-2
QUICK COUPLER DIVERTER VALVE REPLACEMENT 0149 00

INITIAL SETUP

O-ring (9)
10)
Materials/Parts
0233 00)
00)
Drawings Required
TM 5-3805-291-23P, Figure 150
0233 00)
0233 00) 1.0 hr
0149 00-1
TM 5-3805-291-23-2
QUICK COUPLER DIVERTER VALVE REPLACEMENT - CONTINUED 0149 00
REMOVAL
WARNING
• 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.
CAUTION
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).
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
REMOVAL - CONTINUED
427-C1155
0149 00-3
TM 5-3805-291-23-2
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 gog-
gles. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Fail-
ure 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 pres-
sure 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.
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
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
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

Removal, Cleaning and Inspection, Installation, Test and Charge
INITIAL SETUP

Unit Cleaning compound, solvent, type III (Item 7, WP
0233 00)
Test Equipment
Nitrogen technical dry cylinder (Item 25, WP 0233
Test stand, automotive (Item 87, WP 0232 00) 00)
Hose (Item 33, WP 0232 00) Rag, wiping (Item 35, WP 0233 00)
Tools and Special Tools Personnel Required

Tool kit, general mechanic’s, automotive (Item 90, MOS 62B, Construction Equipment Repairer
WP 0232 00)
Shop equipment, automotive maintenance and Front access cover removed (WP 0218 00)
1 (Item 70, WP 0232 00) Steering frame lock connected (TM 5-3805-291-
10)
Charging kit, pressure (Item 23, WP 0232 00)
Pin, shoulder, headless (Item 48, WP 0232 00) 291-10)
Saddle assembly, lifting block (Item 65, WP 0232
Drawings Required
00)
TM 5-3805-291-23P, Figure 152
Stand assembly (Item 79, WP 0232 00)
Tubing assembly set, nonmetallic (Item 93, WP Estimated Time to Complete Task
0232 00) 3.0 hr
0150 00-1
TM 5-3805-291-23-2
PILOT OIL ACCUMULATOR MAINTENANCE - CONTINUED 0150 00
REMOVAL
WARNING
WARNING
NOTE
• Stand capacity must be 5,200 lb (2,359 kg).
1. Raise lift arms (1) and support with stand assembly.
427-C0596
0150 00-2
TM 5-3805-291-23-2
2. Unscrew pilot oil accumulator (2) from block
assembly.
427-C0597
0150 00-3
TM 5-3805-291-23-2
WARNING
sonnel.
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).
WARNING

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
TEST AND CHARGE - CONTINUED
Test - Continued
2. 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).
3. Stop engine (TM 5-3805-291-10).
4. Turn engine start switch to ON position but do not start engine (TM 5-3805-291-10).
5. Move implement levers through full range of travel to relieve any pressure in system (TM 5-3805-291-10).
6. Turn engine start switch to OFF position (TM 5-3805-291-10).
7. Move joystick to lower boom. Pressure on dial gage should decrease steadily.
8. 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-C1141 427-C1142
0150 00-5
TM 5-3805-291-23-2
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).
ing 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

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:
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.
427-C1140-1
e. If reading on pressure gage (10) decreases, open
valve (9) until pressure gage (11) readings are
equal and do not change.
10. Close valve (9) on nitrogen cylinder.
0150 00-7
TM 5-3805-291-23-2

WARNING

12. Pressurize hydraulic system (TM 5-3805-291-10).
END OF WORK PACKAGE
0150 00-8
12
TM 5-3805-291-23-2
RIDE CONTROL ACCUMULATOR MAINTENANCE 0151 00

Removal, Cleaning and Inspection, Installation, Discharging/Charging, Testing Ride Control Diverter Valve
INITIAL SETUP

WP 0232 00)
Personnel Required
1 (Item 70, WP 0232 00) Equipment Conditions
Bracket, link (Item 15, WP 0232 00) Machine parked on level ground (TM 5-3805-291-
Charging kit, pressure (Item 23, WP 0232 00) 10)
Test stand, automotive (Item 87, WP 0232 00) (3) Work tool lowered to ground (TM 5-3805-291-10)
Lifting equipment, 150-lb capacity Parking brake engaged (TM 5-3805-291-10)
Cap set, protective (Item 6, WP 0233 00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
10)
Nitrogen technical dry cylinder (Item 25, WP 0233
00) Hydraulic system pressure relieved (TM 5-3805-
291-10)
0233 00)
0233 00) 3.0 hr
0151 00-1
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
CAUTION
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
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 accu-
mulator 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
WARNING
sonnel.
2. Dry parts with compressed air. Do not wipe parts with rags, which may leave lint deposits on surfaces.
INSTALLATION
NOTE
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
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 con-
trol 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
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. Park the machine on a smooth, level surface.
b. Stop the engine and remove the key.
c. Block the wheels and install the steering frame lock.
0151 00-6
TM 5-3805-291-23-2
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
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
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).
ing 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
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 addi-
tional 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).
427-C1591-1
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.
0151 00-9
TM 5-3805-291-23-2
NOTE
• To ensure accumulator nitrogen charge is correct, accumulator piston must be at bottom of accumula-
tor cylinder. Nitrogen pressure varies with temperature. To obtain most accurate nitrogen charge, tem-
perature 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
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)
WARNING

26. Pressurize hydraulic system (TM 5-3805-291-10).
0151 00-11
TM 5-3805-291-23-2
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. Start engine (TM 5-3805-291-10).
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 prob-
able 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
12
TM 5-3805-291-23-2
TILT CYLINDERS REPLACEMENT 0152 00

INITIAL SETUP

Unit Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233
00)
0233 00)
WP 0232 00)
0233 00)
1 (Item 70, WP 0232 00) Rag, wiping (Item 35, WP 0233 00)
Adapter, shaft puller (Item 11, WP 0232 00) Tag, marker (Item 43, WP 0233 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)
Personnel Required
Pump, hydraulic ram, hand-driven (Item 56, WP
0232 00) MOS 62B, Construction Equipment Repairer (2)
Stud, plain (Item 82, WP 0232 00) Equipment Conditions
Washer, flat (Item 94, WP 0232 00) Tilt kickout position sensor removed (WP 0089 00)
Lifting equipment, 960-lb capacity Hydraulic system pressure relieved (TM 5-3805-
Materials/Parts 291-10)
Cap set, protective (Item 6, WP 0233 00) Drawings Required

Cleaning compound, solvent, type III (Item 7, WP TM 5-3805-291-23P, Figure 153
0233 00)
Grease, automotive and artillery, GAA (Item 15, Estimated Time to Complete Task
WP 0233 00) 4.0 hr
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
CAUTION
NOTE
0152 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
flange halves (3).
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
REMOVAL - CONTINUED
3. Disconnect grease hose assembly (7) from tilt cylinder
(6).

flange halves (10).
5. Disconnect hose assembly (11) from machine and
remove gasket (12). Discard gasket.
427-C0538
0152 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
6. 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
cedure. 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
• 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.
8. Attach lifting equipment to tilt cylinder (6).
427-C0535
0152 00-5
TM 5-3805-291-23-2
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
WARNING
sonnel.
INSTALLATION
1. Lubricate pin bores with GAA before installing tilt cylinder (6).
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during
0152 00-7
TM 5-3805-291-23-2
NOTE
• Special tools should be assembled as
shown in illustration.
2. 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
5. 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
7. Connect grease hose assembly (7) to tilt cylinder (6).
0152 00-10
TM 5-3805-291-23-2
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).
END OF WORK PACKAGE
0152 00-11/(0152 00-12 Blank)

10
TM 5-3805-291-23-2
LIFT CYLINDERS REPLACEMENT 0153 00

INITIAL SETUP

Unit Cap set, protective (Item 6, WP 0233 00)
Tools and Special Tools 0233 00)
Tool kit, general mechanic’s, automotive (Item 90, Grease, automotive and artillery, GAA (Item 15,
WP 0232 00) WP 0233 00)
Shop equipment, automotive maintenance and Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233
repair: organizational maintenance, common no. 00)
1 (Item 70, WP 0232 00)
Inserter end remover, pin (Item 36, WP 0232 00) 0233 00)
Nut, fastener (Item 43, WP 0232 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP
0233 00)
Pin, shoulder, headless (Item 48, WP 0232 00)
O-ring (3)
Pump, hydraulic ram, hand-driven (Item 56, WP
0232 00) Personnel Required
MOS 62B Construction Equipment Repairer (2)
Saddle assembly, lifting block (Item 65, WP 0232
Stand assembly (Item 79, WP 0232 00) Front fenders removed (WP 0136 00)
Stud, plain (Item 82, WP 0232 00) Steering frame lock connected (TM 5-3805-291-
10)
Tube, metallic (Item 92, WP 0232 00)
Tubing assembly set, nonmetallic (Item 93, WP Drawings Required
0232 00) TM 5-3805-291-23P, Figure 154
Washer, flat (Item 94, WP 0232 00) Estimated Time to Complete Task
0153 00-1
TM 5-3805-291-23-2
LIFT CYLINDERS REPLACEMENT - CONTINUED 0153 00
REMOVAL
WARNING
WARNING
CAUTION
NOTE
• Stand capacity must be 5,200 lb (2,359 kg).
0153 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
1. 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
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
REMOVAL - CONTINUED
9. Support hydraulic pump and puller assembly with lift-
ing 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
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
sonnel.
0153 00-6
TM 5-3805-291-23-2
INSTALLATION
WARNING
NOTE
1. Use lifting equipment to position lift cylinder (3) on
machine.
0153 00-7
TM 5-3805-291-23-2
NOTE
• 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).
2. With assistance, use hydraulic pump and puller assem-
bly 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
5. 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-C1293-1 427-C0395
0153 00-9
TM 5-3805-291-23-2
7. Raise lift arms and remove stands and associated tool-
ing.
427-C0394
WARNING

9. Install front fenders (WP 0136 00).
10. Run engine and verify correct operation of lift cylinder (TM 5-3805-291-10).
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

INITIAL SETUP

WP 0232 00)
WP 0155 00
repair: organizational maintenance, common no. WP 0159 00
1 (Item 70, WP 0232 00) WP 0193 00
Materials/Parts
00) Hydraulic filter access door opened (TM 5-3805-
291-10)
0233 00) Right rear fender removed (WP 0137 00)
0233 00)
TM 5-3805-291-23P, Figure 157
O-ring (27) 0.5 hr
0154 00-1
TM 5-3805-291-23-2

HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED 0154 00
REMOVAL
WARNING
CAUTION
NOTE
0154 00-2
TM 5-3805-291-23-2

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. Disconnect hose (6) from hydraulic tank (WP 0159 00) and remove hose from machine.
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

REMOVAL - CONTINUED
Hydraulic Oil Filter Base - Continued
7. Disconnect hose (9) from fitting (10). Remove O-ring

(11) from hose. Discard O-ring.
8. Remove fitting (12) from machine (WP 0117 00).
9. Disconnect hose (9) from fitting (12). Remove O-ring
(11) from hose. Discard O-ring.
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

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.
427-C1381
0154 00-5
TM 5-3805-291-23-2

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

5. Disconnect hose (44) and remove O-ring (45) from fit-
ting (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

REMOVAL - CONTINUED
Drain Valve
1. Remove bolt (47), washer (48), and clip (49) from hose (44).
2. Disconnect hose (44) and remove O-ring (50) from fitting (51). Discard O-ring.
3. Remove fitting (51) and O-ring (52) from drain valve (53). Discard O-ring.
0154 00-7
TM 5-3805-291-23-2

INSTALLATION
Drain Valve
NOTE
Apply a thin coat of clean oil to all O-
rings 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).

on machine.
427-C1560
Case Drain Filter Base
1. Install new O-ring (45) in hose (44) and connect hose to fitting (42).
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

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

on radiator (28).
on fitting (26).
3. Install new O-ring (25) in line (16) and connect line to
elbow (24).
427-C1342
0154 00-9
TM 5-3805-291-23-2

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 junc-

tion block (20).
on T (14).
7. Install new O-ring (18) in line (16) and connect line to
elbow (17).
on T (14).
9. Install fitting (12) on machine (WP 0117 00).
10. Install new O-ring (11) in hose (9) and connect hose to
fitting (12).
11. Install new O-ring (11) in hose (9) and connect hose to 427-C1343
fitting (10).
0154 00-10
TM 5-3805-291-23-2

Hydraulic Oil Filter Base
1. Install new O-ring (8) in hose (1) and connect hose to hydraulic cooler (WP 0193 00).
3. Install fitting (5) on machine.
5. Install new O-ring (4) in tube (2) and connect tube to fitting (5).
6. Install new O-ring (4).
7. Connect hose (1) and tube (2) to hydraulic system oil filter bases (3) (WP 0155 00). Install all associated clips.
8. Install right rear fender (WP 0137 00).

13. Close hydraulic filter access door (TM 5-3805-291-10).
END OF WORK PACKAGE
0154 00-11/(0154 00-12 Blank)

6
TM 5-3805-291-23-2
HYDRAULIC SYSTEM OIL FILTER BASES REPLACEMENT 0155 00

INITIAL SETUP

O-ring (8)
1 (Item 70, WP 0232 00) Hydraulic system pressure relieved (TM 5-3805-
291-10)
Materials/Parts Hydraulic oil filters removed from machine (WP
Cleaning compound, solvent, type III (Item 7, WP 0148 00)
0233 00) Case drain hoses removed from machine (WP 0154
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 00)
00)
Drawings Required
0233 00)
0233 00) 1.5 hr
0155 00-1
TM 5-3805-291-23-2
HYDRAULIC SYSTEM OIL FILTER BASES REPLACEMENT - CONTINUED 0155 00
REMOVAL
Hydraulic Filter Base 0155 00
1. 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
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
sonnel.
0155 00-3
TM 5-3805-291-23-2
INSTALLATION
Case Drain Filter Base 03 00
Install case drain filter base (18), two washers (17),
427-C1592
Hydraulic Filter Base 03 00
NOTE
1. 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
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).
10. Check hydraulic system pressure (TM 5-3805-291-10).
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

INITIAL SETUP

TM 5-3805-291-10
WP 0232 00)
repair: organizational maintenance, common no. WP 0152 00
1 (Item 70, WP 0232 00)
WP 0153 00
Materials/Parts
WP 0157 00
WP 0158 00
0233 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Side panels removed (WP 0133 00)
0233 00)
Drawings Required
TM 5-3805-291-23P, Figures 156, 158, 159, 160,
Strap, tiedown, electrical components (Item 42, WP and 171
0233 00)
O-ring (23) 0.5 hr ea
0156 00-1
TM 5-3805-291-23-2
IMPLEMENT HYDRAULIC HOSES, LINES, AND FITTINGS REPLACEMENT - CONTINUED 0156 00
REMOVAL
WARNING
CAUTION
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
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. Remove two O-rings (11) from lines (9). Discard O-rings.
10. Disconnect two fittings (10) from valve (7).
11. Remove two O-rings (12) from fittings (10). Discard O-rings.
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
REMOVAL - CONTINUED
14. Remove bolt (18) and washer (19) from clip (20) and
remove clip from machine.
427-C1276
427-C1277
0156 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
427-C1278
17. Disconnect two lines (27) from fittings (28) and

remove lines from machine.
18. Remove two O-rings (29) from lines (27). Discard
O-rings.
19. Disconnect two lines (30) from fittings (28).
20. Remove two O-rings (31) from lines (30). Discard
O-rings.
21. Remove two fittings (28) from machine.
427-C1279
0156 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
22. Remove two bolts (32), washers (33), and clips (34)
from machine.
427-C1280
machine.
427-C1281
0156 00-6
TM 5-3805-291-23-2
REMOVAL - CONTINUED
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

hose from machine.
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
REMOVAL - CONTINUED
machine.
427-C1284
machine.
427-C1285
0156 00-8
TM 5-3805-291-23-2
REMOVAL - CONTINUED
machine.
hose from machine.
37. Remove fitting (56) from valve (58).
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.
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
REMOVAL - CONTINUED
Third Function System - Continued 0156 00
6. Repeat steps 1 thru 5 for other tilt hose.

8. Remove fitting (71) from bracket (72).
9. Remove fitting (73) from bracket (72).
427-C1289
Tilt System 0156 00
1. Remove four bolts (74), washers (75), two flange

halves (76), and hose (70) from machine.
427-C1290
0156 00-10
TM 5-3805-291-23-2
REMOVAL - CONTINUED
Tilt System - Continued 0156 00
4. Remove four bolts (81), washers (82), and two flange

halves (83) from hose (84).
Remove tube assembly (89) from machine.
427-C1291

halves (92) from hose (93). Remove hose from
machine.
9. Remove hose (95) from main hydraulic control valve
(WP 0157 00).
0156 00-11
TM 5-3805-291-23-2
REMOVAL - CONTINUED
10. Remove four bolts (96) and washers (97) from bracket
(98) and hose (95) and remove hose from machine.
Lift System 0156 00
1. Remove two hoses (99) and line (100) from lift cylinder (101) (WP 0153 00).
427-C1293
427-C0395-1
0156 00-12
TM 5-3805-291-23-2
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
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
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
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
NOTE
4. Install line (100) and two hoses (99) on lift cylinder

(101) (WP 0153 00).
427-C0395-1 427-C1293
0156 00-15
TM 5-3805-291-23-2
Tilt System 0156 00
1. Position hose (95) on bracket and install four

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 wash-
ers (91), and bolts (90).
0156 00-16
TM 5-3805-291-23-2
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
427-C1291
6. Position clamp (80) on machine and install washer

(79) and bolt (78).
on machine. Install two flange halves (76), four
427-C1290
0156 00-17
TM 5-3805-291-23-2
8. Install fitting (73) on bracket (72).

9. Install fitting (71) on bracket (72).
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).
0156 00-18
TM 5-3805-291-23-2
Coupler System 0156 00

on valve (58).
to fitting (56).
3. Position clip (54) on machine and install washer (53)
and bolt (52).
427-C1286

and bolt (49).
427-C1285
0156 00-19
TM 5-3805-291-23-2

and bolt (46).
427-C1284

on machine.
to fitting (41).
to fitting (41).
427-C1283
0156 00-20
TM 5-3805-291-23-2
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

and bolt (35).
427-C1281
0156 00-21
TM 5-3805-291-23-2
12. Position two clips (34) on machine and install two

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. Install two new O-rings (29) in lines (27) and connect
lines to fittings (28).
427-C1279
0156 00-22
TM 5-3805-291-23-2

and bolt (24).
427-C1278

and bolt (21).
427-C1277
0156 00-23
TM 5-3805-291-23-2

and bolt (18).
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. Install two new O-rings (11) in lines (9) and connect lines to fittings (10).
23. Install two new O-rings (8) in fittings (5) and install fittings on valve (7).
24. Install two new O-rings (6) in lines (2) and connect lines to fittings (5).
427-C1275
0156 00-24
TM 5-3805-291-23-2
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

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

INITIAL SETUP
Unit Tag, marker (Item 43, WP 0233 00)

Gasket (11)
WP 0232 00)
Shop equipment, automotive maintenance and References
1 (Item 70, WP 0232 00) WP 0156 00
WP 0159 00
Materials/Parts
Cap set, protective (Item 6, WP 0233 00) Hydraulic tank drained (WP 0148 00)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Hydraulic system pressure relieved (TM 5-3805-
00) 291-10)
Front access cover removed (WP 0218 00)
Rag, wiping (Item 35, WP 0233 00) 0.5 hr ea
0157 00-1
TM 5-3805-291-23-2

REMOVAL
WARNING
CAUTION
NOTE
0157 00-2
TM 5-3805-291-23-2

REMOVAL - CONTINUED
1. 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. Dis-
card 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

REMOVAL - CONTINUED
9. 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. Disconnect hose (33) from fitting (34). Remove
O-ring (35) from hose. Discard O-ring.
13. Disconnect hose (36) from fitting (34) (WP 0156 00).
427-C1297
0157 00-4
TM 5-3805-291-23-2

REMOVAL - CONTINUED
14. Disconnect hose (37) from main hydraulic control
valve (2). Remove O-ring (38) from hose. Discard O-
ring.
15. Disconnect hose (39) from main hydraulic control
valve (2). Remove O-ring (40) from hose. Discard O-
ring.
427-C1298

hose from machine. Remove O-ring (42) from hose.
Discard O-ring.
hose from machine. Remove O-ring (44) from hose.
Discard O-ring.
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

REMOVAL - CONTINUED
20. 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. Disconnect hose (16) from fitting (57) and remove hose from machine. Remove O-ring (58) from hose. Discard O-ring.
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

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.
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
TM 5-3805-291-23-2

REMOVAL - CONTINUED

disconnect hose (51) from hose (71). Remove
gasket (72) from hose. Discard gasket.
31. Disconnect hose (71) from hydraulic tank
(WP 0159 00) and remove hose from machine.
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
NOTE
1. Install new gasket (76) on hose (55) and position hose on implement pump (75). Install four washers (74) and bolts (73).
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

4. Install three clamps (68) on two hoses (63).
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).
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

14. Position valve (45) on machine and install two
15. Install two new O-rings (46) in fittings (41 and 43)
and install fittings on valve (45).
(37) to fitting (43).
to fitting (41).
427-C1299
to main hydraulic control valve (2).
to main hydraulic control valve (2).
427-C1298
20. Connect hose (36) to fitting (34) (WP 0156 00).

to fitting (34).
on main hydraulic control valve (2). Install four wash-
ers (30) and bolts (29).
23. Install new gasket (27) on hose (28) and position hose
on main hydraulic control valve (2). Install four wash-
427-C1297
0157 00-10
TM 5-3805-291-23-2

24. 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. Install new O-ring (21) in fitting (19) and install fitting on machine.
27. Install two O-rings (20) in tube (18) and connect tube to main hydraulic control valve (2) and fitting (19).
28. Install new O-ring (17) in hose (16) and connect hose to main hydraulic control valve (2).
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 wash-
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

33. Install front access cover (WP 0218 00).
36. Check hydraulic system pressure (TM 5-3805-291-10).
END OF WORK PACKAGE
0157 00-12
6
TM 5-3805-291-23-2
QUICK COUPLER CYLINDER REPLACEMENT 0158 00

INITIAL SETUP

1 (Item 70, WP 0232 00)
Wheels chocked
Materials/Parts
3805-291-10)
0233 00) Work tools removed (TM 5-3805-291-10)
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Hydraulic system pressure relieved (TM 5-3805-
00) 291-10)
0233 00)
10)
Cotter pin (2) Estimated Time to Complete Task
O-ring (4) 1.5 hr
0158 00-1
TM 5-3805-291-23-2
QUICK COUPLER CYLINDER REPLACEMENT - CONTINUED 0158 00
REMOVAL
WARNING
CAUTION
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
REMOVAL - CONTINUED
5. Remove two fittings (2) from pin coupler cylinder (6).
6. Remove two O-rings (7) from fittings (2). Discard O-
rings.
427-C0580
WARNING
sonnel.
0158 00-3
TM 5-3805-291-23-2
INSTALLATION
NOTE
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
WARNING

7. Verify proper operation of pin coupler cylinder (TM 5-3805-291-10).
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

Removal, Cleaning and Inspection, Component Transfer, Installation
INITIAL SETUP

Tools and Special Tools 41, WP 0233 00)
WP 0232 00) Gasket (2)
Shop equipment, automotive maintenance and O-ring (27)
Personnel Required
1 (Item 70, WP 0232 00)
References
Materials/Parts TM 5-3805-291-10
0233 00)
Air cleaner removed (WP 0030 00)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Hydraulic tank drained (WP 0148 00)
00)
Drawings Required
0233 00) TM 5-3805-291-23P, Figure 163
0233 00) 4.0 hr
0159 00-1
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
CAUTION
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
REMOVAL - CONTINUED
5. 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
REMOVAL - CONTINUED
13. 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
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
REMOVAL - CONTINUED
20. Remove four bolts (44), washers (45), and mount (43)
from machine. Repeat for other side.
427-C0575
WARNING
sonnel.
0159 00-6
TM 5-3805-291-23-2
COMPONENT TRANSFER
WARNING
NOTE
• Hydraulic tank weighs 600 lb (272 kg).
• Apply a thin coat of clean oil to all O-rings before installation.
1. Remove breather assembly (46) from hydraulic
tank (19).
427-C1887
0159 00-7
TM 5-3805-291-23-2
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

8. 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

11. Remove two fittings (69) from hydraulic tank (19).
12. Remove two O-rings (70) from fittings (69). Discard
O-rings.
427-C1891
NOTE
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

18. 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

24. 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
2. 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
6. 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
9. 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 427-C0568
0159 00-15
TM 5-3805-291-23-2
15. 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.

20. Operate machine and verify correct operation of AC and hydraulic system (TM 5-3805-291-10).
END OF WORK PACKAGE
0159 00-16
2
TM 5-3805-291-23-2
SIGHT GAGE REPLACEMENT 0160 00

INITIAL SETUP

O-ring (2)
Personnel Required

repair: organizational maintenance, common no. TM 5-3805-291-10
1 (Item 70, WP 0232 00)
Materials/Parts
Hydraulic tank drained below level of sight gage
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 (WP 0148 00)
00)
Drawings Required
TM 5-3805-291-23P, Figure 163
0233 00)
0233 00) 0.5 hr
0160 00-1
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).
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).
6. Check for leaks.
END OF WORK PACKAGE
0160 00-2
12
TM 5-3805-291-23-2
ARCTIC HEATER REPLACEMENT 0161 00

INITIAL SETUP

WP 0232 00) 10)
Wheels chocked
1 (Item 70, WP 0232 00)
Materials/Parts
Diesel fuel, DF-1 (Item 10, WP 0233 00) 3805-291-10)
Handrails and left side cover removed (WP 0134 00
Fuel, turbine, aviation (Item 12, WP 0233 00) and WP 0135 00)
Drawings Required
TM 5-3805-291-23P, Figures 124 and 164
0233 00)
O-ring (8) 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,
• 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.
CAUTION
NOTE
• Tag hoses and wiring prior to removal to ensure correct installation.
• Use a container to catch any fluid that may drain from hoses or system. Dispose of oil IAW local policy
1. Close both arctic heater valves (1) on machine.
0161 00-2
TM 5-3805-291-23-2
2. 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
4. 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).
machine.
0161 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
10. 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
REMOVAL - CONTINUED
11. 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
REMOVAL - CONTINUED
14. 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.
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
4. Connect hose (13) to fitting (25) and tighten
clamp (29).
5. Position two clips (28) on machine and install washer
(27) and bolt (26).
0161 00-8
TM 5-3805-291-23-2
6. 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).
and bolt (20).
0161 00-9
TM 5-3805-291-23-2
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
TM 5-3805-291-23-2
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)

26
TM 5-3805-291-23-2
ARCTIC HEATER INSTALLATION 0162 00
Installation
INITIAL SETUP

Unit Antifreeze drained (WP 0041 00)
Tools and Special Tools Left side ladders removed from machine (WP 0129
WP 0232 00) Battery box removed from machine (WP 0128 00)
Materials/Parts Fuel tank removed from machine and fuel hose fit-
Antifreeze (Item 1, WP 0233 00) tings removed from tank (WP 0033 00)
Diesel fuel, DF-1 (Item 10, WP 0233 00) Transfer fuel level sending unit (WP 0081 00) to
arctic kit fuel tank
Fuel, turbine, aviation (Item 12, WP 0233 00) Drawings Required
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 Estimated Time to Complete Task
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 avail-
able prior to beginning procedure.
PART
NOMENCLATURE QUANTITY
NUMBER
2836489 HEATER ASSEMBLY 1

2802866 HEATER, VEHICULAR CO 1
5P0765-235 HOSE, NON METALLIC MAKE FROM 1
HOSE P/N 5P0765, 92.5 INCHES (235
CM)
5D1026 CLAMP, HOSE 4
2D3165 ADAPTER STRAIGHT, HO 2
9Y2238 ADAPTER, BRUSHING 2
3K0360 O-RING 7
8T0119 CATCH, ELBOW 2
0162 00-1
TM 5-3805-291-23-2
ARCTIC HEATER INSTALLATION - CONTINUED 0162 00
PART
NUMBER
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 M10X1.15- 1
THD
5P0765-123 HOSE, NONMETALLIC MAKE FROM 1
HOSE P/N 5P0765, 48.5 INCHES (123
CM)
6V2235 FASTENER, POSITIVE L 2
1886185 GROMMET 1
5P1076 WASHER, SHOULDERED A 4
2836498 BRACKET, MOUNTING 1
8T4224 WASHER, FLAT 8.8X16X2-MM THK 4
2836493 COVER, ACCESS 1
7X7729 WASHER, FLAT 11X25X3-MM THK 12
4J5477 O-RING 1
0162 00-2
TM 5-3805-291-23-2
PART
NUMBER
2364850 HEATER, DIESEL OIL, 1

2847695 GROMMET, BLANK, NONME 1
2836491 PLATE, MOUNTING 1
5P1076 WASHER, SHOULDERED A 13.5X30X4 8
MM THK
8T4139 BOLT, MACHINE M12X1.75X30 MM 8
2802929 BATTERY BOX 1
2G9524 LATCH, HOOD, VEHICULA 3
2921078 PLATE, MOUNTING 1
8T4121 WASHER, FLAT 11X21X2.5 MM THK 8
2802888 PLATE 1
8T4133 NUT, PLAIN, HEXAGON M10X1.5 THD 4
3E6602-80.7 SEAL MAKE FROM SEAL P/N 3E6602 2
80.7 INCHES (205 CM)
3E6602-250.4 SEAL MAKE FROM SEAL P/N 3E6602, 1
98.6 INCHES (250.4 CM)
3053159 PAWL 1
2942382 LATCH, DOOR, VEHICULA 5 PIECES 1
2802919 COVER, BATTERY BOX 1
2802881 LADDER, STRAIGHT LH BOARDING 1
LADDER
5P1076 WASHER, SHOULDERED A 13.5X30X4 4
MM THK
1503674 HANDRAIL, VEHICULAR 2
8T4196 SCREW, CAP, HEXAGON H 4
M10X1.5X35 MM
2978744 LEAD, STORAGE BATTER 1
3S2093 STRAP 8
2V1771 GROMMET, NONMETALLIC 2
0919035 SPACER, STRAIGHT 1
0162 00-3
TM 5-3805-291-23-2
PART
NUMBER
6D4246 CLAMP, LOOP 2

8T4186 BOLT, MACHINE 1
3259333 HARNESS 1
7K1181 STRAP 5
2668944 GROMMET, NONMETALLIC 1
4S1936 CLAMP, LOOP 2
2V8259 GROMMET, NONMETALLIC 2
2978743 CABLE ASSEMBLY, POWE 1
1160080 LEAD, ELECTRICAL 1
2978745 LEAD, STORAGE BATTER 1
5P8245 WASHER, FLAT 13.5X25X.5X3-MM 1
THK
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 1
ARCTIC HEATER
1978743 WIRING HARNESS 1
1342418 MOUNT PLATE 2
9R2613 BOSS 2
0162 00-4
TM 5-3805-291-23-2
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
1. Lift off left side cover (1) from machine.
0162 00-6
TM 5-3805-291-23-2
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
3. 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 00-9
TM 5-3805-291-23-2
13. 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
WARNING
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
16. Connect sending unit connector (23) to wiring harness
(22).
17. Install nut (25), washer (26), and sending unit connec-
tor (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
23. 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
WARNING
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
26. Install two washers (39) and bolts (40) on battery box
(38).
0162 00-15
TM 5-3805-291-23-2
27. Install two washers (48) and bolts (41) on battery box (38).
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
30. 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.
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
38. 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).
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
47. 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
50. 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
52. 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
53. Connect fuel hose (32) with O-ring (83) to fitting (82).
54. Connect hose (69) to fitting (81) and tighten clamp (64).
55. Connect hose (52) to fitting (81) and tighten clamp (64).
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
58. 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
59. 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
61. 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
66. 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).
WARNING
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).
END OF WORK PACKAGE
0162 00-26
4
TM 5-3805-291-23-2
BRISTLES REPLACEMENT 0163 00
INITIAL SETUP

10)
WP 0232 00) Wheels chocked (TM 5-3805-291-10)
Shop equipment, automotive maintenance and Battery disconnect switch in OFF position (TM 5-
repair: organizational maintenance, common no. 3805-291-10)
1 (Item 70, WP 0232 00)
Work tool raised slightly (TM 5-3810-291-10)
Materials/Parts
Drawings Required
Locknut (12) TM 5-3805-291-23P, Figure 168

0163 00-1
TM 5-3805-291-23-2
BRISTLES REPLACEMENT - CONTINUED 0163 00
REMOVAL
WARNING
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
REMOVAL - CONTINUED
NOTE
Bracket and motor weigh approxi-
mately 65 lb (29 kg).
3. Secure bracket (6) with lifting equipment.
4. With assistance, remove motor (7) from frame (8) and
brush (9).
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
8. 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

Hose: Removal, Installation
Manifold: Removal, Installation
Angle Link: Removal, Installation
INITIAL SETUP

Unit Locknut (13)
O-ring (20)
Personnel Required

repair: organizational maintenance, common no. Broom assembly removed (TM 5-3805-291-10)
1 (Item 70, WP 0232 00)
Drawings Required
Materials/Parts TM 5-3805-291-23P, Figures 168 and 170
Cap set, protective (Item 6, WP 0233 00) Estimated Time to Complete Task
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
HOSE REMOVAL - CONTINUED
4. Remove four bolts (11), two clamps (12), and

hoses (1) from frame (13).
427-C1538
5. Remove two hoses (1) and O-rings (14) from

fittings (15). Discard O-rings.
6. Remove two hoses (1) from broom (16).
7. Repeat steps 1 thru 6 for opposite side.
427-C1539
HOSE INSTALLATION
NOTE
1. Install two hoses (1) on broom (16).
2. Install two new O-rings (14) in hoses (1) and connect hoses to fittings (15).
3. Install two hoses (1), clamps (12), and four bolts (11) on frame (13).
0164 00-3
TM 5-3805-291-23-2
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. Install two new O-rings (2) in hoses (1) and connect

hoses to fittings (3).
7. Repeat steps 1 thru 6 for opposite side.
427-C1536
0164 00-4
TM 5-3805-291-23-2
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
NOTE
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
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).

END OF WORK PACKAGE
0164 00-6
4
TM 5-3805-291-23-2
BROOM MOTOR REPLACEMENT 0165 00
INITIAL SETUP

10)
WP 0232 00)
1 (Item 70, WP 0232 00)
Materials/Parts Broom assembly removed (TM 5-3805-291-10)

O-ring (4) 1.0 hr
REMOVAL
WARNING
CAUTION
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
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
REMOVAL - CONTINUED
motor (5).
5. Remove motor (5) from bracket (12).
427-C1535
INSTALLATION
NOTE
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).
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
Forward Shield: Removal, Installation

Aft Shield: Removal, Installation
Spring: Removal, Installation
INITIAL SETUP

Broom assembly removed (TM 5-3805-291-10)
WP 0232 00) Drawings Required
TM 5-3805-291-23P, Figure 169
repair: organizational maintenance, common no. Estimated Time to Complete Task
1 (Item 70, WP 0232 00) 1.0 hr
Chain come-along (Item 22, WP 0232 00)
Materials/Parts
Locknut (9)
FORWARD SHIELD REMOVAL 0166 00
1. 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
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
SPRING REMOVAL
WARNING
Spring is under tension. Wear eye protection and use extreme caution when removing spring to avoid
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 come-
along.
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).
END OF WORK PACKAGE
0166 00-4
8
TM 5-3805-291-23-2
PALLET FORKS REPAIR 0167 00

Disassembly, Assembly
INITIAL SETUP

Unit Oil, lubricating, OEA-30, Arctic (Item 29, WP
0233 00)
WP 0232 00) Tag, marker (Item 43, WP 0233 00)
Shop equipment, automotive maintenance and Cotter pin (6)
repair: organizational maintenance, common no. O-ring (22)
1 (Item 70, WP 0232 00)
Bracket, link (Item 15, WP 0232 00) Personnel Required
Lifting equipment, 400-lb capacity MOS 62B, Construction Equipment Repairer (2)
Lifting equipment, 3,000-lb capacity Equipment Conditions
Materials/Parts Pallet fork assembly removed (TM 5-3805-291-10)

Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 TM 5-3805-291-23P, Figure 171
00)
0233 00) 4.0 hr
DISASSEMBLY
WARNING
CAUTION
0167 00-1
TM 5-3805-291-23-2
PALLET FORKS REPAIR - CONTINUED 0167 00
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.
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. Dis-
card O-ring.
10. Remove fitting (19) from cylinder (20). Remove O-ring (21) from fitting. Discard O-ring.
427-C1377
0167 00-2
TM 5-3805-291-23-2
13. Disconnect hose (6) from elbow (25) and remove hose from pallet fork assembly. Remove O-ring (8) from hose. Dis-
card O-ring.
14. Remove elbow (25) from valve (26). Remove O-ring (27) from elbow. Discard O-ring.
16. Remove fitting (29) from valve (26). Remove O-ring (31) from fitting. Discard O-ring.
17. Disconnect hose (28) from fitting (32) and remove hose from pallet fork assembly. Remove O-ring (30) from hose. Dis-
card O-ring.
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
24. Disconnect hose (34) from fitting (44) and remove hose from pallet fork assembly. Remove O-ring (36) from hose.
Discard O-ring.
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 427-C1380
0167 00-4
TM 5-3805-291-23-2
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).
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
13. Install new O-ring (37) in elbow (35) and install elbow on valve (26).
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).
427-C1378
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
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

INITIAL SETUP

Tools and Special Tools 10)
WP 0232 00)

0233 00)
TM 5-3805-291-23P, Figures 172 and 178

REMOVAL
427-C0135
0168 00-1
TM 5-3805-291-23-2
AIR CONDITIONING/HEATER BLOWER MOTOR REPLACEMENT - CONTINUED 0168 00
REMOVAL - CONTINUED
427-C0136
427-C0137
0168 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
4. Remove three screws (6) and washers (7) from cover
assembly (5).
427-C0138
5. Loosen two thumbwheel screws (8) on air filter

cover (9) and remove from cover assembly (5).
427-C0139
0168 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
427-C0140

427-C0141
0168 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
9. Disconnect wiring harness (12).

machine.
11. Remove two bolts (15), washers (16), and bracket (17)
from machine.
12. Remove blower motor (18) from machine.
427-C0142
WARNING
sonnel.
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
427-C0141
427-C0140
0168 00-6
TM 5-3805-291-23-2
9. Tighten two thumbwheel screws (8) on air filter
cover (9).
427-C0139
10. Install three washers (7) and screws (6) on cover

assembly (5).
427-C0138
0168 00-7
TM 5-3805-291-23-2
427-C0137

427-C0136
0168 00-8
TM 5-3805-291-23-2
14. Install three screws (1) on tray (2).
427-C0135
15. Start engine (TM 5-3805-291-10).

16. Verify correct operation of blower motor (TM 5-3805-291-10).
END OF WORK PACKAGE
0168 00-9/(0168 00-10 Blank)

6
TM 5-3805-291-23-2
QUICK COUPLER REPLACEMENT 0169 00

INITIAL SETUP

0233 00)
WP 0232 00)
O-ring (4)
repair: organizational maintenance, common no. Personnel Required
1 (Item 70, WP 0232 00) MOS 62B, Construction Equipment Repairer (2)
Inserter end remover, pin (Item 36, WP 0232 00)
Nut, plain, round (Item 47, WP 0232 00) Machine parked on level ground (TM 5-3805-291-
Puller, hydraulic (Item 52, WP 0232 00) 10)
Pump, hydraulic ram, hand-driven (Item 56, WP Work tool removed (TM 5-3805-291-10)
0232 00) Parking brake engaged (TM 5-3805-291-10)
Stud, plain (Item 82, WP 0232 00) Wheels chocked
Lifting equipment, 1,500-lb capacity Battery disconnect switch in OFF position (TM 5-
3805-291-10)
Materials/Parts
Grease, automotive and artillery, GAA (Item 15, 10)
WP 0233 00) Hydraulic system pressure relieved (TM 5-3805-
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 291-10)
00)
Drawings Required
TM 5-3805-291-23P, Figure 180
0233 00)
0233 00) 1.5 hr
0169 00-1
TM 5-3805-291-23-2
QUICK COUPLER REPLACEMENT - CONTINUED 0169 00
REMOVAL
WARNING
CAUTION
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
REMOVAL - CONTINUED
WARNING
NOTE
Tilt link weighs approximately 140 lb
(64 kg).
4. Attach lifting equipment to tilt link (7).
5. Remove bolt (8), washer (9), and spacer (10) from pin
assembly (11).
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. Remove bolt (14), washer (15), and spacer (16) from

pin assembly (17).
10. Use puller to remove pin assembly (17) from quick

coupler (5).
11. Remove two shims (18) from quick coupler (5).

427-C1923
12. Repeat steps 8 thru 11 to remove pin assembly from
opposite side of quick coupler (5).
WARNING
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
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 assem-
blies in opposite side of quick coupler (5).
427-C1923
0169 00-4
TM 5-3805-291-23-2
WARNING
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
WARNING
END OF WORK PACKAGE
0169 00-5/(0169 00-6 Blank)

8
TM 5-3805-291-23-2
BUCKET TIPS AND CUTTING EDGES REPLACEMENT 0170 00

Bucket Tips: Inspection/Removal, Cleaning, Installation
Bucket Cutting Edges: Inspection/Removal, Cleaning, Installation
INITIAL SETUP

WP 0232 00) 10)
Wrench, torque, click, ratcheting, 1/2” drive, 250 Parking brake engaged (TM 5-3805-291-10)
lb-ft (Item 99, WP 0232 00)
Multiplier, torque 3805-291-10)
Wood block, 4 x 4 in.
Drawings Required
Materials/Parts
TM 5-3805-291-23P, Figures 182 and 183
Rag, wiping (Item 35, WP 0233 00) 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
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
• Injury to personnel or death can result from the bucket falling. Block the bucket before changing
bucket tips.
1. 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
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
BUCKET TIPS CLEANING
WARNING
sonnel.
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
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
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. Start machine (TM 5-3805-291-10).

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 cut-
ting 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
sonnel.
0170 00-6
TM 5-3805-291-23-2
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. Start machine (TM 5-3805-291-10).
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

Removal, Cleaning and Inspection, Component Transfer, Installation
INITIAL SETUP

Direct Support Gasket (2)
Tools and Special Tools Lockwasher
WP 0232 00)
Personnel Required
repair: field maintenance, basic, less power (Item MOS 62B, Construction Equipment Repairer (2)
68, WP 0232 00)
References
TM 5-3805-291-10
Chain come-along (Item 22, WP 0232 00) Equipment Conditions
Nipple, pipe (Item 41, WP 0232 00) Transmission fluid drained (WP 0100 00)
Wrench, torque, click, ratcheting, 1/2” drive, 250 Air intake hoses and lines removed (WP 0034 00)
lb-ft (Item 99, WP 0232 00) Air cleaner removed (WP 0030 00)
Beam, hoisting
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)
Serpentine belt removed (WP 0048 00)
00)
Belt tensioner removed (WP 0047 00)
0233 00) Battery cables disconnected from starter (WP 0051
Oil, lubricating, OEA-30, Arctic (Item 29, WP 00)
TM 5-3805-291-23P, Figures 1 and 2
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
CAUTION
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.
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
REMOVAL - CONTINUED
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 mani-
fold (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
REMOVAL - CONTINUED
14. 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 fil-
ter base (37). Discard O-ring.
427-C0486
17. Disconnect two wiring harnesses (38).

18. Remove four bolts (39) and washers (40) from com-
pressor (41).
19. Position compressor (41) aside.
427-C0485
0171 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
20. 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
REMOVAL - CONTINUED
25. 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
engine (15).
427-C1896
0171 00-6
TM 5-3805-291-23-2
REMOVAL - CONTINUED
28. 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 mani-
fold (72). Discard gaskets.
427-C0495
0171 00-7
TM 5-3805-291-23-2
REMOVAL - CONTINUED
32. Disconnect wiring harness lead (73) from engine wir-
ing 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
REMOVAL - CONTINUED
40. If equipped with arctic heater, disconnect three wiring
harnesses (87 and 88).
427-C1898
41. Turn valve (89) to OFF position.

valve (89).
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
REMOVAL - CONTINUED
WARNING
NOTE
• 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.
46. 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
REMOVAL - CONTINUED
WARNING
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
REMOVAL - CONTINUED
49. 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 equip-
ment to remove engine (15) from machine.
427-C0501
0171 00-12
TM 5-3805-291-23-2
WARNING
sonnel.
1. Clean all parts and mating surfaces of engine with solvent cleaning compound.
0171 00-13
TM 5-3805-291-23-2
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. Remove bolt (117), washer (118), and bracket (119) from engine (15).
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. Remove bolt (127), washer (128), and bracket (129) from engine (15).
427-C1910
0171 00-14
TM 5-3805-291-23-2

9. 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

12. 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
15. 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

18. Remove three bolts (169), washers (170), and starter
(165) from engine (15).
19. Remove bolt (171), washer (172), and ground cable
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
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

26. 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 fit-
tings, hoses, brackets, clips, etc., that may have been
overlooked. Transfer those parts as necessary. If possi-
ble, 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

31. 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

35. 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

39. 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
42. 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

45. 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

48. 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. Install bracket (119), washer (118), and bolt (117) on engine (15).
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
INSTALLATION
WARNING
NOTE
• Engine weighs approximately 3,200 lb (1,451 kg).
1. With assistance, use hoisting beam and lifting equip-
ment 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
NOTE
• Raise engine to release tension from come-along.
• Link bracket has to be removed and a bracket installed where link bracket was removed.
3. With assistance, remove come-along from torque converter (98) and hydraulic tank (97).
427-C0500 427-C0499
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
7. 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
12. 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
17. If equipped with arctic heater, turn valve (78) to ON
position.
18. Connect hose (77) to valve (75) and tighten clamp
(76).
19. Turn valve (75) to ON position.
20. Connect wiring harness lead (73) to engine wiring har-
ness (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
23. Place plate (67) on machine.
24. Install three washers (66) and bolts (65) on plate (67).
427-C0494

engine (15).
427-C1896
0171 00-32
TM 5-3805-291-23-2
26. 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
30. 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 pis-
ton 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
34. 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
41. 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).
427-C0481
0171 00-36
TM 5-3805-291-23-2
48. 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
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).
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).
END OF WORK PACKAGE
0171 00-37/(0171 00-38 Blank)

12
TM 5-3805-291-23-2
CYLINDER HEAD REPLACEMENT 0172 00
INITIAL SETUP
Direct Support Gasket (2)
O-ring (4)
Seal
repair: field maintenance, basic, less power (Item
68, WP 0232 00) References
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- WP 0041 00

ft (Item 98, WP 0232 00)
Wrench, torque, click, ratcheting, 1/2” drive, 250 Muffler removed (WP 0040 00)
lb-ft (Item 99, WP 0232 00)
Cooling system package removed (WP 0190 00)
Materials/Parts Thermostat housing removed (WP 0044 00)
Antiseize compound (Item 2, WP 0233 00) Accessory drive mechanism removed (WP 0194
00)
Valve cover and base removed (WP 0024 00)
00) Rocker arm assembly and pushrods removed (WP
0180 00)
Fuel injectors removed (WP 0187 00)
0233 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP 10)
0233 00)
Drawings Required
TM 5-3805-291-23P, Figure 3
0172 00-1
TM 5-3805-291-23-2
CYLINDER HEAD REPLACEMENT - CONTINUED 0172 00
REMOVAL
CAUTION
NOTE
• Tag hoses and wiring harnesses prior to removal to ensure correct installation.
• Remove and discard all associated tiedown straps.
1. Disconnect two hoses (1) and remove O-rings (2) from fittings (3). Discard O-rings.
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
REMOVAL - CONTINUED
6. 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).
O-rings.
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
REMOVAL - CONTINUED
15. Remove two bolts (36) and washers (37) from oil tube
(38).
16. Remove oil tube (38) and gasket (39) from turbo-
charger (40). Discard gasket.
17. Remove two bolts (41) and washers (42) from oil tube
(43).
18. Remove oil tube (43) and gasket (44) from turbo-
charger (40). Discard gasket.
427-C0544
WARNING
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
REMOVAL - CONTINUED
427-C0546
0172 00-5
TM 5-3805-291-23-2
WARNING
sonnel.
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
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. Tighten bolt (1) through bolt (26) in numerical sequence as shown to 125 ± 7 lb-ft (170 ± 10 Nm).
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. Tighten bolt (27) through bolt (33) in numerical sequence as shown to 41 ± 7 lb-ft (55 ± 10 Nm).
427-C0546
0172 00-7
TM 5-3805-291-23-2
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
9. 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
17. 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
23. 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).
30. Install muffler (WP 0040 00).
WARNING
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

Removal, Inspection, Installation
INITIAL SETUP

Direct Support MOS 62B, Construction Equipment Repairer (2)

WP 0232 00) Serpentine belt removed (WP 0048 00)
repair: field maintenance, basic, less power (Item 10)
68, WP 0232 00)
Drawings Required
Lifting equipment, 90-lb capacity TM 5-3805-291-23P, Figure 5
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
427-C0547-1
0173 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
4. 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
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
3. 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

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

9. Run engine and verify there is no vibration (TM 5-3805-291-10).
10. Inspect vibration damper for signs of damage.
END OF WORK PACKAGE
0173 00-5/(0173 00-6 Blank)

4
TM 5-3805-291-23-2
FRONT MAIN SEAL REPLACEMENT 0174 00

INITIAL SETUP

Direct Support MOS 62B, Construction Equipment Repairer
WP 0232 00)
repair: field maintenance, basic, less power (Item Crankshaft vibration damper removed (WP 0173
68, WP 0232 00) 00)
TM 5-3805-291-23P, Figure 7
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). Dis-
card seal.
427-C0553
WARNING
sonnel.
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).

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

INITIAL SETUP

Direct Support Gasket
Tool kit, general mechanic’s, automotive (Item 90, Seal
WP 0232 00)
68, WP 0232 00)
Materials/Parts References
Cleaning compound, solvent, type III (Item 7, WP TM 5-3805-291-10
0233 00)
WP 0176 00
Gasket cement (Item 14, WP 0233 00)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Equipment Conditions
00) Flywheel removed (WP 0177 00)
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). Dis-
card 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
WARNING
sonnel.
INSTALLATION
NOTE
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
Rear Main Seal
NOTE
• 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.
1. 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

7. Check for leaks.
END OF WORK PACKAGE
0175 00-4
6
TM 5-3805-291-23-2
FLYWHEEL HOUSING REPLACEMENT 0176 00

Removal, Cleaning, Installation, Inspection
INITIAL SETUP

Direct Support Gasket cement (Item 14, WP 0233 00)

References
68, WP 0232 00) TM 5-3805-291-10
Diesel engine repair stand, 6,000-lb (Item 25, WP Equipment Conditions
0232 00)
Engine removed (WP 0171 00)
Diesel engine repair stand, adapter plate (Item 26,
Starter removed (WP 0051 00)
WP 0232 00)
Flywheel removed (WP 0177 00)
Indicator, dial (Item 35, WP 0232 00)
TM 5-3805-291-23P, Figure 9
Materials/Parts
Cleaning compound, solvent, type III (Item 7, WP Estimated Time to Complete Task
0233 00) 42.0 hr
0176 00-1
TM 5-3805-291-23-2
FLYWHEEL HOUSING REPLACEMENT - CONTINUED 0176 00
REMOVAL
WARNING
NOTE
Flywheel housing weighs approxi-
mately 137 lb (62 kg).
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).
427-C1944
5. With assistance, remove flywheel housing (1) from
engine.
427-C0559
0176 00-2
TM 5-3805-291-23-2
CLEANING
WARNING
sonnel.
1. Remove all gasket material from mounting surfaces.

INSTALLATION
WARNING
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
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-C0561
427-C0560
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
INSPECTION - CONTINUED
Bore Runout (Radial Eccentricity) - Continued
NOTE
Write measurements for dial indicator with correct notations. This notation is necessary for making calcu-
lations 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 eccentric-
ity.
427-C0563
0176 00-5
TM 5-3805-291-23-2
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).
23. Inspect for flywheel interference.
END OF WORK PACKAGE
0176 00-6
4
TM 5-3805-291-23-2
FLYWHEEL REPLACEMENT 0177 00

Removal, Installation, Inspection
INITIAL SETUP

Direct Support Rag, wiping (Item 35, WP 0233 00)
Tools and Special Tools Stud (M16x2x180 mm)

References
68, WP 0232 00) TM 5-3805-291-10
Bracket, link (Item 16, WP 0232 00) Equipment Conditions
Diesel engine repair stand, 6,000-lb (Item 25, WP Engine removed (WP 0171 00)
0232 00)
Drawings Required
Diesel engine repair stand, adapter plate (Item 26,
WP 0232 00) TM 5-3805-291-23P, Figure 8
Indicator, dial (Item 35, WP 0232 00) Estimated Time to Complete Task
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
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 measure-
ments 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
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 measure-
ments 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).
END OF WORK PACKAGE
0177 00-4
4
TM 5-3805-291-23-2
FRONT COVER REPLACEMENT 0178 00

INITIAL SETUP


WP 0232 00)
Shop equipment, automotive maintenance and Fuel transfer pump removed (WP 0188 00)
68, WP 0232 00) Accessory mechanism removed (WP 0194 00)
Front main seal removed (WP 0174 00)
Materials/Parts
Drawings Required
0233 00) TM 5-3805-291-23P, Figure 13
Gasket 27.0 hr
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
sonnel.
0178 00-2
TM 5-3805-291-23-2
FRONT COVER REPLACEMENT - CONTINUED 0178 00
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).
9. Check for leaks.
END OF WORK PACKAGE
0178 00-3/(0178 00-4 Blank)

6
TM 5-3805-291-23-2
INTAKE/EXHAUST VALVE LASH ADJUSTMENT 0179 00

Intake Valve Adjustment, Exhaust Valve Adjustment
INITIAL SETUP
Personnel Required
References
WP 0232 00)
WP 0187 00
repair: field maintenance, basic, less power (Item Equipment Conditions
68, WP 0232 00) Valve cover removed (WP 0024 00)
Pinion turning tool (Item 49, WP 0232 00) Drawings Required
Timing pin (Item 89, WP 0232 00) TM 5-3805-291-23P, Figure 10
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- Estimated Time to Complete Task
ft (Item 98, WP 0232 00) 3.0 hr
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
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 fly-
wheel. 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.
TC Compression Stroke (1) Inlet Valves Exhaust Valves
Valve Lash 0.0150 ± 0.0031 in. 0.0252 ± 0.0031 in.

(0.38 ± 0.08 mm) (0.64 ± 0.08 mm)
Cylinders 1-2-4 1-3-5
(1)
Position for No. 1 cylinder
0179 00-3
TM 5-3805-291-23-2
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
EXHAUST VALVE ADJUSTMENT

1. Put No. 6 piston at top center position on compression stroke.
Table 2. Exhaust Valve Lash Adjustment.
TC Compression Stroke (1) Inlet Valves Exhaust Valves
Valve Lash 0.0150 ± 0.0031 in. 0.0252 ± 0.0031 in.

(0.38 ± 0.08 mm) (0.64 ± 0.08 mm)
Cylinders 3-5-6 2-4-6
(1)
Position for No. 6 cylinder 360 ° from TC Compression Stroke
2. 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
EXHAUST VALVE ADJUSTMENT - CONTINUED

6. Install valve cover (WP 0024 00).
9. Check for leaks.
END OF WORK PACKAGE
0179 00-6
4
TM 5-3805-291-23-2
ROCKER ARMS AND PUSH RODS MAINTENANCE 0180 00

INITIAL SETUP


WP 0232 00)
WP 0179 00
repair: field maintenance, basic, less power (Item WP 0187 00
68, WP 0232 00)
Bushing driver set (Item 19, WP 0232 00)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- Valve cover removed (WP 0024 00)
ft (Item 98, WP 0232 00)
Drawings Required
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
sonnel.
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).

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

INITIAL SETUP
Maintenance Level Materials/Parts – Continued

WP 0232 00)
repair: field maintenance, basic, less power (Item References
68, WP 0232 00) TM 5-3805-291-10
Cleaning compound, solvent, type III (Item 7, WP Engine oil drained (WP 0025 00)
0233 00)
Rear axle removed (WP 0208 00)
00) Fuel tank removed (WP 0032 00)
0233 00)
TM 5-3805-291-23P, Figure 15
0181 00-1
TM 5-3805-291-23-2
ENGINE OIL PAN MAINTENANCE - CONTINUED 0181 00
REMOVAL
1. Loosen clamp (1) and disconnect hose (5) from valve (2).
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
DISASSEMBLY
2. Remove two bolts (21), washers (22), oil pickup tube (23), and O-ring (26) from machine. Discard O-ring.
WARNING
sonnel.
1. Remove all gasket material from mounting surfaces.
ASSEMBLY
NOTE
1. Install oil pickup tube (23), new O-ring (26), two washers (22), and bolts (21) on machine.
0181 00-3
TM 5-3805-291-23-2
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. Connect hose (5) to valve (2) and tighten clamp (1).
0181 00-4
TM 5-3805-291-23-2
8. Install rear axle (WP 0208 00).
9. Install fuel tank (WP 0032 00).
10. Fill engine with recommended engine oil (WP 0025 00).
END OF WORK PACKAGE
0181 00-5/(0181 00-6 Blank)

6
TM 5-3805-291-23-2
ENGINE OIL PUMP REPLACEMENT 0182 00

INITIAL SETUP
Direct Support Oil, lubricating, OEA-30, Arctic (Item 29, WP

0233 00)

TM 5-3805-291-10
Materials/Parts
Cleaning compound, solvent, type III (Item 7, WP Oil pan removed (WP 0181 00)
0233 00)
Drawings Required
00) TM 5-3805-291-23P, Figure 19
Oil, lubricating, OE/HDO-15/40 (Item 28, WP Estimated Time to Complete Task

0233 00) 19.0 hr
0182 00-1
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
REMOVAL - CONTINUED
3. 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
WARNING
sonnel.
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
INSTALLATION
NOTE
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
8. 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).

END OF WORK PACKAGE
0182 00-6
2
TM 5-3805-291-23-2
PISTON COOLING JETS REPLACEMENT 0183 00

INITIAL SETUP


WP 0232 00)
repair: field maintenance, basic, less power (Item Oil pan removed (WP 0181 00)
68, WP 0232 00)
Drawings Required
ft (Item 98, WP 0232 00) TM 5-3805-291-23P, Figure 14

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).

7. Check for leaks.
END OF WORK PACKAGE
0183 00-2
2
TM 5-3805-291-23-2
EXHAUST MANIFOLD REPLACEMENT 0184 00

INITIAL SETUP

References
WP 0232 00) TM 5-3805-291-10
68, WP 0232 00)
Turbocharger removed (WP 0031 00)
ft (Item 98, WP 0232 00) Drawings Required
Antiseize compound (Item 2, 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).
END OF WORK PACKAGE
0184 00-2
6
TM 5-3805-291-23-2
INTAKE MANIFOLD REPLACEMENT 0185 00

INITIAL SETUP

Personnel Required
WP 0232 00)
References
68, WP 0232 00)
TM 5-3805-291-10
Materials/Parts
0233 00) Air intake assembly hoses removed (WP 0034 00)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Ether atomizer removed, if necessary (WP 0037 00)
00)
0233 00) TM 5-3805-291-23P, Figure 21
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
REMOVAL - CONTINUED
5. 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
sonnel.
4. Inspect oil passages in air intake manifold to ensure they are clean and unobstructed.
0185 00-3
TM 5-3805-291-23-2
INSTALLATION
NOTE
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
8. 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).
END OF WORK PACKAGE
0185 00-5/(0185 00-6 Blank)

4
TM 5-3805-291-23-2
IDLER GEARS REPLACEMENT 0186 00
INITIAL SETUP
TM 5-3805-291-10
WP 0232 00) WP 0013 00

68, WP 0232 00) Front cover removed (WP 0178 00)
Drawings Required
Materials/Parts
TM 5-3805-291-23P, Figure 13
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
REMOVAL - CONTINUED
2. 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
sonnel.
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 fol-
low this caution may result in engine damage.
NOTE
Electronic injection timing must be calibrated after reassembly of the front gear train. Refer to Trouble-
shooting, 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), crank-

shaft gear (3), and idler gear (2) are aligned.
427-C0566
5. Install front cover (WP 0178 00).
8. Check for leaks.
END OF WORK PACKAGE
0186 00-3/(0186 00-4 Blank)

6
TM 5-3805-291-23-2
FUEL INJECTORS AND WIRING HARNESS MAINTENANCE 0187 00

Removal, Cleaning and Inspection, Installation, Testing, Adjustment, Injector Trim File, Exchanging Injectors
INITIAL SETUP

Tools and Special Tools Strap, tiedown, electrical components (Item 42, WP
Tool kit, general mechanic’s, automotive (Item 90, 0233 00)
WP 0232 00) O-ring (3)
repair: field maintenance, basic, less power (Item Personnel Required
68, WP 0232 00)
Software kit (Item 75, WP 0232 00) References
Test set, electronic systems (MSD) (Item 86, WP TM 5-3805-291-10
0232 00)
WP 0010 00
Wrench, torque, dial, 1/4” drive, 30 lb-in. (Item 96,
WP 0232 00) WP 0011 00
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- WP 0179 00
ft (Item 98, WP 0232 00)
Materials/Parts
Rocker arms removed (WP 0180 00)
Diesel fuel, DF-1 (Item 10, WP 0233 00)
TM 5-3805-291-23P, Figures 24 and 78
Fuel, turbine, aviation (Item 12, WP 0233 00) Estimated Time to Complete Task
Grease, multipurpose (Item 18, 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
sonnel.
0187 00-2
TM 5-3805-291-23-2
INSTALLATION
1. Evacuate as much fuel and oil as possible from cylin-
der head before installing injector. Several evacuations
may be necessary.
2. Use brush to clean injector seating (6) and tip bore (7).
NOTE
Apply a thin coat of clean oil to all O-rings
before installation.
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
• 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 repro-
grammed as quickly as possible in order to optimize engine performance.
5. 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
6. 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.
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
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 427-C0444
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
TM 5-3805-291-23-2
EXCHANGING INJECTORS
Exchanging injectors can help determine if combustion problem is in injector or in cylinder. If two injectors that are cur-
rently 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
427-C0442
ECM.
10. Repeat steps 1 thru 9 for each cylinder, as required.
END OF WORK PACKAGE
0187 00-6
4
TM 5-3805-291-23-2
FUEL TRANSFER PUMP REPLACEMENT 0188 00
INITIAL SETUP

Direct Support Tag, marker (Item 43, WP 0233 00)
O-ring (5)
Personnel Required
68, WP 0232 00) TM 5-3805-291-10
Materials/Parts
Side cover removed (WP 0135 00)
Drawings Required
0233 00) TM 5-3805-291-23P, Figure 25
Fuel, turbine, aviation (Item 12, WP 0233 00) Estimated Time to Complete Task
WARNING
CAUTION
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).
3. Remove two fittings (2) from fuel transfer pump (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
sonnel.
0188 00-2
TM 5-3805-291-23-2
FUEL TRANSFER PUMP REPLACEMENT - CONTINUED 0188 00
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).
7. Check for leaks.
END OF WORK PACKAGE
0188 00-3/(0188 00-4 Blank)

10
TM 5-3805-291-23-2
AFTERCOOLER REPLACEMENT 0189 00
INITIAL SETUP

Personnel Required

repair: field maintenance, basic, less power (Item Engine compartment shield removed (WP 0212 00)
68, WP 0232 00)
Bracket, link (Item 17, WP 0232 00) (2) Steering frame lock connected (TM 5-3805-291-
Lifting equipment, 300-lb capacity 10)

TM 5-3805-291-23P, Figures 31 and 42
0233 00) 11.0 hr
CAUTION
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
REMOVAL - CONTINUED
4. 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
REMOVAL - CONTINUED
10. Remove clamp (17) from upper hose (18).

11. Disconnect upper hose (18) from aftercooler (19).
427-C0160
WARNING
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
REMOVAL - CONTINUED
13. 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
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).
(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
WARNING
sonnel.

INSTALLATION
WARNING
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
3. 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
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
11. 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
16. 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 oppo-
site side.
427-C0156

19. Install engine compartment shield (WP 0212 00).
WARNING
20. Secure steering frame lock in the stowed position (TM 5-3805-291-10).
21. Check coolant level (TM 5-3805-291-10).
END OF WORK PACKAGE
0189 00-10
14
TM 5-3805-291-23-2
COOLING SYSTEM PACKAGE (RADIATOR, FAN,

AFTERCOOLER, AND OIL COOLER) REPLACEMENT 0190 00

INITIAL SETUP

Direct Support Spill containment unit, hazardous material (Item
41, WP 0233 00)
WP 0232 00) O-ring (2)
Shop equipment, automotive maintenance and Seal
repair: field maintenance, basic, less power (Item Personnel Required
68, WP 0232 00)
Bracket, link (Item 17, WP 0232 00) (2)
Oil check tube removed (WP 0029 00)
Materials/Parts
Engine coolant drained (WP 0041 00)
Hydraulic fluid drained (WP 0148 00)
Radiator access door opened (TM 5-3805-291-10)
00)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 10)
00)
Drawings Required
0233 00) TM 5-3805-291-23P, Figures 17, 28, 31, 40, 42, and
45
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.
• Engine coolant used in the performance of maintenance can be very slippery. Immediately wipe up any
0190 00-1
TM 5-3805-291-23-2

AFTERCOOLER, AND OIL COOLER) REPLACEMENT - CONTINUED 0190 00
CAUTION
NOTE
• Tag hoses, lines, and wires prior to removal to ensure correct installation.
REMOVAL
1. Disconnect hose assembly (1) from elbow (2).
427-C0217
0190 00-2
TM 5-3805-291-23-2

REMOVAL - CONTINUED
2. Remove bolt (3), washer (4), and clamp (5) from cool-
ing 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).
427-C0220
0190 00-3
TM 5-3805-291-23-2

REMOVAL - CONTINUED
6. 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

REMOVAL - CONTINUED
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

REMOVAL - CONTINUED
14. Disconnect hydraulic hose assembly (40) from fitting
(41) and position hydraulic hose assembly aside.
water pump (45).
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

REMOVAL - CONTINUED
WARNING
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

INSTALLATION
WARNING
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

NOTE
Perform step 5 only if equipped with
arctic heater.
5. Connect hose assembly (50) to fitting (51) and tighten
clamp (49).
6. Connect hose (47) to fitting (48) and tighten clamp
(46).
7. Connect hose (44) to water pump (45) and tighten
clamp (43).
NOTE
Apply a thin coat of clean oil to all O-
rings 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

11. 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 con-
nect 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

15. 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 5-3805-
291-10).
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

19. 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

WARNING

END OF WORK PACKAGE
0190 00-13/(0190 00-14 Blank)

10
TM 5-3805-291-23-2
RADIATOR REPLACEMENT 0191 00
INITIAL SETUP

Tools and Special Tools Personnel Required

Tool kit, general mechanic’s, automotive (Item 90, MOS 62B, Construction Equipment Repairer
WP 0232 00)
References
repair: field maintenance, basic, less power (Item TM 5-3805-291-10
68, WP 0232 00)
Cooling system drained (WP 0041 00)
Drawings Required
Materials/Parts
TM 5-3805-291-23P, Figure 40
Antifreeze (Item 1, WP 0233 00)
0233 00) 2.0 hr
REMOVAL

aftercooler (3).
427-C1929
0191 00-1
TM 5-3805-291-23-2
RADIATOR REPLACEMENT - CONTINUED 0191 00
REMOVAL - CONTINUED
2. 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
REMOVAL - CONTINUED
4. Loosen clamp (13) and remove hose (14) from radia-
tor (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
REMOVAL - CONTINUED
10. 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
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
sonnel.
0191 00-5
TM 5-3805-291-23-2
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
4. 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
12. 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
14. 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).

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
INITIAL SETUP

0233 00)
WP 0232 00) O-ring (3)
68, WP 0232 00) MOS 62B, Construction Equipment Repairer (2)
Bracket, link (Item 17, WP 0232 00) (2) References

Wrench, torque, click, ratcheting, 1/2” drive, 250 TM 5-3805-291-10
lb-ft (Item 99, WP 0232 00)
Puller set, mechanical Radiator top tank removed (WP 0042 00)
Materials/Parts
Engine coolant drained (WP 0041 00)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 TM 5-3805-291-23P, Figure 45
00)
0233 00) 11.5 hr
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
REMOVAL - CONTINUED
2. 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
REMOVAL - CONTINUED
4. 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
REMOVAL - CONTINUED
WARNING
NOTE
Fan group weighs 255 lb (116 kg).
(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
REMOVAL - CONTINUED
8. 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
REMOVAL - CONTINUED
11. 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
WARNING
sonnel.
INSTALLATION
NOTE
1. Position fan motor (33) on guard (22) and install two
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
3. Position fan (25) on guard (22) and install eight
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
6. 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
8. 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
10. 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
13. Install radiator top tank (WP 0042 00).
END OF WORK PACKAGE
0192 00-12
4
TM 5-3805-291-23-2
HYDRAULIC OIL COOLER REPLACEMENT 0193 00

INITIAL SETUP

O-ring (2)
68, WP 0232 00) Equipment Conditions
Hydraulic system drained (WP 0148 00)
Materials/Parts
Cooler assembly unlatched (TM 5-3805-291-10)
00)
Drawings Required
0233 00)
0233 00) 2.5 hr
WARNING
CAUTION
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
from fitting (3). Discard O-ring.
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 assem-
bly (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
WARNING
sonnel.
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
WARNING

7. Fill hydraulic system (WP 0148 00).
8. Start machine (TM 5-3805-291-10).
9. Run machine until operating temperature is reached (TM 5-3805-291-10).
END OF WORK PACKAGE
0193 00-4
4
TM 5-3805-291-23-2
ACCESSORY SUPPORT BRACKETS REPLACEMENT 0194 00
Removal, Cleaning and Inspection, Transfer, Installation
INITIAL SETUP
Tool kit, general mechanic’s, automotive (Item 90, Serpentine belt removed (WP 0048 00)
WP 0232 00)
AC compressor removed (WP 0221 00)
Shop equipment, automotive maintenance and Alternator removed (WP 0046 00)
68, WP 0232 00)
10)
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
WARNING
Use extreme caution when handling
heavy parts. Provide adequate support
and use assistance during procedure.
Failure to follow this warning may
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 427-C1902
accessory mechanism (13).

6. Remove accessory mechanism (13) from engine.
WARNING
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.
3. Inspect all parts for damage, wear, pitting, cracks or corrosion and replace if necessary.
0194 00-2
TM 5-3805-291-23-2
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
WARNING
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 wash-
ers (2), and bolts (1) on bracket (6).
427-C1901
7. Install alternator (WP 0046 00).

8. Install AC compressor (WP 0221 00).
10. Install cooling package (WP 0190 00).
0194 00-3
TM 5-3805-291-23-2
WARNING
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.
12. Start machine (TM 5-3805-291-10).
13. Run until operating temperature is reached and verify correct operation of machine (TM 5-3805-291-10).
END OF WORK PACKAGE
0194 00-4
24
TM 5-3805-291-23-2
CAB WIRING HARNESS AND FUSE/RELAY BLOCK REPLACEMENT 0195 00

Removal, Fuse/Relay Block Removal, Fuse/Relay Block Installation, Installation
INITIAL SETUP

References
TM 5-3805-291-10
Shop equipment, automotive maintenance and Cab wiring harness disconnected from turnlamp
repair: field maintenance, basic, less power (Item switch (WP 0066 00)
68, WP 0232 00) Cab wiring harness disconnected from instrument
and switch panels (WP 0055 00)
Materials/Parts Interior panels removed from machine (WP 0138

0233 00) TM 5-3805-291-23P, Figure 73
Lockwasher (16) 4.0 hr
0195 00-1
TM 5-3805-291-23-2
CAB WIRING HARNESS AND FUSE/RELAY BLOCK REPLACEMENT - CONTINUED 0195 00
REMOVAL
WARNING
NOTE
• Tag wires prior to removal to
• 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
REMOVAL - CONTINUED
6. Disconnect shift lever (10) from lower cab wiring har-
ness (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
REMOVAL - CONTINUED
8. 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
REMOVAL - CONTINUED
10. Disconnect heater/AC wiring harness (15) from lower
427-C1951
11. Remove and discard tiedown straps (16) from lower

12. Disconnect cab wiring harness (11) from powertrain
ECM (17).
from powertrain ECM (17).
427-C1952
0195 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
14. 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 har-
ness (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
REMOVAL - CONTINUED
18. Disconnect lower cab wiring harness (11) from imple-
ment ECM (27).
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
REMOVAL - CONTINUED
21. Remove and discard tiedown strap (34) from lower
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 con-
nections (41) from machine.
427-C1432
27. Remove clamp (44) from lower cab wiring harness
(11).
427-C1433
0195 00-8
TM 5-3805-291-23-2
REMOVAL - CONTINUED
28. Remove two tiedown straps (45) from lower cab wir-
ing 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.
32. Remove clamp (50) from lower cab wiring harness (11).
33. Remove lower cab wiring harness (11) from machine.
427-C1435
0195 00-9
TM 5-3805-291-23-2
REMOVAL - CONTINUED
34. 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
REMOVAL - CONTINUED
38. 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
REMOVAL - CONTINUED
40. 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
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
TM 5-3805-291-23-2
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
3. 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
5. 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
9. Install lower cab wiring harness (11) on machine.
10. Install clamp (50) on lower cab wiring harness (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 oper-

ated control harness (46).
14. Install two new tiedown straps (45) on lower cab wir-
ing harness (11).
427-C1434
0195 00-17
TM 5-3805-291-23-2
427-C1433
17. Install two ground connections (41), washers (40), and

nuts (39) on machine.
427-C1432

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
22. Install lower cab wiring harness (11), two washers
(32), and nuts (31) on relay block (33).
427-C1430
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
25. 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 instal-

lation 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
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
33. 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
36. 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
38. 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. Start machine (TM 5-3805-291-10).
46. Run machine and verify correct operation of cab wiring harness (TM 5-3805-291-10).
END OF WORK PACKAGE
0195 00-24
8
TM 5-3805-291-23-2
ENGINE WIRING HARNESS REPLACEMENT 0196 00

INITIAL SETUP

Direct Support TM 5-3805-291-10
Tool kit, general mechanic’s, automotive (Item 90, Battery cables disconnected from batteries (WP
WP 0232 00) 0096 00)
Wiring harness disconnected from fuel injector har-
Materials/Parts ness (WP 0187 00)
Rag, wiping (Item 35, WP 0233 00) Wiring harness disconnected from engine ECM
Strap, tiedown, electrical components (Item 42, WP (WP 0057 00)
0196 00-1
TM 5-3805-291-23-2
ENGINE WIRING HARNESS REPLACEMENT - CONTINUED 0196 00
REMOVAL
WARNING
NOTE
• Note location of all tiedown straps and fasteners to ensure correct installation.
• 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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
427-C0329
0196 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
14. 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
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
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
TM 5-3805-291-23-2
427-C0329
23. Connect wiring harness to engine ECM (WP 0057 00).

24. Connect wiring harness to fuel injector harness (WP 0187 00).
26. Start machine (TM 5-3805-291-10).
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

INITIAL SETUP

Front harness disconnected from blackout drive
WP 0232 00)
lights (WP 0068 00)
Materials/Parts Front harness disconnected from service lights and
Rag, wiping (Item 35, WP 0233 00) turnlamps (WP 0071 00)
Drawings Required
0233 00)

0197 00-1
TM 5-3805-291-23-2
FRONT CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED 0197 00
REMOVAL
WARNING
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. Remove bolt (21), washer (22), and clip (23) from machine.
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.
21. Remove two nuts (43) and washers (44) from machine.
23. Remove front wiring harness (1) from machine.
0197 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
427-C0334
0197 00-3
TM 5-3805-291-23-2
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.
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.
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
TM 5-3805-291-23-2
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

INITIAL SETUP

WP 0232 00) Battery cables disconnected from battery (WP 0096
00)
Materials/Parts
Left rear interior panel removed (WP 0138 00)
0233 00)
TM 5-3805-291-23P, Figure 77

0198 00-1
TM 5-3805-291-23-2
HEATER AND AIR CONDITIONING WIRING HARNESS REPLACEMENT - CONTINUED 0198 00
REMOVAL
WARNING
NOTE
1. Disconnect heater/AC wiring harness (1) from cab
wiring harness (2).
2. Remove tiedown strap (3) from heater/AC wiring har-
ness (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
REMOVAL - CONTINUED
4. 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 temper-
ature 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. Start machine (TM 5-3805-291-10).
14. Run machine and verify correct operation of AC and heater systems (TM 5-3805-291-10).
END OF WORK PACKAGE
0198 00-3/(0198 00-4 Blank)

32
TM 5-3805-291-23-2
REAR CHASSIS WIRING HARNESS REPLACEMENT 0199 00

INITIAL SETUP

References
WP 0232 00) TM 5-3805-291-10
68, WP 0232 00) Cab removed (WP 0132 00)
Materials/Parts Chassis wiring harness disconnected from hydrau-

lic oil temperature sensor (WP 0083 00)
0233 00)
TM 5-3805-291-23P, Figure 72
Grommet (6) Estimated Time to Complete Task
Lockwasher 4.0 hr
0199 00-1
TM 5-3805-291-23-2
REAR CHASSIS WIRING HARNESS REPLACEMENT - CONTINUED 0199 00
REMOVAL
WARNING
NOTE
• Tag wires prior to removal to
• Note location of all tiedown straps
and fasteners to ensure correct
installation.
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
REMOVAL - CONTINUED
3. At bottom of hydraulic tank (4), disconnect chassis
wiring harness (1) from oil temperature sensor (5).
4. Remove chassis wiring harness nut (6) and lock-

washer (7) from starter solenoid (8). Discard lock-
washer.
5. Disconnect chassis wiring harness (1) from starter
solenoid (8).
427-C1957
0199 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
6. 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
REMOVAL - CONTINUED
9. 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
REMOVAL - CONTINUED
11. Disconnect chassis wiring harness (1) from backup alarm connector (14).
13. Remove clamp (17) from chassis wiring harness (1).
0199 00-6
TM 5-3805-291-23-2
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 dam-
aged chassis wiring harness.
14. Disconnect chassis wiring harness (1) from five con-
nectors (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
REMOVAL - CONTINUED
16. 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
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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
22. Remove and discard tiedown strap (29) from chassis wiring harness (1).
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
REMOVAL - CONTINUED
27. 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).
32. Remove nut (43), washer (44), and clamp (45) from clip (46).
33. Remove clip (46) and clamp (45) from chassis wiring harness (1).
0199 00-11
TM 5-3805-291-23-2
REMOVAL - CONTINUED
36. Remove three bolts (50), washers (51) and cover (53) from box (52).
0199 00-12
TM 5-3805-291-23-2
REMOVAL - CONTINUED
37. 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
TM 5-3805-291-23-2
REMOVAL - CONTINUED
47. 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).
52. Remove two bolts (75), washers (76), clips (77), and bracket (78) from machine.
54. Disconnect jumper harness (79) of secondary steering wiring harness from chassis wiring harness (1).
0199 00-14
TM 5-3805-291-23-2
REMOVAL - CONTINUED
55. 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).
60. Disconnect chassis wiring harness (1) from engine wiring harness (88).
62. Remove two bolts (91) and washers (92) from clips (93).
0199 00-15
TM 5-3805-291-23-2
REMOVAL - CONTINUED
64. Remove and discard 14 tiedown straps (94) from chassis wiring harness (1).
65. Remove two bolts (95) and washers (96) from clips (97).
67. Remove chassis wiring harness (1) and four grommets (98) from machine. Discard grommets.
0199 00-16
TM 5-3805-291-23-2
INSTALLATION
1. Position four new grommets (98) and chassis wiring harness (1) on machine.
2. Install two clips (97) on chassis wiring harness (1).
3. Install two washers (96) and bolts (95) on clips (97).
4. Install 14 new tiedown straps (94) on chassis wiring harness (1).
6. Install two washers (92) and bolts (91) on clips (93).
7. Install chassis wiring harness (1), washer (90), and nut (89) on machine.
8. Connect engine wiring harness (88) to chassis wiring harness (1).
9. Install clip (87) on chassis wiring harness (1).
10. Install washer (86) and nut (85) on clip (87).
11. Install clips (83 and 84) on chassis wiring harness (1).
12. Install washer (82) and nut (81) on clips (83 and 84).
13. Install seven new tiedown straps (80) on chassis wiring harness (1).
0199 00-17
TM 5-3805-291-23-2
14. Connect jumper harness (79) of secondary steering wiring harness to chassis wiring harness (1).
16. Install bracket (78), clip (77), two washers (76), and bolts (75) on machine.
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
TM 5-3805-291-23-2
22. 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
TM 5-3805-291-23-2
32. Install three washers (51), bolts (50), and cover (53) on box (52).
0199 00-20
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).
38. Install washer (41) and bolt (40) on two clips (42).
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
TM 5-3805-291-23-2
42. Install three clips (35) on chassis wiring harness (1).
43. Install three nuts (33) and washers (34) on clips (35).
46. Install new tiedown strap (29) on chassis wiring harness (1).
427-C1441
0199 00-22
TM 5-3805-291-23-2
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).
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
TM 5-3805-291-23-2
51. 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
53. 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
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 dam-
aged chassis wiring harness.
56. Connect chassis wiring harness (1) to five connectors
(18) of rear lamp.
0199 00-26
TM 5-3805-291-23-2
57. Connect chassis wiring harness (1) to backup alarm connector (14).
0199 00-27
TM 5-3805-291-23-2
58. Connect chassis wiring harness (1) to hood tilt actua-
tor 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
60. 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
63. Install chassis wiring harness nut (6) and new lock-
washer (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 wir-

ing harness (1) to oil temperature sensor (5).
0199 00-30
TM 5-3805-291-23-2
66. 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. Connect chassis wiring harness to hydraulic oil temperature sensor (WP 0083 00).
70. Start machine (TM 5-3805-291-10).
71. Run machine until normal operating temperature is reached and verify correct operation of chassis wiring harness
(TM 5-3805-291-10).
END OF WORK PACKAGE
0199 00-31/(0199 00-32 Blank)

4
TM 5-3805-291-23-2
SECONDARY STEERING WIRING HARNESS REPLACEMENT 0200 00

INITIAL SETUP
References
TM 5-3805-291-10
Battery cables disconnected from battery (WP 0096
Materials/Parts 00)

0200 00-1
TM 5-3805-291-23-2
SECONDARY STEERING WIRING HARNESS REPLACEMENT - CONTINUED 0200 00
REMOVAL
WARNING
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
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
12. Connect battery cables to battery (WP 0096 00).
13. Start machine (TM 5-3805-291-10).
END OF WORK PACKAGE
0200 00-4
4
TM 5-3805-291-23-2
TRANSMISSION CONTROL WIRING HARNESS REPLACEMENT 0201 00

INITIAL SETUP


TM 5-3805-291-10
Materials/Parts
TM 5-3805-291-23P, Figure 84
0201 00-1
TM 5-3805-291-23-2
TRANSMISSION CONTROL WIRING HARNESS REPLACEMENT - CONTINUED 0201 00
REMOVAL
WARNING
NOTE
2. Remove clip (3) from transmission control wiring harness (4).
3. Remove tiedown strap (5) from transmission control wiring harness (4). Discard tiedown strap.
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
REMOVAL - CONTINUED
8. 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).
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).

17. Start machine (TM 5-3805-291-10).
18. Drive and verify correct operation of machine (TM 5-3805-291-10).

END OF WORK PACKAGE
0201 00-3/(0201 00-4 Blank)

4
TM 5-3805-291-23-2
TRANSMISSION HYDRAULIC CONTROL RELIEF VALVE REPLACEMENT 0202 00

INITIAL SETUP

0233 00)
Tools and Special Tools Oil, lubricating, refrigerant compressor: Synthetic
Tool kit, general mechanic’s, automotive (Item 90, Ester (Item 30, WP 0233 00)
Shop equipment, automotive maintenance and Tag, marker (Item 43, WP 0233 00)
repair: field maintenance, basic, less power (Item O-ring (4)
68, WP 0232 00)
Personnel Required
ft (Item 98, WP 0232 00) MOS 62B, Construction Equipment Repairer
Materials/Parts
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 10)
00)
Drawings Required
TM 5-3805-291-23P, Figure 85
00)
0233 00) 4.0 hr
0202 00-1
TM 5-3805-291-23-2
TRANSMISSION HYDRAULIC CONTROL RELIEF VALVE REPLACEMENT - CONTINUED 0202 00
REMOVAL
CAUTION
NOTE
• The transmission hydraulic control relief valve is located on the left rear side of the transmission hous-
ing.
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
NOTE
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).
WARNING

7. Start machine (TM 5-3805-291-10).
END OF WORK PACKAGE
0202 00-3/(0202 00-4 Blank)

4
TM 5-3805-291-23-2
TRANSMISSION MODULATING VALVE REPLACEMENT 0203 00

INITIAL SETUP

Direct Support
O-ring (6)
ft (Item 98, WP 0232 00) MOS 62B, Construction Equipment Repairer
WP 0014 00
0233 00)
00) Cab removed (WP 0132 00)
00)
10)
0233 00) TM 5-3805-291-23P, Figure 85
Oil, lubricating, refrigerant compressor: Synthetic
Ester (Item 30, WP 0233 00)
0203 00-1
TM 5-3805-291-23-2
TRANSMISSION MODULATING VALVE REPLACEMENT - CONTINUED 0203 00
REMOVAL
WARNING
CAUTION
NOTE
• Use a container to catch any fluid that may drain from hoses or system. Dispose of oil IAW local policy
1. Disconnect wiring harness assembly (1) from modulating valve (2).
2. Disconnect hose assembly (3) from modulating valve (2).
3. Remove O-ring (4) from hose assembly (3). Discard O-ring.
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
sonnel.
INSTALLATION
NOTE
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.
7. Perform Fill Time for Transmission Clutch (MSD) Calibration (WP 0014 00).
WARNING

9. Start machine (TM 5-3805-291-10).
10. Operate machine and verify correct operation of transmission system (TM 5-3805-291-10).
END OF WORK PACKAGE
0203 00-3/(0203 00-4 Blank)

20
TM 5-3805-291-23-2
TRANSMISSION AND TORQUE CONVERTER REPLACEMENT 0204 00
INITIAL SETUP

Direct Support
Tool kit, general mechanic’s, automotive (Item 90, References
WP 0232 00)
WP 0205 00
68, WP 0232 00)
Bracket, link (Item 16, WP 0232 00) Cab removed (WP 0132 00)
Bracket, link (Item 17, WP 0232 00) (3) Transmission oil drained (WP 0100 00)
Lever puller hoist (Item 37, WP 0232 00)
Transmission cooler lines removed (WP 0102 00)
lb-ft (Item 99, WP 0232 00) Fill tube removed (WP 0103 00)
Beam, hoisting
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) Secondary steering control valve removed (WP
0126 00)
0233 00) Center drive shaft removed (WP 0107 00)
00) Rear drive shaft removed (WP 0110 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Steering frame lock connected (TM 5-3805-291-
0233 00) 10)
Drawings Required
Paint, heat resisting (Item 32, WP 0233 00)
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
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
REMOVAL - CONTINUED
Transmission Assembly - Continued 0204 00
427-C0348-1
0204 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
4. Disconnect hose assembly (10) from modulating valve

(11).
O-ring.
6. Repeat steps 4 and 5 for remaining modulating valves.
427-C1594-1

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
REMOVAL - CONTINUED
9. 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 427-C0984
10. Attach lifting equipment to transmission assembly

(21) and torque converter (16).
427-C1936
0204 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
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
REMOVAL - CONTINUED
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).
19. Remove six bolts (28) and washers (29) from upper
427-C0987
0204 00-7
TM 5-3805-291-23-2
REMOVAL - CONTINUED
WARNING
NOTE
20. With assistance, remove torque converter and trans-

mission 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
REMOVAL - CONTINUED
Torque Converter 0204 00
1. Position torque converter (16) on wood blocks as

shown.
427-C0988
WARNING
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
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 0204 00

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
TM 5-3805-291-23-2
REMOVAL - CONTINUED 0204 00
Torque Converter Disassembly - Continued 0204 00
0204 00-11
TM 5-3805-291-23-2
WARNING
sonnel.
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
Torque Converter Assembly-Continued 0204 00
0204 00-13
TM 5-3805-291-23-2
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
Torque Converter - Continued 0204 00
3. Install 12 washers (33) and bolts (32) on torque converter (16) and transmission (21).
.
427-C0990
Transmission Assembly 0204 00
1. Install link bracket with 19 mm bolt on top of torque converter.
WARNING
NOTE
0204 00-15
TM 5-3805-291-23-2
2. 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).
427-C0987
0204 00-16
TM 5-3805-291-23-2
6. Install six washers (29) and bolts (28) on upper torque

converter (16).
7. Install five washers (29) and bolts (28) on lower
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
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 427-C0984

427-C1935
0204 00-18
TM 5-3805-291-23-2
NOTE

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
18. Install new O-ring (3) in test port line (1) and connect
line assembly to fitting (2).
427-C0975
19. Install rear oil cooler line (WP 0102 00).

20. Install handrails (WP 0134 00).
21. Install fill tube (WP 0103 00).
22. Install rear drive shaft (WP 0110 00).
24. Install secondary steering control valve (WP 0126 00).
25. Install steering control valve (WP 0127 00).
26. Install hydraulic tank (WP 0159 00).
27. Install implement piston pump (WP 0216 00).
29. Refill transmission with clean oil (WP 0100 00).
WARNING

31. Start machine (TM 5-3805-291-10).
END OF WORK PACKAGE
0204 00-20
4
TM 5-3805-291-23-2
TRANSMISSION OIL COOLER REPLACEMENT 0205 00
INITIAL SETUP

Direct Support Tag, marker (Item 43, WP 0233 00)
Personnel Required
WP 0232 00)
Lifting equipment, 100-lb capacity TM 5-3805-291-10

Cleaning compound, solvent, type III (Item 7, WP Side covers removed (WP 0135 00)
0233 00)
00) Turbocharger removed (WP 0031 00)
Oil, lubricating, OEA-30, Arctic (Item 29, WP Engine oil cooler removed (WP 0027 00)
0233 00)
Oil, lubricating, refrigerant compressor: Synthetic Drawings Required
Ester (Item 30, WP 0233 00) TM 5-3805-291-23P, Figure 89
41, WP 0233 00) 7.5 hr
WARNING
CAUTION
0205 00-1
TM 5-3805-291-23-2
TRANSMISSION OIL COOLER REPLACEMENT - CONTINUED 0205 00
NOTE
• Transmission oil cooler weighs 52 lb (24 kg).
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 trans-
mission 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

bracket (12). Position wiring harness (13) aside.
(12).
(18).
7. With assistance, remove transmission oil cooler (4)
from machine.
427-C1945
0205 00-2
TM 5-3805-291-23-2
WARNING
sonnel.

INSTALLATION
WARNING
NOTE
Transmission oil cooler weighs 52 lb (24 kg).
1. Attach lifting equipment and position transmission oil cooler (4) on machine.
4. Position wiring harness (13) and clip (11) on bracket (12) and secure with washer (10) and bolt (9).
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
8. Install engine oil cooler (WP 0027 00).
9. Install turbocharger (WP 0031 00).
12. Start machine (TM 5-3805-291-10).
13. Run machine until operating temperature is reached (TM 5-3805-291-10).
END OF WORK PACKAGE
0205 00-4
4
TM 5-3805-291-23-2
TRANSMISSION OIL PUMP (GEAR PUMP) REPLACEMENT 0206 00

INITIAL SETUP

Direct Support Oil, lubricating, TO-4 (Item 31, WP 0233 00)
O-ring (3)
Lifting equipment, 120-lb capacity Implement piston pump removed (WP 0216 00)
Materials/Parts 10)
Drawings Required
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 TM 5-3805-291-23P, Figure 90
00)
0233 00) 8.0 hr
0206 00-1
TM 5-3805-291-23-2
TRANSMISSION OIL PUMP (GEAR PUMP) REPLACEMENT - CONTINUED 0206 00
REMOVAL
CAUTION
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).
5. Remove two bolts (11) and disconnect tube assembly
(12).
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
REMOVAL - CONTINUED
9. 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
4. 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 assem-
bly (9).
9. Connect hose assembly (9), two flange halves (8), four
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
WARNING

13. Start machine (TM 5-3805-291-10).
END OF WORK PACKAGE
0206 00-4
8
TM 5-3805-291-23-2
FRONT AXLE REPLACEMENT 0207 00

INITIAL SETUP
Tools and Special Tools 0233 00)
Tool kit, general mechanic’s, automotive (Item 90, Oil, lubricating, TO-4 (Item 31, WP 0233 00)
68, WP 0232 00) O-ring
Pin, shoulder, headless (Item 48, WP 0232 00) Personnel Required
Saddle assembly, lifting block (Item 65, WP 0232 MOS 62B, Construction Equipment Repairer (2)
00)
References
TM 5-3805-291-10
WP 0015 00
Tubing assembly set, nonmetallic (Item 93, WP
0232 00) WP 0111 00
Wrench, torque, click, ratcheting, 1/2” drive, 250 Equipment Conditions
lb-ft (Item 99, WP 0232 00) 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
0233 00) 10.0 hr
WARNING
CAUTION
0207 00-1
TM 5-3805-291-23-2
FRONT AXLE REPLACEMENT - CONTINUED 0207 00
NOTE
• Use a container to catch any fluid that may drain from hoses or system. Dispose of fluids IAW local pol-
REMOVAL
1. Support machine frame with suitable support equip-
ment.
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
REMOVAL - CONTINUED
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
REMOVAL - CONTINUED
WARNING
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
REMOVAL - CONTINUED
13. Remove eight bolts (19) and washers (20) from axle
(15).
14. Use lifting equipment to lower axle (15) from
machine.
427-C1038
WARNING
sonnel.
0207 00-5
TM 5-3805-291-23-2
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
6. 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).
11. Lubricate and install new O-ring (6) on hose (5).
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
15. 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).
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
INITIAL SETUP

WP 0232 00) WP 0015 00
Shop equipment, machine shop, field maintenance,
heavy, less power (Item 69, WP 0232 00)
Rear axle drained (WP 0111 00)
lb-ft (Item 99, WP 0232 00) Rear drive shaft removed (WP 0110 00)
Lifting equipment, 5,400-lb capacity Rear tires and rims removed (WP 0120 00)
Multiplier, torque Axle temperature sensor removed (WP 0081 00)

Cap set, protective (Item 6, WP 0233 00) TM 5-3805-291-23P, Figure 97
0233 00)
10.0 hr
0233 00)
O-ring (4)
WARNING
CAUTION
0208 00-1
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.
from oscillating axle (3). Discard O-ring.
427-C0455
0208 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
4. 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
REMOVAL - CONTINUED
6. Fasten retainer around oscillating axle (3), front axle
support (12), and yoke (13) to prevent front axle sup-
port and yoke from falling.
427-C0510
WARNING
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
REMOVAL - CONTINUED
8. Remove two nuts (14) and washers (15) from rear axle
support (16) and machine frame.
427-C0512
10. With assistance, remove two nuts (17) and washers

(18) from front axle support (12) and machine frame.
12. Remove oscillating axle (3) from machine.
427-C0513
0208 00-5
TM 5-3805-291-23-2
WARNING
sonnel.
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
WARNING
NOTE
• Oscillating axle weighs 3,600 lb (1,635 kg).
2. 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).
427-C0513
0208 00-7
TM 5-3805-291-23-2
5. Install two washers (15) and nuts (14) in rear axle sup-
port (16) and machine frame.
427-C0512
7. Connect wiring harness (11).
427-C0458
0208 00-8
TM 5-3805-291-23-2
8. Position guard (10) on machine and install two wash-
ers (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
11. 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).
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
INITIAL SETUP

Bearing
Lip seal
Personnel Required
WP 0232 00)
repair: field maintenance, basic, less power (Item References
68, WP 0232 00) TM 5-3805-291-10
Lifting equipment, 150-lb capacity Equipment Conditions
Materials/Parts Rear axle removed (WP 0208 00)

0233 00) TM 5-3805-291-23P, Figures 98 and 99
Gasket cement (Item 14, WP 0233 00) Estimated Time to Complete Task
Grease, multipurpose (Item 18, WP 0233 00) 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
REMOVAL - CONTINUED
2. Remove thrust washer (5), four bolts (6), washers (7),

plate (8), and thrust washer (9) from end of trunnion
(10).
427-C0515
WARNING
NOTE
Rear support weighs 100 lb (45 kg).
3. Attach lifting equipment to rear support (4).

4. With assistance, remove rear support (4) from trun-
nion (10).
427-C0516
0209 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
5. 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
WARNING
sonnel.
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
4. 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
WARNING
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
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).
END OF WORK PACKAGE
0209 00-7/(0209 00-8 Blank)

4
TM 5-3805-291-23-2
STEERING NEUTRALIZER VALVE REPLACEMENT 0210 00

INITIAL SETUP

WP 0232 00) 10)
68, WP 0232 00)
Materials/Parts
3805-291-10)
Wheels chocked
00) Hydraulic system pressure relieved (TM 5-3805-
291-10)
10)
O-ring (6) 2.0 hr
WARNING
CAUTION
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
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 fit-

4. Remove fitting (8) and O-ring (9) from steering neu-

tralizer valve (5). Discard O-ring.
5. Disconnect tube (10) and remove O-ring (11) from fit-

6. Remove fitting (12) and O-ring (13) from steering

neutralizer valve (5). Discard O-ring.
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).
NOTE
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).
6. Install new O-ring (7) and connect tube (6) to fitting (8).
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
WARNING

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

Separation, Connection
INITIAL SETUP

Direct Support Antiseize compound (Item 2, WP 0233 00)
Tools and Special Tools Grease, molybdenum (Item 17, WP 0233 00)
Tool kit, general mechanic’s, automotive (Item 90, Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233
WP 0232 00) 00)
Shop equipment, machine shop, field maintenance, Oil, lubricating, OE/HDO-15/40 (Item 28, WP
heavy, less power (Item 69, WP 0232 00) 0233 00)
Adapter, mechanical puller (Item 8, WP 0232 00) Rag, wiping (Item 35, WP 0233 00)
Adapter, mechanical puller (Item 9, WP 0232 00) Tag, marker (Item 43, WP 0233 00)
Bearing (4)
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)
Nut, plain, hexagon (Item 44, WP 0232 00) Personnel Required
Puller, hydraulic (Item 51, WP 0232 00) MOS 62B, Construction Equipment Repairer (2)
Pump, hydraulic (Item 55, WP 0232 00) References
Pump, hydraulic ram, hand driven (Item 57, WP TM 5-3805-291-10
0232 00)
WP 0016 00
Remover, bearing and bushing (Item 61, WP 0232
Screw, cap hexagon head (Item 66, WP 0232 00) Hydraulic tank drained (WP 0148 00)
Spacer, sleeve (Item 76, WP 0232 00) Cab removed (WP 0132 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)
Hydraulic hose assemblies disconnected from front
Wrench, torque, click, ratcheting, 1/2” drive, 250 frame (WP 0156 00)
lb-ft (Item 99, WP 0232 00)
Bottle jack Drawings Required
Lifting equipment, 75,000-lb capacity TM 5-3805-291-23P, Figure 117
Multiplier, torque Estimated Time to Complete Task

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
CAUTION
NOTE
• Machine without cab weighs 50,044 lb (22,700 kg).
1. Remove bolt (1), washer (2), and pin assembly (3)
from frame (4).
2. Position steering cylinder (5) aside. Repeat for
remaining steering cylinder.
427-C1004
0211 00-2
TM 5-3805-291-23-2
SEPARATION - CONTINUED
3. Use Pump, hydraulic (Item 55, WP 0232 00) and
Stand, lift gp (Item 80, WP 0232 00) as shown to sup-
port 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
6. 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
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
11. 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
13. 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
19. Remove and discard lip seal (25) from cap (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
bearing sleeve (31) from upper hitch (19) of rear
frame. Discard bearing sleeve.
427-C1019

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
24. 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.
427-C1021 427-C1022

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
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
427-C1024
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 roll-
ing 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-C1050
0211 00-11
TM 5-3805-291-23-2
CONNECTION - CONTINUED
13. Use Bushing driver set (Item 20, WP 0232 00) to
install new lip seal (38) in cap (33).
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
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

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

install so upper bearing cup makes contact with upper 427-C1053
bearing (29).
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
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
35. 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
38. 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
42. 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
50. 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).
56. Connect front wiring harness to chassis wiring harness (WP 0197 00).
57. Start machine (TM 5-3805-291-10).
END OF WORK PACKAGE
0211 00-18
10
TM 5-3805-291-23-2
ENGINE COMPARTMENT SHIELD REPLACEMENT 0212 00

INITIAL SETUP

0233 00)
WP 0232 00) O-ring (6)
68, WP 0232 00)
References
Materials/Parts
TM 5-3805-291-10
Oil, lubricating, OE/HDO-40 (Item 26, WP 0233 Cooling system package removed (WP 0190 00)
00)
Drawings Required
00) TM 5-3805-291-23P, Figure 124

0233 00) 9.5 hr
0212 00-1
TM 5-3805-291-23-2
ENGINE COMPARTMENT SHIELD REPLACEMENT - CONTINUED 0212 00
REMOVAL
CAUTION
NOTE
• Tag hoses prior to removal to
• Use a container to catch any fluid
that may drain from hoses or sys-
tem. Dispose of fluid IAW local pol-
icy and ordinances. Ensure all spills
are cleaned up.
1. Disconnect hose (1) and remove O-ring (2) from fit-
2. Remove grommet (4) from engine compartment shield
(5). 427-C0304
3. Remove hose (6) from engine compartment shield (5)

and position aside.
0212 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
4. Remove hose (7) and O-ring (8) from fitting (9). Dis-
card O-ring.
5. Remove two fittings (9) and O-rings (10) from adapt-
ers (11). Discard O-rings.
6. Remove hose (12) and O-ring (13) from fitting (14).
Discard O-ring.
7. Remove hose (15) and O-ring (16) from fitting (17).
Discard O-ring.
427-C0305
8. Remove four bolts (18), washers (19), and plate (20).
427-C1968
0212 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
9. Loosen clamp (21) on hose (22).
10. Remove tube (23) from hose (22) and engine compart-
ment shield (5).
427-C0306
11. Remove two bolts (24), washers (25), and nut (26)
from engine compartment shield (5). Repeat for oppo-
site side.
427-C0307
0212 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
12. Remove two bolts (27), washers (28), and nuts (29)
from engine compartment shield (5). Repeat for oppo-
site side.
13. Remove engine compartment shield (5) from cooling
assembly (30).
427-C0308
WARNING
sonnel.
0212 00-5
TM 5-3805-291-23-2
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
4. 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).
NOTE
Apply a thin coat of clean oil to all
7. Install new O-ring (16) and hose (15) on fitting (17).
427-C1968
0212 00-7
TM 5-3805-291-23-2
9. Install two new O-rings (10) and fittings (9) on adapt-
ers (11).
427-C0305
11. Install hose (6) through engine compartment shield

(5).
12. Install grommet (4) on engine compartment shield (5).
13. Install new O-ring (2) and connect hose (1) to fitting
(3).
427-C0304
0212 00-8
TM 5-3805-291-23-2
15. Start engine (TM 5-3805-291-10).
END OF WORK PACKAGE
0212 00-9/(0212 00-10 Blank)

4
TM 5-3805-291-23-2
WINDSHIELD FRONT/REAR AND DOORS GLASS REPLACEMENT 0213 00

INITIAL SETUP

WP 0232 00)
Wheels chocked
68, WP 0232 00)

0233 00) TM 5-3805-291-23P, Figure 130
Twine, 20 ft 1.5 hr ea
0213 00-1
TM 5-3805-291-23-2
WINDSHIELD FRONT/REAR AND DOORS GLASS REPLACEMENT - CONTINUED 0213 00
REMOVAL
WARNING
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:
• 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).
4. 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
sonnel.
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. Pres-
sure 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.
END OF WORK PACKAGE
0213 00-3/(0213 00-4 Blank)

28
TM 5-3805-291-23-2
SEAT ASSEMBLY REPAIR 0214 00

Disassembly, Cleaning and Inspection, Assembly
INITIAL SETUP

Direct Support Lockwasher
Personnel Required
WP 0232 00)
References
68, WP 0232 00)
Wrench, torque, click, ratcheting, 3/8” drive, 75 lb- TM 5-3805-291-10
ft (Item 98, WP 0232 00)
Wood block, 2 x 4 in. x 1 ft
Seat removed from machine (WP 0140 00)
Materials/Parts
Seat belts removed from seat (WP 0141 00)
Cotter pin (2) 4.5 hr
DISASSEMBLY
Seat Assembly 0214 00
1. 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
Seat Assembly - Continued 0214 00
2. 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
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
WARNING
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
WARNING
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
16. 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
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
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
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 sus-
pension assembly (44).
427-C1412
5. Remove and discard tiedown strap (51) from two wir-

ing connectors (52).
6. Disconnect two wiring connectors (52) from upper
housing assembly (53).
427-C1413
0214 00-8
TM 5-3805-291-23-2
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
11. 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
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-C1418 427-C1419
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
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 assem-
bly (83). Discard O-ring.
23. Remove bolt (84) and spring assembly (83) from scis-
sor assembly (57).
427-C1422
0214 00-12
TM 5-3805-291-23-2
24. 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
WARNING
sonnel.

ASSEMBLY 0214 00
Suspension Assembly 0214 00
NOTE
1. Install and firmly seat compressor assembly (86) in mount (87).
427-C1424
0214 00-14
TM 5-3805-291-23-2
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
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
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
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
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 connec-
tors (52).
427-C1413
0214 00-19
TM 5-3805-291-23-2
23. Install two shafts (50) and four nuts (49) on suspen-
sion 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
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
5. Install handle (32) and two springs (31) on seat assem-

bly (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
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
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
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
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 assem-
bly (3).
427-C1249
0214 00-26
TM 5-3805-291-23-2
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. Start engine (TM 5-3805-291-10).
23. Verify correct operation of seat assembly (TM 5-3805-291-10).
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

INITIAL SETUP

Tool kit, general mechanic’s, automotive (Item 90, Gasket
WP 0232 00) O-ring (8)
Personnel Required
68, WP 0232 00) MOS 62B, Construction Equipment Repairer
Cap set, protective (Item 6, WP 0233 00) TM 5-3805-291-10
0233 00)
0233 00)
0233 00) 4.0 hr
0215 00-1
TM 5-3805-291-23-2
BRAKING AND HYDRAULIC FAN PUMP REPLACEMENT - CONTINUED 0215 00
REMOVAL
WARNING
CAUTION
NOTE
0215 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
2. Disconnect hose assemblies (2 and 3) from fittings (4
and 5).
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
REMOVAL - CONTINUED
5. 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).

427-C0589
0215 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
piston pump (15).
427-C0590
9. Disconnect oil fill tube (22) from block (23) and posi-
tion oil fill tube aside.
427-C0591
0215 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
10. 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
sonnel.
1. Scrape all gasket material from mating surfaces and clean with solvent cleaning compound.
0215 00-6
TM 5-3805-291-23-2
INSTALLATION
NOTE
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
5. Install two new O-rings (18) and connect hose assem-
bly (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 spac-

ers (9), washers (8), and bolts (7).
427-C0587
0215 00-8
TM 5-3805-291-23-2
blies (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
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
12
TM 5-3805-291-23-2
PISTON PUMPS (STEERING AND IMPLEMENT/PILOT) REPLACEMENT 0216 00
INITIAL SETUP

WP 0232 00)
Personnel Required
Lifting equipment, 360-lb capacity TM 5-3805-291-10
Cap set, protective (Item 6, WP 0233 00) Cab removed (WP 0132 00)
0233 00)
Hydraulic service box removed (WP 0133 00)
0233 00)
0233 00) 10.0 hr
0216 00-1
TM 5-3805-291-23-2
PISTON PUMPS (STEERING AND IMPLEMENT/PILOT) REPLACEMENT - CONTINUED 0216 00
REMOVAL
WARNING
CAUTION
NOTE
Piston Pump (Steering) 0216 00
1. Disconnect three hose assemblies (1) from piston

steering pump (2). Remove and discard three O-rings
(3).
halves (6) and disconnect hose assembly (7) from pis-
ton steering pump (2). Remove and discard O-ring (8).
3. Disconnect tube assembly (9) from piston steering
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
REMOVAL - CONTINUED
Piston Pump (Steering) - Continued 0216 00
6. 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 steer-
ing pump (2) from machine.
427-C0578
0216 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
9. Remove coupling (22) from piston steering pump (2).
11. Remove two fittings (24) from piston steering pump
(2).
O-rings.
427-C0579
Piston Pump (Implement/Pilot) 0216 00

1. Disconnect two hose assemblies (26) from fittings (27).
3. Remove four bolts (29), washers (30), and two flange halves (31).
4. Remove tube (32) from hydraulic tank (33).
6. Remove four bolts (35), washers (36), and flange (37).
7. Disconnect tube (38) from piston implement pump (39).
0216 00-4
TM 5-3805-291-23-2
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).
427-C0582
427-C1886
0216 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
13. Attach lifting equipment to piston implement pump
(39).
(49) from piston implement pump (39). Remove pis-
ton 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
WARNING
sonnel.
0216 00-7
TM 5-3805-291-23-2
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
4. 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
Piston Pump (Steering) 0216 00
NOTE
Apply a thin coat of clean oil to all
1. Install two new O-rings (25) in fittings (24). Install fit-
tings on piston steering pump (2).
2. Install new O-ring (23) on coupling (22). Install cou-
pling 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
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 assem-
blies (1) to piston steering pump (2).
427-C0577

13. Install hydraulic service box (WP 0133 00).
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).
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

INITIAL SETUP

O-ring (14)
Materials/Parts 291-10)
Cap set, protective (Item 6, WP 0233 00) Steering frame lock connected (TM 5-3805-291-
10)
0233 00) Hood opened (TM 5-3805-291-10)
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 Right side cover removed (WP 0135 00)
00)
Drawings Required
TM 5-3805-291-23P, Figure 147
0233 00)
0233 00) 2.0 hr
WARNING
0217 00-1
TM 5-3805-291-23-2
BRAKE CHARGE AND HYDRAULIC FAN CONTROL MANIFOLD REPLACEMENT - CONTINUED 0217 00
CAUTION
NOTE
REMOVAL
1. Disconnect engine wiring harness (1) from demand
fan solenoid (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
REMOVAL - CONTINUED
5. Remove two fittings (10) and O-rings (11) from con-
trol manifold (7). Discard O-rings.
427-C1102
6. Disconnect three hoses (12) and remove O-rings (13)

7. Remove three fittings (14) and O-rings (15) from con-
trol manifold (7). Discard O-rings.
427-C1103
0217 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
8. Remove two bolts (16) and spacers (17) from control
manifold (7).
9. Remove control manifold (7) from engine (18).
427-C1104
INSTALLATION
WARNING
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 depos-
ited 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
NOTE
3. Install three new O-rings (15) and fittings (14) on con-
trol 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 con-

trol 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
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 sole-
noid (2).
10. Install right side cover (WP 0135 00).

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

END OF WORK PACKAGE
0217 00-6
14
TM 5-3805-291-23-2
MAIN HYDRAULIC CONTROL VALVE REPLACEMENT 0218 00
Main Hydraulic Control Valve: Removal, Cleaning and Inspection, Installation

Solenoid Valve: Removal, Installation
INITIAL SETUP

Direct Support Oil, lubricating, OE/HDO-15/40 (Item 28, WP
0233 00)
Tool kit, general mechanic’s, automotive (Item 90, Oil, lubricating, OEA-30, Arctic (Item 29, WP
WP 0232 00) 0233 00)
Shop equipment, automotive maintenance and Rag, wiping (Item 35, WP 0233 00)
repair: field maintenance, basic, less power (Item Strap, tiedown, electrical components (Item 42, WP
68, WP 0232 00) 0233 00)
Bracket, link (Item 17, WP 0232 00) (2) Tag, marker (Item 43, WP 0233 00)
Lever puller hoist (Item 37, WP 0232 00) (2)
O-ring (20)
Pin, shoulder, headless (Item 48, WP 0232 00)
Saddle assembly, lifting block (Item 65, WP 0232 Personnel Required
00) MOS 62B, Construction Equipment Repairer (2)
Shackle assembly (Item 67, WP 0232 00)
Tube, metallic (Item 92, WP 0232 00)
291-10)
ft (Item 98, WP 0232 00) Wheels chocked
Materials/Parts
0233 00)
00) 12.0 hr
0218 00-1
TM 5-3805-291-23-2
MAIN HYDRAULIC CONTROL VALVE REPLACEMENT - CONTINUED 0218 00
MAIN HYDRAULIC CONTROL VALVE REMOVAL
WARNING
CAUTION
NOTE
1. Use stand assembly to support lift arms (1).
427-C0599
0218 00-2
TM 5-3805-291-23-2
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
427-C1106
0218 00-3
TM 5-3805-291-23-2

10. Disconnect two hose assemblies (22) from main
hydraulic control valve (20).
Discard O-rings.
427-C1107
12. Disconnect hose assembly (24) from main hydraulic control valve (20).
13. Remove O-ring (25) from hose assembly (24). Discard O-ring.
14. Disconnect two hose assemblies (26) from main hydraulic control valve (20).
15. Remove two O-rings (27) from hose assembly (26). Discard O-ring.
16. Disconnect two hose assemblies (28) from main
hydraulic control valve (20).
Discard O-rings.
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 con-
trol valve.
Discard O-rings.
20. Disconnect 12 connectors (35) from main hydraulic
control valve (20).
427-C1108
0218 00-4
TM 5-3805-291-23-2
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 427-C1110
0218 00-5
TM 5-3805-291-23-2
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
MAIN HYDRAULIC CONTROL VALVE CLEANING AND INSPECTION
WARNING
sonnel.
0218 00-7
TM 5-3805-291-23-2
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
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 cylin-
der (39).
427-C1112
0218 00-9
TM 5-3805-291-23-2
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

5. 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).

valve (20).

valve (20).
427-C1108
10. Install new O-ring (25) in hose assembly (24) and con-
nect hose assembly to main hydraulic control valve
(20).

valve (20).
427-C1107
0218 00-11
TM 5-3805-291-23-2

12. 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

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

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).
END OF WORK PACKAGE
0218 00-13/(0218 00-14 Blank)

2
TM 5-3805-291-23-2
ELECTROHYDRAULIC CONTROL (JOYSTICK) REPLACEMENT 0219 00

INITIAL SETUP

Direct Support Work tool lowered to ground (TM 5-3805-291-10)
Tool kit, general mechanic’s, automotive (Item 90, Wheels chocked
WP 0232 00)
Tag, marker (Item 43, WP 0233 00) 10)
TM 5-3805-291-23P, Figure 151
10) 0.5 hr
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
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 for-
ward 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. Position electrohydraulic control (3) on machine and install four bolts (2).
3. Adjust boot (1) to cover four bolts (2) on electrohydraulic control (3).
WARNING

5. Run engine and verify correct operation of electrohydraulic control (TM 5-3805-291-10).
END OF WORK PACKAGE
0219 00-2
2
TM 5-3805-291-23-2
HEATER CORE REPLACEMENT 0220 00
INITIAL SETUP
WP 0232 00)
AC system recovered (WP 0222 00)
Shop equipment, automotive maintenance and Lower housing removed from heater assembly (WP
repair: field maintenance, basic, less power (Item 0227 00)
68, WP 0232 00)
Drawings Required
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 cool-
ing. 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 sys-
tem. 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
REMOVAL - CONTINUED
1. 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).
WARNING

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
INITIAL SETUP
Direct Support MOS 52C, Utilities Equipment Repairer

Hood opened and side cover removed (TM 5-3805-
WP 0232 00)
291-10)
repair: field maintenance, basic, less power (Item Steering frame lock connected (TM 5-3805-291-
68, WP 0232 00) 10)
AC refrigerant recovered (WP 0222 00)

Materials/Parts
Cap set, protective (Item 6, WP 0233 00) Serpentine belt removed (WP 0048 00)

TM 5-3805-291-23P, Figure 173
O-ring (2) 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.
CAUTION
0221 00-1
TM 5-3805-291-23-2
AIR CONDITIONING SYSTEM COMPRESSOR REPLACEMENT - CONTINUED 0221 00
REMOVAL - CONTINUED
NOTE
2. Remove two hoses (3) and O-rings (4) from fittings (5). Discard O-rings.
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
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).
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).
WARNING

11. Start engine (TM 5-3805-291-10).
12. Verify AC system operation (TM 5-3805-291-10).
END OF WORK PACKAGE
0221 00-3/(0221 00-4 Blank)

8
TM 5-3805-291-23-2
AIR CONDITIONING SYSTEM SERVICE 0222 00
Recovery, Evacuation, Charging
INITIAL SETUP

WP 0232 00) Hood opened (TM 5-3805-291-10)
Shop equipment, automotive maintenance and Machine parked on level ground (TM 5-3805-291-
68, WP 0232 00)
Reclaimer, refrigerant R-134a (Item 60, WP 0232
00) Parking brake engaged (TM 5-3805-291-10)

Oil, lubricating, refrigerant compressor: Synthetic Battery disconnect switch in OFF position (TM 5-
Ester (Item 30, WP 0233 00) 3805-291-10)
Tetrafluoroethane, technical (Refrigerant, R-134a)
(Item 46, WP 0233 00) 2.0 hr
RECOVERY 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 com-
pressed 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
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
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
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
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
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).
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
INITIAL SETUP


Tool kit, general mechanic’s, automotive (Item 90, Discharge AC system (WP 0222 00)
WP 0232 00) Hoses removed from heater core (WP 0220 00)
Shop equipment, automotive maintenance and Hoses removed from compressor (WP 0221 00)
68, WP 0232 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)
10)
Drawings Required
TM 5-3805-291-23P, Figure 174
Tetrafluoroethane, technical (Refrigerant, R-134a)
(Item 46, WP 0233 00) Estimated Time to Complete Task
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
ing. 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 perme-
ation.
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

REMOVAL - CONTINUED
3. 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

REMOVAL - CONTINUED
9. Remove three bolts (19), washers (20), and clips (21) from hoses (13 and 16).
427-C1252
0223 00-4
TM 5-3805-291-23-2

REMOVAL - CONTINUED
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

REMOVAL - CONTINUED
17. 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

REMOVAL - CONTINUED
24. 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).
427-C1256
0223 00-7
TM 5-3805-291-23-2

REMOVAL - CONTINUED
30. 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
NOTE
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

3. Install three clips (54) on hoses (36 and 34) and position hoses on machine.
4. Install three washers (53) and bolts (52) on machine.
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

9. 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

16. 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).
427-C1253
0223 00-11
TM 5-3805-291-23-2

22. Position hoses (16 and 13) on machine.
23. Install three clips (21), washers (20), and bolts (19) on hoses (16 and 13).
427-C1252
0223 00-12
TM 5-3805-291-23-2

26. 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

30. 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).
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

WARNING

END OF WORK PACKAGE
0223 00-15/(0223 00-16 Blank)

4
TM 5-3805-291-23-2
INLINE REFRIGERANT DRYER REPLACEMENT 0224 00

INITIAL SETUP

WP 0232 00) Hood opened (TM 5-3805-291-10)
68, WP 0232 00)
Materials/Parts
AC refrigerant serviced (WP 0222 00)
TM 5-3805-291-23P, Figure 175
O-ring (2) 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
REMOVAL - CONTINUED
2. 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 mount-
ing bracket (9).
4. Remove two bolts (10) and washers (11) from mount-
ing 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).
NOTE
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
5. Install new O-ring (2) in tube (1) and connect tube to
inline refrigerant dryer (3).
WARNING

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

INITIAL SETUP

WP 0232 00) Hood opened (TM 5-3805-291-10)
68, WP 0232 00)
Materials/Parts
AC refrigerant recovered (WP 0222 00)
TM 5-3805-291-23P, Figure 175
O-ring (2) 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
REMOVAL - CONTINUED
2. 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 accumu-
lator (3) from hydraulic tank (9).
5. Drain and measure old oil from refrigerant accumula-
tor (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).
NOTE
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).
WARNING

12. Close hood (TM 5-3805-291-10).
END OF WORK PACKAGE
0225 00-3/(0225 00-4 Blank)

6
TM 5-3805-291-23-2
AIR CONDITIONING SYSTEM CONDENSER REPLACEMENT 0226 00

INITIAL SETUP

WP 0232 00) Steering frame lock connected (TM 5-3805-291-
repair: field maintenance, basic, less power (Item Radiator screen access door opened (TM 5-3805-
68, WP 0232 00) 291-10)
Materials/Parts AC refrigerant recovered (WP 0222 00)
Ester (Item 30, WP 0233 00) TM 5-3805-291-23P, Figure 176
O-ring (2) 4.0 hr
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 O-

rings (2) from condenser (3). Discard O-rings.
2. Remove two bolts (4) and washers (5) from mounting
bracket (6).
0226 00-2
TM 5-3805-291-23-2
REMOVAL - CONTINUED
3. Remove two bolts (7) and washers (8) from mounting
bracket (9).
4. Remove refrigerant condenser (3) from mounting
brackets (6 and 9).
427-C1193
WARNING
sonnel.
0226 00-3
TM 5-3805-291-23-2
INSTALLATION
NOTE
1. Position refrigerant condenser (3) on mounting brack-
ets (9 and 6).
2. Install two washers (8) and bolts (7) on mounting
bracket (9).
427-C1193
3. Install two washers (5) and bolts (4) on mounting

bracket (6).
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
WARNING

8. Close radiator screen access door (TM 5-3805-291-10).
END OF WORK PACKAGE
0226 00-5/(0226 00-6 Blank)

10
TM 5-3805-291-23-2
EVAPORATOR CORE REPLACEMENT 0227 00
INITIAL SETUP

WP 0220 00
68, WP 0232 00)
Outside cab filter removed (TM 5-3805-291-10)
Materials/Parts AC system discharged (WP 0222 00)
Cap set, protective (Item 6, WP 0233 00) AC refrigerant R-134a recovered (WP 0222 00)
Coolant drained (WP 0041 00)
Ester (Item 30, WP 0233 00) AC/heater blower motor removed (WP 0168 00)

Evaporator core Estimated Time to Complete Task

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
• Tag hoses and wiring harnesses prior to removal to ensure correct installation.
1. Disconnect wiring harness (1) from wiring harness

(2).
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
REMOVAL - CONTINUED
4. 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
REMOVAL - CONTINUED
6. 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
REMOVAL - CONTINUED
10. 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
REMOVAL - CONTINUED
12. 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
4. 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
7. 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
blies (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
13. 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).
WARNING

20. Check for coolant leaks.
END OF WORK PACKAGE
0227 00-10
16
TM 5-3805-291-23-2
BUCKET TILT LEVER AND LINK REPLACEMENT 0228 00
INITIAL SETUP
Maintenance Level Tools and Special Tools - Continued
Direct Support Sleeve, assembly (Item 73, WP 0232 00)

Sleeve assembly (Item 74, WP 0232 00)
Stud, plain (Item 82, WP 0232 00)
Tool kit, general mechanic’s, automotive (Item 90, Washer, flat (Item 94, WP 0232 00)
WP 0232 00)
Washer, flat (Item 95, WP 0232 00) (4)
Shop equipment, automotive maintenance and Lifting equipment, 1,300-lb capacity
68, WP 0232 00) Jack stand
Adapter, mechanical puller (Item 7, WP 0232 00) Materials/Parts

Adapter, puller (Item 10, WP 0232 00) 0233 00)
Adapter, threaded (Item 12, WP 0232 00) Grease, automotive and artillery, GAA (Item 15,
WP 0233 00)
Extractor, screw (Item 28, WP 0232 00) Lip seal (6)
Inserter end remover, pin (Item 36, WP 0232 00) Personnel Required
Nut, fastener (Item 43, WP 0232 00) MOS 62B, Construction Equipment Repairer (2)
Nut, plain, hexagon (Item 45, WP 0232 00) Equipment Conditions
Nut, plain, round (Item 46, WP 0232 00) Steering frame lock connected (TM 5-3805-291-
10)
Nut, plain, round (Item 47, WP 0232 00) Battery disconnect switch in OFF position (TM 5-
3805-291-10)
Tilt kickout position sensor removed (WP 0089 00)
Pump, hydraulic ram, hand driven (Item 57, WP
0232 00) (2) Drawings Required
TM 5-3805-291-23P, Figure 181
Remover, bearing and bushing (Item 61, WP 0232
00) Estimated Time to Complete Task
Rod, threaded end (Item 64, WP 0232 00) (4) 6.0 hr
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
REMOVAL - CONTINUED
Tilt Link - Continued 0228 00
NOTE
Items 36, 47, 52, 57, 82, and 94 (WP 0232
00) are assembled to make puller assem-
bly 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 assem-
bly as shown.
5. Using puller assembly, remove rear pin assembly (9)
from machine.
427-C1126
0228 00-3
TM 5-3805-291-23-2
REMOVAL - CONTINUED
WARNING
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
REMOVAL - CONTINUED
Tilt Lever 0228 00
1. Place jack stand under bucket tilt link (1).
427-C1128

pin assembly (15).
427-C1130
WARNING
NOTE
• Tooling weighs 75 lb (34 kg).
0228 00-5
TM 5-3805-291-23-2
REMOVAL - CONTINUED
Tilt Lever - Continued 0228 00
NOTE
Items 36, 43, 52, 57, 82, and 94 (WP
assembly as shown.
3. Use lifting equipment to support rod end of tilt cylin-
der (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
• Tilt lever weighs 840 lb (380 kg).
• Tooling weighs 75 lb (34 kg).
7. Use lifting equipment to support tilt lever (17).
427-C1132
0228 00-6
TM 5-3805-291-23-2
REMOVAL - CONTINUED
8. With assistance, remove bolt (18), washer (19), and

spacer (20) from pin assembly (21).
427-C1133
NOTE
• 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.
9. Using puller assembly, remove pin assembly (21)
from machine.
427-C1134
pin assembly (25).
427-C1135
0228 00-7
TM 5-3805-291-23-2
REMOVAL - CONTINUED
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
REMOVAL - CONTINUED
NOTE
Items 43, 47, 52, 57, 82, 94, and 95 (WP
assembly as shown.
14. Using puller assembly, remove bearing (27) from tilt
lever (17).
427-C1138
WARNING
sonnel.
0228 00-9
TM 5-3805-291-23-2
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
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
CAUTION
Aligning bores of tilt lever and bucket tilt link is important. Improper alignment can damage lip seals dur-
ing 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
13. 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
Tilt Link 0228 00
NOTE
Items 10, 36, 47, 52, 57, 82, and 94 (WP
assembly as shown.
1. Lower temperature of all bearings (11) before installa-
tion.
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
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).
WARNING

9. Operate machine and verify correct operation of bucket tilt system (TM 5-3805-291-10).
END OF WORK PACKAGE
0228 00-15/(0228 00-16 Blank)

16
TM 5-3805-291-23-2
BUCKET LIFT ARMS REPLACEMENT 0229 00
INITIAL SETUP

Direct Support Cap set, protective (Item 6, WP 0233 00)
Tools and Special Tools Cleaning compound, solvent, type III (Item 7, WP
0233 00)
WP 0232 00) Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233
00)
repair: field maintenance, basic, less power (Item Oil, lubricating, OE/HDO-15/40 (Item 28, WP
68, WP 0232 00) 0233 00)
Adapter, mechanical puller (Item 5, WP 0232 00) Oil, lubricating, OEA-30, Arctic (Item 29, WP
0233 00)
Adapter, mechanical puller (Item 6, WP 0232 00)
Adapter, puller (Item 10, WP 0232 00)
Bushing driver set (Item 19, WP 0232 00) Tag, marker (Item 43, WP 0233 00)
Bushing driver set (Item 20, WP 0232 00) Lip seal (6)
Inserter end remover, pin (Item 36, WP 0232 00) O-ring (6)
Nut, plain, round (Item 47, WP 0232 00) Personnel Required

Pin, shoulder, headless (Item 48, WP 0232 00) (2) MOS 62B, Construction Equipment Repairer (2)
Pump, hydraulic ram, hand driven (Item 57, WP
0232 00) Bucket removed (TM 5-3805-291-10)
Saddle assembly, lifting block (Item 65, WP 0232 Bucket tilt link and lever removed (WP 0228 00)
00) (2)
Tilt cylinder removed (WP 0152 00)
Sleeve (Item 72, WP 0232 00)
Lift kickout position sensor and mounting bracket
Stand assembly (Item 79, WP 0232 00) (2) removed (WP 0085 00)
Stud, plain (Item 82, WP 0232 00) Quick coupler removed (WP 0169 00)
Tubing assembly set, nonmetallic (Item 93, WP
Drawings Required
0232 00) (2)
TM 5-3805-291-23P, Figures 179 and 181
Washer, flat (Item 94, WP 0232 00)
Lifting equipment, 4,600-lb capacity Estimated Time to Complete Task
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. Remove bolt (5), washer (6), and spacer (7) from pin assembly (2).
WARNING
NOTE
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
REMOVAL - CONTINUED
NOTE
7. Disconnect two wiring harnesses (12) from lighting

assembly (9).
8. Remove four bolts (10) and washers (11) from light-
ing assembly (9) and position aside.
WARNING
CAUTION
0229 00-3
TM 5-3805-291-23-2
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

disconnect hose assembly (18) from fitting (19).
O-ring.
14. Repeat steps 12 and 13 for other side of machine.
427-C1170
0229 00-4
TM 5-3805-291-23-2
REMOVAL - CONTINUED
15. Remove four bolts (21) and washers (22) and discon-
nect hose assembly (23) from fitting (24).
O-ring.
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
REMOVAL - CONTINUED
20. 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
REMOVAL - CONTINUED
WARNING
NOTE
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
REMOVAL - CONTINUED
25. 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

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
WARNING
sonnel.
0229 00-9
TM 5-3805-291-23-2
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

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
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
WARNING
NOTE
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
8. 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 assem-
bly set, nonmetallic (Item 93, WP 0232 00).
427-C1273
NOTE
9. Install all associated clips and brackets to secure wir-
ing harness (26) to lift arm (1).
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
12. 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
16. Position lighting assembly (9) on machine and install
four washers (11) and bolts (10).
17. Connect two wiring harnesses (12) to lighting assem-
bly (9).
427-A1581
0229 00-15
TM 5-3805-291-23-2
WARNING
NOTE
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).
END OF WORK PACKAGE
0229 00-16
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 mainte-
nance 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 spe-
cial 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 characteris-
tics 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 decon-
taminate, 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 diag-
nostic equipment used in precision measurement. Consists of comparisons of two instruments, one of which is a certi-
fied 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 assem-
bly) 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 Recover-
ability (SMR) code.
9. Repair. The application of maintenance services, including fault location/troubleshooting, removal/installation, disas-
sembly/assembly procedures, and maintenance actions to identify troubles and restore serviceability to an item by cor-
recting 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 mal-
functioning; 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 con-
dition 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 appro-
priate 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 repre-
sents 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 nec-
essary 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 indi-
vidual tools), common Test, Measurement, and Diagnostic Equipment (TMDE), special tools, special TMDE, and spe-
cial 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 indi-
cated 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) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT
UNIT DS GS DEPOT TOOLS AND

GROUP COMPONENT/ MAINTENANCE EQUIPMENT REMARKS
NUMBER ASSEMBLY FUNCTION C O F H D REF CODE CODE
01 ENGINE
Engine Test 1.0 3,13,49,68,75, E
84,86,87,89,90
0100 Engine Assembly Inspect 0.3 B
Service 0.1 0.7 70,90 B
Replace 40.5 15,22, A
41,68,90,99
Rebuild 60 D
Engine Mounts Inspect 0.3
Replace 0.8 70,90
0101 Crankcase, Block, and
Cylinder Head
Cylinder Block Inspect 0.7 D
Replace 20.0 D
Repair 8.0 D
Cylinder Head Inspect 0.5
Assembly Replace 22.5 68,90,98,99 A
Rebuild 8.0 D
0102 Crankshaft
Crankshaft Inspect 0.5 D
Replace 14.5 D
Repair 1.5 D
Front Main Seal Replace 10.5 68,90
Rear Main Seal Replace 39.0 68,90
Vibration Damper and Inspect 0.3 68,90
Pulley Replace 9.0 68,90
0103 Flywheel
Flywheel Inspect 38.0 25,26,
68,90
Replace 38.0 25,26,
68,90
Flywheel Housing Inspect 42.0 25,26,68,90
Replace 42.0 25,26,68,90
0104 Piston, Connecting Rods Inspect 0.5 D
Replace 8.0 D
0232 00-1
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) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

01 ENGINE - Continued
0105 Valves, Camshaft, and
Timing System
Camshaft Inspect 0.5 D
Replace 3.5 D
Front Cover Replace 27.0 68,90
Housing (Front) Replace 48.0 D
Intake/Exhaust Valves Adjust 3.0 49,68,89,90,98 B
Replace 4.0 D
Rocker Arm Group Replace 5.0 19,68,90,98
Valve Cover and Base Replace 1.5 70,90
0106 Engine Lubrication
System
Crankcase Breather Service 0.7 70,90 B
Replace 0.7 70,90
Oil Cooler Core Inspect 0.1 B
Replace 2.0 70,90 A
Oil Filler Tube and Inspect 0.01 B
Dipstick Tube Replace 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 16.0 68,90
Repair 16.0 68,90 A
Oil Pump Replace 19.0 68,90
Piston Cooling Jets Replace 16.5 68,90,98
Turbocharger Oil Lines Replace 0.5 70,90
0108 Manifolds
Exhaust Manifold Replace 4.0 68,90
Intake Manifold Replace 3.0 68,90
0109 Accessory Driving
Mechanisms
Idler Gears Replace 15.0 68,90 A
0232 00-2
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

03 FUEL SYSTEM
Fuel System Inspect 1.0 21,70,84, E
87,88,90
Test 1.0 21,70,84, E
87,88,90
0301 Fuel Injector Test 3.0 3,68,75,
86,90,96,98
Adjust 3.0 3,68,75, B
86,90,96,98
Replace 3.0 3,68,75,
86,90,96,98
0302 Fuel Pumps
Filter Lines and Fittings Replace 2.0 70,90
Fuel Priming Pump Replace 2.0 70,90
Fuel Transfer Pump Replace 2.0 68,90 A
Secondary Fuel Filter Replace 2.0 70,90
Base
0304 Air Cleaner Assembly Inspect 0.2 B
Service 0.3 B
Replace 2.0 17,70,90
0305 Turbocharger
After Cooler Inspect 0.1 B
Replace 11.0 17,68,90
After Cooler (Air Replace 3.0 70,90
Intake) Air Lines
Turbocharger Inspect 0.5 70,90,98
Replace 0.5 70,90,98
Turbocharger Air Lines Inspect 0.03 0.5 B
Replace 3.0 70,90
0306 Tanks, Lines, Fittings,
and Headers
Fuel Tank Inspect 0.1 B
Replace 4.0 70,90
Fuel Tank Lines, Inspect 0.03 B
Fittings, and Hoses Replace 0.5 70,90
0232 00-3
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

03 FUEL SYSTEM -
Continued
0309 Fuel Filter Elements
Primary Fuel Filter Service 0.1 B
Replace 0.5 70,90 B
Secondary Fuel Filter Replace 0.5 70,90 B
0311 Engine Starting Aids
Cold (Ether) Starting Inspect 0.1 B
Aid Replace 1.5 90
0312 Throttle Pedal Replace 0.5 70,90,96
Repair 0.5 70,90
04 EXHAUST SYSTEM
0401 Muffler and Pipes
Exhaust Pipes and Inspect 0.1 B
Clamps Replace 0.5 70,90,98
Muffler Inspect 0.1 B
Replace 0.5 70,90,98
05 COOLING SYSTEM
Cooling System Inspect 0.5 E
Test 0.2 1.0 70,85,88,90 B,E
Service 0.2 1.0 70,90 B
0501 Radiator or Heat
Exchanger
Fan Shroud Replace 11.0 5,17,68,90
Radiator Inspect 0.1 0.3 B
Service 0.2 70,90 B
Replace 2.0 16,68,90
0503 Water Manifold, Headers,
Thermostats, and
Housings
Cooling System Lines Inspect 0.01 B
Replace 2.0 70,90
Thermostat Replace 1.5 70,90 B
Top Tank Replace 1.0 70,90
0504 Water Pump Test 0.5 70,87,90
Replace 1.0 70,90
0232 00-4
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

05 COOLING SYSTEM -
Continued
0505 Fan Assembly Inspect 0.03 B
Replace 11.5 5,17,68,90
Hydraulic Motor, Fan Replace 11.0 5,17,68,90,98 A
0507 Hydraulic Oil Cooler Inspect 0.1 B
Replace 2.5 68,90
06 ELECTRICAL
SYSTEM
Electrical System Test 0.3 1,2,3,4,14,18, E
40,50,62,75,
83,86,90,91,97,
98
0601 Generator, Alternator
Accessory Support 14.5 68,90
Brackets
Alternator Replace 2.0 70,90,98,99 A
Belt Tensioner and Idler Replace 1.0 70,90,98
Pulleys
Serpentine Belt Inspect 0.2 90 B
Replace 0.5 90
0603 Starting Motor
Starter Adjust 2.0 70,90
Replace 1.5 70,90,98
0607 Instrument Panel
Fuse/Relay Block Replace 1.0 90
Fuse, Relay, and Circuit Replace 0.3 90
Breakers
Instrument Cluster Replace 0.2 70,90
Instrument Panels Inspect 0.1 B
Replace 1.0 90
Repair 1.0 90
Messenger ECM Replace 2.0 3,75,86,90
0608 Miscellaneous Items
0232 00-5
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

06 ELECTRICAL
SYSTEM - Continued
ARC Suppressor Replace 0.5 90
Engine Electronic Replace 2.0 3,75,86,90
Control Module (ECM)
Hood Tilt Actuator Service 0.2 0.2 70,90 B,C
Replace 1.0 17,70,90
Hood Tilt Switch Replace 0.5 90
Implement Electronic Calibrate 1.0 3,75,86,90 E
Control Module (ECM) Replace 2.0 3,75,86,90,97
Main Light Switch Replace 0.2 90
Power Converter Replace 1.0 70,90
Power Train Electronic Replace 2.0 3,75,86,90
Control Module (ECM)
Rear Camera Replace 5.0 98
Stoplight Limit Switch Adjust 0.5 70,90
Replace 0.5 70,90
Turnlamp Flasher Replace 0.5 70,90
Turnlamp Switch Replace 0.5 70,90
Wiper Switch Replace 0.3 90
0609 Lights
Blackout Drive Inspect 0.02 B
Replace 0.2 90
Dome Light Replace 0.5 90 B
Service Lights Inspect 0.02 B
Replace 0.5 70,90
Stoplight Inspect 0.02 B
Replace 0.5 90
Turnlamps Inspect 0.02 B
Replace 0.3 70,90
Worklights Inspect 0.02 B
Replace 0.2 90
Repair 0.1 90
0610 Sending Units, Sensors,
and Warning Switches
0232 00-6
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

06 ELECTRICAL
SYSTEM - Continued
Brake Pedal Position Replace 0.5 90
Sensor
Engine Speed/Timing Replace 0.5 70,90,98
Sensors
Fuel Level Sending Unit Replace 1.0 70,90
Hydraulic Oil Replace 3.5 90
Temperature Sensor
Kickout and Position Adjust 0.3
Sensors Replace 1.0 90
Pressure Sensor/ Replace 0.5 70,90,98
Switches
Temperature Sensors/ Replace 0.5 70,90,98
Switches
Throttle Position Sensor Replace 0.5 70,90
Transmission Oil Filter Replace 0.5 90
Bypass Switch
Transmission Sensors Adjust 0.5 70,90
Replace 0.5 70,90
0611 Horns and Alarms
Backup Alarm Inspect 0.02 B
Replace 0.3 90
Electric Horn Inspect 0.02 B
Replace 0.3 90
Quick Coupler Alarm Replace 0.5 98
0612 Batteries and Storage
Batteries Inspect 0.2 0.2 B
Service 0.2 90 B
Test 0.5 90 F
Replace 1.2 90
Battery Box Replace 0.5 70,90
Battery Cables Inspect 0.2 B
Replace 2.0 90
Battery Disconnect Replace 0.5 90
Switch
0232 00-7
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

06 ELECTRICAL
SYSTEM - Continued
NATO Slave Inspect 0.02 B
Receptacle Replace 0.5 90
0613 Hull or Chassis Wiring
Harness
Cab Harnesses Replace 4.0 68,90 A
Engine and Engine Replace 4.0 90 A
ECM Harnesses
Front Chassis Harness Replace 3.0 90 A
Fuel Injector Wiring Replace 1.0 90 A
Harness
Heater and Air Replace 1.5 90 A
Conditioning Harness
Rear Chassis Harness Replace 4.0 68,90 A
Secondary Steering Replace 2.0 90 A
Harness
Transmission Control Replace 4.0 90 A
Harness
07 TRANSMISSION
Transmission Test 1.0 3,12,75,86,87, E
90,95
Adjust 1.0 3,12,75,86,87, E
90,95
Calibrate 1.0 3,12,75,86,87, E
90,95
0705 Transmission Shifting
Components
Modulating Valve Replace 8.0 90,98
Relief Valve Replace 4.0 68,90,98
(Transmission
Hydraulic Control)
Shift Lever Replace 2.8 90
0232 00-8
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

07 TRANSMISSION -
Continued
0710 Transmission Assembly Inspect 0.02 B
with Torque Converter Service 1.0 41,70,90 B
Replace 24.0 17,37,68,90,99 A
Rebuild 60.0 D
Transmission Mounts Inspect 0.3 B
Replace 1.3 17,37,68,90
0721 Coolers, Pumps, and
Motors
Fill Tube Inspect 0.01 B
Replace 0.5 90
Magnetic Screen Service 1.0 B
Oil Filter Base Replace 2.5 70,90,98
Test Oil Lines and Replace 3.0 70,90
Fittings
Transmission Filter Replace 0.2 90 B
Element
Transmission Oil Replace 7.5 68,90,98
Cooler
Transmission Oil Replace 1.5 70,90
Cooler Lines
Transmission Oil Pump Replace 8.0 68,90 A
(Gear Pump) Repair 1.0 D
09 PROPELLER AND
PROPELLER SHAFTS
0900 Propeller Shafts
Carrier Bearing Replace 1.3 70,90
Drive Shaft Inspect 0.01 B
(Front) Replace 3.0 70,90,99 A
Drive Shaft Inspect 0.01 B
(Rear) Replace 3.0 70,90,99 A
Slip Joint Inspect 0.01 B
(Center) Service 0.03 B,C
Replace 2.2 70,90,99
0232 00-9
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

10 FRONT AXLE
1000 Front Axle Inspect 0.01 0.1 70,90 B
Service 0.5 70,90 B,C
Replace 10.0 48,65,68,78,79, A
90,93,99
Rebuild 40.0 D
11 REAR AXLE
1100 Rear Axle Inspect 0.01 0.1 70,71,90 B
Service 0.5 70,90 B,C
Replace 10.0 69,90,99 A
Rebuild 42.0 D
Axle Trunnion Group Replace 14.0 68,90 A
12 BRAKES
Brakes System Test 0.1 1.0 30,34,69,75,86, B,E
87,90
Adjust 1.0 30,34,69,75,86,
87,90
Inspect 1.0 30,69,75,86,90 B,E
1201 Parking Brake Test 0.1 B
Inspect 4.0 66,70,90,99
Replace 4.0 57,70,90,99
Parking Brake Actuator Replace 4.0 70,90
1202 Service Brake Discs Inspect 0.3 3,30,69,70,75, B
86,90
1204 Hydraulic Brake System
Brake Accumulator Test 0.1 0.5 3,33,23,70,75, B
86,87,90
Service 0.5 3,33,23,70,75,
86,87,90
Replace 3.0 3,33,23,70,75,
86,87,90
Parking Brake Control Replace 2.0 70,90
Valve
Service Brake Control Replace 2.0 70,90 A
Valve
0232 00-10
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

12 BRAKES - Continued
Service Brake Lines and Replace 3.0 70,90
Hoses
1206 Service Brake Pedal Inspect 0.01 B
Replace 1.0 90
13 WHEEL AND TRACK
1311 Wheel and Tire Assembly Inspect 0.1 B
Service 0.2 48,53,55,56,63,
Replace 1.5 71,78,80,90,99
1313 Tire Inspect 0.1 B
Replace 1.5 90 F
14 STEERING
1401 Steering System Inspect 0.1 B
Test 1.0 31,48,65,72,79, E
87,90,93,97,98
Adjust 1.0 31,48,65,72,79, E
87,90,93,97,98
Steering Column Replace 2.0 70,90
Steering Wheel Inspect 0.01 B
Replace 0.5 54,70,90,98
1410 Hydraulic Pump or Fluid
Motor
Secondary Steering Replace 1.5 70,90,98 A
Pump/Motor Assembly Repair 1.5 9.5 70,90,98 A,D
Steering Neutralizer Replace 2.0 68,90
Valve
Steering Pump Repair 10.0 68,90 A
4.0 D
1411 Steering Hoses, Lines, Replace 4.0 90
and Fittings
0232 00-11
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

14 STEERING -
Continued
1412 Steering Cylinders Inspect 0.1 B
Service 0.1 B,C
Replace 3.0 70,90 A
Repair 4.0 D
1414 Steering System Valves
Steering Control Valve Replace 1.5 70,90,98 A
Repair 1.5 70,90,98
Steering Metering Pump Replace 2.5 70,90
Secondary Steering Replace 3.0 78,90
Valve
15 FRAME, TOWING,
AND ATTACHMENTS
1501 Frame Assembly
Hydraulic Service Box Replace 0.5 70,90
Steering Frame Lock Inspect 0.01
1502 Counterweight Replace 4.0 70,90
1503 Articulation Pivot Pin Inspect 0.02 B
Service 0.2 B,C
Replace 14.0 9,20,32,
42,44,51,55,57,
61,66,69,76,77,
80,81,90,97
Remote Lubrication Inspect 0.01 0.2 B
Lines and Fittings Service 0.4
Replace 0.5 70,90
18 BODY, CAB, HOOD
1801 Body, Cab, Hood, and
Hull
Cab Assembly Replace 8.0 44, 64, 72,
70,90,99
Chassis Guards Replace 0.5 70,90
Door Assembly Inspect 0.01 B
Replace 1.0 70,90
Repair 3.0 70,90
0232 00-12
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

18 BODY, CAB, HOOD -
Continued
Engine Compartment Replace 9.5 68,90
Shield
Hood and Side Guards Replace 3.0 17,70,90
Ladders, Steps, and Inspect 0.02 B
Hand Rails Replace 3.0 70,90
ROPS Inspect 0.03 0.2 B
Replace 1.0 90 C
1802 Fenders, Windshield and
Glass
Front Fenders Replace 0.5 15,90
Glass Inspect 0.01 B
Replace 1.5 68,90
Rear Fenders Replace 1.2 15,70,90
1806 Upholstery, Seats, and

Carpets
Cabliners Replace 3.0 70,90
Seat Assembly Inspect 0.1 B
Replace 1.5 70,90,98
Repair 4.5 68,90
Seat Belt Inspect 0.2 B
Replace 0.2 90 B
Sunvisor and Mounting Replace 0.5 70,90
1808 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
22 BODY ACCESSORY
ITEMS
2202 Accessory Items
Cab Air Filter Inspect 0.1 B
Service 0.3 B
Replace 0.3 B
0232 00-13
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

22 BODY ACCESSORY
ITEMS - Continued
Mirrors and Mounting Inspect 0.1 70,90 B
Replace 0.5
Washer Bottle Service 0.1 B
Replace 2.0 90
Windshield Wipers Inspect 0.5 B
Replace 0.3 70,90,98
Wiper Motor Replace 1.0 70,90,98
2210 Data Plates Inspect 0.2 B
Replace 0.2 78,90
24 HYDRAULIC AND
FLUID SYSTEMS
Hydraulic Systems Test 1.0 3,24,33,48, E
65,68,72,75,79,
86,87,90,93,97
Calibrate 1.0 3,24,33,48, E

65,68,72,75,79,
86,87,90,93,97
Adjust 1.0 3,24,33,48, E

65,68,72,75,79,
86,87,90,93,97
2401 Hydraulic Pump
Hydraulic Brake and Replace 4.0 68,90 A
Fan Pump Repair 7.0 D
Hydraulic Pump Replace 10.0 68,90 A
(Implement) Repair 7.0 D
2402 Hydraulic Control Valves
Brake and Fan Control Replace 2.0 68,90 A
Valve (Manifold)
Main Hydraulic Control Replace 12.0 17,37,48,65,67, A
Valve 68,78,90,92,98
Repair 12.0 D
Quick Coupler Diverter Replace 1.0 70,90
Valve
0232 00-14
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

24 HYDRAULIC AND
FLUID SYSTEMS -
Continued
2403 Accumulators Test 1.0 15,33,23,48,65,
70,79,87,90,
93
Replace 3.0 15,33,23,48,65,
70,79,87,90,
93
Electro-Hydraulic Joy Inspect 0.2 B
Stick Replace 0.5 90 A
2404 Tilt Cylinder Inspect 0.03 B
Service 0.1 B,C
Replace 4.0 11,36,47,53,56, A
70,82,90,94
Repair 6.0 D
2405 Lift Cylinders Inspect 0.03 B
Service 0.4 B,C
Replace 3.0 36,43,48,51,52, A
56,65,70,79,82,
90,92,93,94
Repair 2.0 D
2406 Hydraulic Filters, Lines,
and Fittings
Filters Replace 0.2 90 B
Hoses, Lines, and Inspect 0.04
Fittings Replace 0.5 70,90
Hydraulic Filter Base Replace 1.5 70,90 A
2407 Coupler Cylinder Replace 1.5 70,90 A
Repair 2.0 D
2408 Tanks and Reservoirs
Cap, Filler Replace 0.1
Hydraulic Tank Inspect 0.2 B
Service 0.5 41,70,90 B
Replace 4.0 70,90 A
Sight Gage Inspect 0.02 B
Replace 0.5 70,90
0232 00-15
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

33 SPECIAL PURPOSE
KITS
3303 Arctic Kit Test 0.3 B
Replace 2.3 70,90
Install 16.0 98
Battery Box (Arctic) Replace 0.5 70,90
3307 Sweeper Bristles Inspect 0.2 B
Replace 1.0 70,90
Broom Manifold and Replace 1.0 70,90
Hoses
Broom Motor Replace 1.0 70,90
Broom Shields and Replace 1.0 22,70,90
Springs
Pallet Forks Inspect 0.02 B
Repair 4.0 15,70,90
52 REFRIGERATION
AND AIR
CONDITIONING
COMPONENTS
(HVAC)
5200 Air Conditioning Test 2.0 38,39,60,68,90 E
Service 2.0 60,68,90
Compressor Replace 4.0 68,90 A
5217 Refrigerant Hoses, Replace 6.0 68,90
Valves, Flanges and
Fittings
5221 Refrigerant Accumulator
Accumulator Replace 3.0 68,90 B
Dryer Replace 3.0 68,90 B
5230 Condenser Replace 4.0 68,90
Heater Core Replace 4.0 68,90
5241 Evaporator Core Replace 4.0 68,90
5243 Blower Motor Replace 2.0 70,90
Blower Motor Resistor Replace 0.5 90
HVAC Blend Door Replace 1.5 70,90
Actuator
0232 00-16
TM 5-3805-291-23-2
(1) (2) (3) (4) (5) (6)

MAINTENANCE LEVEL
FIELD SUSTAINMENT

74 CRANES, SHOVELS
AND EARTH MOVING
EQUIPMENT
7436 Bucket Lift Arms Replace 8.0 5,6,10,19,20,
36,47,48,52,57,
65,68,72,79,82,
90,93,94
Bucket Linkage Tilt Service 0.1
Lever Replace 6.0 7,10,13,20, A
36,43,45,46,47,
52,57,61,64,68,
73,74,82,90,94,
95
Quick Coupler Inspect 0.03 B
Service 0.3 B,C
Replace 1.5 36,47,52,56,70,
82,90
7437 Loader Buckets Inspect 0.02 B
Service 0.2 B,C
Replace 0.1 A
Repair 0.5 71,90,99
0232 00-17
TM 5-3805-291-23-2
Table 2. Tools and Test Equipment Requirements for 966H Loader.

(1) (2) (3) (4) (5)
ITEM MAINTENANCE NATIONAL PART NUMBER/

NO. LEVEL ITEM NAME STOCK NUMBER CAGEC
2 $GDSWHUFDEOHEUHDNRXW ;

2 $GDSWHUFDEOHEUHDNRXW ;
2 $GDSWHUWHVW
2 $GDSWHUFRQQHFWRU 9
) $GDSWHUPHFKDQLFDOSXOOHU 3
) $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 8
) &KDUJLQJNLWSUHVVXUH
2 &RXSOLQJKRVH 9
) 'LHVHOHQJLQHUHSDLUVWDQGOE 8
) 'LHVHOHQJLQHUHSDLUVWDQGDGDSWHUSODWH 8
) 'ULYHUSODWH 3
) ([WUDFWRUVFUHZ 8
2 )LOWHUIOXLG 3
) *DJHEORFN )7
2 *DJHSUHVVXUHGLIIHUHQWLDOGLDOLQGLFDWLQJ 8
) +HDG )
0232 00-18
TM 5-3805-291-23-2
Table 2. Tools and Test Equipment Requirements for 966H Loader - Continued.

(1) (2) (3) (4) (5)

) +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
2 3UREHPXOWLPHWHU ;
) 3XOOHUK\GUDXOLF 9
) 3XOOHUK\GUDXOLF 9
2 3XOOHUK\GUDXOLF 3
2 3XOOHUNLWVWHHULQJZKHHO
) 3XPSK\GUDXOLF &
2 3XPSK\GUDXOLFUDPKDQGGULYHQ 8
) 3XPSK\GUDXOLFUDPKDQGGULYHQ 8
2 4XLFNGLVFRQQHFWWRRO
2 4XLFNGLVFRQQHFWWRRO
) 5HFODLPHUUHIULJHUDQW5D (($&$

) 5HPRYHUEHDULQJDQGEXVKLQJ ,3
2 5HPRYHUHOHFWULFDOFRQWDFW
) 5HSDLUWRROVSHFLDO 6
) 5RGWKUHDGHGHQG 7
0232 00-19
TM 5-3805-291-23-2

(1) (2) (3) (4) (5)

2 6DGGOHDVVHPEO\OLIWLQJEORFN 6

) 6FUHZFDSKH[DJRQKHDG )
) 6KDFNOHDVVHPEO\
) 6KRSHTXLSPHQWDXWRPRWLYHPDLQWHQDQFH $
DQGUHSDLUILHOGPDLQWHQDQFHEDVLFOHVV
SRZHU /,17
) 6KRSHTXLSPHQWPDFKLQHVKRSILHOG $
PDLQWHQDQFHKHDY\OHVVSRZHU /,17
2 6KRSHTXLSPHQWDXWRPRWLYHPDLQWHQDQFH 6&&/$
DQGUHSDLURUJDQL]DWLRQDOPDLQWHQDQFH
FRPPRQQR /,1:
2 6KRSHTXLSPHQWDXWRPRWLYHPDLQWHQDQFH 6&&/$
DQGUHSDLURUJDQL]DWLRQDOPDLQWHQDQFH
FRPPRQQR /,1:
) 6OHHYH )7
) 6OHHYHDVVHPEO\ 6
) 6OHHYHDVVHPEO\ 8
2 6RIWZDUHNLW -(%'
) 6SDFHUVOHHYH 9
) 6SDFHUVOHHYH 0
) 6WDQGDVVHPEO\ 6
2 6WDQGDVVHPEO\ 6
) 6WDQGOLIWJS 8
) 6WXGSODLQ &
2 6WXGSODLQ &
2 7DFKRPHWHUVWURERVFRSLF 8
2 7HVWHULQWHUQDOFRPEXVWLRQHQJLQH 8
2 7HVWNLWUDGLDWRU
2 7HVWVHWHOHFWURQLFV\VWHPV06'
2 7HVWVWDQGDXWRPRWLYH 9
2 7KHUPRPHWHULQIUDUHG
) 7LPLQJSLQ
2 7RRONLWJHQHUDOPHFKDQLF¶VDXWRPRWLYH %

/,17
0232 00-20
TM 5-3805-291-23-2
(1) (2) (3) (4) (5)

2 7UDQVGXFHUSUHVVXUH 9

2 7XEHPHWDOOLF 6
2 7XELQJDVVHPEO\VHWQRQPHWDOOLF 6
2 :DVKHUIODW .
) :DVKHUIODW 7
2 :UHQFKWRUTXHGLDO´GULYHOELQ 16.7&6
2 :UHQFKWRUTXHGLDO´GULYHOE 16.7&6
LQ
2 :UHQFKWRUTXHFOLFNUDWFKHWLQJ´ 16.7&6
GULYHOEIW
2 :UHQFKWRUTXHFOLFNUDWFKHWLQJ´ 16.7&6
GULYHOEIW
) 7RROVHW6$76EDVH 6&$

Table 3. Remarks for the 966H Loader.
Remarks
Code Remarks
$ /LPLWHGUHSDLUDXWKRUL]HGE\UHSODFHPHQWRIFRPSRQHQWV21/<
% 3UHYHQWLYHPDLQWHQDQFHFKHFNVDQGVHUYLFHV30&6
& 7DVNUHTXLUHVXVHRI%,,
' )XQFWLRQSHUIRUPHGE\VSHFLDOL]HGUHSDLUDFWLYLW\65$7KHDWHU/RJLVWLFV6XSSRUW
&HQWHU$UP\RUDXWKRUL]HGFRQWUDFWRUIDFLOLW\
( 6\VWHPWHVWVIRXQGLQ9ROXPH,RIWKLVPDQXDO
) 5HIHUWR70Operator’s, Unit Direct Support, and General Support
Maintenance ManualIRUFDUHPDLQWHQDQFHUHSDLUDQGLQVSHFWLRQRISQHXPDWLFWLUHV
DQGLQQHUWXEHVIRUWLUHUHSODFHPHQWDQGWRROUHTXLUHPHQWV

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 instruc-
tions 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 gal-
lon, 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 NATIONAL DESCRIPTION, CAGEC,

NUMBER LEVEL STOCK NUMBER AND PART NUMBER U/M
1 O Antifreeze 1
1 6850-01-383-4068 (1QK63) 6724354 (1 Gallon Bottle) GAL
6850-01-441-3257 (58536) A-A52624 (5 Gallon Can) CN
6850-01-383-3918 (58536) A-A52621 (55 Gallon Drum) DR
2 F Antiseize compound 2 EA
(11083) 4C-5598
3 O Axle oil additive 3
1U-9891
4 O 8135-00-132-9589 Barrier material, grease proofed, flexible 4 RO
(81349) MIL-B-121
5 O 6840-00-300-6373 Biocide, fuel preservative 5 QT
(0U7J1) BIOBOR JF
6 O 5340-00-450-5718 Cap set, protective 6 EA
Dust and Moisture Seal
(19207) 10935405
7 O Cleaning compound, solvent, type III 7
(81349) MIL-PRF-680
7 6850-01-474-2318 1 Gallon Can GAL
6850-01-474-2320 5 Gallon Can GAL
6850-01-474-2321 55 Gallon Drum GAL
8 O Cloth, abrasive 8
(80204) ANSI B74.18
8 5350-00-584-4654 50 Sheet Package EA
9 O Detergent, general purpose, liquid 9
9 6850-01-159-4844 1 Gallon Can GAL
10 C Diesel fuel, DF-1 10
(81346) ASTM D 975
10 9140-00-286-5286 Bulk GL
9140-00-286-5287 5 Gallon Can CN
9140-00-286-5288 55 Gallon Drum DR
11 C 9140-00-286-5294 Fuel oil, diesel, DF-2 11
ASTM D 975 (81346) GAL
12 C 9130-01-031-5816 Fuel, turbine, aviation 12 GL
(81349) MIL-T-83133 GR JP-8
0233 00-2
TM 5-3805-291-23-2
Table 1. Expendable and Durable Items List for 966H Loader - Continued.
0(1) 0(2) 0(3) 0(4) 0(5)

13 O Flux, soldering 13
(58536) A-A-51145TY FORM A
14 F 8040-01-437-6864 Gasket cement 14
1U-8846 (11083)
15 C Grease, automotive and artillery, GAA 15
15 9150-01-197-7688 2-1/4 Ounce Tube
(81349) M-10924-A OZ
9150-01-197-7690 1-3/4 Pound Can
(81349) M-10924-C LB
9150-01-197-7692 35 Pound Can
(81349) M-10924-E LB
9150-01-197-7693 14 Ounce Cartridge
(81349) M-10924-B OZ
16 O 9150-01-361-8919 Grease, electrically conductive 16 OZ
(53711) 5190179
17 O Grease, molybdenum 17
5P-0960
18 O Grease, multipurpose 18
1P-0808
19 O Insulating sleeving, electrical 19
(11530) 08-196485-06
19 5970-00-815-1295 250 Foot Spool FT
(11530) 08-196485-06
20 O Insulating varnish, electrical 20
(75037) 1602
20 5970-00-476-6717 13 Ounce Aerosol Can CN
21 O 9150-00-111-0208 Lubricating oil, engine 21 GAL
(81349) MIL-PRF-21260
22 O 9150-01-293-7696 Lubricating oil, engine, preservative 22 GAL
(81349) M21260-3-15W40
23 O 5935-01-507-0644 Maintenance kit, electrical connector 23 EA
(11083) 190-8900
24 O Nitrate test strips 24
6850-01-154-3653 100 Strip Package PK
25 O 6803-00-782-2641 Nitrogen technical dry cylinder 25 CYL
(58536) A-A-59503-1B1187
0233 00-3
TM 5-3805-291-23-2
0(1) 0(2) 0(3) 0(4) 0(5)

25 25 25 25 25
25 25 25 25 25
26 C Oil, lubricating, OE/HDO-40 26
(81349) MIL-PRF-2104
9150-00-188-9862 55 Gallon Drum DR
27 C Oil, lubricating, OE/HDO-5/40 27
(81349) MIL-PRF-2104
27 9150-01-524-9155 55 Gallon Drum DR
28 C Oil, lubricating, OE/HDO-15/40 28
(81349) MIL-PRF-2104
28 O 9150-01-152-4117 1 Quart Can QT
9150-01-152-4118 5 Gallon Can GAL
9150-01-152-4119 55 Gallon Drum GAL
29 O Oil, lubricating, OEA-30, Arctic 29
29 9150-00-402-4478 1 Quart Can QT
(81349) MIL-L-46167
29 9150-00-402-2372 5 Gallon Can GAL
(81349) MIL-PRF-46167
29 9150-00-491-7197 55 Gallon Drum GAL
(81349) MIL-PRF-46167
30 F 9150-01-524-4276 Oil, lubricating, refrigerant compressor:
Synthetic Ester 30
(59595) Capella HFC-68NA
30 9150-01-410-8972 1 Quart Can QT
31 O Oil, lubricating, TO-4 31
31 9150-00-402-2372 5 Gallon Can GAL
(11083) 8T-9576
31 9150-00-491-7197 55 Gallon Drum GAL
(11083) 8T-9577
32 O Paint, heat resisting 32
33 O Petrolatum, technical 33
(81348) V-P-236
33 9150-00-250-0926 7.5 lb Can CN
0233 00-4
TM 5-3805-291-23-2
0(1) 0(2) 0(3) 0(4) 0(5)

34 O 8010-01-359-9245 Primer coating 34 GA

(80244) GG00265
35 O Rag, wiping 35
(64067) 7920-00-205-1711
36 F Refrigerant dye 36
37 O 2815-01-521-1638 Repair kit, diesel engine 37 EA
(11083) 175-3700
38 O 8030-01-509-1597 Sealing compound 38 OZ
(11083) 9S-3263
39 O 6810-00-297-0092 Sodium bicarbonate, technical 39 BG
(81346) ASTM D 928
40 O Solder, lead-tin alloy, rosin core 40
(81346) SN60WRP2 0.032 1LB
40 3439-00-555-4629 1 Pound Spool LB
41 O 4235-01-510-1292 Spill containment unit, hazardous material 41
41 20 in. x 20 in., box of 4
(1BW54) B-1400-rdp
42 O Strap, tiedown, electrical components 42
42 42 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
43 O Tag, marker 43
(64067) 9905-00-537-8954
43 9905-00-537-8954 Pack of 50 EA
44 O Tape, duct - Roll 44 RL
45 O 7510-00-040-5895 Tape, pressure sensitive adhesive 45 RL
(81755) P5113-3
46 F 6830-01-439-0614 Tetrafluoroethane,technical(Refrigerant,R-134a) 46 43 LB
CYL
END OF WORK PACKAGE
0233 00-5/(0233 00-6 Blank)

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 val-
ues 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.
1
8 5
10 12
4 3
11 9
6 7
2
CIRCULAR TORQUE PATTERN
9 7 5 3 1 2 4 6 8
STRAIGHT TORQUE PATTERN
0234 00-1
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 origi-
nal. 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 Cater-
pillar 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
ENGLISH (SAE) FASTENERS - CONTINUED
Table 2. English (SAE) Taperlock Studs.

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.

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
METRIC (ISO) FASTENERS
427-C2065
Table 4. Metric (ISO) Nuts and Bolts.

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.

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
METRIC (ISO) FASTENERS - CONTINUED
427-C2064
Table 6. Metric (ISO) Machine Screws.

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.
Torque (1)
Thread Size In.
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
(1)
These values are only for Caterpillar bolts for cutting edges.
0234 00-5
TM 5-3805-291-23-2
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 crit-
ical 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 compo-
nent (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 fit-
ting. 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
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. Start engine (TM 5-3805-291-10).

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
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 compo-
nents 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
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 Thread Size

Standard Torque
Diameter of the Tube (In.)
.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
427-C2070
Table 9. Straight Thread O-Ring Plugs (Hex Bolt/Nut Drive).
Thread Size
Torque
(In.)
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
427-C2071
Table 10. Straight Thread O-Ring Plugs (Socket Drive).
Thread Size
Torque
(In.)
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
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 Thread Size

Torque
Type (In.)
1/2 - 13 15 ± 4 lb-ft (20 ± 5 Nm)
5/8 - 11 26 ± 4 lb-ft (35 ± 5 Nm)
A 3/4 -12 37 ± 4 lb-ft (50 ± 5 Nm)

3/4 -16
7/8 - 14 52 ± 11 lb-ft (70 ± 15 Nm)
1 1/8 - 12
1 5/16 - 12 66 ± 11 lb-ft (89 ± 15 Nm)
B 1 1/2 - 12
2 - 12 92 ± 11 lb-ft (125 ± 15 Nm)
1 1/8 - 12 52 ± 11 lb-ft (70 ± 15 Nm)
C
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)
D
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
427-C2073
Table 12. Straight Thread O-Ring Plugs (Mechanical Joint Tube Assemblies).
Thread Size
Torque
(In.)
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
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
Standard Torque for Nut (3)
(In.)
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
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 Torque

(In.)
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
FLARE FITTINGS
37 Degree Flare Fittings
427-C2076
(1) 37 Degree Flare Fitting

(2) Swivel Nuts
Table 15. Nuts for 37 Degree Flare Fittings.

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
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.

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
AIR CONDITIONING FITTINGS
(1) O-RING SEAL (2) 45 DEGREE FLARE FITTING 427-C2078
Table 17. Air Conditioning Fittings.
O-Ring Fitting End 45 Degree Flare Fitting End

Thread Size
(In.) Torque for Torque for
Torque
Steel Tubes Aluminum Tubes
5/8 - 18 10 ± 3 lb-ft 22 ± 2 lb-ft 17 ± 2 lb-ft
(14 ± 4 Nm) (30 ± 3 Nm) (23 ± 3 Nm)
3/4 - 16 20 ± 3 lb-ft 38 ± 4 lb-ft 24 ± 4 lb-ft
(27 ± 4 Nm) (52 ± 5 Nm) (33 ± 5 Nm)
7/8 - 14 30 ± 3 lb-ft 44 ± 5 lb-ft 28 ± 3 lb-ft
1 - 14 (41 ± 4 Nm) (60 ± 7 Nm) (38 ± 4 Nm)
1 1/16 - 14 33 ± 4 lb-ft 55 ± 6 lb-ft 37 ± 4 lb-ft
(45 ± 5 Nm) (75 ± 8 Nm) (50 ± 5 Nm)
0234 00-18
TM 5-3805-291-23-2
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 Cat-
erpillar engines.
Table 18. Tapered Pipe Thread Fittings.
Standard Torque
Diameter of the Pipe
Thread (In.) Threads with Threads without
5P-3413 Pipe Sealant 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
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
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 re-
used.
0234 00-21
TM 5-3805-291-23-2
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 col-
lapsed 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
Preparation for Short-Term Storage Preparation for Return to Service from Long-Term
Preparation for Return to Service from Short-Term Storage
Storage Preparation for Shipment
Preparation for Long-Term Storage
INITIAL SETUP

0233 00)
WP 0232 00) Tape, pressure sensitive adhesive (Item 45, WP
0233 00)
repair: organizational maintenance, common no. Lubricating oil, engine, preservative (Item 22, WP
1 (Item 70, WP 0232 00) 0233 00)
Materials/Parts Personnel Required

Barrier material, grease proofed, flexible (Item 4, MOS 62B, Construction Equipment Repairer (2)
WP 0233 00)
References
Biocide, fuel preservative (Item 5, WP 0233 00)
TB 750-651
Diesel fuel, DF-1 (Item 10, WP 0233 00)
Fuel oil, diesel, DF-2 (Item 11, WP 0233 00) TM 9-6140-200-14
Fuel, turbine, aviation (Item 12, WP 0233 00) WP 0019 00
Grease, automotive and artillery, GAA (Item 15, WP 0020 00

WP 0233 00) WP 0024 00
Lubricating oil, engine (Item 21, WP 0233 00) WP 0025 00
Lubricating oil, engine, preservative (Item 22, WP WP 0030 00
0233 00)
WP 0033 00
Nitrate test strips (Item 24, WP 0233 00)
WP 0035 00
00) WP 0036 00
Oil, lubricating, OE/HDO-5/40 (Item 27, WP 0233 WP 0041 00
00) WP 0048 00
Oil, lubricating, OEA-30, Arctic (Item 29, WP WP 0051 00
0233 00)
WP 0096 00
Paint, heat resisting (Item 32, WP 0233 00)
WP 0097 00
Primer coating (Item 34, WP 0233 00)
WP 0100 00
Sodium bicarbonate, technical (Item 39, WP 0233 WP 0111 00
00) WP 0187 00
0235 00-1
TM 5-3805-291-23-2
PREPARATION FOR STORAGE OR SHIPMENT - CONTINUED 0235 00
Equipment Conditions Estimated Time to Complete Task

Machine parked on level ground (TM 5-3805-291- 8.0 hr
10)
Wheels chocked
3805-291-10)
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 DIS-
CONNECTED” in driver’s compartment. Maintain batteries IAW TM 9-6140-200-14.
WARNING
Do not smoke, use open flame, make sparks, or create other ignition sources around batteries. If a bat-
tery 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.
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. 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.
0235 00-2
TM 5-3805-291-23-2
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 sensi-
tive 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.
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 equip-
ment. 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 cyl-
inder seal from being damaged by contaminated grease.
0235 00-3
TM 5-3805-291-23-2
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 lubrica-
tion 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 mini-
mum 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 preser-
vative (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
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 OPER-
ATING 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, tur-
bine, 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
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” (with-
out 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. 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 5-3805-
291-10. Maintain oil level between ADD and FULL marks on dipstick.
k. Check condition of ALL rubber hoses. Replace damaged hoses as necessary.
0235 00-6
TM 5-3805-291-23-2
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
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 SOLENOID 1 (REVERSE)
CLUTCH 1 REVERSE CLUTCH SOLENOID 1 (REVERSE)
CLUTCH 2 (FORWARD) CLUTCH SOLENOID 2 (FORWARD)
CLUTCH 2 FORWARD CLUTCH SOLENOID 2 (FORWARD)
CLUTCH 2-FWD CLUTCH SOLENOID 2 (FORWARD)
CLUTCH 3 (FOURTH GEAR) CLUTCH SOLENOID 3 (SPEED 4)
CLUTCH 3 (SPEED 4) CLUTCH SOLENOID 3 (SPEED 4)
CLUTCH 3-4TH CLUTCH SOLENOID 3 (4TH GEAR)
CLUTCH 4 (THIRD GEAR) CLUTCH SOLENOID 4 (SPEED 3)
CLUTCH 5 (SECOND GEAR) CLUTCH SOLENOID 5 (SPEED 2)
CLUTCH 5-2ND CLUTCH SOLENOID 5 (2ND GEAR)
CLUTCH 6 (FIRST GEAR) CLUTCH SOLENOID 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 COOLANT TEMPERATURE SENSOR (GROUND)
RETURN)
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
Manual Schematic
IMAGE 427 C1616 XMSN OIL TEMP SENSOR (ECM) TRANSMISSION OIL TEMPERATURE SENSOR
IMAGE NUMBER 427-C0700 “THROTTLE POSITION THROTTLE POSITION SENSOR GROUND
SENSOR” DIGITAL RETURN
IMAGE NUMBER 427-C0705 ENGINE SHUTDOWN EMERGENCY SHUTDOWN SWITCH
SWITCH (RUN POSITION)
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 INTAKE AIR TEMPERATURE SENSOR (GROUND)
RETURN)
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 SCHEMATIC REFERS TO THIS SENSOR AS THE LIFT
SENSOR POSITION SENSOR
PARA 5 D. (1) TILT LINKAGE ROTARY POSITION SCHEMATIC REFERS TO THIS SENSOR AS THE TILT
SENSOR 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
Manual 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 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
Manual 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) SECONDARY STEER PRESSURE SWITCH (N/C)
SEC STEERING PRESSURE SW (N/O) SECONDARY STEER PRESSURE SWITCH (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 STEER PRESSURE SWITCH (N/C)
SECONDARY STEERING PRESSURE SWITCH (N/O) SECONDARY STEER 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
Manual Schematic
TORQUE CONVERTER OUTPUT SPEED SENSOR (-) TC OUT SPEED SENSOR -

TORQUE CONVERTER OUTPUT SPEED SENSOR (+) TC OUT SPEED SENSOR +
TRANSMISSION DIRECTION CONTROL SWITCH DIRECTION SWITCH FORWARD
(FORWARD)
TRANSMISSION DIRECTION CONTROL SWITCH DIRECTION SWITCH NEUTRAL
(NEUTRAL)
TRANSMISSION DIRECTION CONTROL SWITCH DIRECTION SWITCH REVERSE
(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
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. Electrical Schematics - Lighting Circuit (Sheet 1 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-5/(FP-6 Blank)
FO-1. Electrical Schematics - Lighting Circuit (Sheet 2 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-7/(FP-8 Blank)
FO-1. Electrical Schematics - Accessories Circuit (Sheet 3 of 21) . . . . . . . . . . . . . . . . . . . . . . . FP-9/(FP-10 Blank)
FO-1. Electrical Schematics - Accessories Circuit (Sheet 4 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-11/(FP-12 Blank)
FO-1. Electrical Schematics - Implement Circuit (Sheet 7 of 21) . . . . . . . . . . . . . . . . . . . . . . . FP-17/(FP-18 Blank)
FO-1. Electrical Schematics - Implement Circuit (Sheet 10 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-23/(FP-24 Blank)
FO-1. Electrical Schematics - Implement Circuit (Sheet 11 of 21) . . . . . . . . . . . . . . . . . . . . . . FP-25/(FP-26 Blank)
FO-1. Electrical Schematics - Engine Circuit (Sheet 12 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . FP-27/(FP-28 Blank)
FO-1. Electrical Schematics - Engine Circuit (Sheet 13 of 21) . . . . . . . . . . . . . . . . . . . . . . . . . FP-29/(FP-30 Blank)
FO-1. Electrical Schematics - Transmission Circuit (Sheet 14 of 21) . . . . . . . . . . . . . . . . . . . . FP-31/(FP-32 Blank)
FO-1. Electrical Schematics - Starting Circuit (Sheet 17 of 21). . . . . . . . . . . . . . . . . . . . . . . . . FP-37/(FP-38 Blank)
FO-1. Electrical Schematics - Starting Circuit (Sheet 18 of 21). . . . . . . . . . . . . . . . . . . . . . . . . FP-39/(FP-40 Blank)
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)
END OF WORK PACKAGE
0237 00-1/(0237 00-2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1
Pilot Oil Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1
Refrigerant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00-1
Ride Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1
Actuator
Hood Tilt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
Parking Brake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
Aft Shield
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-3
Aftercooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0189 00-1
Air Conditioning System
Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-6
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0221 00-1
Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0226 00-1
Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-3
Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0222 00-1
Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198 00-1
Arc Suppressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
Arctic Heater
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1
Switch
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-3
Arctic Heater Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1
Atmospheric Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
Axle
Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1
Rear, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 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
B - Continued
Battery
Batteries Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1
Cables Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1
Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0114 00-1
Charge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0217 00-1
Maintenance, Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1
Pedal Position Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1
Pedals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0118 00-1
Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00-1
Service
Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1
Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1
Braking and Hydraulic Fan Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00-1
Bristles Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1
Broom
Hose, Manifold, and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1
Shields and Springs and Links Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-1
Bucket
Lift Arms Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229 00-1
Tilt Lever and Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00-1
Tips and Cutting Edges Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1
C
Cab
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-7
Dome Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1
Doors Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
Liner Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
Sun Visor and Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1
Index-2
TM 5-3805-291-23-2
INDEX - Continued
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
Circuit Breaker Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
Guard Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
Hydraulic Service Box Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
Rear, Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
Side Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
Circuit Breaker
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-7
Panel Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-7
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0227 00-1
Heater, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00-1
Counterweight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
Coupler
Quick, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
System, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-2
Cover, Front, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
Crankshaft
Speed/Timing Sensor (Primary) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1
Vibration Damper and Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
Cutting Edges Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1
Index-3
TM 5-3805-291-23-2
INDEX - Continued
C - Continued
Cylinder
Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
Lift, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
Quick Coupler, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
Tilt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1
Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1
Implement, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1
Powertrain, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0063 00-1
Engine
Compartment Shield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212 00-1
Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1
Intake/Exhaust Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1
Oil Pan Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
Oil Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
Oil Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1
Start Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-13
Evaporator Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0227 00-1
Exhaust
Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1
Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1
Index-4
TM 5-3805-291-23-2
INDEX - Continued
E - Continued
Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0233 00-1
F
Fan
Group Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
Hydraulic Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1
Fender Replacement, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136 00-1
Filter
Bases, Hydraulic System Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1
Element Replacement, Transmission Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
Hydraulic System Oil, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1
Flasher, Turnlamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1
Flywheel
Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
Forks, Pallet, Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1
Forward Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0166 00-1
Front
Axle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0207 00-1
Chassis Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197 00-1
Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0178 00-1
Drive Shaft Carrier Bearing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0108 00-1
Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109 00-1
Fender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136 00-1
Loader Frame, Separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00-1
Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
Turnlamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00-1
Fuel
Injector and Wiring Harness Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1
Level Sending Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0080 00-1
Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
Transfer Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
Fuse
Relay, Circuit Breaker, and Arc Suppressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
G
Gear, Idler, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1
Index-5
TM 5-3805-291-23-2
INDEX - Continued
H
Handrails, Ladders, and Steps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00-1
Head, Cylinder, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
Heater
Arctic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0161 00-1
Blower Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1
Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0220 00-1
Hood
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00-1
Tilt Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
Tilt Relay Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-5
Tilt Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00-1
Horn Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
Hose
Manifold, Link, and Broom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
Windshield Washer Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
Hoses, Lines, and Fittings
Hydraulic System Oil Filter Bases and Cooler, Replacement . . . . . . . . . . . . . . . . . . . . . . 0154 00-1
Implement Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1
Implement Pump Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
Main Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
Remote Lubrication, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00-1
Valves, Flanges, and Refrigerant, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0223 00-1
Housing, Flywheel, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
HVAC Blend Door Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-1
Hydraulic
Fan
Control Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0217 00-1
Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0215 00-1
Filter Base Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-2
Main Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00-1
Oil
Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1
Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1
Index-6
TM 5-3805-291-23-2
INDEX - Continued
H - Continued
Hydraulic System
Oil
Change and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1
Filter Bases and Cooler Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . 0154 00-1
Filter Bases Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0155 00-1
I
Idler Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0186 00-1
Implement
Electronic Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0060 00-1
Hydraulic Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1
Pump Hydraulic Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
Inline Refrigerant Dryer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0224 00-1
Instrument
Cluster Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-1
Panels Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
Intake
Manifold
Air Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
Valve Lash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0229 00-1
Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-12
Light
Blackout Drive, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1
Work, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1
Liner, Cab, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1
Lines, Transmission Oil
Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1
Filter Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00-1
Index-7
TM 5-3805-291-23-2
INDEX - Continued
M
Main Control Valve
Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00-1
Main Light Switch
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1
Maintenance Allocation Chart (MAC)
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0231 00-1
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0232 00-1
Manifold
Exhaust Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0184 00-1
Intake Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0185 00-1
Messenger
Configuration Parameters, System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-2
Copy Configuration (Program ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-6
Copy Configuration From ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-3
ECM Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1
ECM, Copy Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-3
Flash Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-5
System Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-2
Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1
Motor
Broom Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0165 00-1
Fan Hydraulic Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0192 00-1
Front Windshield Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
Rear Windshield Wiper, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1
Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0190 00-1
Cooler, Hydraulic, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0193 00-1
Cooler, Transmission, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1
Hydraulic System Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0148 00-1
Pan Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0181 00-1
Pressure Switch Replacement, Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
Index-8
TM 5-3805-291-23-2
INDEX - Continued
O - Continued
Oil - Continued
Pump
(Gear Pump), Transmission, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0182 00-1
Sensors, Front and Rear Axle Temperature Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1
Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1
P
Pallet Forks Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1
Panel Box Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-7
Parking Brake
Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1
Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
Pilot Oil Accumulator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1
Piston
Cooling Jets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0183 00-1
Pump
Implement/Pilot Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216 00-4
Replacement (Steering and Implement/ Pilot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0216 00-1
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-3
Return to Service from Long-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-5
Return to Service from Short-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-3
Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-7
Short-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-2
Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-1
Pulley, Crankshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
Pump, Fuel Transfer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0188 00-1
Push Rods Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1
Index-9
TM 5-3805-291-23-2
INDEX - Continued
Q
Quick Coupler
Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
Diverter Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0169 00-1
R
Rack, Rifle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00-1
Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0191 00-1
Rear
Axle
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0208 00-1
Trunnion Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1
Drive Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1
Fenders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00-1
Frame, Separate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00-1
Main Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0225 00-1
Hoses, Lines, Valves, Flanges, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0223 00-1
Relay
Hood Tilt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0180 00-1
Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-11
Rotary Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-11
S
Seal, Main
Front Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
Rear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
Index-10
TM 5-3805-291-23-2
INDEX - Continued
S - Continued
Seat
Assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00-1
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0140 00-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0141 00-1
Suspension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0214 00-7
Secondary
Steering Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1
Steering Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1
Steering Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
Sensor
(Primary) Crankshaft Speed/Timing, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1
Atmospheric Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
Boost Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1
Brake Pedal Position, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1
Camshaft Speed/Timing (Secondary), Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00-1
Coolant Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1
Engine Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
Fuel Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
Hydraulic Oil Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0083 00-1
Intake Manifold Air Temperature, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00-1
Lift Kickout Position and Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0085 00-1
Tilt Kickout Position and Mounting Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0089 00-1
Torque Converter
Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00-1
Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
Transmission
Separate Front Loader Frame and Rear Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0211 00-1
Service
Light
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00-2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00-1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00-1
Service Brake
Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
Lines and Hoses Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1
Oil Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
Index-11
TM 5-3805-291-23-2
INDEX - Continued
S - Continued
Shaft Replacement
Center Drive (Slip Joint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00-1
Front Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0109 00-1
Rear Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1
Shield
Engine Compartment Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0212 00-1
Forward, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00-1
Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1
Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00-1
Hoses, Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0124 00-1
Metering Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1
Neutralizer Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210 00-1
Oil Pressure Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
Secondary Pump and Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1
Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1
Steps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0134 00-1
Stoplight
Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070 00-1
Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0070 00-1
Limit Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1
Storage
Long-term, Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0235 00-3
Short-term, Preparation for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
INDEX - Continued
T - Continued
Switch
12V, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-12
Arctic Heater
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-3
Battery Disconnect, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1
Engine Start, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-13
Instrument Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
Main Light
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-2
Parking Brake, Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
Replacement, Transmission Oil Filter Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00-1
Rocker, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-11
Rotary, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-11
Service Brake Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
Steering Oil Pressure, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
Stoplight, Limit, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0064 00-1
Turnlamp, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1
Windshield Wiper, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1
Lever Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00-5
Link Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0228 00-2
System Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-10
Tire Assembly Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1
Toolbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00-1
Torque
Converter
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204 00-9
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204 00-1
Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0234 00-1
Index-13
TM 5-3805-291-23-2
INDEX - Continued
T - Continued
Transmission
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204 00-2
Control Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00-1
Hydraulic Control Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0202 00-1
Modulating Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1
Oil Cooler Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1
Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0205 00-1
Oil Filler Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
Oil Filter Base, Lines, and Bypass Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00-1
Oil Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
Oil Pump (Gear Pump) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0206 00-1
Oil Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00-1
Output Speed Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0204 00-1
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00-1
Test Lines, and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00-1
Trunnion, Rear Axle, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0209 00-1
Tube Replacement, Transmission Oil Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
Turnlamp
Flasher Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0065 00-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0071 00-9
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0066 00-1
V
Valve
Lash, Intake/Exhaust, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0179 00-1
Main Hydraulic Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0218 00-1
Parking Brake Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0115 00-1
Quick Coupler Diverter, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0149 00-1
Service Brake Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
Steering Neutralizer, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0210 00-1
Transmission Modulating, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0203 00-1
Vibration Damper, Crankshaft, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
Visor, Sun, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1
W
Wheel Replacement
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1
Index-14
TM 5-3805-291-23-2
INDEX - Continued
W - Continued
Windshield
Front Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
Front Wipers Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
Front/Rear and Doors Glass Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0213 00-1
Rear Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1
Rear Wiper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1
Washer Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
Washer Hoses, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
Wiper Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00-1
Wiring Harness
Cab, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0195 00-1
Engine, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0196 00-1
Front Chassis Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0197 00-1
Fuel Injector, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0187 00-1
Heater and Air Conditioning, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0198 00-1
Rear Chassis, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0199 00-1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0059 00-1
Secondary Steering, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0200 00-1
Transmission Control, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0201 00-1
Worklights
Bulb Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-2
Lamp Housing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0072 00-1
Index-15/(Index-16 Blank)
RECOMMENDED CHANGES TO PUBLICATIONS Use Part II (reverse) for Repair Parts and DATE
AND BLANK FORMS Special Tool Lists (RPSTL) and Supply
Date you filled out
Catalogs/Supply Manuals (SC/SM).
For use of this form, see AR 25-30; the proponent agency is ODISC4. this form.
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 Your mailing address
1 Rock Island Arsenal, Rock Island, IL 61299-7630
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE Title )LHOG0DLQWHQDQFH0DQXDO,QFOXGHV
8QLWDQG'6PDLQWHQDQFHIRU+
TM -DQ /RDGHU+HDY\7\SH,DQG,,
ITEM PAGE PARA- LINE FIGURE TABLE RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO. (Provide exact wording of recommended changes, if possible).
3DUWQXPEHUVXSSOLHGIRULWHPLVLQFRUUHFW
*Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION Signature
Your Signature
Your Name
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPPC V3.00
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U. S. Army TACOM Life Cycle Management Command Your address Date you filled out this
ATTN: AMSTA-LCL-MPP/TECH PUBS form
PART II – REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
TITLE )LHOG0DLQW0DQXDOZ8QLW '60DLQW
PUBLICATION NUMBER DATE
TM -DQ IRU+/RDGHU+HDY\7\SH,DQG,,
TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
NO. NO. NO. NUMBER NO. NO. NO. ITEMS RECOMMENDED ACTION
SUPPORTED
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.)
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION SIGNATURE
Your Name Your Signature

USAPPC V3.00
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) FROM: (Activity and location) (Include ZIP Code)
U.S. Army TACOM Life Cycle Management Command

ATTN: AMSTA-LCL-MPP/TECH PUBS
PART I – ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE )LHOG0DLQWHQDQFH0DQXDO,QFOXGHV8QLWDQG'6
TM -DQ 0DLQWHQDQFHIRU+/RDGHU+HDY\7\SH,DQG,,
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, PLUS SIGNATURE

EXTENSION
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
U. S. Army TACOM Life Cycle Management Command
PUBLICATION NUMBER DATE TITLE )LHOG0DLQWHQDQFH0DQXDOZ8QLWDQG'6
TM -DQ 0DLQWHQDQFHIRU+/RDGHU+HDY\7\SH,,,
TOTAL NO.
SUPPORTED
USAPPC V3.00


EXTENSION
FROM: (Activity and location) (Include ZIP Code) DATE
TO: (Forward direct to addressee listed in publication)
TOTAL NO.
SUPPORTED
USAPPC V3.00


EXTENSION
FROM: (Activity and location) (Include ZIP Code) DATE
TO: (Forward direct to addressee listed in publication)
TOTAL NO.
SUPPORTED
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

FP-11/(FP-12 Blank)
TM 5-3805-291-23-2
483-1590

FP-13/(FP-14 Blank)
TM 5-3805-291-23-2
483-1591

FP-15/(FP-16 Blank)
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

FP-19/(FP-20 Blank)
TM 5-3805-291-23-2
483-1594

FP-21/(FP-22 Blank)
TM 5-3805-291-23-2
483-1595

FP-23/(FP-24 Blank)
TM 5-3805-291-23-2
483-1596

FP-25/(FP-26 Blank)
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 Sq Centimeter = 100 Sq Millimeters = 0.155 Sq Inches
1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Sq Meter = 10,000 Sq Centimeters = 10.76 Sq Feet
1 Kilometer = 1000 Meters = 0.621 Miles 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 Cu Centimeter = 1,000 Cu Millimeters = 0.06 Cu Inches
1 Kilogram = 1000 Grams = 2.2 Pounds 1 Cu Meter = 1,000,000 Cu Centimeters = 35.31 Cu Feet
1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons
Temperature
Liquid Measure
5/9 (°F - 32) = °C
1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 212° Fahrenheit is equivalent to 100° Celsius
1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 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 Kilopascals 6.895 Kilopascals Pounds per Sq 0.145

Inch Inch
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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TM 5-3805-291-23-2

LOADER, HEAVY, SCOOP:

4.5 CUBIC YARD ROCK BUCKET

5.0 CUBIC YARD GENERAL PURPOSE BUCKET

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

HEADQUARTERS, DEPARTMENT OF THE ARMY

This page is blank.

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

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

HAZARDOUS WASTE DISPOSAL

HYDRAULIC SYSTEM PRESSURE

HYDRAULIC SYSTEM PRESSURE

• Refer to FM 3-3, Chemical and Biological Contamination Avoidance, TM 3-4230-236-10, Decontamination

• Failure to follow these warnings may cause injury or death to personnel.

To order this NBC decal use:

SOLVENT CLEANING COMPOUND

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Date of issue for original manual is:

Page/WP No. Change No. Page/WP No. Change No.

Page/WP No. Change No. Page/WP No. Change No.

Page/WP No. Change No. Page/WP No. Change No.

FIELD MAINTENANCE MANUAL

LOADER, HEAVY, SCOOP:

4.5 CUBIC YARD ROCK BUCKET

5.0 CUBIC YARD GENERAL PURPOSE BUCKET

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

Table of Contents - Continued

Table of Contents - Continued

Table of Contents - Continued

Table of Contents - Continued

Table of Contents - Continued

Refrigeration and Air Conditioning

Figure 1. Electrical Schematics - Key to Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-1/(FP-2 Blank)

Table of Contents - Continued

Figure 2. Hydraulic Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FP-47/(FP-48 Blank)

HOW TO USE THIS MANUAL

CONTENTS OF THIS MANUAL

FEATURES OF THIS MANUAL

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT 0050 00

THIS WORK PACKAGE COVERS

Removal, Cleaning and Inspection, Installation

Maintenance Level Equipment Conditions

Personnel Required Estimated Time to Complete Task

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

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

5. Remove bracket (3) from hood (6).

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

18. Disconnect cab camera cable (30) from upper connec-

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

CLEANING AND INSPECTION

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

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

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

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

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

REARVIEW CAMERA, CABLE, AND DISPLAY REPLACEMENT - CONTINUED 0050 00

26. Push grommet (5) through hood (6).